PAITON Ⅲ EXPANSION PROJECT

COURSE – B-1

CONTENTS ： Basics of Boiler

TRAINER: Yuki Yoshikawa

MITSUBISHI HEAVY INDUSTRIES, LTD.

B-1 Basics OF BOILER PAGE-
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Instructor Guide Material Objectives

General Objective:
Upon completion of the lesson, the
trainee will be able to describe the
features and design considerations
for Paiton boiler.

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Outline
n Basics of Boiler
n Feature of Paiton Boiler
– Major Specification
– Coal Property
– Design for Sub-bituminous Coal
n Design of Paiton Boiler
– Combustion Systems
– Vertical Water Wall
– Pressure Parts
– Boiler Expansion Systems
– Air and Gas Systems
n Operation
n Summary
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Outline
n Basics of Boiler
n Feature of Paiton Boiler
– Major Specification
– Coal Property
– Design for Sub-bituminous Coal
n Design of Paiton Boiler
– Combustion Systems
– Vertical Water Wall
– Pressure Parts
– Boiler Expansion Systems
– Air and Gas Systems
n Operation
n Summary
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Basics of Boiler

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Purpose : To generate high pressure and high temperature steam

to operate steam turbine

Typical Relation

Boiler
=
Steam High Pressure
Generator High Temperature
Feed Water Steam

Condenser TURBINE

Make-up Exhaust Steam

Water
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Process of Steam Generation

Input Materials Output Materials

Water Steam

Fuel Heat transfer

Combustion
Reaction Flue Gas
Fuel energy
Air

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Typical Scheme of Boiler System

Superheater

Economizer
Combustion
Fuel

Reheater
Furnace
Flue Gas

Air heater
Air

Steam

Water

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Superheated Steam

SH Water wall

Superheated Saturated
Steam Steam Steam
turbine

Water

Heated by fuel
combustion

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Saturation Pressure and Temperature

Boundary
= Saturation
20
Pressure (MPa(g))

Compressed Water
10

100℃ in the
Water boils at 100℃
atmosphere.
Superheated Steam
0
0 100 200 300 400
Temperature (℃)

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Pressure and Enthalpy Chart

Enthalpy (kcal/kg) 1000

800 600℃

500℃
600 Supercritical
Saturation
(Steam/Water) 400℃
400 Critical pressure
22.1 MPa 300℃
200 200℃
Water
0
0 10 20 30 40
Pressure (MPa)

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Supercritical Sliding Pressure Operation

1000
SH Outlet
Enthalpy (kcal/kg)

800 600℃
Superheater
W.W Outlet 500℃
600
Saturation Water Wall
400℃
400 (Water/Steam)
W.W Inlet Economizer 300℃
Eco. Inlet
200 200℃
35% 50% 75% 100% BMCR
Water
0
0 10 20 30 40
Pressure (MPa)

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Comparison of Drum Type Boiler and Once-through Boiler
Boiler Type Drum type boiler Once-Through boiler
Operating Press. Sub-critical Supercritical
to to
SH Steam Turbine SH Steam Turbine

Steam Water
System Schematic Drum Separator

Eco Furnace
Furnace BCP

BFP BFP
Eco
Better
Load Change Rate Base
(Less Heat Capacity)
Plant Heat Rate Base Approx. 3% Better
(Required heat input per 1kW ) (Higher Steam Condition)
Environmental Base
Less
Impact (Better plant heat rate)
Tube Material Base Higher Grade
(Higher steam condition)

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Pressure Parts

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Comparison of Drum Type Boiler and Once-through Boiler
Tube Materials of Pressure Parts
● Paiton (One-through Boiler)

1ry 2ry 3ry 1ry 2ry

Material Eco Furnace
SH SH SH RH RH
SA-210C （Carbon Steel） ● ●
SA-213T12 （1Cr） ● ● ● ● ●
SA-213T22 （2Cr） ● ● ●
ASME Code Case 2199
●
（2.25Cr）
SA-213T91 （9Cr） ● ●
ASME Code Case 2328-1
● ● ● ●
（18Cr）

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Comparison of Drum Type Boiler and Once-through Boiler
Tube Materials of Pressure Parts
● T Plant (Drum Type Boiler) ● Paiton (One-through Boiler)

2ry SH 3ry SH
Material Inlet Outlet Inlet Outlet
Panel Panel
Stub Stub Stub Stub
SA-213T12 （1Cr） ● ● ● ● ● ● ●
SA-213T22 （2Cr） ● ●
Alloy
Steel ASME Code Case
● ● ●
2199 （2.25Cr）
SA-213T91 （9Cr） ● ● ● ●
SA-213TP347H
●
Stainless （18Cr）
Steel ASME Code Case
● ● ●
2328-1 (18Cr）

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Supercritical Sliding Pressure Operation Boilers in Japan
〈Vertical Water Wall 〉

Chugoku EPCO. Misumi P/S (1998) Kansai EPCO. Maizuru P/S (2004)
Soma Joint EPCO. Shinchi P/S (1995)
1,000MW 24.5MPa×600/600℃ 900MW 24.5MPa×595/595℃
1,000MW 24.1MPa×538/566℃

Kyushu EPCO. Matsuura P/S (1989)

700MW 24.1MPa×538/566℃

Tohoku EPCO. Haramachi P/S (1997)

