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F. Belin
M. Maryamchik
D.J. Walker
D.L. Wietzke
The Babcock & Wilcox Company
Barberton, Ohio, U.S.A.
Over the same period, the design of the MDC separator has Fig. 3 Multicyclone dust collector.
been improved for better efficiency, reliability and maintain-
ability. The current design (Figure 3) has a top gas inlet and a sis for all new offerings including the most recent contract for a
side gas outlet. The cyclone elements have 9 in. (229 mm) di- 90 MWe IR-CFB in Tychy, Poland.
ameter regardless of boiler capacity. The cyclone sleeves and Operating experience of B&W coal-fired CFB boilers has
spin vanes are made of high hardness (550 BHN) material. The clearly confirmed their efficient performance and high reliability.
MDC solids recycle system has evolved from dense-phase pneu-
matic transport (first generation) to dilute-phase pneumatic
transport (second generation) to gravity conveying (third gen- Design Features
eration). The design of a solids separator is the core of a CFB com-
The second-generation CFB boiler at Ebensburg, Pennsyl- bustion technology since it has major impact on the boiler lay-
vania, in a cogeneration plant commissioned in early 1991, ex- out, cost, fuel and sorbent utilization, operational flexibility and
emplifies the long-term boiler performance. This boiler (Figure reliability. In all these aspects B&W’s CFB boilers with the two-
4) burns high-ash (average 45% ash) Western Pennylvania waste stage solids separation provide the following design features:
bituminous coal. The unit was designed for 55 MWe capacity
(211 tph steam flow), but was uprated in 1995 and again in a) High solids collection efficiency
1997 and since has been operated at 10% overload. Boiler per- The collection efficiency of the two-stage solids separator is
formance and availability are shown in Table 1 and Figure 5 intrinsically high due to the greater efficiency of the MDC in-
respectively. The Ebensburg plant received the Association of ternal collection elements. Higher solids collection efficiency
Independent Power Producers of Pennsylvania (ARIPPA) award helps to achieve greater inventory of fine circulating particles
for the highest availability among plants firing coal mine waste in the furnace that provides: a) higher furnace heat transfer rate,
fuels. b) ability to better control furnace temperature, and c) better
The CFB boiler at Southern Illinois University (SIU) in carbon and sorbent utilization due to the increased residence
Carbondale, Illinois, represents the third generation design. The time of fine particles.
boiler (Figure 6) was designed for 35 MWt output for cogen-
eration application, utilizing high-sulfur Illinois bituminous coal.
Boiler performance and availability are shown in Table 2 and
Figure 7, respectively. The third generation design was also used
for the Kanoria Chemical project in India and is the design ba-
Furnace Roof
Gas Flow
In -Furnace
U-Beams
External
In -Furnace U-Beams
U-Beams
Solids
External U-Beams Transfer
Hopper
Solids Transfer Hopper
Furnace
Fig. 2 IR-CFB primary particle collection system. Fig. 4 Ebensburg CFB boiler.
Emissions
NOx, ppm (lb/106 Btu) <100 (<0.14)
SO2, ppm (lb/106 Btu) <300 (<0.60)
CO, ppm (lb/106 Btu) <230 (<0.20)
80
0
1991 1992 1993 1994 1995 1996 1997 1998 1999 2000
(May-Dec.) (Jan.-July) (Jan.-June)
Boiler Availability, %
10.7
Load Turndown Ratio Without Auxiliary Fuel 5:1 85 89.0 89.7 87.9
Emissions 80
NOx, ppm (lb/106 Btu) <100 (<0.14)
SO2, % removal 90 85
CO, ppm (lb/10 6 Btu) <200 (<0.17)
1997 1998 1999 2000
(Jul 15-Dec 31) (Jan-Jun)
Ca/S Molar Ratio 2.3
Fig. 7 SIU boiler availability.
e) High solids separator reliability vided to accommodate possible U-beam temperature deviations
U-beams and MDC have high reliability and low mainte- from the expected value based on average gas temperature leav-
nance since they do not include any maintenance-intensive com- ing the furnace. These margins eliminate the possibility of the
ponents such as refractory, loop-seals, expansion joints, vortex U-beams being damaged during operational upsets.
finders, etc. The U-beam design that has evolved through 15 Mechanical conditions of U-beams along with related boiler
years of operating experience has proven to be very reliable, thermal performance data have been monitored over the 10 years
requiring no maintenance. U-beam design criteria includes con- of operation at the Ebensburg CFB boiler. B&W confirmed that
servative assumptions of 25 year life of U-beam materials and erosion losses were negligible due to a tough, erosion-resistant
supports. The MDC internals require some maintenance during film formed on the surface of the U-beams. B&W also deter-
planned shutdowns; this expense has been minimal on the oper- mined that the material was resistant to corrosion and deforma-
ating B&W CFBs. tion when operated within the design margins.
