A New Generation of Pulverized Coal Technology

ST. JOHN’S UNITS 1 & 2 SUPPLIEDBY FOSTER WHEELER TO

JACKSONVILLE ELECTRIC AUTHORITY IN OPERATION SINCE 1987

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A LONG HISTORY WITH PULVERIZED COAL STEAM GENERATORS

For over half a century, Foster Wheeler has been designing and manufacturing utility pulverized coal (PC) steam generators. Our utility steam generators have proven themselves with over 50 million hours of operation, up to 1,100 MWe in size, and have the capability of burning a wide range of coals from anthracite to sub-bituminous fuels as well as petroleum coke.

Our natural circulation boilers are designed to be inherently safe by naturally increasing water flow as tube heat flow increases, under normal or upset scenarios, without relying on pumps, back-up systems or mechanical equipment.

The natural circulation characteristic is also included in our supercritical once-through BENSON Vertical Tube (BVT) technology, offered as a design option on all our utility PC steam generators.

Our units feature many other time tested advanced design features like low NOx firing systems, MBF and ball mills, SCR systems, split and series back pass resulting in improved reliability, low emissions and peak plant performance.

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• Automatically detects coal slugging that can lead to fires and load reductions• Pinpoints distribution problems that cause uneven temperature profiles, localized slagging

and elevated unburned carbon• Rugged long-life tungsten carbide probes• Intuitive graphical interface

• Ceramic or high chrome composite grinding rollers and table segments• Refractory lined classifier housing & mill discharge assembly• Refractory lined roller coal shields• Individually tensioned, fixed rollers• Three point maintenance access• Low internal fuel air velocities

• Only three moving components• No radial vanes to bind• Independent swirl & air flow control for burner-to-burner biasing• Four port “silhouette” burner tip for optimized velocity control • Refractory lined elbow, outer barrel and anti roping vanes to handle high ash

abrasive coals

FW’s Wall-Fired Vortex SeriesHighly Reliable Low NOx Burners

FW’S MBF Coal Pulverizers are Designed and Built to Handle Abrasive High Ash Coals

Real Time Fuel/Air Monitoring and Control for Optimum Combustion Efficiency, Reliability and Low EmissionsElectrostatic Charge Technology (ECT)

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FW PCs STAND OUT DUE TO THEIR TIME TESTED DESIGN FEATURES

OUR STATE-OF-THE-ART LOW NOx COMBUSTION SYSTEMS DELIVER HIGH COMBUSTION EFFICIENCY AND THE LOWEST EMISSIONS

• On-line biasing of coal flow between coal pipes • Compatible with common industry riffle distributors• Available for 2 or 3 way distribution

FW PC’s Have Proven Themselves On High Ash Coals

Adjustable Riffle Distributor

FW’s Arch-Fired Preheat BurnersLow NOx Burners for Low Volatile Fuels• Multi-level air staging for the lowest NOx emissions• Fuel preheating for improved combustion efficiency• Air separating cyclone burners for easy Ignition• Natural hot gas recirculation for flame stability• Unit turndown to 40% load without support oil

Start-Up Year(s) Plant Owner Plant & Unit Country Capacity MWe Fuel %

Fuel Ash

1974, 1984 Hidroelectrica del Cantabrico Abono #1 & #2 Spain 355 - 556 Bituminous Coal 30%

1972, 1981, 1984 Endesa, SA Compostilla II - #3, #4, #5 Spain 320 - 350 Anthracite Coal 28%

1980 ENECO, SA Puente Nuevo #3 Spain 315 Coal 49%

1964 Termicas del Norte Espana, SA Guardo #2 Spain 350 Coal 29%

1995, 1996 CFE - Mexico Carbon II - #1/2 Mexico 385 Coal 43%

2000, 2000 Shandong Rizhou Rizhou #1 & #2 China 350 Coal 31%

1996, 1997 Shandong Electric Zouxian #5 & #6 China 660 Coal 29%

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5

10

15

20

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Conventional Spiral Technology

Advanced BVT Technology

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9.1

NOT ALL SUPERCRITICAL TECHNOLOGIES ARE THE SAME

Foster Wheeler’s BENSON Vertical Tube (BVT) supercritical steam technology has significant advantages over conventional spiral technology. Since the evaporator tubes are vertical along the entire furnace height, the furnace walls are easier to fabricate, erect and repair.