1,000MW 24.5MPa×566/593℃

Kobe steel IPP Kobe P/S (2002) Tokyo EPCO. Hirono P/S (2004)
700MW 24.1MPa×538/566℃ 600MW 24.5MPa×600/600℃

Chubu EPCO. Hekinan P/S (1991)

700MW 24.1MPa×538/566℃

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Global Supply Record for Vertical Water Wall Boiler

No.1 Share / 5 countries /
32,896MW / 45units
China； 32 units Japan； 10 units
(by Licensee)

Since 1989,
As of September 2010
( ): COD
Henung Yuhuan #1 to #4 Chugoku EPCO Misumi #1
1000MW
100 26.4MPa×600/600℃ (2006), 1000MW
10 24.5MPa×600/600℃ (1998),
and other 28 units for other customers and other 9 units for other customers

Indonesia； 1 unit Mexico； 1 unit

India； 11 units
(by L&T-MHI Boilerｓ Pvt. Ltd.
as Joint Venture)
Jaypee Nigrie #1, #2
700MW 24.5MPa×566/593℃ (2011),
and other 9 units for other customers
SC : Supercritical
USC : Ultra-Supercritical Paiton CFE Pacifico #1
856MW 24.1MPa×538/566℃ (2012) 700MW 24.2MPa×538/566℃ (2010)
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Availability of Supercritical Sliding Pressure Operation Boiler

(Vertical Water Wall)
100%

80%
Availability

60%

40%

20%

0%
Misumi
Misumi Haramachi Shinchi Matsuura
1,000MW 1,000MW 1,000MW 700MW
Reliability (%) = (Calendar date hours(h)- forced outage hours (h)) / (Calendar date hours(h))

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Outline
n Basics of Boiler
n Feature of Paiton Boiler
– Major Specification
– Coal Property
– Design for Sub-bituminous Coal
n Design of Paiton Boiler
– Combustion Systems
– Vertical Water Wall
– Pressure Parts
– Boiler Expansion Systems
– Air and Gas Systems
n Operation
n Summary
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Feature of Paiton Boiler

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Major Specification
Unit Paiton
Net Power Output MW 815
Steam Flow t/h 2,695
SH Outlet ℃ 542
Temperature
RH Outlet ℃ 568
SH Outlet MPa(g) 25.78
Pressure
RH Outlet MPa(g) 4.85
Depth mm 14,335
Width mm 29,414
Furnace Height mm 55,149
Plan Area m2 421.65
Volume m3 21,369
Fuel Heat Input (*1) / Plan Area Gcal/m2h 4.66
Fuel Heat Input (*2) / Volume Gcal/m3h 0.089
(*1)：Include combustion air sensible heat and H2,H2O latent heat (HHV)
(*2)：Exclude combustion air sensible heat and H2,H2O latent heat (HHV)

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Material and Design Code

Material Design

ASME Pressure Vessel

ASME Pressure Vessel
Pressure Parts Code Section Ⅱ,
Code Section Ⅰ
ASME Code Case

JIS or
Non Pressure Parts MHI Standard
Equivalent

ASME Pressure Vessel

Design for Implosion, Explosion Code Section Ⅰ
NFPA Code 85B, D E

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Outline
n Basics of Boiler
n Feature of Paiton Boiler
– Major Specification
– Coal Property
– Design for Sub-bituminous Coal
n Design of Paiton Boiler
– Combustion Systems
– Vertical Water Wall
– Pressure Parts
– Boiler Expansion Systems
– Air and Gas Systems
n Operation
n Summary
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ASTM* Coal Rank
(*American Society for Testing and Materials)
100

Anthracite
Dry Mineral-Matter Free Fixed Carbon (%)

90

80
Coals for Paiton
70 Project are
classified into Sub-
60
Bituminous coal.
Sub-
Sub-
Bituminous Bituminous Lignite
50
Pasir Roto North
Loa janan
Mahakam Enviro
40 Melawan Performance
Pasir Roto South coal
30
16000 14000 12000 10000 8000 6000
Gross Calorific Value Moist Mineral Matter Free(BTU/Lb)

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ASTM* Coal Rank
(*American Society for Testing and Materials)
100

Anthracite
Dry Mineral-Matter Free Fixed Carbon (%)

90

80
Coals for Paiton
70 Project are
classified into Sub-
60
Bituminous coal.
Sub-
Sub-
Bituminous Bituminous Lignite
50
Pasir Roto North
Loa janan
Mahakam Enviro
40 Melawan Performance
Pasir Roto South coal
30
37200 32600 27900 23300 18600 14000
Gross Calorific Value Moist Mineral Matter Free (kJ/kg)

