A REPORT ON CFBC BOILER

ABSTRACT improved sulfur capture. Circulating Fluidized Bed (CFB) boilers are widely used for multi-fuel combustion of waste BOILER INTRODUCTION and bio-fuels. When several non-homogeneous fuels, having varying heat values, are burned Simultaneously, the boiler control system can WHAT IS A BOILER? be affected by various control challenges, According to Indian Boiler Regulation a boiler especially since it is not feasible to reliably is a closed pressure vessel with capacity exceeding measure the energy content of the multi-fuel 22.75 liters used for generating steam under pressure. It flow. In order to fulfill energy production needs includes all the mountings fitted to such vessels which and maintain the ability to burn low grade remain wholly or partly under pressure when steam is fuels, co-firing with high heat value fuels such shut-off. as gas, oil or coal is needed. According to the It is a closed vessel in which industrial experiments, the four applications the heat produced by the combustion (steam pressure control, Compensation of fuel of fuel is transferred to water for its quality fluctuation, fuel-feed optimization and conversion into steam at the desired increased bed inventory monitoring) discussed temperature and pressure. in this thesis, showed satisfactory Broadly speaking a boiler is a device used for performance and various improvements to the generating, boiler control were achieved. (A) steam for power generation (B) hot water for heating purpose. KEY WORDS: multi-fuel combustion, steam pressure control, optimization. WHAT IS BOILER ACCORDING TO I.B.R? According to Indian Boiler Regulation a boiler INTRODUCTION is a closed pressure vessel with capacity exceeding In a circulating fluidized-bed boiler, a portion of 22.75 liters used for generating steam under pressure. It air is introduced through the bottom of the bed. The bed includes all the mountings fitted to such vessels which material normally consists of fuel, limestone and ash. The remain wholly or partly under pressure when steam is bottom of the bed is supported by water-cooled shut-off. membrane walls with specially designed air nozzles which distributes the air uniformly. The fuel and WHAT IS THE DIFFERENCE BETWEEN limestone (for sulfur capture) are fed into the lower bed. A STEAM BOILER AND STEAM In the presence of fluidizing air, the fuel and limestone GENERATIOR? quickly and uniformly mix under the turbulent Technically speaking a steam boiler consists environment and behave like a fluid. Carbon particles in only of the containing vessel and convection heating the fuel are exposed to the combustion air. The balance of surfaces. While steam generator covers the whole unit combustion air is introduced at the top of the lower, encompassing water wall tubes, superheater, air heaters dense bed. This staged combustion limits the formation and economizer. of nitrogen oxides (NOx). The bed fluidizing air velocity is greater than the CLASIFICATION OF BOILER:terminal velocity of most of the particles in the bed and The boilers may be classified as under. thus fluidizing air elutriates the particles through the 1.Horizonatal, Vertical or Inclined boilers. combustion chamber to the U-beam separators at the a. Horizontal boiler: If the axis of the boiler is furnace exit. The captured solids, including any unburned Horizontal, it is called horizontal boiler. carbon and unutilized carbon oxide (CaO), are re-injected Ex. Lancashire & locomotive boilers. directly back into the combustion chamber without Passing through an external recirculation. This internal

solids circulation provides longer residence time for fuel and limestone, resulting in good combustion and b. Vertical boiler: If the axis of the boiler is vertical, it is called vertical boiler. Ex. Cochran boiler c. Inclined boiler: If the axis of the boiler is inclined, it is called inclined boiler. 2.Fire tube and Water tube boilers: a. Fire tube boiler: The boiler in which hot gases are inside the tubes and water is Surrounding the tubes is called fire tube boiler. Ex.cocharan, Lancashire and locomotive. b. Water tube boiler: The boiler in which water is inside the tubes and hot gases are surrounding the tubes is called fire tube boiler. Ex. Babcock and Wilcox boiler, stirling boiler. 3. External fired and Internal fired boiler: a. Externally fired boiler: In the boiler if the fire is outside the shell, that boiler is known as externally fired boiler. Ex. Babcock and Wilcox boiler b.Internally fired boiler: In the boiler in which the furnace is located inside the boiler shell is known as internally fired boiler. Ex. Cochran and Lancashire. 4.Forced circulation and Natural circulatation boiler: a. Forced circulation boiler: If the circulation of water is done by the pump than the boiler is known as forced circulation boiler. Ex. Velox and Lamount and Benson boiler. b.Natural circulation boiler: If the circulation of the water takes place due to difference in density resulting from the difference in temperature, it is known as natural circulation boiler. Ex. Lancashire, Babcock and Wilcox boiler. 5.High pressure, Medium pressure and low pressure boiler: a. High pressure boiler: It is the boiler whose working pressure is more than 25bar. Ex.babcock and Wilcox boiler. b.Low pressure boiler: It is the boiler whose working pressure is between 3.5bar to 10bar. Ex.cochran and Cornish boiler.

