Alstom CFB boilers achieve high combustion efficiency with challenging discarded coal Hugh Kennedy 16 th July 2013
Agenda Baima 300 MWe CFB demonstration plant Page 3 Emile Huchet 125 MWe captive power plant Page 9 Seward 2 x 260 MWe Page 13 Conclusion Page 16
Baima 300 MW el CFB Demonstration Plant Technology CFB Fuel Anthracite Province Sichuan, P.R.C. Capacity 1025 t/h MS Pressure 174 bar MS/HR Temperature 540/540 c FW Temperature 281 C Sulphur removal rate 94% Emissions level, mg/nm 3 (@6%O 2 DG) : SO 2 600 NO x 250 Dust 100 First 300 MW CFB Boiler in China
Baima 300 MW el CFB Demonstration Plant Owner: Sichuan Baima CFB Demonstration Power Plant Co Ltd. ( State Power Grid / Sichuan Bashu Development Company) Milestones Contract signed July 2002 Contract into effect April 2003 Commercial operation April 2006 Performance tests May 2007 Technical challenges Carbon burnout with anthracite Limestone consumption Potential uncontrolled SO 2 : 10 000 mg/nm 3 Sulphur removal rate 94% Added Ca/S < 2 The Baima Project also includes a ToT for CFBs 200-350 MWel
Baima 300 MW el CFB Demonstration Plant Trial run April 17 th 2006, performance tests May and June 2007 Baima performance tests BECR Perf test 1 BECR Perf test 2 Design Date 26 th June 2007 27 th June 2007 BECR Coal quality stability Good Good Good Coal LHV MJ/kg 15.38 16.49 18.5 Ash % 43.5 40.5 35.3 LHV boiler efficiency % (corr) > 93 > 93 < 92 Added Ca/S (corr) < 1.5 < 1.7 < 2.0 Sulfur capture % > 95 > 94 > 94 SO2 emission mg/nm3 @6% O2 dry < 600 < 600 600 CO emission mg/nm3 @6% O2 dry < 150 < 130 NA NOx emission mg/nm3 @6% O2 dry < 100 < 100 250 Carbon heat loss < 3% LHV carbon content in fly ash: 1.5 2.5%. Successful performance tests with the worst coal
C Cyclone fule gas C mg/nm3 Reheat steam Temp. C Super / Reheat steam C Baima 300 MW el CFB Demonstration Plant 550 500 450 400 360 350 300 LTR inlet temp HTR Bed 4 inlet temp HTR Bed 1 inlet temp HTR Bed 4 Outlet temp HTR Bed 1 Outlet temp HTS outlet temp Hours 960 250 07:12 08:24 09:36 10:48 12:00 13:12 14:24 15:36 16:48 18:00 960 940 920 900 880 860 840 820 800 780 760 ~70% MCR 40% MCR time Cyclone 301 outlet temp Cyclone 201 outlet temp 760 07:12 08:24 09:36 10:48 12:00 13:12 14:24 15:36 16:48 18:00 Hours time 250 200 Gross Output Power 150 100 50 Load variation from ~70% to 40% MCR: MS and HR temperatures close to full-load value Combustion temperature remains above 860 C CO emission drops from 80 to 50 mg/nm 3 NOx emission remains below 100 mg/nm 3 0 ~70% MCR Flue gas to stack CO Flue gas to stack NOX 40% MCR 80 mg/nm 3 NOx < 100 mg/nm3 CO emission 50 mg/nm 3 time Hours 0 09:36 10:48 12:00 13:12 14:24 15:36
Baima 300 MW el CFB Demonstration Plant ash content 40 % to +60% 35% fuel flow reduction within 1 hour at constant output Automatic boiler control despite coal quality variations
Baima 300 MW el CFB Demonstration Plant Ash content > 45% (out of the contractual range) Large amount of stones in the raw coal Very abrasive ash Coal quality the real challenge Rapid wear of secondary crusher hammers Required coal PSD never achieved Oversized particles including stones Stone build-up in the FBACs impacts heat transfer Erosion of water walls above the refractory tip Erosion of nozzles in the furnace
Agenda Baima 300 MWe CFB demonstration plant Page 3 Emile Huchet 125 MWe captive power plant Page 9 Seward 2 x 260 MWe Page 13 Conclusion Page 16
Emile Huchet 125 MW el CFB boiler Customer: SODELIF, France Fuel: Coal washing plants byproduct Ultra fine product: d50% =150 microns, d99% < 2 mm Slurry : 30% ash 33% moisture 2500 Kcal/Kg (LHV) Schlamms: 8% moisture, 5000 Kcal/kg (LHV) Steam Conditions: 367 t/h, 155 bar, 545/540 C Emission levels (mg/nm 3 @6%O 2 DG): SO 2 : 330 NO x : 300 CFB-based power plant to burn low grade coal residues
