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A coal particle burns out between 1 and 2 s, depending on its volatile content,
similar to oil, and the combustion is most complete at >99% carbon burn up.
For high-volatile matter (VM) coals and lignites, the combustion efficiency can be
as high as 99.7%.
The limitations relate to the inability of PF to
Deal with variation in fuel without risking
fouling and slagging of boilers
Provide multi-fuel firing
Fire fuels with >40% total moisture unless
there is enough VM such as in brown coals
Burn very low-volatile fuels such as petcoke
Combustion is very poor in fuels with
Gross calorific value (GCV) <2000 kcal/kg
A burden >65% (ash and H2O)
Very high S
Prompt NOx results when fuel hydrocarbons break down and recombine with
nitrogen in air (this reaction generally takes place before the flame tip).
Accounts for 15-20% of total NOx Emission.
Thermal NOx forms when Nitrogen in air reacts with Oxygen along with intense
heat. These kind of Nox Rate of formation increases,
Exponentially with Temperature
The primary Combustion in Furnace bed with primary air and secondary
combustion in free board area with Secondary and Tertiary air.
The Final resulting NOx emission in CFBC will be almost 50% that formed
in BFBC boilers.
In CFBC boilers, PA forms only
50 to 60% of total air required
for combustion. Remaining part
of air is taken care by SA
Figure, captures the effect of
Secondary Air on the NOX
emissions.
Higher the SA air %, lower the
Nox emission.
NOX emissions effort-lessly stay
at <200 mg/N m3 on 6% O2
when 30% or more SA is given.
Secondary air %
De-Sulphurisation
Limestone Requirement
(Dis)Advantages
In-bed desulfurization is a breakthrough in CFBC boilers.
Lime stone-sulphur as SO2 reaction within the furnace bed,
along with the combustion reaction and the resultant gypsum
exit with ash is simplification personified.
A good understanding of the mechanics of this reaction and
the limitations is very necessary for ensuring realistic emission
of Sox.
It also helps to correctly set up the limestone and ash handling
systems that meet the present and future requirements.
5 to 6 % Sulphur in fuel (typically pet coke) can lead to 10000
mg/NM3 of SOx in exit flue gas.
Sulphur Capturing in CFBC has been done by adding
Limestone (CaCO3) or dolomite (MgCO3) along with
bed material as sulphur absorbent.
Sulphation
The Limestone (Calcium Carbonate CaCO3) added into the
furnace along with fuel decomposes as Calcium oxide (CaO) is
called Calcination. The Reaction is,
Bed Temperature C
The sulfation takes place on the surface of the lime particle in the bed and so
the core of the particle fails to participate.
Some sulfur in fuel, which is inorganically bound, does not oxidize to SO2.
Some SO2 escapes when sorbent is less or accompanies the volatile matter
(VM) of fuel.
Available Limestone purity is lower than optimumtypically 92%.
Maintaining the bed temperature around 800-900 C is important for de-
sulphurisation because
Calcination is not complete at Temperature <800 C
Sulfation reaction falls off rapidly beyond 850C because CaSO4 formed on the
sur-face of CaO melts due to high temperature and forms a coating on CaO, and
isolates that for further reaction.
Within the residence time SO2 gas molecules do not encounter reactive solid
CaO particles despite high bed turbulence.
Bed Temperature
Particle Resident Time
Bed Quality
Gaseous Environment (O2%)
Furnace Pressure
Chemical Composition (purity of limestone)
Porosity of Limestone
Surface area
Particle Size
The Calcination process of Limestone is an Endothermic reaction. As shown in the
figure below, each kg of CaCO3 will consume 1783 kJ/kg heat from furnace.
Oxygen.
These elements form the three legs of
the fire triangle. Ignition source
simultaneously:
Fuel Explosion
Heat
Suspension
Oxygen
Oxygen
Suspension
Confinement
Heat
These form the five sides of the explosion pentagon. Like the fire
triangle, removing any one of these requirements would prevent an
explosion from Confinement propagating.
