Research & Development and Its Application of 

Circulating Fluidized Bed Boiler Technology in China

Junfu LYU, Hairui YANG, Guangxi YUE

Tsinghua University, Beijing, PRC
20171023
 Content

1. General introduction on CFB technology and its application in China

2. Supercritical CFB boiler design and operation in China

2.1 Gas-solid two-phase flow of large riser
2.2 Heat flux in a CFB boiler
2.3 Heat transfer of the supercritical water
2.4 Practices of supercritical CFB boiler

3. Ultra-low emission CFB boiler research and application

3.1 SO2 controlled by limestone injection
3.2 NOx controlled by low NOx combustion

4. Conclusion
1. Circulating fluidized bed (CFB) for electric power generation in China

 Coal is the dominate fuel in China

 Coal is dirty, its utility produces pollution emission
 Washing coal is an effective way to control the coal pollution
 Coal washing by-products a large number of low heating value fuel
 It should be used cleanly
1. Circulating fluidized bed (CFB) for electric power generation in China

 The unique advantages of CFB is high fuel flexibility and low cost emission control.
 CFB boiler is one of the best way to deal with low grade coal.
 CFB is very important for the countries in which coal is major energy resource
 CFB boiler is playing an important role of electric power generation in China.

Utility
Washed coal for power

Washed coal High efficiency PC boiler

For coal
washing Coal
Raw
coal waste washing
Washery rejects,
slurry
Circulating fluidized bed boiler

low heating value coal

1. Circulating fluidized bed (CFB) for electric power generation in China

 It is in 1960s that China started the R&D on bubbling bed boiler (BFB). By 1980, over
including 300MW
3000 BFBs subcritical
of capacity CFB
ranging boilers,
from 350MW
4 to 130t/h were&operating
600MWinsupercritical
China. CFB
TheThen
 design
boilers whichtheory now are
dominates
Chinese started widely
toChinese accepted
CFB
investigate CFB in
toChina
market. to
thedevelop
avoidNow, series capacities
the ultra-super
shortage of BFB. criticalCFB
CFB
boilers

boiler fromcapacity
with
It costs small
10 oneof
years toof660MW
35t/h to is
understand thebeing
worldcombustion
CFB biggest oneprocess and to improve the CFB
developed.
boiler design theory and finalized their own understanding on the CFB boiler.

Supercritical
Supercritical
800
Subcritical

Unit capacity of CFB boiler

Over high pressure
Medium High temperature Once reheat 600
Medium temperature High pressure
temperature Medium
Medium pressure 400 SC 600MW
pressure SC 350MW
300MW
200
125~200MW
25-100MW
15-25MW 2005-present
0
6-15MW 2000-2005 1980 1990 2000 2010 2020
1995-2000 Developing Year
1990-1994 Scaling-up
1980-1989 Improving The scaling of CFB boiler in China
Learning Understanding
1. Circulating fluidized bed (CFB) for electric power generation in China
10000
100
Commercial operation
Boiler number n

1000 Under construction

Availability index, %
95

100
90
as well as the maximum continuous running time. The CFB boiler plays a essential role
10
in Chinese power generation, the total capacity of CFB 85
unit is more than 100 GW.
1
<50 ~50 100~150 ~200 ~300 ~350 ~600 80
1995 2000 2005 2010 2015
Boiler capacity MW Year
Number of CFB boiler in China Availability of CFB power plant in China

600
100
Max continuous running time, days

Total capacity of CFB unit GW

And CFB
450 boilers are widely used in China. The CFB 10
boiler number increases every year,
by the end of two thousand fifteen, there are about two thousand and eight hundred unit
300 1
were in commercial operation, and more than three hundreds were under construction.
150 0.1
In the same time, the availability of CFB power plant increases also.
0 0.01
1990 1995 2000 2005 2010 2015
1995 2000 2005 2010 2015
Year Year
Maximum continuous running time Total capacity of CFB Boiler unit
1. Circulating fluidized bed (CFB) for electric power generation in China

 China could supplied varies capacity CFB boiler with varies parameter and varies
kinds of fuel: varies kinds of coal, biomass, petroleum coke, and RDF.
 There are many boiler workers devotes themselves for CFB, such as:
 Harbin Boiler Workers co., LTD.
 Dongfang Boiler Group co., LTD.
 Shanghai boiler Workers co., LTD.
 Taiyuan Boiler Group co., LTD.
 Wuxi Huaguang boiler co., LTD.
 Jinan boiler group co., LTD.
 

