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SCALING-UP CIRCOFLUED
BOILERS FOR UTILITY APPLICATIONS

by

Dietmar J. Kestner
Robert A. l.isauskas
Riley Stoker Corporation
5 Neponset Street
Worcester, Massachusetts 01606

Presented at
EPRI Conference
on
Application of Fluidized Bed Combustion
for Power Generation
Cambridge, Massachusetts
September 23-25, 1992

RST-111

~~> RILEY
Riley Stoker Corporation
PO. Box 15040, Worcester, MA- 01615-0040
A Member of the Deutsche Babcock Group
 SCALING-UP CIRCOFLUID
BOILERS FOR UTILITY APPLICATIONS

by

Dietmar I Kestner
Robert A. Lisauskas
Riley Stoker Corporation
5 Neponset Street
Worcester, Massachusetts 01606

Presented at
EPRI Conference
on
Application of Fluidized Bed Combustion
for Power Generation
Cambridge, Massachusetts
September 23-25, 1992

RST-111
 SCALING-UP CIRCOFLUII ,
BOILERS FOR UTILITY APPLICATIONS

Dietmar J. Kestner
Robert A. Lisauskas
Riley Stoker Corporation
5 Neponset Street
Worcester, Massachusetts 01606

ABSTRACT

The Circofluul fluidized bed boiler is a hybrid of bubbling and circulating fluidized bed combustion
technology. Its unique design offers a number of advantages in scaling-up atmospheric fluidized bed
combustion (AFBC) systems for utility power generation. This paper addresses key scale-up issues and
describes a Circofluid utility reheat boiler design. The evolution of commercial Circofluid boiler designs
and their operating history are also reviewed.

