Unit 2

Applied Thermodynamics-1

By Dr. Pranjali Deole

1 @Dr.Pranjali deole
 FBC

2 FLUIDISED BED COMBUSTION BOILER

@Dr.Pranjali deole
 FBC BOILER
⚫ In 1921, the first fluidized bed being used successfully
in Germany.
⚫ Fluidized bed combustion has emerged as a feasible
alternative and has significant advantages over
conventional firing system and offers multiple benefits
– compact boiler design, fuel flexibility, higher
combustion efficiency and reduced emission of
noxious pollutants such as SOx and NOx.
⚫ The fuels burnt in these boilers include coal, washery
rejects, rice husk, wood chips & other agricultural
wastes.
⚫ The fluidized bed boilers have a wide capacity range-
0.5 T/hr to over 100 T/hr.
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 MECHANISM:Fluidisation of solids:
⚫ Sand particles resting on a mesh (left)
become fluidised when air is blown
through (right) and take on the appearance
and some of the properties of a boiling
fluid.
⚫ Granular solids remain in layers when one
is poured on to another (left), but rapid
mixing occurs on fluidisation (right).
⚫ A bed of stationary particles supports
objects whatever their density (left). On
fluidisation, an object of lower density
(the green ball) floats while the higher
density (red ball) sinks.
⚫ In a bed of stationary particles (left), heat
is transferred slowly and there are big
differences in temperature. In a fluidised
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(right), deolerapid mixing ensures
 Principle of FBC System
⚫ When an evenly distributed air or gas is
passed upward through a finely divided
bed of solid particles such as sand
supported on a fine mesh, the particles are
undisturbed at low velocity.
⚫ As air velocity is gradually increased, a
stage is reached when the individual
particles are suspended in the air stream –
the bed is called “fluidised”.
⚫ With further increase in air velocity, there
is bubble formation, vigorous turbulence,
rapid mixing and formation of dense
defined bed surface. The bed of solid
particles exhibits the properties of a
boiling liquid and assumes the appearance
of a fluid – “bubbling fluidized bed”.
⚫ At higher velocities, bubbles disappear,
and particles are blown out of the bed.
Therefore, some amounts of particles
have to be recirculated to maintain a
stable system - "circulating fluidised bed".
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 CHARACTERISTICS OF FLUDIZED
BED
⚫ Fluidization depends largely on the particle size and the
air velocity.
⚫ Combustion process requires the three “T”s that is Time,
Temperature and Turbulence. In FBC, turbulence is
promoted by fluidisation.
⚫ If sand particles in a fluidized state is heated to the
ignition temperatures of coal, the coal will burn rapidly
and bed attains a uniform temperature.
⚫ The fluidized bed combustion (FBC) takes place at about
840OC to 950OC. Since this temperature is much below
the ash fusion temperature, melting of ash and associated
problems are avoided.
⚫ The lower combustion temperature is achieved because of
high coefficient of heat transfer due to rapid mixing in the
fluidized bed.
⚫ Limestone is used as particle bed, control of sulphur
dioxide and nitrogen oxide emissions in the combustion
6 chamber.
@Dr.Pranjali deole
 https://www.youtube.com/watch?v=EB0r6A5Vx
FU
https://www.youtube.com/watch?v=DLbhAS2Ww6
U

Types of Fluidized Bed Combustion Boilers

⚫ 1. Atmospheric Fluidised Bed Combustion
System(AFBC)

⚫ 2. Atmospheric circulating (fast) Fluidised Bed

Combustionsystem(CFBC)

⚫ 3. Pressurised Fluidised Bed Combustion System

(PFBC).
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 AFBC / Bubbling Bed
⚫ Coal is crushed to a size of 1
– 10 mm depending on the
rank ofcoal.
⚫ The atmospheric air, which
acts as both the fluidization
airand combustion air.
⚫ The velocity of fluidising air
is ranges from 1.2 to 3.7 m
/sec.
⚫ Almost all AFBC/ bubbling
bed boilers usein-bed
evaporator for extracting the
heatfrom the bed to maintain
the bed temperature.
⚫
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The bed depth
@Dr.Pranjali deole is 0.9 m to 1.5
m deep. Air Distributor
 General Arrangements of AFBC Boiler

⚫ AFBC boilers
comprise of
followingsystems:

⚫ i) Fuel feeding system

⚫ ii) Air Distributoriii)

Bed & In-bed heat
transfersurface

⚫ iv) Ash handling

@Dr.Pranjali deole
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system
 1. FUEL FEEDING SYSTEM