In addition, the steam flow of BVT technology is much lower in each tube than spiral technology, resulting in a lower steam pressure loss which further improves plant efficiency. BVT technology also features a self cooling characteristic which can limit the temperature rise of tubes receiving higher heat flows for longer tube life.

To further improve the life of the furnace, evaporator tubes which receive high heat are rifled resulting in a spiral ridge along the length of the tube. After years of research, the ridge geometry has been perfected so that a film of liquid water will coat the tube wall to provide effective cooling at much higher steam qualities and tube metal temperatures than conventional smooth tube technology.

For ease of operation, BVT supercritical technology utilizes in-line tangential steam/water separators which allow the steam generator’s evaporator to automatically transition from circulating to once-through steam mode during unit start-up and shut-down, while providing a wide range of operation in the once-through mode.

Steam Pressure Drop Across Evaporator at

100% Boiler Load (bar)

Foster Wheeler’s Advanced BVT Steam Generator Technology

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• Small tubes for self cooling effect• Simple support system• Low pressure drop• Easy to maintain• Lower cost to build

ADVANCING UTILITY PC TECHNOLOGY – The Longview Power Project

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GOING SUPERCRITICALWe have coupled our proven wall-fired pulverized coal (PC) steam generators with advanced BENSON vertical-tube (BVT) supercritical steam technology. Supercritical steam technology can achieve plant efficiencies well beyond conventional subcritical drum-type units, thereby producing more electricity and less emissions from a steam power plant. By coupling these technologies together, we offer a steam generator design balanced with both proven and advanced design features, such as:

• Simple vertical tube furnace construction which is easier to fabricate, build and repair

• Built-in self cooling characteristic for maximum furnace life

• Generous furnace volumes for complete combustion of the fuel

• MBF and ball mill pulverizers for the widest solid fuel range

• Staged low NOx combustion systems

• SCR for the lowest NOx emissions

Plant Electrical Output (Gross/Net)Net Plant Efficiency (LHV/HHV)Net Plant Heat Rate (LHV/HHV)Steam Flow (SH/RH)Steam Pressure (SH/RH)Steam Temperature (SH/RH)Feedwater Temperature

770 MWe/695 MWe40.8%/39.1%8370/8733 Btu/kWh616/507 kg/s258/55 bar569/567 °C298 °C

4876/4012 kpph3735/802 psig1056/1052 °F569 °F

Fuel West VirginiaBituminous Coal

LONGVIEW PROJECT SUMMARYPlant Location: Maidsville, WV, USA Customer: Longview Power, LCC FW Full Release: December 2007 Plant Start-Up: Spring 2011

Quezon Power PlantLocation: Quezon, PhilippinesCustomer: Quezon Power Limited Co.Start-Up Year: 2000Capacity: 1 x 486 MWeFuel: Coal, Oil

FW’S SUBCRITICAL NATURAL CIRCULATION WALL FIRED PCs – Designed and Built For Long Life and High Reliability

Springerville Generating Station Units 3 & 4Location: Springerville, Arizona, USACustomer: Bechtel Power Corp./

Salt River Project (SRP)Start-Up Year: 2006, 2009Capacity: 2 x 400 MWeFuel: PRB Coal

Wall Fired Subcritical Natural Circulation Steam

Generator

• Natural circulation furnace circuitry “self compensates” for heat flux unbalances

• Optimized furnace size yields high combustion efficiency and minimizes flame impingement on furnace walls

• Low NOx Vortex Series burners maximize carbon burnout, with minimal NOx production

• Evenly spaced burners on furnace walls provide uniform gas temperature at furnace exit

• Direct firing system from silo to burner offers safe fuel storage and simple fuel controls

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Santee Cooper Cross StationLocation: Moncks Corner, North Carolina, USACustomer: Santee CooperStart-Up Year: 1999Capacity: 1 x 550 MWeFuel: Bituminous Coal