INTRODUCTION

Atmospheric fluidized bed combustion (AFBC) combustion temperature and the ability to
has come of age. In the past decade AFBC stage the combustion process make fluidized
boilers have grown from small industrial systems inherently low-NOx emitters. The
installations to 150-200 MW operating units ability to capture sulfur in-situ by the
(1). This scale-up in size has also been introduction of sorbents directly to the
accompanied by numerous design refinements. fluidized bed has avoided the need for wet
As a result of this commercial experience, scrubbers. Perhaps the major advantage of
AFBC systems have become a viable option AFBC systems is their fuel flexibility.
for utility power generation. AFBC systems Fluidized bed boilers are capable of burning all
are capable of meeting near term utility needs ranks of coal including low quality and high-
for both new capacity and for repowering sulfur coals. Coal-fired AFBC's can also be
older plants. The following paper discusses used to co-fire a variety of combustible waste
the scale-up of the Riley/Deutsche Babcock materials.
Circofluid , AFBC system for utility scale power
generation. While these features are also important and
relevant to today's utility power generation
UTILITY BOILER REQUIREMENTS market, there are a number of design and
operating factors that differentiate utility and
The emission characteristics of AFBC have industrial boiler requirements. Some of the
made fluidized bed boilers an attractive option scale-up issues affecting utility AFBC design
for industrial boiler applications. Low decisions are as follows:
 • Plant size between 570 and 930°F (300 to 500°C;). This
is considerably lower than the 1500 to
• Reheat steam cycles 1600°F typical of most CFBC systems. Solids
captured by the cyclone are circulated back
• Load following requirements to the lower dense bed through an air.-
fluidized siphon system. The remaining
• Maintenance and reliability heating surfaces, eg, the air heater and
economizer, are arranged in the second
The Circofluid system is well suited to these boiler pass.
utility boiler requirements.
Fuel is fed to the dense bed directly or
CIRCOFLUID SYSTEM premixed with the circulating solids. The
maximum feed size for bituminous coal is
Process Description approximately 1/a to 1/z" (6 to 12 mm).
The essential features of Circofluid steam Nitrogen oxide (NOx) control is achieved
generators are illustrated schematically in through staged combustion. Preheated
Figure 1 for both reheat and non-reheat combustion air is supplied as primary air
boiler configurations. The basic design through a distributor plate to the fluidized
principles of this technology were developed dense bed and as secondary air to the
as enhancements to both bubbling and classic freeboard. Limestone for sulfur dioxide
circulating fluidized bed combustion (CFBC) (S02) control may be added with the fuel on
technologies. Circofluid boilers consist of the conveyor feed belt or fed directly to the
two boiler passes connected by cyclone dense bed through a separate pneumatic
separators. The first boiler pass, which feed system.
contains the combustion chamber, is formed
by cooled membrane walls. These walls form One of the characteristic features of
part of the evaporation system and may be Circofluid boilers is the dense bed and the
designed for either natural circulation or control of combustion temperature. In
once-through forced flow. The lower section Circofluid systems the heat transfer and
of the first pass includes the fluidizing air combustion processes are controlled
plenum, dense bed combustion zone and separately. The dense bed, in which the
freeboard. The transition from the dense coarse particles are burned, is operated at
bed to freeboard is marked by a distinct drop velocities of 13 to 15 fps. More than one
in suspended particle density. half of the fuel heat release occurs in this
zone with no in-bed cooling surfaces. Dense
A thin coating of insulating refractory on the bed temperature is controlled to a constant
combustor walls produces near adiabatic value of less than 1600°F over the entire
conditions for high combustion efficiency at load range. Cooling is provided by the flow
all loads. The resulting rise in freeboard of recirculated cyclone solids or ash. The
temperature is also conducive to the thermal flow of circulated ash is controlled by air
destruction of trace gas species such as flow to the siphons. Heat absorbed by the
nitrous oxide (N 20). Low particle densities recirculated ash is transported through the
leaving the freeboard permit conventional freeboard and transferred to the convective
heating surfaces to be placed above the heating surfaces upstream of the cyclone. As
freeboard before the cyclones. Convective a result of this design arrangement,
heating surfaces such as superheater and approximately 80% of the total heat duty of
reheaters, therefore, can be located in the the boiler occurs in the first boiler pass. An
upper portion of the first pass. Flue gas external heat exchanger is not required.
entering the cyclone separators is cooled to
 rience scale-up of Circofluid boilers from 25 to 150
Riley and Deutsche Babcock (DB) have MW. Circofluid boiler designs have also
been designing commercial fluidized bed been developed for capacities up to 300
steam generators since 1978. Currently, MW.
there are over 30 Riley or DB operating
plants and facilities worldwide. The first There are other factors, in addition to , cross-
commercial Circofluid unit went into sectional area, that influence scale-up. As
operation in 1988 at the ROmerbrOcke shown in Figure 2, the boiler portion of the
cogeneration plant in Saarbrilcken, Germany Circofluid system does not differ from a
(2). Riley installed the first Circofluid boiler conventional pulverized coal boiler.
in the U. S. in 1990 at the Archbald Power Therefore, pressure part components and
Cogeneration Facility located near Scranton, auxiliaries such as fans, air heater and
PA (3). Overall, 24 Circofluid units have baghouse are not limiting factors in scale-up.
now been sold. Eight units are in operation This is true of even process components.
with 16 soon to come on-line. A listing and Since the solids recycle temperature is. lower
description of these units is given in Table 1. than other CFBC systems, the cyclones and
The units now in operation have achieved recycle system are much smaller for
NOX emissions of 0.15 lb per million Btu or Circofluid boilers.
less without post combustion control. Sulfur
retentions or S0 2 removal efficiencies of Table 2 summarizes the progression in size
90% or more at Ca/S molar ratios of 2 to 3 of Circofluid boilers. Several commercial
have also been demonstrated (2, 3). Overall plant designs are compared with a reference
combustion efficiencies have exceeded 99% 150 MW design fired with Illinois No. 6 coal.
The largest commercial Circofluid installation
has been built for the German utility
SCALE-UP ISSUES Rheinisch-Westfglisches Elektrizitatswerk
(RWE). This 80 MW lignite-fired power
Plant Size station located near Cologne, Germany is
One of the major considerations in scaling currently undergoing start-up. Since the fuel
Circofluid and other fluidized bed is a low rank lignite with moisture content of
combustion systems to utility scale systems of up to 60%, the dimensions of the RWE unit
100 MW or more is the impact on the correspond to a bituminous coal-fired unit of
fluidization and combustion. Dense bed more than 140 MW in size.
mixing is important for both fuel, sorbent
and ash distribution. The penetration depth Reheat Steam , cles
of secondary air into the upper combustor or Reheat steam cycles do not require process
freeboard is another important design design changes to Circofluid boilers. The
consideration. Both of these factors are upper combustor solids particle density in
directly related to the cross-sectional area of Circofluid systems is only 10 to 20% that of
the combustor. classic CFBC systems. As a result, reheat
surface can be placed in the upper portion of
Because of its higher fluidizing velocity and the first boiler pass along with other high
staged air system, Circofluid boilers have pressure heat transfer surface. A typical
smaller cross-sectional areas than bubbling Circofluid reheat boiler design is shown in
bed systems of similar capacity. Higher Figure 3. The heat transfer characteristics
fluidizing velocities promote the mixing of are well known for this reheater
fuel, ash and sorbent in the dense bed and configuration and are identical to high
reduce the number of required fuel feed pressure superheater and economizer
points. Figure 2 illustrates the resulting surfaces.
The Circofluid boiler arrangement is very hours following a cold start and full load after
similar to a pulverized coal tower boiler approximately 3 hours.
design. This similarity is illustrated by the
comparison given in Figure 4. The
complexity of adding an external heat Maintenance and Reliabilit y
exchanger (EHE) in the solids recycle loop Maintenance and reliability are of prime
to accommodate reheat surface has been concern to utility boiler operators. Outages
avoided. due to refractory failure have been a major
problem for many operating industrial
Load Following fluidized bed boiler systems. Here again, the
In the years ahead U. S. electric utilities are low refractory content of Circofluid boilers
likely to experience a growing need for offers an advantage by reducing the risk of
cycling as well as baseload capacity. A forced outage due to refractory failure.
substantial need for peaking capacity already Refractory structural failures due to thermal
exists in some parts of the U. S. Circofluid shock are much less likely in a low weight
systems have the same load response and refractory system. Thin silicon carbide and
part load characteristics as pulverized coal- alumina tiles are used in the furnace and
fired boilers. cyclones. Tiles rather than a monolithic
refractory coating were first employed by
Some of the factors that have limited the load Riley on its anthracite culm fired unit at
response of industrial fluidized boilers is their Archbald, PA (3). The dense bed and
large refractory content and large inventory of freeboard waterwalls were lined with 1 1/z" (40
recycle solids. Circofluid boilers use mm) tiles. This tile system has proven to be
substantially less refractory than other CFBC hard, durable and easily maintained.
systems. Only a thin coating of refractory is Erosion can also be a problem in fluidized
required over the dense bed and freeboard bed boiler systems and can lead to reduced
waterwalls to control erosion and heat unit availability. This is true even for CFBC
absorption. The low cyclone inlet temperature systems without lower furnace "in bed" tube
also significantly reduces the amount of surfaces. As shown in Figure 6, erosion is a
cyclone lining required. Figure 5 compares strong function of gas velocity as well as
the Circofluid cold cyclone refractory design solids particle density, the abrasive nature of
with other CFBC hot cyclone refractory the ash, and the arrangement of heating
designs. Lower hot face temperatures and surfaces. Process parameters place the
smaller temperature difference across the Circofluid system in the pulverized coal-fired
refractory eliminate the cyclone as a limiting boiler operating range and far below that of
factor during cold start-up of Circofluid traditional CFBC boilers. The potential for
boilers. general, as well as localized, erosion in
Circofluid boilers is much lower. We believe
Because of its low refractory content and low this is an important feature for meeting
recirculating solids inventory, the load utility availability and reliability criteria.
response characteristics of Circofluid boilers
are similar to conventional pulverized coal- SUMMARY
fired boilers. The maximum heat up rate is
generally limited by drum thickness and the Circofluid boilers are well suited for large
design of pressure part components. Load power station operation. A new utility-sized
changes of 5 to 6% per minute have been unit operating at a utility site is now coming
achieved on several European units. These on-line in Europe. Riley has developed
operating units have also demonstrated that standard Circofluid boiler designs for a full
minimum load can be achieved within 2.5 range of applications including utility boiler
 systems. Units of 150 MW and larger in size are comparable to pulverized coal-fired
have been designed for reheat steam cycles. boilers. Commercial operating plants have
These designs build upon our recent demonstrated their performance under
commercial experience and can be applied to stringent environmental and operating
both high rank, high sulfur coals as well as requirements. Circofluid boilers have proven
lower grade fuels of variable quality. The to be reliable and capable of following utility
operating characteristics of Circofluid boilers operating cycles.

