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    Internal Recirculation Circulating Fluidized-Bed Boilers: A Simplified Approach To Flexibility and Reliability

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    muhammad nazir
    The document summarizes Babcock & Wilcox's internal recirculation circulating fluidized-bed (IR-CFB) boiler technology. It describes the key features of the IR-CFB design, including its two-stage particle separation system, internal primary solids recirculation via U-beams, low and uniform gas velocities, thin cooled refractory, and in-furnace heat transfer surfaces. It explains that these design aspects provide benefits like high combustion efficiency, compact size, high reliability and availability, lower maintenance costs, reduced erosion, fuel flexibility, and low emissions. The document highlights that the IR-CFB technology offers improved performance and a more cost-effective boiler design compared to other circulating fluidized-bed

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    Internal Recirculation Circulating Fluidized-Bed Boilers: A Simplified Approach To Flexibility and Reliability

    Uploaded by

    muhammad nazir
    71 views8 pages
    The document summarizes Babcock & Wilcox's internal recirculation circulating fluidized-bed (IR-CFB) boiler technology. It describes the key features of the IR-CFB design, including its two-stage particle separation system, internal primary solids recirculation via U-beams, low and uniform gas velocities, thin cooled refractory, and in-furnace heat transfer surfaces. It explains that these design aspects provide benefits like high combustion efficiency, compact size, high reliability and availability, lower maintenance costs, reduced erosion, fuel flexibility, and low emissions. The document highlights that the IR-CFB technology offers improved performance and a more cost-effective boiler design compared to other circulating fluidized-bed

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    The document summarizes Babcock & Wilcox's internal recirculation circulating fluidized-bed (IR-CFB) boiler technology. It describes the key features of the IR-CFB design, including its two-stage particle separation system, internal primary solids recirculation via U-beams, low and uniform gas velocities, thin cooled refractory, and in-furnace heat transfer surfaces. It explains that these design aspects provide benefits like high combustion efficiency, compact size, high reliability and availability, lower maintenance costs, reduced erosion, fuel flexibility, and low emissions. The document highlights that the IR-CFB technology offers improved performance and a more cost-effective boiler design compared to other circulating fluidized-bed

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    71 views8 pages

    Internal Recirculation Circulating Fluidized-Bed Boilers: A Simplified Approach To Flexibility and Reliability

    Uploaded by

    muhammad nazir
    The document summarizes Babcock & Wilcox's internal recirculation circulating fluidized-bed (IR-CFB) boiler technology. It describes the key features of the IR-CFB design, including its two-stage particle separation system, internal primary solids recirculation via U-beams, low and uniform gas velocities, thin cooled refractory, and in-furnace heat transfer surfaces. It explains that these design aspects provide benefits like high combustion efficiency, compact size, high reliability and availability, lower maintenance costs, reduced erosion, fuel flexibility, and low emissions. The document highlights that the IR-CFB technology offers improved performance and a more cost-effective boiler design compared to other circulating fluidized-bed

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 8

    Internal Recirculation

    Circulating Fluidized-Bed Boilers


    A Simplified Approach to Flexibility and Reliability

    The Technology of Choice


    Since 1867, The Babcock & Wilcox Company (B&W) has been the leading worldwide producer
    of steam generation technology and equipment. B&W remains in the forefront of technological
    advancements related to efficient and environmentally sound combustion methods for waste
    fuels, corrosive fuels, biomass fuels, and hard-to-burn fuels. Drawing upon its extensive technical
    expertise and operating experience, B&W developed the Internal Recirculation Circulating
    Fluidized-Bed (IR-CFB) boiler which is the technology of choice for power plant owners seeking
    economy, reliability and flexibility. In addition, supercritical steam conditions are attainable with
    B&Ws in-bed heat exchanger technology.

    B&Ws IR-CFB technology offers:

    U-Beams

    Steam
    Drum
    Superheater

    Wing Wall

    Internal
    Evaporative
    Circuit

    Coal
    Silo

    High combustion efficiency


    A compact, economical design
    Higher reliability and availability
    Lower maintenance costs
    Reduced erosion
    Fuel flexibility
    Low emissions

    Economizer
    Multi-Cyclone
    Dust
    Collector

    Furnace

    Tubular
    Air Heater

    Capacity
    Subcritical: To 2,200,000 lb/h
    (277 kg/s) or greater as required.
    Supercritical: From 2,200,000 lb/h
    (277 kg/s) to more than 4,500,000
    lb/h (567 kg/s).
    Steam pressure
    Subcritical: To 2600 psig
    (17.9 MPa) design.
    Supercritical: Usually at 3500 psi
    (24.1 MPa) throttle pressure with
    5% overpressure; higher pressures
    available.
    Steam temperature
    Subcritical: As required, usually to
    1050F (566C).
    Supercritical: As required, usually
    in the 1100F (595C) range.

