Rafako CFBC Boiler.pdf

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_____________ ...;;;,C;.;_IR.;;...;C:..:U:..:LA;;....;.;;..:T;.;..IN.;,..;;G FLUIDIZED BED BOILERS

Siersza Power Plant. Two CFB boilers OFz-425

2

Due to their low flue gas

temperature in fluidized bed

which causes the reduction of

NOx emissions as well as due to

the addition of sorbent limiting

the formation of sulfur

compounds, fluidized bed boilers

became an alternative solution

for plants operating with

conventional boilers equipped

with low-emission furnaces or

flue gas desulfurization systems.

The advantages of fluidized bed

boilers include

o reduction of NOx emission -

combustion temperature

800°C - 900°C;

o reduction of sulfur oxides

emission by c.a. 90 - 95% -

addition of sorbent to the

furnace;

o possibility of firing with various

low-grade solid fuels;

o operation of the boiler within

the large range of loads

without auxiliary fuel.

-

Basing on the engineering and experience of

Alstom Power (former EVT Stuttgart),

RAFAKO S.A. designs and delivers

circulating fluidized bed boilers. The

construction of this type of boilers enables

the circulation of a dense mass consisting of

ash, fuel and sorbent particles from the

furnace chamber through external cyclones

back to the furnace chamber. The

Company works also on biomass

combustion in CFB boilers.

0Fz-450A boiler in i:eran CHP Plant, Warsaw

In 1993, RAFAKO SA signed a turnkey

contract for the first of two fluidized bed

boilers foreseen as a replacement for three

conventional OP-230 units.

0Fz-450A has a classical two-pass profile.

The first pass consists of furnace chamber

made of membrane walls A partition wall

incorporated into the evaporator circuit as

well as second stage platen superheater

made of "double super omega" tubes are

installed within the furnace chamber. After

separation of ash m two cyclones (coarse

fraction is recirculated to the furnace

chamber via downcomer) flue gas goes to

the second pass consisting of steam

superheater, economizer and tubular air

heater. From the latter, flue gas is directed to

the chimney through electrostatic precipitator

and flue gas fans. 0Fz-450A features the

cyclones made of steel sheets covered with a

layer of coating protecting against

temperature and erosive activity of

circulating ash particles.

Zeran CHP Plant, Warsaw, Poland

OFz-4508 in ieran CHP Plant, Warsaw

In 2001 second CFB boiler was

commissionned at Zeran CHP

Plant When compared with the A

boiler, a number of modifications

were introduced both in pressure

and furnace systems. The main

modification consists in

installation of so called "tubular"

cyclones incorporated into the

boiler steam system. Cyclones

simultaneously act as separators

and heat exchange surfaces.

Within the numerous advantages

of this systems we shall mention

the reduction of heat exchange

surfaces in convective pass,

possibility of use of considerably

simpler expansion joints between

cyclones and double loop as well

as shortening of start-up time

due to the brickwork which is

much thinner than in case of

steel sheet cyclone solutions.

The putting of the boiler into

operation is planned for August

2001'

0Fz-450A

CIRCULATING FLUIDIZED BED BOILERS ___ _

"Tubular' cyclone. Manufacturing workshop of RAFAKO S.A.

0Fz-450A and OFz-4508 technical data:

Boiler nominal capacity 315 MW1

Maximum continuous rating 450 t/h

Outlet steam temperature 510 oc Outlet steam pressure 10 MPa

Feedwater temperature 205 oc Efficiency (0Fz-450NB) 92,2 I 92,0 %

OFz-4508

Fuel characteristics:

Type

Calorific value

Moisture

Ash

Sulfur

0Fz-450A OFz-4508

hard coal

22 - 28 18 - 24 MJ/kg

8-15 8-15%

7- 18

0.6- 0.8

15-25 %

0.6-1 %

Volatile particles vdat 34.4 30 %

Fuel consumption

Start-up fuel

16.38 kg/s

heavy fuel oil

Guaranteed emission levels of pollutants

so2 200 mg/m~

NOx 200 mg/m~

co 0Fz-450A 250 mg/m~

OFz-4508 *150 mg/m~

Ash 50 mg/m~

(for dry flue gas with 6% oxygen contents)

* within the load range from 70% to 1 00%. In

case of lower loads CO emission shall not

exceed 250 mg/m~

Silhouettes of the CFB boilers, Zeran CHP Plant

3

4

II

OFz-230 boiler in Bielsko-Biata II CHP

The design of this fluidized bed

boiler takes into account the fact

that a conventional pulverized

fuel fired OP-230 boiler was

previously designed for Bielsko

CHP Plant.