c. Medium pressure boiler: It is the boiler whose working pressure is between 10 to 25bar. Ex.lancashiere and locomotive boiler. 6. Stationary boiler and Portable boiler: a. Stationary boiler: Boiler which can not be transported from one other place is called stationary boiler. Ex.Lancashire, babcock and Wilcox boiler. b. Portable boiler: The boiler which can be easily transported from one place to another is called portable boiler. Ex. Locomotive boiler. Ex. Cornish boiler. b. Multitube boiler: The boiler having a two or more fire or water tubes for the circulation of hot gases or water is called multitube boiler. Ex. Lancashire and locomotive boiler. MECHANISUM OF FLUIDIZED BED COMBUSTION: When an evenly distributed air or gas is passed upward through finely divided bed of solid particle such as sand supported on a fine mesh, the particles are undistributed at low velocity. As air velocity is gradually increased, a stage is reached when the individual particles are suspended in the air steam the bed is called Fluidized. With further increase in air velocity, there is bubble formation vigorous turbulence, rapid mixing and formation of dense defined bed surface. The bed of solid particles exhibits the properties of a boiling liquid and assumes the appearance of a fluid bubbling fluidized bed. At higher velocities bubbles disappear and particles are blown out of the bed. Therefore some amounts of particles have to recirculation to maintain a stable system circulating Fluidized bed. This principle of fluidized is illustrate in fig.

 CIRCULATING FLUIDIZED BED COMBUSTION SYSTEM: In a circulating fluidized-bed boiler, a portion of air is introduced through the bottom of the bed. The bed material normally consists of fuel, limestone and ash. The bottom of the bed is supported by water-cooled membrane walls with specially designed air nozzles which distributes the air uniformly. The fuel and limestone (for sulfur capture) are fed into the lower bed. In the presence of fluidizing air, the fuel and limestone quickly and uniformly mix under the turbulent environment and behave like a fluid. Carbon particles in the fuel are exposed to the combustion air. The balance of combustion air is introduced at the top of the lower, dense bed. This staged combustion limits the formation of nitrogen oxides (NOx). The bed fluidizing air velocity is greater than the terminal velocity of most of the particles in the bed and thus fluidizing air elutriates the particles through the combustion chamber to the U-beam separators at the furnace exit. The captured solids, including any unburned carbon and unutilized carbon oxide (CaO), are re-injected directly back into the combustion chamber without passing through an external recirculation. This internal solids circulation provides longer residence time for fuel and limestone, resulting in good combustion and improved sulfur capture. ADVANTAGES OF FLUIDIZED BED COMBUSTION BOILER: Ability to burn fines: Coal containing fines below 6mm can be burnt efficiently in FBC boiler, which is avery difficult to achieve in conventional firing system. Pollution control: SO2 formation can be greatly minimized by addition of limestone or dolomite for high sulphur coals, 3% limestones is required for every 1% sulphur in the coal feed. Low combustion temperature eliminates Nox formation. Low corrosion and erosion: The corrosion and erosion effects are less due to lower combustion temperature softness of ash and low particle velocity. Easier ash removal No clinker formation: Since the temperature of the furnace is in the range of 750 oC to 900 oC in FBC boilers even coal of low ash fusion temperature can be burnt without clinker formation , Ash removal is easier as the ash flows like liquid from the combustion chamber .Hence less man power is required for ash handling. Simple operation Quick start up High turbulance of the bed: Facilitates quick start up and shutdown full automation of start up and

operation using reliable equipment is possible. Fast response to load fluctuations: Inherent high thermal storage characteristics can easily absorb fluctuation in fuel feed rates. Response to changing load is comparable to that of oil fired boiler. High efficiency: FBC boiler can burn fuel with a combustion efficiency of over 95% irrespective of ash count. FBC boilers can operate with overall efficiency 84% . Reduction in Boiler size:High heat transfer rate over a small heat transfer area immersed in the bed result in overall size reduction of the boiler. Fuel flexibility:FBC boiler can be operated efficiency with a variety of fuels. Even fuels like floatation slimes, washers, rejects, agro waste can be burnt efficiently. These can be fed either independently; or in combination with coal into the same furnace. Ability to burn low grade fuel:FBC boiler would give thee rated output even with inferior quality fuel. The boiler can fire gas with ash contents as high as 62% and having calorific value as low as 2,500 kcal /kg. Even carbon content of only by weight can sustain the fluidize bed combustion. No sagging in the furnace. No soot blowing. In FBC boilers, volatilization of alkali components in ash does not take place and the ash is nonstick. This means that there is no slugging or soot blowing. Provisions of Automatic coal and Ash Handling system: Automatic system for coal and ash handling can be incorporated, making the plant easy to operate comparable to oil of gas fired installation. Provision of Automatic ignition system:Control system using microprocessors and automatic ignition equipment give excellent control with minimum manual supervision. High Reliability:The absence of moving parts in the combustion zone results in a high degree of reliability and law maintenance costs. Reduced Maintenance:Routine overhauls are infrequent and high efficiency is maintained for long periods. High efficiency of power generation:By operating fluidized bed at elevated pressure, It can be used to generate hot pressurized gas to power a gas turbine. This can be combined with a conventional steam turbine to improve the efficiency of electricity generation and give a potential fuel giving of at least 4%.

