A Verification On Design Performance of 300MW Class CFB Boiler

KEPRI, Plug-in Future
A Verification on Design Performance

of 300MW Class CFB Boiler
Jae-Sung Kim, Jong-Min Lee, Dong-Won Kim
October 29, 2010
Korea Electric Power Research Institute
1
Contents
1. Introduction of the 300MW class CFB boiler design

2. Steam & design coal conditions
3. Heat and mass balance calculations
4. Calculation results
5. Summary
2
Motivation and Objectives
1. First construction of 340MW Yeosu CFB boiler in Korea

2. Necessity of a verification on the boiler design & performance
3. Evaluation of design & performance characteristics of the CFB boiler
4. Development of heat & mass balance calculation modules
• As a reverse engineering
3
Introduction of the 300MW class

CFB Boiler design
4
Boiler outline
SCR
AH EP
5
Furnace
Plane view
Height : 41,500
Side view Width : 34,010
Depth : 8,138
Bed Depth : 4,069
Cyclone Height(長) : 26,031
Cyclone Height(短): 16,055
Cyclone Diameter : 6,854
Return leg : 561 + 561
Evap. Division wall : 2
Rear view
Total Wing Wall : 31
Evap. WW : 4
SH WW : 27
Cyclone: 4
Return leg: 4
6
Furnace, Division Wall, Wing Wall

34m
8.1m
8.1m
3.5m
Furnace Division Wall
Height : 42m Evaporator
Width : 34m Height : 35m
Depth : 8.1m Depth : 3.5m
2.5m 2.7m Bed Depth : 4.1m Number : 2
42m
35m
Wing Wall Wing Wall
21 Superheater Evaporator
23m
m Height : 21m Height : 23m
Depth : 2.5m Depth : 2.7m
Pitch : 1.1m Pitch : 1.1m
Number : 27 Number : 4
6m
4.1m
7
Cyclone arrangement
34m
8.13m
8.06m
1.37m 1.43m
7.45m 7.45m
8
Cyclone specification 7446
1825
12901
2600
1210 16055
2808
30845
4828
R3382
2808
60˚
2704 2600
3224 10401
4100
9
Distributor
Fluidized bed
34m
4.1m
Ash Drain
Grid Nozzle Arrangement Grid Nozzle
180mm
Φ42.2mm
124.8mm
100mm
124.8mm
ⅹ95 ⅹ95
176mm
ⅹ32 ⅹ31
10
Return Leg 7446
561 561 30845
40˚ 10401
4100
11
Furnace model
12
Steam & design coal conditions
13
Water/steam circuitry In Furnace
358.2 366.1 368.8 376.4 385.8 453.0
184.9 184.6 182.9 178.6 174.9 172.9

T(℃)
541.0
P(kg/cm2g)
171.5
358.3
187.5
Cyclone Crossover Convection SH Ⅰ WW WW

duct cage SHⅡ SHⅢ
Drum
RH Ⅰ 308.5
32.33
Economizer Ⅱ RHⅡ 419.5

541.0
Furnace Walls 30.87
(Division Wall 30.26
256.3
Evaporator)
190.4
Economizer Ⅰ
229.1
303.6
191.3
187.5 HP-Heaters
Feed Water Pump
Feed tank
14
Steam conditions
Steam condition BMCR MGR NR 75%MGR 50%MGR 30%MGR
SH outlet steam flow

1,025 1,025 1,005.3 884.1 672.2 499.8
1,000kg/hr
SH outlet steam
541 541 541 541 541 541
temperature, ℃
SH outlet steam pressure,

171.5 171 171 169 167.3 166.3
kg/cm2g
RH outlet steam flow

821.5 800.3 799.8 592.5 412.2 263
1,000kg/hr
RH outlet steam
541 541 541 541 532 526
Temperature, ℃
RH steam pressure
33 32.2 32.2 23.6 16.1 9.9
kg/cm2g
Final Feedwater
229.1 228.3 228.2 212.5 194.6 174.2
temperature, ℃
15
Design coal analysis

