CFB Boiler Design, Operation and

Maintenance
By Pichai Chaibamrung

Content Day1
1. Introduction to CFB
2. Hydrodynamic of CFB
3. Combustion in CFB
4. Heat Transfer in CFB
5. Basic design of CFB
6. Operation
7. Maintenance
8. Basic Boiler Safety
9. Basic CFB control

Objective
To understand the typical arrangement in CFB
To understand the basic hydrodynamic of CFB
To understand the basic combustion in CFB
To understand the basic heat transfer in CFB
To understand basic design of CFB
To understand theory of cyclone separator

Know Principle Solve Everything

1. Introduction to CFB
1.1 Development of CFB
1.2 Typical equipment of CFB
1.3 Advantage of CFB

1.1 Development of CFB

1921, Fritz Winkler, Germany, Coal Gasification
1938, Waren Lewis and Edwin Gilliland, USA, Fluid Catalytic Cracking,
Fast Fluidized Bed
1960, Douglas Elliott, England, Coal Combustion, BFB
1960s, Ahlstrom Group, Finland, First commercial CFB boiler, 15
MWth, Peat

1.2 Typical Component of CFB Boiler

1.2 Typical Component of CFB Boiler

Wind box and grid nozzle
primary air is fed into wind box.
Air is equally distributed on
furnace cross section by passing
through the grid nozzle. This will
help mixing of air and fuel for
completed combustion

1.2 Typical Component of CFB Boiler

Bottom ash drain
coarse size of ash that is not
take away from furnace by
fluidizing air will be drain
at bottom ash drain port
locating on grid nozzle
floor by gravity.
bottom ash will be cooled
and conveyed to silo by
cooling conveyor.

1.2 Typical Component of CFB Boiler

HP Blower
supply high pressure air to
fluidize bed material in loop
seal so that it can overflow to
furnace

Rotameter

Supplying of HP
blower to loop seal

1.2 Typical Component of CFB Boiler

Cyclone separator
located after furnace exit and
before convective part.
use to provide circulation by
trapping coarse particle back to
the furnace
Fluidized boiler without this
would be BFB not CFB

10

1.2 Typical Component of CFB Boiler

Evaporative or Superheat Wing Wall
located on upper zone of furnace
it can be both of evaporative or SH
panel
lower portion covered by erosion
resistant materials

11

1.2 Typical Component of CFB Boiler

Fuel Feeding system
solid fuel is fed into the lower
zone of furnace through the
screw conveyor cooling with
combustion air. Number of
feeding port depend on the
size of boiler

12

1.2 Typical Component of CFB Boiler

Refractory
refractory is used to protect
the pressure part from
serious erosion zone such as
lower bed, cyclone separator

13

1.2 Typical Component of CFB Boiler

Solid recycle system (Loop seal)
loop seal is located between
dip leg of separator and
furnace. Its design physical is
similar to furnace which have
air box and nozzle to
distribute air. Distributed air
from HP blower initiate
fluidization. Solid behave like
a fluid then over flow back to
the furnace.

14

1.2 Typical Component of CFB Boiler

Kick out
kick out is referred to
interface zone between
the end of lower zone
refractory and water tube.
It is design to protect the
erosion by by-passing the
interface from falling
down bed materials

15

1.2 Typical Component of CFB Boiler

Lime stone and sand system
lime stone is pneumatically feed or gravitational feed into
the furnace slightly above fuel feed port. the objective is to
reduce SOx emission.
Sand is normally fed by gravitation from silo in order to
maintain bed pressure. Its flow control by speed of rotary
screw.

16

1.2 Typical Arrangement of CFB Boiler

17

1.3 Advantage of CFB Boiler

Fuel Flexibility

18

1.3 Advantage of CFB Boiler

High Combustion Efficiency
- Good solid mixing
- Low unburned loss by cyclone, fly ash recirculation
- Long combustion zone
In situ sulfur removal
Low nitrogen oxide emission

19

2. Hydrodynamic in CFB
2.1 Regimes of Fluidization
2.2 Fast Fluidized Bed
2.3 Hydrodynamic Regimes in CFB
2.4 Hydrodynamic Structure of Fast Beds

20

2.1 Regimes of Fluidization

Fluidization is defined as the operation through which fine
solid are transformed into a fluid like state through
contact with a gas or liquid.

21

2.1 Regimes of Fluidization

Particle Classification
Distribution

Size (micron)
CFB1

CFB2

BFB

100%

<600

<1000

<1680

75%

<250

<550

<1190

50%

<180

<450

<840

25%

<130

<250

<590

>100

>420

100%

22

2.1 Regimes of Fluidization

Particle Classification

23

2.1 Regimes of Fluidization

Comparison of Principal Gas-Solid Contacting Processes

24

2.1 Regimes of Fluidization

Packed Bed
The pressure drop per unit height of a packed beds of a uniformly size
particles is correlated as (Ergun,1952)

Where U is gas flow rate per unit cross section of the bed called
Superficial Gas Velocity

25

2.1 Regimes of Fluidization

Bubbling Fluidization Beds
Minimum fluidization velocity is velocity where the fluid
drag is equal to a particles weight less its buoyancy.