The majority of systems was

already delivered to the site or

under the final phase of design,

manufacturing or shipping.

A considerable part of these

element s was used in th8 new

boiler. The decision to modify the

type of the boiler was motivated

by environmental requirements.

All these factors resulted in a

fluidized bed boiler having a non

typical profile. Cyclones are

installed on both sides of furnace

chamber and the drum location

follows the axis of the boiler.

OFz-230 boiler was put into

operation in 1997.

---- --~ .:;;:-;;;,..._ __

Silhouette of the OFz-230 boiler, Bielsko-Biata II CHP Plant

Technical data:

Boiler nominal capacity 177 I 165 MW1

Maximum continuous rating 230 t/h Outlet steam temperature 540 oc Outlet steam pressure 13.8 MPa

Feedwater temperature 158/205 oc Efficiency 91 %


S02 300 mg/m~

NOx 250 mg/ m~

CO 250 mg/ m~

Ash 50 mg/ m~



Type hard coal with the addition of mine

sludge:

Calorific value

Moisture

Ash

Sulfur

Volatile particles vdaf

Fuel consumption

Start-up fuel

16- 18.8 MJ/kg

10- 15 %

31-36 %

1.7 %

30 %

ca. 10 kg/s

fuel oil

OFz-230 boiler - Bielsko-Bia/a II CHP Plant, Poland

CIRCULATING FLUIDIZED BED BOILERS __ -----------------------------

Two OFz-75 boilers in "Polpharma" Pharmaceutical Plant, Starogard Gdanski

In 1993 "Polpharma" Starogard

Pharmaceutical Plant and

RAFAKO SA signed a contract

for turnkey construction of heat

and power generating plant

equipped with two fluidized bed

boilers and one 12 MWe

turbogenerator. The heat was to

cover the heating and process

needs of "Polpharma" plant

OFz-75 has a three-pass profile

arranged in a so called

"bacpack" system. Cyclone

separator is installed in the front

part of the boiler and the duct

connecting the separator with

second pass is installed above

furnace chamber. Outlet live

steam superheater is also

located in this duct Second pass

adjoining the furnace chamber

contains steam superheater and

economizer bundles. Tubular air

heater is located in the third

pass.

Guaranteed emission levels of

pollutants

so2 400 mg/m~

NOX 300 mg/m~

co 250 mg/m~

Ash 50 mg/m~

(for dry flue gas with 6% oxygen

contents)

Technical data:

Boiler nominal capacity 60.2 MW1


Outlet steam temperature 455 oc Outlet steam pressure 4.5 MPa

Feedwater temperature 105 oc Efficiency 91.5 %


Type- hard coal:

Calorific value 17-20.1 MJ/kg

Moisture 10- 17 %

Ash 20-30 %

Sulfur 1.0 %

Volatile particles ydat 30 %

Fuel consumption ca. 4 kg/s

Start-up fuel fuel oil

Silhouette ofthe OFz-75 boiler, Polpharma Plant, Starogard Gdanski

OFz-75 boilers- ,Polpharma" Pharmaceutical Plant, Starogard Gdanski, Poland

5

61

Two OFz-425 boilers in Siersza Power Plant

These fluidized bed boilers were

delivered to replace conventional

OP-140 boilers using the latter's

support structure and reinforced

foundations. OFz-425 is a drum

boiler with reheat and rotary air

heaters. It is fired with the mixture

of hard coal and flotation sludge

(1 0% thermal share).

The boilers were commissionned

in 2001 and 2002 respectively.

----

Technical data:

Boiler nominal capacity 336.3 MW1


Outlet steam temperature 560 oc Outlet steam pressure 16.1 MPa

Secondary steam temperature 560 oc Secondary steam pressure 4.0 I 3.8 MPa

Feedwater temperature 250 oc Efficiency 91 %


S02 337.5 mg/m~

NOX

co Ash

307.8 mg/m~

271 mg/m~

50 mg/m~



Type - hard coal•

Calorific value

Moisture

Ash

Sulfur

Volatile particles vdat

Fuel consumption

Start-up fuel

15-16.7 MJ/kg

21.7-25 %

20.6-27 %

2.4-3 %

30 %

22.2 kg/s

fuel oil

Silhouette of the OFz-425 boiler, Siersza Power Plant

Siersza Power Plant, Poland - erection of the OFz-425 CFB boilers

Apart from circulating fluidized

bed boilers RAFAKO SA also

offers bubbling bed boilers. Such

boilers may be operated in small

and medium sized heat and

power generating plants. OF-125

and OF-140 boilers

manufactured for Czech

Komofany CHP Plant may serve

as an example of this solution.

