BOILER DESIGN DEPARTMENT BOILER DESIGN DEPARTMENT RAFAKO CFB BOILERS TECHNOLOGY.

BOILER DESIGN DEPARTMENT BOILER DESIGN DEPARTMENT

RAFAKO CFB BOILERS TECHNOLOGYRAFAKO CFB BOILERS TECHNOLOGY

First CFB contract for RAFAKO S.A. OFz-230 for CHP Lublin Wrotków 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 1990 after signing a licence agreement for CFB with Alstom Power (EVT Stuttgart) in 1990Stuttgart) in 1990..

Total CFB Boilers capacity (approx. 1Total CFB Boilers capacity (approx. 175755 MWt) contracted by RAFAKO 5 MWt) contracted by RAFAKO in Poland:in Poland:

contract awardcontract award start-upstart-up

- - OFz 45O AOFz 45O A Żerań CHPŻerań CHP 19931993 19961996

- - 2 x OFz-752 x OFz-75 Polfa CHPPolfa CHP 19931993 19961996

- - OFz-230OFz-230 Bielsko-Biała CHPBielsko-Biała CHP 1994199419961996

-- 2 x OFz-4252 x OFz-425 Siersza PPSiersza PP 19981998 2001/20022001/2002

-- OFz-450 BOFz-450 B Żerań CHPŻerań CHP 19981998 20012001

-- OFz-201OFz-201 Jaworzno PPJaworzno PP 20102010 20122012

CFBB TECHNOLOGY AT RAFAKOCFBB TECHNOLOGY AT RAFAKO

"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 90 - 95% 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,

CFBB TECHNOLOGY AT RAFAKO - CFBB TECHNOLOGY AT RAFAKO - AdvantagesAdvantages

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.

CFBB TECHNOLOGY AT RAFAKO - CFBB TECHNOLOGY AT RAFAKO - AdvantagesAdvantages


1

2 3

a)

b)

HOT CIRCULATION BED IDEAHOT CIRCULATION BED IDEA

FLUIDISATION PHASES:

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 tothe furnace

b) Fine grains escaping tothe boiler second

pass


Bottom nozzle grateBottom nozzle grate

Primary airPrimary air

nozzlesnozzles

Circulating bedCirculating bed


Grain size

Res

idu

e

Min

us

mes

h

REQUIRED COAL GRAIN SIZE DISTRIBUTION - Bituminous Coal


REQUIRED COAL GRAIN SIZE DISTRIBUTION - Lignite

Res

idu

e

Min

us

mes

hGrain size

REQUIRED LIMESTONE GRAIN SIZE DISTRIBUTION

10 100 1000Grain size d [m]

Re

sid

ue

[%

]

