Boiler Normal Operation

The CFB thermal performance (load, power consumption, furnace temperature, combustion efficiency,
gaseous emissions etc.) is determined by conventional combustion process variables (fuel properties,
excess air, air/fuel-ratio etc.) and additionally it is strongly dependent on the solids mass (inventory)
distribution within the system, size distribution of the solids, and solids flows within the system and
leaving it.

CFB operation variables

Fluidized bed behavior (“bed quality“) mainly is characterised by the amount of total bed inventory and
the particle size distribution and effects combustion efficiency, furnace temperatures and flue gas
emissions. The bed material particle size distribution is a result of the fuel feed size and cyclone
efficiency and particle size degradation during fluidization and circulation through the primary loop.

Bed material particle size distribution

The bed material particle size distribution is a result of the following variables: fuel feed size, sand
particle size, use of additives like Limestone, cyclone efficiency and particle size degradation during
fluidization and circulation through the primary loop. Cyclone efficiency is predetermined by cyclone
design, ash size degradation is predetermined by fuel/ash characteristics, both are therefore no
controllable operating variables.

The bed ash particle size distribution primarily can be controlled by fuel feed size distributions, the sand
particle size and the use of additives.

Changes in the bed ash particle size distribution have a significant impact on boiler operation, bed ash
particle size distributions with too large coarse fraction will reduce heat transfer to heating surfaces and
high bed temperatures will result. Ash that is too fine also tends to result in high furnace temperatures,
because it cannot be kept in the primary loop, whereas a too high amount of circulating material would
cause too low bed temperatures.

100

90

80

70

60

50

40

30

20

10

Excess Air
0
1000
100

1
Excess air for combustion is an important operating variable for all types of boilers. The higher the excess
air, the lower the boiler efficiency and higher the power consumption. Minimization of excess air level is
limited by combustion efficiency (combustion efficiency drops in case of too low excess air levels due to
the lower driving force for O2 to react with fuel combustibles) and flue gas emissions (CO emissions will
increase).

Primary/Secondary Air Ratio

 Combustion air is split between primary and secondary air levels to provide staging of air for lower
NOx emissions.
 This also reduces power consumption since secondary air can be supplied at a lower pressure than
primary air.
 Primary air is actually split between the fluidizing grid and upper primary air nozzles.
 There is functionally no difference between these two, except that it allows the nozzle grid to be
designed for a higher pressure drop at low loads, which consequently improves air distribution and
minimizes back sifting of ash through the grid.
 Increasing primary air has the effect of reducing bed temperature, primarily by increasing solids
circulation in the furnace. Higher gas velocities in the lower part of the furnace as a result of
increased primary air flow entrains more and larger particles and carries them out of the uncooled
lower part into the cooled upper part, leading to an increased heat transfer to the water walls and the
superheater 2 panels.
 The two major drawbacks of increased primary air flows are:
 Increased power consumption
 Higher NOx emissions.

Emissions

1. NOx Emissions

 Fuel type and reactivity: The fuel nitrogen content and the distribution into volatile nitrogen and
char nitrogen determines NOx emission. The conversion rate of volatile nitrogen to NOx is generally
higher than that of char nitrogen. The rate of volatile release can be influenced by fuel particle size
(fine particles lead to rapid volatile release - N as NH3, HCN,.. - and higher NOx emissions).
Conversion of char nitrogen to NOx is much less than conversion of volatile nitrogen. In presence of
char NOx can be reduced to N2.

 Bed temperature: Due to higher efficiency for conversion of volatile nitrogen to NOx and a
reduction of char loading and CO concentration in the combustor at higher bed temperatures NOx
emission increases with increasing temperatures.

 Cyclone exit temperature: The SNCR Process reaches a good efficiency at a cyclone exit
temperature of approximately 850°C

 Excess air and air distribution: Air staging creates fuel rich zones in the lower part of the furnace,
which limits oxidation of nitrogen and enables reduction reactions. Higher excess air ratios increase
availability of oxygen and therefore increase NOx emissions.