OF-125, OF-140 boilers in Komofany CHP Plant, Czech Republic

In Komofany CHP Plant , five

stoker fired boilers were subject

to modernization with bubbling

fluidized bed technology. This

modernization was carried out by

Elektrim I Mostostal Zabrze

consortium on the basis of

deliveries from RAFAKO SA The

scope of works included the

installation of fluidization box,

necessary heat exchange

bundles and boiler auxiliary

equipment. The works were

completed in 1997.

KomoTany CHP Plant, Czech Republic

BUBBLING BED BOILERS ___ -

Successful modernization of the first five

boilers served as a basis for the decision to

modernize further five units. This task was

carried out by Elektrim I RAFAKO consortium.

The offer was enlarged by installation of

membrane walls and increase of capacity

from 125 to 140 t/h

OF-140 is a drum boiler with natural

circulation in furnace chamber wall tubes and

assisted circulation (using circulation pumps)

in evaporator coils located in fluidized bed.

The boiler is equipped with fluidized furnace

being an intermediate solution between

bubbling and circulating furnace.

Combustion air is heated in tubular air heater

and delivered - via primary air fan - to

fluidization chamber and then - via secondary

air fan - to furnace chamber located above

fluidization chamber. The heat contained in

flue gas leaving the furnace chamber is

recovered in superheaters installed in

interconnecting pass and in ECO and air

heater bundles located in the second pass of

the boiler. Flue gas cleaned in fabric filters is

directed to the chimney.

-----

Silhouette of the OF-140 boiler,

Komofany CHP Plant

Technical data:

Boiler nominal capacity

Maximum continuous rating

Minimum continuous rating

Steam temperature

Steam pressure

Efficiency

140 t/h

71 t/h

490 oc 7.5 MPa

91 .5 %


S02 soo mglm~

NOx 400 mg/m~

CO 250 mg/m~

Ash 50 mglm~



Type lignite

Calorific value 9.5- 15 MJikg

Moisture 25-33 %

Ash 19- 30 %

Sulfur 1.1 - 2.7 %

7

Technical data specification of CFB boilers designed and delivered by RAFAKO S.A.

Parameter Units

Boiler nominal capacity MWt

Maximum continuous rating t/h

Live steam temperature oc Live steam pressure MPa

Quantity of reheated steam t/h

Reheated steam temperature oc Reheated steam pressure MPa

Feedwater temperature oc Boiler efficiency %

Emission 802 mglm~

(for dry flue NOX mglm~

gas with co mglm~

0 2 = 6%) ash mglm~

Wd MJikg

w %

Coal p %

s %

volatile particles Vdat %

Number of cyclones pes.

Bed temperature oc depth mm

Furnace chamber dimensions width mm

height mm

Number of fuel inlets pes. --

Ash removal from bed

----

0Fz-450A OFz-230 Zerari Bielsko

315 177 I 165

450 230

510 540

10 13.8

205 158 I 205

92.2 91

200 443

200 250

250 250

50 50

22 --c- 28 16 --c- 18.8

8--c-15 1 0--c- 15

7--c- 18 31 .5 --c- 36

0.6--c-0 8 1.7

34.4 - 30

2 2

850 849

6915 5115

13245 9955

42000 34000

4 4

central lateral

OFz-75 OFz-425 OFz-4508 Polpharma Siersza Zerari

60.2 338.5 315

75 425 450

455 560 510

4.5 16.1 10

382

560

3.5

105 250 205

91 .5 91 92 .2

300 357 200

250 326 200

250 271 150*

50 50 50

17 --c- 20. 1 15 -7- 16.7 18 -7- 24

10 --c- 17 21.7 -7- 25 8 -7- 15

20 --c- 30 20.6 -7- 27 15 -7- 25

2.4 -7- 3 0.6 -7- 1

- 30 - 30 - 30

2 2

850 850 850

4215 8517 6915

4255 11615 13245

25000 37000 42000

2 4 4

lateral central central

* within the load range from 70% to 100%. In case of lower loads CO emission shall not exceed 250 mglm~