K211

50 200 300 700

0,1

1

5

10

20

50

80

90

95

98

99

99,5

30

40

60

70

85

96

97

98,5

3020


REQUIRED LIMESTONE GRAIN SIZE DISTRIBUTION

LIMESTONE REQUIREMENTS

Purity of the limestone (CaCO3 content) 90 %

Moisture content < 0.1 %

Reactivity index - RI > 2.5

REFERENCE LIST OF CFB BOILERSREFERENCE LIST OF CFB BOILERS

CustomerPlant Name

Country

QtyBoiler

capacityt/h

Steampressure

bar

Temperatureof live/reheat

steam ºCFuel

PP Wachtberg - Germany 1 175 190 535 lignite

CHP Köhler - Germany 1 100 136 535 bituminuous coal

CHP Gaisburg - Germany 1 150 90 500 bituminuous coal

CHP Pforzheim - Germany 1 90 166 540 bituminuous coal

PP Emile Huchet - France 1 367 155 545 / 540 Bituminuous coal sludge

PP Berrenrath - Germany 2 250 107 510 lignite

PP Goldenberg - Germany 1 400 135 505 lignite

PP Wählitz - Germany 1 150 115 535 lignite

PP Gardanne - France 1 700 193 565 / 565 bituminuous coal

CHP Bielsko II - Poland 1 230 138 540 bituminuous coal

CHP Żerań - Poland 1 450 100 510 bituminuous coal

CHP Tisova - Czech 1 350 116 505 lignite

CHP Polpharma - Poland 2 75 45 455 bituminuous coal

PP Mironowska - Ukraine 1 260 138 540 anthracit

EC Mlada Boleslav - Czech 2 140 125 535 bituminuous coal

PP Red Hills - USA 2 753 203 568 /540 lignite

PP CAN - Turkey 2 462 175 / 38 543 / 542 lignite

PP Siersza - Poland 2 425 161 560 / 560 bituminuous coal

CHP Żerań - Poland 1 450 100 510 bituminuous coal

CFB BOILERS DESIGNED & PRODUCED BY CFB BOILERS DESIGNED & PRODUCED BY RAFAKORAFAKO

OFz 450 A ŻerańOFz 450 A Żerań450 t/h450 t/h

510°C; 10 MPa510°C; 10 MPa

OFz 230 BielskoOFz 230 Bielsko230 t/h230 t/h

540°C; 13,8 MPa540°C; 13,8 MPa

OFz 75 PolpharmaOFz 75 Polpharma75 t/h75 t/h

455°C; 4,5 MPa455°C; 4,5 MPa

CFB BOILERS DESIGNED & PRODUCED BY CFB BOILERS DESIGNED & PRODUCED BY RAFAKORAFAKO

OFz 450 B ŻerańOFz 450 B Żerań450 t/h450 t/h

510°C; 10 MPa510°C; 10 MPa

OFz 425 SierszaOFz 425 Siersza425 t/h425 t/h

560/560°C; 16,1/3,5 MPa560/560°C; 16,1/3,5 MPa

Boiler OFz-450 “A”, Żerań CHP, WarsawBoiler OFz-450 “A”, Żerań CHP, Warsaw

Fuel: Bituminous coalFuel: Bituminous coal Heating Value Heating Value 22 - 28 MJ/kg22 - 28 MJ/kg MoistureMoisture 8 - 15 %8 - 15 % AshAsh 7 - 18 %7 - 18 % SulphurSulphur 0.6 - 0.8 %0.6 - 0.8 %

Technical DataTechnical Data

Boiler capacity MCRBoiler capacity MCR 315 MWt315 MWt Steam outputSteam output 450 t/h450 t/h Life steam temperatureLife steam temperature 510 510 ooCC Life steam pressure Life steam pressure 10 MPa10 MPa Feed water temp.Feed water temp. 205 205 ooCC Boiler efficiencyBoiler efficiency 92.2 %92.2 %

Boiler OFz-450 “A”, Żerań CHP, WarsawBoiler OFz-450 “A”, Żerań CHP, Warsaw

0

50

100

150

200

250

Em

issi

on

[mg

/Nm

3]

SO2 NOx CO HCl HF FlyAsh

Guaranties

Measurements

Harmful Emissions From the Boiler

(guaranteed and measured values)

67%67% 83%83% 16%16%

48%48%

Real emission value vs. guaranteed

36%36%

11%11%


Boiler capacity MCRBoiler capacity MCR 177/165 177/165 MWtMWt Steam OutputSteam Output 230 t/h230 t/h Life steam temperature 540 Life steam temperature 540 ooCC Life steam pressure Life steam pressure 13.8 MPa13.8 MPa Feed water temp.Feed water temp. 158/205 158/205 ooCC Boiler efficiencyBoiler efficiency 91.2/91 %91.2/91 %

Fuel: Bituminous coalFuel: Bituminous coal

Heating ValueHeating Value 17-20.1 MJ/kg17-20.1 MJ/kg

MoistureMoisture 10-17 %10-17 %

AshAsh 20-30 %20-30 %

SulphurSulphur 1 %1 %

Boiler OFz-230, Bielsko-Biała CHP Boiler OFz-230, Bielsko-Biała CHP

Boiler OFz-230, Bielsko-Biała CHPBoiler OFz-230, Bielsko-Biała CHP

Harmful emissions from the boiler


29%29% 65%65%30%30%

6%6%


0

50

100

150

200

250

300

Em

issi

on

[mg

/Nm

3]

SO2 NOx CO Fly Ash

Guaranties

Measurements

2 x OFz-75, Polfa Starogard Gdański2 x OFz-75, Polfa Starogard Gdański


Boiler capacity MCRBoiler capacity MCR 60,2 60,2 MWtMWt Steam OutputSteam Output 7575 t/h t/h Life steam temperature 455Life steam temperature 455 ooCC Life steam pressure Life steam pressure 4.54.5 MPaMPa Feed water temp.Feed water temp. 105105 ooCC Boiler efficiencyBoiler efficiency 91.5 %91.5 %


Heating ValueHeating Value 16,5-19 MJ/kg16,5-19 MJ/kg

MoistureMoisture 15-2115-21 % %

AshAsh 25-3225-32 % %

SulphurSulphur 1,41,4 % %

0

50

100

150

200

250

300

350

400

Em

issi

on

[mg

/Nm

3]

