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U-Beams
High combustion efciency A compact, economical design Higher reliability and availability Lower maintenance costs Reduced erosion Fuel exibility Low emissions
Coal Silo
Furnace
Capacity: To 1,500,000 lb/h (189 kg/s) or greater as required Steam pressure: To 2850 psig (19.7 MPa) design
Tubular Air Heater
Startup Burner
Secondary Air
Primary Air
captures the ner material that passes through the U-beam particle separator and returns this material to the lower furnace in a controlled manner. The ability to regulate the secondary recycle system provides the operator with unprecedented furnace temperature control, resulting in improved boiler performance and load response.
The two-stage particle collection system of B&Ws IR-CFB provides improved performance, as well as a simplied, cost-effective boiler design.
Bed Drain
B&Ws two-stage particle separation system results in a compact, simplied boiler arrangement. The entire U-beam particle separator is located at the furnace exit. Compared with hot cyclone-type CFB designs, the IR-CFB has signicantly lower furnace exit gas velocity and requires signicantly less building volume. By relying on internal recirculation, the IR-CFB design eliminates J-valves, loop seals, and high-pressure blowers which are required with other CFB designs. For the IR-CFB, compact and simple equals economical.
U-Beam
Gas Flow
B&Ws U-beam primary particle collection system recirculates more than 97% of the solids suspended in the ue gas back to the lower furnace.
Wall Tubes
Ceramic Tile
Thin Refractory
The reduced diameter zone tube section has proven to reduce maintenance by eliminating localized erosion at the refractory interface in the lower furnace.
B&Ws patented reduced diameter zone (RDZ) tube section is another feature designed to reduce maintenance. The RDZ consists of a reduced diameter tube section mating to a specially-shaped ceramic tile. The reduced diameter tube section on each tube slopes away from the solids falling down the wall. This eliminates the solids material from building up and eroding the furnace tubes where the lower furnace refractory ends.
The secondary multi-cyclone dust collector in B&Ws unique two-stage particle separation system provides increased collection efciency of ne particles. By locating the dust collector immediately upstream of the economizer in a region of cooler ue gas, and by using high hardness wear resistant material, maintenance is minimal. The design also permits easy access to all internal components.
Greater than 99.8% particle collection efciency Provides a means to control particle size distribution in furnace, which results in improved carbon burnout, limestone utilization, emissions and heat transfer Reduces operating costs
Compact design requires 20-30% less building volume than cyclone-based CFB boilers critical for repowering projects Lowers auxiliary power consumption compared with cyclone-based CFB boilers
Low, uniform velocities at the furnace exit (16-20 ft/s, 5-6 m/s), U-beam separators (26 ft/s, 8 m/s), and the superheater (25-30 ft/s, 8-9 m/s)
Signicantly reduces erosion in upper furnace and superheater compared with cyclone designs To date, no U-beam erosion maintenance required in B&Ws coal-red CFBs since going into operation in 1989 No high-maintenance vortex nders or hot expansion joints; therefore, no maintenance expenses for these items
No thick refractory due to elimination of hot cyclones and hot return legs
Thin, cooled refractory used by B&W places no restriction on boiler start-up or shut-down rate Signicantly reduces need for refractory maintenance Virtually eliminates forced outages due to refractory failures Requires only 10 to 25% of the total refractory compared with hot cyclone CFB designs
Vertical, at membraned tube panels within furnace perform evaporative or superheat duty Proven reliability and low maintenance
Reduces back sifting of solids during low-load operation Reduces need for periodic cleaning of nozzles and primary air windbox Minimizes erosion inside nozzle caused by the re-entrainment of back-sifted solids
Eliminates maintenance costs and forced outages typically associated with sootblowers
Reduces maintenance, forced outages and auxiliary power requirements by eliminating the mechanical fuel injection and pneumatic y ash recycle systems
Allows wider load swings Reduces operating costs (no auxiliary fuel) during low-load operation
Bituminous coal Bituminous gob or high-ash waste coal Subbituminous coal Lignite and brown coal Anthracite culm Coal cleaning tailings Petroleum coke
Other fuels such as wood, biomass, shredded tires and sludge are also candidates, depending on their percentage of heat input, moisture content and emission requirements. The IR-CFB boiler also can be designed to burn several specied fuels in the same unit. This provides the additional exibility needed to respond to changes in the fuel markets.
Located in Ebensburg, Pennsylvania, USA, this 60 MW power plant burns high-ash waste coal with B&Ws circulating uidized-bed (CFB) technology to produce electricity and process steam.
Emissions Control
The IR-CFB boiler can control SO2 emissions by injecting limestone into the lower furnace. Relatively low NOx emissions are inherent in the IR-CFB due to low furnace temperatures and staged combustion. NOx emissions can be further reduced by using a selective non-catalytic reduction (SNCR) system. In addition, the IR-CFBs patented secondary particle recycle system provides increased control, not found in other CFB technologies, to maintain an optimum uniform furnace temperature which is essential for low SO2 and NOx emissions.
The Babcock & Wilcox Company were the original. Weve been generating powerful solutions in the design, construction and service of steam generating systems since 1867. So put our experience and capabilities to work for you today. Insist on us by name. For more information, or a complete listing of our sales and service offices, call 1-800-BABCOCK (222-2625), send an e-mail to info@babcock.com, or access our Web site at www.babcock.com. The Babcock & Wilcox Company 20 S. Van Buren Avenue Barberton, Ohio, USA 44203 Phone: (330) 753-4511 Fax: (330) 860 -1886 Babcock & Wilcox Canada Ltd. 581 Coronation Boulevard Cambridge, Ontario, Canada N1R 5V3 Phone: (519) 621-2130 Fax: (519) 621-9681
Through our experience, expertise and total-scope services, B&W is dedicated to generating powerful solutions in an environmentally safe, efcient and economical manner.
The information contained herein is provided for general information purposes only and is not intended or to be construed as a warranty, an offer, or any representation of contractual or other legal responsibility. Generating Powerful Solutions is a service mark of The Babcock & Wilcox Company. 2006 The Babcock & Wilcox Company. All rights reserved. A McDermott company. E101-3148A 4MR6H
B&Ws Internal Recirculation Circulating Fluidized-Bed boiler is the technology of choice for power plant owners seeking economy, reliability and exibility.