The Ebensburg CFB boiler capacity was increased by 10%
f) Integral design/small footprint over original design. For evaluated economic reasons no other
The U-beam separator is integral with the boiler enclosure changes to the boiler were made to maintain the design tem-
providing for the most compact and cost-efficient boiler layout perature and excess air at the furnace exit. This resulted in more
similar to the conventional two-pass pulverized coal (PC) boiler. than three years of operation with local U-beam temperatures
This feature is especially important for retrofitting outdated PC approaching or exceeding the design margins.
boilers with CFB technology in repowering applications where After this three year period of operation with excessively
keeping the existing boiler “footprint” is highly desirable. high temperatures, signs of U-beam mechanical degradation
began appearing where the maximum temperatures or maximum
g) Minimal refractory use solids loading occur. Some U-beam channels began to flare, and
The amount of refractory used in the B&W CFB boilers is the mid-sections of several U-beams rotated up to 10 degrees
80-90% less than that used for similar capacity CFB boilers with from the original position. Also, several corrosion spots were
non-cooled hot cyclones and 40-50% less than CFB boilers with
found near the bottom of the rear-most rows of U-beams where
cooled cyclones. For B&W CFB boilers the start-up time is not
U-beams were covered with ash deposits. The current design
limited by rate of temperature rise of the refractory.
has been changed to avoid these degradations even during pro-
Two key areas important for design evaluation of CFB boil-
longed high-temperature operation.
ers with impact separators are high reliability of the two-stage
Regardless of some U-beam deformation observed as a re-
solids separator and its superior collection efficiency. The long-
sult of the off-design operating conditions, no deterioration of
term operating experience and test data provide the definite af-
boiler performance was detected and no U-beams have had to
firmation of the impact separator plus MDC design as described
in the following section. be replaced. Maintenance work on U-beams has been minimal,
consisting primarily of cleaning solids accumulated on the top
side of the alignment pans located near the bottom of U-beams,
Two-stage solids separator experience and an occasional repair of the pan and strap attachment welds.
The resilience of U-beams to operating conditions associ-
Reliability ated with excessive temperatures and increased gas velocities
U-beam experience. U-beams are conservatively designed contrasts to that of vortex finders (a part of hot-cyclones) which
to operate in the flue gas environment at the exit of the CFB are made of similar materials and exposed to a similar gas/sol-
furnace. B&W has selected U-beam materials–typically high ids environment.
nickel, high chromium, austenitic stainless steels–to resist ero- Vortex finder failures have been reported with a substantial
sion and corrosion while possessing adequate long-term strength detrimental effect on boiler performance and considerable main-
at the design temperatures. Substantial design margins are pro- tenance costs.
Collection Efficiency, % 90
80
70
60
20 40 60 80 100
Particle Size, micron
Fig. 8 Fractional collection efficiency of MDC (IR-CFB at SIU).
Fuel is fed to the lower furnace through the front wall using
four air-assisted chutes. Limestone is injected pneumatically
through multiple points uniformly across the width of the fur-
nace near the bottom. Start-up fuel (light oil) is fired using five
burners mounted at the rear wall.
Separate fans supply primary and secondary air. Primary air
is introduced through the bubble cap grid at the furnace floor
with secondary air introduced uniformly across the furnace width
using nozzles at the front and rear walls sized to provide air Fig. 10 Tychy IR-CFB boiler.
distribution across the furnace.
The lower furnace is protected from erosion and corrosive falling down the wall along the surface profile of the tube panel,
conditions by a layer of low-cement, high-strength refractory. thereby eliminating the discontinuity adjacent to the tube. The
This material has proven to require little maintenance in the RDZ feature is applicable for enclosure walls and internal walls,
lower CFB furnace environment. The membrane tubes at the and has been proven effective in B&W CFB boiler commercial
upper edge of the refractory in the lower furnace are protected operation.
from erosion by the patented Reduced Diameter Zone (RDZ) The U-beam separator consists of two rows of in-furnace
(Figure 11). The RDZ consists of a reduced diameter tube sec- and three rows of external U-beams. Pendant superheater banks
tion mating to a specially shaped ceramic tile. The reduced di- are located downstream of the U-beams in the horizontal con-
ameter tube section on each tube slopes away from the solids vection pass. Steam from the drum flows through the side walls
of the pendant superheater enclosure, then through the primary
100
superheater bank followed by the wing walls and the secondary
superheater bank to the main steam outlet.
The MDC is located immediately downstream of the hori-
80 zontal convection pass. Further in the gas path it is followed by
Percent Passing
60
Furnace Wall
40 (inside)
20
Fig. 9 Particle size distribution of fly ash for hot cyclones and
two-stage separation system. Fig. 11 Reduced Diameter Zone.
Fig. 12 Size comparison of PC boiler firing anthracite culm and its repowering CFB boiler.
Fig. 13 Size comparison of PC boiler firing lignite and bituminous coal and its repowering CFB boiler.
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