⚫ For feeding fuel, sorbents like

limestone ,usually two
methods are followed:
⚫ under bed pneumatic feeding
and over-bed feeding.
⚫ Under Bed Pneumatic
Feeding.
If the fuel is coal, it is
crushed to 1-6 mm size and
pneumatically transported
from feed hopperto the
combustor through a feed
pipe piercing the distributor.
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 2.Over-Bed Feeding
⚫ The crushed coal, 6-10 mm
size is conveyed from coal
bunker to a spreader by a
screw conveyor. The
spreader distributes the coal
over the surface of the bed
uniformly.
⚫ This type of fuel feeding
system accepts over size fuel
also and eliminates transport
lines, when compared to
under-bed feeding system
11 coal bunker
@Dr.Pranjali deole screw conveyor
 3. Air Distributor
⚫ Purpose is to introduce the
fluidizing air through the bed
cross section, keeping the
solid particles in constant
motion.
⚫ The distributor, is
constructed from metal plate
having a number nozzles or
nozzles with bubble caps.
⚫ The distributor plate is
protected from high
temperature of the furnace
by: i) Refractory Lining ii) A
Static Layer of the Bed
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Material iii)deole
@Dr.Pranjali Water Cooled
Tubes.
 3. Bed & In-Bed Heat Transfer Surface:
⚫ a ) Bed:The bed material can be
sand, ash, crushed refractory or
limestone, with an average size
of about 1 mm. Depending on
the bed height these are of two
types: shallow bed and deep
bed.
⚫ b) In-Bed Heat Transfer
Surface: In a fluidized in-bed
heat transfer process, it is
necessary to transfer heat
between the bed material and an
immersed surface, which could
be that of a tube bundle, or a
coil. The heat exchanger
orientation can be horizontal,
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vertical or inclined.
 4. Ash Handling Systema) Bottom ash removal

⚫ In the FBC boilers, the

bottom ash constitutes
roughly 30 - 40 % of the
total ash, the rest being
the fly ash.
⚫ Ash from the boiler
furnace outlet falls into
the crusher, where large
ash particle is crushed to
small size.
⚫ Finally ash is carried by
high velocity air to
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delivery point.
 b) Fly ash removal
⚫ The amount of fly ash to be handled
in FBC boiler is relatively very high,
when compared to conventional
boilers.
⚫ Fly ash carried away by the flue gas
is removed in number of stages;
firstly in convection section, then
from the bottom of air
preheater/economizer and finally a
major portion is removed in dust
collectors.
⚫ The types of dust collectors used are
cyclone, bag filters, electrostatic
precipitators (ESP’s) .
⚫ To diminish the SOx, recycling of fly
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ash is practiced in some of the units.
 2. Circulating Fluidized Bed Combustion (CFBC)
⚫ Taller boiler structure Coal is
crushed to a size of 6 –12 mm
depending on the rank of coal.
⚫ The fluidising velocity in circulating
beds ranges from 3.7 to 9 m/sec.
Combustion efficiency as high as
99.5%.
⚫ The combustion takes place at
840-900oC, and the fine particles
(<450 microns) are elutriated out of
the furnace with flue gas velocity of
4-6 m/s.
⚫ The particles are then collected by
the solids separators and circulated
back into the furnace. There are no
https://www.youtube.com/watch?v=4MQVJ6qbRuE
steam generation tubes immersed in
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[email protected]
bed deole
 Advantage over bubbling bed boiler
⚫ Higher combustion efficiency.
⚫ Higher sulphur retention degree.
⚫ Better limestone utilization.
⚫ Lower emission level of NOx and SOx.
⚫ More economic produces 75 – 100 T/hr of steam .
⚫ Capacity range is about 400-500 MW & that of FBC
boiler is10-300 MW.
⚫ No. of feeding point less, because lateral mixing is
done by high velocity fluidizing air.

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 3.Pressurised Fluid Bed Combustion
⚫ Combined cycle i.e Rankine &
Brayton cycle using steam & gas
turbine.Operating temp. & pressure
is 860OC & 16-18 bars.
⚫ The fuel is fed along with the
sorbent and is maintained in
fluidised condition in the
pressurized combustion chamber.
⚫ The pressurized flue gases are
cleaned off & are expanded into a
gas turbine.
⚫ In addition, the excess air
requirements of the boiler are met
by the gas turbine compressor.
⚫
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@Dr.Pranjali deole by steam cycle and
that generated by gas turbine which
 Advantages

⚫ Improved Cycle Efficiency & is estimated to be

4-5 % more than conventional steam plant.
⚫ Lower fluidizing velocities (around 1m/sec) which
reduce the risk of erosion for immersed heat
transfer tubes.
⚫ Reduced Emissions & Improved Combustion.
⚫ Reduced Boiler Size.

