BOILER DESIGN DEPARTMENT RAFAKO CFB BOILERS TECHNOLOGY CFBB

BOILER DESIGN DEPARTMENT RAFAKO CFB BOILERS TECHNOLOGY

CFBB TECHNOLOGY AT RAFAKO l First CFB contract for RAFAKO S. A. OFz-230 for CHP Lublin Wrotków in 1990 after signing a licence agreement for CFB with Alstom Power (EVT Stuttgart) in 1990. l Total CFB Boilers capacity (approx. 1755 MWt) contracted by RAFAKO in Poland: contract award - OFz 45 O A 2 x OFz-75 OFz-230 2 x OFz-425 OFz-450 B OFz-201 Żerań CHP Polfa CHP Bielsko-Biała CHP Siersza PP Żerań CHP Jaworzno PP 1993 1994 1998 2010 start-up 1996 2001/2002 2001 2012

CFBB TECHNOLOGY AT RAFAKO - Advantages n n n "complex" environment protection method, i. e. low combustion temperatures (800 o. C - 900 o. C) result in the release of low quantities of nitric oxides (lower than 200 mg/Nm 3) and due to the addition of calcium compounds to the furnace up to 90 - 95% reduction of sulphur oxides emission is obtained, firing of the unit with the wide range of fuels, minimum furnace load (c. a. 35%) without additional firing (with oil) utilisation of combustible industrial and municipal waste in thermal energy generation, high furnace efficiency obtained due to the high residence time of particles in the furnace (particles circulation) and good mixing of fuel with air,

CFBB TECHNOLOGY AT RAFAKO - Advantages n n n n low air excess (15% - 20%) at nominal load, possibility of quick changes of boiler load like in case of pulverised fuel boilers, i. e. 4% - 6%, high desulphurization level (low Ca/S) due to good mixing of additives and fuel and due to recirculation, possibility of return to the load even after several hours, possibility of firing with high ash coal, simple feeding of fuel to the furnace, good heat exchange coefficient in furnace, dry ash removal from furnace chamber and possibility of its further utilisation.

CFBB TECHNOLOGY AT RAFAKO b) HOT CIRCULATION BED IDEA FLUIDISATION PHASES: 1. 2 3 Moving up to the top of furnace to the cyclone 2. Dropping down along furnace walls surface 3. Separation in cyclone a) Return of coarse grains to the furnace b) Fine grains escaping to the boiler second pass 1 a)

CFBB TECHNOLOGY AT RAFAKO Circulating bed nozzles Primary air * Bottom nozzle grate

CFBB TECHNOLOGY AT RAFAKO Minus mesh Residue REQUIRED COAL GRAIN SIZE DISTRIBUTION - Bituminous Coal Grain size

CFBB TECHNOLOGY AT RAFAKO Minus mesh Residue REQUIRED COAL GRAIN SIZE DISTRIBUTION - Lignite Grain size

CFBB TECHNOLOGY AT RAFAKO REQUIRED LIMESTONE GRAIN SIZE DISTRIBUTION

REFERENCE LIST OF CFB BOILERS

CFB BOILERS DESIGNED & PRODUCED BY RAFAKO OFz 450 A Żerań 450 t/h 510°C; 10 MPa OFz 230 Bielsko 230 t/h 540°C; 13, 8 MPa OFz 75 Polpharma 75 t/h 455°C; 4, 5 MPa

CFB BOILERS DESIGNED & PRODUCED BY RAFAKO OFz 425 Siersza 425 t/h 560/560°C; 16, 1/3, 5 MPa OFz 450 B Żerań 450 t/h 510°C; 10 MPa

Boiler OFz-450 “A”, Żerań CHP, Warsaw Technical Data l Boiler capacity MCR 315 MWt l Steam output 450 t/h l Life steam temperature 510 o. C l Life steam pressure 10 MPa l Feed water temp. 205 o. C l Boiler efficiency 92. 2 % Fuel: Bituminous coal l l Heating Value Moisture Ash Sulphur 22 - 28 MJ/kg 8 - 15 % 7 - 18 % 0. 6 - 0. 8 %

Boiler OFz-450 “A”, Żerań CHP, Warsaw Harmful Emissions From the Boiler (guaranteed and measured values) 36% 67% 83% 16% Real emission value vs. guaranteed 11% 48%

Boiler OFz-230, Bielsko-Biała CHP Technical Data l Boiler capacity MCR 177/165 MWt l Steam Output 230 t/h l Life steam temperature 540 o. C l Life steam pressure 13. 8 MPa l Feed water temp. 158/205 o. C l Boiler efficiency 91. 2/91 % Fuel: Bituminous coal l Heating Value 17 -20. 1 MJ/kg l Moisture 10 -17 % l Ash 20 -30 % l Sulphur 1%

Boiler OFz-230, Bielsko-Biała CHP Harmful emissions from the boiler (guaranteed and measured values) 29% 65% Real emission value vs. guaranteed 30% 6%

2 x OFz-75, Polfa Starogard Gdański Technical Data l Boiler capacity MCR 60, 2 MWt l Steam Output 75 t/h l Life steam temperature 455 o. C l Life steam pressure 4. 5 MPa l Feed water temp. 105 l Boiler efficiency 91. 5 % o. C Fuel: Bituminous coal l Heating Value 16, 5 -19 MJ/kg l Moisture 15 -21 % l Ash 25 -32 % l Sulphur 1, 4 %