For example,
if fuel, heat, oxygen, and confinement occurred together in proper
quantities, an explosion would still not be possible without the suspension
of the fuel.
However, in the above case, a fire could occur and the explosion will not
be possible.
If the burning fuel were then placed in suspension by a sudden blast of air,
water or steam, all five sides of the explosion pentagon would be satisfied
and an explosion would be imminent.
This is where, the CFBC boiler is prone to failure in some critical cases
Furnace explosions in CFBC boilers are rare when both bed and free board
temperatures are above 760 C. Chances of explosions are very high when
these temperatures are below 540 C.
Though not fully established, yet chances of explosions cannot be ruled out
when bed temperature remains between 540 C and 760 C.
All Fluidized bed boilers are exposed to this risk of explosion when they are
stopped/tripped on loaded condition.
The explosions mostly occur in CFBC when
Boiler is restarted after a trip out.
Boiler is restarted after a short period of Hot stoppage
Fast cooling of boiler is resorted to following a tube leakage especially when the
leaking water falls on the bed
The risk is very high when the leakage water wet the bed partially one sided and
other side of the bed is very hot.
During hot stoppage/tripped condition
It has good amount of fuel along with hot bed.
A Typical 100 TPH boiler will have 40 to 50 MT of hot bed material with ~5% of coal
at 850C and Confined in the furnace.
It meets the 3 legs of explosion pentagon,
Heat above 850 C
Fuel Sufficient enough
Confined
Such cases when ever the system gets other 2 legs of explosion pentagon Fuel
Suspension (instant) and Oxygen, it explodes immediately.
There is a possibility of these to happen when the boiler is restarted after hot
stoppage with any abnormality likes of tube leakage.
There are cases where, the PA duct has been exploded during a boiler start up.
When ever there is trip out on CFBC boiler,
The total fluidizing bed comes to static condition.
During this, the PA/FD air passed thru PA nozzle and entered into the fluidized
zone will be pushed back thru the same nozzle to wind box due to the heavy
weight of bed material.
These phenomenon causes the combustion air with high temperature rushes to
wind box taking along some amount of fine fuel with CO as the burning process
is not complete.
These un burnt ready to fire fuel (CO and Char) will cause more CO formation in
the wind box and remain in the PA duct.
When ever the boiler is started after the trip, PA duct will get good amount
of Oxygen as fresh air.
Our Analysis after every hot tripping says that, the O2% in PA duct and wind
box will go down as low as to 12% during hot trip which directly indicates that,
there is some amount other gases formation during tripping expected to be
Carbon monoxide.
This will close all the legs of the Explosion pentagon
Heat
Fuel
Oxygen
Confined (PA duct enclosed in all direction)
Suspended fuel (CO)
With PA/FD has been started, the Wind box is exposed to high heat of bed
material will cause a explosion.
This is mainly applicable for Under bed burners or Hot gas generators
of cold cyclone boilers.
Fuel shut off valve passing also causes HGG explosion. The failed valves
can allow the HSD to pass thru and get dumped in the HGG chamber.
When the actual firing starts this accumulated fuel get exploded.
Fuel should never be fed into the furnace continuously for more than 12
seconds when there is no fire.
Do not start PA/FD fan once the boiler is stopped due to tube leakage.
Continue to run ID and SA fans. Once the SA fan is tripped do not restart
during leakage condition. It can give required Oxygen to the gases formed in
bed due to water injection which leads to an Furnace explosion.
Provide a vent in PA duct for venting out the CO formed during Sudden tripping of
boilers.
Interlocking with an O2 analyser will further reduce the potential PA duct explosion.
Dont start the Under bed burners or HGGs without sufficient purging of furnace.
Continuous tripping of HGG on Flame failure during start up can lead to explosion.
Avoid restarting of HGG before ensuring that the HSD/Fuel sprayed inside HGG
chamber without burning is totally drained out or purged out.
Always take oil burner support when ever the bed temperature drops down below
540C.