26

2.1 Regimes of Fluidization

Bubbling Fluidization Beds
For B and D particle, the bubble is started when superficial
gas is higher than minimum fluidization velocity
But for group A particle the bubble is started when
superficial velocity is higher than minimum bubbling
velocity

27

2.1 Regimes of Fluidization

Turbulent Beds
when the superficial is continually increased through a
bubbling fluidization bed, the bed start expanding, then
the new regime called turbulent bed is started.

28

2.1 Regimes of Fluidization

29

2.1 Regimes of Fluidization

Terminal Velocity

Terminal velocity is the particle velocity when the

forces acting on particle is equilibrium

30

2.1 Regimes of Fluidization

Freeboard and Furnace Height
- considered for design heating-surface area
- considered for design furnace height
- to minimize unburned carbon in bubbling
bed
- the freeboard heights should be exceed or
closed to the transport disengaging heights

31

2.2 Fast Fluidization

Definition

32

2.2 Fast Fluidization

Characteristics of Fast Beds
- non-uniform suspension of slender particle agglomerates or clusters moving
up and down in a dilute
- excellent mixing are major characteristic
- low feed rate, particles are uniformly dispersed in gas stream
- high feed rate, particles enter the wake of the other, fluid drag on the leading
particle decrease, fall under the gravity until it drops on to trailing particle

33

2.3 Hydrodynamic regimes in a CFB

Cyclone Separator :
Swirl Flow
Back Pass:
Pneumatic Transport

Furnace Upper SA:

Fast Fluidized Bed
Lower Furnace below SA:
Turbulent or bubbling
fluidized bed

Return leg and lift leg :

Pack bed and Bubbling Bed

34

2.4 Hydrodynamic Structure of Fast Beds

Axial Voidage Profile
Secondary air is fed

Bed Density Profile of 135 MWe CFB Boiler (Zhang et al., 2005)

35

2.4 Hydrodynamic Structure of Fast Beds

Velocity Profile in Fast Fluidized Bed

36

2.4 Hydrodynamic Structure of Fast Beds

Velocity Profile in Fast Fluidized Bed

37

2.4 Hydrodynamic Structure of Fast Beds

Particle Distribution Profile in Fast Fluidized Bed

38

2.4 Hydrodynamic Structure of Fast Beds

Particle Distribution Profile in Fast Fluidized Bed

39

2.4 Hydrodynamic Structure of Fast Beds

Particle Distribution Profile in Fast Fluidized Bed
Effect of SA injection on particle
distribution by M.Koksal and
F.Hamdullahpur (2004). The
experimental CFB is pilot scale CFB.
There are three orientations of SA
injection; radial, tangential, and mixed

40

2.4 Hydrodynamic Structure of Fast Beds

Particle Distribution Profile in Fast Fluidized Bed
Increasing SA to 40%
does not significant on
suspension density above
SA injection point
but the low zone is
denser than low SA ratio

Increasing solid circulation

rate effect to both
lower and upper zone
of SA injection point
which both zone is
denser than low
solid circulation rate

No SA, the suspension

density is proportional
l to solid circulation rate

With SA 20% of PA,

the solid particle is hold up
when compare to no SA

41

2.4 Hydrodynamic Structure of Fast Beds

Effects of Circulation Rate on Voidage Profile

higher solid recirculation rate

42

2.4 Hydrodynamic Structure of Fast Beds

Effects of Circulation Rate on Voidage Profile

Pressure drop across the L-valve is

proportional to solid recirculation rate

higher solid recirculation rate

43

2.4 Hydrodynamic Structure of Fast Beds

Effect of Particle Size on Suspension Density Profile
- Fine particle - - > higher suspension density
- Higher suspension density - - > higher heat transfer
- Higher suspension density - - > lower bed temperature

44

2.4 Hydrodynamic Structure of Fast Beds

Core-Annulus Model
- the furnace may be spilt into two zones : core and
annulus
core

Core
- Velocity is above superficial velocity
annulus
- Solid move upward
Annulus
- Velocity is low to negative
- Solids move downward
45

2.4 Hydrodynamic Structure of Fast Beds

Core-Annulus Model

core

annulus

46

2.4 Hydrodynamic Structure of Fast Beds

Core Annulus Model
- the up-and-down movement solids in the core and
annulus sets up an internal circulation
- the uniform bed temperature is a direct result of internal
circulation

47

3. Combustion in CFB
3.1 Coal properties for CFB boiler
3.2 Stage of Combustion
3.3 Factor Affecting Combustion Efficiency
3.4 Combustion in CFB
3.5 Biomass Combustion

48

3.1 Coal properties for CFB Boiler

Properties
- coarse size coal shall be crushed by coal crusher
- sizing is an importance parameter for CFB boiler improper size might
result in combustion loss
- normal size shall be < 8 mm

49

3.2 Stage of Combustion

A particle of solid fuel is injected into an FB undergoes the
following sequence of events:
- Heating and drying
- Devolatilization and volatile combustion
- Swelling and primary fragmentation (for some types of coal)
- Combustion of char with secondary fragmentation and attrition

50

3.2 Stages of Combustion

Heating and Drying
- Combustible materials constitutes around 0.5-5.0% by
weight
of total solids in combustor
- Rate of heating 100 C/sec 1000 C/sec
- Heat transfer to a fuel particle (Halder 1989)

