2.2 Fluidized Bed Combustion System

Asiakirjan nimi - Name of Document Tunniste - Identification Rev.
PROCESS DESCRIPTION CFBT-582-1 1

2.2 FLUIDIZED BED COMBUSTION
Osasto - Department Kohde - Subject Sivu - Page
Power Generation RAPP PB3 PROJECT 1 (27)

Systems CFB MULTIFUEL BOILER
TABLE OF CONTENTS
2. PROCESS DESCRIPTION.................................................................................... 2
2.2 Fluidized bed combustion system.......................................................................... 2

2.2.1 System purpose..................................................................................................... 3
2.2.2 General description of the system ......................................................................... 3
2.2.3 Design Criteria ....................................................................................................... 4
2.2.4 Technical data ..................................................................................................... 21
1 2005 - 08 - 30 T. Anttonen
0 2005 - 02 - 11 T. Anttonen
Muut. Pvm Laatinut Pvm Tarkastanut Pvm Hyväksynyt
Rev. Date Prepared by Date Reviewed by Date Approved by
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combustion system(1).doc
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© Kvaerner Power Oy, Tampere, Finland 2005



2. PROCESS DESCRIPTION
2.2 Fluidized bed combustion system



2.2.1 System purpose
The purpose of the fluidized combustion system is to burn efficiently

different kind of specified fuels. Stable combustion is attained also
with fuels having high moisture content because of the large heat
capacity of the bed material.
Small biofuel particles burn rapidly in freeboard area while larger

particles fall into the dense bed zone, where they are dried and
gasified and residual char is burned until particle size has decreased
so much that it is transported by the fluidizing gas to the upper part
of the furnace. Final combustion takes place in freeboard area (dilute
phase). Particles, which have not burnt before leaving the furnace
are separated from flue gas in the cyclones and are returned back to
lower part of the furnace. Biofuel has typically high volatile content,
which burns both in the dense bed and above it.
Coal has high heating value and because coal particles are heavy
they mainly fall into the dense bed. Coal particle size should be
within certain specified range to keep the bed temperature
reasonable. Because coal fuel density is high and volatile content
low the combustion of coal takes a long time, several minutes.
2.2.2 General description of the system
The fluidized combustion system consists of:

• Fluidized bed grate
• Fluidized bed material (sand, ash, fuel and limestone)
• Cyclones (3 pcs)
• Loop seals (3 pcs)



PI-diagrams related to the system:

T582-00017 Combustion air
T582-00018 Cyclones
T582-00021 Fluo seals
2.2.3 Design Criteria
General description
Sand, solid fuel particles, ash and limestone form the bed material
and it is fluidized with primary air and flue gas produced in the
combustion process. Sand is sieved natural sand having particle size
of 0.05 - 0.7 mm and limestone is crushed to 0.1 – 2 mm particle
size. Fluidizing air (primary air) is brought into the furnace by means
of two parallel high-pressure fans (283K005 and 283K006) via
fluidizing air nozzles welded to fins between the tubes of the water
cooled grate.
Fluidization results in an expanded fuel combustion zone, high

turbulence, intimate solids-to-gas contact and a high heat transfer
rate within the bed. The rate of fluid bed combustion is so high that
the steam output can be adjusted by changing the fuel flow
according to the load demand.



Picture 1. A view from the grate (grate tubes, fluidization nozzles

and evaporation element).
In circulating fluidized bed combustion technology fluidization

velocity is kept so high that part of bed material is elutriated with the
fluidizing gas. This leads to dense bed zone in the lower part of the
furnace (283E065) and dilute phase in the upper part of the furnace.
Most of the elutriated particles return back to dense phase zone in
the vicinity of the furnace walls where the velocity of upward flowing
gas is lower (furnace internal circulation) and almost all of the other
elutriated particles are separated from flue gas in the cyclones
(283E066, 283E067 and 283E068) and returned back to dense bed
through the loop seals (283E079, 283E080 and 283E081) (external
circulation). Only smallest particles are conveyed with flue gas
through the cyclones to the ESP (283E071 and 283E072).