Emile Huchet 125 MW el CFB boiler Test facility ( France) Cyclones were designed to achieve the highest collection efficiency
PSD Passing % Emile Huchet 125 MW el CFB boiler Performance test Fuel Schlamm Slurry Unburnt carbon loss % LHV 1,4 1,2 2,55 1,71 Unburnt carbon in bottom ash % 1,2 1,0 0,4 0,4 Unburnt carbon in fly ash % 6,0 5,6 5,0 3,8 Fly Ash - Bottom Ash split % - % 70/30 60/40 62/38 58/42 100 90 80 70 60 50 40 30 20 10 Bottom ash Seal pot Fly ash Field data Fly ash Field data Bottom ash Field Data Seal pot 18/11/92 Field Data Seal pot 08/04/92 Particle size en µm Simulation Field data 0 10 100 1000 10000 Actual performances match computerized PSD forecast Particle size, µm
Agenda Baima 300 MWe CFB demonstration plant Page 3 Emile Huchet 125 MWe captive power plant Page 9 Seward 2 x 260 MWe Page 13 Conclusion Page 16
Seward 2 x 260 MWe CFB boilers Customer: Reliant Resources, USA Commissioning: 2004 Steam Conditions: Capacity: 2 x 872 t/h Pressure: 174 bar SH/RH Temperature: 541/541 C Fuel: Pennsylvania 2 millions tonnes of mining waste coal on site 100 millions within 80 km Carbon % wt 29.32 (25-35) Volatile matter % 11 ( 9-30) Sulphur % 2.75 (2 4.25) Ash % 51 (25-58) Moisture % 8.7 ( 7 12) Heating Value MJ/kg Kcal/kg 12.8 (11.6-14) 3050
Seward 2 x 260 MWe CFB boilers Three-bay arrangement: Coal feeding on the front wall. Three aligned cyclones 2 x FBAC 2 x FBHE Emission levels SO 2 mg/nm³ @ 6 % O 2 780 or sulphur removal 95% NO X mg/nm³ @ 6 % O 2 130 Particulates mg/nm³ @ 6 % O 2 40 Proprietary NID TM dry scrubber SNCR Clean Power from Waste Coal
Agenda Baima 300 MWe CFB demonstration plant Page 3 Emile Huchet 125 MWe captive power plant Page 9 Seward 2 x 295 MWe Page 13 Conclusion Page 16
Conclusions Correctly applied CFB efficiently combusts discard coal 0 2 VM/MAF in % Anthracite Tamuin (petcoke) Mai Liao (petcoke) Baima Coa Ngam Low Volume of Flue Gas Low Reactivity Full fuel knowledge is mandatory: Coal rank Ash chemical composition Uncontrolled moisture Fuel PSD Coal fragmentation and ash attrition Required low load performance drives the CFB technology choice SO 2 and NO x emissions may drive backend treatment options NID TM dry scrubber SNCR 14 22 31 60 Low Vol. Bit Medium Vol. Bit. High vol. A bit. 8890 Seward High vol. B bit. Emile Huchet Gilbert #3 Spurlock #4 High vol. C Bit. or Subbit. A Quinhangdao Zeran Gardanne Subbit. B Subbit. C Lignite 7780 7220 6110 5280 4610 HHV with inherent moisture without mineral matter (kcal/kg) High Volume of Flue Gas High Reactivity Tarahan Kaiyuan Xiaolongtan Can Akrimota Red Hills Alstom leverages off its relevant experience to offer discarded fuel-fired CFB
Alstom - CFB Product portfolio Three Bay Arrangement Dual Grate Arrangement USC CFB Platform From 100 MW to 350MW class Up to 4 cyclones in line 350MW class External bed technology 660 MW and up +6 % increased efficiency 175 bars 565 C/565 C 175 bars 565 C/565 C 275 bars - 600 C/620 C CFB installed base over 13,000 MWe with 140 references
Alstom CFB Product portfolio Leading CFB technology Supplier 3-Bay Arrangement USC CFB Platform 660 MW and up 0 2 22 31 Fuel combustion expertise VM/MAF in % Anthracite Medium Vol. Bit. Low Volume of Flue Gas Low Reactivity 14 High Volume of Flue Gas High Reactivity Low Vol. Bit High vol. A bit. High vol. B bit. High vol. C Bit. or Subbit. A Subbit. B Subbit. C Lignite Over 13GW installed based up to 350MW 175 bar 565/565 C 60 8890 7780 7220 6110 5280 4610 ALSTOM EXPERIENCE WITH CFB HHV with inherent moisture without mineral matter (kcal/kg) World class supplier of SC/USC PC-fired boiler up to 1100MW Dual Grate Arrangement 275 bar - 600 C/620 C +6 % increased efficiency 290 bar 600/620 C Leveraging boiler technology experience
pierre.gauville@power.alstom.com