Ultimate Analysis
Design Coal
(Air Dry Basis)
Carbon(%,wt) 69.8 TGA
Hydrogen(%,wt) 4.9
Nitrogen(%,wt) 1.0
Sulfur(%,wt) 0.3
1.0
Subbituminous
0.9 Bituminous
Oxygen(%,wt) 21.0
Anthracite
0.8 Design Coal
Ash(%,wt) 3.0
0.7
0.6
Proximate Analysis Design Range
M/Mo
0.5
(Air dry Basis) Coal Coal

0.4
0.3
Moisture(%,wt) 15.3 22.0 0.2
0.1
Volatile matter(%,wt) 40.5 17.0 0.0

0 200 400 600 800 1000
Fixed Carbon(%,wt) 41.7 67.3

o
Temperature( C)
Ash(%,wt) 2.5 1.6~18.7
16
Schematic diagram of supplied fuel & air
Fluidizing
Limestone silo Air Blowers
Primary
Air Fans
Coal silo Coal silo

A B
×4
×3 Upper lever SA
×3 22 nozzles
Lower level SA
Secondary
Bed 26 nozzles
Air Fans
Material
Make up
17
Conditions of supplied fuel & air
BMCR MGR 75%MGR 50%MGR 30%MGR
Coal
162 159 139 108 83
(t/h)
Limestone
5.58 5.43 4.53 2.71 2.75
(t/h)
Excess air 1.2 1.2 1.2 1.3 2
Primary air
704 695 607 608 604
(t/h)
Secondary air
564 554 482 313 480
(t/h)
2ndary air
0.44 0.44 0.44 0.34 0.44
ratio
18
Heat and mass balance

calculations
19
Methods of heat and mass balance calculation
 Combustion calculations
 Selection of calculations conditions
 Basic equation of heat balance
 Calculation of enthalpy of gas phase
 Input and Output in a furnace
 Heat balance equations in a furnace
 Calculation of flue gas temperature
20
Flue gas composition
BMCR NR MGR 75%MGR 50%MGR 30%MGR
Excess air(%) 20 20 20 20 30 100
CO2(volume %) 14.35 14.35 14.35 14.35 13.32 8.95
O2(volume %) 3.12 3.12 3.12 3.12 4.35 9.72
N2(volume %) 70.69 70.69 70.69 70.69 71.22 73.40
SO2(volume %) 0.0245 0.0245 0.0245 0.0245 0.0228 0.0153
H2O(volume %) 11.84 11.84 11.84 11.84 11.11 7.93
21
Selections of calculation conditions
Item unit Symbol On literature Selection
Excess air - αfu 1.1~1.2 1.2
Primary air ratio % x 50~75 56
Dense zone combustion rate - δ 0.75~0.85 0.75
Chemical incomplete
% q3 0~1 0.5
combustion loss
Unburned carbon loss % q4 2~6 6
Carbon contents of fly ash % Cf,a <10 8
王敦恩 et al., “工业锅炉设计计算方法”, 中国标准出版社, 2005

22
Basic equation of heat balance
 Simple heat balance equation

Qabs  Qin  Qout
 Determination of control volume

 Every heat exchanger had a control volume except of a furnace
 Furnace was divided into a dense zone and a dilute zone
Qabs (Total heat absorbed in a control volume)
Control Qout
Qin
(Total heat input) Volume (Enthalpy of flue gases
leaving the control volume)
Prabir Basu, Cen Kefa, Louis Jestin, “Boiler and Burners”, Springer-Verlag New York, 2000
23
Calculation of enthalpy of gas phase
 Enthalpy calculation of gas phase

