Foster Wheeler CFB Technology, PLN, May 25, 2004
FOSTER WHEELER CFB TECHNOLOGY
Timo J?ntti timo.jantti@https://www.doczj.com/doc/e814680517.html,
Foster Wheeler Energia Oy
R&D Center, P.O.Box 66 FIN-48601 Karhula FINLAND
Presentation outline
Foster Wheeler CFB Technology, PLN, May 25, 2004
1. 2. 3. 4. 5. 6.
CFB Characteristics & Advantages CFB Design development & Scale-up Design Features of the Foster Wheeler CFB CFB Fuel Flexibility Examples of the Utility Size Projects Design Support & OTU CFB
Foster Wheeler CFB Technology, PLN, May 25, 2004
CFB Characteristics & Advantages
CFB Characteristics and Benefits
Foster Wheeler CFB Technology, PLN, May 25, 2004
Flue gas 800-900°C
FEATURE ? Low furnace temperatures ? Hot circulating solids
BENEFIT ? Low emissions ? No slagging ? Fuel flexibility ? Handles low grade fuels ? Simple feed systems ? Good fuel burnout ? Good sorbent utilization 800-900°C 4.5-5.0 m/s
Limestone <1mm
? Long solid residence time
Coal <10mm Biomass <50mm
Air
CFB ADVANTAGES
Foster Wheeler CFB Technology, PLN, May 25, 2004
? Fuel Flexibility
– Fuels from Biomass to Anthracite Coals – Low-grade fuels (high ash / high moisture) – Co-firing of different fuels / fuel qualities
? Low Emissions
– SO2 –removal with limestone injection (95 - 98 % reduction) – NOx – emissions typically < 200 mg/m3n depending on fuel
? Further NOx –reduction achieved by ammonia injection (SNCR)
? Competitive Investment Cost & Availability
The world leader in fluidized bed boiler technology
Foster Wheeler CFB Technology, PLN, May 25, 2004
Over 40 years experience in fluidized bed combustion
? Pioneer work in fluidized bed combustion began in the 1960s; first bubbling fluidized bed (BFB) boilers delivered ? Circulating fluidized bed technology (CFB) launched in the 1970s ? Simple construction, reliable, and environmentally friendly multifuel designs ? Meets strict emission regulations without complex scrubbing systems
213 CFB BOILERS DELIVERED TO DATE ? 192 in operation ? 21 under construction ? Largest unit in operation: 300 MWe ? Largest unit sold: 460 MWe
ROVANIEMI
Foster Wheeler CFB Technology, PLN, May 25, 2004
CFB Design development & Scale-up
CFB Design Development
Foster Wheeler CFB Technology, PLN, May 25, 2004
1979
1988
1992 -
1996 -
Uncooled cyclone
Water/steam cooled cyclone
Water/steam cooled integrated separator
Water/steam cooled integrated separator with INTREX? SH
Foster Wheeler CFB Boiler
Foster Wheeler CFB Technology, PLN, May 25, 2004
Steam Steam Drum Steam Outlet Water
FOSTER WHEELER CFB FLOW CHART
Downcomer Water Wall Separator Fuel Limestone Economizer
Feed Water Inlet Dust Collector Air Heater Combustion Chamber
Fly Ash
Bottom To Ash Silos Ash
Secondary Air Fan Primary Air Fan
Induced Draft Fan
Scale-Up and Some Key References
Foster Wheeler CFB Technology, PLN, May 25, 2004
UNIT CAPACITY ( MWe)
600 550 500 450 400 350 300 250 200 150 100 50
Pilot plant Pihlava Kauttua Nova Scotia
SECOND GENERATION DESIGN
Lagisza
FIRST GENERATION DESIGN
Turow 1
JEA Turow 5
Vaskiluodon Voima
Kajaani Tri-State Leykam Kokkola
NPS
0 1970 1975 1980 1985
Kuhmo Pilot plant
Thai Kraft
1990
1995
2000
2005
2010
YEAR OF INITIAL OPERATION
CFB deliveries over 80 MWe
Foster Wheeler CFB Technology, PLN, May 25, 2004
Del. year 1987 1989 1990 1990 1991 1992 1992 1994 1994 1995 1995 1995 1996 1997 1998 1998 1999 1999 1999 2000 2000 2001 2001 2002-2004 2003 2003 2004 2003, 2004 2004 2004 2006 Customer Tri-State Generation, Nucla, USA KAVO, Kajaani, Finland Vaskiluodon Voima Oy, Sein?joki, Finland ACE, Trona, USA RWE, Essen, Germany AES-Barbers Point, Hawaiian Island, USA NISCO, Louisiana, USA Nova Scotia Power, Nova Scotia, Canada AES Cedar Bay, Florida, USA Fortum Engineering, Toppila 2, Oulu, Finland Northampton Energy Project, Pennsylvania, USA Colver Power Project, Pennsylvania, USA CMIEC/Neijiang, Neijiang, P.R.C. RAPP,Kerinci, Indonesia Turow Power Station, Bogatynia, Poland NPS, Tha Toom, Thailand Map Ta Phut, Rayong, Thailand Asia P&P, Dagang, P.R.C. EC Katowice, Katowice, Poland Turow Power Station, Bogatynia, Poland Bay Shore