2
 Limestone Concentration: An excess of limestone promotes formation of NOx

2. CO Emissions

 Bed temperature: CO emissions decrease with increasing bed temperatures.

 Excess air: Lowering of excess air may increase CO emission.

 Fuel distribution, fuel type, particle size: High volatile content and small particle size would
release large quantities of volatiles in localized area. With insufficient availability of O2 in this area
and with too less residence time in the furnace this would lead to increased CO emission. Sufficient
feed points, high impulse in feed areas and sufficient air ports nearby the feed points as well as
sufficient residence time ensure good burnout.

 Stable fuel feeding: Above measures ensure low base CO levels. To avoid also peaks the fuel
feeding has to be stable and even.

3. SO2 Emission:

 Sulphur content of the coal

 Ash composition of the coal (The retention of sulphur by the coal ash depends on alkali and earth
alkali concentration in the coal ash)

 Porosity of the limestone

 O2 concentration in the flue gas: The retention of SO 2 increases with increasing O2 concentration in
the flue gas

 Bed temperature: To enable calcination and initiate the sulfur retention reactions of the limestone, the
furnace temperature has to be above 700°C.

 Residence time of the limestone in the combustion chamber. Therefore the limestone has to have the
proper grain size distribution

 The limestone feeding system supplies limestone directly into the furnace. The variable speed rotary
feeder meters the limestone in a fixed relationship to the present coal load. Fine adjustment to this
control is done automatically depending on the flue gas SO 2 emission.

Boiler Chemistry

 The boiler is protected from water-side corrosion by a magnetite layer

 The magnetite layer is protected by chemical dosing

 Volatile alkalization (dosing) with ammonia

 Solid alkalization (dosing) with lithium hydroxide (LiOH)

3
 The volatile alkalization (dosing) minimizes corrosion in the feed water and steam system, the solid
alkalization protects the evaporator against accumulating impurities and the drop in pH caused by
them.

Furnace Pressures

 DP-Grid (dPG): shows the pressure difference over the nozzle grid, indicating the condition of the
nozzles (e.g. plugged nozzles would - at a certain load with a certain fuel mixture – lead to an
increased differential pressure).
 DP-Bed (dPB) shows the differential pressure in the dense bed. An increasing value at a certain load
with a certain fuel mixture indicates that coarse material is accumulating on the nozzle grid.
 DP1 (dP1) shows the differential pressure in the lower part of the furnace and monitors the bed
inventory in the lower furnace.
 DP2 (dP2) shows the differential pressure in the upper part of the furnace. This differential pressure
is an indicator for the amount of circulating material which determines the heat transfer to the water-
and wingwalls. Higher differential pressures – again at a certain load with a certain fuel mixture –
indicate higher circulation rates, which result in a higher heat transfer to the heating surfaces and
consequently to lower bed temperatures.
 DP-Total (dPT) shows the differential pressure of the entire furnace and indicates the total bed
inventory. The optimum for dPT is somewhere between 35 and 50 mbar (depending on actual load
and fuel mixture). Total bed pressures higher than optimum do not bring any benefits in terms of
combustion or emissions performance, while increasing power consumption of the PA fan. A further
result of operating with too high bed pressures is that restart of start-up burners after a trip can be
difficult, because of the inability of the flame detector to see the burner flame with the extra ash
swirling around. Additionally problems with sand back sifting to the wind-box during low load
operation may occur.

Parameters Value
1HBK10CP951 -2 ~ -3 mbar
1HBK10CP941 5 ~ 20 mbar
1HBK10CP910 35 - 50 mbar
1HBK10CP901 110 mbar

Boiler Operation – Special Load Cases

1. Agglomeration of Bed Material

The circulation bed material consists mainly out of quartz sand (SiO2). If fuel with high amount of alkalis
is used (K2O, Na2O) the fuel ash tends to form low melting silicates together with the bed sand (SiO2,
Quartz sand). This leads to formation of deposits in the Sand/Ash circulation system.

This happens also when HFO is used during start-up or as additional fuel, because the start-up burners
have around the flame very high temperatures.