 Enthalpy of flue gas or supplied air
N
mi

T
I gas
i 1 mtotal

T0
C p ,i dT
 Polynomial expression of Specific heat

Gas species a b c d
(1) CO2 22.26 0.05981 -0.00003501 7.469E-09
C p  a  bT  cT  dT 2 3
(2) H2O 32.24 0.001923 0.00001055 -3.595E-09
(3) SO2 25.78 0.05795 -0.00003182 8.612E-09
(4) O2 25.48 0.0152 -0.000007155 1.312E-09
(5) Ar 20.92 0.05981 -0.00003501 7.469E-09
(6) N2 28.9 -0.001571 0.000008081 -2.873E-09
(7) CO 28.16 0.001675 0.000005372 -2.222E-09
(8) Air 28.11 0.001967 0.000004802 -1.966E-09
Yunus A. Cengel and Michael A. Boles, “Thermodynamics - An Engineering Approach, Fifth Edition in SI Unit”, McGraw-Hill, 2006
24
Input and Output in a furnace
Heat absorbed in dilute zone(Qw)

Recycled solid, Dilute zone
Flue gas
Enthalpy of flue gas and solid(Ife)
2ndary air Sensible heat of 2ndary air(1-x)αIai
Recycled solid,
Flue gas of Dense phase Enthalpy of gas & solid leaving the dense zone(Ido)
Heat absorbed in dense zone(Qm)
Fuel, Recycled solid Total heat input(Qi)

,Primary air Sensible heat of primary air(xαIai)
Dense Enthalpy of recycled solid(Irs)
zone
程乐鸣, 岑可法, 倪明江, 骆仲泱, “循环流化床锅炉炉膛热力计算”,中国电机工程学报, Vol.22 No.12 Dec. 2002

25
Heat balance equations in a furnace
Heat absorbed in dilute zone(Qw) Qw  Qdilute  I fe

Dilute zone
Enthalpy of flue gas and solid(Ife)
Sensible heat of 2ndary air(1-x)αfuIai Heat input into Dilute zone(Qdilute)
Qdilute  I do  Qi (1   )  (1  x) fu I air
Enthalpy of gas & solid leaving the dense zone(Ido)
Heat absorbed in dense zone(Qm) Qm  Qdense  I do
Heat input into Dense zone(Qdense)

Total heat input(Qi)
Sensible heat of primary air(xαIai)
Qdense   Qi  x fu I air  I rs
Dense Enthalpy of recycled solid(Irs)
zone
程乐鸣, 岑可法, 倪明江, 骆仲泱, “循环流化床锅炉炉膛热力计算”,中国电机工程学报, Vol.22 No.12 Dec. 2002

26
Calculation of exit gas temperature
• Assumption of exit gas temperature
• Heat transfer calculation

– Difference between heat input and output
• Calculation of temperature
– with polynomial expression of specific
heat
• Iteration until the same of previous

exit gas temperature
27
Results
 Furnace
 Wing Wall Superheater
 Cyclone, Cross over duct, Convection cage
 Backpass – Reheater , Primary Superheater
 Backpass – Economizer
28
Furnace heat & mass balance

 Separation between Dense zone and Dilute zone
 Assumption of combustion rate, unburned carbon, heat transfer
Dilute Zone
INPUT
Dense Zone
Sensible heat of dense zone exit gas [kW] 628852
INPUT
Heating value of coal [kW] 389123
Heating value of coal [kW] 583685
Sensible heat of 2ndary air [kW] 42744
Sensible heat of coal [kW] 1728
Total heat input [kW] 1060719
Sensible heat of primary air [kW] 50232
OUTPUT
Total heat input [kW] 635645
Moisture heat loss in 2ndary air [kW] 3961
OUTPUT
Chemical incomplete combustion loss [kW] 2280
Unburned carbon loss [kW] 1206
Heat transfer [kW] 595000
Sensible heat of ash [kW] 533
Sensible heat of flue gas [kW] 459477
Moisture heat loss [kW] 5054
Total heat output [kW] 1060719
Sensible heat of
dense zone exit gas [kW] 628852
Total heat output [kW] 635645 Furnace exit gas temperature [℃] 871
29
Wing wall superheater

Furnace(Wing Wall) Secondary Superheater
Inlet gas temperature ℃ 871 Operation condition

