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KLY-1 1997-05 P:\582-RAPP-PB3\int\Kayttoonotto\koulutus\Training Manuals\Folder 1\2.7 Limestone system.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
TABLE OF CONTENTS 2.7 LIMESTONE SYSTEM.................................................................................. 3
2.7.1 Purpose of the system ................................................................................ 3
2.7.2 General description of the system............................................................. 4
2.7.3 Design criteria.............................................................................................. 7
2.7.4 Equipment specification ............................................................................. 8
2.7.4.1 Limestone receiving hopper .......................................................................... 8
2.7.4.2 Limestone hopper vibratory feeder ................................................................ 8
2.7.4.3 Limestone intake belt..................................................................................... 9
2.7.4.4 Magnet .......................................................................................................... 9
2.7.4.5 Limestone mill feed hopper ......................................................................... 10
2.7.4.6 Limestone mill vibratory feeder.................................................................... 10
2.7.4.7 Limestone mill and separator ...................................................................... 11
2.7.4.8 Limestone mill fan........................................................................................ 14
2.7.4.9 Limestone drying unit burner ....................................................................... 14
2.7.4.10 Limestone air heater fan.............................................................................. 15
2.7.4.11 Limestone cyclone....................................................................................... 15
2.7.4.12 Limestone cyclone rotary feeder.................................................................. 16
2.7.4.13 Limestone bag filter ..................................................................................... 16
2.7.4.14 Limestone bucket elevator........................................................................... 18
2.7.4.15 Limestone feeding silo ................................................................................. 19
2.7.4.16 Limestone feeding screw ............................................................................. 20
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2.7.4.17 Limestone rotary feeder............................................................................... 21
2.7.4.18 Limestone injection piping ........................................................................... 22
2.7.4.19 Limestone injection air blower ..................................................................... 23
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2.7 LIMESTONE SYSTEM
Flowsheets: T582-00030 Limestone drying T582-00031 Limestone feeding
2.7.1 Purpose of the system
The purpose of the limestone system is to supply to the boiler limestone needed for sulphur removal from the flue gas. Big and moist limestone particles are first crushed and dried in a separate limestone prehandling factory.
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2.7.2 General description of the system
Limestone is delivered to the intake hopper, and a vibratory feeder discharges onto the inclined belt conveyor, which discharges into the mill feed hopper. The feed is extracted from the feed hopper by a vibratory feeder, automatically keeping the mill at constant load. In the mill plows throw the material between the rollers and the die ring for grinding. The rollers are forced against the die ring by centrifugal action, creating great grinding pressure and automatically compensating for wear. Hot air is drawn into the mill, to dry the material being ground and to carry the powder from the mill to the separator, which allows only the correct particles size to pass. The ground product is blown to the (limestone) cyclone, where it is separated from the air stream and discharged to the bucket elevator, which feeds the limestone storage (or feeding) silo.
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Air from the cyclone passes through the mill fan and returns to the mill. Part of the air is vented through a bag filter, and this is replaced by hot air from the heater. The heater firing rate is automatically controlled to keep the product moisture constant. Collected dust from the filter is also discharged to the bucket elevator and furthermore conveyed to the limestone storage (or feeding) silo. From limestone silo material falls through the hand operated slide gate to the variable frequency controlled dosing screw feeder. Above screw feeder there is an intermediate hopper. On the intermediate hopper there is a low level detector which controls the fluidising valves (3pcs) near the discharge chute of the silo. If low level detector gives alarm fluidising is started as long as the material level is under low level. On the screw feeder pocket there are three screw feeders which discharge material to the rotary feeder. Rotary feeder rotor is divided to three separate blocks so that each screw feeds material to its own section. After rotary feeder there are three separate pneumatic feeding lines, one for each section of the rotary valve, where the material is falling from the rotary feeder. Pneumatic line pressure is controlled by the magnetic valves. Limestone feeding capacity is controlled by the speed regulated screw feeders.