From the cyclones particles drop to loop seals, located below the
cyclones. Loop seals are small fluid beds, which are used as gas
lock to prevent flue gas flow from furnace lower part directly to
cyclones. Bed material in loop seals is fluidized by separate high
pressure blowers (283K009 and 283K010) and both loop seals are
divided to two separately controlled parts. Loop seals are refractory
covered and combined to the same water circulation as cyclones.
Picture 2. Loop seal structure
Turbulence is highest in the dense phase zone resulting to good

mixing of bed material, fuel, fluidizing gas and recirculated solids
from the cyclones and thus leading to small temperature differences
between different bed areas.



Elutriated particles improve heat transfer rate considerably in the

freeboard area (dilute phase) because convectional heat transfer to
heating surface from particles is much higher compared to heat
transfer from gas. Elutriated particles also maintain even vertical
temperature profile through the whole furnace height and
temperature profile can be controlled (in restricted range) by the
amount of circulated material.
The lower furnace walls are protected with LC-refractory. The

refractory promotes an elevated combustion temperature zone to
efficiently burn high-moisture fuels and protects tubes from erosion.
Secondary air introduced into the furnace at two levels. Lower

secondary air level is mainly used only in coal combustion and upper
level in both coal and biofuel combustion. Air distribution between
primary and secondary air is determined according to fuel quality,
boiler capacity, and bed temperature.
Bed temperature depends on the quality and amount of the fuel in

the bed and is measured at twelve (12) points around the bed area.
Normally temperatures vary between 750°C to 950°C. The control of
the bed temperature is carried out by fluidization velocity and
recirculation gas system. Increased fluidization velocity increases
solids circulating rate thus lowering bed temperature. In recirculating
gas system flue gas is brought to lower part of the furnace through
separate recirculating gas openings located on the furnace walls.
Recirculated gas increases fluidization velocity without significantly
increasing oxygen content in the bed and thus decreasing bed
combustion temperature.



The bed height is controlled by measuring the pressure difference

across the lower furnace. When the pressure difference exceeds the
permissible limits, sand must be withdrawn or added to the bed. The
amount of impurities in the fuel affects strongly the need of coarse
material removal, thus having also its influence to the amount of
make-up sand. On the other hand, fuel ash content may be enough
to substitute the removed bed material and only minor amount of
make-up sand is needed.
Fluidization refers to fluidizing of solid granular material with gas. At

fluidization stage air or flue gas is blown through solid particle layer
at such a velocity that the particles separate and its properties
become similar to those of a fluid.
The state of the fluidized bed depends on the velocity of the

fluidizing gas. The fluidized bed can be solid, bubbling, turbulent or
circulating (Fig. 1).



Static Bed Bubbling Bed Turbulent Bed Circulating bed

Bed Pressure Differential
Static Bubbling and Turbulent Bed Entrained Flow

Bed
Minimum Fluidization
Velocity
Gas Velocity
Fig. 1 Types of fluidized bed.
The fluidization velocity is defined as the gas velocity calculated for

the free cross-sectional area of the grate at bed pressure and
temperature. The fluidized bed material causes a pressure drop to
the gas flowing through the bed. The pressure drop is due to the
fact that the gas sustains the fluidized particles in the air. By
measuring and monitoring the pressure difference across the
fluidized bed, it can be established whether unfluidized material,
such as stones, has accumulated in the fluidized bed.



Pressure drop of fluidized bed and grate
The curve of pressure drop in fluidized bed is presented in Fig. 2.
Curve 1 refers to the pressure drop of the bed at different fluidization

velocities:
• minimum fluidization point is equal to minimum fluidization velocity
• in a solid bed pressure drop is proportional to velocity
• in a fluidized stage pressure drop of bed is constant
Pressure drop of the grate (curve 2):

• proportional to the square of air velocity in fluidizing nozzles
Pressure drop of the bed + grate (curve 3):

• only pressure drop of the grate changes in the fluidization zone.
14000
Normal Operation Area
13000
12000
11000 3. Sand Bed + Fluidization Nozzles
10000
Pressure Differential [Pa]
9000
1. Sand Bed (55 cm)
8000
7000
6000
5000
4000
3000 2. Fluidization Nozzles
2000
1000
0
0 10 20 30 40 50 60 70 80
Fluidization Air Flow [Nm3/s]
Fig. 2 The pressure drop of fluidized bed and grate.