4
2. Detection of upcoming agglomerations:

 Bed temperatures 1HBK10CT021/022/023/024 located at 0,5 m above nozzle grid show different
values. The bed temperatures decrease even though constant coal or HFO firing.

 Furnace temperatures at 1,5m 1HK10CT032/033 and at 4m 1HBK10CT041/042 decrease even

though constant coal or HFO firing.

 Furnace pressures at 120mm 1HBK10CP011/012, at 1,5m 1HBK10CP031/032 and at 7,5m

1HBK10CP041/042 show differences between left and right value.

 Pressure in the siphon 1HDF10CP001/002 is decreasing or fluctuating.

3. Actions:

 Increase of fluidization gas flow (gas flow to nozzle grid) by increasing the recirculation gas flow or
increase of the primary air flow or changing the distribution of the gas between nozzle grid and
primary air level 1.

 Reduction of oil firing

 Removal of bed material and addition of fresh sand. No storage of the bed material in the bed
material silo.

 Visual detection of agglomeration through the sight glasses in the furnace 

4. Attention:

 If the above mentioned actions have no positive effect (visual check through the sight glasses in the
furnace), shut down the boiler and cool it down. Then remove manually the agglomerations in the
furnace, the cyclone and the siphon.

Boiler Operation – Preparations

Before starting the CFB-boiler ensure that all consumables listed below are available or
have been supplied into the named storage equipment:
 
• Electrical power supply
• Cooling water supply
• Instrument and transport air supply
• Make up water / condensate supply
• Chemicals for chemical dosing system
• Heavy fuel oil supply for start-up burners and bed lances
• Medium pressure steam supply for start-up burners and bed lances
• Sufficient fuel for start up and operation

5
 • Coal bunker filled
• Chemical analysis and grain size distribution of fuels and additives must meet the
specified requirements
• Sand supplied into the sand silo
• Limestone supply for desulphurization
• Urea water solution supply for SNCR
•
In case the boiler has been fully drained it has to be filled again before start-up. Ensure sufficient
feed water supply for the boiler filling and starting procedure. Fill the boiler system by carrying
out the following instructions.

• Adjusting the boiler stop valves

• Switch on feed water pump 
• Pre-stressing feed water line up to control station
• Filling economizer, evaporator and drum
• Starting water/steam sampling system
• Starting the chemical dosing system
• Finishing boiler filling

The following start-up procedure is prepared for the CFB Boiler

 It does not include the start-up procedure for other parts of the plant e.g. FGC,
water/steam circle (turbine)

 The sequence of steps can be changed and should be adapted to current situations
as required

Boiler Operation – Start Up

• Preconditions finished
• Valve positions are according operation manual checked and adjusted in:
• Combustion air and flue gas system
• Feedwater and condensate system
• Boiler system
• Start of Condensate and Feedwater System

6
 • Start Fans of combustion air and flue gas systems
• Sand / bed material filling into furnace
• Boiler purging
• Start Fly Ash Conveying System
• Start Flue Gas Cleaning
• Igniting start-up burners
• Start boiler system– evaporation and pressure increase
• Starting Bed Lances if release temperature of heavy fuel oil firing is reached
• Load Increase
• Switch to solid fuel firing if release criteria for coal firing are fullfilled
• Reduce HFO firing
• Start Bed Ash Conveying
• Reduce and switch off HFO firing
• Start the Bed Temperature Controller

Step 1 – Valves in combustion air and flue gas systems:

Check and in case adjust the valve position:
• of the CFB-system according to op. manual chapter 8.1
• of the combustion air system and flue gas system according to op. manual chapter 8.2 and
8.3
 
Step 2 – Valves in boiler system:
• The boiler shall be filled at this moment according to op. manual chapter 4
Check and in case adjust the valve positions of the boiler system according to op. manual chapter
8.4
 
Step 3 – Start Fans of combustion air and flue gas systems:
• Starting Sequence Air Flue Gas according to op. manual chapter 8.2
• This sequence program starts automatically all fans of the combustion air and flue gas
system and adjusts their related valves, including the steam valves of the steam air
preheaters. The purging of the boiler is done in a later step.