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Furthermore pneumatic feeding is divided to six feeding points at furnace front wall. Feeding openings are located close to the fuel feeding points. The pneumatic conveying air comes from a separate high pressure blower. Amount of dosed limestone is adjusted according to fuel sulphur content and boiler load and fine tuning is carried out based on flue gas SO2-measurement.
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2.7.3 Design criteria
Limestone
Requirement for limestone is the following: 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 – 97,1MgCO3 % 1,5 - 3,0
Assumed maximum moisture content % 3
Limestone prehandling factory
Equipment is capable to handle 40t/h limestone when having properties as explained above. The expected maximum end moisture of the limestone is 0,5%. The expected limestone size distribution after the prehandling is: 99 % mm < 250 % mm < 0,220 % mm < 0,045
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2.7.4 Equipment specification 2.7.4.1 Limestone receiving hopper
Equipment number 283T018Number pcs 1Manufacturer RAPP (Bradley Pulverizer
Company design)Volume m3 20Dimensions m 4 x 3Feed height m 5Material steelEquipment − weather cover − supports to ground
2.7.4.2 Limestone hopper vibratory feeder
Equipment number 283C032Number pcs 1Manufacturer Bradley Pulverizer CoCapacity (max) t/h 60Drive Magnetic motor with variable
amplitude from manual thyristor drive
Accessories − thyristor in local panel
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2.7.4.3 Limestone intake belt
Equipment number 283C033Number pcs 1Manufacturer Bradley Pulverizer CoCapacity (max) t/h 40Lenght m 26Drive kW 4Materials: − 2 ply nylon − 3 mm rubber face − 1,5 mm rubber reverse Accessories − dust covers − supports to ground − foundation bolts
2.7.4.4 Magnet
Equipment number 283E095Number pcs 1Manufacturer Type permanent magnetMotor kW 2Accessories − suspension chains − draw plate to remove tramp iron
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2.7.4.5 Limestone mill feed hopper
Equipment number 283T027Number pcs 1Manufacturer RAPP (Bradley Pulverizer
Company design)Dimensions m 5 x 3Feed height m 8,5Material steelEquipment − weather cover − isolating slide gate at exit Level probes Type Magnetrol VSH-S2BA-00Size 235 insertion lenghtQuantity 3 off
2.7.4.6 Limestone mill vibratory feeder
Equipment number 283C035Number pcs 1Manufacturer Bradley Pulverizer CoCapacity (max) t/h 60Drive 2 kW with variable amplitude from
automatic thyristor driveAccessories − local panel houses controls to keep mill amps contstant
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2.7.4.7 Limestone mill and separator
Figure 1 Grinding chamber of the limestone mill
Limestone mill Equipment number 283E099Number pcs 1Manufacturer Bradley Pulverizer CoManufacturer’s type BM20 Pendulum 3 rollerCapacity t/h 40Materials − cast iron base − cast steel gearbox, grinding chamber and roll carrier − wear resistant cast alloy die ring and rollheads
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Accessories − foundation bolts − four large spanners (special tools) Drive Type Bradley supply belt drive
and pulleys with slide railsMotor (supplied by RAPP) kW 250 (6 pole) Limestone mill lubrication pump Equipment number 283P030Type Lubricator for gearbox with
low pressure switchMotor kW 0,25 Limestone mill purge air fan Equipment number 283K018Type Air fan for mill rollsFlow at design point m3/h 400Motor kW 1,1
The airswept mill system grinds, classifies and dries material simultaneously. Pulverized material from the grinding zone is carried by air stream to a separator, mounted directly above the mill. Product-size material is carried to the collection cyclone while oversize particles are rejected and recycled for further grinding.