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Coal Property
Item Bituminous Sub-bituminous coal
AS: As Received coal (Paiton)
AD: Air Dry Base Unit
DB: Dry Base Performance Design Coal
Range
DSF: Dry Ash Free Coal Range
Fuel Ratio (AD) － ≦2.5 0.96 0.86～1.07
Combustion
C/H Ratio (DAF) － ≦18 16.7 13.4～17.6
Characteristic
Volatile Matter (AD) % ≧20 41 40.5～43.5
Ash Softening Temperature ℃ ≧1200 1200 1200～1320
Base/Acid Ratio(*1) (DB) － ≦0.5 0.84 0.31～1.5
Slagging
Fe2O3 (DB) % ≦15 20 12.5～20
Characteristic
Total Sulfur (AD) % ≦2.0 0.1 0.1～0.3
Ash Loading kg/106kcal ≦35 5.21 1.9～5.28
Na2O (DB) % ≦3.0 0.2 0.2～1.8
Fouling
Na2O＋K2O (DB) % ≦4.0 0.8 0.8～2.7
Characteristic
Ash Loading kg/106kcal ≦35 5.2 1.9～5.3
NOx Emission Nitrogen 〔N〕 (DAF) % ≦1.8 1.0 0.9～1.8
Characteristic Fuel Ratio (AD) － ≦2.5 0.96 0.86～1.07
HGI － ≧40 47 43～53
Coal Fineness
Total Moisture (AR) % ≦18 25 21～32
Quartz(SiO2) (DB) kg/106kcal ≦10 1.7 0.7～2.5
Erosion
Al2O3＋SiO2 (DB) kg/106kcal ≦20 2.5 1.1～3.8
Characteristic
Ash Loading kg/106kcal ≦35 5.2 1.9～5.3
(＊１)： The ratio of basic substances (Fe2O3, CaO,MgO,Na2O,K2O) to acid substances (SiO2, Al2O3, TiO2)

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Coal Property
Bituminous Sub-bituminous coal
coal (Paiton)
Item Unit
Performance Design Coal
Range
Coal Range
Fuel Ratio － ≦2.5 0.96 0.86～1.07
Combustion
C/H Ratio － ≦18 16.7 13.4～17.6
Characteristic
Volatile Matter (Air Dry Base) % ≧20 41 40.5～43.5
Ash Softening Temperature ℃ ≧1200 1200 1200～1320
Base/Acid Ratio(*1) － ≦0.5 0.84 0.31～1.5
Slagging
Fe2O3(in Ash) % ≦15 20 12.5～20
Characteristic
Total Sulfur % ≦2.0 0.1 0.1～0.3
Ash Loading kg/106kcal ≦35 5.21 1.9～5.28
Na2O (in Ash) % ≦3.0 0.2 0.2～1.8
Fouling
Na2O＋K2O (in Ash) % ≦4.0 0.8 0.8～2.7
Characteristic
Ash Loading kg/106kcal ≦35 5.2 1.9～5.3
NOx Emission Nitrogen 〔N〕 (Dry Ash Free) % ≦1.8 1.0 0.9～1.8
Characteristic Fuel Ratio － ≦2.5 0.96 0.86～1.07
HGI － ≧40 47 43～53
Coal Fineness
Total Moisture (As Received) % ≦18 25 21～32
Quartz(SiO2) kg/106kcal ≦10 1.7 0.7～2.5
Erosion
Al2O3＋SiO2 kg/106kcal ≦20 2.5 1.1～3.8
Characteristic
Ash Loading kg/106kcal ≦35 5.2 1.9～5.3
(＊１)： The ratio of basic substances (Fe2O3, CaO,MgO,Na2O,K2O) to acid substances (SiO2, Al2O3, TiO2)

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Outline
n Basics of Boiler
n Feature of Paiton Boiler
– Major Specification
– Coal Property
– Design for Sub-bituminous Coal
n Design of Paiton Boiler
– Combustion Systems
– Vertical Water Wall
– Pressure Parts
– Boiler Expansion Systems
– Air and Gas Systems
n Operation
n Summary
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Design Considerations for Sub-bituminous Coal

Coal Fineness High moisture content

Slagging
characteristic
High spontaneous
Coal Property of combustibility
sub-bituminous
coal Low calorific value

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Design Considerations for Sub-bituminous Coal

Coal Fineness High moisture content

Slagging
characteristic
High spontaneous
Coal Property of combustibility
sub-bituminous
coal Low calorific value

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Design Considerations for Sub-bituminous Coal

l High spontaneous combustibility
Decrease Pulverizer Outlet Air Temperature
Pulverizer Outlet Air Temp.
100

77℃
60℃
(℃)

50

0
Bituminous Sub-Bituminous
Coal Coal (Paiton)
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Design Considerations for Sub-bituminous Coal

l High moisture content
Increase Pulverizer Inlet Air Temperature
300
Pulverizer Inlet Air Temp.
241℃ 255℃

200
(℃)

100

0
Bituminous Sub-Bituminous
Coal Coal (Paiton)
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Design Considerations for Sub-bituminous Coal

l Low calorific value (More coal flow)
Larger capacity pulverizer is selected.
150
Pulverizer Capacity

108 t/h
100 95 t/h
(t/h)

50

0
Bituminous Sub-Bituminous
Coal Coal (Paiton)
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Design Considerations for Sub-bituminous Coal
lSlagging characteristic
Proper arrangement of Wall Deslagger

Wall Deslagger : 68
Long Retractable
Sootblower : 26

Half Retractable
Sootblower : 10

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Outline
n Basics of Boiler
n Feature of Paiton Boiler
– Major Specification
– Coal Property
– Design for Sub-bituminous Coal
n Design of Paiton Boiler
– Combustion Systems
– Vertical Water Wall
– Pressure Parts
– Boiler Expansion Systems
– Air and Gas Systems
n Operation
n Summary
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Combustion Systems

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Combustion Systems
Boiler Front

In-Furnace DeNOx
System MACT*
(*Mitubishi Advanced
Combustion Technology)

Circular Corner
Firing CCF

Low NOx
A-PM* Burner
(*Advanced Pollution minimum)

Fixed
Separator
Pulverizer

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Circular Corner Firing (CCF)

1. High Efficient Combustion Plan View Side View
・Better mixing of fuel and air
・Long flame path by effective use of
furnace
2. High Combustion Stability
・Mutual supporting combustion by
adjacent burner

3. Low NOx Emission - Main Structure -

4. Less Furnace slagging
・Uniform combustion without peak
heat flux.
l Twin furnace
l Eight(8) burners
l No division wall
l Two concentric circles are
formed by circular firing.