CIRCULATING FLUIDIZED BED BOILERS

RAFAKO S.A. and Alstom Power reference list Circulating fluidized bed boilers

Boiler Live/reheated Live/reheated

Ordered in Plant name Country Number capacity steam pressure steam Fuel of boilers t/h MPa temperature °C

1985 Wachtberg Power Plant Germany 175 17.8 I 3.8 530 I 425 lignite

1985 Kohler CHP Plant Germany 100 10.5 535 hard coal , paper pulp

1986 Gaisburg CHP Plant Germany 150 7.3 500 hard coal

1986 Pforzheim CHP Plant Germany 90 14.3 I 2.9 540 I 535 hard coal

1987 Emile Huchet Power Plant France 367 13.413.0 545 I 540 hard coal sludge

1988 Berrenrath Power Plant Germany 2 250 9.0 510 lignite

1989 Goldenberg Power Plant Germany 400 11.5 505 lignite

1991 Wahlitz Power Plant Germany 150 11.5 535 lignite

* 1991 Lublin-Wrotk6w CHP Plant Poland 230 13.5 540 bituminous coal

1992 Gardanne Power Plant France 700 19.3 567 I 565 lignite

1992 Bielsko-Biala II CHP Plant Poland 230 13.8 540 hard coal

1993198 i:eran CHP Plant Poland 2 450 10.0 510 hard coal

1993 Tisova CHP Plant Czech Republic 350 9.4 510 lignite

1993 Polpharma Plant Poland 2 75 4.5 455 hard coal

1994 Mironowska Power Plant Ukraine 260 13.8 540 anthracite

1996 Mlada Boleslav CHP Plant Czech Republic 2 140 12.5 535 hard coal

1998 Red Hills Power Plant USA 2 753 20.3 I 4.0 568 I 540 lignite

1998 CAN Power Plant Turkey 2 462 17.5 I 3.8 543 I 542 lign1te

1998 Siersza Power Plant Poland 2 425 16.1 I 4.0 560 I 560 hard coal

Boilers designed and manufactured by RAFAKO SA are outlined in bold characters.

* design and workshop documentation - RAFAKO SA

9

CIRCULATING FLUIDIZED BED BOILERS

RAFAKO S.A. and Alstom Power reference list Circulating fluidized bed boilers

Boiler Live/reheated Live/reheated

Ordered 1n Plant name Country Number capacity steam pressure steam Fuel of boilers t/h MPa temperature °C .,

1985 Wachtberg Power Plant Germany 175 17.8 I 3.8 530 I 425 lignite

1985 Kohler CHP Plant Germany 100 10.5 535 hard coal, paper pulp

1986 Gaisburg CHP Plant Germany 150 7.3 500 hard coal

1986 Pforzheim CHP Plant Germany 90 14.3 I 2.9 540 I 535 hard coal

1987 Emile Huchet Power Plant France 367 13.4 13.0 545 I 540 hard coal sludge

1988 Berrenrath Power Plant Germany 2 250 9.0 510 lignite

1989 Goldenberg Power Plant Germany 400 11.5 505 lignite

1991 Wahlitz Power Plant Germany 150 11.5 535 lignite

* 1991 Lublin-Wrotk6w CHP Plant Poland 230 13.5 540 bituminous coal

1992 Gardanne Power Plant France 700 19.3 567 I 565 lignite

1992 Bielsko-Biata II CHP Plant Poland 230 13.8 540 hard coal

1993198 Zerari CHP Plant Poland 2 450 10.0 510 hard coal

1993 Tisova CHP Plant Czech Republic 350 9.4 510 lignite

1993 Polpharma Plant Poland 2 75 4.5 455 hard coal

1994 Mironowska Power Plant Ukraine 260 13.8 540 anthracite

1996 Mlada Boleslav CHP Plant Czech Republic 2 140 12.5 535 hard coal

1998 Red Hills Power Plant USA 2 753 20.3 I 4.0 568 I 540 lignite

1998 CAN Power Plant Turkey 2 462 17.513.8 543 I 542 lignite

1998 Siersza Power Plant Poland 2 425 16.1 I 4.0 560 I 560 hard coal

Boilers designed and manufactured by RAFAKO SA are outlined in bold characters.

* design and workshop documentation - RAFAKO SA

9

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Rafako CFBC Boiler.pdf