51

3.2 Stages of Combustion

Devolatilization and volatile combustion
- first steady release 500-600 C
- second release 800-1000C
- slowest species is CO (Keairns et al., 1984)
- 3 mm coal take 14 sec to devolatilze
at 850 C (Basu and Fraser, 1991)

52

3.2 Stages of Combustion

Char Combustion
2 step of char combustion
1. transportation of oxygen to carbon surface
2. Reaction of carbon with oxygen on the carbon surface
3 regimes of char combustion
- Regime I: mass transfer is higher than kinetic rate
- Regime II: mass transfer is comparable to kinetic rate
- Regime III: mass transfer is very slow compared to kinetic rate

53

3.2 Stage of Combustion

Communition Phenomena During Combustion
Volatile release in non-porous
particle cause the high
internal pressure result in
break a coal particle into
fragmentation

Attrition, Fine particles from

coarse particles through
mechanical contract like
abrasion with other particles

Char burn under regime I

which is mass transfer is
higher than kinetic trasfer.
The sudden collapse or other
type of second fragmentation
call percolative fragmentation
occurs

Volatile release cause the

particle swell

Char burn under regime I, II,

the pores increases in size
weak bridge connection of
carbon until it cant withstand
the hydrodynamic force. It will
fragment again call
secondary fragmentation

54

3.3 Factor Affecting Combustion Efficiency

Fuel Characteristics
the lower ratio of FC/VM result in higher combustion
efficiency (Makansi, 1990), (Yoshioka and Ikeda,1990),
(Oka, 2004) but the improper mixing could result in lower
combustion efficiency due to prompting escape of volatile
gas from furnace.

55

3.3 Factor Affecting Combustion Efficiency

Operating condition (Bed Temperature)
- higher combustion temperature --- > high combustion
Limit of Bed temp
efficiency
-Sulfur capture
-Bed melting
-Water tube failure

High combustion temperature result in high

oxidation reaction, then burn out time
decrease. So the combustion efficiency
increase.

56

3.3 Factor Affecting Combustion Efficiency

Fuel Characteristic (Particle size)

-The effect of this particle size is not clear

-Fine particle, low burn out time but the
probability to be dispersed from cyclone
the high
-Coarse size, need long time to burn out.
-Both increases and decreases are
possible when particle size decrease

57

3.3 Factor Affecting Combustion Efficiency

Operating condition (superficial velocity)
- high fluidizing velocity decrease combustion efficiency because
Increasing probability of small char particle be elutriated from
circulation loop

- low fluidizing velocity cause defluidization, hot spot and sintering

58

3.3 Factor Affecting Combustion Efficiency

Operating condition (excess air)
- combustion efficiency improve which excess air < 20%
Combustion loss
decrease
significantly when
excess air < 20%.

Excess air >20% less

significant improve
combustion efficiency.

59

3.3 Factor Affecting Combustion Efficiency

Operating Condition
The highest loss of combustion result from elutriation of char particle
from circulation loop. Especially, low reactive coal size smaller than 1
mm it can not achieve complete combustion efficiency with out fly
ash recirculation system.
However, the significant efficiency improve is in range 0.0-2.0 fly ash
recirculation ratio.

60

3.4 Combustion in CFB Boiler

Lower Zone Properties
- This zone is fluidized by primary air constituting about
40-80% of total air.
- This zone receives fresh coal from coal feeder and
unburned coal from cyclone though return valve
- Oxygen deficient zone, lined with refractory to protect
corrosion
- Denser than upper zone

61

3.4 Combustion in CFB Boiler

Upper Zone Properties
- Secondary is added at interface between lower and upper
zone
- Oxygen-rich zone
- Most of char combustion occurs
- Char particle could make many trips around the furnace
before they are finally entrained out through the top of
furnace

62

3.4 Combustion in CFB Boiler

Cyclone Zone Properties
- Normally, the combustion is small when compare to in
furnace
- Some boiler may experience the strong combustion in
this zone which can be observe by rising temperature in
the cyclone exit and loop seal

63

3.5 Biomass Combustion

Fuel Characteristics
- high volatile content (60-80%)
- high alkali content sintering, slagging, and fouling
- high chlorine content corrosion

64

3.5 Biomass Combustion

Agglomeration
SiO2 melts at 1450 C
Eutectic Mixture melts at 874 C

Sintering tendency of fuel is indicated by the following

(Hulkkonen et al., 2003)

65

3.5 Biomass Combustion

Options for Avoiding the Agglomeration Problem
- Use of additives
- china clay, dolomite, kaolin soil
- Preprocessing of fuels
- water leaching
- Use of alternative bed materials
- dolomite, magnesite, and alumina
- Reduction in bed temperature

66

3.5 Biomass Combustion

Agglomeration

67

3.5 Biomass Combustion

Fouling
- is sticky deposition of ash due to evaporation of alkali salt
- result in low heat transfer to tube

68

3.5 Biomass Combustion

Corrosion Potential in Biomass Firing
- hot corrosion
- chlorine reacts with alkali metal from low
temperature melting alkali chlorides
- reduce heat transfer and causing high temperature
corrosion

69

4. Heat Transfer in CFB

4.1 Gas to Particle Heat Transfer
4.2 Heat Transfer in CFB

70

4.1 Gas to Particle Heat Transfer

Mechanism of Heat Transfer
In a CFB boiler, fine solid particles
agglomerate and form clusters or
stand in a continuum of generally
up-flowing gas containing sparsely
dispersed solids. The continuum is
called the dispersed phase, while
the agglomerates are called the
cluster phase.
The heat transfer to furnace wall
occurs through conduction from
particle clusters, convection from
dispersed phase, and radiation
from both phase.

