2.1 Process Introduction

Asiakirjan nimi - Name of Document Tunniste - Identification Rev.
PROCESS DESCRIPTIONS
2.1 INTRODUCTION
CFBT-582-1 1

Osasto - Department Kohde - Subject Sivu - Page
Power Generation
Systems
RAPP PB3 PROJ ECT
CFB MULTIFUEL BOILER
1 (26)

1 2005 - 08 - 30 T. Anttonen
0 2005 - 02 - 11 T. Anttonen
Muut.
Rev.
Pvm
Date
Laatinut
Prepared by
Pvm
Date
Tarkastanut
Reviewed by
Pvm
Date
Hyvksynyt
Approved by
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Process_introduction(1).doc
This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
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Kvaerner Power Oy, Tampere, Finland 2005
TABLE OF CONTENTS

2. PROCESS DESCRIPTION.................................................................................... 2
2.1 Introduction............................................................................................................ 2
2.1.1 General.................................................................................................................. 2
2.1.2 Circulating Fluidized Bed Process ......................................................................... 3
2.1.3 Condensate and feedwater system....................................................................... 5
2.1.4 Boiler water/steam system..................................................................................... 6
2.1.5 Vents, Drains and Blowdown............................................................................... 12
2.1.6 Chemical Dosing and Sampling........................................................................... 13
2.1.7 Air System........................................................................................................... 15
2.1.8 Flue Gas System................................................................................................. 18
2.1.9 Solid fuel handling system................................................................................... 20
2.1.10 Limestone Feeding System.............................................................................. 22
2.1.11 Sand feeding system........................................................................................ 22
2.1.12 Coarse Material Removal System.................................................................... 23
2.1.13 Fly Ash Handling System................................................................................. 24
2.1.14 Oil System........................................................................................................ 24
2.1.15 Sootblowing steam system............................................................................... 25
2.1.16 Cooling Water System..................................................................................... 26
2.1.17 Medium and Low Pressure Steam System...................................................... 26
2.1.18 Compressed Mill Air System............................................................................ 26
2.1.19 Compressed Instrument Air System................................................................. 26


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2. PROCESS DESCRIPTION

2.1 Introduction

This section describes general operation principles and technical
data of a circulating fluid bed boiler with auxiliaries.

2.1.1 General

The unit will be designed to generate 650 t/h of high pressure steam,
at 142 bar(a) and 540C from feedwater at 130 C.

The main fuel for the boiler is bituminous coal. Also bark and
woodwaste can be fired. The design allows also use of smaller
amount of sludge (reservation made for sludge silo and feeding
equipment). Boiler start-up burners are designed for heavy fuel oil
and diesel oil.

Kvaerner's circulating fluidized bed boiler is a single drum unit which
consists of a gas-tight, membrane construction furnace, three
parallel cyclones and a second pass where the primary and tertiary
superheaters and smooth economizer section are located. In the
third pass are located finned tube economizers and air preheaters.

Kvaerner Power CFB technology ensures low emission and high
efficiency combustion process. The boiler is furnished with limestone
injection to meet sulfur dioxide emission requirements.


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2.1.2 Circulating Fluidized Bed Process

A fluid bed contains a mass of particulate solids through which an
upwardly flowing fluid is passed at a velocity sufficient to cause the
particles to behave like a liquid. The bed material consists mainly of
fine sand particles, fuel ash and limestone which can be fed to the
furnace to reduce SO
2
emission. The fluidizing medium consists of
air and flue gas produced by the combustion of the fuel.

In the circulating fluidized bed (=CFB) boiler the velocity of fluidizing
medium is so high that part of the particles is carried with the gas.
There are two distinctive phases of solids in the combustion
chamber, the dense phase and the dilute phase. The dense phase,
or bed, consists of fuel ash, sand, a small percentage of unburned
fuel and possibly of limestone. The fluidization gas elutriates fine
particles into the dilute phase. The dilute phase density has a direct
effect on the heat transfer rate in the furnace. Most of the solids
elutriated from the combustion chamber are separated from the flue
gas stream in the cyclone separators and cleaned flue gas flows to
the second pass. The separated solids fall down to the bottom of the
cyclones where so called loop seals are located. The loop seals are
small fluid beds, which act as a seal preventing flue gas to flow from
lower part of the furnace to the cyclones. From the loop seals solid
particles are returned back to the furnace.

