Design Considerations of B&W Industrial and Utility

Size Reheat / Non-Reheat IR-CFB Boilers

S. Kavidass
M.J. Szmania
K.C. Alexander
Babcock & Wilcox
Barberton, Ohio, U.S.A.

Presented to: BR-1618

Power-Gen Asia ’96 Exhibition & Conference
September 17-19, 1996
New Delhi, India

Abstract
Circulating Fluidized-Bed (CFB) boiler technology has been
in operation for many years producing steam for process and
electric power generation. Worldwide, the use of CFB technol-
ogy is increasing due to the ability to burn low-grade fuels such
as high-ash, low-Btu and high-sulfur coals, lignite, anthracite,
and petroleum coke. CFB boilers meet the stringent NO x, SO2,
CO, and particulate emissions requirement for these fuels.
This paper discusses various aspects of Babcock & Wilcox
(B&W) internal recirculation circulating fluidized-bed (IR-CFB)
boiler design considerations including fuel, boiler process pa-
rameters, and emissions. The B&W CFB boiler is unique in
design and utilizes proven impact-type particle separators (U-
beams) with in-furnace solids circulation. B&W offers IR-CFB
boilers up to 150 MW e, both reheat and non-reheat, and is pur-
suing units above 300 MWe.
This paper describes the methodology for setting up process
parameters, heat duty, and boiler design, including auxiliary
equipment selection and advantages. The paper also updates
the ongoing IR-CFB boiler contracts design.
Introduction
B&W has more than 36 years in developing fluidized-bed
boilers and now has developed four major product lines: atmo-
spheric bubbling fluidized-bed boilers (BFB), atmospheric in-
ternal recirculation circulating fluidized-bed boilers (IR-CFB),
fast internal circulating-bed boilers (FICB) (through a techni-
cal agreement with Austrian Energy & Environment), and pres-
surized bubbling fluidized-bed boilers (PFBC).
To date, B&W and its joint venture and licensee companies
have sold more than 40 fluidized-bed projects worldwide of
which 12 are atmospheric circulating fluidized-bed boilers, given
in Table 1.
In 1984, B&W licensed CFB technology from Studsvik A.B.
of Sweden. B&W developed a boiler design based on Studsvik’s
technology, then developed and improved the original design
concept. Currently, B&W has worldwide ownership of this CFB
technology, including all patents.
At its Alliance Research Center, B&W built several CFB pi-
lot units to investigate the process and characterize performance
of various fuels and sorbents. This includes a 0.7 x 0.7 x 7 m
cold CFB model, a 0.23 x 0.23 x 10 m (0.28 MWt) CFB com-
bustor and a 0.7 x 0.7 x 23 m (2.5 MWt) CFB combustor. The
latter unique facility is used to evaluate innovative concepts for
components or process changes, while providing results repre-
sentative of commercial-size unit performance.
B&W has progressed through three CFB boiler design gen-
erations in the commercial market, as shown in Figure 1. In the
first generation design, the U-beam separators are located out-
side the furnace, and all separated solids recirculate through
L-valves to the lower furnace. In the second generation design,
patented in-furnace U-beams were added. These in-furnace U-
beams separate about 75% of the solids for circulation within
the furnace. The remaining solids are separated by the external
U-beams and recirculate through L-valves to the lower furnace.
B&W currently offers a third generation IR-CFB boiler de-
sign based on operating experience from the two coal-fired
second generation CFB boilers and results from the 2.5 MWt
CFB test facility as given in Table 2. In this design, all solids

Babcock & Wilcox 1

 Table 1
Circulating Fluidized Bed Projects — B&W, Austrian Energy, B&W Joint Ventures
Capacity Start-Up
Customer Plant Location lb/h (t/h) Fuel Date
Ultrapower West Enfield, Maine, U.S.A. 220,000 (100) Wood Wastes, Wood Chips 1986
Ultrapower Jonesboro, Maine, U.S.A. 220,000 (100) Wood Wastes, Wood Chips 1986
Sithe Energy Marysville, California, U.S.A. 164,000 (74.3) Wood Wastes 1986
Lauhoff Grain Co. Danville, Illinois, U.S.A. 225,800 (102.4) Bituminous Coal 1989
Ebensburg Power Co. Ebensburg, Pennsylvania, U.S.A. 465,000 (211) High Ash Waste Coal 1990
Pusan Dyeing Co. Pusan, Republic of Korea 176,370 (80) Coal, Heavy Oil 1991
Thai Petrochemical Ind. Rayong, Thailand 286,750 (130) Coal, Lignite, Oil, Gas 1994
Kanoria Chemicals & Renukoot, India 231,480 (105) High Ash Coal 1995
Industries Ltd.
Southern Illinois University Carbondale, Illinois, U.S.A. 101,500 (46.1) Coal, Petroleum Coke, Natural Gas 1996
Los Angeles County Carson, California, U.S.A. 48,000 (21.8) Sewage Sludge —
Sanitation District (3 boilers)
Kharkov GRES-2 Kharkov, Ukraine 507,000 (230) High Ash Anthracite 1998
Zmiev GRES Komsomolsky, Ukraine 1,410,000 (640) High Ash Anthracite 2000