71

4.1 Heat Transfer in CFB Boiler

Effect of Suspension Density and particle size

Heat transfer coefficient is proportional to the square root of suspension density

72

4.1 Heat Transfer in CFB Boiler

Effect of Fluidization Velocity

No effect from fluidization velocity when leave the suspension density constant

73

4.1 Heat Transfer in CFB Boiler

Effect of Fluidization Velocity

74

4.1 Heat Transfer in CFB Boiler

Effect of Fluidization Velocity

75

4.1 Heat Transfer in CFB Boiler

Effect of Vertical Length of Heat Transfer Surface

76

4.1 Heat Transfer in CFB Boiler

Effect of Bed Temperature

77

4.1 Heat Transfer in CFB Boiler

Heat Flux on 300 MW CFB Boiler (Z. Man, et. al)

78

4.1 Heat Transfer in CFB Boiler

Heat transfer to the walls of commercial-size

Low suspension density low

heat transfer to the wall.

79

4.1 Heat Transfer in CFB Boiler

Circumferential Distribution of Heat Transfer Coefficient

80

5 Design of CFB Boiler

5.1 Design and Required Data

5.2 Combustion Calculation
5.3 Heat and Mass Balance
5.4 Furnace Design
5.5 Cyclone Separator

81

5.1 Design and Required Data

The design and required data normally will be specify by owner
or client. The basic design data and required data are;

Design Data :
- Fuel ultimate analysis
- Feed water quality

- Weather condition
- Feed water properties

Required Data :
- Main steam properties
- Flue gas emission

- Flue gas temperature

- Boiler efficiency

82

5.2 Combustion Calculation

Base on the design and required data the following data
can be calculated in this stage :
- Fuel flow rate
- Combustion air flow rate
- Fan capacity
- Fuel and ash handling capacity
- Sorbent flow rate

83

5.3 Heat and Mass Balance

Main steam
Heat input
Radiation

Heat output

Feed water
Blow down

Flue gas

Moisture in fuel
and sorbent

Unburned in fly ash

Fuel and
sorbent

Combustion air

Unburned in
bottom ash

Moisture in
combustion air
84

5.3 Heat and Mass Balance

Mass Balance

Mass input

Mass output
SolidSolid
Fluein
gas
Flue gas

Make up
bed material

Fuel and
sorbent

Moisture in fuel
and sorbent

fly ash

Fuel and
sorbent
Make up
bed material
bottom ash
bottom ash

fly ash

85

5.4 Furnace Design

1.
2.
3.

The furnace design include:

Furnace cross section
Furnace height
Furnace opening

1. Furnace cross section

Criteria
- moisture in fuel
- ash in fuel
- fluidization velocity
- SA penetration
- maintain fluidization in lower
zone at part load

86

5.4 Furnace Design

2. Furnace height
Criteria
- Heating surface
- Residual time for sulfur
capture

3. Furnace opening
Criteria
- Fuel feed ports
- Sorbent feed ports
- Bed drain ports
- Furnace exit section

87

5.5 Cyclone Separator

6.1 Theory
6.2 Critical size of particle

88

5.5 Cyclone Separator

The centrifugal force on the particle entering the cyclone
is

The drag force on the particle can be written as

Under steady state drag force = centrifugal force

89

5.5 Cyclone Separator

Vr can be considered as index of cyclone efficiency, from

above equation the cyclone efficiency will increase for :

- Higher entry velocity

- Large size of solid
- Higher density of particle
- Small radius of cyclone
- low value of viscosity of gas
90

5.5 Cyclone Separator

The particle with a diameter larger than theoretical cutsize of cyclone will be collected or trapped by cyclone
while the small size will be entrained or leave a cyclone

Actual operation, the cut-off size diameter will be defined

as d50 that mean 50% of the particle which have a
diameter more than d50 will be collected or captured.

91

6. Operation

92

Content
6.1 Before start
6.2 Grid pressure drop test
6.3 Cold Start
6.4 Normal Operation
6.5 Normal Shutdown
6.6 Hot Shutdown
6.7 Hot Restart
6.8 Malfunction and Emergency

93

6.1 Before Start

all maintenance work have been completely done

All function test have been checked
cooling water system is operating
compressed air system is operating
Make up water system
Deaerator system
Boiler feed water pump
Condensate system
Oil and gas system
Drain and vent valves
Air duct, flue gas duct system
94

6.1 Before Start

Blow down system

Sand feeding system
Lime stone feeding system
Solid fuel system
Ash drainage system
Control and safety interlock system

95

6.2 Grid Pressure Drop Test

For check blockage of grid
nozzle
Furnace set point = 0
Test at every PA. load
Compare to clean data or design
data
Shall not exceed 10% from
design data
Perform in cold condition

