R&D and Demonstration of Large Domestic CFB Boilers

In order to develop large CFB boilers with independent intellectual property, Xi'an Thermal Power Research Institute (TPRI) established a laboratory with complete functions for the technical development of CFB boilers. This laboratory consists of a 1-MW and a 4-MW CFB combustion test facilities and a laboratory for limestone desulphurization performance evaluation. It carried out tests on CFB combustion and desulphurization for Chinese typical coals and limestone and research on heat-transfer characteristics and key parts, and developed the first home-made 100-MW CFB boiler. Based on the experience of R&D, the laboratory further researched key techniques for enlarging capacity systematically, and cooperating with Harbin Boiler Co. (HBC), developed the first domestic 210-MW CFB boiler with independent intellectual property and put it into engineering demonstration, laying a solid foundation for the development of CFB boilers of even larger capacity.

Fault Analysis and Innovation in Slag Discharge System of 440-t/h CFB Boiler

CFB boilers have been widely used in China in recent years with their perfect performances in coal adaptability, load variation capability and lower pollutant emission. The No.3 135-MW CFB unit in Lianzhou Power Plant is the f irst 440-t/h series CFB unit in Guangdong Province. It f inished 72-hour trial operation in Feb. 2004 and was transferred to trial operation. During the trial operation and the next commercial operation, there were some problems happened in the boiler slag discharging system, seriously affecting the safe and reliable operation and the loading capability. After innovation, these problems have been completely solved. Hopefully the solutions may be used for reference to the units with similar problems.

Flexible Co-Combustion of High Ratios of Sustainable Biomass with Coal in Oxy-CFB Boiler for CO₂Capture

Coal-fired plants are under pressure to reduce their carbon-intensity. Available options include co-firing CO2-neutral biomass, oxy-fuel-combustion as part of a carbon capture process or a combination of both to give a “CO2-negative” power plant. BioCCS, the combination of CO2 Capture and Storage (CCS) with sustainable biomass conversion, is the only large-scale technology that can achieve net negative emissions. Combining, developing and demonstrating the oxy-combustion of high ratios of sustainable biomass with coal in flexible circulating fluidized bed (CFB) boiler will bring significant advances in the reduction of greenhouse gases (GHG) emissions. Areas addressed include possibilities for: biomass characterization;handling and feeding;co-firing ratios definition;CFB oxy-co-combustion studies;combustion performance;boiler flexibility in fuel and load;main emissions analysis;slaging, fouling and agglomeration;corrosion and erosion;and implications on plant operation and associated costs. The article will detail a comprehensive understanding on sustainable biomass supply, co-firing ratios and how direct biomass co-combustion under oxy-fuel conditions can be implemented. It seeks to push biomass co-combustion in future large-scale oxy-fuel CFB power stations to high thermal shares while enhancing the power plants’ operational flexibility, economic competitiveness and give operational procedures. There will be a need to consider the public acceptance of power production from coal and coal sustainability, by its combination with renewable sources of energy (biomass).

CPFD modeling of hydrodynamics,combustion and NOx emissions in an industrial CFB boiler

The ultra-low NOx emission requirement(50 mg/m^(3))brings great challenge to CFB boilers in China.To further tap the NOx abatement potential,full understanding the fundamentals behind CFB boilers is needed.To achieve this,a comprehensive CPFD model is established and verified;gas-solid flow,combustion,and NOx emission behavior in an industrial CFB boiler are elaborated;influences of primary air volume and coal particle size on furnace performance are evaluated.Simulation results indicate that there exists a typical core-annular flow structure in the boiler furnace.Furnace temperature is highest in the bottom dense-phase zone(about 950℃)and decreases gradually along the furnace height.Oxygen-deficient combustion results in high CO concentration and strong reducing atmosphere in the lower furnace.NOx concentration gradually increases in the bottom furnace,reaches maximum at the elevation of secondary air inlet,and then decreases slightly in the upper furnace.Appropriate decreasing the primary air volume and coal particle size would increase the CO concentration and intensify the in-furnace reducing atmosphere,which favors for NOx reduction and low NOx emission from CFB boilers.