collected by U-beams are internally recirculated to the upper
furnace. B&W is the pioneer and leader in developing the inter-
nal circulation CFB boiler. In addition, many design improve-
ments have been made in several areas for higher availability
and lower maintenance. Currently several units are being pro-
posed up to 200 MWe and the company is pursuing unit designs
300 MWe and above.
Economics of Using Opportunity Fuels in
a CFB Boiler
The primary objective of selecting a CFB boiler is to reduce
the capital and operating costs. The CFB boiler provides the
economic benefit of burning low-grade fuels with superior en-
vironmental performance. The favorable economics of CFB
boilers are mainly due to the following:
• Accepts low quality and less expensive fuels.
• Reduces fuel crushing cost.
• Lower capital cost (no emissions control equipment) and
lower operating cost.
• Fuel flexibility (within the specified range).
B&W IR-CFB Boiler Process
In B&W’s internal recirculation circulating fluidized-bed
boiler, a portion of combustion air (55%-70%, depending on
fuel) is introduced through the bottom of the bed. The bed ma-
terial typically consists of fuel, limestone, sand and ash. The
bottom of the bed is supported by water-cooled membrane walls
with air nozzles for air distribution. The fuel and limestone are
fed into the lower bed. In the presence of fluidizing air, the fuel
and limestone quickly and uniformly mix in a turbulent envi-
ronment and behave like a fluid at bed velocity. Carbon par-
ticles in the fuel are exposed to the combustion air at fluidized-
bed temperatures of 843 to 899 C (1550 to 1650 F).
The balance of the combustion air is admitted as overfire air
at two levels at the top of the lower furnace, both furnace front
and rear, through special nozzles for staged combustion. This
limits the formation of nitrogen oxides (NOx). The fluidizing
air velocity is greater than the terminal velocity of most of the
particles in the bed. Thus, fluidizing air elutriates the solid par-
ticles through the combustor freeboard (dilute bed). The tran-
sition between these two regions is gradual. The entrained sol-
ids and gas mixture enters the two rows of in-furnace U-beam
separators and approximately 75% of solids, including unburned
carbon and unutilized calcium oxide (CaO), are separated. Most
of the remaining 25% of the solids are separated by the external
four rows of U-beams and collected solids are returned to the
lower furnace, falling as a curtain along the rear wall.
The fines collected by the secondary separator (typically a
multi-cyclone dust collector – MDC) are also recirculated to
the lower furnace. While enhancing fuel burnout and sorbent
utilization, B&W also uses its patented secondary recycle sys-
tem to control upper furnace solids density and bed tempera-
ture.
B&W IR-CFB boilers can operate at higher solids densities
in the upper furnace compared with hot cyclone based CFB units.
This can provide a higher rate of gas-solids reaction for com-
bustion, good sulfur capture, and a high heat transfer rate be-
tween the bed and the furnace walls.
IR-CFB Boiler Design Procedure
B&W IR-CFB boiler design procedure is outlined including
the methodology involved for setting up the boiler heating sur-
faces.
Data Required for Boiler Design
Fuel. Fuel type and range of fuel properties, proximate and
ultimate analysis, HHV or LHV, fuel ash chemical analysis.
Limestone. Chemical analysis, reactivity or attrition charac-
teristics.
Sand. Chemical composition, shape factor and hardness.
Steam. Main steam flow/pressure/temperature, reheat steam

2 Babcock & Wilcox

flow, reheat steam inlet and outlet pressure/temperature, feed- fuel (sizing, ash and moisture content, FC, VM, total sulfur),
water temperature at MCR and peak load conditions; additional limestone, and emissions data are carefully reviewed as key in-
data on desuperheating spray water temperature, superheater puts to the computerized heat and material balance and fuel ef-
steam temperature control range, and boiler turndown. ficiency calculation program.
Auxiliary Fuel. Fuel analysis for start-up and load carrying. The key process parameters used to establish the heat and
Site Data. Site data and ambient conditions. material balance in addition to the steam conditions are the fur-
Emissions. Emission requirements such as NOx , SO2, CO, nace temperature, calcium to sulfur (Ca/S) molar ratio for the
and particulate. specified sulfur capture efficiency, combustion efficiency, ex-
cess air, bottom/fly ash split, secondary collector (MDC) solids
Heat and Material Balance Including Fuel Efficiency recycle rate, U-beams and MDC solid collection efficiencies,
B&W has established CFB functional standards based on and flue gas temperature leaving the air heater. Typical process
pilot facility test data for various fuels and the commercial op- parameters for different fuel types are given in Table 2.
erating boiler database to select the process parameters. The The fuel efficiency is calculated based on PTC 4.1 heat loss
method, which includes heat credits for fan power input. The
American Boiler Manufacturers’ Association recommendations
for sorbent reactions and radiation loss are used. B&W IR-CFB
Cumulative Efficiency 95% 99.5%
Component Collection 95% 90.0%
boiler radiation loss is close to that of a conventional PC-fired
Efficiency boiler (hot cyclone CFB loss is higher). Ash heat loss from the
100 5.0 5.0 0.5 bed drain and elsewhere is accounted for in the efficiency cal-
Fly Ash culation. Some of the typical output data established from the
heat and material balance program are fuel efficiency, heat in-
Solids put and output, and flow rates for all major streams (fuel, sor-
Storage Hopper Multiclone
Dust Collector bent, air, flue gas, ash). Gas and solid stream compositions are
95 Solids 4.5 estimated for over forty (40) state points.
Flow
Control