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Coal Fired Supercritical Pressure Operation Boiler

-CCF Units (Twin Furnace)-
Commercial
No. Plant Name Capacity Fuel
Operation
1 Chubu EPC Hekinan #1 700MW Oct.1991 Coal
2 Soma Kyodo PC Shinchi #2 1000MW Jul.1995 Coal
3 Tohoku EPC Haranomachi #1 1000MW Jul.1997 Coal
4 Chugoku EPC Misumi #1 1000MW Jul.1998 Coal
5 Taiwan Mailiao FP #1 600MW Jun.1999 Coal
6 Taiwan Mailiao FP #2 600MW Sep.1999 Coal
7 China FPC USA CP #1 600MW Mar.2000 Coal
8 China FPC USA CP #2 600MW Sep.2000 Coal
9 Taiwan Mailiao FPCC #6 600MW .2000 Coal
10 China FPC USA CP #3 600MW Jan.2000 Coal
11 Taiwan Mailiao FP #4 600MW .2002 Coal
12 Taiwan Mailiao FPCC #7 600MW .2002 Coal
13 China FPC USA CP #4 600MW Mar.2003 Coal
14 Kansai EPC Maizuru #1 900MW Aug.2004 Coal

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A-PM Burner (1/2)

AA A-PM Burner : Advanced - Pollution Minimum Burner
AA
AA : Additional Air
AA
AA Conc.
Coal Weak
Aux.1(U)
Aux.1
Coal Conc.
Oil / Air
Coal
Aux.1
Aux.1
Coal Conc. flame
Coal
surface is extended
Oil / Air
Coal Oil / Air
Aux.1
Aux.1
Coal Stable Ignition
Oil / Air Coal
Coal
Aux.2

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A-PM Burner (2/2)

Single Flame
Burner
A
NOx (ppm)

A-PM Burner

C1 C0 C2
Conc
Flame Weak
Flame

0 3～4 7～8
Primary Air / Coal Ratio
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In-Furnace DeNOx System
-
- MACT (Mitsubishi Advance Combustion Technology)
Furnace
outlet

Combustion
Completion
Zone
Additional
40%
Air Reductive
DeNOx
Zone
Combustion
Main Burner
Air
Main Combustion
Burner Zone 60%

Stable and Low NOx

Combustion
with A-PM Burner
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Fixed Separator and Pulverizer (1/2)

Fine Coal Raw Fixed

Coal Separator

Hydraulic
Loading
Device Pulverized
Coal
Coarse Coal

Roller

Grinding
Table

Hot Air

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Fixed Separator and Pulverizer (2/2)

Pulverizer and Coal Pipe Arrangement
Boiler
Front

Coal Pipe

units
:6
erizer
v
Pul

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Combustion Systems
Boiler Front

In-Furnace DeNOx
System MACT*
(*Mitubishi Advanced
Combustion Technology)

Circular Corner
Firing CCF

Low NOx
A-PM* Burner
(*Advanced Pollution minimum)

Fixed
Separator
Pulverizer

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Outline
n Basics of Boiler
n Feature of Paiton Boiler
– Major Specification
– Coal Property
– Design for Sub-bituminous Coal
n Design of Paiton Boiler
– Combustion Systems
– Vertical Water Wall
– Pressure Parts
– Boiler Expansion Systems
– Air and Gas Systems
n Operation
n Summary
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Vertical Water Wall

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Boiling Phenomenon

Film
Boiling

Nucleate
Boiling
Nucleate
Boiling

Rifled Tube Smooth Tube

(Vertical Wall) (Spiral Wall)
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Boiler Type
Rifled Tube Smooth Tube

Merits of Vertical Water Wall

(1) Simple Structure
(2) Low ΔP at Water Wall
(3) Easy Removal of Slag

Vertical Water Wall (Paiton) Spiral Water Wall

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Boiling Phenomenon

Film
Boiling

Nucleate
Boiling
Nucleate
Boiling
ΔPww → -5 kg/cm2

Mass Velocity 1,500 kg/m2s Mass Velocity 3,100 kg/m2s

Rifled Tube Smooth Tube
(Vertical Wall) (Spiral Wall)
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Steam Quality and Tube Metal Temperature

700
2,000kg/m2･s
Tube Metal Temperature (℃)

Design
600 3,100 kg/m2･s
3,000
Maximum
500 Allowable Temp.
3,500
Design
Smooth
400 Tube 1,500 kg/m2･s
Rifled Tube 2,000 2,500
0.0 0.2 0.4 0.6 0.8 1.0
Water Steam Quality Steam
Steam Quality = ( Steam Flow ) / ( Steam Flow + Liquid Flow )

Furnace Hopper Burner Zone Upper Furnace

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Spiral Water Wall

Vertical
Water Wall For smooth tube,
Sufficient mass
8P velocity is required.