Influence of Limestone Addition on Combustion and Emission Characteristics of Coal Slime in the 75 t/h CFB Boiler with Post-Combustion Chamber

Coal slime can be disposed in quantity and fully utilized in a well-designed circulating fluidized bed(CFB)boiler,but the nitrogen oxides(NO_(x))and sulphur dioxide(SO_(2))emissions generated in the combustion of coal slime have contributed to serious atmospheric pollution.High Temperature&Post-combustion Technology,a novel and high-efficient way to reduce the NO_(x)emission in the process of combustion,is applied to a 75 t/h CFB boiler burning exclusively coal slime,which will succeed to meet the ultra-low NO_(x)emission standard.To further explore an appropriate method to reduce the SO_(2)emission under the condition of new technology,the experiments were conducted on a 75 t/h CFB boiler with post-combustion chamber to study the influence of limestone addition on the combustion and emission characteristics of coal slime.The experimental results showed that High Temperature&Post-combustion Technology combined with the sorbent injection in the furnace is a very promising technology to control the NO_(x)and SO_(2)emissions simultaneously.Limestone addition can cause the slight decrease in combustion temperature.Limestone addition will lead to the increase in NO_(x)emission in the combustion of coal slime.In 75 t/h coal slime CFB boiler,the desulfurization efficiency of limestone injection in furnace is close to 98%,achieving the ultra-low SO_(2)emission.To meet the standard of ultra-low NO_(x)and SO_(2)emission,the two technologies for simultaneous removal of NO_(x)and SO_(2)emissions are economical and feasible currently:Removal of SO_(2)under ultra-low NO_(x)emission and Removal of NO_(x)under ultra-low SO_(2)emission.

The Heat Transfer Coefficients of the Heating Surface of 300 MWe CFB Boiler

A study of the heat transfer about the heating surface of three commercial 300 MWe CFB boilers was conducted in this work. The heat transfer coefficients of the platen heating surface, the external heat exchanger (EHE) and cyclone separator were calculated according to the relative operation data at different boiler loads. Moreover, the heat transfer coefficient of the waterwall was calculated by heat balance of the hot circuit of the CFB boiler. With the boiler capacity increasing, the heat transfer coefficients of these heating surface increases, and the heat transfer coefficient of the water wall is higher than that of the platen heating surface. The heat transfer coefficient of the EHE is the highest in high boiler load, the heat transfer coefficient of the cyclone separator is the lowest. Because the fired coal is different from the design coal in No.1 boiler, the ash content of the fired coal is much lower than that of the design coal. The heat transfer coefficients which calculated with the operation data are lower than the previous design value and that is the reason why the bed temperature is rather high during the boiler operation in No.1 boiler.

COAL COMBUSTION EFFICIENCY IN CFB BOILER

The carbon content in the fly ash from most Chinese circulating fluidized bed (CFB) boilers is much higher than expected, thus directly influencing the combustion efficiency. In the present paper, carbon burnout was investigated both in field tests and laboratory experiments. The effect of coal property, operation condition, gas-solid mixing, char deactivation, residence time and cyclone performance are analyzed seriatim based on large amount of experimental results. A coal index is proposed to describe the coal rank, defined by the ratio of the volatile content to the coal heat value, is a useful parameter to analyze the char burnout. The carbon content in the fly ash depends on the coal rank strongly. CFB boilers burning anthracite, which has low coal index, usually have high carbon content in the fly ash. On the contrary, the CFB boilers burning brown coal, which has high coal index, normally have low carbon content. Poor gas-solid mixing in the furnace is another important reason of the higher carbon content in the fly ash. Increasing the velocity and rigidity of the secondary air could extend the penetration depth and induce more oxygen into the furnace center. Better gas solid mixing will decrease the lean oxygen core area and increase char combustion efficiency. The fine char particles could be divided into two groups according to their reactivity. One group is 'fresh' char particles with high reactivity and certain amount of volatile content. The other group of char particles has experienced sufficient combustion time both in the furnace and in the cyclone, with nearly no volatile. These 'old' chars in the fly ash will be deactivated during combustion of large coal particles and have very low carbon reactivity. The generated fine inert char particles by attrition of large coal particles could not easily burn out even with the fly ash recirculation. The fraction of large coal particles in coal feed should be reduced during fuel preparation process. The cyclone efficiency controls the particle residence time in CFB loop, especially for that of the fine particles. So the cyclone efficiency, especially the cut size, will greatly influence the carbon content in the fly ash.