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 Advantages of FBC boiler over Conventional boiler
⚫ High Efficiency. Combustion efficiency of over
95% Overall operating efficiency is 84%
⚫ Fuel Flexibility.
⚫ Ability to Burn Low Grade Fuel.
⚫ Pollution Control. SOx formation is minimised by
addition of limestone for high sulphur coals.
CaCO3 (solid) + SO2 (gas) → CaSO3 (solid) +
CO2 (gas) SO3 + CaCO3 = CaSO3 + CO3 Low
combustion temperature eliminates NOx
formation. NOx formation takes place
around1500o C
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⚫@Dr.Pranjali
EasierdeoleAsh Removal – No Clinker Formation.
 Contnd…

⚫ Simple Operation, Quick Start-Up

⚫ No Slagging in the Furnace-No Soot Blowing

⚫ Provisions of Automatic Coal and Ash Handling

System

⚫ Provision of Automatic Ignition System

⚫ High Reliability and low maintenance costs

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 Disadvantages of FBC boiler over Conventional boiler
⚫ The only disadvantage is that, a large amount of power
will be required to lift up the silica surface. So motor
of force draft fan will be twice bigger than that of other
conventional system.

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 Fuel handling/gradation of coal

⚫ Three Types of Fuels

1.Solid fuel such as coal
2.Liqid fuel such as oil
3.Gaseous fuel such as gas

⚫ Following factors should be considered in selecting

the fuel handling system
1.Plant fuel rate
2.Plant location in respect of fuel shipping
3.Storage area available

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 Fuels in steam generators/coal gradation

⚫ Coal is the oldest fuel and still used on large scale

throughout the world for power generation.

⚫ Coal a major source of power in India and world

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 Analysis of Coal

⚫ Proximate Analysis
Constituents Moisture Volatile Ash Fixed
Matter Carbon
Percentage 3 to 30 % 3 to 50 % 2 to 30% 16 to 92%

⚫ Ultimate Analysis
Constituents Carbon Hydrogen Oxygen Sulphur Nitrogen Ash

Percentage 50-90% 1-5.5% 2-40 % 0.5-3% 0.5-7% 2-30%

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 Basic Coal Ingredients and their effects on furnace design
⚫ Volatiles and carbon
⚫ Fines
⚫ Ash
⚫ Quantum of Ash
Classification of Coal

⚫ Peat
⚫ Lignite
⚫ Bituminous coal
⚫ Anthracite Coal

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 ⚫ The coal from the coal mines may be transported by
the following means

⚫ The pipeline coal transport system offers the

following advantages

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 Requirement of good coal handling plant

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 Coal Handling System

⚫ “Mechanical Handling "of coal is preferred over

“Manual handling” due to the following reasons

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 Disadvantages
⚫ Needs continuous maintenance and repair

⚫ Capital cost of the plant is increased.

⚫ In mechanical handling some power generated is

usually consumed, resulting in less net power available
foe supply to consumer

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 Coal Handling

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 Outline of coal handling equipment
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 From the supply point the coal may be delivered to
power station through rail, road,river or sea.

2.Unloading with lift truck with scoop

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 Transfer/fuel(coal) handling equipment

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 Grab Bucket Conveyer

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 Lay out of fuel handling equipment

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 Pulverised coal preparation using /puveriser/mill

Coal is pulverized (powdered) to increase its surface area (and

therefore exposure) thus permitting rapid combustion. The
pulverized coal is obtained by grinding the raw coal in
pulverizing mills.
Various types of pulverizing mills are:
⚫ Ball mill
⚫ Ball and race mill
⚫ Hammer mill
⚫ Bowl mill
Essential functions of pulverizing mills are:
1 Drying of the coal
2. Grinding
3. Separation of particles of a desired size.
4. Coal pulverizing mills reduce coal to powder by any (or all)
action such as Impact, Abrasion and Crushing

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 Ball and Race mill for pulverizing coal
⚫ This is a low speed unit in
which grinding pressure is
maintained by adjustable
springs.
⚫ The coal passes between
the two rotating elements
again and again until it has
been pulverized to desired
degree of fineness.