Power Co., Ohio, USA Taiheiyo Cement, Niigata, Japan JEA, Florida, USA Turow Power Station 4-6, Bogatynia, Poland EC Chorzow, Elcho, Poland Southern Illinois Power, Illinois, USA Zhenhai, Ningbo, P.R.C. AS Narva Elekrtrijaamad, Narva, Estonia ESB, West Offaly Power, Shannonbridge, Ireland ESB, Lough Ree Power, Lanesborough, Ireland PKE, Elektrownia Lagisza, Bedzin, Poland MWe 110 88 125 110 100 80 2x100 180 80 100 100 100 100 110 2x235 2x150 2x140 2x100 120 235 180 149 2x300 3x262 2x113 120 2x100 4x100 150 100 460 MWth 291 240 299 306 313 238 2x285 410 245 291 277 270 285 314 2x520 2x370 2x360 2x287 352 520 460 341 2x689 3x557 2x274 349 2x293 4x234 318 216 966 t/h 420 360 400/348 413 400 301/271 374/331 532/465 316/247 371/321 360/331 356/356 410 468 667/598 482/439 434 400 483 667/598 435/375 475/385 904/804 704/650 404 517 410 324/279 408/354 279/237 1300/1109 bar 104 136 139/48 105 115 136/32 112/32 128/35 136/29 156/20 174/40 174/37 98 140 132/25 161/35 182 125 138 132/25 139/31 170/36 182 170/40 135 60 104 131/27 170/35 144/34 283/51 °C 540 535 540/540 540 504 540/540 540/540 540/540 540/540 540/540 540/540 540/540 540 540 540/540 542/542 568 537 540 540/540 565/540 569/541 540/540 568/568 538 485 540 540/540 563/563 563/563 563/582 Fuels Coal Peat, wood, coal Peat, coal Coal Brown coal Coal Petroleum coke Coal Bituminous coal Peat, coal Anthracite culm Anthracite culm Bituminous coal Bark, coal Polish brown coal Anthracite, bit. coal Coal Coal, sludge Coal Polish brown coal Petroleum coke Coal, pet. coke, RDF Pet. coke, bit. coal Polish brown coal, lignite Bituminous coal Bituminous coal fines Bit. coal, pet. coke Oil shale Peat Peat Bituminous coal, coal slurry (option)
Foster Wheeler CFB Technology, PLN, May 25, 2004
Design Features of the Foster Wheeler CFB - Cyclone - Wall Seal - Kickout - INTREX?
CURRENT FW CFB SOLIDS SEPARATOR DESIGN
Foster Wheeler CFB Technology, PLN, May 25, 2004
FEATURES: ? Separator and return leg integrated with furnace ? Steam or water cooled panel wall structure ? High separation efficiency ? Small space requirements ? Maintenance and availability problems due to furnace/cyclone expansion joints eliminated – No expasion joints needed when watercooled – Simple expansion joints to compensate small movements when steam-cooled
SEPARATOR WITH PANEL WALL CONSTRUCTION
Foster Wheeler CFB Technology, PLN, May 25, 2004
? Manufacturing with automated welding machines – High quality of pressure parts ? Water or steam cooled – Provides additional heat surface ? Normal mineral wool insulation – Low skin temperature, – Lower radiation loss – Cooler boiler house ? Thin refractory anchored with dense studding – Fast load change rates and startup – Low refractory maintenance – High availabilty
Thermal Insulation
Refractory 25–50 mm Panel wall
SEPARATOR ARRANGEMENT, SCALE-UP AND MODULARIZATION
Foster Wheeler CFB Technology, PLN, May 25, 2004
400-600 MWe
200-300 MWe
Module
300-400 MWe
150-200 MWe
100 MWe
SEPARATOR PERFORMANCE
Foster Wheeler CFB Technology, PLN, May 25, 2004
FW Solids Separator has: ? High separation efficiency ? Uniform velocity field at the walls due to advanced gas inlet design – low pressure drop – low erosion
m/s
Velocity Magnitude (CFD-calculation):
Same separation efficiency Higher pressure loss
FW Solids Separator
Conventional Cyclone Design
Wall Seal Design Solids Return to Lower Furnace
Foster Wheeler CFB Technology, PLN, May 25, 2004
KICKOUT
Foster Wheeler CFB Technology, PLN, May 25, 2004
INTREX? System
Foster Wheeler CFB Technology, PLN, May 25, 2004
Solids return leg
Integrated Heat Exchanger ? Heat exchange from solid bed material to tube surface ? High heat transfer rate ? Heat transfer controlled with fluidization Simple Design ? No moving parts: no wear Resistant to Erosion ? Low fluidization velocities, fine particles Resistant to Corrosion ? Cl-free environment
Solids return channels
INTREX? Superheater
Air plenums
Fluent Flow Models > INTREX
Foster Wheeler CFB Technology, PLN, May 25, 2004
Solids return leg
Solids return channels
INTREX? Superheater Air plenums