Step 4 – Sand / bed material filling into furnace:

• Check and in case adjust the valve position of the sand system according to chapter op.
manual 8.9.
• If bed material has been drained completely for standstill, start the sand filling according
to op. manual chapter 8.9 in order to reach the basic furnace differential-pressures for
operating the CFB-plant. Don’t start a burner with empty combustion chamber.

Step 5 – Boiler purging:

7
 • Execute the boiler purging program according to op. manual chapter 8.2.
 
Step 6 – Fly Ash Conveying System:
• Start the pneumatic fly ash system
 
Step 7 – Igniting start-up burners:
• Start the burners acc. to op. manual chapter 8.7. Ignite the first start-up burner.
Considering maximum admissible temperature gradients of the flue gas of 150 K/h and
boiler drum wall 1HAD10CT901, ignite further start-up burners and increase burner load.
The duty of the startup burner can be set with the “setpoint heat start up burners”.
• Totally 3 ignition trials for burner start or 1 trial for burner gun purging are allowed
before purge sequence must be repeated.
 
Step 8 – Start boiler system:
• Switch on the boiler system according to op. manual section 8.4.
• Open the drain valve on the steam section according to op. manual chapter 8.4.
• Drum level control stays on manual mode and the feedwater control valve stay closed.
• Open the HP bypass station 1LBA10AA102 to 15% and the startup vent 1LBH10AA001
to 10% but keep the control on manual mode.

Step 9 – Evaporation Start / Pressure increase:

• When the start-up burners are in operation, the temperature in the boiler water circuit is
rising. The evaporation system is vented by the drain valves of the superheaters

Several items need to be observed:

1.) Flue gas temperature gradient.

• In order not to stress the refractory too much, the flue gas temperature gradient of the flue
gas temperature at 1.5 m must be below the limit.

2) Drum level and economizer outlet temperature

• Watch drum water level (local gauge as well as remote level indication) and in case
supply feedwater with feedwater CV or drain boilerwater with drum overflow valve
1HAD30AA001 that limits the level to be not above +50mm and opens automatically at
level +100 mm.
• If the temperature difference between drum temperature and economizer outlet
temperature 1HAC10CT002 come below 5 K, the feedwater flow through economizer
must be increased to prevent evaporation in the economizer. The feedwater flow shall be

8
 increased too, if the flue gas temperature 1HNA10CT901 exceeds 180°C. Open the
feedwater CV as late as possible.

3.) Difference Metal Temperature Drum Wall

 The difference Metal Temperature Boiler Drum wall 1HAD10CT901 shall be below the
limit of -18.87 to – 76.63 K, depending on pressure (alarm indication). If it is out of the
limit open the HP start up valve 1LBH10AA001 a few percent more to reduce the
pressure increase rate in the boiler.
When the steam temperature difference between super heater 1 outlet 1HAH15CT001
and drum exceeds +20 K, all manual drain valves in the steam section should be closed.
 When all manual drain valves are closed set the start up control valve 1LBH10AA001 to
auto mode. Enter a set point for start-up valve which is the corresponding actual pressure
at the boiler and switch the controller on auto. Increase the pressure by increasing the set
point of the start-up control valve under observing the difference temperature of the drum
wall.
 When the drum pressure is around 50bar switch the drum level controller on auto.

Step 10 – Start Sand System:

• The sand filling must be finished before the first bed lance is started. If the sand filling is
completed or the furnace was already filled with sand start the sand system according to
op. manual chapter 8.7.
 
Step 11 – Starting Bed Lances:
• As soon as furnace bed temperature 1HBK10CT921 has exceeded 350 °C the first bed
lance can be started according to op. manual chapter 8.7 from the DCS. Further bed
lances are started from the group control “bed lances” according to demand. The duty of
the bed lances can be set with the “setpoint heat bed lances”.
• If the flue gas temperature at 1,5 m increases too much reduce the load of the start up
burners.
• Further load increase should be made by the bed lances and not by the start up burners.