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 Ball mill

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 Pulverized Fuel Handling
⚫ Pulverized fuel handling can be devided in to two
types,unit System and Central System

Unit System

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 Pulverized Coal firing

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 Pulverized fuel plant
⚫ Basically, pulverized fuel plants
may be divided into two
systems based on the method
used for firing the coal:
1.Unit System or Direct System .
2. Bin System or Central System
⚫ Unit or Direct System: This
system works as follows:
⚫ Coal from bunker drops on to
the feeder. Coal is dried in the
feeder by passage of hot air. The
coal then moves to a mill for
pulverizing. A fan supplies
primary air to the pulverizing
mill. Pulverized coal and
primary air are mixed and sent
to a burner where secondary air
is added.
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 Bin or Central System
⚫ Coal from bunker is fed by gravity to a dryer where hot
air is admitted to dry the coal. Dry coal is then
transferred to the pulverizing mill. Pulverized coal then
moves to a cyclone separator where transporting air is
separated from coal.
⚫ Primary air is mixed with coal at the feeder and
supplied to the burner. Secondary air is supplied
separately to complete the combustion

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 Advantages of Unit system
⚫ 1) Simple layout and easy operation.
⚫ 2) It requires less space.
⚫ 3) It is cheaper when compared with central system.
⚫ 4) Less maintenance.
⚫ 5) Simple coal transportation system.
⚫ 6) Direct control of combustion from the pulveriser is
possible.
⚫ 7) Better control over fuel feed rate.

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 Disadvantages of Unit system
⚫ 1) Less flexible when compared to central system.
⚫ 2) With the load factor in common practice, the total
capacity of all the mills must be higher than for the
control system.
⚫ 3) Any fault in the coal preparation unit may stop the
entire steam generating system.
⚫ 4) Excessive wear and tear of the fan blades as it
handles air and coal particles

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 Central System

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 Advantages of Central System
⚫ 1) More flexible because the quantity of fuel and air
can be controlled separately.
⚫ 2) More reliable.
⚫ 3) No problem of excessive wear of fan blades.
⚫ 4) Less labour is required.
⚫ 5) Low power consumption per tonne of coal handled.

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 Disadvantages of Central System
⚫ 1) High initial cost.
⚫ 2) It requires large space area.
⚫ 3) Possibility of fire and explosion hazards.
⚫ 4) Driers are necessary.
⚫ 5) Operation and maintenance costs are high when
compared to unit system of same capacity.
⚫ 6) More number of auxiliaries.

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 Burners

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 Pulverized fuel Burners

⚫ Various types of burners are used for combustion of

pulverized coal

⚫ Long flame burners

⚫ Turbulent Burners
⚫ Tangential Burners
⚫ Cyclone Burners

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 Long flame Burners
In this burner, air and coal mixture travels a
considerable distance thus providing sufficient time
for complete combustion

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 Turbulant Burners

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 Tangential Burners

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 Cyclone Burner
In this system, the coal and air will be mixed due to cyclonic
whirling action . The coal is crushed into tiny powder in
addition to pulverized coal .The ash is easily collected due to
cyclonic action

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 Cyclone Burner:
⚫ In this system, the cyclonic action whirls coal and air
against the wall of the furnace to facilitate thorough
mixing of coal and air.
⚫ Advantage of this burner is that it can also use crushed
coal in addition to pulverized coal thus providing an
option.
⚫ When crushed coal is used, ash is collected in molten
form for easy disposal.

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 Advantages of Cyclone Burner

⚫ Costly pulverisers are not required. Instead, simple

coal crushing equipment can be used.
⚫ By using forced draught fan it can be operated with
small quantities of excess air.
⚫ It can burn low grades of coal effectively.
⚫ High temperatures are obtained.
⚫ Boiler fouling (sticking) problems can be reduced as
all the incombustibles are retained in the cyclone
burner.
⚫ Boiler efficiency is increased.

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 Ash handling

Handling of ash includes

⚫ 1.Its removal from the furnace
⚫ 2.Loading on the conveyors and delivery to the fill or
dump from where it can be disposed off by sale or
otherwise.

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 Ash handling Characteristics

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 Equipments commonly used for ash handling:

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 Uses of Ash and dust

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 Ash Disposal Equipment

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 General Layout of Ash Handling system

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 Ash Handling System:

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 Mechanical Handling System

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 Hydraulic System

⚫ Low pressure system

⚫ High pressure system

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 Low Pressure system

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 High Pressure system

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 Advantages of Hydraulic System

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 Pneumatic system

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 Steam Jet system

⚫ In the high pressure steam jet system,a jet of high

pressure steam is passed in the direction of ash travel
through a conveying pipe in which the ash from the
boiler ash hopper is fed.

