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
CFBB TECHNOLOGY AT RAFAKOCFBB TECHNOLOGY AT RAFAKO
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
CFBB TECHNOLOGY AT RAFAKOCFBB TECHNOLOGY AT RAFAKO
Bottom nozzle grateBottom nozzle grate
Primary airPrimary air
nozzlesnozzles
Circulating bedCirculating bed
CFBB TECHNOLOGY AT RAFAKOCFBB TECHNOLOGY AT RAFAKO
Grain size
Res
idu
e
Min
us
mes
h
REQUIRED COAL GRAIN SIZE DISTRIBUTION - Bituminous Coal
CFBB TECHNOLOGY AT RAFAKOCFBB TECHNOLOGY AT RAFAKO
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
CFBB TECHNOLOGY AT RAFAKOCFBB TECHNOLOGY AT RAFAKO
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%
Technical DataTechnical Data
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
(guaranteed and measured values)
29%29% 65%65%30%30%
6%6%
Real emission value vs. guaranteed
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
Technical DataTechnical Data
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 %
Fuel: Bituminous coalFuel: Bituminous coal
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
Harmful emissions from the boiler
(guaranteed and measured values)
75%75%
50%50% 40%40%
Real emission value vs. guaranteed
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
Fuel: Bituminous coalFuel: Bituminous coal
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
Harmful emissions from the boiler
(guaranteed and measured values)
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%
Real emission value vs. guaranteed
50%50%
Boiler OFz-450 “B”, Żerań CHP, WarsawBoiler OFz-450 “B”, Żerań CHP, Warsaw
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 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 %%
Boiler OFz-450 “B”, Żerań CHP, WarsawBoiler OFz-450 “B”, Żerań CHP, Warsaw
020406080
100120140160180200
Em
issi
on
[mg
/Nm
3]
SO2 NOx CO
Guaranties
Measurements
Harmful Emissions From the Boiler
(guaranteed and measured values)
75%75%
Real emission value vs. guaranteed
60%60%
50%50%
Boiler OFz-450 “B”, Żerań CHP, WarsawBoiler OFz-450 “B”, Żerań CHP, Warsaw
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
Target No 1:Target No 1:
Operating Conditions Operating Conditions ImprovementImprovement
Target No 2:Target No 2:
Simplification of CFB Simplification of CFB InstallationInstallation
Target No 2:Target No 2:
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
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)
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
Mechanical shield (Mechanical shield (Żerań B, Siersza)Żerań B, Siersza)
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
Mechanical shield (Mechanical shield (Żerań B, Siersza)Żerań B, Siersza)
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
Protective shape of the hopper refractory lining (Protective shape of the hopper refractory lining (Żerań Żerań B, Siersza)B, Siersza)
Boiler Construction OptimisationBoiler Construction Optimisation
Target: Operating Conditions Improvement Target: Operating Conditions Improvement Target: Operating Conditions Improvement Target: Operating Conditions Improvement
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)
Boiler Construction OptimisationBoiler Construction Optimisation
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)
Target: Operating Conditions Improvement Target: Operating Conditions Improvement Target: Operating Conditions Improvement Target: Operating Conditions Improvement
Boiler Construction OptimisationBoiler Construction Optimisation
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
Boiler Construction OptimisationBoiler Construction Optimisation
Target: Operating Conditions Improvement Target: Operating Conditions Improvement Target: Operating Conditions Improvement Target: Operating Conditions Improvement
Antiradiation shields (Antiradiation shields (Polfa, Polfa, Żerań A & B, Siersza)Żerań A & B, Siersza)
Target: Simplification of Target: Simplification of Installation Installation
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
Boiler Construction OptimisationBoiler Construction Optimisation
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)
Boiler Construction OptimisationBoiler Construction Optimisation
Boiler Construction OptimisationBoiler Construction Optimisation
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
Target: Simplification of Target: Simplification of Installation Installation
Target: Simplification of Target: Simplification of Installation Installation
Boiler Construction OptimisationBoiler Construction Optimisation
Target: Simplification of Target: Simplification of Installation Installation
Target: Simplification of Target: Simplification of Installation Installation
Boiler Construction OptimisationBoiler Construction Optimisation
Target: Simplification of Target: Simplification of Installation Installation
Target: Simplification of Target: Simplification of Installation Installation
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