Beruflich Dokumente
Kultur Dokumente
Stephen J. Goidich Foster Wheeler Energy Corporation Perryville, New Jersey, USA ABSTRACT
Foster Wheeler has been supplying circulating fluidized bed boilers to industrial clients for over two decades. The technology has now evolved into large scale utility size units with units as large as 250 MWe in operation, two (2) 300 MWe units in the construction phase and nearing start-up, and designs developed for units as large as 600 MWe in size. The successful operating experience of conventional CFB boilers with cyclone separators, as well as the more recently developed Compact CFB boilers, have demonstrated the ability to scale-up unit size to meet the requirements for utility power generation. Technology improvements are continually being developed and incorporated into the designs to enhance performance, increase operational flexibility, and improve reliability in a cost effective way. Described in this paper is the operating experience of current large scale conventional and Compact CFB boilers, the design and status of the next generation of utility CFB boilers which are scheduled to go into operation in the near term, and what lies ahead with integration of the state-of-the-art supercritical oncethrough utility boiler technology with CFB boiler technology.
1. INTRODUCTION
As shown in Figure 1, commercialization of CFB technology began back in the late 1970s. Since that time there has been a steady scale-up into the utility boiler size range with implementation of many new design features to increase reliability and operational flexibility to meet utility boiler standards. Examples of these enhancements include : o Steam-cooled solids separators and cross-over ducts in combination with advanced refractory systems to minimize refractory maintenence and enhance unit performance o In-duct start-up burner systems to shorten start-up times and save fuel o Fluidized bed ash coolers to reliably discharge spent bed material and recover heat o INTREXTM heat exchangers to increase operational flexibility to adjust furnace temperature and extend the steam temperature control range o Reheat steam bypass system for reliable and cost effective reheat steam temperature control During the early 1990s, a new generation of CFB boilers was introduced by Foster Wheeler, the Compact CFB (see Figure 2). Experiences of conventional CFB combustors was applied in the scale-up of Compact units. Presently, scale-up of Compact boilers has reached the maximum capacity level of todays conventional CFB boilers. As shown in Figure 1, the more rapid scale-up of the Compact CFB was possible UNIT CAPACITY (MWe) because of experience and lessons learned in 350 scale-up of the conventional CFB boilers. The progress made in the development of CFB technology can be seen in the rehabilitation of Turow Power Station which is located in Bogatynia, Poland. Old pulverized-fuel boilers were replaced by three(3) conventional 235 MWe CFB boilers, which are currently in operation, and three(3) 262 MWe Compact CFB units which are in the fabrication/construction phase and are scheduled to go into operation starting in late 2002. Operating experiences of Units 1,2, and 3, firing brown coal, have proven the
VASKILUODON TUROW 5
250 200
KAJAANI
TRI-STATE
LEYKAM
PIHLAVA
50 0 1970
1975
1980
1985
1990
KUHMO
1995
CO
100
PILOT PLANT
PILOT PLANT
KOKKOLA
MP AC T
150
THAI KRAFT
AL ON TI EN NV CO
NOVA SCOTIA
300
TUROW 1
NPS
2000
JEA
2005
technology to be a mature and advanced solution at the utility scale meeting the requirements of high reliability, performance and economy. Further improvements will be achieved in Units 4, 5, and 6 using Compact boiler technology with integrated cooled panel structures for the furnace, solids separator, and INTREX heat exchangers. Experiences from the scale-up and success of the Compact technology make it possible to provide the most advanced configurations for the utility scale CFB boilers. With the current status of CFB units, commercially feasible options for power production are available in the capacity range of 300 600 MWe. Further advantages in plant efficiency will be achieved by applying once-through steam cycle with supercritical steam parameters.