SO2 NOx CO

Guaranties

Measurements

2 x OFz-75, Polfa Starogard Gdański2 x OFz-75, Polfa Starogard Gdański



75%75%

50%50% 40%40%


Technical DataTechnical Data Boiler capacity MCR 338.5 MWt Boiler capacity MCR 338.5 MWt Life steam output 425 t/hLife steam output 425 t/h Life steam temp. (40-100%) 560 Life steam temp. (40-100%) 560 ooCC Life steam pressure 16.1 MPaLife steam pressure 16.1 MPa Reheated steam outputReheated steam output 371 t/h 371 t/h Reheated steam temp. (50-100%) 350/560Reheated steam temp. (50-100%) 350/560ooCC Reheated steam pressure 3.7/3.5 MPaReheated steam pressure 3.7/3.5 MPa Flue gas outlet temp. (at MCR)Flue gas outlet temp. (at MCR) 135 135 ooCC Efficiency (coal - 16.7 MJ/kg )Efficiency (coal - 16.7 MJ/kg ) 91.0 % 91.0 %

2 x Boiler OFz-425 , Siersza PP2 x Boiler OFz-425 , Siersza PP

2 x Boilers OFz-425, Siersza PP2 x Boilers OFz-425, Siersza PP


Heating value Heating value 16.7 16.7 MJ/kgMJ/kg AshAsh 20.6 20.6 %% MoistureMoisture 21.7 21.7 %% SulphurSulphur 2.4 2.4 %% Volatile matter 36.6Volatile matter 36.6 %%

Emission GuarantiesEmission Guaranties

SOSO22 337.5 337.5 mg/Nmmg/Nm33

NONOxx 307.8 307.8 mg/Nmmg/Nm33

CO 250 CO 250 mg/Nmmg/Nm33

for normal, dry conditions with Ofor normal, dry conditions with O22

content of 6%content of 6%

Overview of the erection phase of Overview of the erection phase of steel structure and cyclonessteel structure and cyclones

Boiler OFz-425, Siersza PPBoiler OFz-425, Siersza PP



0

50

100

150

200

250

300

350

Emis

sion

[m

g/N

m3]

(Ca/

S x1

00)

(Fly

Ash

g/N

m3)

SO2 Ca/S NOx CO Fly Ash

Guaranties

Measurements

85%85%

80%80%

55%55%

15%15%


50%50%

Boiler OFz-450 “B”, Żerań CHP, WarsawBoiler OFz-450 “B”, Żerań CHP, Warsaw


Boiler capacity MCRBoiler capacity MCR 315 MWt315 MWt Steam outputSteam output 450 t/h450 t/h Life steam temperatureLife steam temperature 510 510 ooCC Life steam pressure Life steam pressure 10 MPa10 MPa Feed water temperatureFeed water temperature 205 205 ooCC Boiler efficiencyBoiler efficiency 92%92%

Fuel: Bituminous coalFuel: Bituminous coal Heating ValueHeating Value 18 - 2418 - 24 MJ/kgMJ/kg MoistureMoisture 8 - 158 - 15 %% AshAsh 15- 2515- 25 %% SulphurSulphur 0.6 - 1.00.6 - 1.0 %%


020406080

100120140160180200

Em

issi

on

[mg

/Nm

3]

SO2 NOx CO

Guaranties

Measurements

Harmful Emissions From the Boiler


75%75%


60%60%

50%50%


Steam drum “piping spider” in engineering Steam drum “piping spider” in engineering and in fabrication phaseand in fabrication phase

Comparison of Coals Burnt in CFB Boilers Comparison of Coals Burnt in CFB Boilers iin n PolandPoland

Coal Parameters Comparison

SierszaPP

(design)Siersza

PP(present)

Żerań "A"CHP Żerań "B"

CHPBielsko

CHP Polfa CHP

sulphur [%]

ash [%]

moisture [%]

LHV [MJ/kg]

16,718,1

26

21

17

16,4

21,7

16,418

10

30

25

20,621,8

15 20

10 14,82,4

1,6

0,8

0,8

1

1,4

Boiler Construction Optimisation Resulting Boiler Construction Optimisation Resulting From Operational ExperienceFrom Operational Experience

Target No 1:Target No 1:

Operating Conditions Operating Conditions ImprovementImprovement


Operating Conditions Operating Conditions ImprovementImprovement


Simplification of CFB Simplification of CFB InstallationInstallation


Simplification of CFB Simplification of CFB InstallationInstallation

Target: Operating Target: Operating Conditions Conditions Improvement Improvement

Target: Operating Target: Operating Conditions Conditions Improvement Improvement

Antierosion protection for furnace Antierosion protection for furnace wallswalls

Antierosion protection for other Antierosion protection for other heating surface within the boilerheating surface within the boiler

