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BOILER DESIGN DEPARTMENT BOILER DESIGN DEPARTMENT RAFAKO CFB BOILERS TECHNOLOGY.

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Presentation on theme: "BOILER DESIGN DEPARTMENT BOILER DESIGN DEPARTMENT RAFAKO CFB BOILERS TECHNOLOGY."— Presentation transcript:

1 BOILER DESIGN DEPARTMENT BOILER DESIGN DEPARTMENT RAFAKO CFB BOILERS TECHNOLOGY

2 First CFB contract for RAFAKO S.A. OFz-230 for CHP Lublin Wrotków in 1990 after signing a licence agreement for CFB with Alstom Power (EVT Stuttgart) in First CFB contract for RAFAKO S.A. OFz-230 for CHP Lublin Wrotków in 1990 after signing a licence agreement for CFB with Alstom Power (EVT Stuttgart) in Total CFB Boilers capacity (approx MWt) contracted by RAFAKO in Poland: Total CFB Boilers capacity (approx MWt) contracted by RAFAKO in Poland: contract awardstart-up - OFz 45O AŻerań CHP x OFz-75Polfa CHP OFz-230Bielsko-Biała CHP x OFz-425Siersza PP /2002 -OFz-450 BŻerań CHP OFz-201Jaworzno PP CFBB TECHNOLOGY AT RAFAKO

3 n n "complex" environment protection method, i.e. low combustion temperatures (800 o C o C) result in the release of low quantities of nitric oxides (lower than 200 mg/Nm 3 ) and due to the addition of calcium compounds to the furnace up to % reduction of sulphur oxides emission is obtained, n n firing of the unit with the wide range of fuels, n n minimum furnace load (c.a. 35%) without additional firing (with oil) n n utilisation of combustible industrial and municipal waste in thermal energy generation, n n high furnace efficiency obtained due to the high residence time of particles in the furnace (particles circulation) and good mixing of fuel with air, CFBB TECHNOLOGY AT RAFAKO - Advantages

4 n n low air excess (15% - 20%) at nominal load, n n possibility of quick changes of boiler load like in case of pulverised fuel boilers, i.e. 4% - 6%, n n high desulphurization level (low Ca/S) due to good mixing of additives and fuel and due to recirculation, n n possibility of return to the load even after several hours, n n possibility of firing with high ash coal, n n simple feeding of fuel to the furnace, n n good heat exchange coefficient in furnace, n n dry ash removal from furnace chamber and possibility of its further utilisation. CFBB TECHNOLOGY AT RAFAKO - Advantages

5 CFBB TECHNOLOGY AT RAFAKO a) b) HOT CIRCULATION BED IDEA FLUIDISATION PHASES: 1. 1.Moving up to the top of furnace to the cyclone 2. Dropping down along furnace walls surface 3.Separation in cyclone a)Return of coarse grains to the furnace b)Fine grains escaping to the boiler second pass

6 CFBB TECHNOLOGY AT RAFAKO Bottom nozzle grate Bottom nozzle grate Primary air nozzles Circulating bed

7 CFBB TECHNOLOGY AT RAFAKO Grain size Residue Minus mesh REQUIRED COAL GRAIN SIZE DISTRIBUTION - Bituminous Coal

8 CFBB TECHNOLOGY AT RAFAKO REQUIRED COAL GRAIN SIZE DISTRIBUTION - Lignite Residue Minus mesh Grain size

9 CFBB TECHNOLOGY AT RAFAKO REQUIRED LIMESTONE GRAIN SIZE DISTRIBUTION

10 REFERENCE LIST OF CFB BOILERS

11 CFB BOILERS DESIGNED & PRODUCED BY RAFAKO OFz 450 A Żerań 450 t/h 510°C; 10 MPa OFz 230 Bielsko 230 t/h 540°C; 13,8 MPa OFz 75 Polpharma 75 t/h 455°C; 4,5 MPa

12 CFB BOILERS DESIGNED & PRODUCED BY RAFAKO OFz 450 B Żerań 450 t/h 510°C; 10 MPa OFz 425 Siersza 425 t/h 560/560°C; 16,1/3,5 MPa

13 Boiler OFz-450 A, Żerań CHP, Warsaw Fuel: Bituminous coal Heating Value MJ/kg Heating Value MJ/kg Moisture % Moisture % Ash % Ash % Sulphur % Sulphur % Technical Data Boiler capacity MCR315 MWt Boiler capacity MCR315 MWt Steam output450 t/h Steam output450 t/h Life steam temperature510 o C Life steam temperature510 o C Life steam pressure 10 MPa Life steam pressure 10 MPa Feed water temp.205 o C Feed water temp.205 o C Boiler efficiency92.2 % Boiler efficiency92.2 %