⚫ The ash is deposited in the ash hopper

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 Dust collection

⚫ If smoke, the indication is that combustion conditions

are faulty and the proper remedy is in the design and
management of the furnace.
⚫ If dust, the particles are mainely fine ash particles
called fly ash intermixed with some quantity of carbon
ash material called cinder.
Removal of Smoke
⚫ Some is produced due to incomplete combustion
⚫ Smokey atmosphere is unhealthy
⚫ Smoke corrodes the metals

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 Dust collectors

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 Mechanical Dust Collector
⚫ Basic Principles of Mechanical Dust Collectors .
⚫ Fig A.Enlarging the duct cross sectional area to slow down
the gas gives the heavier particles a chance to settle out.
⚫ Fig B When a gas makes a sharp change in flow direction,
the heavier particles tend to keep going in the original
direction and so settle out.
⚫ Fig C Impingement baffles have more effect on the solid
particles than the gas, helping them to settle.

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 Mechanical Dust Collectors
i) Wet type dust collectors:
⚫ Wet types called scrubbers operate with water sprays to
wash dust from the air.
⚫ Large quantities of wash water are needed for central
station gas washing that this system is seldom is used.
⚫ It also produces a waste water that may require chemical
neutralization before it can be discharged into the central
bodies of water.

ii) Dry type dust collectors:

⚫ These are commonly used dust collectors.
⚫ a) Gravitational Separators: These collectors act by slowing
down gas flow so that particles remain in a chamber long
enough to settle in the bottom. They are not very suitable
because of large chamber volume needed
⚫ b)cyclone separator
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 Cyclone Separator
⚫ The cyclone is a separating chamber
where in high-speed gas rotation is
generated for the purpose of
centrifuging the particles from the
carrying gases.
• There is an outer downward flowing
vortex which turns into an inward
flowing vortex.
• Involute inlets and sufficient velocity
head pressures are used to produce
the vortices.
• The factors which affect the
performance are gas volume, particles
loading, inlet velocity, temperature,
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diameter- to- height ratio of cyclone
 Advantages and Disadvantages of cyclone separator

ADVANTAGES:
⚫ Rugged in construction
⚫ Maintenance costs are relatively low
⚫ Efficiency increases with increase in load
⚫ Easy to remove bigger size particles

DISADVANTAGES:
⚫ Requires more power than other collectors
⚫ Incapable to remove dust and ash particles which remain in
suspension with still air
⚫ Less flexible
⚫ High pressure loss
⚫ Requires considerable head room and must be placed
outside the boiler room
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 Electrical Dust Collector

The main elements of an electrostatic precipitator are:

⚫ Source of high voltage
⚫ Ionizing and collecting electrodes
⚫ Dust removal mechanism
⚫ Shell to house the elements

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 Electrical Dust Collector
⚫ The precipitator has two sets of electrodes, insulated from
each other, that maintain an electrostatic field between
them at high voltage.
⚫ The field ionizes dust particles that pass through it,
attracting them to the electrode of opposite charge.
⚫ The high voltage system maintains the negative potential of
30,000 to 60,000 volts with the collecting electrodes
grounded.
⚫ Accumulated dust falls of the electrode when it is rapped
mechanically .
⚫ Wet type of unit removes dust by a water film flowing
down on the inner side of the collecting electrode.
⚫ These units have collection efficiency around 90%.
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 Advantages and disadvantages of an electrical
precipitator
ADVANTAGES:
⚫ Can effectively remove very small particles like smoke, mist
and fly-ash
⚫ Easy operation
⚫ Draught loss is quite less
⚫ Most effective for high dust loaded gas
⚫ Maintenance charges are minimum
⚫ The dust collected in dry form and can be removed either dry or
wet
DISADVANTAGES:
⚫ Space requirement is more
⚫ Need to protect the collector from sparking
⚫ Running
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deole are high
⚫ Capital cost of equipment is high
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 Introduction

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 Components of flue gases

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 Composition of flue gases in varying proportion of
air

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 Chemical Method

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 Instrumental method

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 Trace Component Analysis

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 Conclusion

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 Feed water Treatment

⚫What is the necessity of

Feed water
treatment???????
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 Different Impurities in water

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 Different Impurities in water

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 Effects of Impurities

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 Effects of impurities contd..

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 Effects of Impurities contnd..

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 Effects of Impurities contnd,,,,

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 pH & its role in corrosion and scale
formation

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 pH & its role in corrosion and scale
formation

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 Different methods of water treatment

⚫ Internal boiler water treatment for scale formation

⚫ External water treatment system

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