Restart-up Performance of a CFB Boiler after a Sudden Power Failure Accident

Due to the massive bed materials in its typical main loop,a circulating fluidized bed(CFB)boiler may face greater trouble in operation and restart-up if an unplanned sudden power failure happens in the power plant.This study aims to explore the restart-up performance of a 170 t/h natural circulation CFB boiler after a sudden power failure and evaluate whether the hot restart-up can be realized.The heat transfer process after the restoration of the primary air is modeled.Validating the isothermal property of the bed after the restoration of the power and air supply,the correlation among the accident duration time,bed temperature after the power restores,inlet air temperature,air supply time,and air velocity is proposed.The predicted results indicate that the major influencing factor of the bed temperature during this process is primary air velocity.To provide guidelines for judgment on whether the hot restart-up can be realized,the maximum values of the air supply time and accident duration time for hot restart-up for different types of coals are given.The results show both of them have a rapid decrease as the coal ignition temperature in a CFB boiler increases from 450°C to 650°C,which also means that the coal ignition temperature plays a very important role in the restart-up process.Based on the simulation results of bed temperature during the accident,it is also estimated that the drum level drops by 77.7 mm after 8 hours but still stays in the permissible range.

Numerical Investigation on the Heat Transfer Characteristics of Supercritical Water in a Non-Uniformly Heated Tube for a Supercritical CFB Boiler

In this paper,a numerical model was built by ANSYS FLUENT to investigate the heat transfer performances of supercritical water in a circumferential non-uniformly heated vertical tube.The Shear Stress Transport(SST)k-ωmodel was adopted for describing turbulence.The operating parameters are chosen according to a 660 MW ultra-supercritical CFB boiler.The heat transfer performances under different operating parameters,such as boiler load,flow direction and heat flux distribution are analyzed.The temperature and heat flux on inner wall varies along the circumference and show symmetric distributions.The overall heat transfer performances at each cross section are better than the local heat transfer performance of midpoint of heating side.Flow direction has a great influence on heat transfer performance;it changes the radial distribution of axial velocity and then affects the turbulence distribution.Therefore,upward flow condition shows a better heat transfer performance.Smaller heat flux improves both the overall and local heat transfer performances.Reducing the heat flux area is not conducive to the overall heat transfer,but does not affect the local heat transfer at the midpoint of heating side.Finally,a new correlation is fitted based on the simulated results of supercritical water heat transfer with circumferential non-uniform heat flux distributions.

基于TF-NGO算法的CFB锅炉床温系统建模研究

床温是循环流化床(CFB)锅炉重要的运行参数之一。针对床温耦合性强、干扰因素多、控制复杂的问题,亟需建立床温的数学模型,以实现床温控制,从而保证CFB锅炉安全、平稳地运行。为此,首先引入了混沌映射、切线飞行(TF)和柯西变异策略改进北方苍鹰优化(NGO)算法,并用实际工况的系统模型测试TF-NGO算法。测试结果表明,TF-NGO算法拥有更快的收敛速度和更高的寻优精度。其次,采集并预处理山西某电厂350 MW超临界CFB锅炉的现场运行数据。最后,采用TF-NGO算法对所建模型的参数进行辨识,并用实际工况数据进行模型验证。辨识和验证结果表明,由TF-NGO算法辨识的床温模型与实际输出拟合度高,能有效反映床温的动态特性,证明所建模型的有效性。该研究为后续对350 MW超临界CFB锅炉床温的优化控制研究奠定了基础。

300 MW CFB锅炉旋风分离器改造数值模拟研究

旋风分离器分离性能会显著影响循环流化床锅炉的运行。为解决某300 MW循环流化床锅炉旋风分离器分离器性能差的问题,基于欧拉-拉格朗日框架,使用UGNX12.0软件对该300 MW循环流化床锅炉的炉膛、旋风分离器、返料阀按照实际尺寸1∶1建立全回路几何模型,根据实际参数设置边界条件,并通过Barracuda软件进行数值模拟,分析旋风分离器烟道入口各参数(入口烟道高度、入口烟道宽度、入口下倾角大小及中心筒插入深度)对旋风分离器效率及压降的影响;综合考虑分离器的分离效率、压降以及磨损量,提出了2个改造方案。仿真结果表明:炉膛内压力模拟值与实际值的偏差均在5%以内,模拟结果较为精确;2个方案在各负荷下均能提升旋风分离器分离性能,方案1满负荷下效率相较于较改造前提升了0.260%,压降降低了13.1 Pa,方案2满负荷下效率相较于改造前提升了0.240%,压降降低了53.7 Pa;随着负荷降低,旋风分离器效率提升逐渐不明显,在300、260和160 MW负荷下,方案1分别提升0.263%、0.178%和0.023%,方案2分别提升0.243%、0.174%和0.020%。