Out gas temperature ℃ 871 Operation condition
Flue gas flow rate Nm3/h 2,494 Imported(Proximate)
Inlet steam temperature ℃ 386 Operation condition
Enthalpy of inlet steam kJ/kg 2,851 Steam Table
Outlet steam temperature ℃ 471 Operation condition
Enthalpy of outlet steam kJ/kg 3,193 Steam Table
Steam flow rate kg/h 1,025,000 Operation condition
Heat duty in secondary superheater kJ/h 350,750,366
Furnace(Wing Wall) Final Superheater

Flue gas flow rate Nm3/h 1,127,870 Imported(Proximate)
Heat duty in final superheater kJ/h 277,178,818
30
Cyclone, Cross Over Duct, Convection Cage
Cyclone
Heat duty in cyclone kJ/h 77,914,450
Cross over duct

Out gas temperautre ℃ 825 Operation condition
Heat duty in COD superheater kJ/h 22,847,510
Convection cage
Heat duty in CC kJ/h 54,876,047
31
Backpass - RH, SH
Final Reheater
Steam flow rate kg/h 821,500 Operation condition
Heat duty in final Reheater kJ/h 322,858,983
Primary Reheater
Steam flow rate kg/h 821,500
Heat duty in primary reheater kJ/h 326,281,726
Primary Superheater
Flue gas flow rate Nm3/h 3,016 Imported(Proximate)
Steam flow rate kg/h 1,025,000
Heat duty in primary superheater kJ/h 35,971,046
32
Backpass - Economizer
Secondary Economizer

Inlet water temperature ℃ 256 Operation condition
Outlet water temperature ℃ 304 Operation condition
Heat duty in Secondary Eco kJ/h 255,875,764
Primary Economizer

Inlet water temperature ℃ 229 Operation condition
Enthalpy of inlet steam kJ/kg 989 Steam Table
Outlet water temperature ℃ 256 Operation condition
Heat duty in Primary Economizer kJ/h 135,505,607
33
Heat calculation results
 Heat duty
 Heat transfer
 Comparison of temperature between design value and calculation
34
Heat duty and Heat transfer calculations

 Heat duty calculation from steam condition
 Using an overall heat transfer coefficient(U) with Log Mean
Temperature Difference(∆LMTD)
 Q=UA∆LMTD
2ry Final Cross Convectio Final Primary Primary Primary

Unit furnace cyclone 2ry Eco
SH SH over duct n cage RH RH SH Eco
Inlet gas temperature ℃ 871 871 871 871 853 825 777 642 513 450 344
Outlet gas temperature ℃ 871 871 871 853 825 777 642 513 450 344 269
Inlet water/steam temp. ℃ 303 386 453 358 366 369 420 309 376 256 229
Enthalpy kJ/kg 1352 2851 3133 2642 2718 2741 3273 3010 2794 1116 989
Outlet water/steam temp. ℃ 358 471 541 366 369 376 541 420 392 304 256
Enthalpy kJ/kg 2642 3193 3403 2718 2741 2794 3547 3273 2883 1355 1115
LMTD ℃ 541 443 374 500 471 428 203 188 92 98 47
Heat duty kW 367399 97431 76994 21643 6347 15243 62485 60211 25144 68218 35980
Heat absorbtion GJ/h 1160 368 292 148 38 85 234 229 103 184 127
Heat absorbtion Gcal/h 278 88 70 35 9 20 56 55 25 44 31
Heat absorbtion rate kcal/m2h 58753 61917 53722 17147 9515 20228 10708 9145 4931 6778 3489
Calculated area m2 4723 1423 1301 2059 956 1004 5230 5992 4989 6477 8742
Heat transfer coefficient W/m2K 144 155 158 21 14 36 59 53 55 108 88
35
Heat duty and Heat transfer
400
180 Heat transfer
Heat Duty(MW) coefficient(W/m2K)
160
350
140
300
120
250
100
200
80
150
60
100 40
50 20
0 0
36
Comparison of temperature
Convection
Furnace Furnace Cyclone Final RH Primary RH Primary SH 2ndary Eco. Primary Eco. AH
cage
Calculation 871 855 786 654 520 459 349 270 136
Design value 871 853 777 642 513 450 344 269 141
Δt 0 +2 +9 +12 +7 +9 +5 +1 -5
1000
900
800
700
600
500
Calculation
400 Design value
300
200
100
˚C 0
Furnace Cyclone Convection Final RH Primary RH Primary SH 2ndary Eco. Primary AH
cage Eco.
37
Summary
1. Get the Input conditions from Technical Specification