    Bottom Ash
    Fluid Bed Cooler

    Startup
    Burner

    Secondary
    Air

    Primary
    Air

    Forced Draft
    Fan

    Improves Performance, Reduces Costs, Minimizes Maintenance


    Two-Stage Particle Separation for
    Superior Combustion Efficiency
    B&Ws unique IR-CFB boiler design
    employs a patented two-stage
    particle separation system to provide
    high-solids loading and a uniform
    furnace temperature profile. The
    benefits of this technology include
    superior combustion efficiency, low
    emissions, low maintenance, low
    pressure drop, and low turndown,
    resulting in improved overall plant
    performance.

    Our two-stage system includes a


    primary U-beam impact separator
    and a secondary multi-cyclone dust
    collector (MDC) which work together
    to provide a combined particle
    collection efficiency in excess of
    99.8%. The U-beams, a staggered
    array of stainless steel channels
    at the furnace exit plane, capture
    nearly all of the solids suspended in
    the flue gas leaving the furnace and
    internally recirculate these solids to
    the lower furnace. The MDC, with

    small diameter (<10 in., 250 mm)


    cyclones, captures the finer material
    that passes through the U-beam
    particle separator and returns this
    material to the lower furnace in
    a controlled manner. The ability
    to regulate the secondary recycle
    system provides the operator with
    unprecedented furnace temperature
    control, resulting in improved boiler
    performance and load response.

    U-Beams
    (Primary Particle Collector)

    The two-stage particle collection


    system of B&Ws IR-CFB provides
    improved performance, as well
    as a simplified, cost-effective
    boiler design.

    Primary
    All-internal
    Recirculation Loop

    Bed
    Solids

    Multi-Cyclone
    Dust Collector
    (Secondary
    Particle
    Collector)

    Fuel and
    Sorbent

    To ESP or
    Baghouse

    Secondary
    Recirculation Loop

    Bed Drain

    Compact, Economical Design

    Sidewall Membrane Panel

    Thin Refractory
    Seal
    Baffle
    Gas
    Flow

    Gas
    Plus
    Solids
    Flow

    U-Beam

    Water-Cooled
    Support Tube

    Gas
    Flow

    U-Beams
    In-Furnace
    U-Beams

    Furnace
    Gas and
    Solids Flow

    B&Ws U-beam primary


    particle collection system
    recirculates more than 97%
    of the solids suspended in
    the flue gas back to the
    lower furnace.

    B&Ws two-stage particle separation


    system results in a compact, simplified
    boiler arrangement. The entire U-beam
    particle separator is located at the furnace
    exit. Compared with hot cyclone-type
    CFB designs, the IR-CFB has significantly
    lower furnace exit gas velocity and requires
    significantly less building volume. By
    relying on internal recirculation, the IR-CFB
    design eliminates J-valves, loop seals, and
    high-pressure blowers which are required
    with other CFB designs. For the IR-CFB,
    compact and simple equals economical.

    Higher Availability,
    Lower Maintenance
    One goal of CFB boiler manufacturers
    has been to eliminate thick, uncooled
    refractory and hot expansion joints from
    their designs to reduce the expense
    and lost time associated with refractory
    maintenance. B&Ws engineers achieved
    this goal with the development of the
    IR-CFB boiler. The furnace, U-beam
    separator, and superheater enclosures are
    constructed entirely of top-supported,
    gas-tight, all-welded membraned tube
    walls which do not require hot expansion
    joints. The small amount of refractory that
    is used in the IR-CFB is applied to selected
    areas of the water-cooled enclosure surface
    in a thin layer which is only 5/8 in. (16 mm)
    thick in the lower furnace and never more
    than 2 in. (52 mm) thick over the tube
    face elsewhere in the furnace. As a result,
    B&Ws IR-CFB requires only 10 to 25% of the
    total refractory found in a hot cyclone CFB
    design and less than 50% of the refractory
    used in a water-cooled or steamcooled
    cyclone CFB unit. This construction
    has significantly reduced the need for
    refractory maintenance in B&Ws operating
    CFB units.