14 Boiler OFz-450 A, Żerań CHP, Warsaw Harmful Emissions From the Boiler (guaranteed and measured values) 67%83% 16% 48% Real emission value vs. guaranteed 36% 11%

15 Technical Data Boiler capacity MCR177/165 MWt Boiler capacity MCR177/165 MWt Steam Output230 t/h Steam Output230 t/h Life steam temperature 540 o C Life steam temperature 540 o C Life steam pressure 13.8 MPa Life steam pressure 13.8 MPa Feed water temp.158/205 o C Feed water temp.158/205 o C Boiler efficiency91.2/91 % Boiler efficiency91.2/91 % Fuel: Bituminous coal Heating Value MJ/kg Heating Value MJ/kg Moisture10-17 % Moisture10-17 % Ash20-30 % Ash20-30 % Sulphur 1 % Sulphur 1 % Boiler OFz-230, Bielsko-Biała CHP

16 Harmful emissions from the boiler (guaranteed and measured values) 29% 65% 30% 6% Real emission value vs. guaranteed

17 2 x OFz-75, Polfa Starogard Gdański Technical Data Boiler capacity MCR60,2 MWt Boiler capacity MCR60,2 MWt Steam Output75 t/h Steam Output75 t/h Life steam temperature 455 o C Life steam temperature 455 o C Life steam pressure 4.5MPa Life steam pressure 4.5MPa Feed water temp.105 o C Feed water temp.105 o C Boiler efficiency91.5 % Boiler efficiency91.5 % Fuel: Bituminous coal Heating Value16,5-19 MJ/kg Heating Value16,5-19 MJ/kg Moisture15-21 % Moisture15-21 % Ash25-32 % Ash25-32 % Sulphur 1,4 % Sulphur 1,4 %

18 2 x OFz-75, Polfa Starogard Gdański Harmful emissions from the boiler (guaranteed and measured values) 75% 50% 40% Real emission value vs. guaranteed

19 Technical Data Boiler capacity MCR MWt Boiler capacity MCR MWt Life steam output 425 t/h Life steam output 425 t/h Life steam temp. (40-100%) 560 o C Life steam temp. (40-100%) 560 o C Life steam pressure 16.1 MPa Life steam pressure 16.1 MPa Reheated steam output 371 t/h Reheated steam output 371 t/h Reheated steam temp. (50-100%) 350/560 o C Reheated steam temp. (50-100%) 350/560 o C Reheated steam pressure 3.7/3.5 MPa Reheated steam pressure 3.7/3.5 MPa Flue gas outlet temp. (at MCR)135 o C Flue gas outlet temp. (at MCR)135 o C Efficiency (coal MJ/kg ) 91.0 % Efficiency (coal MJ/kg ) 91.0 % 2 x Boiler OFz-425, Siersza PP

20 2 x Boilers OFz-425, Siersza PP Fuel: Bituminous coal Heating value 16.7MJ/kg Heating value 16.7MJ/kg Ash 20.6 % Ash 20.6 % Moisture 21.7% Moisture 21.7% Sulphur 2.4 % Sulphur 2.4 % Volatile matter 36.6% Volatile matter 36.6% Emission Guaranties SO mg/Nm 3 SO mg/Nm 3 NO x mg/Nm 3 NO x mg/Nm 3 CO 250 mg/Nm 3 CO 250 mg/Nm 3 for normal, dry conditions with O 2 content of 6% Overview of the erection phase of steel structure and cyclones

21 Boiler OFz-425, Siersza PP Harmful emissions from the boiler (guaranteed and measured values) 85% 80% 55% 15% Real emission value vs. guaranteed 50%

22 Boiler OFz-450 B, Żerań CHP, Warsaw Technical Data Boiler capacity MCR315 MWt Boiler capacity MCR315 MWt Steam output450 t/h Steam output450 t/h Life steam temperature510 o C Life steam temperature510 o C Life steam pressure 10 MPa Life steam pressure 10 MPa Feed water temperature205 o C Feed water temperature205 o C Boiler efficiency 92% Boiler efficiency 92% Fuel: Bituminous coal Heating Value MJ/kg Heating Value MJ/kg Moisture8 - 15% Moisture8 - 15% Ash15- 25% Ash15- 25% Sulphur % Sulphur %

