10.1 Design Data

Asiakirjan nimi - Name of Document Tunniste - Identification Rev.
10.1 DESIGN DATA OF THE BOILER CFBM-582-1 0
Osasto - Department Kohde - Subject Sivu - Page
Power Generation RAPP PB3 PROJECT 1 (16)

Systems CFB MULTIFUEL BOILER
TABLE OF CONTENTS
10. APPENDICES ....................................................................................................... 2
10.1 Design data of the boiler........................................................................................ 2

10.1.1 General .............................................................................................................. 2
10.1.2 Boiler .................................................................................................................. 4
10.1.3 Water ............................................................................................................... 13
10.1.4 Sand and limestone ......................................................................................... 15
0 2005 - 08 - 30 T. Anttonen
Muut. Pvm Laatinut Pvm Tarkastanut Pvm Hyväksynyt
Rev. Date Prepared by Date Reviewed by Date Approved by
KLY-1 1997-05 P:\582-RAPP-PB3\int\Kayttoonotto\käyttöohje\Operation and Maintenance Manuals\Folder
2\10.1 Design data.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
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
 Kvaerner Power Oy, Tampere, Finland 2005

Osasto - Department Kohde – Subject Sivu - Page

10. APPENDICES
10.1 Design data of the boiler
10.1.1 General
10.1.1.1 Plant Location
The boiler plant is located in Kerinci mill about 75 km east from

Pekanbaru, in Sumatra, Indonesia.
10.1.1.2 Ambient Climatic Conditions
Ambient temperature for performance

calculations and guarantees is °C 30
Maximum ambient temperature for

boiler design °C 40
Relative Humidity % 80
Water content of air g/kgdry air 22
10.1.1.3 Mill Services
Cooling Water
Design temperature °C 32
Pressure at 0-level bar(a) 3.0
Filtration µm 50
Pressure loss inside the delivery limits is maximum 1 bar.


Process Water
Pressure at 0-level bar(g) 4.0
Low pressure steam
Operating pressure bar(a) 3,5

Design pressure bar(a) 7
Operating temperature °C 150
Medium pressure steam

Operating pressure bar(a) 11
Design pressure bar(a) 17
Operating temperature °C 210
Fire fighting water

Pressure High enough to fulfill
authority requirements
Instrument Air
Air pressure bar(g) 5 ... 7
Quality Clean, oil and moisture free
Mill air
Operating pressure bar(g) 5 ... 7
Assumed dew point °C < +4


10.1.2 Boiler
The boiler is designed for bituminous coal and bark firing and it is
based on circulating fluidized bed (CFB) technology.
Diesel oil / heavy fuel oil is used in start-up burners.
10.1.2.1 Steam
The boiler has the following capacities with design coal.
- MCR t/h 650

- The minimum stable load 25% of MCR t/h 162,5
Operating pressure bar(a) 142
o
Operating temperature C 540 ± 5
Full superheating range % 50 – 100
t/h 325 – 650
10.1.2.2 Feed Water
Feed water temperature at economizer inlet °C 130
10.1.2.3 Fuels
The fuels shall be as homogenous as possible when entering supply

silos. When the fuel is homogeneous, flue gas emissions are
minimized and smooth and easy operation of the boiler is ensured.
The design of the boiler is based on the following design fuel data
only. The availability guarantee and mechanical warranty are valid
for operation within the given range. Performance guarantees are
given with design fuels. Small variation from design fuels will be
corrected with correction curves to correspond the design fuels.
Kvaerner is not responsible of the damages caused to equipment by

big stones or other corresponding impurities coming with fuel.


10.1.2.3.1 Coal
The boiler is designed using the following analysis for bituminous

coal.
Higher heating value (HHV), as air

dry basisreceived)**
• design kcal 5902
MJ/kg 24,71
• • •
• range kcal 5500 - 6500

MJ/kg 23,03 – 27,21
Moisture content as received

• design wt-% 13,2
• range wt-% 10 – 15
Ash content (air dry basis)**

• range wt-% 8 – 15
Sulphur content (air dry basis)**

• design wt-% 1,5
• range wt-% 0,6 – 2,0
Volatile matter (as received)**

• range wt-% 35,0 – 42,0


Ultimate analysis for coal range and analysis used for performance
calculations (air dry basis)’’
Range Design
Carbon C wt-% 55 – 65 59,7
Hydrogen H wt-% 4,0 – 6,0 4,7
Oxygen O wt-% 11,0 – 13,5 11,58
Nitrogen N wt-% 0,45 – 0,65 0,52
Sulphur S wt-% 0,6 – 2,0 1,50
Ash wt-% 8,0 – 15,0 11,5
Moisture 10,5
Total 100,0
**
Moisture of air dried sample for design is 10,5 %
Following properties relate to performance coal:
Ash fusion temperature