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Figure 2 Limestone separator above the mill
Limestone separator Equipment number 283E099Number pcs 1Manufacturer Bradley Pulverizer CoType Inverted cone separatorAdjustment hand winch to raise or lower
inner coneCapacity t/h 40Material steelAccessories − antivibration mountings − isolating rubber sleeve at base
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2.7.4.8 Limestone mill fan
Equipment number 283K017Number pcs 1Manufacturer Bradley Pulverizer CoType centrifugalCapacity m3/h 50000Material steelDrive Vee belt drive, guard and
base frame with slide railsMotor (supplied by RAPP) kW 250 (4 pole)Accessories − rubber sleeve on inlet (anti-vibration) − foundation bolts
2.7.4.9 Limestone drying unit burner
Equipment number 283E126Number pcs 1Manufacturer Type Fully modulating diesel
burner, sideplate mounted in duct packaged heater.
Capacity kW 1500 (5 x 106 kJ/h)Motor kW 0,2Materials − cast iron manifold − stainless steel diffuser plate and end wings − mil steel housing
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Accessories − panel with controls and temperature indicator direct mounted on
duct − flame monitoring − ignition system − foundation bolts
Burner is automatically adjusted to keep mill exit temperature constant.
2.7.4.10 Limestone air heater fan
Equipment number 283K011Number pcs 1Manufacturer Bradley Pulverizer CoFlow at design point m3/h 1745Motor kW 2,2 (2 pole)
2.7.4.11 Limestone cyclone
Equipment number 283E124Number pcs 1Manufacturer RAPP (Bradley Pulverizer
Company design)Type Standard mill cycloneCapacity m3/h 50000Dimensions, diameter mm 3600Efficiency % 90 – 92Material steelAccessories − fixing bolts to steelwork − support to ground level
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2.7.4.12 Limestone cyclone rotary feeder
Equipment number 283E124Number pcs 1Manufacturer Bradley Pulverizer CoType rotary airlockSize, diameter mm 450Drive Geared motor with chain
set and guardMotor kW 2,2
2.7.4.13 Limestone bag filter
Equipment number 283E097Number pcs 1Manufacturer Bradley Pulverizer CoType Reverse jet, top bag
removal, tubular bagsCapacity m3/h 15000Filter bag area m2 150Controls Timer for compressed air
pulsesConsumption, pressurized air m3/h 15Materials steel− bags polyester needle felt cloth− casing steelAccessories − fixing bolts to steelwork − access platform for valves − ladder to filter top
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Figure 3 Limestone bag filter
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Limestone filter fan Equipment number 283K012Number pcs 1Manufacturer Bradley Pulverizer CoFlow at design point m3/h 15300Type Belt driveMotor kW 15 Limestone filter rotary feeder and screw Equipment number 283E098Number pcs 1Manufacturer Bradley Pulverizer CoType Combined drive with
chainsetDiameter mm 200Motor kW 2,2
2.7.4.14 Limestone bucket elevator
Equipment number 283C038Number pcs 1Manufacturer Raumaster OyCapacity t/h 40Accessories steel− feed chute from cyclone and filter − discharge chute to silo
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2.7.4.15 Limestone feeding silo
Equipment number 283T019Number pcs 1Manufacturer RAPP (Raumaster design)Gross volume m3 300Diameter m 6,5Height (total) m 18Equipment: − legs and support steel construction − fluidizing air ring − filter A = 10 m², pneumatic cleaning − standard service doors Hand operated slide gate (below the silo) Opening size mm 400 x 400Materials: − frame carbon steel− slide gate stainless steel
Pneumatic cleaning system removes limestone dust which appears when feeding the limestone silo. Pneumatic cleaning system (motor 1,5 kW + cleaning) is started at the same time when starting the conveyor which is feeding the silo. Cleaning system has a control system of its own which controls the magnetic valves of cleaning. The motor of the cleaning system is stopped with 5 minutes delay after the silo feeding conveyor is stopped. The cleaning is stopped with 2 minutes delay after the motor of the cleaning system is stopped.