A - First Generation
Table 2
IR-CFB Process Parameters
Cumulative Efficiency 75% 97.5% 99.7%
Combustion Excess Furnace
Component Collection 75% 90.0% 88.0%
Efficiency Fuel Type Efficiency Air Temperature
Waste Wood >99.5% 20% 843C 1550F
100 25 2.5 2.5 0.3
Fly Ash
Lignite 99.0-99.5% 15% 843C 1550F
75
Sub-Bituminous Coal 98.5-99.0% 20% 857C 1575F
Solids
Storage Hopper Multiclone Bituminous Coal – 98.0-99.0% 20% 857C 1575F
Dust Collector High Volatile
22.5 Solids Bituminous Coal – 97.5-98.0% 20% 871C 1600F
Flow 2.2
Control Low Volatile
Bituminous Waste – 96.5-97.0% 20% 871C 1600F
High Ash Coal (Low to Medium Volatile)
B - Second Generation
Delayed Petroleum Coke 97.5-98.0% 20% 871C 1600F
Anthracite 96.5-97.5% 25% 885C 1625F
(6-8% Volatile Matter)
Cumulative Efficiency 75% 97.5% 99.7%
Anthracite 96.0-96.5% 25% 885C 1625F
Component Collection 75% 90.0% 88.0%
Efficiency (4-6% Volatile Matter)

100 25 2.5 2.5 0.3

Fly Ash
75
Solids Multiclone
Storage Dust Collector
22.5 Solids Hopper Furnace Design Procedure
Transfer The success of any CFB boiler design and operation starts
Hopper
Solids with furnace design. The important aspects of the furnace de-
Flow
Control sign are the furnace temperature, furnace inventory and distri-
2.2
bution, limestone and fuel particle size, gas residence time, fur-
C - Third Generation nace depth and furnace heating surface.
The output data of the heat and material balance program is
Note: Values are based on 100 units of solids exiting the furnace shaft. transferred to the furnace program. Additional process param-
eters are required to run the computer program: furnace height,
number of zones, effective heating surface per zone, (including
Figure 1 B&W CFB Solids Circulation Schematics. division walls – evaporative surface and wing walls – super-

Babcock & Wilcox 3

 90
heater surface), heat release rate per zone, lower furnace ve-
~ ~ ~ ~ ~
(21.3)
locity, typically 3.7 to 4.3 m/s (12-14 ft/s) and upper furnace
superficial velocity, typically 5.2 to 6.1 m/s (17-20 ft/s), fur- 60
nace depth 3.7 to 4.6 m (12-15 ft), particle density and size for (18.3)