Change of the bed pressure drop during the operation
Effect of bed height:

• pressure drop is proportional to the static height of the sand bed
• static height can vary between 0.4 and 0.6 m
• high bed consumes more electric power, whereas low bed may
cause disturbances in fluidization
Effect of bed material coarseness:

• a small particle is fluidized more easily than a large one
• higher fluidization velocity is required for the bed becoming
coarser
• bed behavior is monitored by means of temperature
measurements
12
11
h = 0,65 m
10
Bed Pressure Differential [kPa]
7
h = 0,4 m
6
3
dp = 0,35 mm
dp = 0,7 mm
0
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9
Fluidizing Velocity [m/s]
Fig. 3 Bed pressure differential as a function of bed height and

sand particle size.



Factors affecting minimum fluidization velocity
Effect of particle size:

• Growth in particle size increases minimum fluidization velocity
according to Fig.4
• Higher temperature decreases minimum fluidization velocity up to
a particle size of abt. 2 mm.
Gas flow under minimum fluidization conditions:

• Increase in gas volume as the temperature rises, decreases the
air flow required = hot bed is fluidized more easily.
2,4
2,2
dp = 3,0 mm
1,8
Minimum Fluidization Velocity [m/s]
1,6
1,4
dp = 2,0 mm
1,2
0,8
dp = 1,2 mm
0,6
0,4 dp = 0,9 mm
dp = 0,7 mm
0,2 dp = 0,5 mm
0
0 100 200 300 400 500 600 700 800 900
Bed Temperature [°C]
Fig. 4 Minimum fluidization velocity as a function of

particle size and bed temperature.



1,2
0 °C
1,1
1
100 °C
0,9
Comparative Fluidization Gas Flow
0,8
200 °C
0,7
0,6
400 °C
0,5
600 °C
0,4
800 °C
0,3 1000 °C
0,2
0,1
0
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2 2,2 2,4
Particle Size [mm]
Fig. 5 Required fluidization gas flow as a function of

fluidization gas temperature.



Minimum and maximum fluidization velocity with hot bed
• Maximum fluidization velocity equals terminal velocity, gas

velocity, at which a particle starts to move along with the gas flow
• The size of the particle remaining in the bed depends on the
velocities to be used and the stability of fluidization (local and
temporary variation in velocity)
• In Kvaerner Power's circulating fluidized bed boilers fluidizing
velocity is chosen so that terminal velocity of most of the particles
is exceeded
• Operating range in practice is marked with lines in Figure 6.
12
u(max)
10
Fluidization Velocity [m/s]
0,5 x u(max)
8
2u(min) < u < 0,5u(max)

4
CFB
2 x u(min)
2
u(min)
BFB
0
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2 2,2 2,4
Particle Size [mm]
Fig. 6. Minimum and maximum fluidization velocity as a

function of particle size.



Change of sand particle size distribution during the operation
Bed material is getting coarser during the operation. This happens

because fuel contains always some sand and gravel. On the other
hand, bed grinds particles smaller until particle diameter is so small
that cyclone is not any more capable to separate it from flue gas. If
bed material is getting too coarse it can be seen through big
variation in the bed temperature readings. Bed material coarseness
can be controlled by increasing or decreasing coarse material
removing frequency. Bed material is good if the removed sand
contains less than 10-15 % particles over 1,2 mm.
100
NEW SAND
90
USED SAND
80
70
Cumulative % Passed
60
50
40
30
20
10
0
0,01 0,1 1 10
Particle size [mm]
Fig. 7. New sand, average particle size 0.35 mm,

particles less than 0,2 mm = 10%.
Old sand, average particle size 0.50 mm,

particles less than 0,2 mm = 5%.