Pf= 0

Pb
Pw
FI

96

6.3 Cold Start

Fill boiler

-100 mm normal level

Start Fan

ID,HP,SA,PA

Boiler Interlock

Purge
300 S

Start up Burner

Low level cut off

Boiler Warm Up

Tb 150-200 C

Feed Bed Material

30-50 mbar, Tb 550-600 C

Feed Solid Fuel

Raise to MCR
97

Fill Boiler
-Close all water side drain valve
-Open all air vent valve at drum and
superheat
-Open start up vent valve 10-15%
-Slowly feed water to drum until level 1/3 of
sigh glass

98

Start Fan

1.Start ID.Fan

2.Start HP Blower

4.Start PA.Fan

3.Start SA.Fan

99

Boiler Interlock
Emergency stop in order
Furnace P. < Max (2/3)

Trip Solid Fuel

ID. Fan running

HP Blower start
Drum level > min (2/3)

Trip Soot Blower

Trip Oil

SA. Fan running

Trip Sand

PA. Fan running

Trip Bottom Ash

HP. Blower P. > min

Trip Lime Stone

PA. Flow to grid > min

Flue gas T after Furnace < max
100

Purge
To carry out combustible gases
To assure all fuel are isolated
from furnace
Before starting first burner for
cold start
If bed temp < 600 C or OEM
recommend and no burner in
service
Total air flow > 50%
300 sec for purging time

101

Purge
NFPA85: CFB Boiler purge logic

102

Start up burner
Help to heat up bed temp to allowable temperature for
feeding solid fuel
Will be stopped if bed temp > 850 C
Before starting, all interlock have to passed
Main interlock
Oil pressure > minimum
Control air pressure > minimum
Atomizing air pressure > minimum

103

Start up burner
NFPA85 - Typical burner safety for CFB boiler

104

Drum and DA low level cut-off

Test for safety
During burner are operating
Open drain until low level
Signal feeding are not allow
Steam drum low level = chance
to overheating of water tube
DA low level = danger for BFWP

105

Boiler warm up
Gradually heating the boiler to reduce the effect of
thermal stress on pressure part, refractory and drum swell
Increase bed temp 60-80 C/hr by adjusting SUB
Control flue gas temperature <470 C until steam flow >
10% MCR
Close vent valves at drum and SH when pressure > 2 bar
Continue to increase firing rate according to
recommended start up curve
Operate desuperheater when steam temperature are with
in 30 C of design point
Slowly close start up and drain valve while maintain steam
flow > 10% MCR
106

Feed bed material

Bed material should be sand which size is according to
recommended size
Start feed sand when bed temp >150 C
Do not exceed firing rate >30% if bed pressure <20 mbar
otherwise overheating may occur for refractory and nozzle
Continue feed bed material unit it reach 30 mbar

107

Feed solid fuel

Must have enough bed material
Bed temperature > 600 C or manufacturer
recommendation or refer to NFPA85 Appendix H
Pulse feed every 90 s
Placing lime stone feeding, ash removal system
simultaneously
Slowly decrease SUB firing rate while increasing solid fuel
feed rate
Stop SUB one by one, observe bed temperature increasing
Turn to auto mode control

108

Rise to MCR
Continue rise pressure and temperature according to
recommended curve until reach design point
Drain bottom ash when bed pressure >45-55 mbar
Slowly close start up valve
Monitor concerning parameters

109

6.4 Normal Operation

Changing Boiler load (manual)

Increasing
- manual increase air flow
- manual increase fuel flow
- monitor excess oxygen
- monitor steam pressure

Decreasing
- manual decrease air flow
- manual decrease fuel flow
- monitor excess oxygen
- monitor steam pressure

110

6.4 Normal Operation

Furnace and Emission Monitoring

Furnace and emssion

- monitor fluidization in hot
loop
- monitor gas side pressure drop
- monitor bed pressure
- monitor bed temperature
-monitor wind box pressure
- monitor SOx, Nox, CO

111

6.4 Normal Operation

Bottom ash and Soot Blower

Bottom ash drain

- automatic or manual draining
of bottom ash shall be judged by
commissioning engineer for the
design fuel.
- when fuel is deviated from the
design, operator can be judge by
themselves that draining need
to perform or not.
- bed pressure is the main
parameter to start draining

Soot blower
- initiate soot blower to clean
the heat exchanger surface in
convective part
- frequent of soot blowing
depend on the degradation of
heat transfer coefficient.
- normally 10 C higher than
normal value of exhaust
temperature

112

6.4 Normal Operation

Boiler Walk Down
- boiler expansion joint
- Boiler steam drum
- Boiler penthouse
- Safety valve
- Boiler lagging
- Spring hanger
- Valve and piping
- Damper position
- Loop seal
- Bottom screw
- Combustion chamber
- Fuel conveyor
113

6.4 Normal Operation

Sizing Quality
- crushed coal, bed material, lime stone and bottom ash
sizing shall be periodically checked by the operator
- sieve sizing shall be performed regularly to make sure
that their sizing is in range of recommendation

114

6.5 Normal Shut Down

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Reduce boiler load to 50% MCR