Reducing atmosphere:
initial deformation °C 1510
spherical °C 1530
hemispherical °C 1550
fluid °C >1550
Oxidizing atmosphere:
initial deformation °C >1550
spherical °C >1550
hemispherical °C >1550
fluid °C >1550


Ash chemical analysis:

SiO2 % 56,8
Al2O3 % 28,6
Fe2O3 % 7,2
MgO % 0,8
CaO % 1,1
Na2O % 0,4
P2O5 % 0,1
SO3 % 0,8
Volume weight kg/m3 850
Coal size at receiving hopper inlet

100 % mm < 10
Recommended coal size distribution:

100 % mm <8
90% mm <6
max 10% (target value) mm < 0,1


10.1.2.3.2 Bark
Performance is based on the following bark analysis.

Higher heating value (dry solids)
• design for performance MJ/kg 17,0
Lower heating value (dry solids)
• range MJ/kg 15,0 – 18,9
Moisture content
• design for performance wt-% 50
• range wt-% 40 – 60
Ash content (dry solids)

• design for performance wt-% 8,3
• range wt-% 3–9
• Na + K content in dry fuel, max mg/kg 2500

• Cl content in dry fuel is max mg/kg 550
Ultimate analysis for bark used for performance calculations (bone

dry basis)
Carbon C wt-% 45,6

Hydrogen H wt-% 4,2
Oxygen O wt-% 41,3
Nitrogen N wt-% 0,5
Sulphur S wt-% 0,07
Chlorine Cl wt-% 0,055
Ash wt-% 8,3
Total 100,0


Following properties relates to bark:

o
Ash melting point C >1100
Volume weight kg/m3 300 ... 400
Bark particle size side+side+side

100 % mm < 50
Note! Due to bark chlorine content and high superheating

temperature bark shall be fired together with coal. It is
estimated that about 10% of fuel heat input shall be from
the coal.
10.1.2.3.3 Sludge burning capability in the future
Performance is based on the following sludge analysis.

Higher heating value (dry solids)
Lower heating value (dry solids)
• range MJ/kg 11 – 15
Moisture content
• range wt-% 60 – 80
Ash content (dry solids) wt-%

• range wt-% 20 – 40


• Na + K content in dry fuel, max wt-% 0,81

• Cl content in dry fuel is max wt-% 0,29
Maximum sludge amount BDt/d 125
Ultimate analysis for sludge used for performance calculations (bone

dry basis)
Carbon C wt-% 29,5

Hydrogen H wt-% 3,8
Oxygen O wt-% 27,66
Nitrogen N wt-% 0,46
Sulphur S wt-% 0,29
Chlorine Cl wt-% 0,29
Ash wt-% 38,0
Total 100,0
Following properties relates to sludge:

o
Ash melting point C >1100
Volume weight kg/m3 700 ... 900
Note! Due to sludge chlorine and alkaline content and high

superheating temperature sludge shall not be fired with
bark only. It is estimated that about 30% of fuel heat input
shall be from the coal when firing sludge.


10.1.2.3.4 Heavy Fuel Oil
Heavy fuel oil will be used as start-up and auxiliary fuel.

Net calorific value, min MJ/kg 40,0
Viscosity @ 50 °C cSt max 350
Sulphur content wt-% max 2,8
Temperature at battery limit °C 60
10.1.2.3.5 Diesel Oil
Diesel oil is used as limestone drying unit fuel. It is also

recommended that diesel oil is used as a boiler start-up fuel in the
beginning when furnace is cold.
Gross calorific Value, min MJ/kg 43

Specific gravity @60 °F kg/m3 0,84 – 0,92
Viscosity Redwood @ 1050 °CF Secs 35 – 45
Pour point °F max 65
Carbon residue wt-% max 1
Water content vol-% max 0,25
Sediment wt-% max 0,02
Ash wt-% max 0,02
Flash point °F min 150
Sulphur wt-% max 1,5


10.1.2.4 Combustion Air
Air temperature at the suction duct inlet

- for performance calculations °C 30
- maximum °C 40
- minimum °C 21
10.1.2.5 Heat balance reference temperature
Reference temperature for heat balance °C 30
10.1.2.6 Design Pressure and Pressure Vessel Code
Max allowable working pressure (prelim.) bar(g) 166
Design Pressure Vessel code is ASME.