Step 12 – Load Increase:

• By keeping the CFB boiler plant always in stable conditions increase the load of bed
lances.
• Watch always the amount of bed material (inventory) indicated by the differential
pressure of the entire furnace DP-Total. Keep this value between 35 and 50 mbar. Some
material is entrained to the upper furnace and collected in the downleg below the cyclone
separator.

9
 • Further increasing of the start-up burner and bed lance load is limited by the temperature
gradients of the flue gas regarding the refractory lining, see step 9.

Step 13 – Solid Fuel Feeding

• Check and in case adjust the valve position of the coal feeding system according to op.
manual chapter 8.6. As soon as furnace bed temperature 1HBK10CT921 has exceeded
650 °C coal feeding can be started according to op. manual chapter 8.6. Increase the load
by changing the output “Setpoint coal heat”. Don’t set this controller to auto mode.
• Further load increase shall be done with coal firing only.
 
Step 14 – Bed Ash Conveying:
• Check and in case adjust the valve position of the bed ash system according to op.
manual chapter 8.10. Start also the pneumatic bed ash conveying system. On demand
start the mechanical bed ash system according to op. manual chapter 8.10.
 

Step 15 – Reduce and switch off oil firing

• Now the start up burner duty can be reduced. If all start up burners are on minimum load
switch off one burner after the other.
• Now reduce the bed lance duty. If all bed lances are on minimum load stop one bed lance
after the other.
• Watch the combustion chamber temperature trends and the steam flow, pressure and
temperature trends and keep the boiler in stable operation
 
Step 21 – Start the Bed Temperature Controller
• After the bed temperature is stabilized, start the bed temperature controller.

Start Up Diagram

10
 CFPP
Boiler Drains and Vents
SR NO. System   Valves KKS Status
01HAH21AA651  
1 High Pressure Steam V13
0HAH21AA652  
Boiler Vents
01HAH13AA651  
2 High Pressure Steam V09
01HAH13AA652  

11
 01HAH30AA651  
3 High Pressure Steam V14
01HAH30AA652  
01HAC10AA651  
4 Feed Water Economizer V04
01HAC10AA652  
01LAB50AA651  
5 Feed Water V01
01LAB50AA652  
01HAH10AA651  
6 Super Heater V05-V08
01HAH10AA652  
01HAH21AA653  
7 Super Heater V15
01HAH21AA654  
01HAH13AA601  
8 Super Heater D15
01HAH13AA602  
01HAH15AA601  
9 Super Heater D16
01HAH15AA602  
01LBA10AA601  
10 Live Steam D28
01LBA10AA602  
Super Heater Drains
01HAH21AA601  
11 Super Heater D21-D22 01HAH21AA602  
01HAH21AA603  
01HAH21AA604  
12 Super Heater D23-D24 01HAH21AA605  
01HAH21AA606  
01LAB40AA601  
13 Feed Water D01
01LAB40AA602  
14 Boiler Water D07-D08 01HAD10AA602  
01HAD11AA601  
15 Boiler Water D13
01HAD11AA602  
01HAD11AA603  
16 Boiler Water D14
01HAD11AA604  
01HAD22AA601  
17 Boiler Water D12
01HAD22AA602  
01HAD23AA601  
18 Boiler Drains Boiler Water D10
01HAD23AA602  
01HAD21AA601  
19 Boiler Water D09
01HAD21AA602  
01HAD24AA601  
01HAD24AA602  
20 Boiler Water D11
01HAD24AA501  
01HAD24AA701  
01LAB40AA603  
21 Feed Water D02
01LAB40AA604  
22 Feed Water D03 01LAB50AA601  