Normally the bed temperature varies between 750 940 C and due
to large mass of the circulating material the temperature is almost
constant throughout the furnace. The bed temperature is controlled
by variating the air distribution, using flue gas recirculation and
changing excess air level.


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The fuel properties can vary within given range without adversely
effecting the combustion. The rate of combustion is so high that the
steam output can be increased/decreased rapidly by changing the
fuel flow according to the load demand. The lower part of furnace
walls and other areas where risk for erosion exists are covered by
refractory to minimize wearing in these sections. Fluidizing velocity is
designed to be a moderate to ensure low erosion impact into
refractory in dense bed area.

The welds are grinded in furnace walls and the number of openings
is minimized to avoid erosion. The boiler is furnished with the
functionally needed maintenance doors and sight glasses.

Moderate inlet velocity of flue gas is used in cyclones. The round
form of cyclone is used, which ensures high separation efficiency.
The cyclones, located between the furnace and the second pass,
are totally water cooled operating in the parallel natural circulation
loops to the furnace. The gas tight walls of the cyclones are of
membrane construction. From the flue gas side cyclones are
completely protected against erosions by refractory.

The thermal expansion of the cyclones and furnace is the same due
to same cooling media in water circulation. Therefore there is no
need for expansion joints between the cyclones and the furnace.


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2.1.3 Condensate and feedwater system

Condensate water from the mill processes and turbine is introduced
to the condensate collecting tank (not in scope). From the
condensate tank water is pumped to the deaerator. Make-up water
from the demineralization plant and the condensated water from the
primary air steam preheater are also led to the deaerator. In the
dearator most of oxygen dissolved in condensate and make-up
water is thermally removed by heating make-up water with the same
low pressure steam which is used to feedwater tank pressure
control. Feedwater tank serves as feedwater storage having about
15 minutes storing capacity when boiler is operated at MCR load.

The deaerator is integrated to the feed water tank so that the water
is first sprayed in a part of the steam space (pre-deaeration) and
then in the second stage the steam is injected to the water (final
deaeration). During start-up water is heated to the operating
temperature by leading low pressure steam below the water level of
the feedwater tank through a perforated pipe and by distributing the
steam evenly over the whole length of the feedwater tank.

From the feedwater tank water is pumped by direct drive feedwater
pumps (not in scope) to the boiler. Normally three parallel feedwater
pumps are in operation while the fourth one is stand-by.


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2.1.4 Boiler water/steam system

Feedwater is introduced to the CFB boiler at the inlet of an
economizer. After the economizer sections water enters the steam
drum.

From the steam drum boiler water is fed to the furnace walls and
floor and to the cyclone walls via downcomers, supply pipes and
distribution headers. The furnace and the cyclones have separate
downcomers and circulation pipes and thus they form separate
circulation loops.

In boilers with natural circulation the circulation of water and
steam/water mixture is based on the change of specific density, i.e.
the heavier steamless water column in the downcomers presses the
lighter steam/water mixture from the steam generating surfaces to
the drum.

From the steam drum the saturated steam flows to the superheaters.
The superheated steam temperature is controlled in two-stage
steam attemperators by spraying feedwater to steam flow.

High pressure parts of the boiler are protected by safety valve
system consisting of two safety valves located in the drum and two
located in main steam line before the main steam stop valve.


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2.1.4.1 Economizers

The feedwater is introduced at the both ends of the distribution
header of the first economizer section.

In the three stage economizer sections feedwater temperature is
raised by flue gas before entering the steam drum.