(Performance & Technical Data) and drawing
2. Establishing Heat balance equation of each control volume
3. Calculating heat and mass balance
4. Acquiring results of heat transfer coefficients, heat duty, exit gas
temperature and so on
38
39

A Verification On Design Performance of 300MW Class CFB Boiler

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KEPRI, Plug-in Future

A Verification on Design Performance

Jae-Sung Kim, Jong-Min Lee, Dong-Won Kim

October 29, 2010

Korea Electric Power Research Institute

1. Introduction of the 300MW class CFB boiler design

Motivation and Objectives

1. First construction of 340MW Yeosu CFB boiler in Korea

Introduction of the 300MW class

Evap. Division wall : 2

Furnace, Division Wall, Wing Wall

Cyclone specification 7446

Grid Nozzle Arrangement Grid Nozzle

Return Leg 7446

561 561 30845

Steam & design coal conditions

Water/steam circuitry In Furnace

358.2 366.1 368.8 376.4 385.8 453.0

184.9 184.6 182.9 178.6 174.9 172.9

Cyclone Crossover Convection SH Ⅰ WW WW

Economizer Ⅱ RHⅡ 419.5

Steam condition BMCR MGR NR 75%MGR 50%MGR 30%MGR

SH outlet steam flow

SH outlet steam pressure,

RH outlet steam flow

Design coal analysis

Proximate Analysis Design Range

(Air dry Basis) Coal Coal

Moisture(%,wt) 15.3 22.0 0.2

Volatile matter(%,wt) 40.5 17.0 0.0

Fixed Carbon(%,wt) 41.7 67.3

Ash(%,wt) 2.5 1.6~18.7

Schematic diagram of supplied fuel & air

Coal silo Coal silo

Conditions of supplied fuel & air

BMCR MGR 75%MGR 50%MGR 30%MGR

Excess air 1.2 1.2 1.2 1.3 2

Heat and mass balance

Methods of heat and mass balance calculation

Flue gas composition

BMCR NR MGR 75%MGR 50%MGR 30%MGR

Excess air(%) 20 20 20 20 30 100

CO2(volume %) 14.35 14.35 14.35 14.35 13.32 8.95

O2(volume %) 3.12 3.12 3.12 3.12 4.35 9.72

N2(volume %) 70.69 70.69 70.69 70.69 71.22 73.40

SO2(volume %) 0.0245 0.0245 0.0245 0.0245 0.0228 0.0153

H2O(volume %) 11.84 11.84 11.84 11.84 11.11 7.93

Selections of calculation conditions

Item unit Symbol On literature Selection

Excess air - αfu 1.1~1.2 1.2

Primary air ratio % x 50~75 56

Dense zone combustion rate - δ 0.75~0.85 0.75

Unburned carbon loss % q4 2~6 6

Carbon contents of fly ash % Cf,a <10 8

王敦恩 et al., “工业锅炉设计计算方法”, 中国标准出版社, 2005

Basic equation of heat balance

 Simple heat balance equation

 Determination of control volume

Qabs (Total heat absorbed in a control volume)

Calculation of enthalpy of gas phase

 Enthalpy calculation of gas phase

 Polynomial expression of Specific heat

Input and Output in a furnace

程乐鸣, 岑可法, 倪明江, 骆仲泱, “循环流化床锅炉炉膛热力计算”,中国电机工程学报, Vol.22 No.12 Dec. 2002

程乐鸣, 岑可法, 倪明江, 骆仲泱, “循环流化床锅炉炉膛热力计算”,中国电机工程学报, Vol.22 No.12 Dec. 2002