circulating solids, refractory height/thickness/conductivity, sol-

50
ids mass flux at furnace outlet, U-Beams cavity heating sur- (15.2)
face, etc. Dilute Bed
Predicted furnace performance includes the furnace vertical
temperature profile, heat transfer rates at each zone and cavity,
solid bulk densities with pressure drop profile, and furnace exit
gas/solids temperature.
In setting furnace surface, the furnace plan area is set by
velocity and the furnace height is set by the flue gas residence
time. Furnace depth is set by air penetration and U-beam con-
siderations. Internal surface is added as required to control bed
temperature and satisfy heat absorption requirements.
Furnace temperature is one of the key parameters in the CFB
boiler design as it influences sorbent utilization to meet required
SO2 emissions, NOx emissions, combustion efficiency, and heat
transfer to the furnace walls. The furnace temperature is se-
lected based on fuel properties and emission control consider-
ations. Figure 3 Typical atmospheric circulating fluidized bed furnace
B&W has spent considerable effort establishing the heat density profile.
transfer correlations and the furnace design procedures for IR-
CFB boilers. The furnace is typically divided, for heat transfer
calculations, into as many as 8 to 10 zones depending upon the
height of the furnace. Local heat transfer correlations include Convective Heating Surface Design
convection and radiation (gas-wall and particulate-wall). A typi- The output data from the furnace performance and heat and
cal overall heat transfer coefficient (UT) of the furnace is in the material balance programs are transferred to the convective heat-
range of 153.3 to 199 W/m2 K (27-35 Btu/hr-ft2 F). ing surface program to design the reheater, superheater, econo-
The B&W IR-CFB boiler design featuring MDC or ESP first mizer, and air heater. Other input data (such as physical arrange-
pass ash recycle to the furnace utilizes a high solids recircula- ment) are typical for convection heating surface design, set spe-
tion rate, thus establishing relatively high furnace inventory. IR- cifically for CFB conditions.
CFB upper furnace inventory is around 0.04 to 0.06 kPa (0.16 The B&W IR-CFB boiler uses a pendant reheater and super-
to 0.20 in. wg) per 0.305 m (ft) of furnace height. Typical tem- heater design arrangement with the hot reheater and secondary
perature and density profiles are shown in Figures 2 and 3. A superheater located after the U-beam separator as shown in Fig-
careful evaluation is done to select the optimum furnace with ure 4. The cold reheater can be pendant or horizontal, depend-
consideration to performance requirements, capital cost and aux- ing on heat duty, and is located after the secondary superheater.
iliary power consumption. Convection pass side walls are steam-cooled. The flue gas ve-
locity through the superheater and reheater is set as low as 7.6
30F
to 8.5 m/s (25 to 28 ft/s) and is very uniform across the super-
100 heater and reheater. As a result, the potential for erosion is
90
greatly reduced.
On reheat units, all primary superheater surface is typically
80 located in the upper furnace as wing walls. On non-reheat units,
some or all primary superheater is pendant surface in the con-
70
vection pass. The economizer surface is horizontal and is de-
Furnace Height, ft

60 signed for flue gas velocity of 6.1 to 10.6 m/s (20 to 35 ft/s),
depending on solids loading. The economizer flue gas outlet
50 temperature is selected considering the feedwater temperature
plus 42 to 56 C (75-100 F) to optimize heat absorption split
40
between the economizer and air heater. The economizer
30 feedwater outlet temperature is normally limited to 28 C (50 F)
less than saturation temperature.
20 The tubular air heater is designed to recover the remaining
heat in the flue gas to meet the boiler efficiency requirement.
10
On CFBs, B&W typically designs the air heater with flue gas
0 outside the tubes. The tube spacing and arrangement are in-line
1450 1500 1550 1600 1650 to minimize fouling potential and erosion. Design flue gas ve-
Furnace Temperature, F locities are 9 to 13.7 m/s (30-45 ft/s). Air temperature entering
the air heater is selected to prevent cold-end tube corrosion and
Figure 2 A typical IR-CFB furnace predicted temperature profile. is dependent on fuel properties and flue gas end temperature.

4 Babcock & Wilcox

Dewpoint corrosion potential from SO 3 is greatly reduced with Non-Reheat Duty
in-furnace sulfur capture. Subcooled Evaporation Superheat

Boiler Heat Duty Distribution

The boiler heat duty is summarized by using the outputs from
the furnace and convection pass calculations. Non-Reheat Distribution In-Furnace SH
A typical IR-CFB boiler heat duty distribution is given in Eco Furnace PSH FSH
Figure 5. The final superheater temperature and the control
range are set by the customer. Economic considerations are used
to determine superheater and reheater heat duty split, location
for the primary and secondary superheater surfaces and cold Reheat Duty
and hot reheater surfaces, and the amount of attemperator spray Subcooled Evaporation Superheat Reheat
for the superheater.
The economizer and air heater heat duty split requires a
careful evaluation. The economizer heat transfer coefficient of
45.4 to 65.1 W/m2K (8-12 Btu/hr-ft 2 F) is 2.0 to 3.0 times higher
than the air heater heat transfer coefficient. To take advantage Reheat Distribution In-Furnace SH
of this fact, it is desirable to maximize economizer heat absorp- Eco Furnace PSH FSH Reheat
tion within the limits prescribed earlier.
Saturated units or very low superheater temperature units of-
ten require a boiler bank to meet the additional evaporative heat 0 10 20 30 40 50 60 70 80 90 100
duty. (See Figure 6.) Ultimately, the boiler design will be based Actual Distribution, %
on performance and economic considerations.
Figure 5 Typical IR-CFB boiler heat duty distribution (water &
steam).
IR-CFB Boiler Design Description
B&W IR-CFB boiler design has incorporated the following
improved features based on operating experience with coal and
wood-fired CFB boilers:
• Improved fuel feed system.
• Simplified MDC ash recycle system.
• Pendant superheater and reheater.
• Full internal solids recirculation system from the primary
separator.
• Reduced number of U-beam rows. Superheater
U-Beams

Hot Reheater

Secondary Dust
Primary Superheater Collector
Impact Furnace
Separator: Cold Reheater

Internal Particle Transfer

External Hopper Refractory Economizer
Economizer
In-Furnace
Superheater Dust Collector

Tubular Air Heater

To Baghouse

Coal Feeder

Start-Up ject ion

Ash Rein
Burners
Limestone Feed

Bed Drain
Cooler

Figure 4 Third generation reheat CFB boiler. Figure 6 Southern Illinois University CFB boiler.

