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KLY-1 1997-05 P:\582-RAPP-PB3\int\Kayttoonotto\koulutus\Training Manuals\Folder 1\2.9 Flue gas system.doc
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TABLE OF CONTENTS

2.9 FLUE GAS SYSTEM..................................................................................... 2
2.9.1 Purpose of the system................................................................................ 3
2.9.2 General description of the system............................................................. 3
2.9.3 Design criteria.............................................................................................. 6
2.9.4 Equipment specification............................................................................. 7
2.9.4.1 Flue gas fans................................................................................................. 7
2.9.4.2 Electrostatic Precipitator (not in scope) ....................................................... 11
2.9.4.3 Stack ........................................................................................................... 12
2.9.4.4 Recirculation gas nozzles............................................................................ 12

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2.9 FLUE GAS SYSTEM



Flowsheets: T582-00017 Combustion air
T582-00019 Flue gas
T582-00039 Oil lubrication units of the ID
fans
T582-00040 Oil lubrication unit of the
recirculation fan
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2.9.1 Purpose of the system

The purpose of the flue gas system is to:
supply flue gas from the boiler to the stack
control flue gas pressure inside the furnace
control combustion temperature by means of flue gas
recirculation
clean the flue gas from particulates
purge the boiler before starting the combustion

2.9.2 General description of the system

The flue gas system consists of:
furnace
cyclones
second and third pass
flue gas ducts and dampers
electrostatic precipitator (not in scope)
flue gas fans
flue gas recirculation fan
stack (not in scope)


Furnace
The boiler furnace is a combustion chamber where the thermal
energy bound in the fuel is released. The flue gas amount and
properties generated in the combustion process depend on the
fuels used.
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Cyclones
In three parallel cyclones most of particles conveyed with flue
gas from the combustion chamber are separated and returned
back to the furnace.


Second and third pass
The walls of the 2
nd
pass are cooled by superheated steam
flowing in the wall tubes. After plain tube economizer flue gas is
led to third pass where walls are constructed with a plate casing.

In the second and third pass flue gas cools down when it flows
across superheater, economizer and air preheater sections.


Electrostatic precipitator (not in scope)
Fly ash is removed from the flue gas in electrostatic precipitator
(not in scope), which comprises two parallel chambers and three
fields. Both ESP chambers are designed for 60% boiler capacity.
Flue gas ducts before the ESP chambers are equipped with
guillotine dampers.

Dust-laden flue gas from the boiler is sucked by means of a flue
gas fan into the inlet funnel of the electrostatic precipitator and
further to the precipitator casing where dust collection takes
place. The cleaned gas is led from the precipitator casing
through the outlet funnel via the flue gas fan and the flue gas
ducts to the stack.

The collected dust falls down to the precipitator bottom cones
and is led via ash conveyors to the ash silo.
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Flue gas fans
The two parallel operated radial-type induced draft (ID) fans,
located after the electrostatic precipitator, provide the draft
required to keep flue gas pressure in upper part of the furnace at
about -0,1 ... -0,2 kPa. The draft is controlled by the variable
frequency drives of the fans. The ID fans also discharge flue gas
into the stack.


Recirculating gas system
When needed, part of the flue gas can be recirculated after the
ID fans through recirculation flue gas fan to the lower part of the
furnace. Flue gas recirculation system is used to lower
combustion temperature in the furnace and it can also be used
to increase full superheating range. Recirculation flue gas
pressure in controlled by inlet vanes of the fan and flow to
separate sections is adjusted by dampers. Recirculation gas
nozzles are divided into two separately controlled sections.
Recirculation flue gas duct before and after the fan is equipped
with guillotine dampers.

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2.9.3 Design criteria

Flue gas paths, electrostatic precipitators and flue gas fans are
designed to transfer combustion process products in a controlled
way from the furnace to the stack when fired design fuels at
specified boiler operation range.

Both flue gas fans are able to generate required draft up to 60%
boiler load.

Dimensioning basis for ESP at 100% boiler load when both
chambers are in service and design fuels are fired is dust
content of 135 mg/Nm
3
(converted to dry gas @ 7% O
2
) after the
ESP. It is possible also to run 60% boiler load through one ESP
chamber, then dust emission is 150 mg/Nm
3
.

Dimensioning basis for recirculation flue gas fan is to produce
together with fluidizing air fans such a high fluidizing velocity
inside the furnace that combustion temperature during coal firing
remains at an acceptable level.
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2.9.4 Equipment specification

2.9.4.1 Flue gas fans

Flue gas (I.D.) fans
Equipment number 283K002 (1) and 283K003 (2)
Supplier Flkt Woods Oy
Number of fans 2
Model HACP-224-285-cc-d-e
Type radial fan
Control (supplied by RAPP) variable frequency control
Bearings oil lubricated

Motor (supplied by RAPP) kW 1800

Performance at design point
Gas flow / fan Nm
3
/s 122,2
Gas flow / fan m
3
/s 202,4
Inlet density kg/m
3
0,786
Total pressure rise Pa 5900
Inlet temperature C 155
Fan efficiency % 74,2
Impeller power demand kW 1580

Figure 1 shows Flue gas fan curve. Both of the fans are
equipped with an oil lubrication unit.

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Figure 1 Flue Gas Fan Curve
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Recirculation flue gas fan
Equipment number 283K004
Supplier Flkt Woods Oy
Number of fans 1
Model HACP-090-205-cc-d-e
Type radial fan
Control inlet vane control
Bearings oil lubricated

Motor (supplied by RAPP) kW 710

Performance at design point
Gas flow Nm
3
/s 25,1
Gas flow m
3
/s 39,8
Inlet density kg/m
3
0,821
Total pressure rise Pa 12300
Inlet temperature C 155
Fan efficiency % 81,1
Impeller power demand kW 581

Figure 2 shows Recirculation gas fan curve. The fan is equipped
with an oil lubrication unit.
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Figure 2 Recirculation Gas Fan Curve
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2.9.4.2 Electrostatic Precipitator (not in scope)

Equipment numbers 283E071 (1) and 283E072 (2)
Supplier F.L.Smidth Airtech
Suppliers type 1E400/H2P1/3*45-
104125/C/C/6P/6A

Number of precipitators one (1)
Number of parallel chambers two (2)
Number of fields / chamber three (3)

Process design
design flow / chamber 115,6 Nm
3
/s
design flow / chamber 183,6 m
3
/s
flue gas temperature 136 C
flue gas pressure -2000 Pa
O
2
-content 2,82 % vol wet
H
2
O-content 11,86 % vol
SO
2
-content 157 ppm
inlet dust contents (in wet flue gas) 31,0 g/Nm
3
outlet dust content (wet gas; O
2
=3 %) 50 mg/Nm
3
collecting efficiency 99,458 %

The mechanical operating range of the precipitator
the maximum flue gas temperature 200 C
static pressure max / min +6 / - 6 kPa

Pressure drop between the inlet and the outlet
flanges at boiler MCR load with 2 chambers <260 Pa

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-
stainless steel AISI316
2.9.4.4 Recirculation gas nozzles
AVESTA 253 MA
enings
16
eight from furnace bottom mm 500

Nozzles inclined 10 downwards


2.9.4.3 Stack

Equipment number 283E122
Delivery by the Purchaser (Kvaerner design)
Height 100 m
Inner liner diameter 4100 mm
- made of 5 mm Cor-Ten B steel
upper 5 m made of 4 mm



Material
Number of op
front wall pcs 12
rear wall pcs 12
Diameter of openigs mm 8,3
H