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Intermediate hopper (above the feeding screw) Volume (about) l 120Material stainless steelLevel switch Drexelbrook or equivalent
2.7.4.16 Limestone feeding screw
Equipment number 283C039Number pcs 1 (3 separate screws)Manufacturer Raumaster OyCapacity (total) m3/h 2,6 ... 25Screw rotation speed rpm 4 ... 42Screw flight diameter mm 219Screw length m 1,2Motors kW x 2,2 with thermistors (3 pcs)− variable frequency drive (supplied by RAPP) Accessories: − ventilation pipeline connection DN80 in the discharge chute and in
intermediate hopper − pipeline to the upper part of the limestone silo
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Figure 4 Limestone feeding screw
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2.7.4.17 Limestone rotary feeder
Equipment number 283E101Number pcs 1 (3 separate sections)Manufacturer Raumaster OyManufacturer’s type ALF 30/60 PCapacity (total) m3/h 25Rotation speed rpm 24Motor kW 5,5Zero speed swith manufacturer TelemecaniqueMaterials: − inner lining of cells stainless steel− inner surface of frame hard crome plating− other parts carbon steel
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2.7.4.18 Limestone injection piping
Manufacturer Kvaerner Power OyPipe from the feeding air blower DN400Piping from rotary feeder 3 x DN250Piping to boiler 6 x DN150Injection nozzle location Furnace front wallInjection nozzle height m 2,5 from furnace bottomNozzle inclination 30° downwards
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2.7.4.19 Limestone injection air blower
Equipment number 283K014Manufacturer Oy Ekstrom Flow Ab /
DresserNumber of blowers 1Model XLP408Type Three-bladed roots blowerMotor (supplied by RAPP) kW 355 Performance at maximum pressure difference Differential pressure kPa 73Air flow Nm3/s 2,6Temperature increase °C 80Rotary blower speed rpm 1924 Accessories: − pressure relief valve − acoustic enclosure (about 4m x 2,2m x 3,6m) − suction side silencer − ventilation air fan for the acoustic enclosure (fan motor rated
power 0,55 kW – 0,75 kW, manufacturer WEG, CMG or equal) − flexible connection (either a stainless steel bellows type with mild
steel flanges or a silicon tube type with mild steel flanges)
Figure 5 shows Limestone injection air blower curve and figures 6 and 7 the structure of the blower.
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DRESSER ROOTSHOLMES OPERATIONPO BOX B7 TURNBRIDGEHUDDERSFIELD HD1 6RB
PERFORMANCE BASED ON AIR, INLET PRESSURE = 1013
MBAR INLET TEMPERATURE = 20 0C
0.000
50.000
100.000
150.000
200.000
250.000
300.000
350.000
400.000
500 1000 1500 2000 2500SPEED - RPM
POW
ER -
KW
0.000
50.000
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150.000
500 1000 1500 2000 2500
TEM
P. R
ISE
- 0 C
2000.0
4000.0
6000.0
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10000.0
12000.0
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500 1000 1500 2000 2500
ACTU
AL IN
LET
FLO
W -
M3 /H
200 MBAR400 MBAR600 MBAR800 MBAR
800 MBAR
PRESSURE PERFORMANCEFRAME XLP 408
MAX. PRESSURE RISE = 800 MBARMAX. SPEED = 2000 RPM
600 MBAR
400 MBAR
200 MBAR
800 MBAR
600 MBAR
400 MBAR
200 MBAR
Figure 5 Limestone injection air blower curve
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
Asiakirjan nimi - Name of Document Tunniste - Identification Rev.
PROCESS DESCRIPTION CFBT-582-1 0
Osasto - Department Kohde - Subject Sivu - Page
Power Generation Systems
RAPP PB3 PROJECT CFB MULTIFUEL BOILER
25 (25)
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
Figure 6 Limestone injection air blower (type XLP)
Figure 7 Three-bladed rotor of the blower