Place O2 control in manual mode
Monitor bed temperature
Continue reducing load according to shut down curve
Maintain SH steam >20 C of saturation temperature
Start burner when bed temperature <750 C
Empty solid fuel and lime stone with bed material >650 C
Decrease SUB firing rate according to suggestion curve
Maintain drum level in manual mode
Stop solid fuel, line stone, sand feeding system

115

6.5 Normal Shut Down

11. Maintain drum level near upper limit
12. Continue fluidizing the bed to cool down the system at 2
C/min by reducing SUB firing rate
13. Stop SUB at bed temperature 350 C
14. Continue fluidizing until bed temperature reach 300 C
15. Slowly close inlet damper of PAF and SAF so that IDF
can control furnace pressure in automatic mode
16. Stop all fan after damper completely closed
17. Stop HP blower 30 S after IDF stopped
18. Stop chemical feeding system when BFWP stop
19. Continue operate ash removal system until it empty
116

6.5 Normal Shut Down

20. Open vent valve at drum and SH when drum pressure
reach 1.5-2 bar
21. Open manhole around furnace when bed temp < 300 C

117

6.6 Emergency Shut down

Boiler can be held in hot stand by condition about 8 hrs
Hot condition is bed temp >650 C otherwise follow cold
star up procedure
Boiler load should be brought to minimum
Stop fuel feeding
Wait O2 increase 2 time of normal operation
Stop air to combustion chamber to minimize heat loss

118

6.7 Hot restart

Purge boiler if bed temperature < 600 C

Start SUBs if bed temperature > 500 C
Monitor bed temperature rise
If bed temperature does not rise after pulse feeding solid
fuel. stop feeding and start purge

119

6.8 Malfunction and Emergency

Bed pressure
Bed temperature
Circulation
Tube leak
Drum level

120

Bed Pressure
Bed pressure is an one of importance
parameter that effect on boiler efficiency
and reliability.
Measured above grid nozzle about 20 cm.

Pf= 0

Pb
Pw
FI

121

Bed Pressure
Effect of low bed pressure
- poor heat transfer
- boiler responds
- high bed temperature
- damage of air nozzle and refractory
Effect of high bed pressure
- increase heat transfer
- more efficient sulfur capture
- more power consumption of fan

122

Bed Pressure
Cause of low bed pressure
- loss of bed material
- too fine of bed materials
- high bed temperature
Cause of high bed pressure
- agglomeration
- too coarse of bed material

123

Bed Temperature
Measured above grid nozzle about
20 cm
Measured around the furnace cross
section
It is the significant parameter to
operate CFB boiler

124

Bed temperature
Effect of high bed temperature
- ineffective sulfur capture
- chance of ash melting
- chance of agglomeration
- chance to damage of air nozzle

125

Bed temperature
Cause of high bed temperature
- low bed pressure
- too coarse bed material
- too coarse solid fuel
- improper drain bed material
- low volatile fuel
- improper air flow adjustment

126

Circulation
Circulation is particular
phenomena of CFB boiler.
Bed material and fuel are
collected at cyclone separator
Return to the furnace via loop
seal
HP blower supply HP air to
fluidize collected materials to
return to furnace

127

Circulation
Effect of malfunction circulation
- No circulation result in forced shut down
- high rate of circulation
- high circulation rate need more power of blower
- low rate of circulation

128

Circulation
Cause of malfunction circulation
- insufficiency air flow to loop seal nozzle
- insufficient air pressure to loop seal
- plugging of HP blower inlet filter
- blocking or plugging of loop seal nozzle
-

129

Tube leak
Water tube leak
- furnace pressure rise
- bed temperature reduce
- stop fuel feeding
- open start up valve
- dont left low level of drum
- continue feed water until flue gas temp < 400 C
- continue combustion until complete
- small leak follow normal shut down

130

Drum level
Sudden loss of drum level
- when the cause is known and immediately correctable
before level reach minimum allowable. Reestablish steam
drum level to its normal value and continue boiler
operation
-if the cause is not known. Start immediate shut down
according to emergency shut down procedure

131

Drum level
Gradual loss of drum level
- boiler load shall be reduced to low load
- find out and correct the problem as soon as possible
- if can not maintain level and correct the problem, boiler
must be taken out of service and normal shut down
procedure shall be applied.

132

7. Maintenance

133

Before maintenance work

Make sure that all staff are understand about safety
instruction for doing CFB boiler maintenance work
Make sure that all maintenance and safety equipments
shall be a first class

134

Overview Boiler Maintenance

Refractory and tube are the main
area that need to be checked

135

6.1 Windbox Inspection

Inspect sand inside windbox
after shutdown
Drain pipe
Crack
Air gun pipe

Refractory
Crack, wear and fall down inspect

Drain pipe

by hammer(knocking) if burner is
under bed design

136

6.2 Furnace Inspection

Nozzle :
Wear
Fall-off

Refractory
Crack, wear and fall down inspect

by hammer knocking if burner is

under bed design

Refractory

Feed fuel port

Wear
Crack

Burner

Burner
Nozzle

Feed Fuel

137

6.2 Furnace Inspection

Limestone port
Crack
Deform
Refractory damage at connection

between port and refractory

Secondary & Recirculation Air

port
Crack
Deform
Refractory damage at connection

between port and refractory

Bed Temperature
Check thermo well deformation
Check wear

Secondary & Recirculation Air port

138

6.3 Kick-Out Inspection

Refractory
Wear
Crack and fall down by

hammer(knocking)

Water tube
Wear
Thickness

139

6.3 Kick-Out Inspection

Water Tube:
Thickness measuring
Erosion at corner
CO Corrosion due to incomplete

combustion at fuel feed side.