Babcock & Wilcox 5

 • Furnace inventory control through adjustable MDC or ESP
first-pass ash recycle rate.
The following components of the IR-CFB boiler are the heart
of the CFB process and are described in more detail:
• Boiler furnace.
• Fuel/limestone feed system.
• Primary air nozzles.
• U-beam solids separators and recirculation system.
• Secondary solids separator and recirculation system.
• Bed drain ash coolers.
Steam Cooled Wing Wall
Boiler Furnace
The furnace cross section dimensions are selected based on
flue gas superficial velocity. Currently, B&W uses 3.7 and 4.6 m
(12 and 15 ft) deep furnaces. The furnace wall is made of gas-
tight membraned water cooled walls 76 mm tube diameter on
102 mm centers (3 in. on 4 in.). The bottom, or primary zone,
furnace cross section is reduced to provide good solids mixing,
promote solids entrainment and provide good turndown. The
auxiliary start-up burners and flyash re-injection points from
the secondary separator are located in the primary zone.
A thin layer of refractory is applied to all lower furnace wall
surfaces (including division walls) to protect against corrosion
and erosion. B&W normally uses 16 mm (0.625 in.) thick
refractory over a dense pin studded pattern. Refractory thick-
ness selection may vary depending upon the fuel properties. An
ultra-high-strength, abrasion-resistant low-cement alumina re-
fractory is used for the lower furnace. Refractory is also in-
stalled at the furnace roof tubes and each wing wall nose.
B&W uses carefully designed overfire air nozzles to admit
secondary air to complete the combustion through good flue gas
and air mixing. The good mixing is achieved by using variable
diameter high velocity nozzles in the front and rear furnace walls. 2 1/8 in.
5/ in.
In addition to the enclosure walls, internal heat transfer sur- 8

faces such as division and wing walls are used to achieve the
desired furnace temperature. The division walls, 76 mm tube
diameter on 102 mm centers (3 in. on 4 in.), span up to 60% of
the furnace depth with full furnace height. The wing walls, 51
mm on 63.5 mm centers (2 in. on 2.5 in.), are located in the
upper furnace and expand down from the furnace roof near the
front wall (See Figure 7). Length and quantity of steam-cooled Shop Installed Division Wall
wing walls are varied depending on final steam conditions. Pin Studs (Membrane)

Division Wall Cross Section at Refractory Zone

Fuel/Limestone Feed System
Fuel handling (crushing, storing and feeding into the fur-
nace) is one of the major challenges in CFB boiler operation,
especially with “opportunity” fuels. The feed system should be
designed to ensure reliable fuel feed over the CFB boiler life-
time with low maintenance. Fuel characteristics, including flow
properties, abrasiveness, moisture content, fuel size, etc., have
to be investigated to select the proper feed system. Fuel is fed
to the boiler front wall through a series of feed chutes (see Fig-
ure 8). The fuel chute with stand pipe should have at least a 70
degree angle from horizontal. This system also provides the seal
between furnace operating pressure and atmospheric pressure.
Primary air is used to sweep the fuel into the furnace and as
seal air to the fuel feeder.
The number of feed points is set to achieve acceptable com-
bustion in the furnace. Lower volatile fuels require fewer feed
points. To minimize the number of coal feeders, bi-directional
screws or a pair of drag chain conveyors can be used to connect
the discharge of each fuel feeder to the individual fuel chutes.
Figure 7 IR-CFB wing wall and division wall.
Limestone crushing, storing and feeding are relatively easy
compared to the fuel when the limestone moisture content is
kept within an acceptable range. The limestone size distribu-
tion is important for sulfur capture and furnace inventory. The
limestone is fed either pneumatically or mechanically into the
CFB boiler. In a mechanical system, the limestone is fed into
the discharge end of the fuel feeder via rotary seal feeders. The
limestone falls by gravity down to the fuel feed chute with fuel
into the furnace. The pneumatic feed system feeds the lime-
stone directly into the furnace through furnace openings in the
front and rear walls.
Primary Air Nozzles
Bubble caps are fitted on the distributor floor panel as shown

