Welcome to

Presentation on AFBC Boilers

FLUIDISED BED COMBUSTION

BUBBLING (AFBC) Developed in-house

CIRCULATING (CFBC) Based on LEE, Germany

AFBC Facilities
Combustion Test Rig-1979 0.5 M X 0.5 m (4,00,000 kcal/h)

10 t/h Prototype Boiler - 1977

USAID Test Facility-1986

(90 t/h Hot water)

7.5 t/h Prototype Shell Boiler-1982

Samples of Fuels Tested

Gujarat Lignite

Municipal Solid Waste

Shivsankar Ind., Bangalore SelCo, Hyderabad

Kiln Char
Sunflag Industries,Bandara

Washery Rejects
Tisco, Jamadobha

Samples of Fuels Tested

High Ash coal

Bellampalli, AP

Neyveli Lignite

Mill Rejects
Parli TPS

Biomass Fuels Tested

Rice Husk
Rice Mill, Tiruchi

Rice Straw
Tiruchi

Mustard Crop Residue

Manipal Int., Gurgaon

Biomass Fuels Tested

Wood Chips
Tiruchi

Palm Shells
Kerala Electricity Board,

Petcoke

Petcoke Lumps Before Crushing

Petcoke Pile
RIL, Jamnagar

Petcoke After Crushing

Coals , Rejects Tested

Fuel Sulphur Moisture Ash HHV % % % kcal/kg

Coals : Singareni Chanda Bellampalli Assam Coal Middlings / Rejects : Bhojudih Kathara Jamadoba Mill rejects LECO fines

0.6 0.21 0.3 5-6

7.0 5.0 6.0 9.0

26.0 36.0 55.0 33.0

4900 4300 2460 7100

0.23 0.31 0.45 5-7 1.1

1.0 1.0 1.0 1.5 1.0

55.0 73.0 65.0 57.3 14.0

3100 1900 2100 3300 6700

Steel Plant Wastes

FUEL Proximate anlysis % Moisture Ash Volatile Fixed Carbon Heating Value kcal/kg
Sulphur in tracees

COAL fines

Char

ESP DUST

10 - 12 20 - 30 22 - 30 40 - 48 4500 to 5000

5 - 12 50 - 70 0.5 - 1 20 - 25 2400 to 2600

4-8 70 - 80 2-7 22 28 2600 to 2800

Lignites Tested
Source Sulphur Moisture % % 0.5 0.8 0.82 1.8 2.1 56.0 19.3 12.5 38.0 5.1 Ash HHV % kcal/kg 3.0 2800 44.0 2080 63.9 1500 16.0 3600 52.1 1912

Neyveli J & K Lignite J & K Clayey Lignite Kutch Lignite Kutch Lignite Shale

Petcoke Analysis
Ultimate Analysis (% by weight)
Fixed Carbon Hydrogen Sulphur Oxygen (by diff) Nitrogen Moisture Ash kcal/kg 85.23 2.66 6.93 1.91 0.39 2.00 0.77 7850

HHV

Petcoke Testing
Petcoke tested independently and along with Coal for about 110 hrs
60 h in Test Rig in combination with Coal 50 h in AFBC Facility independantly with limestone

Bed Temparature 800 - 900 C Fluidisation Velocity 2 - 3 m/s Sulphur Capture about 85 % (Ca/s 3 - 4.5)

BHELs Unique Design Approach

Every New Fuel is Test Fired and Design Parameters finalised before offering commercially:  Various Coals, Lignites  Washery Middlings and Rejects  Rice Straw, Husk, Bagasse Pith  Kiln Char, Steel Plant ESP dust  Petroleum Coke Design Improvements made based on about one million operating hours

FBC Technology Development at BHEL

BHEL has Pioneered the FBC Technology development in India Road Map
1984 : First 10 MW power plant for Washery Rejects 1987 : First 10 MW power plant for Straw 1992 : First 20 MW (100 t/h) power plant for Rejects and Char 1995 : Largest CFBC boilers of 125 MW for Gujarat Lignite 2000 : Largest AFBC boiler of 180 t/h (45 MW)

AFBC Boilers Status

Technology developed in-house Boiler Design Developed and Offered for a variety of fuels Petroleum Coke All Types of Coals and Lignites Washery Rejects Steel Plant Wastes (Coal fines , Kiln Waste, ESP dust) Wastes (Oil Sludge, Paper Sludge, Pelletised MSW) Biomass (Rice Straw, Rice Husk, Palm Wastes, Pith) 54 boilers contracted so far Largest capacity in Operation 165 t/h 300 t/h Boiler being offered