ZouxianLocation: Zouxian City, Shandong Province, ChinaCustomer: Zouxian Power Generating CompanyStart-Up Year: 1996Capacity: 2 x 660 MWeFuel: Bituminous Coal

Wall Fired Subcritical Natural Circulation Steam

Generator

• Wide tube spacing and in-line tubes to prevent ash bridging

• Low gas velocities for low erosion

• Refractory and erosion shield protection in high wear areas

• Patented induct heater for economical SCR ammonia vaporization

• Flue gas or steam bypass for efficient reheat temperature control

• Robust MBF coal mills to handle abrasive high ash coals

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Bruce Mansfield Units 2 & 3Location: Shippingport, PA, USACustomer: Pennsylvania Power Co.Start-Up Year: 1977, 1980Capacity: 2 x 800 MWeFuel: Eastern Bituminous Coal

Datang Supercritical Arch-Fired PC Power PlantLocation: Heshan City, Guangxi Province, ChinaCustomer: Datang Guiguan Heshan Power Gen Co, Ltd.Start-Up Year: 2012Capacity: 2 x 670 MWeFuel: Anthracite Coal

FW’S ADVANCED PULVERIZED COAL TECHNOLO GY FOR LOW VOLATILE FUELS

Arch-Fired Once-Through Supercritical

Steam Generator • Double cyclone burners creates a “W” flame shape for high carbon burnout of low volatile fuels

• Burner vent-to-overfire air system aids ignition and minimizes NOx formation

• Selective refractory covering in lower furnace enhances ignition and promotes complete combustion

• Direct firing system from silo to burner offers safe fuel storage and simple fuel controls

• Self compensating “natural circulation characteristic” to minimize temperature unbalances

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Hanfeng Arch-Fired BoilersLocation: Handan, Hebei Province, ChinaCustomer: Hanfeng Power Generating

Company Ltd.Start-Up Year: 2000, 2001Capacity: 2 x 716 MWeFuel: Anthracite Coal

Vinh Tan Arch-Fired Units I & IILocation: Binh Thuan Province, South

VietnamCustomer: Vietnam Electricity (EVN)Start-Up Year: 2013 - 2014Capacity: 2 x 622 MWeFuel: Anthracite

Arch-Fired SubcriticalNatural CirculationSteam Generator• Vertical tube wall

construction simplifies erection, maintenance, and repair

• Low minimum load which reduces start-up time, auxiliary fuel and start-up pump power consumption

For Supercritical Designs• BVT technology provides safe

self cooling protection and simple vertical tube furnace design

• Optimized rifled tubes for effective tube cooling

• Low steam/water pressure loss provides improved plant efficiency

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Nghi Son 1 Arch-Fired ProjectLocation: Thanh Hoa Province, VietnamCustomer: Vietnam Electricity (EVN)Start-Up Year: 2013 - 2014Capacity: 2 x 300 MWeFuel: Pulverized Anthracite Coal

PC_032613

We offer a full range of steam generator equipment, aftermarket products and services to the power, industrial, and waste-to-energy sectors. Our global manufacturing and engineering network can deliver cutting edge products and expertise, quickly and cost competitively with best-in-class quality. Established in 1891, our experience comes from a heritage of designing, servicing, and continually improving steam generating equipment.

CONTACT US

Steam Generators• Circulating Fluid Bed • Pulverized Coal • Oil & Gas • Solar• Bubbling Fluid Bed• Package • Grate and MSW• Metallurgical Waste Heat• HRSG

Environmental Products• Circulating Fluid Bed Scrubbers• Fabric Filters• SCR and SNCR Systems• Low NOx Combustion Systems• Biomass Combustion Retrofits • Coal/Air Control System

Upgrades

Aftermarket Services • Condition Assessment• Engineered and Replacement

Pressure Parts• Weld Overlay and Refractory

Upgrades • Replacement Parts• Cyclone Burner Retrofits• Coal Mill Service and Upgrades • Maintenance Services• Outage Construction• Engineering Studies

Auxiliary Equipment• Condensers• Feedwater Heaters• Biomass Gasifiers

Plant Operation • Plants owned and

operated by FW• Long-term Service

Agreements

GLOBALLYwww.fwc.com

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