6 Babcock & Wilcox


Lower
Furnace
Frontwall
Figure 8 IR-CFB gravity feed chutes.
in Figure 9. The B&W bubble cap pressure drop at full load is
about 406 mm wg (16 in.wg). The bubble caps are designed to
distribute the air uniformly, prevent the back sifting of solids at
low load operation, and create good turbulence and fuel/sor-
bent mixing in the primary zone. The bubble cap material is SS
304. The spacing between the caps is 114 mm x 102 mm (4.5 in. x
4 in.).
U-Beam Solids Separators and Recirculation System
The solids separation system is a key element to any CFB
boiler design, influencing both capital and operating costs. B&W
has invested heavily in research and development to produce
efficient and economical U-beam separators, as shown in Fig-
ure 10. The boiler has two stages of primary solids separators:
in-furnace U-beam separators and external U-beam separators.
The in-furnace U-beams (two rows) can collect about 75%
of the entering solids. The flue gas velocity across the U-beams
is 8 m/s (26 ft/s).This provides high collection efficiency and
limits the gas-side pressure drop across all U-beam rows to 25
mm wg (<1.0 in. wg) as compared with cyclone-type separa-
tors’ pressure drop of 100-200 mm wg (4-8 in. wg). The mate-
rial used for U-beams is either TP 309 H/TP 310 H or TP 253
MA depending upon the furnace design temperature.
Four rows of U-beams are installed externally to the furnace
and most of the remaining solids are collected by these U-beams.
A particle transfer hopper is located at the bottom of the U-
beams. The separated solids are recycled internally into the fur-
Babcock & Wilcox
Bubble Cap
Air From Windbox
Furnace Sidewall Furnace
Rearwall
Distributor
Plate with
Bubble Caps
Windbox
Figure 9 Furnace distributor plate and bubble caps.
nace. The important technical issue associated with internal
solids recycle design is providing a pressure seal between the
furnace and solids transfer hopper. To confirm validity of the
internal recycle design, the concept was extensively tested in
the 2.5 MWt CFB test facility at B&W's Alliance Research Center.
To prevent furnace flue gas from flowing into the transfer
hopper, the discharge opening and hopper internals are designed
to operate with a column of falling solids which forms a pres-
sure seal. Providing the pressure seal in this design is an easier
task as compared with the solids return to the lower furnace for
two reasons. First, the pressure differential of 50 mm wg (<2
in. wg) is much smaller than the 812 mm wg (32 in. wg) differ-
ential at the lower furnace. Second, the pressure differential
quickly decreases with load reduction while in the lower fur-
nace the pressure remains essentially the same. Deflector plates
are used to divert the solids towards the lower furnace.
Secondary Solids Separation and Recirculation System
The (MDC) device is located at the bottom of the convection
pass after the economizer; flue gas enters the top of the MDC
and leaves the rear. The MDC inlet velocity is chosen for 21.3
m/s (70 ft/s). The collecting tube diameter is 229 mm (9 in.),
distributed evenly over the second pass entire cross section. The
MDC provides good retainment of fine particles (> 50 mm and
above), as compared to large diameter hot cyclones used in cy-
clone-type CFBs. MDC tubes and spin vanes have high hard-
ness ( up to 550 BHN), designed for several years of useful life.
The MDC tubes can be easily inspected and replaced during a
planned boiler outage.
7
 for these countries, ESP first-pass ash recycle can be used (see
Figure 11). The ESP first-pass ash is relatively coarse and aver-
age particle size is around 70 microns. Collected ash is stored
in a separate ash hopper, with controlled recycle to the furnace.

Bed Drain Ash Coolers and Solids Re-Injection System

The purpose of draining the bed material from the furnace is
Gas
to control the bed solids inventory and remove oversized mate-
Plus Gas rial accumulated during operation. 203 mm (8 in.) diameter bed
Solids Flow drain pipes are used to drain the material. The number of bed
Flow
drain points is selected based on the furnace plan area and the
fuel. The drained material is at bed temperature and carries a
considerable amount of sensible heat. The material is cooled to
an acceptable temperature before disposal into the ash system.
Water-cooled screws or fluidized-bed ash coolers can be used
for the bed drain cooling. The type of ash cooler depends on
the fuel properties, plant economics, heat utilization, and the
need for bed material classification for reinjection of fine par-
1. Sidewall Membrane Panel ticles. Fluidized-bed ash coolers typically can strip the fine
2. U-Beam
3. Seal Baffle particles less than 200 mm and reinject them to the furnace with
fluidizing air.

Figure 10a U-Beam separators – plan view.

Advantages of the B&W IR-CFB Boiler
• The boiler is compact with primary U-beam separators and
internal solids recycle.
External U-Beams • The boiler has a smaller footprint (up to 20 to 25% less
In-Furnace U-Beams building volume compared to a cyclone-based CFB boiler).

Solids Returned to
Gas & Solids Particle Transfer Hopper

Solids Returned to Furnace

Figure 10b U-Beam separator.

