cfb presn-ntpc11.07.06

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SUPER CRITICAL TECHNOLOGY

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Presentation on CFBC Boilers

WelcometoPresentation on

CFBC Boilers

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers CFBC Development Journey Test Facility installed 1991 Collaboration with LLB ( LEE ) 1993 Technology transfer/Training of Engineers - 1996 First non reheat boiler (175 t/h ) installed at BILT , Bhigwan - 1998 First Utility reheat boiler ( 2x125 MW ) installed at SLPP , Mangrol - 1999 Testing of Lignite 2001 125 MW order received from RVUNL, Giral 2003 75 MW order received from GEB, Kutch 2004 2 x 135 t/h order received from M/s Gujarat Ambuja cement - 2004 2 x 250 MW order received from Neyveli Lignite Corporation 2005 125 MW repeat order received from RVUNL, Giral 2005 2 x 125 MW order received from NLC Barsingsar firing Rajasthan Lignite Oct 2005 2 x 125 MW repeat order received from SLPP March 2006 Bharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

Presentation on CFBC BoilersBasic Flow Diagram of CFBC Boiler

SECONDARY AIR

ID Fan

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

Advantages of CFBC Simplified Fuel Preparation and feeding (No Pulveriser) In-Situ SOx and NOx control Oil support for load below 30% and start up only Slag-Free Combustion. Dry ash powder only FSSS avoided. Burner Management for Start-Up Burner only Lower Temperature / Less Intense (no flame) Combustor Environment Suitable for using wide range of fuels in the same boiler Suitable for fuels which are difficult to burn High Carbon Burn-out (Very low carbon in ash)

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

Why Fluid Bed Combustion ?

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

SOx Control Sulphur in fuel captured in combustor by addition of limestone Ca/S Molar Ratio varies between 1.5 to 2.5 depending on the Limestone Quality Expensive (FGD) add-on equipment avoided. Reliability improved

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

SO2 Control Reactions Straightforward method - Limestone addition along with fuel into combustor Reactions S + O2 CaCO3 SO2 CaO + CO2 CaSO4 (Calcination) (Sulphation)FBC & HRSG

CaO + SO2 + 1/2 O2

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Presentation on CFBC Boilers Limestone RequirementLimestone Requirement

TemperatureBharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

Presentation on CFBC Boilers

Formation of NOx and Control NOx formation Thermal NOx - Nitrogen in Air Fuel NOx - Nitrogen in Fuel Thermal NOx depends on Combustion temperature In FBC boilers, the Combustion temperature is around 850C, hence Thermal NOx is negligible Fuel NOx depends on excess air levels & Staging In addition to low excess air levels, the combustion air is staged. Hence Fuel NOx is also lowBharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

Presentation on CFBC BoilersAdvantages of FBHE

Spiess Valve

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

Distinct Advantages of FBHE` ` Elimination of heat transfer bundle / panel in combustor Very Low carbon in ash and Limestone consumption even at part load due to Optimum combustor temperature (about 850 Deg C ) Better fuel flexibility due to provision for adjusting heat absorption Higher efficiency and reduced NOx emission even at part load due to constant excess air Unique RH temperature control option

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Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC BoilersComb. Temp.

With FBHE

Without FBHE

FBHE CombustorHeat duty

Conv. Pass

Fuel Quality / Load

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

SINARMAS 175 t/h CFBC Boiler Fuel Commissioned Total hours logged Minimum load achieved (without Oil support) Coal (Imported+Indian) March 1998 65,000 20 % MCR

Controllability Range (achieved) 30 to 100% Generally in Continuous operation between planned annual stoppagesBharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers Arrangement (Elevation) of Bilt Graphics CFBC Boiler

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

SLPP 2 x 125 MW CFBC BOILERLocation Fuel : : Mangrol , Surat Dt , Gujarat Lignite ( 50 % M & 2.5 %S) HHV - 2500 to 5500

Total hours loggedBoiler Parameters SH Steam RH Steam

:

65,000

: :

390 T/H, 132 ATA, 540 0C 350 T/H, 32.5 ATA, 540 0C

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers Arrangement (Plan) of SLPP CFBC Boiler

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers Arrangement (Elevation) of SLPP CFBC Boiler

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC BoilersView of 2 x 125 MWe SLPP