Experience Summary

AFBC Boilers for Coal

Customer No of Units
1 1 1 1 3 1 2 4

Capacity t/h
60 50 80 77 75 60 95 40

West Coast Paper, Dandeli Baroda Rayons, Surat Hindalco, Renukoot Rajashree Cements, Gulbarga Grasim Industries, Nagda TNPL, Pugalur Rourkela Steel Plant ACC, Chanda / Madukkarai

AFBC Boilers for Rejects, Opportunity Fuels

Customer No of Units
1 4 2 2 1 1 4

Capacity t/h (MW)

56 (10) 53 (10) 62 (10) 100 50 65 165

TISCo. Jamadobha CIL, Kathara / Moonidih TISCo. West Bokaro Jindal Strips Ltd., Raigarh Sunflag Iron & Steel* Prakash Industries* Jindal Steel Ltd.,**
** Utilises Char, Rejects

* Utilise Opportunity Fuels like Kiln Char, Kiln ESP Dust, Coal Fines etc.

AFBC Boilers for Power

Customer Repeat Customers
Jindal Strips, Raigarh Rajashree Cements Grasim Industries, Nagda Birla Cellulosic, Kharach Jindal Steel & Power, Raigarh 2 2 2 2 4 2 1 20 19 22 22 45 25 23

No of Units

Capacity MW

For Cement Industries

Tata Projects ACC, Wadi Aditya Cements, Shambhupura

Export
PT IBR, Indonesia 3 17

AFBC - Future Development

Based on the above experience

 Designs for 60 MW and 120MW evolved

CIL, Kathara 53, 66, 485 TISCo, West Bokaro 62, 24, 400 CIL, Moonidih 53, 65, 485 TISCo, Jamadobha 56, 24, 400

SUNFLAG IRON AND STEEL 50, 64, 485

PRAKASH INDUSTRIES 65, 63, 485 JINDAL STRIPS, RAIGARH 2 x100, 35, 430 JINDAL STRIPS, RAIGARH 2 x165, 94, 540

Rajashree Cements, Malkhed 77, 67, 485 & 2 X 95, 68, 485

Drum

SHI Coal Bunker DESH

Eco

Air Heater S H II EVA Ash Air Distributor I D Fan ESP

Feeder

Main Steam

P A Fan F D Fan

A F B C Schematic

Salient Design Features

In - Bed Evaporator & Superheater

STUDDED BED EVAPORATOR TUBES

STUDDED BED EVAPORATOR TUBES

Fluidising Air Nozzles

Start up System

START-UP DUCT BURNER

800

BED

700

Temperature, Deg-C

600

500

400

FUEL FEED
300 0 30 60 90 120 150

WIND BOX

180

Time, Minutes

Compartmental Operation of FBC Boiler

COMPARTMENT ACTIVATION
Coal feed to II compartment Bed Temp. - Compartment I
600

800

Activate Comp. II Air flow

Compt I Active
400

Steam Pressure

Bed Temp. - Compartment II

200

0 0 1 2 3 4 5 6 7 8

Time, minutes

Turn down - Compartmental Operation

1000

900

Bed Temperature, Deg-C

800

700

12 - 37 %
600

28 - 65 % 46 - 90 % 60 - 110 %

500 0 10 20 30 40 50 60 70 80 90 100 110 120

Load, % MCR

Hot Restart

800

Bed Temp. - Compartment II Bed Temp. - Compartment I

Bed Temperature, Deg-C

600

400

Steam pressure

Air flow Reactivation Compartment II 126 127 128

Power Trip

200

Reactivation Compartment I 0 1 2 123 124 125

129

130

Time, minutes

Water Cooled DP Plate

Ash Removal System

Boiler Fuel Line

Fuel Bunker

New Arrangement

Boiler

Old Arrangement

Fuel Line Fuel Bunker

Fuel Feed Line Arrangement

Erosion in Fuel Feed Lines Eliminated

General Arrangement

Availability - Rajashree
100
98.7 99.9 96.8 93.3 93.2

98.3

100.0

100.0

99.1

90 80 70 60 % 50 40 30 20 10 0 97-average

boiler 1 boiler2 boiler 3

98-average

99-average

Availability for 1999 - Birla Cellulosic

100 100 100 100 100 100 100 90 80 70 60 % 50 40 30 20 10 0 Jan-99 Feb-99 Mar-99 Apr-99 May-99 Jun-99 Jul-99 Aug-99 month 99 100

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