REFERENCES

1. J. Makansi. "Boilers, Combustion Systems, and their Auxiliaries." Power,

vol. 136, No. 6, June 1992, p. 51.

2. K D. Tigges and D. Kestner. "Experience with the Commissioned Operation of

the SaarbrOcken Circofluid Boiler." In Proceedings of the 1989
International Conference on Fluidized Bed Combustion . Vol 1, 1989,
pp. 625-631.

3. D. J. Kestner. "Operating History of a 20 MW Culm-Fired Circofluid Boiler."

Presented at the International Power Generation Conference, 91-JPGG-Pwr-41,
San Diego CA, October 1991.
 SUPERHEATER
33

EVAPORATOR
227

MALLS
FIRST BORER PASS
TUBES _
I BACK
PASS
TTUBES
I LOSS

WALLS
FIRST BOILER PASS LASS

I
TUBES TUBESI
_EVAP I EVAP SUPERHEATER REHEAT ETON AIR EVAP EVAP SUPERHEAT'? ETON [A M
0 10 20 30 40 so so 70 so POX 100 10 20 30 40 so so m go 90% 100
HEAT ABSORPTION
HEAT ABSORPTION

a. Reheat Design b. Non-Reheat Design.

Figure 1. Circofluid Process Diagrams for Reheat and Non-Reheat Boiler Designs Fired with Bituminous
Coal.
25MW 50MW 75MW 8oMW 1 50MW
( NO REHEAT ) ( WITH REHEAT ) ( WITH REHEAT )

Figure 2. Scale-up of Circofluid Boilers From 25 to 150 MW.