 The CFB boiler performance becomes better and better even better than PC boiler in
China. This is due to the technical progress. Here, I would like to take some time to
shown two major examples. The first one is:
 Content

1. General introduction on CFB technology and its application in China

2. Supercritical CFB boiler design and operation in China

2.1 Gas-solid two-phase flow of large riser
2.2 Heat flux in a CFB boiler
2.3 Heat transfer of the supercritical water
2.4 Practices of supercritical CFB boiler

3. Ultra-low emission CFB boiler research and application

3.1 SO2 controlled by limestone injection
3.2 NOx controlled by low NOx combustion

4. Conclusion
2. Supercritical CFB boiler design and operation in China

 CFB performs very well in fuel flexibility but is not very efficient in power generation
 Increasing steam parameter to supercritical is the way to improve the power generation
efficiency
Milestone of SU CFB in China
2000—technology feasibility study of SC CFB It was realized the CFB future is supercritical
2003—the classification of key questions of SC CFB
2006—research program on SC CFB
2007—600MW SC CFB demon. approval
2011—approval of invest.
2012 end— erection
2013.4—commissioning and full load test
2014.7: performance test

From then a series of investigation on supercritical CFB were conducted including two
phase flow, combustion and heat transfer in a larger furnace that never be
2. Supercritical CFB boiler design and operation in China
2.1 Gas-solid flow of large riser
 The height of a 600MW CFB is 15 m higher than that of a 300MW.
 The gas- solid two-phase flow was studied

Comparison of solid suspension density distribution between measurement

and model prediction

A 55m height CFB test facility was built to investigate the fluidization in such high riser. Based on the
systematic measurements in this rig and many other real CFB boilers, a model predicting solid
density is suggested. It seems that the model is reasonable by comparison between model and test.
2. Supercritical CFB boiler design and operation in China
2.2 Heat flux in a CFB boiler
 The safety of the water wall in a SC boiler depends on the heat flux
 Heat flux in a CFB boiler is unknown
 The flux distribution model is suggested

150
25% error
+25%

Measured heat flux (kW/m2)

10% error +10%
130
-10%

110

-25%
90

70

50
50 70 90 110 130 150
2
Predicted heat flux (kW/m )

Heat transfer coefficients vs particle density and temperature Heat flux model accuracy
Nature circulation Once through for supercritical
This model is the combination of the local heat transfer model and solid density distribution
P11
model. The heat flux distribution model prediction agrees very well with the measurement.
2. Supercritical CFB boiler design and operation in China
2.3 Heat transfer of the supercritical water
 With the heat flux model
 The hydrodynamic of the water wall was calculated
 The prediction agrees well with the real boiler operation

to+20
the outlet of No.n ℃
Steam temperature at

to+20

to+10
Prediction
Operation
to+15

to+0
1 50 100 150 200
Tube location(the tube number from the wall corner) n
Comparison between model prediction and operation on the water tube outlet temperature
2. Supercritical CFB boiler design and operation in China
2.4 Practices of SC CFB boiler
 Based on the clear understanding of supercritical CFB boiler principle
 A series of patent are invented
 A new thermal process is created
 System integration technologies including control are developed
 The world’s first 600MW SC CFB boiler was built in Baima Power Plant
2. Supercritical CFB boiler design and operation in China
2.4 Practices of SC CFB boiler
Coal in Baima

Item Unite Value

Mar % 7.58
Aar % 43.82
Vdaf % 14.74
Qnet,ar MJ/kg 15.17
Sar % 3.3

 The 600MW SC CFB was successfully demonstrated in Baima Power Plant.

 It was put into commercial operation in April 2014. it runs very well.
2. Supercritical CFB boiler design and operation in China
2.4 Practices of SC CFB boiler
The performance test data are well matching with the design
item unit design test
Power load MW 600 601
Living Steam pressure MPa 25.39 24.81
Living Steam temperature Ԩ 571 569.88
Reheat steam pressure MPa 4.149 4.04
Reheat steam temperature Ԩ 569 566.96
Total attemperation flow t/h 142 109.2
Furnace temperature Ԩ 890 ~890
Boiler efficiency % >91.01 91.52
3
SO2 emission mg/m <380 192.04
Calcium/Sulfur mol. ratio mol/mol 2.1 2.07
De-SO2 efficiency % 96.7 97.12
3
NOx emission mg/m <200 111.94
3
Particulate emission mg/m 30 9.34
Beside Baima project, there are also other three 600MW SC CFB boiler
are ordered.
2. Supercritical CFB boiler design and operation in China
2.4 Practices of SC CFB boiler
 With the research and technologies, 350MW are then developed.
 More than 70 are ordered (3 for oversea). 16 boilers are in operation.