The flue gas flows downwards, across horizontally arranged
economizer sections. The feedwater rises counter/cross flow to the
flue gas. Two first two economizer packages are of finned tube
construction and the last, the third one is constructed of smooth
tubes. The advantage of the finned tube construction is the effective
heat transfer ability and space utilization.

2.1.4.2 Steam Drum

The purpose of the drum is to operate as a separator in the water-
steam circulation between the steam generator and the superheater
as well as boiler short-term water storage.

The feedwater coming from economizer enters the drum at the both
ends through a perforated distribution pipe. From the drum, water is
supplied to the steam generating surfaces, furnace and cyclones via
downcomers. From the steam generating surfaces the steam/water
mixture is returned back to the drum through cyclone type steam
separators. After cyclone separators steam is furthermore dried in
chevron type secondary scrubbers before leaving steam drum.


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2.1.4.3 Furnace

The size of the furnace is determined by the design fuels and the
required evaporation capability. The heat released in the furnace is
transferred effectively by the means of radiation heat transfer and
particle convection to the furnace wall tubes.

Proper water circulation in the furnace walls is ensured by using a
sufficient amount of downcomers, circulating pipes and supply and
collection headers. The water circulation in the furnace walls is
carried out by natural circulation.

By downcomers (5 pcs) originating from the drum, the water is
introduced to the level of the lower section of the furnace.
Distribution headers of the furnace are fed through supply pipes
originating from lower part of the downcomers. The furnace bottom
forms a fluidized combustion grate which is also fully water cooled
since it is used to provide water to the rear wall distribution header.

In the furnace wall tubes part of the boiler water is evaporated.
Furnace walls are made of gas tight membrane construction.

From the collection headers of each wall section the water/steam
mixture is introduced by the upper circulation pipes (raiser pipes)
back to the drum.

The furnace is equipped with tight inspection openings (sight
glasses) in order to monitor the burners, grate and furnace. For the
maintenance and repair of the furnace and heat transfer surfaces the
boiler is equipped with tightly closed access doors.


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2.1.4.4 Cyclone separators and loop seals

The size of the cyclones is determined by produced flue gas amount
and the required dust separation efficiency. The heat released in the
cyclones and loop seals is transferred by particle convection to the
refractory layer protecting wall tubes. Gas tight cyclone and loop
seal walls are same type of membrane construction as furnace
walls.

By downcomers (2 pcs) originating from the drum, the water is
introduced through supply pipes to distribution headers of the loop
seals. After flowing through loop seal tubes water/steam mixture
enters to wall tubes of the cyclones. In upper parts of the cyclones
water/steam mixture is collected to round shaped collection headers
and then led through upper circulating pipes (raisers) back to the
steam drum.

Since cyclones and loop seals are totally refractory covered only
little heat is transferred to those evaporation surfaces. Most of
evaporation takes place in the furnace wall tubes.

2.1.4.5 Superheaters

The purpose of the superheater section is to achieve a steam
temperature of 540 C after the superheaters.


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The superheater has been divided into three stages. The first stage
(primary superheater) is a convective type superheater (located in
the 2nd pass), the second stage (secondary superheater) is a
radiant type superheater (located inside the furnace) and the third
stage (tertiary superheater) again a convective type superheater
(located in upper part of the 2nd pass).

From the drum the saturated steam is introduced by connection
pipes (saturated steam pipes) to the 2nd pass front wall distribution
header. Second pass walls, roof and load carrying tubes (supporting
tubes for heat transfer bundles in the 2nd pass) are the first part of
the primary superheater. Steam flows first downwards in front wall
tubes and is then divided to side wall tubes and to first row of load
carrying tubes. Steam which has flown upwards through side walls is
collected to upper headers of the side walls and then led through
connection pipes to 2nd pass roof distribution header. Steam then
flows downwards through second pass roof and rear wall tubes to
rear wall collection header. To this same header is collected steam
from load carrying tubes after it has flown the second row of carrying
tubes. From the second pass rear wall collection header steam flows
through connection pipes to the actual primary superheater sections.