The collected fines are stored at the bottom of the MDC hop-
per or a separate ash hopper in the case of ESP first-pass ash
recycle. Variable drive rotary feeders are used to control the
ash recycle flow from the hopper to the furnace. The ash is
dropped onto the air-assisted conveyor which transports the sol-
ids for reinjection. The ash flow rate can be adjusted by vary-
ing the rotary feeder speed for furnace temperature control.
In some developing countries, MDC tube cost and availabil-
ity are a major concern. To meet the CFB boiler requirements Figure 11 Kanoria CFB boiler.

8 Babcock & Wilcox

 • Boiler design is especially suitable for repowering of PC-
fired boilers where space is limited.
• Two-stage solids separation efficiency (>99.7%) provides
for higher carbon burn-up efficiencies, better limestone uti-
lization and higher solids residence time.
• Dynamic load change response is achieved due to the ab-
sence of massive refractory and the ability to control fur-
nace inventory using variable ash recycle from the MDC
or ESP first-pass.
• Wide turndown ratio (5:1) without auxiliary fuel is pos-
sible due to the selection of furnace velocity and control-
lable solids recycle.
• Less refractory in the boiler allows for quick start-up and
less maintenance (hot cyclone can have 4 to 5 times the
amount of refractory).
• Provides higher reliability, operability, and availability with
lower maintenance.
IR-CFB Boiler Emissions Control
Environmental regulations impose limits on emissions from
boilers and combustion processes. The emissions limits vary,
but the pollutants controlled are generally the same. These are
sulfur dioxide (SO 2), nitrogen oxide (NOx), carbon monoxide
(CO), hydrocarbons and particulate matter. Circulating fluid-
ized-bed boilers are designed to burn solid fuels while control-
ling many of these emissions.
Control of SO2 Emissions
When sulfur bearing fuels are burned, most of the sulfur is
oxidized to SO 2, which becomes one of the constituents of the
flue gas. When limestone is added to the bed in the temperature
range of 816 to 899 C (1500-1650 F), it undergoes a transfor-
mation called calcination to form lime (CaO) by endothermic
reaction:
CaCO3 → CaO + CO2 – 766 Btu/lb of CaCO3
Once formed, solid CaO reacts with gaseous SO 2 and oxy-
gen to form CaSO4 according to the following exothermic reac-
tion:
SO2 + 1/2 O2 + CaO → CaSO 4 (s) + 6733 Btu/lb of S
The resulting calcium sulfate is a chemically stable solid at
fluidized-bed operating temperatures and is removed from the
system for disposal.
Sulfur dioxide reductions of 90% are typically achieved in a
circulating fluidized-bed boiler with calcium to sulfur (Ca/S)
mole ratios of 2 to 2.5, depending on the sulfur content of the
fuel and the reactivity of the limestone. In general, the lower
the sulfur concentration in the fuel, the greater the calcium to
sulfur mole ratio must be for a given SO2 removal efficiency.
For removal requirements greater than 90%, the amount of lime-
stone needed must be increased. Limestone utilization is also
dependent on the bed temperature, decreasing quickly when the
temperature is outside of a 816 to 871 C (1500-1600 F) range.
The physical properties and reactivity of limestone vary sig-
nificantly and it may be necessary to try several different lime-
stones before the most economical one is found.
Control of NOx Emissions
NO x present in flue gas generally comes from two sources:
the oxidation of nitrogen compounds in the fuel (fuel NOx), and
the reaction between the nitrogen and oxygen in the combus-
tion air (thermal NOx).
Babcock & Wilcox
As a result of the low temperatures at which a fluidized bed
operates, thermal NOx makes a minor contribution to overall
emissions. Circulating fluidized-bed boilers are also designed
to suppress the amount of fuel NOx formed. This is accom-
plished by supplying less than the theoretical amount of com-
bustion air as primary air. As a result of this staged air admis-
sion process, some of the fuel nitrogen compounds released in
the lower furnace decompose into molecular nitrogen rather than
forming fuel NOx.
The degree of air staging (or primary-to-secondary air ratio)
is a function of the fuel. It is established when the boiler is
designed to provide for both good combustion efficiency and
low NOx formation. In practice, the primary-to-secondary air
ratio may be adjusted, to a limited degree, to arrive at the best
combination of fuel burnout and NOx emissions.
Control of CO and Hydrocarbons Emissions
A CFB boiler is designed to maximize combustion efficiency
by minimizing unburned carbon and the quantity of CO and hy-
drocarbons in the flue gas. This is done by choosing the bed
temperature, primary-to-secondary air split, proper number of