Typical features of fluidized bed combustion
Advantages:
• Low combustion temperature abt. 600-1000 °C --> ash does not
melt, low emissions
• Possibility to burn several fuels at the same time
• High heat capacity of the bed material and refractories
compensates variations in fuel moisture content
• High combustion rate --> with wood-based fuels no fuel
accumulates in the bed
• Fuel is ground and mixed efficiently
• Almost all ash leaves in the form of fly ash (except extra large
particles, such as stones and iron objects)
• No temperature profile --> monitoring of fluidization
• High control rate by regulating fuel supply
• Bed condition is controlled by measuring bed temperature, bed
pressure drop, fluidizing gas flow and flue gas oxygen content
• Sulphur reduction by limestone injection to the furnace
Requirements:
• Balanced fuel feeding rate is required --> draft, O2
• Fuel particle size (max.) limited due to fluidization requirements
and bed temperature control
• Adequate coarse material removal and sand replacement ---> no
accumulation of unwanted components and material to bed



Factors affecting combustion temperature
1600
1500
1400
1300
1200
Adiabatic Combustion Temperature [°C]
1100
w = 45 %
1000 w = 50 %
w = 55 %
900 w = 60 %
800
700
600
500
400
300
200
100
0
0 0 ,2 0 ,4 0 ,6 0 ,8 1 1 ,2 1 ,4 1 ,6 1 ,8 2 2 ,2 2 ,4
A ir C o e ffic ie n t
Fig. 8 Adiabatic combustion temperature as a function

of fuel moisture content and air coefficient.



1500
1400
1300
1200
1100
Adiabatic Combustion Temperature [°C]
1000 T = 200 °C
T = 100 °C
900
T = 0 °C
800
700
600
500
400
300
200
100
0
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2 2,2 2,4
Air Coefficient
Fig. 9 Adiabatic combustion temperature as a function

of air temperature and air coefficient.



Bed temperature control
The aim is to keep bed temperature at approximately 700°C-950°C,

depending on the fuel. Bed temperature can be controlled by air
distribution, by use of recirculation gas and with the help of start-up
burner (283E059, 283E060, 283E061, 283E062, 283E063 and
283E064).
Air Distribution:
• Optimal air coefficient for each fuel; optimal bed temperature
• Increase of fluidizing air:
− decreases bed temperatures
− decreases differences in bed temperatures
• Reduced fluidizing air:

− increases bed temperatures
− increases differences in bed temperatures
• Limitations:
1) Increased air flow:
− higher O2 content after boiler (total air)
− increased electric power consumption
2) Decreased air flow:

− minimum fluidization velocity (primary air)
Use of Recirculation Gas:

• Very flexible way of control:
− allows large variations in fuel quality
• Use:
− for cooling the bed by means of mixing effect
− intensifying gasification in the bed



• Disadvantages:
− larger flue gas amounts
− increases electric power consumption
− increases flue gas outlet temperature
Use of start-up burner

• Use:
− for heating the bed in case of very wet fuel or during solid fuel
feeding disturbances
• Disadvantages:
− risk for bed agglomeration
− risk for erosion in burner



2.2.4 Technical data
2.2.4.1 Furnace
PI-diagram T582-00017
Furnace 283E065
Water-cooled membrane construction

Width mm 21080
Depth mm 8330
Height (furnace bottom-roof) m 40
Furnace reduction to grate % 60
Freeboard area m2 175,6
Grate area m2 105,36
Walls and roof

Diameter of tubes mm 60,3
Minimum thickness of tubes mm 8,0
Material SA-210-A1
Tube spacing mm 85
Evaporation elements
There are two evaporation elements (intermediate walls) inside the
furnace to give some extra heating surface and to partly support the
furnace floor. These elements are of same type of membrane wall as
furnace walls.
Material SA-210-A1
Tube spacing mm 76,2
Element width mm 4300



Grate size
Width mm 21080
Depth mm 4998
Effective bed area m2 86,6
Grate construction
The furnace bottom is formed by water cooled grate (membrane
type) which is part of the overall circulation. Water is supplied from
downcomers to the grate, which in turn feeds the rear wall.
Tube spacing mm 340
Tube material SA-210-A1
Fluidizing air nozzles pcs 2643

