CFBC DESIGN COMPARISION

Comparison with other Design

Parameter
1.Solid particle separation

LurgiLenges ( A)
External uncooled Hot cyclone

U- Beam (B)
In furnace & external U Beam( many rows) Uncooled, u beams bank suspended from top, inside the flue gas path, outlet of combustor

CVL (C)
External water cooled hot cyclone.

2. Solid separator construction

Uncooled, Hot, Mechanical type large cyclone with 300-350 mm thick refractory lined

Water cooled membrane type , mechanical construction with 25-50 mm refractory

Comparison with other Design

Parameter
3.Expansion of Solid particle separator

LurgiLenges ( A)
Hot cyclonemoves upward., Combustor moves downwards & requires very large special expansion joint Critical

U- Beam (B)
In furnace & external U Beam. No issue

CVL (C)
External water cooled hot cyclone.- Both combustor & Cyclone moves downward together- no issue

4.Supports for separator

Bottom supported

Suspended from top of extended wall. Lot many opening on the roof.

Top supported

Comparison with other Design

Parameter
5.Solid particle separator efficiency

LurgiLenges ( A)
High

U- Beam (B)
Relatively less than Hot cyclone. It largely depends on recirculation effect at Ubeam lower part Recirculation is falling at the high elevation in the combustor. Sufficient time is not given for combustion of particles which are reentering

CVL (C)
High

6. Solid recirculation location

Bottom of combustor. But portion of solids are cooled in the FBHEs

All collected solids particles are entering in the lower portion of combustor& have more time in combustor

Comparison with other Design

Parameter
5.Solid particle separator shape retaining

LurgiLenges ( A)
Hot cyclonemaintenance on the refractory

U- Beam (B)
U Beams may undergo erosion & possibility to get twisted leading to out of position and gas leaning affecting ash collection efficiency. Needs inspection

CVL (C)
Water cooled hot cyclone rugged construction being almost circular. Small refractory touch-ups.

6. Location of separator

External to combustor

In furnace External to combustor combustor beams uncooled may face erosion .

Comparison with other Design

Parameter
7. Success of CFB process

LurgiLenges ( A)
High

U- Beam (B)
Relatively less than Hot cyclone due to collection effiency.

CVL (C)
High

8. Dust loading at second pass

1.0

More than 1.7 as the ESP first hopper ash is re-injected into the combustor

1.0

Design superiority
Due to above listed differences CVL CFB design is superior to U- Beam. Our reference list is the testimony for the design superiority in such a short span of introduction.

Lurgi

Additional re-injection is done.

CFBC DESIGN WITH COLD CYCLONE

UPPER FURNACE / HORIZONTAL PASS IS PACKED WITH HTS (SUPER HEATER, EVAPORATOR & ECONOMISER

TOP BANK) HIGH CONCENTRTAED SOLIDS PAASING OVER ABOVE HEAT TRANSFER SURFACES THE LIFE OF HEAT TRANSFER SECTION (HTS) IS INFERIOR TO HOT CYCLONE THE VELOCITY IN THIS DESIGN IS LOWER THAN VELOCITY FOLLOWED FOR CFB TECHNOLOGY COLD CYCLONE IS OPERATING AROUND 450 C GAS TEMPERATURE. THE COLLECTION EFFICIENCY IS INFERIOR TO HOT CYCLONE OPERATING AROUND 850 TO 900 C AS THE COLD CYCLONE IS BOTTOM SUPPORTED & THE RETURN LEG TO THE CUMBOSTOR IS AT 45O C, THERE IS A DIFFERENTIAL THERMAL EXPANSION BETWEEN COMBUSTOR & CYCLONE / RETURN LEG MORE UNBURNT CARBON LOSS DUE TO REDUCED

COLLECTION EFFICIENCY ( COLLECTION EFFICIENCY WILL

BE SLIGHTLY BETTER THAN BUBBLING BED DESIGN)

THE LIFE OF HTS CONSIDERING HIGH ASH % IN INDIAN COAL IS EXPECTED TO BE LOW.

Typical CFBC Boiler

WATER COOLED HOT CYCLONE