23 Boiler OFz-450 B, Żerań CHP, Warsaw Harmful Emissions From the Boiler (guaranteed and measured values) 75% Real emission value vs. guaranteed 60% 50%

24 Boiler OFz-450 B, Żerań CHP, Warsaw Steam drum piping spider in engineering and in fabrication phase and in fabrication phase

25 Comparison of Coals Burnt in CFB Boilers in Poland Coal Parameters Comparison

26 Boiler Construction Optimisation Resulting From Operational Experience Target No 1: Operating Conditions Improvement Target No 2: Simplification of CFB Installation

27 Target: Operating Conditions Improvement Antierosion protection for furnace walls Antierosion protection for furnace walls Antierosion protection for other heating surface within the boiler Antierosion protection for other heating surface within the boiler Antiradiation protection for boiler heating surfaces Antiradiation protection for boiler heating surfaces Improvement of boiler element connection Improvement of boiler element connection Boiler Construction Optimisation

28 Target: Operating Conditions Improvement Antierosion protection for furnace membrane walls Metal coating (Żerań A & B, Siersza)

29 Boiler Construction Optimisation Target: Operating Conditions Improvement Antierosion protection for furnace membrane walls Mechanical shield (Żerań B, Siersza)

30 Boiler Construction Optimisation Target: Operating Conditions Improvement Antierosion protection for furnace membrane walls Mechanical shield (Żerań B, Siersza)

31 Boiler Construction Optimisation Target: Operating Conditions Improvement Antierosion protection for furnace membrane walls Protective shape of the hopper refractory lining (Żerań B, Siersza)

32 Boiler Construction Optimisation Target: Operating Conditions Improvement Protective shape of the refractory lining on the return ash chute and burners openings in the furnace chamber (Siersza)

33 Boiler Construction Optimisation Antierosion protection for other heating surfaces within the boiler (Żerań A & B, Siersza) Target: Operating Conditions Improvement

34 Boiler Construction Optimisation Antierosion protection for furnace corners Previous solution New solution Target: Operating Conditions Improvement

35 Boiler Construction Optimisation Target: Operating Conditions Improvement Antiradiation shields (Polfa, Żerań A & B, Siersza)

36 Target: Simplification of Installation Optimisation of cyclone separators shape Optimisation of cyclone separators shape Improved bed ash extraction system Improved bed ash extraction system Improved start-up system of the boiler Improved start-up system of the boiler Simplified inert material recirculation system Simplified inert material recirculation system Boiler Construction Optimisation

37 Cyclones shape and arrangement modification Cyclone with the spiral inlet Centric placement of the vortex finder Sloping inlet to the cyclone regarding to furnace chamber (Żerań A) Tangent and narrow inlet to the cyclone Increase of cyclone diametr Eccentric placement of the vortex finder Vertical inlet to the cyclone regarding to furnace chamber (Żerań B, Siersza) Boiler Construction Optimisation

38 Simplified inert material recirculation system abandoning of fly-ash recirculation system abandoning of fly-ash recirculation system abandoning of ash mill with auxiliaries and mill ash vessel abandoning of ash mill with auxiliaries and mill ash vessel abandoning of ash separator and hot ash scraped conveyor abandoning of ash separator and hot ash scraped conveyor implementation of main screw ash extractor implementation of main screw ash extractor Improved start-up system of the boiler: abandoning of oil lances abandoning of oil lances better flame control better flame control better burner nozzle adjustment better burner nozzle adjustment improved protection of burner tips improved protection of burner tips Target: Simplification of Installation

39 Boiler Construction Optimisation Target: Simplification of Installation

40 Boiler Construction Optimisation Target: Simplification of Installation

41 Participation and supervision of Supplier at erection and commissioning of the boiler Participation and supervision of Supplier at erection and commissioning of the boiler Co-operation with the Client during boiler operation Co-operation with the Client during boiler operation Adaptation of specific construction measures needed for the coal fired in CFB Adaptation of specific construction measures needed for the coal fired in CFB CFB Boilers achieves all guarantied performance and environmental values even for very wide coal spectrum (including coal outside contract characteristic) CFB Boilers achieves all guarantied performance and environmental values even for very wide coal spectrum (including coal outside contract characteristic) Summary Operational Experience With Circulating Fluid Bed Technology In Poland

42 PP Siersza OFz 425 t/h

43 CHP Żerań OFz 450 t/h

44 CHP Bielsko-Biała OFz 230 t/h

45 BOILER DESIGN DEPARTMENT BOILER DESIGN DEPARTMENT RAFAKO CFB BOILERS TECHNOLOGY THANK YOU FOR YOUR ATTENTION


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