Defect from weld build up
Water tube sampling for internal
check every 3 years

Inside water tube inspect by borescope

welded build up excessive metal because use welding rod
size bigger than tube thickness

140

6.4 Superheat I (Wingwall)

Water Tube:
Thickness measuring
Erosion at tube connection

Refractory
Crack and fall down by

hammer(knocking)

Guard
Crack
fall down

141

6.4 Superheat I (Omega Tube)

Offset Water Tube:
Thickness measuring
Erosion at offset tube

Omega Guard

SH tube
Thickness measuring

Omega Guard
Crack
fall down

Offset Water
Tube

142

6.5 Roof
Water Tube:
Thickness measuring
Erosion

Refractory
Crack, wear and fall down by

hammer(knocking)

143

6.6 Inlet Separator

Water Tube:
Thickness measuring near opening

have more erosion than another

tube because of high velocity of flue
gas

Refractory
Crack, wear and fall down by

hammer(knocking)

144

6.7 Steam Drum

Surface :
Surface were black by magnetite

Deposits
Deposits at bottom drum need to

check chemical analysis

Cyclone Separator
Loose

Demister
Blowdown hole
Plugging

U-Clamp
Loose

Deposits at bottom drum

145

6.8 Separator
Central Pipe:
Deformation
Crack

Refractory
Wear at impact zone due to high

impact velocity
Crack and fall down by
hammer(knocking)

146

6.9 Outlet Separator

Water Tube
Tube Thickness
Erosion

Outlet Central Pipe:

Support or Hook

Refractory
Crack and fall down by

hammer(knocking)

147

6.10 Screen Tube

Water Tube

Thickness measuring upper part of

screen tube at corner have more
erosion than another area because
of high velocity of flue gas

Guard
Loose

Refractory
Crack and fall down by

hammer(knocking)

upper part of screen tube at corner have more erosion

Weld build up or install guard to prevent tube erosion

148

6.11 Superheat Tube

Tube
Thickness measuring
High erosion between SH tube and
wall
Steam erosion due to improper soot
blower

Guard
Fall down
Crack

149

6.12 Economizer
Water Tube
Thickness measuring
High erosion between economizer
tube and wall
Steam erosion due to improper soot
blower

Guard
Fall down
Crack

Guard

Install guard to
prevent tube erosion

150

6.13 Air Heater

Tube
Cold end corrosion due to high
concentrate SO3 in flue gas
Steam erosion due to improper soot
blower

Inlet air heater

Cold end corrosion due to SO3 in fluegas

151

8. Basic Boiler Safety

152

Warning
Operating or maintenance procedure which, if
not as described could result in injured death
or damage of equipment

153

General safety precaution

Electrical power shall be turned off before performing
installation or maintenance work. Lock out, tag out shall
be indicated
All personal safety equipment shall be suit for each work
Never direct air water stream into accumulation bed
material or fly ash. This will become breathing hazard
Always provide safe access to all equipment ( plant from,
ladders, stair way, hand rail
Post appropriate caution, warning or danger sign and
barrier for alerting non-working person
Only qualify and authorized person should service
equipment or maintenance work
154

General safety precaution

Do not by-pass any boiler interlocks
Use an filtering dust mask when entering dust zone
Do not disconnect hoist unless you have made sure that
the source is isolated

155

Equipment entry
Never entry confine space until is has been cooled, purged
and properly vented
When entering confine space such as separator, loop seal
furnace be prepared for falling material
Always lock the damper, gate or door before passing
through them
Never step on accumulation of bottom ash or fly ash. Its
underneath still hot
Never use toxic fluid in confine space
Use only appropriate lifting equipment when lift or move
equipment
156

Equipment entry
Stand by personnel shall be positioned outside a confine
space to help inside person incase of emergency
Be carefully aware the chance of falling down when enter
cyclone inlet or outlet.
Don not wear contact lens with out protective eye near
boiler, fuel handing, ash handing system. Airborne particle
can cause eye damage
Don not enter loop seal with out installing of cover over
loop seal downcomer to prevent falling material from
cyclone

157

Operating precautions
CFB boiler process
Use planks on top of bed materials after boiler is cooled
down. This will prevent the chance of nozzle plugging
Do not open any water valve when boiler is in service
Do not operate boiler with out O2 analyzer
Do not use downcomer blown donw when pressure > 7
bar otherwise loss of circulation may occure
Do not operate CFB boiler without bed material
When PA is started. PA flow to grid must be increase to
above minimum limit to fully fluidized bed maerial
Do not operate CFB boiler with bed pressure > 80mbar.
This might be grid nozzle plugging
158