--

Figure 3. Typical Circofluid Reheat Boiler.

 P C FIRED a DIL ER
CURCEW-LMU© €10 I L r_ R

Figure 4. A Comparison of Circofluid and Pulverized Coal-Fired

Boiler Designs.

HOT STEEL CASING

2S0'F

I 30'F UL Z

1 600' F - W00' F 7SO'F-900 7

1 600 7-1700 7
EROSION PROTECTION &-EROSION PROTECTION
REFRACTORY REFRACTORY
THERMAL INSULATINC
A EROSION PROTECTION
REFRACTORY

REFRACTORY REFRACTORY REFRACTORY

AT - 1950 7 - 1450 7 AT - 9507 - 11507 LT - 207 - 257

HOT NON-COOLED CYCLONE HOT STEAM-COOLED CYCLONE COLD NON-COOLED CYCLONE

Figure 5. Cyclone Refractory Comparison.

 Erosion E I s a function of

v3.5
E=f, • fz • c•

• Gas velocity v
• Solids concentration
• Ash characteristics f,
• Surface arrangement and
gas flow pattern fz

CFBC

I PC. Carolina Type

Clrcolluld

I PC. Tower Type I

I I I I I I IIII I I I I I
1 2 3 4 6 10 20 ]0 40 60 100

Relative Erosion Potential

Figure 6. Erosion Potential of Circofluid Versus Other

Coal-Fired Boilers.
 Table 1

Circofluid Installation List.

Client and Location of Plant Number Steam Steam Stcnm Fuel Year of
Capacity Pressure 'Temp Commission.
kpph psig 'F
Deutsche Babcock AG
Fricdrichsfcld/Germany 1 7 MBIUAtr -- - C/US 1985
Energieversorgung
Offenbach AG 2 244 1,155 995 C 1988
Offenbach/Germany
Stadtwerke SaarbrUckcn AG
14KW R6mcrbrocke 1 330 1,640 995 C/S 1983
SaarbrUckcn/Germany

Kawasaki Heavy Industries

Akashl/Japan 1 3 MB11J/hr -- -- C/US 1988
Deutsche Solvay-Wcrkc
Rheinberg/Germany 1 1,13 1,700 977 C 1989
Archbald Power Corporation
Pennsylvania/USA 1 200 1,335 995 S 1990
GEW Min AG - HKW
Mcrheim 1 114 1,230 977 L 1991
Cologne/Germany
CEZ - HKW Trmice V
Trnticc/CSFR 2 353 1,960 1,004 L 1993
Rhelnisch-Wcstf5liscltcs
Eiektrizitdtswcrk AG 1 640 1,155 941 L 1992
Goldenbcrg-Werk/Gennany
Hal Cheng lleat & Power
Llaoning/China 3 165 780 842 C 1993
Bayer AG
Krefeld-Uerdingen/Germany 1 300 1,870 1,004 C/L 1992
Zhang Zhou
Fujian/China 3 165 570 842 A 1993
Suedzucker AG
Zcitz/Germany 1 220 1,350 999 L 1993
SEP Novaky A
Novaky/CSFR 1 276 1,380 1,004 L 1994
Luoyang
Henan/China 2 287 I 780 842 C 1994
Jin-Zhou 842
Llnoning/China 3 165 780 C 1994

TATA Chemicals Ltd.

Mithopur/fndia 1 441 1,620 1,058 C/L 1994

A = Anthracite
C = Bituminous Coal
L = Lignite
S = Special Fuels
 Table 2

Circofluid Boiler Scale-Up Parameters.

UNIT ARCHBALD BAYER SAARBRUCKEN RWE 150 MW+

Design Fuel Culm Anthracite Bituminous Lignite ' Bituminous

HHV, Btu/lb 4,200 60: 14,000 8 9 600 4,200 11,250
Ash, 6 36 8 12
8 50
Moisture, 5;, 6 12
Sulfur, 0.3 0.8 1.2 . 0.5 3.5

Steam Flow, lb/hr 300,000 330,000 640,000 1,005,000

20,Fuelowb/hr 25,000 56,000 220,000 120,000
300,000 59,0FlueGasb/hr 340,000 450,000 1,140,000 1,320,000

Furnace Bottom Plan, ft x ft 7 x '26 9 x` 20 12 x 20 _ 17 x 44 18 x 47

Freeboard Plan, ft x ft 14 x 26' 20 x 20 21x20 32x44 30x47
Number of Feed Points 8/4*

Number of Cyclones 2 2 4 4 4
Cyclone Diameter, ft 10 11 8 12.5 13

* Fuel feed on one side only

Reference Plant Design