    B&Ws patented reduced diameter


    zone (RDZ) tube section is another
    feature designed to reduce
    maintenance. The RDZ consists of
    a reduced diameter tube section
    mating to a specially-shaped
    ceramic tile. The reduced diameter
    tube section on each tube slopes
    away from the solids falling down
    the wall. This eliminates the solids
    material from building up and
    eroding the furnace tubes where
    the lower furnace refractory ends.

    Low Flue Gas Velocities to


    Reduce Erosion
    Erosion is a major cause of
    maintenance problems in CFB
    boilers due to the high solids
    loading in the flue gas. The severity
    of this erosion is exponentially
    related to the velocity of the flue
    gas through the system. On hot
    cyclone CFBs the particle separator
    depends upon an extremely high
    flue gas velocity [approaching 90
    ft/s (27 m/s) at the cyclone inlet]
    to provide the energy needed to
    efficiently disengage the particles
    from the flue gas. By comparison,

    the U-beam particle separator is


    designed to operate efficiently with a
    flue gas velocity of only 26 ft/s (8 m/s)
    at full-load operating conditions. The
    particle capture efficiency actually
    increases as the flue gas velocity
    through the U-beam separator
    decreases. By operating at such a
    low gas velocity, the potential for
    erosion in the IR-CFB is significantly
    reduced. To date, because of proper
    material selection and low flue gas
    velocities, the U-beam separators in
    B&Ws coal-fired CFB units have not
    required any maintenance due to
    erosion throughout years of operation
    at design load conditions.

    Wall
    Tubes
    Individual Gas
    Outlet Hoods

    Ceramic
    Tile

    Pin Studs
    (To Anchor
    and Cool
    Refractory)

    Thin
    Refractory

    The reduced diameter zone tube section


    has proven to reduce maintenance by
    eliminating localized erosion at the
    refractory interface in the lower furnace.

    The secondary multi-cyclone dust


    collector in B&Ws unique two-stage
    particle separation system provides
    increased collection efficiency of fine
    particles. By locating the dust collector
    immediately upstream of the economizer
    in a region of cooler flue gas, and by
    using high hardness wear resistant
    material, maintenance is minimal. The
    design also permits easy access to all
    internal components.

    Access for
    Inspection

    High Hardness
    Collection Components

    Features and Benefits


    IR-CFB Design Features

    IR-CFB Design Benefits and Operating Results

    Two-stage particle separation


    system

    Greater than 99.8% particle collection efficiency


    Provides a means to control particle size distribution in furnace, which results
    in improved carbon burnout, limestone utilization, emissions and heat transfer
    Reduces operating costs

    All-internal primary solids


    recirculation (U-beams)

    Compact design requires 20-30% less building volume than cyclone-based CFB
    boilers critical for repowering projects
    Lowers auxiliary power consumption compared with cyclone-based CFB boilers

    Low, uniform velocities at the


    furnace exit (16-20 ft/s, 5-6 m/s),
    U-beam separators (26 ft/s, 8
    m/s), and the superheater (2530 ft/s, 8-9 m/s)

    Significantly reduces erosion in upper furnace and superheater compared with


    cyclone designs
    To date, no U-beam erosion maintenance required in B&Ws coal-fired CFBs
    since going into operation in 1989
    No high-maintenance vortex finders or hot expansion joints; therefore, no
    maintenance expenses for these items

    No thick refractory due to


    elimination of hot cyclones
    and hot return legs

    Thin, cooled refractory used by B&W places no restriction on boiler start-up or


    shut-down rate
    Significantly reduces need for refractory maintenance
    Virtually eliminates forced outages due to refractory failures
    Requires only 10 to 25% of the total refractory compared with hot cyclone CFB designs

    In-furnace heat transfer surface

    Vertical, flat membraned tube panels within furnace perform evaporative or


    superheat duty
    Proven reliability and low maintenance

    Unique primary air nozzles


    (bubble caps)

    Reduces back sifting of solids during low-load operation


    Reduces need for periodic cleaning of nozzles and primary air windbox
    Minimizes erosion inside nozzle caused by the re-entrainment of back-sifted solids