Operating precautions
on cold start up the rate of chance in saturated steam shall
not exceed 2 C/min
On cold start up the change of flue gas temp at cyclone
inlet shall not exceed 70 C/min
Do not add feed water to empty steam drum with
different temperature between drum metal and feed water
greater than 50 C
All fan must be operated when add bed material

159

Operating precautions
Refractory
When entering cyclone be aware a chance of falling down
Refractory retain heat for long period. Be prepared for hot
surface when enter this area
An excessive thermal cycle will reduce the life cycle of
refractory
After refractory repair, air cure need to apply about 24 hr
or depend on manufacturer before heating cure
Heating cure shall be done carefully otherwise refractory
life will be reduced

160

Operating precautions
Solid Fuel
Chemical analysis of all solid fuel shall be determined for
first time and compared with OEM standard
Sizing is important
Burp feeding shall be performed during starting feeding
solid fuel instead of continuous feeding

161

9. Basic CFB Boiler Control

162

Basic control
Furnace control
Main pressure control
Main steam pressure control
Drum level control
Feed tank control
Solid fuel control
Primary air control
Secondary air control
Oxygen control

163

Basic control
Simple feedback control
PR IM ARY VA RIA B LE
XT

PR O CE S S

SE T P OIN T

f(x)
M A NIP U LAT E D VAR IA BLE
164

Basic control
Simple feed forward plus feedback control
P R IM A R Y VA R IA B L E
XT
SECO NDARY
VA R IA B L E
YT
K
P ROCE SS

S E T P O IN T
A

f(x)
M A N IP U L AT E D VA R IA B LE

165

Basic control
Simple cascade control
PR IM ARY VA RIABLE
XT
SEC O N DA RY
VAR IA BLE
ZT
K
PR O C ESS
K
SE T PO IN T
A

f(x)
M AN IPU LATED VAR IABLE

166

Basic control
Control Mode of PID

PID

SP

Percent

0-100 %

Eng. Unit

0-15 m3/h

Electrical signal

4-20 mA

-MAN (Manual)
-AUT (Automatic)
-CAS (Cascade)

PV

0-15 m3/h

CO

0-100%
0-100% (closed open)
4-20 mA

Signal to open
167

Feed water control

PID

PID

Make up water

PT
Heating steam

LT

Pressure

Level

-Manual mode 0-100% heating steam valve

position

-Manual mode 0-100% make up water valve

-Auto mode, specify pressure set point

-Temperature compensation

-Auto mode, specify level set point

-Temperature compensation
-Protection, high level over flow

168

Drum Level control

Main steam Pressure

Manual mode, 0-100%

control valve
Auto mode, specify drum
level. Automatically adjust
valve

Main steam flow

A, SP

Control valve
M, 0-100%
Protection
-lower limit
DP feed
water pump

-2/3 principle
- 10 s delay
-Close steam valve for low level

169

Main steam pressure control

PV

SP
FF

CO

170

Main steam
Pressure

Combustion
Calculation

Total air SP

Total Fuel SP

PA SP

SA SP

Fuel1 SP

Fuel2 SP

Fuel3 SP

PA.Fan

SA.Fan

Conveyor1

Conveyor2

Conveyor3

171

Solid Fuel Control

Cascade

PID

Auto

WT
Manual

M
Manual : speed of coal conveyor is
specified by operator
Auto : operator specify fuel flow load
Cascade: fuel flow set point calculated by
main steam pressure control
172

Primary air control

Manual: position of damper is
specified
Auto
Cascade

Auto: desired air flow is specified by

operator

PID

Cascade: set point is calculated from

master combustion
Flow (interlock) > minimum
Manual
PV

FT

PA wind box P > minimum

PA running

173

Secondary air control

FT

PID

Auto
Cascade

Upper SA

PID

Auto
Cascade

Manual
Manual
PV

FT

M
PT

FT

Manual

Lower SA

174

HP Blower Control
Pressure is controlled by control valve
Control valve is connected to primary air
It will release the air to primary air duct if pressure higher
than set point
If operating unit stop due to disturbance or pressure fall
down, stand by unit shall be automatically started
Pressure should be higher than 300 mbar, boiler interlock
Pressure < 350 mbar parallel operation start

175

Furnace Pressure control

Auto

Furnace
pressure

PID

Auto

PID

PT

2/3 furnace P < max (35 mbar)

Manual

Manual

176

Lime stone control

Lime stone can be control by
lime stone/ fuel flow ratio
SO2 feed back control
Manual feed rate

177

Fuel oil control

Pressure control

Auto

Pressure
control valve
Manual
Flow control
valve

178

Referenced
Prabir Basu , Combustion and gasification in fluidized bed, 2006
Fluidized bed combustion, Simeon N. Oka, 2004
Nan Zh., et al, 3D CFD simulation of hydrodynamics of a 150 MWe circulating fluidized bed
boiler, Chemical Engineering Journal, 162, 2010, 821-828
Zhang M., et al, Heat Flux profile of the furnace wall of 300 MWe CFB Boiler, powder
technology, 203, 2010, 548-554
Foster Wheeler, TKIC refresh training, 2008
M. Koksal and F. Humdullahper , Gas Mixing in circulating fluidized beds with secondary
air injection, Chemical engineering research and design, 82 (8A), 2004, 979-992

179