Welcome to Everyone

EA-EM Met-2019

Date :06th -7th March 2019

Organized By: Gujarat Energy Development Agency & NPC Gandhinagar
IR- CFBC - 4th Generation Boiler – Why??
 Agenda
IR – CFBC Generation
IR- CFBC Silent Features
Comparison of AFBC/CFBC
Why We go with IR- CFBC
IR- CFBC Start Up
Emission Control
IR- CFBC Proven Facts
U- Beam Technology
MDC & Ash Collection Efficiency
Other Features
Protection & Interlocks
Evolution of CFBC Design- Generation Gap
IR – CFBC 4Th Generation
IR- CFBC Silent Features
 Multi Fuel Flexibility
 Small Capacity upto 50TPH
 High Capacity > +500TPH
 Higher Efficiency
 Ash Disposal
 Higher Availability
 Operation- Made Simple
 Less Operating Cost
 Less Maintenance
 Environment Friendly & Minimal Refractory use
 High Turndown Ratio with Respect to Fuel
 Low Emission
AFBC Vs CFBC
CFBC Vs PFBC
Why We go with IR- CFBC Boiler??
Better Combustion – Why??

 Uniform combustion Temperature

 Small fuel sizes
 Higher turbulence in Bubbling bed zones
 Higher residence time in furnace
 Fuel inside recirculation
 Up to RDZ refectory applied – Hold Furnace
temperature
Fuel Flexibility
 Accept wide range of fuels
- volatile matter (%) – 4-40%
- Ash (%) - 0-70%
-Moisture (%) -<50%
- GCV (kcal/kg) - >1500
 Lower grade/rank of Fuel reduce fuel cost.
 Fuel Flexibility – gives stability and minimizes
fuel uncertainty
 Ability to burn low and waste grade fuels
IR- CFBC Boiler - View
IR- CFBC- Pressure parts

For Subcritical Boiler

 Steam Drum
 Steam Cooled Wing wall
 Divisional Water Panel
 PSH
 SSH
 Economizer Coils
 Water Wall panel
 U Beam Enclosure Panel
Difference of AFBC /CFBC Design
Parameters
IR- CFBC Boiler start-up

 Cold Start-up
 Warm Start -Up
 Hot Start -up
 Emission Control

 Sox <200ppm (Maintain through Lime addition in Bed)

 Nox <100ppm ( Furnace Temp less than 1000 degree C, So Nox reaction not
occurred)
 SPM<50ppm(Through good ESP performance achieve)
 IR- CFBC Boiler Proven Facts
 Specific Coal Consumption = 0.4 (For Coal having GCV 3500-4000 kcal/kg )
 Evaporation Ratio=500
 Steam to fuel ratio=4.5
 Turn-down ratio = 5:1
 Ramp Rate= 3%of running steam generation Load/minutes
 Specific Total air Consumption (TPH/TPH of Steam Generation)=
 Bed Ash LOI =<2%
 Fly Ash LOI= <5%
 Aux Consumption = 5.5MWH (Note – Considering 2x60MCR of ID/PA /SA Fan/ LT Drives/ESP loading/BFP)
 Total Steam Loss = NIL
 Boiler Efficiency = 88% (By PTC 4.1)
 Bottom Ash Generation= 20%
 Fly Ash Generation = 80%
Features of IR - CFBC

 Design of Air Supply Bubble caps

 U Beam
 MDC
 RDZ
 Thin Furnace Refractory
 Steam Purging in Wind Box
 Air Slide Arrangement to Back furnace in 1st Pass
 Bed Ash Cooler
 Sonic Horn in APH
Boiler Furnace Temperature & dp Profile
Typical Bubble caps
U beam Separators
U Beam Technology
U beam from Furnace inside view
Ash Collection Efficiency
Refractory – RDZ
Thin Cooled Refractory in Furnace
Thin Cooled Refractory in Furnace
MDC – view
MDC In details
Advantages of MDC

 Residence time of fine coal increased

 Better ability to control furnace & bed temperature control
 Reduced the Erosion rate in APH Tubes
 Reduced Aux Consumption
Ash Sliding Arrangement

 MDC hopper discharge to control flow rate of ash is gone the ash
sliding .
 Ash sliding Arrangement contain SS Mesh Arrangement for ash mobility.
Why Wind Box Steam Purging
required??
 Purpose Of Steam Purging in wind Box to remove CO gas may formed
during un-burnt fuel settled at bottom of furnace.
 During Black – out Condition or PA Fan Trip , wind box steam purging
done & remove combustibles gases.
Wind Box CO Venting

 In case of Boiler Trip or Tripping of PA Fan Wind Box venting automatic

damper valve open and (wind box to APH Hopper)
Bed Ash Cooler – Energy Efficient

 Bed Ash Cooler is lower part of IR- CFBC boiler – Function as Bed
Draining System
 Hot Bed Ash/ Bed Ash are drain through Bed Ash Cooler.

Operation Philosophy
As Wind Box Pressure goes high , we processed for draining.
Bed ash Temp inlet to cooler 750- 850 Degree C
Bed Ash cooler outlet Temp -160 Degree C
Cooling Media – Air Through PA discharge to APH
Fly Ash Utilization in Boiler as Bed Inventory

 In IR- CFBC Boiler we use Fly Ash & Bottom Ash as Bed Inventory.
 Boiler Bed Ash having sleeve size less 500micron & Bulk Density 1100-
1200kg/m3 and Fe(Iron) less than 4% by weight, then We can use Bed Ash as
bed Materials.(inventory)
 Boiler Fly Ash collected from ESP 1st Field directly can use as Bed inventory.
Air Blaster In Coal Bunker
Sonic Horn in APH
Major Protection & Interlocks

 Drum Level Protection (HH 80% & LL 10%)

 Furnace Pressure HH protection (+150mmwc)
 Furnace Pressure LL protection (-150mmwc)
 Wing wall Protection (>500 u beam temp)
 U Beam Protection( 800degree C)
 Wind Box Steam Purging
 Boiler MFT act ( bed temp 1000)
 Wind box CO Venting
 ESP protection
Thank You…

 Dinanath Akela
 Mob:+91-7228044210
 Mail-Id : akelanptidgp@gmail.com
 Hazira, Surat

 References:
 Note: All content are taken from B&W international Paper
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 No any Site(RIL) Specific