Spiral Water Wall

4P
n 30 deg. Incline
n Half pcs. of tubes

30ﾟ

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Support Structure of Spiral Water Wall

Lug
Horizontal
Buckstay

Holder

Holder

Vertical Tie

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Support Structure of Vertical Water Wall

Horizontal tie
Holder
Holder

Horizontal
Buckstay
Keeper Lug

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Easy Removal of Slag

Vertical Water Wall Spiral Water Wall
Adhere on
Fall easily the shelf
of tube fin

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Rifled Tube Smooth Tube

Merits of Vertical Water Wall

(1) Simple Structure
(2) Low ΔP at Water Wall
(3) Easy Removal of Slag

Spiral water wall has been adopted previously.

Now, MHI has developed and adopted vertical
water wall with rifled tube over 20 years,
considering above merits.
Vertical Water Wall (Paiton) Spiral Water Wall

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B-1 Basics OF BOILER PAGE-
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Outline
n Basics of Boiler
n Feature of Paiton Boiler
– Major Specification
– Coal Property
– Design for Sub-bituminous Coal
n Design of Paiton Boiler
– Combustion Systems
– Vertical Water Wall
– Pressure Parts
– Boiler Expansion Systems
– Air and Gas Systems
n Operation
n Summary
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PAGE- 54
Pressure Parts Arrangement
3ry Superheater 2ry Reheater

1ry Reheater

2ry Superheater 1ry Superheater

Economizer

Water Wall

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PAGE- 55
Eco Outlet
Header

Arrangement and Flow Diagram Furnace

Inlet Pipe
(1/12) Intermediate
Header

Eco Inlet Header

Economizer Eco
Inlet Pipe

Furnace
Eco Inlet Inlet Pipe
Header
Eco Outlet
Header

Intermediate
Header
Eco
Inlet Pipe

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Economizer
Outlet Header

Roof Tube Design considerations

u Counter flow for more

efficient heat transfer
u Intermediate HDR for
Hanger
Intermediate
temp. equalization
Part
Header
u Heating surface area is
Intermediate
Header designed considering Eco.
outlet temp.
u Sufficient Eco. outlet
subcool is ensured.
Horizontal
Part

Inlet Header

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Economizer horizontal part

Eco Hanger Tube
Eco Intermediate HDR

Eco Hanger Tube

Eco Clevis
Intermediate
HDR

Support Assembly

Spiral Fin
A

Eco Tube

Eco Tube

A A-A

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Furnace Outlet
Header

Arrangement and Flow Diagram

(2/12)
Furnace
Intermediate
manifold

Water Wall
(Furnace)

Furnace Furnace Inlet

Manifold
Intermediate
Manifold
Furnace Inlet Furnace
Manifold Outlet
Header

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PAGE- 59
Roof Inlet
Manifold
Roof Inlet Roof Outlet
Header
Arrangement and Flow Diagram Header

(2/12)

Water Wall
(Roof)

Roof Inlet
Manifold
Roof Inlet
Header

Roof Outlet
Header

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Outlet Header

Arrangement and Flow Diagram

Rear Wall Hanger Inlet Manifold
(4/12) Passage Side Wall Inlet Manifold
Inlet Header

Water Wall
(Passage Side Wall)
(Rear Wall Hanger)

Inlet Header

Passage Side Wall

Inlet Manifold
Rear Wall Hanger
Inlet Manifold
Outlet Header

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PAGE- 61
Water Separator
Outlet Header Inlet Pipe

Arrangement and Flow Diagram

(5/12) Back Pass
Inlet Pipe
Inlet Header

Water Wall Inlet Manifold

(Back Pass)

Water Separator
Inlet Header
Inlet Pipe
Back Pass
Inlet Pipe

Inlet
Manifold

Outlet Header

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Water Wall
SECONDARY PASS SIDE
FRONT WALL OUTLET HDR. REAR WALL HANGER PASSAGE SIDE WALL 2RY PASS DIVISION WALL
WALL
OUTLET HDR. OUTLET HDR. OUTLET HDR
OUTLET HDR.
Rifled Tube ROOF INLET HDR. SIDE WALL OUTLET HDR. 2RY PASS FRONT
WALL OUTLET HDR.
2RY PASS REAR
WALL OUTLET HDR.
+64200

Design considerations

FIN

FIN
FIN
ROOF OUTLET HDR.

1st TUBE OF PASSAGE SIDE WALL

1st TUBE OF PASSAGE SIDE WALL FROM BOILER REAR TO BE INCLUDED
FROM BOILER FRONT TO BE WITH FURNACE SIDE WALL TUBE PANEL.
SMOOTH TUBE

INCLUDED WITH FURNACE

u Plan area is designed

SIDE WALL TUBE PANEL. OUTSIDE WELDING
GROOVE
PRIMARY SH INLET
HDR.

REAR WALL HANGER

PASSAGE SIDE WALL
considering the coal
INLET HDR

+45120
REAR WALL HANGER
TUBE
INLET HDR.
slagging characteristic

MEMBRANE
PRIMARY RH INLET
HDR.
u Furnace size is designed
FURNACE INTER MEDIATE
HDR. (SIDE)
2RY PASS DIVISION WALL
INLET HDR
SECONDARY PASS SIDE WALL
SECONDARY PASS SIDE WALL
INLET HDR. so that 2ry SH outlet gas
temp is below the ash
RIFLE TUBE

softening temp.
u Rifled tube is used at
CL OF FURNACE

furnace lower wall

+16500

FURNACE INLET PIPE

SMOOTH TUBE

LEFT SIDE ONLY

ME

NE

RIGHT SIDE ONLY

MB

RA
MB
RA
NE

ME

SIDE WALL INLET HDR.