The actual primary superheater sections (2 pcs) are located in the
middle part of the 2nd pass. In the superheater tubes the steam
flows counterflow to the flue gas. The primary superheater sections
are supported from the above mentioned load carrying tubes.


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From the collection header of the primary superheater the steam is
introduced to two parallel steam attemperators. Attemperator is
divided to parallel units because then it is easier to control
temperature across the wide superheater. The purpose of the first
stage steam attemperators is to keep steam temperature after the
secondary superheater on the required level.

The steam attemperators are so-called spraying attemperator where
the feedwater is injected into the steam. While being vaporized and
superheated it binds the heat whereupon the temperature of the
steam leaving the attemperators falls. The spraying attemperator
consists of a spraying chamber, a spraying nozzle and an internal
venturi tube.

The vertical secondary superheater is located in the upper part of
the furnace, near the furnace front wall. It is a radiant type
superheater that operates on a so called parallel-flow principle,
where steam is led to superheater lower part header and steam then
flows upwards to collection headers of the superheater elements
located above the furnace roof.

From the collection header of the secondary superheater the steam
is introduced to the second attemperator stage. Also this
attemperator is divided into two parallel spray chambers located on
both sides of the boiler and in these units steam temperature is
controlled to correspond required temperature after the tertiary
superheater section.


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From the second stage attemperators steam flows to the tertiary
superheater sections located in the upper part of the second pass.
Tertiary superheater consists of two sections and is convective type
superheater where steam flows counterflow to flue gas flow. From
the final superheater collection header steam is lead to the steam
turbine.

2.1.5 Vents, Drains and Blowdown

Vents are supplied for the purpose of venting the boiler during start-
up and shutdown. High pressure part vents are piped to the common
collection funnel to where vent valves are also gathered.

Air and vent steam are then led to the blowdown tank vent pipe. Also
water coming to funnel with vents is drained to that same vent pipe.

Drains are used for the drainage of the boiler during start-up and
shutdown. The drains from the economizer, furnace, cyclones,
superheaters and sootblowing system are piped to a common
drainage header and further to the blowdown tank. Drains from low
pressure parts are introduced to the blowdown tank through own
drainage header.

One furnace drain, which can be used for limiting drum high water
level, and feedwater tank overflow pipe are connected directly to
blowdown tank.

In the blowdown tank hot drains are cooled down and then led to the
sewer.


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All high pressure part vent and drain lines are equipped with two
sequential shut off valves.

Since small amounts of unvolatile matters (salts) enter the boiler
continuously with feedwater, these are enriched in water and the
quality of boiler water and steam becomes poor. To eliminate this
problem, continuous blowdown from the drum is taken out all the
time. The blowdown water is introduced to the continuous blowdown
tank where part of water evaporates due to lower pressure. Flash
steam (expansion steam) generated in continuous blowdown tank is
led to feedwater tank and condensate flows to blowdown tank where
it is cooled and finally led to sewer.

The flashed water vapor from the blowout tank is vented to
atmosphere via vent steam pipe to roof and water is lead to sewer.

2.1.6 Chemical Dosing and Sampling

Chemical dosing stations includes own tanks for:

oxygen scavenger
pH control chemical (amine)
phosphate

The dosing tanks are used for preparation of chemical solutions. In
preparation of dosing solutions make-up water is used. System is
equipped with necessary ejectors for solution preparation and
venting fan, which removes harmful vent gases to safe location.


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Each tank is furnished with two parallel dosing pumps of which one
is in operation and the other ones are stand-by. Pumps used for
oxygen scavenger and pH control chemical dosing are diaphragm
type pumps and pumps for phosphate dosing piston type pumps.

The sampling system consists of:

sample probes
sample piping with valves
sample coolers

Sample tapping probes are installed in the condensate pipe before
deaerator, feedwater tank, feedwater pipe, continuous blow-down
pipe, downcomer, saturated and superheated steam pipes. The
water or steam is led into the sample cooler, where it is condensed
and cooled. Condensated and cooled sample is then analyzed in
laboratory or in on-line analyzers.