Steam Output Capacity, MWt Steam Flow, t/h (SH/RH) Steam Pressure, bar (SH/RH) Steam Temperature,C (SH/RH) Fuel Moisture, wt% Ash, wt% Sulfur, wt% HHV, kcal/kg Emission Limits NOx, ppm SO2, ppm
210 140
Before the units were turned-over to the customer, each had to complete a rigorous 30-day trial run program. All plant performance guarantees had to be demonstrated including the requirements of the Union for the Coordination of Production and Transmission of Energy (UCPTE) which is the European utility power plant standard that contains strict guidelines for load ramp changes and plant dispatching (Ref. 2). These requirements included: 72 hour full load test +/- 4% MCR load ramp between 40% and 100% +/- 5% MCR step load changes load rejection to house load followed by resynchronization in a specified time load run back to 50% on loss of HP heaters, fans, condensate or primary cooling water pumps minimum time to reach full load from cold, warm, and hot restart conditions
All units met or exceeded the trial run requirements, demonstrating that large scaleup CFB boilers can meet utility market requirements for cycling and that the scale-up of the furnace solids circulation loop beyond previous experience was successful. Furnace Height, m Width, m Depth, m Cyclones 42.5 21.1 9.9
Boiler No. Steam Output, kg/s Boiler Efficiency, % Thermal Output, MWt Gross Power, MWe Heat Rate, kJ/kWh Limestone, Ca/S Emissions: NOx, g/GJ SOx, g/GJ Dust, mg/Nm3 Noise, dBA
The JEA Northside demonstration project involves repowering the existing steam turbine at Unit 2 with a 297.5 MWe CFB boiler. The DOE cost sharing for the project includes two years of demonstration test runs during which Unit 2 will be operated on several different types of coal and coal/petroleum coke blends. Unit 1 is also being repowered with an identical CFB boiler which will be privately financed. Construction began in mid1999. Unit 2 is scheduled for initial operation in January 2002; Unit 1 will follow three months later.
Table 4 lists the steam capacity, design fuels, and emission limits for each boiler. The basic dimensions for the units are listed in Table 5. Figure 4 illustrates the unit design. Key design features of the boiler include a single, watercooled furnace, steam-cooled cyclone separators, INTREXTM heat exchangers, a parallel pass heat recovery area (HRA), in-duct start-up burners, fluidized bed ash coolers, and an air swept fuel feed system. A detailed description of these design features can be found in Reference 3. Furnace Height, m Width, m Depth, m Cyclones Number Diameter Table 5. JEA Dimensions 3 7.3 35.1 26.1 6.7
Steam Output Capacity, MWt Steam Flow, t/h (SH/RH) Steam Pressure, bar (SH/RH) Steam Temperature,C (SH/RH) Fuel Moisture, wt% Ash, wt% Sulfur, wt% HHV, kcal/kg Emission Limits NOx, mg/Nm3 SO2, mg/Nm3
220 130
Emissions Limits NOx, ppmvd@6%O2 SO2, ppmvd@6%O2 Table 6. NPS Design Parameters
180 450
34 339
The boiler configuration for these units (see Figure 5) was the first to include a pair of double vortex Compact Separators on both the furnace front and rear walls. Internal furnace heat transfer surface in the form of superheat and reheat omega panels were included to achieve the desired furnace operating temperature. 4.2 Turow Units No. 4,5,6 The two (2)-sided Compact CFB boiler arrangement developed for the NPS project was the basis for scale-up to the 262 MWe Turow Units 4,5, and 6 configuration which is shown in Figure 6. The design fuels, emission and performance requirements defined for Units 1, 2, and 3 are the same for Units 4, 5, and 6 except for the steam conditions defined in Table 6.
Boiler Thermal Power, MWt Gross Output, Mwe Net Output, Mwe Main Steam Flow, kg/s Main Steam Pressure, bar Main Steam Temperature,C Reheat Steam Flow, kg/s Reheat Steam Pressure, bar Reheat Steam Temperature, C
HOIST
STEAM DRUM
RH II
CONVEYOR BRIDGE
RH I
ESP
AIR PREHEATER
Figure 6. Turow Unit No. 5 An enhancement included in the Turow Compact units are the eight (8) INTREX cells which include intermediate and finishing superheater heat transfer surface; four (4) cells per front and rear wall positioned to accommodate a well distributed arrangement of fuel feeders . The ability to control the rate of solids flow through the INTREX tube bundles provides increased operational flexibility for furnace and steam temperature control. The layout of the NPS and Turow units includes Compact separators on both sides of the furnace and a series pass heat recovery area with the FW reheat steam bypass arrangement for reheat steam temperature control. Project specific details will dictate if a one-sided Compact separator design is required and which type of reheat steam temperature control system will be used (reheat steam bypass, parallel pass HRA with gas flow proportioning, or INTREX reheat with solids and fluidization control.