350MW SC CFB boilers in Hequ Power Plant 350MW SC CFB boilers in Guojin Power Plant

350MW SC CFB boilers in Datuhe Power Plant 350MW SC CFB boilers for oversea P16
 Content

1. General introduction on CFB technology and its application in China

2. Supercritical CFB boiler design and operation in China

2.1 Gas-solid two-phase flow of large riser
2.2 Heat flux in a CFB boiler
2.3 Heat transfer of the supercritical water
2.4 Practices of supercritical CFB boiler

3. Ultra-low emission CFB boiler research and application

3.1 SO2 controlled by limestone injection
3.2 NOx controlled by low NOx combustion

4. Conclusion
3. Ultra-low emission of CFB boiler research and application
 One of the CFB boiler advantage is low cost emission control
 CFB matches most regulation by limestone injection and low Nox combustion
 China Emission Limit for Coal-fired Power Plants is most strict
(GB 13223-2011) : NOx<100 mg/m3; SO2<100 mg/m3
careful design and operation of a CFB boiler is necessary
 Upgrade action plan requires(2014):
NOx<50 mg/m3; SO2<35 mg/m3
 CFB is facing great challenge in China
250

（@6%）
dust NOx SO2
200
Due to the pressure of fog

Emission, mg/Nm
Because of the large

3
and haze 150
number of coal
100
consumption
50

0
China USA JPN Euro
3. Ultra-low emission of CFB boiler research and application
3.1 SO2 controlled by limestone

 Factors that effect SO2 emission

the final SO2 emission concentration C: ks, E: reactivity

1 Ar: surface area Particle size
C=
 E  1 : residence time
Ar ks  exp    Cyclone collection efficiency 
 RT  Co T: temperature
What we can do is to increase 
Co: initial SO2 concentration

If the cyclone collection efficiency is better, the size of limestone could be finer for the
same residence time. If the cyclone collection efficiency is not so good, the limestone
has to be coarser.
3. Ultra-low emission of CFB boiler research and application
3.1 SO2 controlled by limestone

 the effect of temperature

• Calcination reaction:   100

CaCO3 
煅烧
 CaO  CO 2 750~900Ԩ 95

脱硫效率 S/%
90
• Desulphurization reaction:
1 85
CaO + SO 2  O 2   CaSO 4 800~950Ԩ
2 80

75
• Decomposition of desulfurization products: 700 750 800 850 900 950
床层温度 tb/oC
CaS  3CaSO 4 
 4CaO  4SO 2 >850Ԩ The effect of temperature on
desulphurization efficiency
CaSO 4  CO 
 CaO  SO 2  CO 2 >880Ԩ

The temperature should be balanced because the higher temperature causes higher
SO2 capture reaction speed, however, the decomposition speed of desulfurization
products is also increases. The temperature is optimized to around 850C.
3. Ultra-low emission of CFB boiler research and application
3.1 SO2 controlled by limestone

 The cyclone collection efficiency should be improved:

fly ash d<50 m, bottom ash d <200 m In the optimized temperature,
 A new limestone size distribution： limestone particle size could be smaller

Recommended particle size distribution of limestone

for higher efficiency SO2 capture
 The original SO2 emission could be less than 35 mg/m3
3. Ultra-low emission of CFB boiler research and application
3.2 NOx controlled by low NOx combustion
 In CFB combustion, most NOx is fuel NOx
H
NCO N
N2
O2, O
HCN NO NH
N
Volatile
挥发分 N NO, N NH2
N2
NO
Colatile-N
N
燃料 N NH3 Coal Fuel-N
particle
O2,OH,O char
燃料 N NH NO

N
OH,H,O

N2
NH2,NH,N

Char-N
挥发分 N NH2

So the combustion atmosphere should be

OH,H,O

NO
controlled carefully to reduce the formation
of NOx from fuel Nitrogen.
NH3 N2
3. Ultra-low emission of CFB boiler research and application
3.2 NOx controlled by low NOx combustion
 The fuel particles are in emulsion phase. The gas pass through it at minimum velocity.
This velocity depends on particle size.
 The mass transfer in the emulsion phase is also depends on the particle size. The trend
is same
 The finer the particle, the less the gas velocity, the less the Oxygen, the more reduced
the atmosphere.
Flue gas In the dense bed of a CFB
~850Ԩ

~ 850Ԩ
4~6m/s

Air
Fuel
limestone
Air
3. Ultra-low emission of CFB boiler research and application
3.2 NOx controlled by low NOx combustion
 The effect of particle size on NOx emission in dense bed is confirmed by experimental.