BOILER DESCRIPTION:
The main components of a typical CFB boiler are shown in Fig. 3. These consist of a combustion chamber, a cyclone separator and a return leg for recirculation of the bed particles. The combustion chamber is enclosed with water-

DIAGRAM GENERAL CIRCUIT:

The circuit diagram of CFBC boiler is shown as above this diagram shown steam and water circuit, air supply and gas circuit. From the lignite bunker, the lignite is supplied to the rotary feeder by the means of chain

WATER AND STEAM CIRCUIT:

The water from the feed water pump is supplied to drum. The water from drum is supplied to down comes lines by gravitational force During the flow, the water converts to saturated steam by absorbing the heat from combustion. The saturated steam again goes to drum and stored in drum above water level. From the drum the saturated steam is supplied to the super heater 1 to 4. During the flow through super heater the attemperator is provided to control the temp. of the superheated steam. After leaving the super heater, the stream is in the super heated and pressurized form. This steam goes to the main header. From the main header the steam is supplied to the process plant or turbine as per design of plant.

Concrete. Bricks can be made with fly ash. These are durable and strong.

AIR DISTRIBUTION SYSTEM:

For the complete combustion and fluidization air supply to boiler is necessary. In the boiler air is supplied in two forms (1) primary air (2) secondary air. The primary air fan sucks the air from atmosphere and part of the air supply to the secondary air fan. Air from both PA fan and SA fan passes through airpreheater and the primary air is supplied to the boiler from the bottom of furnace and the secondary air is supplied from the middle walls. This air conveyors the heat from combustion to the water and steam. For the effective working of seal pot, the air is supplied it by the root blower as shown in the fig. The pressurized air is also supplied to many pneumatic valves and instruments for their operation.

FLY ASH AND BOTTOM ASH HANDLING SYSTEM :

Boiler burning pulverized coal has dry bottom furnaces. The large ash particles are collected under the furnace in water filled ash hopper. Fly ash is collected in dust collectors with either an ESP on a bag filter. A PC boiler generates approximately 80% fly ash and 20% bottom ash. Ash must be collected and transported from various point of the plants. Pyrites, which are the rejects from the pulverizes, are disposed with the bottom ash system. Three major factors should be considered for ash disposal systems. - Plant site - Fuel source - Environmental regulation. Needs for water and land are important considerations for many ash-handling systems. Ash quantities to be disposed depend on the kind of fuel source. Ash storage and disposal sites are guided by environmental regulations. The sluice conveyor system is the most widely used for bottom ash handling,. While the hydraulic vacuum conveyor is the most frequently used for fly ash system, Bottom ash and slag may be used as filling material for road construction. Fly ash can partly replace cement for making

COMBUSTION CHAMBER :
The combustion chamber is designed to contain a slight negative pressure and consist of a membrane wall gas tight enclosure. The lower combustion chamber section has an air distribution grid for introducing the primary air and a bottom ash removal system. The lower combustion chamber also has openings for the recirculated solids secondary air nozzles, fuel, limestones,makeup sand and startup burners as required.There are no heat transfer tubes inside the high density lower combustor. In this region, a rapid change of solids flow pattern occurs, thus heat transfer wall tubing is protected by a thin layer of abrasion resistant refractory. Fuels fed into the lower combustion chamber mix quickly and uniformaly with bed materials. There is no visible bed level in the CFB combustor. Instead the bed density decreases progressively with

height In typical full load operation, about 40-50% of heat generated by combustion is absorbed by the water colled membrane wall s of the combustion chamber. Also the high circulating solids and back mixing intensity providing the high heat transfer rate typical of CFB. The amount of primary air needed for initial fluidization of the bed material has to be maintained under all condition. The proportion of the

SEAL POT:
Since the lower furnace of each CFB operates at a positive pressure and the cyclone separators operate at balanced to slightly negative pressure, there must be a seal between the two to allow solids to circulate through the CFB being employed. For the Project, in accordance with the design of the CFB a seal pot arrangement is used to achieve this.