SIDE WALL

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Water Wall
Heat absorption in each tube is not equal.
p Heat distribution in furnace
p Burner shaded part

Adjustment of heat absorption

p In-tube orifice
Variation of orifice diameter
p Intermediate HDR and manifold
Elimination of temp. difference
in upper wall tubes

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PAGE- 64
1ry SH
Inlet Pipe WS

Arrangement and Flow Diagram

(6/12)
Drain
Tank

Water Separator
& Drain Tank

Water
Separator

Drain Tank

1ry SH
Inlet Pipe

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Outside 1000mm
Water Separator
diameter
Thickness 120mm (Shell)
Height 3310mm (Shell)
Material SA-387-11-2
(Shell)

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Water Separator Drain Tank
Outside 1000mm
diameter
Thickness 120mm (Shell)
Height 16.4m (Shell)
Material SA-387-11-2
(Shell)

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1ry SH-
SH-DeSH
1ry SH
Outlet Header
2ry SH
Arrangement and Flow Diagram Inlet Pipe
(7/12) 1ry SH
Inlet Header

1ry Superheater

1ry SH 2ry SH
Inlet Inlet Pipe
Header

1ry
SH-
SH-DeSH

1ry SH
Outlet
Header

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1ry Superheater
Outlet Header

Design considerations
Roof Tube u Counter flow for more
efficient heat transfer.
Terminal u Heating surface area is
Part
decided so that necessary
total heat absorption of
SH is obtained.
u The height is within the
effective area of soot
Horizontal
blowing.
Part

Inlet Header

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2ry SH-
SH-DeSH
3ry SH
2ry SH
Inlet Pipe
Arrangement and Flow Diagram Inlet Header
2ry SH
(8/12) Outlet Header

2ry Superheater

2ry SH
Inlet Header 2ry SH-
SH-DeSH

3ry SH
Inlet Pipe

2ry SH
Outlet Header

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2ry Superheater
Inlet Header Outlet Header Design considerations
u Panel type, which
Roof Tube
absorbs the radiant heat
from furnace effectively.
u Heating surface area is
designed based on the
furnace size.
u 2ry SH outlet gas temp.
is designed below the
Girdling Tube ash softening temp.
u Girdling tube and
wrapper tube are
provided for anti-vibration.

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PAGE- 71

Girdling tube / 2ry SH Wrapper tube

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PAGE- 72
3ry SH 3ry SH
Inlet Header Outlet Header

Arrangement and Flow Diagram

(9/12)

3ry Superheater

3ry SH
Inlet Header Main
Steam

Main
3ry SH Steam
Outlet Header

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PAGE- 73

3ry Superheater
Outlet Header
Inlet Header
Design considerations
u Platen type, which absorbs
Roof Tube the radiant heat from
furnace and convection
heat from flue gas.
u Heating surface area is
designed based on the
furnace size.
u Girdling tube and spacer
Girdling Tube tube are provided for anti-
vibration.

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PAGE- 74

Spacer tube

1ry SH Inlet HDR

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PAGE- 75
2ry RH
Inlet Pipe
1ry RH
RH-
RH-DeSH Outlet Header
Arrangement and Flow Diagram
(10/12)
LTR 1ry RH
Inlet Header

1ry Reheater

LTR RH-
RH-DeSH

1ry RH 2ry RH
Inlet Inlet Pipe
Header

1ry RH Outlet Header

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PAGE- 76

1ry Reheater
Outlet Header

Design considerations

u Counter flow for more

Terminal
Part
efficient heat transfer
u Heating surface area is
decided so that necessary
total heat absorption of RH
is obtained.
u The height is within the
Horizontal
Part effective area of soot blowing.

Inlet Header

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2ry RH 2ry RH
Inlet Header Outlet Header

Arrangement and Flow Diagram

(11/12)

2ry Reheater

2ry RH
Inlet Header

2ry RH
Outlet Header

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2ry Reheater
Inlet Header Outlet Header

Design considerations

u Pendant type, which absorbs

Roof Tube the convection heat from flue
gas.
u Heating surface area is designed
based on the furnace size.
u Spacer tube are provided for
anti-vibration.

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PAGE- 79

3ry 2ry 1ry 1ry

2ry SH SH RH RH SH
WS
Arrangement and Flow Diagram
(12/12)
Eco

2ry SH
ECO Furnace Back Pass WS 1ry SH 3ry SH 1ry RH 2ry RH
Roof
Passage Side Wall
Rear Wall Hanger

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PAGE- 80

Design Pressure Diagram

Included
33
Eco - Furnace Not Included
32 31.49 Roof, PSW Predicted Performance + MSV Inlet Operating
Press.×5%
31
30.11
Back Pass Predicted Performance
30 29.80 WS 1ry SH
Pressure (MPa)

29
28.77 28.61 2ry SH
28.00 3ry SH
28 27.56 SH out
27 27.05
Operating Pressure
26
25 RH
24
6 6 5.84
5 5
4 4

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PAGE- 81

Design Temperature Diagram

600 3ry SH 600 582
1ry SH Inlet 2ry SH 550
550
HDR 533 550 RH
Furnace Roof,
1ry SH 513
Temperature （℃）

Interm. 496
500
PSW Back Pass WS 500
ECO HDR 450 450 450
467
454
450
450 Interm. 450
HDR
400 391 Eco - Furnace 400
362 Operating Temperature 350
350
350 350
Included
300 Not Included 300

250 250

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PAGE- 82
Safety Valve Design
As per ASME Boiler & Pressure Vessel Code, SectionⅠ, PG-67
Main Steam Line Reheat Steam Line
34 6.5

33
Spring Loaded Spring Loaded
32 31.64
31.49
6.07
6.01

3.95%
31.34
31.19 31.04
Spring Loaded 6.0 5.96 RH Design Press.