12
 01LAB50AA602  
SR. CFPP Boiler Area
EQUIPMENT
NO PARAMETER REMARKS
DESCRIPTION KKS TAG DESIGN
.
CAPACITY I (LTR) 12465
Pmax(barg) 113
1 STEAM DRUM 1HAD10BB001 15NiCuMoNb5 Andritz
MATERIAL
-6-4
DESIGN TEMPERATURE 321
CAPACITY (ltr) 4212
ATMOSPHERE MATERIAL 16Mo3
2 BLOW DOWN DESIGN 1HAN10BB001 Andritz
495
TANK TEMPERATURE(CELCIUS)
Pmax(barg) 0.5
CAPACITY (m³/hr) 6.4
SECONDARY POWER KW 73
3 1HLB(21/22)AN001 TLT-TURBO GmbH
AIR FAN 1&2 MOTOR KW 90
MOTOR RPM 1485
CAPACITY (Nm³/hr) 24000
PRIMARY AIR POWER KW 149
4 1HLB11AN001-2 ABB
FAN 1&2 MOTOR KW 200
MOTOR RPM 2980
KW 55
FLUIDISING AIR
5 P(SUC) 1HLB71/72AN001 0.988 AERZEN Delta Blower
BLOWER 1&2
P(DIS) 1.788
CAPACITY (m³/hr) 28
INDUCED POWER KW 290
6 01HNC11/12AN001 TLT-TURBO GmbH
DRAFT FAN 1&2 MOTOR KW 355
MOTOR RPM 1488
CAPACITY (m³/hr) 8.4
RECIRCULATION POWER KW 161
7 1HNF10AN001 ABB
FAN MOTOR KW 200
MOTOR RPM 2980
Volume (m³/hr) 399
Cooling Air Fan
8 Allowable Pressure 1HJQ(01/02)AN001 1.2 ABB
1&2
MOTOR RPM 3000
UREA MIXING CAPACITY (m³) 3.5
9 1HTS05BB001 CHRISTEN & LAUDON
TANK MATERIAL CSS-3
UREA STORAGE CAPACITY (m³/hr) 12
10 1HTS10BB001 CHRISTEN & LAUDON
TANK HEAD (m) GRP
Urea Filling HEAD (m) 22
11 1HTS05AP001 GRUNDFOS
Pump MOTOR KW 2.2

13
 MOTOR RPM 2899
BLOWER POWER KW 45
1QED(01/02)AN00
12 LIMESTONE PRESSURE SUCTION(bar) 0.988 AERZEN Delta Blower
1
LINE 1&2 PRESSURE Discharge(bar) 1.888
CAPACITY (m³/hr) 284
FREQUENCY(HERTZ) 50
13 HFO Pumps 10ERB10AP001/2 SIEMENS
MOTOR KW 3.85
MOTOR RPM 1450
Capacity (MW) 8 MEHLDAU & STEINFATH
14 Bed Lance 1/2 1HJA21/22AV001 FEUERUNGSTECHNICK
Pmax(barg) 16 GmbH
Capacity (MW) 12 MEHLDAU & STEINFATH
Startup Burners
15 1HJA(11/12)AV001 FEUERUNGSTECHNICK
1/2 Pmax(barg) 16 GmbH
AMMONIA
HYDROXIDE MPT Meb-und
16 Volume (m³) 1LFN10BB001 0.5
DOSING TANK Prozebbtechnik GmbH
(NH4OH)
LITHIUM
HYDROXIDE MPT Meb-und
17 Volume (m³) 1LFN20BB001 0.5
(LiOH) DOSING Prozebbtechnik GmbH
TANK
SAND / BED
18 MAXIMUM CAPACITY 1EMB10BB001 30m³ ANDRITZ
MATERIAL SILO
19 FLY ASH SILO MAXIMUM CAPACITY 10ETH10BB001   FAT
LIMESTONE
20 MAXIMUM CAPACITY 1EMA20BB001 200m³ ANDRITZ
SILO
SAND / BED
21 MAXIMUM CAPACITY 1EMB10BB001 30m³ RAUMASTER
MATERIAL SILO
HYDRAULIC Pmax(barg) 200 BOTT SMART
22  
Tank Flow(ccm/u) 3*25 HYDRAULICS
AMPERE(I) 28.5
HYDRAULIC FREQUENCY(HERTZ) 10EAC01AP001- 50
23 SIEMENS
PUMPS 1-4 MOTOR KW 004 15
MOTOR RPM 1475
CAPACITY (m³/hr) 284
FREQUENCY(HERTZ) 50
24 HFO Pumps 10ERB10AP001/2 SIEMENS
MOTOR KW 3.85
MOTOR RPM 1450

14
15