2 x OFz-75, Polfa Starogard Gdański Harmful emissions from the boiler (guaranteed and measured values) Real emission value vs. guaranteed 75% 50% 40%

2 x Boiler OFz-425 , Siersza PP Technical Data l Boiler capacity MCR 338. 5 MWt l Life steam output 425 t/h o. C l Life steam temp. (40 -100%) 560 l Life steam pressure 16. 1 MPa l Reheated steam output 371 t/h l Reheated steam temp. (50 -100%) 350/560 o. C l Reheated steam pressure 3. 7/3. 5 MPa o. C l Flue gas outlet temp. (at MCR) 135 l Efficiency (coal - 16. 7 MJ/kg ) 91. 0 %

2 x Boilers OFz-425, Siersza PP Fuel: Bituminous coal l Heating value 16. 7 MJ/kg l Ash 20. 6 % l Moisture 21. 7 % l Sulphur 2. 4 % l Volatile matter 36. 6 % Emission Guaranties l SO 2 337. 5 mg/Nm 3 l NOx 307. 8 mg/Nm 3 l CO mg/Nm 3 250 for normal, dry conditions with O 2 content of 6% Overview of the erection phase of steel structure and cyclones

Boiler OFz-425, Siersza PP Harmful emissions from the boiler (guaranteed and measured values) 85% Real emission value vs. guaranteed 55% 15% 80% 50%

Boiler OFz-450 “B”, Żerań CHP, Warsaw Technical Data l Boiler capacity MCR 315 MWt l Steam output 450 t/h l Life steam temperature 510 o. C l Life steam pressure 10 MPa l Feed water temperature 205 o. C l Boiler efficiency 92% Fuel: Bituminous coal l Heating Value l l l Moisture Ash Sulphur 18 - 24 MJ/kg 8 - 15 % 15 - 25 % 0. 6 - 1. 0 %

Boiler OFz-450 “B”, Żerań CHP, Warsaw Harmful Emissions From the Boiler (guaranteed and measured values) 75% 60% 50% Real emission value vs. guaranteed

Boiler OFz-450 “B”, Żerań CHP, Warsaw Steam drum “piping spider” in engineering and in fabrication phase

Comparison of Coals Burnt in CFB Boilers in Poland Coal Parameters Comparison

Boiler Construction Optimisation Resulting From Operational Experience Target No 1: Operating Conditions Improvement Target No 2: Simplification of CFB Installation

Boiler Construction Optimisation Target: Operating Conditions Improvement l l Antierosion protection for furnace walls Antierosion protection for other heating surface within the boiler Antiradiation protection for boiler heating surfaces Improvement of boiler element connection

Boiler Construction Optimisation Target: Operating Conditions Improvement Antierosion protection for furnace membrane walls Metal coating (Żerań A & B, Siersza)

Boiler Construction Optimisation Target: Operating Conditions Improvement Antierosion protection for furnace membrane walls Mechanical shield (Żerań B, Siersza)

Boiler Construction Optimisation Target: Operating Conditions Improvement Antierosion protection for furnace membrane walls Protective shape of the hopper refractory lining (Żerań B, Siersza)

$Boiler Construction Optimisation Target: Operating Conditions Improvement Protective shape of the refractory lining on$

Boiler Construction Optimisation Target: Operating Conditions Improvement Protective shape of the refractory lining on the return ash chute and burners openings in the furnace chamber (Siersza)

Boiler Construction Optimisation Target: Operating Conditions Improvement Antierosion protection for other heating surfaces within the boiler (Żerań A & B, Siersza)

Boiler Construction Optimisation Target: Operating Conditions Improvement Previous solution Antierosion protection for furnace corners New solution

Boiler Construction Optimisation Target: Operating Conditions Improvement Antiradiation shields (Polfa, Żerań A & B, Siersza)

Boiler Construction Optimisation Target: Simplification of Installation l Optimisation of cyclone separators shape l Improved bed ash extraction system l Improved start-up system of the boiler l Simplified inert material recirculation system

Boiler Construction Optimisation Cyclones shape and arrangement modification Cyclone with the spiral inlet Centric placement of the vortex finder Sloping inlet to the cyclone regarding to furnace chamber (Żerań A) Tangent and narrow inlet to the cyclone Increase of cyclone diametr Eccentric placement of the vortex finder Vertical inlet to the cyclone regarding to furnace chamber (Żerań B, Siersza)

Boiler Construction Optimisation Target: Simplification of Installation Simplified inert material recirculation system l abandoning of fly-ash recirculation system l abandoning of ash mill with auxiliaries and mill ash vessel l l abandoning of ash separator and hot ash scraped conveyor implementation of main screw ash extractor Improved start-up system of the boiler: l abandoning of oil lances l better flame control l better burner nozzle adjustment l improved protection of burner tips

Boiler Construction Optimisation Target: Simplification of Installation

Operational Experience With Circulating Fluid Bed Technology In Poland Summary l Participation and supervision of Supplier at erection and commissioning of the boiler l Co-operation with the Client during boiler operation l Adaptation of specific construction measures needed for the coal fired in CFB l CFB Boilers achieves all guarantied performance and environmental values even for very wide coal spectrum (including coal outside contract characteristic)

PP Siersza OFz 425 t/h

CHP Żerań OFz 450 t/h

CHP Bielsko-Biała OFz 230 t/h

BOILER DESIGN DEPARTMENT RAFAKO CFB BOILERS TECHNOLOGY THANK YOU FOR YOUR ATTENTION