30 20
煤焦AA
Char
0.18-0.20 mm
煤焦BB
Char
(%)(%)

0.275-0.30 mm
煤焦CC
Char 15

(ppmv)
0.40-0.45 mm
to NOx

emission (ppmv)
20
转化率
Char-N

NO排放浓度
10
焦炭氮向 rateNO

10

NOx
Conversion

0 0
150 300 450 600 750 0 1000 2000 3000 4000

床料粒度 m)(m)
Bed particle(size 时间time
Resident (s) (s)

With the bed particle size decreasing, the NOx emission decreases.
3. Ultra-low emission of CFB boiler research and application
3.2 NOx controlled by low NOx combustion
 The combustion behavior in free board is similar as that in dense bed. The cluster is
enhanced and its density is higher by smaller particle size or higher circulating flow
rate. The finer the particle and the bigger the circulating flow rate, the more reduced
the atmosphere.
Flue gas
~850Ԩ

0.06
in cluster ( )

~850Ԩ
颗粒团中的固含率   sc sc

4~6m/s
0.04
Solid concentration

Air
0.02 sa=sc 
Fuel

limestone
0.00
0.00 0.04 0.08 0.12  0.16 0.20
Air 截面平均固含率 
Sectional sa
solid concentration (sa)
3. Ultra-low emission of CFB boiler research and application
3.2 NOx controlled by low NOx combustion
 The reduction of NOx by CO and Char decreases NOx emission.
The concentration of carbon
monoxide in CFB is pretty high
Flue gas
800~900 Ԩ
100 100

NO reduction percentage %
NO reduction percentage %
CNO=220mg/Nm3 CNO=220mg/Nm3
80 80
Tb=860oC res=2.1s
res=1.68s
60 60

800~900 Ԩ
40 40
4~6m/s
20 Over ash 20 Over char Mixed with ash
Over sand Over char mixed with sand
Air 0 0
0 0.5 1.0 1.5 2.0 2.5 750 800 850 900 950 1000
Fuel Temperature oC
mole ratio of CO to NO
limestone  9.561 107   2.063  105  2.92
 4.41 10 exp     ash
12
 4.43  10 exp     ash
k NO CO 10 k NO char
 RT   RT 
Air
 ash  X SiO  1.18 X Al O  4.74 X CaO/MgO  110.23 X Fe O
2 2 3 2 3
 ash  X SiO  1.18 X Al O  4.74 X CaO/MgO  110.23 X Fe O
2 2 3 2 3

There is a large number of The ash from fuel combustion promotes the
char in bed material. reduction reaction as a catalyst.
3. Ultra-low emission of CFB boiler research and application
3.2 NOx controlled by low NOx combustion
 Technical routing of low NOx combustion Thus the key of Low-nitrogen 
 fly ash d<50 m, bottom ash d <200 m combustion of CFB boiler is 

To increase performance of
circulating system

To increase bed quality To increase circulating flow rate

Air distribution Reduced atmosphere Reducing NOx emission

Reducing gas from the combustion

Reduction of NOx
and unburnt carbon

Ultra low NOx

This requires the better cyclone and loopseal performance. emission
This is confirmed by real boilers. Practices shown that the
better bed quality is necessary for low NOx emission .
3. Ultra-low emission of CFB boiler research and application
3.2 NOx controlled by low NOx combustion
 Typical practices
SO2 emission
 Lean coal, bituminous concentration De-SO2 efficiency %
Ca/S molar ratio
 Only limestone injection into furnace and low NOx combustion
NOx emission
 Limestone promotes NOx emission

A 220t/h lean coal fired CFB boiler: A bituminous coal fired CFB boiler:
The SO2 emission is controlled less than 10 The SO2 emission is controlled less than 22
mg/m3 only by limestone injection. NOx mg/m3 by only limestone injection. In the
emission is less than 50mg/m3. same time, the NOx is lees than 50mg/m3.
SO2 emission concentration
SO2 emission
concentration De-SO2 efficiency % NOx emission concentration
Ca/S molar ratio
NOx emission

National inspection
and measurement
institute of China

National inspection
and measurement De-SO2 efficiency %
institute of China Ca/S molar ratio
 Content

1. General introduction on CFB technology and its application in China

2. Supercritical CFB boiler design and operation in China

2.1 Gas-solid two-phase flow of large riser
2.2 Heat flux in a CFB boiler
2.3 Heat transfer of the supercritical water
2.4 Practices of supercritical CFB boiler

3. Ultra-low emission CFB boiler research and application

3.1 SO2 controlled by limestone injection
3.2 NOx controlled by low NOx combustion

4. Conclusion
 4. Conclusion

• CFB is the best choice for low grade coal utilization for the countries where coal is major energy source.

• Chinese spend several decades to study CFB boiler. Now there are several boiler workers in China could supply CFB boilers.

• By the end of 2015, there are more than 2800 CFB boilers with total capacity of more than 100GW were in commercial operation in
China.

• The achievements of supercritical CFB and ultra-low emission CFB are successful, and this encourages the CFB boiler future in
China.
Thank you for your attention!