fuel feed points, proper design of the overfire air system, and
sufficient furnace residence time for mixing and maximum fuel
burnout.
Since some of these factors also influence SO2 capture and
NOx emissions, a compromise is usually sought during boiler
design and tuning to achieve the optimal overall performance.
Typical NO x and CO values are shown in Table 3. Addi-
tional NO x reduction (40% to 60% of CFB process NOx) can be
achieved by injecting ammonia (NH3) either in the upper fur-
nace or after the U-beams. In both cases a sufficient residence
time (not less than 0.5 sec) is provided for NOx reduction reac-
tions before gases enter U-beams or the superheater surface,
respectively.
Table 3
Typical IR-CFB Emissions (lb/MBtu)
Fuel NOx CO
Bituminous Coal
Low Volatile 0.05 - 0.10 <
– 0.20
High Volatile 0.10 - 0.15 <
– 0.10
Lignite and Sub-Bituminous Coal 0.10 - 0.20 <
– 0.10
Waste Wood 0.15 -0.25 <
– 0.06
Petroleum Coke 0.10 - 0.20 <
– 0.20
<
Anthracite 0.10 - 0.15 – 0.25
Control of Particulate Emissions
To meet the particulate emission requirements, a final dust
collector is required. Often there is a question whether an ESP
or a baghouse should be used. B&W usually selects a baghouse
when limestone is used for sulfur capture. A baghouse is less
sensitive to excursions in dust loading and ash content varia-
tion in the fuel. A baghouse has a high gas-side pressure drop of
1.5 to 2.0 kPa (6-8 in.wg) and requires occasional bag replace-
ment, giving higher O&M costs than an ESP. An ESP can be
selected as an alternate particulate control device in places where
9
baghouses are not readily available or where there is no lime-
stone used for sulfur capture. There is concern that the presence
of CaO and CaSO 4 affects the resistivity and may reduce the
ionization potential. The ESP should have enough fields to ac-
commodate excursions and fuel ash variation. ESP gas-side
pressure drop is less than 0.5 kPa (2 in.wg).
IR-CFB Boiler Existing Contracts
Two projects utilizing the B&W IR-CFB boilers design are
in progress:
Southern Illinois University IR-CFB Boiler Contract
The IR-CFB boiler for Southern Illinois University (Figure
6) will generate 12.8 kg/s of 4.5 MPa/399 C (101,500 lb/hr of
675 psig/750 F) steam. This boiler will utilize Illinois bitumi-
nous coal and, as an alternate fuel, petroleum coke. The unit is
also capable of carrying 67% load while firing natural gas. The
boiler erection is completed and commissioning activity is in
progress. Start-up of the unit is scheduled at the end of August
1996.
Kanoria Chemicals IR-CFB boiler Contract
Another IR-CFB boiler has been designed and erected (un-
der license) by Thermax B&W Ltd. (TBW), one of B&W’s joint
venture companies located in Pune, India. TBW is supplying
References
1. Belin, F., Maryamchik, M., Fuller, T.A., and Perna, M.A.,
CFB Combustor with Internal Solids Recirculation - Pilot Test-
ing and Design Applications,” 13th International Conference on
Fluidized-Bed Combustion, Orlando, Florida, May 7-10, 1995.
2. Kavidass, S., Alexander, K.C., Belin, F., James, D.E., “Op-
erating Experience with High Ash Waste Coal in a B&W CFB
Boiler,” Power-Gen Asia ’94, Hong Kong, August 23-25, 1994.
10
this boiler for Kanoria Chemicals & Industries Ltd. in Renukoot,
UP, India. The boiler, shown in Figure 11, will generate 29.2
kg/s of 6.3 MPa and 485 C (231,480 lb/hr of 938 psig and 905
F) steam. The fuel is high-ash low-heating value sub-bitumi-
nous coal. The boiler erection is completed and the commis-
sioning is in progress. Start-up of the unit is scheduled at the
end of July 1996.
Conclusion
B&W has established IR-CFB boiler design based on more
than 36 years of fluidized-bed experience plus the knowledge
gained from test facilities and the data from commercial oper-
ating units. B&W’s IR-CFB boiler is a unique, simple and com-
pact design providing lower capital and operating costs and high
reliability.
This information and knowledge is integrated with sophisti-
cated computer programs to provide the tools needed to design
CFB boilers for specific fuels. CFB boiler designers use de-
tailed information on fuel, sorbent, steam conditions, stack tem-
perature and emission requirements for setting process param-
eters and configurations providing an economic CFB boiler de-
sign.
B&W IR-CFB boiler design is valuable for repowering of
the existing power plants where the IR-CFB boiler fits into the
plan area of PC-fired boilers.
3. Jones, C.S., Alexander, K.C., Belin, F., “CFB boilers for
Ukrainian Low Grade Coals,” Power-Gen Americas ’94 Con-
ference, Orlando, Florida, December 7-9, 1994
4. Steam/its generation and use, 40th edition, Chapter 16,
“Atmospheric Pressure Fluidized-Bed Boilers,” Babcock & Wil-
cox, 1992.
Babcock & Wilcox