2 1 0
Historically, conventional pulverized coal (PC) OTU units have been designed for high steam/water mass flow rates through the furnace enclosure tubes to minimize peak tube metal temperatures and limit the differential temperature between adjacent tubes. To provide high mass flow rates, the evaporative furnace walls were designed in a multiple pass or spiral arrangement. While meeting the thermal/hyraulic requirements for reliable operation, these arrangements require increased auxiliary power because of the pressure loss resulting from the high mass flow rates and also, some increased mechanical complexity because of the pressure part circuitry.
5.1 BENSON Vertical Technology The current state-of-the-art technology for once-through boiler design is the BENSON Vertical technology developed by Siemens. This technology offers significant functional and economic advantages for OTU power generation such as: Low Pressure Loss. A single upflow evaporative pass with low mass flow rates results in low steam/water pressure losses and therefore, low auxiliary power consumption.
ES SU RE
Simple Support System. With vertical tubing, the furnace enclosure tubes are self supporting and do not require special support straps to account for thermal growth. Minimum Tube Temperature Unbalance. With low mass flow rates, the strongest heated tubes gets the highest flow rate because of a natural circulation flow characteristic. Full Variable Steam Pressure. Since a single upflow evaporative pass is used, full variable pressure over the operating load range can be used to better match steam and turbine blade temperature for cycling operation.
In order to incorporate these advantageous features into Foster Wheeler conventional and CFB boilers, FW became a licensee of the BENSON Vertical technology. (A more detailed description of the BENSON Vertical technology and its integration with the Compact CFB boiler can be found in Reference 7.) 5.2 600 MWe OTU CFB Using the BENSON Vertical technology, Foster Wheeler has developed a design for a 600 MWe supercritical CFB boiler which is illustrated in Figure 9. The design is similar in configuration to that described for the Turow Units No. 4,5,and 6 in that includes a double-sided arrangement with a pair of double vortex Compact Figure 9. 600 MWe CFB Boiler Separators on each side of the unit, INTREX heat exchangers (8), and a series pass HRA with reheat steam bypass system for reheat steam temperature control. The development and analysis of the 600 MWe unit has shown that there are no technical reasons to limit the boiler size to the existing capacities and that the benefits of CFB technology can be achieved in large scale utility size units.
6. CONCLUSIONS
The successful operation of large scale-up CFB boilers, such as Turow 1,2,and 3, has demonstrated the operational flexibility and reliability required for utility power production. The design enhancements incorporated in the soon to operate JEA Units 1 and 2, and Turow 4,5,and 6 will further demonstrate the capabilities of CFB technology. Future integration of supercritical once-through boiler technology with CFB technology will provide the best combination of features for efficient, cost effective, and environmentally safe power production.
7. REFERENCES
1. S.J. Goidich and T. Hyppanen, Foster Wheeler Compact CFB Boilers for Utility Scale, 16th International Conference on Fluidized Bed Combustion, Reno, Nevada, May 13-16, 2001. 2. J. Jablonski, W. Nowak, T. Ozimowski, Rehabilitaiton of Turow Power Plant, The Sixth Foster Wheeler Fluidized Bed Customers Conference, San Diego, CA, August 18-20, 2000. 3. R.A. Dyr, J. Hebb, and S.L. Darling, The JEA CFB Demonstration Project: An Update, 16th International Conference on Fluidized Bed Combustion, Reno, Nevada, May 13-16, 2001., 4. S.J. Goidich, T. Hyppanen, K. Kauppinen, CFB Boiler Design and Operation Using the INTREXTM Heat Exchanger, 6th International Conference on Circulating Fluidized Beds, Wrzburg, Germany, August 2227, 1999.
5. P.K. Gounder, J.P. Risse, Circulating Fluidized Bed with Reheat, Joint Power Generation Conference, Atlanta, FL, October 19-21, 1992. 6. K. M. Retzlaff and G. Schlottner, Steam Turbines for Ultrasupercritical Power Plants, POWER-GEN 98 Europe, Milan, June 9-11, 1998. 7. S. J. Goidich, Integration of the BENSON Vertical OTU Technology and the Compact CFB Boiler, POWER-GEN International 2000, Orlando, FL, November 14-16, 2000.