With continuous pH-monitoring are equipped the following samples:

condensate water
feedwater
boiler water


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With continuous conductivity monitoring are equipped the following
samples:

condensate water
feedwater from the feedwater tank and from feedwater line
boiler water
saturated steam
superheated steam

In addition to those continuous O
2
-monitoring is provided for
feedwater line sample and continuous silica monitoring for boiler
water sample.

The adjustments to the continuous blow-down flow and to dosing
chemical feeding will be done based on the indications from the
samples. There are no actual control loops and the adjustments will
be done by the operator.

2.1.7 Air System

The combustion air is divided into primary (fluidizing) air, secondary
air and loop seal air. The combustion air for the start-up burners is
supplied from the secondary air system.

Combustion air distribution to different locations depends mainly on
fuel (coal / woodwaste) and boiler load. Boiler control system takes
care of air distribution according to preset values but in some
operation situations fine tuning may be required by the operators.


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Along with the low combustion temperatures, the combustion air is
staged to obtain low NO
x
-emission levels by utilizing fluidizing air
and secondary air. The fluidizing air is introduced into the furnace
through air nozzles penetrating the furnace floor. The secondary air,
which completes the combustion, is introduced through air ports
located on the furnace walls at two separate levels. The fluidization
results in an expanded combustion zone with high turbulence,
intimate solids to-gas contact that results in a high heat transfer rate
within the bed.

The bed temperature depends on the quality and amount of the fuel
in the bed and bed material circulation rate (fluidizing velocity).

2.1.7.1 Primary Air System

The primary air (fluidizing air) is introduced into the furnace by two
parallel high pressure primary air fans (2 x 60 %), located at ground
floor. The primary air pressure is controlled by inlet vanes and air
flows to two separately controlled windbox sections are controlled by
dampers.

Primary air is preheated by low pressure steam in steam coil
preheater, when needed, before entering tubular flue gas air
preheater.

Flue gas air heater bundles are made of vertically arranged plain
tubes where air flows inside the tubes and flue gas outside them.
The flue gas air heater sections are located in the lower part of the
third pass and they are the last heat transfer surfaces of the boiler.


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The purpose of flue gas air preheater is to increase combustion air
temperature, which helps the combustion of wet fuels. At the same
time it decreases flue gas outlet temperature and thus increases
boiler thermal efficiency.

The fluidizing air is introduced into the furnace from the windbox,
located underneath the furnace, through evenly spaced fluidizing air
nozzles penetrating the furnace floor.

2.1.7.2 Secondary Air System

The secondary air is fed into the furnace by two parallel high
pressure secondary air fans (2 x 60 %), located at ground floor. The
secondary air pressure is controlled by variable frequency drive of
the fan and air flows to separate sections are controlled by dampers.

Secondary air is not preheated.

The secondary air is introduced into the furnace through secondary
air ports on the furnace walls. The secondary air ports are located at
two elevations. The first level is located directly above the bed and
the second is above the fuel feeding openings few meters above the
bottom.

2.1.7.3 Loop seal air system

Fluidizing air for loop seals is produced by two parallel roots type
high pressure blowers. During the cold start-up both blowers are
running parallel but when normal operation temperature is reached
only one blower is needed and the other is stand-by.


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Air pressure is adjusted by rotation speed of the blowers and air flow
for each loop seal section is controlled by dampers.

2.1.8 Flue Gas System

2.1.8.1 Furnace and Cyclones

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.

In three parallel cyclones most of particles conveyed with flue gas
from the combustion chamber are separated and returned back to
the furnace.

2.1.8.2 Second and third pass

The walls in the 2nd 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.


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2.1.8.3 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.

2.1.8.4 Flue gas fans

The two (2 x 60 %) 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.


