COMBUSTION IN A

CFBC BOILER
TAPASH NAG
TN - 28 Nov 2013 V0

CFBC CHARACTERISTICS
Operates under special fluid dynamic
condition
Solid particles are mixed through furnace at a
velocity exceeding the average terminal
velocity of the particles
Major fractions of solids are captured by
cyclone
High recycle rate intensifies solid mixing and
evens out combustion temperature
High turbulence, solid mixing and absence of
a defined bed level
Solids are distributed through out the furnace
with
steadily decreasing density from bottom2
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COMBUSTION FACTORS
PA
FURNAC
E
VOLUME

COAL
QUALI
TY

COMBUSTIO
N

BED
TEMP
COAL
SIZE
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SA
ASH
REC
BED
HEIGH
T

PRIMARY
AIR

Conveys coal
Uniform distribution of coal in
furnace
Provides air for combustion
Fluidizes the bed ash
Ensures proper mixing
Provides sealing air to feeders
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SECONDAR
Y AIR

Staged Combustion
Maintains bed temperature
Burner air
Provides excess air
requirement
Controls overboard
temperature
Eliminates NOx formation
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AIR DISTRIBUTION CRITERIA

The primary air shall be adjusted in such a manner that it
provides minimum fluidization and better combustion
The secondary air shall be adjusted in such a manner that it
has maximum penetration so that there is adequate reaction of
oxygen with fuel.
High pressure for bottom SA is required, to guarantee high
penetration and better mixing of air with bed material
If PA quantity is high and SA quantity is not adequate, the fuel
combustion in dense phase of furnace, i.e., the lower portion will
decrease but increase in the lean phase or the upper portion
resulting in more water wall erosion.
Secondary combustion shall occur in boiler cyclone and seal
pot due to less SA quantity.
The temperature of flue gas at cyclone outlet will rise and
there will be wide variation between cyclone inlet and outlet
temperatures
RU - 30 July 2013 V0 The heat transfer in back pass will increase due to
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high flue gas temperature. Attemperation will increase and

AIR ADJUSTMENT TABLE

SA DAMPER
POSITION (%)
S
R

LOAD
(MW)
TOP

BOTTOM

SA
HEADER
PRESSU
RE (kPa)

50

45

25

6.0

50-80

40-50

30-40

6.0-7.5

80-100

60-70

40-50

7.5-8.0

100120

70-80

50-60

8.0-9.0

120135

80-90

60-70

9.5

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PA
QUANTITY

Critical
fluidizing
air
Critical
fluidizing
air
Adjust bed
temperatu
re
Adjust bed
temperatu
re
Adjust bed
temperatu
re

BED
HEIGH
T (kPa)

BED
TEMP
()

OXYGE
N
(%)

10.0

Around
700

4.0-5.0

11.0

700850

3.5-4.2

11.5

800850

3.5-4.0

12.0

800900

~ 3.5

12.5

800910

3.0-3.5

OXYGEN PROFILE IN CFBC FURNACE

POOR
OXYGE
N
CORE

RU - 30 July 2013 V0

1. Poor oxygen core formed

due to the combustion in
reducing atmosphere due to
insufficient mixing of air
2. Results in bad combustion
efficiency when burning
coals with low volatile
content
3. Staged air supply to be
provided for better
SECONDARY combustion
AIR
4. Proper PA to SA ratio should
be maintained
5. Proper air velocities should
be maintained
6. Angle and size of SA duct
should be such that the
penetration length of air jet
is deep in to the furnace
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OPERATION PRACTICES
RATIO OF PRIMARY AIR
FUEL

VOLATILE
CONTENT(%)

RATIO OF PA TO TOTAL
AIR

ANTHRACITE

<20

~65

BITUMINOUS

20~40

~60

LIGNITE

>40

~50

VELOCITY OF AIR (m/s)

PA(Based on throat area of
Nozzle)

SA

~40

55~85

RU - 30 July 2013 V0

EXCESS AIR REQUIREMENTS

Coefficient of Excess air is a function of
the fuel
Reasonable air supply ensures better
temperature distribution in the furnace
and better combustion efficiency
Ensures lower NOX generation
EXCESS AIR AT FURNACE OUTLET

FUEL

VOLATILE
CONTENT(%)