3.99%
3.98%

5.90
3.97%

5.90

3.86%
30.89
3.99%

31 30.74
3.98%

3.99%

3.90%
3.98%

Pressure (MPa)
Pressure (MPa)

3.97%
5.83
30.38 5.77 5.68
30 30.24
30.09 5.73
29.95

3.87%
29.80 5.67
29.66 29.52
29 WS Design Press. 5.5
MFT 28.67
28.77 5.46
SH Outlet Design Spring Loaded
28 PCV Press.
Operating Pressure
27.05 27.05 Operating Pressure
WS Outlet Press.
2.99%

27 ANN RH Inlet Press. 5.03

27.36 26.83 5.0
26.24
26
SH Outlet Press. RH Outlet Press.
26 25.80 4.86
WS outlet SH outlet RH inlet RH Outlet
24 4.5

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PAGE- 83
2ry RH
Inlet Pipe
1ry RH
RH-
RH-DeSH Outlet Header
Arrangement and Flow Diagram
(10/12)
LTR 1ry RH
Inlet Header

1ry Reheater

LTR RH-
RH-DeSH

1ry RH 2ry RH
Inlet Inlet Pipe
Header

1ry RH Outlet Header

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PAGE- 84

3ry 2ry 1ry 1ry

2ry SH SH RH RH SH
WS
Arrangement and Flow Diagram
(12/12)
Eco

2ry SH
ECO Furnace Back Pass WS 1ry SH 3ry SH 1ry RH 2ry RH
Roof
Passage Side Wall
Rear Wall Hanger

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B-1 Basics OF BOILER PAGE-
PAGE- 85

Outline
n Basics of Boiler
n Feature of Paiton Boiler
– Major Specification
– Coal Property
– Design for Sub-bituminous Coal
n Design of Paiton Boiler
– Combustion Systems
– Vertical Water Wall
– Pressure Parts
– Boiler Expansion Systems
– Air and Gas Systems
n Operation
n Summary
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B-1 Basics OF BOILER PAGE-

PAGE- 86

Furnace Bottom
BOILER FRONT

OF
FURNACE
CENTER
Seal

L
C
Free Plate
Furnace
Hopper Free Free

Free

Drag
Chain
Conveyor

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PAGE- 87

Buckstay Arrangement

ITEM DESCRIPTION
1 WATER WALL TUBES
2 BLOCK INSULATION
(MINERAL FIBER BOARD)
Free
3 INSULATION PINS
Free
Fix 4 PIN CLIPS
5 OUTER CASING
Fix Free 6 LOOSE MINERAL FIBER
Free 7 BUCKSTAY
8 TIE PLATE
9 HOLDER
10 CORNER LINK
11 CORNER PLATE
12 STOPPER BEAM
13 BOILER STRUCTURE COLUMN
14 STIFFENER

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Outline
n Basics of Boiler
n Feature of Paiton Boiler
– Major Specification
– Coal Property
– Design for Sub-bituminous Coal
n Design of Paiton Boiler
– Combustion Systems
– Vertical Water Wall
– Pressure Parts
– Boiler Expansion Systems
– Air and Gas Systems
n Operation
n Summary
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B-1 Basics OF BOILER PAGE-

PAGE- 89

Air & Gas Systems

1ry Cold Air
Pulverizer Outlet
Temp. control PAF
1ry Hot Air
Stack

Air Heater
2ry Air FDF
Furnace
Eco.
Gas IDF FGD
EP
Furnace
(Boiler) Gas
EP

Air heater
IDF
Pulverizer 2ry Air FDF
1ry Hot Air
Pulverizer Outlet PAF
Temp. Control 1ry Cold Air

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PAGE- 90
Air Heater (1/3)

Regenerative, Rotary
Type
Vertical Trisector
Number 2 sets
1,683 t/h
Inlet Gas Flow
(BMCR, Design coal)
Gas Temp.
369 ℃ / 145 ℃
(Inlet / Outlet (Uncorrected))
Soot blower Gas side,
Arrangement Cold end
Stationary Water Gas side,
Washing device Hot end
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PAGE- 91
Air Heater (2/3)

