Towards New Milestones In CFB Boiler Technology – CFB 800MWe / New 460 MWe super
critical plant with CFB boiler in Lagisza - First experience update
Arto Hotta, Timo Jäntti, Kari Kauppinen, Ari KettunenFoster Wheeler Energia Oy, Finland
Presentation Outline
• CFB Technology Status & Key Design Features of the Foster Wheeler Once-through (OTU) CFB
• Łagisza 460 MWe Project– Project Summary– Boiler Design– Operation Experience
• CFB Technology up to 800MWe
Key Advantages of CFB & CFB Technology Status
• Fuel flexibility is a special advantage– Wide range for design coals– Opportunity fuels (biomass etc)– Hard-to-Burn fuels (petcoke etc)
• Excellent emission performance– No DeSOx / DeNOx –plants required
• Technology Status > CFB has reached the large utility scale
– Drum based units in scale 330 MWe in operation– 460 MWe supercritical CFB in commercial operation– Readiness to offer the 800 MWe supercritical CFB now!
Foster Wheeler Once-through (OTU) CFB Key Design Features
• Proven and Efficient CFB Process• High Plant Efficiency
– Supercritical Steam Parameters
• BENSON Vertical Tube Technology– Sliding Pressure Operation– Low Pressure Drop– Simple support System
• Integrated Steam Cooled Solids Separators
– Minimum Amount of Refractory– Minimum Expansion Joints– Most Compact Design
• INTREX™ Fluidized Bed Heat Exchangers
• Regenerative Air Heaters
World’s Largest CFB and World’s First CFB with Supercritical Steam Parameters
Łagisza 460 MWe - Project
Łagisza 460 MWe CFB – Project
Re-powering of the Łagisza powerplant in Poland
• Customer: Południowy Koncern Energetyczny SA (PKE)
• 460 MWe supercritical OTU – CFB– World’s largest Single CFB unit– World’s first supercritical CFB
• Start of Project Execution (NTP): December 2005
• Start-up: 36 Months after NTP
• Foster Wheeler providing boiler island supply and erection with foundations
PKE -Lagizsa
SH / RH• Steam flow kg/s 361 / 306• SH pressure bar 275 / 55• SH temperature °C 560 / 580• Feed water temperature °C 290
Plant Design Parameters
Gross / Net• Electrical Output MW 460 / 439• Plant efficiency % 45.3 / 43.3
FUELS (as received) Coal
SulfurAshMoistureLHV
% wt
MJ/kg
1.2231220
% wt% wt
Performance Range0.6 - 1.410 - 256 - 2318 - 23
Coal Slurry(max. 30 %)
Range0.6 - 1.628 - 6527 - 457 - 17
Fuel Flexi-bility
EMISSION (6 % O2, dry) (follows EU’s LCP directive)SO2 mg/Nm3 200NOx (as NO2) mg/Nm3 200CO mg/Nm3 200Dust mg/Nm3 30
Low Emissions
Łagisza 460 MWe CFBHigh Fuel Flexibility & Emissions without DeSOx, DeNOx
Łagisza 460 MWe - Boiler Design
Boiler Layout & Furnace Design
Furnace10.6 m * 27.6 mHeight 48 m
Integratedseparators
INTREX™superheaters
BENSON Vertical Tube Technology
Boiler Inline Arrangement
Steam Cycle
INTREX-chambers
Furnace
Economizer
2nd passwalls
Hanger tubes
SH III Solids separators
SH II SH IVINTREX
HP- bypass
To turbine
Feed water pump
Furnaceroof
To flash tank
Water/Steam separators
SH I
HP-heatersFrom feed tank
From turbineRH I
RH IIINTREX To turbine
Plant Layout – Front View
Boiler Building Dimensions:
-Length 86 m-Width 41 m-Height 78 m
Łagisza 460 MWe –Start-up & Initial Operation Experience
2006 2009
Łagisza 460 MWe CFB Start-up Schedule
• Erection completed July, 2008• First firing, Acid cleaning, Steam blowings based on schedule• First steam to turbine > beginning of Feb, 2009• Turbine Synchronization > Middle of Feb, 2009• 720h Trial Run > 12th May, 2009• Plant hand-over > 27th June, 2009
Łagisza 460 MWe CFB & Project StatusStable Process Behaviour over the Whole load Range
40 %MCR 65 %MCR 80 %MCR 100 %MCR
Main steam flow kg/s 144 235 287 361
Main steam pressure Bar 131 186 231 271
Main steam temperature °C 560 560 560 560
Reheat temperature °C 550 572 580 580
Bed temperature °C 753 835 853 889
Flue gas exit temperature °C 80 81 86 88
SO2 emission* mg/m3n 143 197 140 < 200 **
NO2 emission* mg/m3n 167 154 188 < 200 **
CO emission* mg/m3n 45 48 48 22*@ 6 % O2, dry
** Demonstrated to be met
Łagisza 460 MWe CFB in Commercial OperationGenerator Output
Conclusions from the operating performance of Łagisza 460 MWe CFB
The first Year operating experiences from Łagisza 460 MWe CFB prove:
• Good and stable operation of the CFB combustion process in large scale• Successful integration of the BENSON vertical tube technology with the CFB process• Performance of the boiler is very close to the design. The CFB process models and
design tools have proven to simulate and predict the actual operation of a large scale furnace.
• Good dynamic behaviour of the large scale OTU CFB meets the requirements of the grid
• Successful design of the mechanical features and challenges of a large furnace and cyclones
Łagisza has validated our utility CFB design platform providing know-how for designing larger units
• CFB Technology up to 800MWe
Foster Wheeler Technology base ready to propose the supercritical CFB up to 800MWe now!
SH / RH• Steam flow kg/s 598 / 518• SH pressure bar 300 / 45• SH temperature °C 600 / 620• Feed water temperature °C 290
Plant Design Parameters
Gross / Net• Electrical Output MW 853 / 800• Plant efficiency % 47.2 / 44.8 (LHV)
– Cooling water temperature °C 18
CFB 800 – Boiler Design
Main Characteristics:• Single pass evaporator• Low mass flux BENSON
technology; vertical tubes • Single fluidization grid• Steam cooled solids
separators• Staged INTREX
Superheaters• Regenerative Air Heaters
The similar design features validated in Łagisza will be used
Summary
• Foster Wheeler is Leading the CFB Technology in the World
• Modern CFB Design with Integrated Water/Steam Cooled Solid Separators
– High fuel flexibility– Excellent emissions performance
• Foster Wheeler OTU CFB Concept demonstrated in Łagisza 460 MWe
– Performance meets the Design over the whole load range
• Foster Wheeler Technology base ready to propose the supercritical CFB up to 800MWenow!
Thank You for Your Attention !
Better Technology
For a Cleaner Environment
