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BOILER DESIGN DEPARTMENT

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Presentation on theme: "BOILER DESIGN DEPARTMENT"— Presentation transcript:

1 BOILER DESIGN DEPARTMENT
RAFAKO CFB BOILERS TECHNOLOGY

2 CFBB TECHNOLOGY AT RAFAKO
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 1990. Total CFB Boilers capacity (approx MWt) contracted by RAFAKO in Poland: contract award start-up - OFz 45O A Żerań CHP - 2 x OFz-75 Polfa CHP - OFz-230 Bielsko-Biała CHP - 2 x OFz-425 Siersza PP /2002 - OFz-450 B Żerań CHP - OFz-201 Jaworzno PP

3 CFBB TECHNOLOGY AT RAFAKO - Advantages
"complex" environment protection method, i.e. low combustion temperatures (800oC - 900oC) result in the release of low quantities of nitric oxides (lower than 200 mg/Nm3) and due to the addition of calcium compounds to the furnace up to % reduction of sulphur oxides emission is obtained, firing of the unit with the wide range of fuels, minimum furnace load (c.a. 35%) without additional firing (with oil) utilisation of combustible industrial and municipal waste in thermal energy generation, high furnace efficiency obtained due to the high residence time of particles in the furnace (particles circulation) and good mixing of fuel with air,

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

5 CFBB TECHNOLOGY AT RAFAKO
1 2 3 a) b) HOT CIRCULATION BED IDEA FLUIDISATION PHASES: 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
Primary air nozzles Circulating bed Bottom nozzle grate

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

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 425 Siersza 425 t/h 560/560°C; 16,1/3,5 MPa OFz 450 B Żerań 450 t/h 510°C; 10 MPa

13 Boiler OFz-450 “A”, Żerań CHP, Warsaw
Technical Data Boiler capacity MCR 315 MWt Steam output 450 t/h Life steam temperature 510 oC Life steam pressure 10 MPa Feed water temp. 205 oC Boiler efficiency 92.2 % Fuel: Bituminous coal Heating Value MJ/kg Moisture % Ash % Sulphur %

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 Boiler OFz-230, Bielsko-Biała CHP
Technical Data Boiler capacity MCR 177/165 MWt Steam Output 230 t/h Life steam temperature 540 oC Life steam pressure MPa Feed water temp. 158/205 oC Boiler efficiency 91.2/91 % Fuel: Bituminous coal Heating Value MJ/kg Moisture % Ash % Sulphur 1 %

16 Boiler OFz-230, Bielsko-Biała CHP
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 MCR 60,2 MWt Steam Output 75 t/h Life steam temperature 455 oC Life steam pressure 4.5 MPa Feed water temp oC Boiler efficiency 91.5 % Fuel: Bituminous coal Heating Value 16,5-19 MJ/kg Moisture % Ash % Sulphur 1,4 %

18 Harmful emissions from the boiler (guaranteed and measured values)
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 2 x Boiler OFz-425 , Siersza PP
Technical Data Boiler capacity MCR MWt Life steam output t/h Life steam temp. (40-100%) oC Life steam pressure MPa Reheated steam output t/h Reheated steam temp. (50-100%) 350/560oC Reheated steam pressure / MPa Flue gas outlet temp. (at MCR) oC Efficiency (coal MJ/kg ) %

20 2 x Boilers OFz-425, Siersza PP
Fuel: Bituminous coal Heating value MJ/kg Ash % Moisture % Sulphur % Volatile matter % Overview of the erection phase of steel structure and cyclones Emission Guaranties SO mg/Nm3 NOx mg/Nm3 CO mg/Nm3 for normal, dry conditions with O2 content of 6%

21 Harmful emissions from the boiler (guaranteed and measured values)
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 MCR 315 MWt Steam output t/h Life steam temperature 510 oC Life steam pressure 10 MPa Feed water temperature 205 oC Boiler efficiency 92% Fuel: Bituminous coal Heating Value MJ/kg Moisture % Ash % 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

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

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

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

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

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

37 Boiler Construction Optimisation
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)

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

39 Boiler Construction Optimisation
Target: Simplification of Installation

40 Boiler Construction Optimisation
Target: Simplification of Installation

41 Operational Experience With Circulating Fluid Bed Technology In Poland
Summary Participation and supervision of Supplier at erection and commissioning of the boiler Co-operation with the Client during boiler operation 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)

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
RAFAKO CFB BOILERS TECHNOLOGY THANK YOU FOR YOUR ATTENTION


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