Antiradiation protection for boiler Antiradiation protection for boiler heating surfaces heating surfaces

Improvement of boiler element Improvement of boiler element connectionconnection

Boiler Construction OptimisationBoiler Construction Optimisation


Target: Operating Conditions Improvement Target: Operating Conditions Improvement Target: Operating Conditions Improvement Target: Operating Conditions Improvement

Antierosion protection for furnace membrane wallsAntierosion protection for furnace membrane walls

Metal coating (Metal coating (Żerań A & B, Siersza)Żerań A & B, Siersza)




Mechanical shield (Mechanical shield (Żerań B, Siersza)Żerań B, Siersza)




Mechanical shield (Mechanical shield (Żerań B, Siersza)Żerań B, Siersza)




Protective shape of the hopper refractory lining (Protective shape of the hopper refractory lining (Żerań Żerań B, Siersza)B, Siersza)



Protective shape of the refractory lining on the return Protective shape of the refractory lining on the return ash chute and burners openings in the furnace ash chute and burners openings in the furnace chamber (chamber (Siersza)Siersza)


Antierosion protection for other heating surfaces within the boiler Antierosion protection for other heating surfaces within the boiler ((Żerań A & B, Siersza)Żerań A & B, Siersza)



Antierosion protection for furnace corners Antierosion protection for furnace corners

Previous solutionPrevious solution

New solutionNew solution

Target: Operating Target: Operating Conditions Improvement Conditions Improvement

Target: Operating Target: Operating Conditions Improvement Conditions Improvement



Antiradiation shields (Antiradiation shields (Polfa, Polfa, Żerań A & B, Siersza)Żerań A & B, Siersza)

Target: Simplification of Target: Simplification of Installation Installation


Optimisation of cyclone separators Optimisation of cyclone separators shapeshape

Improved bed ash extraction systemImproved bed ash extraction system

Improved start-up system of the Improved start-up system of the boiler boiler

Simplified inert material recirculation Simplified inert material recirculation systemsystem


Cyclones shape and arrangement modificationCyclones shape and arrangement modification

Cyclone with the spiral inletCyclone with the spiral inletCentric placement of the vortex finderCentric placement of the vortex finderSloping inlet to the cyclone regarding toSloping inlet to the cyclone regarding tofurnace chamber furnace chamber ((Żerań A)Żerań A)

Tangent and narrow inlet to the cycloneTangent and narrow inlet to the cycloneIncrease of cyclone diametrIncrease of cyclone diametrEccentric placement of the vortex finderEccentric placement of the vortex finderVertical inlet to the cyclone regarding toVertical inlet to the cyclone regarding tofurnace chamberfurnace chamber((Żerań B, Siersza)Żerań B, Siersza)



Simplified inert material recirculation system 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 vesselabandoning of ash mill with auxiliaries and mill ash vessel

abandoning of ash separator and hot ash scraped conveyorabandoning of ash separator and hot ash scraped conveyor

implementation of main screw ash extractorimplementation of main screw ash extractor

Improved start-up system of the boiler:Improved start-up system of the boiler: abandoning of oil lances abandoning of oil lances

better flame controlbetter flame control

better burner nozzle adjustmentbetter burner nozzle adjustment

improved protection of burner tipsimproved protection of burner tips









Participation and supervision of Supplier at erection and Participation and supervision of Supplier at erection and commissioning of the boilercommissioning of the boiler

Co-operation with the Client during boiler operationCo-operation with the Client during boiler operation

Adaptation of specific construction measures needed for Adaptation of specific construction measures needed for the coal fired in CFBthe coal fired in CFB

CFB Boilers achieves all guarantied performance and CFB Boilers achieves all guarantied performance and environmental values even for very wide coal spectrum environmental values even for very wide coal spectrum (including coal outside contract characteristic)(including coal outside contract characteristic)

SSummaryummary SSummaryummary

Operational Experience With Circulating Fluid Bed Technology In PolandOperational Experience With Circulating Fluid Bed Technology In Poland

PP Siersza OFz 425 t/hPP Siersza OFz 425 t/h

CHP Żerań OFz 450 t/hCHP Żerań OFz 450 t/h

CHP Bielsko-Biała OFz 230 t/hCHP Bielsko-Biała OFz 230 t/h

BOILER DESIGN DEPARTMENT BOILER DESIGN DEPARTMENT

RAFAKO CFB BOILERS TECHNOLOGYRAFAKO CFB BOILERS TECHNOLOGY

THANK YOU FOR YOUR ATTENTIONTHANK YOU FOR YOUR ATTENTION

Date post:	31-Mar-2015
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