COEFFICIENT OF
EXCESS AIR

ANTHRACITE

<20

1.23~1.25

BITUMINOUS

20~40

1.22~1.24

LIGNITE

>40

1.20~1.22

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COAL
QUALITY

GCV
Moisture
Ash Content
Volatile material
Carbon content
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COAL SIZE

Fines
Oversize
Distribution
Volatile material
Carbon content

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FEW FACTS
Hard Coal with less volatile dont burn effectively in CFBC
boiler
Reactivity of carbon decreases while in circulation for a long
time
Coals having low fusion temperature can be burnt as
temperature in dense bed and free board is around 850-900 oC
Fuel grain size distribution depends upon the material balance,
the rate of combustion in the dense phase and free board and
combustion efficiency
The biggest grain size will be fluidized in dense phase and will
start burning
The finer grains shall be entrained in the flue gas and burn in
free board zone
- 30 finest
July 2013 V0
RU
The
grains up to 90 microns shall be returned by the

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COAL INDEX
COAL INDEX

%C IN ASH LEAVING FURNACE

30
25

I = Vdaf
QLHV

20
15
10
5
0
0

10

15

20

25

30

35

Vdaf = Volatile
content in coal on
dry basis

I (MJ/kg)

QLHV = Lower heating

value of coal

RU - 30 July 2013 V0

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SIZE DISTRIBUTION
SIZE DISTRIBUTION IN A CFBC BOILER

60

FLY ASH
50

SIZE FRACTION (%m)

CIRCULATING ASH
DRAIN ASH

40

30

20

10

0
0

100

200

300

400

500

600

700

800

PARTICLE SIZE (m)

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BED HEIGHT
Should be sufficient enough to burn the large size
particles in dense phase
Bed height should be such that it provides enough
resistance to the PA supplied to the furnace
Lower bed height will increase the PA velocity
resulting in erosion of water walls and entrainment
of high size particles in lean phase
Depends on the coal quality and size
Bed height higher than normal will reduce the bed
temperature and will reduce combustion efficiency
Bed height is a function of load
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BED
TEMPERATURE
Should be around 850-900oC
Too low the temperature will result in inefficient
combustion, will increase the cyclone and seal pot
temperatures. Back pass temperatures will increase. Will
increase attemperation.
Too high the temperature will result in clinker formation
and agglomeration
Depends on coal quality, bed height, air velocity and
quantity
Maintaining bed temperatures within the specified range
is very important for ensuring that the heat transfer
takes place in the boiler as per the design specifications
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FURNACE
VOLUME
Cross section determines the velocity(5 to 6m/s) of
air in the furnace
If cyclone separators are arranged in one direction,
the ratio of furnace width to depth is equal to the
no of cyclones
If cyclone separators are arranged in side, the ratio
of furnace width to depth is equal to th of no of
cyclones
Ratio of width and depth determines the SA
penetration in the furnace
Minimum 20m height is required for a CFBC boiler
for ensuring better combustion efficiency
TN -Furnace
28 Nov 2013 V0 height is too high for the water wall length
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RECOMMENDED FURNACE HEIGHT

IT IS OF PRIME IMPORTANCE THAT THE FURNACE
HEIGHT SHOULD BALANCE THE COMBUSTION
EFFICIENCY AND THE HEATING SURFACE. BELOW
IS THE RECOMMENDATIONS FOR DIFFERENT
CAPACITY CFBC BOILERS
FUEL

BOILER CAPACITY(TPH)
35

75

130

220

410

680

1000

ANTHRACI
TE

20

21

26

32

36

43

54

BITUMINO
US

20

20

25

29

34

39

50

LIGNITE

20

20

24

28

30

37

47

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ASH
RECIRCULATIO
N
If Combustion is the heart, loop seal is the valve of
the heart

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LOOP SEAL FUNCTION &

Returns solids captured by the cyclone to the furnace
ADVANTAGES
Prevents backflow of flue gas from furnace to cyclone
Failure of loop seal to transfer the solids at required rate will
result in an entrained bed conditions
Large temperature gradient along the furnace, low heat
absorption & higher back pass temperature
Loss in steam output, excessive steam temperatures & high
stack temperature
Height of dip leg is very important. It shall be always more than
riser leg
Pressure difference between dip leg and riser shall be around
2kPa
The air velocity in dip leg shall be around 0.3m/s and in riser
leg shall be around 1.3 m/s
The velocity of circulating material in loop seal shall be around
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0.2m/s

QUESTIONS PLEASE
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