    Sootblowers usually not


    required upstream of MDC

    Eliminates maintenance costs and forced outages typically associated with


    sootblowers

    Gravity fuel feed and fly ash


    recycle system

    Reduces maintenance, forced outages and auxiliary power requirements by


    eliminating the mechanical fuel injection and pneumatic fly ash recycle systems

    High turndown (up to 5:1)


    without auxiliary fuel support

    Allows wider load swings


    Reduces operating costs (no auxiliary fuel) during low-load operation

    Fuel Flexibility,
    Lower Emissions
    Fuel Flexibility
    One of the main advantages of CFB
    technology is that it allows the owner to
    specify a wide variety of fuels to optimize
    the profitability of the facility. B&W has
    the engineering expertise and operating
    experience needed to supply an IR-CFB
    boiler that is capable of burning specified
    fuels, such as:
    Bituminous coal
    Bituminous gob or high-ash waste coal
    Subbituminous coal
    Lignite and brown coal
    Anthracite culm
    Coal cleaning tailings
    Petroleum coke
    Other fuels such as wood, biomass,
    shredded tires and sludge are also
    candidates, depending on their percentage
    of heat input, moisture content and
    emission requirements. The IR-CFB boiler
    also can be designed to burn several
    specified fuels in the same unit. This
    provides the additional flexibility needed
    to respond to changes in the fuel markets.

    Emissions Control
    The IR-CFB boiler can control SO2 emissions
    by injecting limestone into the lower
    furnace. Relatively low NOx emissions are
    inherent in the IR-CFB due to low furnace
    temperatures and staged combustion. NOx
    emissions can be further reduced by using
    a selective non-catalytic reduction (SNCR)
    system. In addition, the IR-CFBs patented
    secondary particle recycle system provides
    increased control, not found in other CFB
    technologies, to maintain an optimum
    uniform furnace temperature which is
    essential for low SO2 and NOx emissions.

    Located in Ebensburg, Pennsylvania, USA, this 60 MW power plant burns


    high-ash waste coal with B&Ws circulating fluidized-bed (CFB) technology
    to produce electricity and process steam.

    Fluidized-Bed Technologies to
    Meet Every Need
    There is no substitute for actual
    operating experience. B&W has that
    experience and a proven track record
    of high availability for all types of
    boiler technologies including all
    of our fluidized-bed combustion
    technologies circulating (IR-CFB)
    and bubbling (BFB).

    Bubbling Fluidized-Bed
    Technology
    For fuels with high moisture
    contents and low heating values
    such as sludges and high moisture
    biomass, B&W recommends the
    use of bubbling fluidized-bed (BFB)
    technology. B&W offers an open
    bottom BFB design which is ideal
    for burning fuels containing large

    pieces of noncombustible material,


    such as rocks and scrap metal. BFB
    technology also is well-suited for
    retrofit applications on stoker-fired
    or chemical recovery boilers.

    Innovative Energy Solutions


    B&W is committed to the
    continuing advancement of its
    fluidized bed technologies. This
    commitment is demonstrated
    through continued research and
    development. In addition, field
    demonstrations and testing have
    led to many improvements that are
    now implemented into our design
    standards as well as our operating
    CFB and BFB boilers.

    Babcock & Wilcox Power Generation Group, Inc. is a


    subsidiary of The Babcock & Wilcox Company (B&W).
    Established in 1867, B&W is a world leader in providing
    steam generating and emissions control equipment,
    nuclear operations and components, and defense
    program management services.
    For more information, or a complete listing of our sales
    and service offices, call 1-800-BABCOCK (222-2625),
    send an e-mail to info@babcock.com, or access
    our website.

    www.babcock.com

    Babcock & Wilcox Power Generation Group, Inc.


    20 S. Van Buren Avenue
    Barberton, Ohio 44203 USA
    Phone: 330.753.4511
    Fax: 330.860.1886
    The information contained herein is provided for general information
    purposes only and is not intended nor to be construed as a warranty, an
    offer, or any representation of contractual or other legal responsibility.

    2006 Babcock & Wilcox Power Generation Group, Inc.


    All rights reserved.

    E101-3148A 1KDC3A

    Through our experience,


    expertise and total-scope
    services, B&W is dedicated
    to generating powerful
    solutions in an environmentally safe, efficient
    and economical manner.

    B&Ws internal recirculation


    circulating fluidized-bed boiler is
    the technology of choice for power
    plant owners seeking economy,
    reliability and flexibility.

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