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

SLPP Fuel Fixed Carbon Volatile Matter Moisture Ash Sulphur* HHV

Lignites UsedDesign % % % % % 14 - 40 25 - 44 10 - 50 7 - 48 0.36 2.5 Actual 18 - 33 21 - 26 41 - 48 4-8 0.3 - 2

kcal/kg 2500 -5500 2300 - 4775

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

SLPP PerformanceFuel Carbon Hydrogen Sulphur Nitrogen Oxygen (by diff.) Moisture Ash HHV % % % % % % % Design 43.30 3.14 1.20 (2.5) 0.81 8.53 24.00 19.02 Actual 30.75 3.48 1.18 0.43 7.61 42.44 14.10 30900.3-0.4% FBC & HRSG

kcal/kg 4250Not identified

Chlorine content in Lignite

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Presentation on CFBC Boilers

RVUNL Giral 125 MW

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

Comparison of SLPP Giral(Boiler parameters )Parameter Unit SLPP 125 Natural 390 / 350 132 / 30.5 540 / 540 235 Giral 125 Natural 405 / 336 132 / 34 540 / 540 237FBC & HRSG

Unit Rating MW Type of Circulation SH/RH Flow SH/RH Pres. SH/RH Tem. FW Tem. t/h kg/cm2 Deg C Deg C

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Presentation on CFBC Boilers Lignite Analysis - ComparisonSLPP Proximate Analysis (% by weight) Moisture Ash Volatile Matter Fixed Carbon (by diff.) HHV, kcal/kg Ultimate Analysis (% by weight) Carbon Hydrogen Sulphur Oxygen Nitrogen Moisture Ash 24 19.02 32.52 24.46 4240 10-50 7-48 25-44 14-40 2500-5500 Giral 40 15 20 25 3000 30.09 2.24 6.00 6.27 0.4 40.0 15.0FBC & HRSG

43.3 3.14 1.2 (max 2.5) 8.55 0.81 24.0 19.02

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Presentation on CFBC Boilers Limestone Analysis - Comparison

SLPP Analysis (% by weight) CaCO3 MgCO3 SiO2 Moisture Others 85.23 1.18 8.65 2.05 2.89

Giral 96.8 1.2 1.15 0.28 0.57

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

Giral Design Evolution

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

Giral CFBC Boiler Design - Evolution About 50 feedbacks from the operational experience from SLPP and BILT Graphics Learnings from 158 SARs from SLPP and Bilt Graphics incorporated Discussions with Manufacturing and OP&C groups Discussions with Erection Group PSWR

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers250 MW CFBC Flow Schematic

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC BoilersCOAL BUNKERS CONVECTIVE PASS CYCLONES

SPECIAL COMBUSTOR FBHE

SEC. APH ( REGEN )

250 MW CFBC BoilerBharat Heavy Electricals Limited TIRUCHIRAPALLI FBC & HRSG

Presentation on CFBC BoilersGardanne 250 MW CFBC Plant

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

Presentation on CFBC Boilers

General Arrangement of 250 MW CFBC boiler

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

FBC & HRSG

BHEL Presentation on CFBC Boilers - LEE Foster wheelerLLB (BHEL)TO BACKPASS

PYROPOWER (IJT)TO BACKPASS

Fuel - Coal 650-850CCOMBUSTORWING WALL SH

850C

CYCLONE

870CCL- < 1.5%

800-1000CCYCLONE

CL- 2-3%CFB COMBUSTOR

SOx - 150-250 NOx - 50-200

CFB COMBUSTOR

SOx - 100SEAL POTSPIESS VALVE

SECONDARY AIR

NOx - 50

SECONDARY AIR

LOOP SEAL

850CFUEL

700-900CFUEL PRIMARY AIR

FBHE PRIMARY AIR

BHELAFBC CL < 3.5%FBC

Krupp IndustrieDBW (KRUPP)TO BACKPASS

SOx 150-300 NOx 200-300

TBWIN FURNACE U-BEAMS

FBC

B&W (TBW )

U-BEAMSEP.

SUPERHEATERS

300-400CECO

TO BACKPASS CYCLONE DIVISION WALL

300-400CCL - 3-4% SOx - 150-300

650-790CBED MATERIAL BIN

SH1 SH2

CFB COMBUSTOR

FlyAsh reinjection 150CCL - 3-4%

SECONDARY AIR

SECONDARY AIR

FUEL

NOx - 150-300SIPHON SEAL

FUEL

700-900CPRIMARY AIR