Nozzle spacing (staggered) mm 200 x 155/185
Bed material temperature
measurements pcs 12
Bottom ash chutes pcs 12
Fluidizing air nozzles

Type “CFB”
Material cast nozzle
Holes/nozzle pcs 12
Diameter of holes mm 11
Flow, design Nm3/s 118,4
Temperature °C 141
Pressure loss kPa 4,1



Refractory
Refractory is used for erosion protection in the lower furnace as well
as to promote an elevated combustion temperature to efficiently burn
the high moisture content fuel.
Supplier Termorak Oy
Lower part of the furnace

Walls of the furnace
Refractory height from the grate m 5,9
Thickness from the surface of
the fin mm 80
Fastening type stud welding
Material Casted wear resistant
low cement
Area m2 417,6
Evaporative elements (intermediate walls)

Refractory height from the grate m 5,9
the fin mm 80
low cement
Area m2 102



Upper part of the furnace

Inlet openings to the cyclones
-from the side mm 600
-lower edge mm 900
-upper edge to the roof
-furnace side walls mm 2890
the fin mm 80
Fastening type Y-anchors
low cement
Secondary superheater Lower part of the element

and through holes
the fin mm 60
low cement
Metal Spraying
In the furnace the critical areas where refractory ends and heat
surfaces begin are hard metal spray protected against erosion. Metal
spraying is protecting the pressure parts from circulating solids where
the edge of refractory affects disturbance to the down falling solids.
The height of the metal spraying layer is about 300 mm above the
refractory and 100 mm below it.
Supplier MH Engineering AB
Area, about m2 200



2.2.4.2 Cyclones
Cyclone 1 (left) 283E066
Cyclone 2 (middle) 283E067
Cyclone 3 (right) 283E068
The cyclones are totally water-cooled construction operating in

natural circulation loop. The cyclone walls consist of totally refractory
covered gas-tight membrane.
Number pcs 3
Diameter of cylindrical part (c-c) mm 7224

Tube material in cylindrical part SA-210-A1
Diameter of conical part mm 7224 --> 3356

Tube material in conical part SA-210-A1
Diam. of return duct upper part mm 3356

Size of return duct lower part mm 1644 x 1644
Tube material in return duct SA-210-A1



Refractory
Inside the cyclones the walls are totally protected by refractory. Also
inlet ducts from the furnace to the cyclones are refractory covered as
well as flue gas ducts from cyclones to second pass.
Ducts to the second pass are not water cooled and they have thicker
refractory layer.
2.2.4.3 Loop seals
Fluo seal 1 (left) 283E079
Fluo seal 2 (middle) 283E080
Fluo seal 3 (right) 283E081
Loop seals are small fluid beds, which are used to prevent flue gas
flow from furnace lower part to cyclones and to feed separated solids
back to the furnace. All three loop seals are divided to two sections.
Fluidization of each section is controlled independently.
Loop seals are connected to the same evaporator circulation as

cyclones.
Number of loop seals pcs 3
Size
Downleg area m2 2,7
Upleg area m2 2,7



Loop seal construction

Water cooled (evaporator)
Tube material SA-210-A1
Fluidizing air nozzles

Downleg
Number pcs 35
Nozzle spacing (staggered) mm 152,4 x 300
Material AISI 304 L
Holes/nozzle pcs 7
Diameter of holes mm 3,9
Flow, design (hot) Nm3/s 0,6
o
Temperature C 85
Upleg
Number pcs 36
Nozzle spacing (staggered) mm 152,4 x 300
Material AISI 304 L
Holes/nozzle pcs 9
Diameter of holes mm 3,9
Flow, design (hot) Nm3/s 0,6
o
Temperature C 85
Refractory
Loop seal walls and roof are totally protected by refractory.

2.2 Fluidized Bed Combustion System

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Asiakirjan nimi - Name of Document Tunniste - Identification Rev.

PROCESS DESCRIPTION CFBT-582-1 1

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 1 (27)