10.1.3 Water
10.1.3.1 Make-up Water Quality
The make-up water quality requirement at the battery limit is as

follows
pH-25 6,5 – 8
Hardness (Ca++ + Mg++), max ppb 3
Iron, max mg/kg 0,02
Copper, max mg/kg 0,003
Silica, max mg/kg 0,02
Na+K, max mg/kg 0,01
Oil mg/kg 0
Cation conductivity at 25 °C, max µS/cm 0,2
Temperature °C 32
10.1.3.2 Condensate Quality
pH-25 8,8 – 9,2

Hardness (Ca++ + Mg++), max ppb 3
Iron, max mg/kg 0,02
Dissolved oxygen, max ppb 10
Oil mg/kg 0
Cation conductivity at 25 °C, max µS/cm 0,2
Temperature °C 80


10.1.3.3 Feed water Quality
The feed water quality requirement is as follows:
pH – 25 8,8 – 9,2
Oxygen, max mg/kg 0,01
Hardness, max ppb 3
Total Iron, max mg/kg 0,02
Oil + sludge + foaming substances mg/kg 0,0
Cation conductivity at 25 °C, max µmS/cm 0,2
10.1.3.4 Boiler Water Quality
The boiler water quality requirement is as follows:
pH-25 9,2 – 9,7

Iron, max mg/kg 0,5
o
Conductivity at 25 C (after neutralization) µS/cm < 40
(Na+K) mg/kg <8
SiO2 content mg/kg < 0,35
PO4 content mg/kg 2 -– 6
TDS mg/kg < 0,2


10.1.4 Sand and limestone
10.1.4.1 Sand
Fluidized bed make-up sand shall be of natural sand with the

amount of quarz as mineral less than 70%.
Typical size distribution is as follows:
100 % mm < 4,76

99,6 % mm < 2,38
98,5 % mm < 1,19
88,0 % mm < 0,59
43,1 % mm < 0,297
5,0 % mm < 0,149
1,3 % mm < 0,074
Assumed maximum moisture content % 83


10.1.4.2 Limestone
Particle size before crushing:

100 % mm < 25
Reactivity TGA index based on Kvaerner

Power analysis method % >50
Limestone properties according to report

dated February 09, 2001 and laboratory test
in Finland 19.06.2003:
CaCO3 % 96,6 – 97,1
MgCO3 % 1,5 - 3,0
Assumed maximum moisture content % 3

10.1 Design Data

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Asiakirjan nimi - Name of Document Tunniste - Identification Rev.

10.1 DESIGN DATA OF THE BOILER CFBM-582-1 0

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 1 (16)

10. APPENDICES ....................................................................................................... 2

10.1 Design data of the boiler........................................................................................ 2

 Kvaerner Power Oy, Tampere, Finland 2005

10.1 DESIGN DATA OF THE BOILER CFBM-582-1 0

Osasto - Department Kohde – Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 2 (16)

10.1 Design data of the boiler

10.1.1.1 Plant Location

The boiler plant is located in Kerinci mill about 75 km east from

10.1.1.2 Ambient Climatic Conditions

Ambient temperature for performance

Maximum ambient temperature for

Water content of air g/kgdry air 22

10.1.1.3 Mill Services

Pressure loss inside the delivery limits is maximum 1 bar.

 Kvaerner Power Oy, Tampere, Finland 2005

10.1 DESIGN DATA OF THE BOILER CFBM-582-1 0

Osasto - Department Kohde – Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 3 (16)

Low pressure steam

Operating pressure bar(a) 3,5

Medium pressure steam

Fire fighting water

Quality Clean, oil and moisture free

Assumed dew point °C < +4

 Kvaerner Power Oy, Tampere, Finland 2005

10.1 DESIGN DATA OF THE BOILER CFBM-582-1 0

Osasto - Department Kohde – Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 4 (16)

Diesel oil / heavy fuel oil is used in start-up burners.

The boiler has the following capacities with design coal.

- MCR t/h 650

10.1.2.2 Feed Water

Feed water temperature at economizer inlet °C 130

The fuels shall be as homogenous as possible when entering supply

Kvaerner is not responsible of the damages caused to equipment by

 Kvaerner Power Oy, Tampere, Finland 2005

10.1 DESIGN DATA OF THE BOILER CFBM-582-1 0

Osasto - Department Kohde – Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 5 (16)

The boiler is designed using the following analysis for bituminous

Higher heating value (HHV), as air

• range kcal 5500 - 6500

Moisture content as received

Ash content (air dry basis)**

Sulphur content (air dry basis)**

Volatile matter (as received)**

 Kvaerner Power Oy, Tampere, Finland 2005

10.1 DESIGN DATA OF THE BOILER CFBM-582-1 0

Osasto - Department Kohde – Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 6 (16)

Following properties relate to performance coal:

Ash fusion temperature

 Kvaerner Power Oy, Tampere, Finland 2005

10.1 DESIGN DATA OF THE BOILER CFBM-582-1 0

Osasto - Department Kohde – Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 7 (16)

Ash chemical analysis:

Volume weight kg/m3 850

Coal size at receiving hopper inlet