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2.1.8.5 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. Recirculating flue gas pressure in controlled by
inlet vanes of the fan and flow to separate sections is adjusted by
dampers. Recirculating flue gas duct before the fan is equipped with
guillotine damper.

2.1.9 Solid fuel handling system

2.1.9.1 Coal feeding system

From the coal storage (not in scope) crushed coal is fed by belt
conveyor (not in scope) to dividing drag conveyor (not in scope)
which transfer fuel to two coal silos located by the furnace left side
wall.

The coal is conveyed from the silos to the furnace with three
independent feeding lines.

Coal is discharged from the feeding silos by variable frequency
controlled chain dischargers, two pieces on each silo. Dischargers
carry coal to the mixing screws where it is mixed to the fuel coming
from biofuel silos. After mixing screws fuel (or fuel mixture) goes to
drag chain type feeding conveyors.


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On the furnace front wall fuel is divided to two parallel drag
conveyors from which the fuel is divided to the six feeding points, so
that each drag conveyor is feeding three separate feeding points. On
the rear wall side there is only one drag conveyor. Each of the three
conveyors are equipped with variable frequency drives.

The even distribution of fuel to all feeding points is controlled by
metering screws on each feeding points. Also these screws are
variable frequency controlled.

Each fuel feeding chute is equipped with rotary lock feeders in order
to prevent any backflows from the furnace. The lower part of each
fuel feed chutes on the front wall is equipped with constant speed
feeding screw. These screws are equipped with a feed/purge air
system that improves the fuel injection and distribution while also
cooling the feeding system. On the rear wall fuel is fed from the
rotary feeders directly to loop seals.

2.1.9.2 Bark feeding system

Biofuel is fed from the bark yard (not in scope) by a belt conveyor
(not in scope) to dividing drag conveyor (not in scope) located above
the biofuel feeding silos.

Round shaped bark silos are equipped with slewing screw
dischagers. Dischargers drop biofuel to drag conveyors, which
furthermore take biofuel to mixing screws, where biofuel and coal
are mixed. After that biofuel is fed to the combustion chamber
through same conveyor system and feeding points as coal.


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Bark flow is controlled by variable frequency controlled electric motor
drives of the silo discharger, drag conveyor and metering screw.

2.1.10 Limestone Feeding System

Limestone system is used to reduce flue gas SO
2
emission.

Big and moist limestone particles are first crushed and dryed in a
separate limestone prehandling factory consisting of limestone
receiving hopper, intake belt with magnet, mill feeding hopper with
feeder, integrated mill and separator, cyclone, baghouse filter, diesel
oil fired burner, fans and all necessary connections in the drying and
crushing loop. Dried limestone is then conveyed to limestone
storage (or feeding) silo by bucket conveyor.

From the storage silo limestone is discharged by variable frequency
controlled dosing screws. After screws there is a rotary lock feeder,
which drops the limestone to the pneumatic feeding lines. Pneumatic
feeding is divided in six feeding points at furnace front wall. Feeding
openings are located close to the fuel feeding points. The pneumatic
conveying air comes from separate high pressure blower.

2.1.11 Sand feeding system

Sand handling system is used to produce suitable bed material for
fluid bed combustion.


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Sand handling system includes sand receiving hopper with
discharger screw, elevator type of conveyor, rotary feeder and
piping.

Sand is received to the hopper (volume 20 m3), which also serves
as a small storage. To this hopper comes also sieved ash from the
bottom ash screening. Sand is discharged from the hopper via screw
into the elevator which lifts sand up enough to be able to gravitation
fed it via rotary feeder and piping to fuel feeding screw located on
the front wall of the furnace.

2.1.12 Coarse Material Removal System

The bottom ash, including coarse particles, is removed from the
furnace through twelve chutes, which penetrate the furnace floor and
the primary air windbox. The coarse material chutes are equipped
with pneumatic valves, which are opened only when bottom ash is
discharged. The bottom ash from the chutes falls into the water
cooled bottom ash screws (3 pcs).