Gas Inlet

2ry Air
Outlet

1ry Air
Outlet

Soot
blower

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PAGE- 92
Air Heater (3/3)
1ry Duct

lRotation Speed
A side
Approx. 1 rpm

lRotating Direction 2ry Duct Gas Duct

① Flue Gas Path

② 2ry Air Path B-side

③ 1ry Air Path

1ry Duct

Over View

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PAGE- 93
Fans
Fan FDF PAF IDF
Axial Flow Centrifugal Axial Flow
Type
Horizontal Horizontal Horizontal
Impeller Stage 1 1 2
Number 2 2 2
Capacity 21,000m3/min 9,900m3/min 45,400m3/min
Discharge Pressure 480mmAq 1,570mmAq 430mmAq
Inlet Pressure -50mmAq -50mmAq -540mmAq
Inlet Air/Gas
25.5℃ 25.5℃ 140℃
Temperature
Motor Capacity 2,500kW 3,400kW 8,580kW
Variable Blade Inlet Vane Variable Blade
Control System
Pitch Control Control Pitch Control

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PAGE- 94

Bottom Ash Handling System

Drag Chain Conveyor

Drive Unit

Grinder
Furnace Dewatering
Crush
Falling of the Clinker
Seal Plate
Transport
To Bottom ash storage pit
Cooling
Upper Trough Chain Roller

Link Chain

Flight
Lower Trough Dewatering section

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B-1 Basics OF BOILER PAGE-
PAGE- 95

Outline
n Basics of Boiler
n Feature of Paiton Boiler
– Major Specification
– Coal Property
– Design for Sub-bituminous Coal
n Design of Paiton Boiler
– Combustion Systems
– Vertical Water Wall
– Pressure Parts
– Boiler Expansion Systems
– Air and Gas Systems
n Operation
n Summary
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B-1 Basics OF BOILER PAGE-
PAGE- 96

Operation
n Operation Mode

n Main Steam Temp. Control

n Reheat Outlet Steam Temp. Control

n Pulverizer Operation

n NOx Tuning

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PAGE- 97

Boiler Operation Mode

Dry Mode (Once-Through Mode) Wet Mode (Circulation Mode)

to to
SH Steam Turbine SH Steam Turbine

Water Water
Separator Separator
System Furnace Furnace
Schematics BCP
BFP BFP
Eco Eco

BCP is stopped. Same system as drum type boiler.

BCP is operated to re-circulate the
water for the heat recovery.
Load 30% – 100% 0% - 20%
Temp. Control Water Fuel Ratio (WFR) Spray
Press. Control Feed Water Flow Fuel flow

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Supercritical Sliding Pressure Operation

1000 W.W outlet Enthalpy in
W.W outlet Enthalpy in (20～30%Load)
Transition (20～
(0～20%Load)
Wet Mode (0～ SH Outlet
Enthalpy (kcal/kg)

800 600℃
W.W Outlet Superheater
500℃
600
Saturation Water Wall
400 (Water/Steam) 400℃
W.W Inlet Economizer
300℃
200 Eco. Inlet 200℃
35% 50% 80% BMCR
Water
0
0 10 20 30 40
Pressure (MPa)

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Wet Mode
1ry SH Inlet Pipe

Water Separator
to Drain Tank
SH Steam Turbine
Eco

Water BCP Inlet Pipe

Separator Eco Inlet Pipe

Furnace Furnace Inlet Pipe

BCP
BFP
Eco
BCP

BCP Outlet Pipe

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PAGE- 100

Dry Mode
1ry SH Inlet Pipe

Water Separator
to
SH Steam Turbine
Eco
Water
Separator Eco Inlet Pipe

Furnace Furnace Inlet Pipe

BFP
Eco

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Boiler Operation Mode

100
Water Flow through Furnace wall (%)

Wet Mode Transition Dry Mode

• BCP is in-
in-service. • BCP is stopped.

75

Boiler minimum flow

50 for furnace wall tubes
protection

25%
25
20% 35% 50% 70%
▼ ▼ ▼ ▼
No.1,2 No.3 No.4 No.5 Mill
0
0 20 25 30 50 75 100
Load (%)

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Main Steam Temperature Control Systems
Operation mode
Control
Matter Dry Mode Wet Mode

- Main -
・Control avg. value of
Water / Fuel Ratio N/A
final SH outlet steam
temp.

- Supplementary - ・Separate control

SH spray ・Load change ・Over injection
(2 Stages) ・Quick response protection function
・Separate control

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SH Desuperheater
Spray
Spray

Steam Temp.

1SH 1ry DeSH 2SH 2ry DeSH 3SH

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RH Outlet Steam Temperature Control Systems
Division Wall
RH spray
(For load change
and emergency)

RH SH
Pass Pass

Gas Distribution
Damper (Main)
Adjustable
Burner
Nozzle angle
(Auxiliary)

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Pulverizer Operation
100
Upper Limit 90% ers
iz s e rs ce
ve
r er eriz an
l eriz lv r form
Pu u lv 4P
u
er s Pe al
75 2 P riz co
Pulverizer Load (%)

3 e
P ulv
5 R oto
i r
iz ers Pas h
u lver Nort
50 6P

Lower Limit 30%

25

BMCR
100%
50%

75%
25%
30%

0
20 40 60 80 100
Boiler Load (%)
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Operating Parameter for NOx Tuning

Low NOx High NOx

Open Additional Air

Close
Damper
Decrease Excess Air Increase
Burner Nozzle
Downward Angle
Upward
Close Coal Damper Open

Close Auxiliary Air Open

Damper

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Summary
n Boiler design for Paiton project is
based on a lot of MHI’s experiences.

n Boiler design for Paiton project is

based on design coal properties.

n We are looking forward to

demonstrating high performance
and high reliability of Paiton Boiler.
MHI BUSINESS
CONFIDENTIAL