The cooling of these bottom ash screws is done with closed cooling
water system, which includes unpressurized cooling water tank, two
circulating pumps (with the other pump as a reserve), heat
exchanger and all the necessary piping needed. The circulating
water is cooled via heat exchanger, which is using cooling water of
temperature 32 C.


2.1 INTRODUCTION
CFBT-582-1 1

Power Generation
Systems
RAPP PB3 PROJ ECT
24 (26)


Bottom ash is transferred from the screws by bottom ash conveyor
to bottom ash screening. From the screen coarse material is led via
drag conveyor and bucket elevator to ash silo and fine particles are
returned to sand hopper. When it is not necessary to return fine
material to the process, screening system can be bypassed, and all
bottom ash material is conveyed to ash silo.

2.1.13 Fly Ash Handling System

Fly ash consists of the ash in the fuel, unburned carbon, fine sand
fractions and limestone. The fly ash is mainly collected from the flue
gas in the electrostatic precipitator. The fly ash is collected from the
electrostatic precipitator hoppers to the drag conveyors and
transferred mechanically to ash silo.

Fly ash retained in the 2nd and 3rd pass hoppers is collected and
mechanically transferred to the ash silo. Fly ash silo is equipped with
moisturizing screw discharger.

2.1.14 Oil System

Heavy fuel oil and diesel oil are used as a boiler start-up fuels in six
start-up burners. Diesel oil is used also for limestone drying. Both
oils are delivered from pumping units, designed for 2 x 100 % burner
capacity of power boiler including all necessary equipment.


2.1 INTRODUCTION
CFBT-582-1 1

Power Generation
Systems
RAPP PB3 PROJ ECT
25 (26)


The start-up burners are located on furnace walls, two on each side
wall and two on rear wall. The combustion air is supplied from the
secondary air ducting. The start-up burners are utilized to heat the
bed (sand or ash) to the temperature required to begin the firing of
solid fuel.

The combustion air to the burners is measured with aerofoil type
flow measuring devices and controlled with a control damper.
Burners utilize a gas electric igniter system. The propane gas
igniters offer maintenance free igniters, which allow in a very smooth
burner start-up operation.

2.1.15 Sootblowing steam system

The boiler is furnished with sootblowers for the removal of ash
deposits from the heat transfer surfaces.

Due to wide second and third pass width sootblowers are located on
the both sides of the boiler. The tertiary superheater packages are
equipped with totally retractable sootblowers. The multi-nozzle type
sootblowers with motion (partial stroke) are utilized to clean the
primary superheaters, plain tube economizer and air preheaters.
Finned tube economizers are equipped with rake type sootblowers.

Sootblowing steam is taken after the primary superheater. The
sootblowing steam pressure is reduced by pressure reduction valve
prior to the sootblowers and system is protected against
overpressure by safety valve.


2.1 INTRODUCTION
CFBT-582-1 1

Power Generation
Systems
RAPP PB3 PROJ ECT
26 (26)


2.1.16 Cooling Water System

Closed circuit cooling water is furnished to the heat exchanger of the
closed circulation of the water-cooled bottom ash screws, feedwater
pumps, sample coolers and to five lubrication oil units of the fans.

2.1.17 Medium and Low Pressure Steam System

Medium pressure steam is used for heavy fuel oil preheating and oil
atomizing in the burners.

Low pressure steam is used for feedwater tank pressure control and
combustion air preheating (primary air) and as extinction steam for
fuel feeding equipment.

2.1.18 Compressed Mill Air System

Compressed mill air is taken from the existing compress air system.
The biggest mill air consumers are the start-up burners, fuel feeding
rotary feeders cleaning and limestone storage silo fluidizing. Some
mill air is also used in ash, coal and limestone silo filter cleaning and
for bag filter cleaning in the limestone prehandling.

2.1.19 Compressed Instrument Air System

Instrument air is primarily used for burner flame detector cooling and
for pneumatic actuators of control valves and dampers.

2.1 Process Introduction

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