基于集成学习的CFB锅炉氮氧化物排放质量浓度在线建模研究

针对循环流化床锅炉氮氧化物排放质量浓度变化规律复杂、自相关性强等特点,利用有关变量及其历史信息,分别建立了氮氧化物排放质量浓度的整合移动平均自回归(ARIMA)和随机森林(RF)、梯度提升树(GBDT)、极致梯度提升树(XGBoost)等集成学习在线模型,并对预测效果进行对比择优,其中以GBDT回归器为最优。为了进一步改进模型的预测效果,提出将一阶差分与GBDT回归算法相结合,建立了GBDT差分回归模型。测试表明所建立的GBDT差分回归模型比前述模型具有更好的预测性能,其预测值的均方差比单纯GBDT回归器降低了20.2%,并比参考文献采用的在线贯序极限学习机(OS-ELM)模型低46.5%。所建的在线模型还充分考虑避免仪表吹扫过程的影响,具有较强的实用性。

CFB锅炉宽筛分颗粒临界流化风速研究

基于计算颗粒流体力学(CPFD),通过表征常规CFB锅炉床料(Set 1)、增加炉内细颗粒含量(Set 2)和减小初始床支撑料粒度(Set 3) 3种筛分分布的SiO_(2)颗粒,研究颗粒筛分变化对临界流化风速的影响。研究结果表明:在相同床层高度下,Set 1、Set 2和Set 3床料的临界流化风速分别为0.51、0.30和0.20 m/s。表明增加炉内细颗粒含量和减小初始床支撑料粒度均可明显降低临界流化风速。将宽筛分颗粒临界流化风速的数值模拟结果与相关关联式预测结果进行对比,表明ERGUN关联式的预测结果偏差较小,WEN-YU关联式的预测结果明显偏低。

超临界CFB锅炉水冷壁管分区段热应力分析

为确保循环流化床锅炉水冷壁的正常运行,以避免发生蠕变变形、高温腐蚀等生产事故。以600 MW超临界循环流化床(circulating fluidized bed,CFB)锅炉为研究对象,建立了水冷壁温度应力场数值模型。并利用分区段炉膛热力计算理论和新IAPWS-IF97公式,对运行状态中水冷壁分区段进行壁温和热应力分析。结果表明:各区段管壁温度与应力场分布变化一致,但由于工质焓值和高温烟气的交叉作用,区段5存在最高壁温与最大热应力。进一步对区段5进行传热恶化分析可得,管壁最高温度部位发生转移,且壁温与热应力最大值皆超过设计值,可能导致水冷管爆管或断裂。随后针对安全隐患,通过数值模拟方法从降低局部热负荷和控制质量流速的角度来防止锅炉传热恶化,为锅炉安全监测提供了有效建议与防治手段。

CFB锅炉输煤系统增设筛分破碎设施方案研究

苏晋朔州电厂循环流化床锅炉所需合格的燃煤(0~8 mm)原设计由附近选煤厂筛分破碎后直接提供,自公司2×660 MW机组投产后,因配套选煤厂供电厂煤量不足且其燃煤粒径超标,同时电厂从周边露天矿协调调入汽运煤,汽运煤颗粒度更是超标严重,造成锅炉频繁结焦、下渣口堵塞等问题,严重时造成停机事故。为严格控制入炉煤粒径,提高设备运行稳定性和经济性,针对燃煤粒径超标问题,电厂提出在厂内增加筛分破碎设施,由于电厂设计阶段未做预留,没有合适的场地可供筛分破碎系统建设。专家组经过对生产厂区进行踏勘,提出2种较为可行的方案,经分析论证,最终选择在1号转运站处向地下深挖并采用大倾角皮带等方式建造紧凑型筛分破碎楼的创新方案,有效解决了建造空间不足的问题,改善了入炉煤的颗粒度,为同类型电厂新增破碎设施改造工作提供参考和依据。

350 MW超临界CFB锅炉掺烧生活污泥现场试验研究

燃煤锅炉掺烧生活污泥技术具有无害化处置污泥、回收利用污泥热量、推动煤电行业清洁低碳发展等优点,发展前景广阔。目前,燃煤电厂进行生活污泥掺烧的主要炉型为煤粉炉和CFB锅炉,然而针对CFB锅炉的研究相对较少。为了探究超临界CFB锅炉掺烧生活污泥的燃烧效率和环保特性规律,基于国内某电厂的2台350 MW超临界CFB锅炉,对180、260、350 MW三类锅炉负荷共14个工况开展现场试验研究。研究结果表明,污泥掺烧对电厂原有生产系统不产生影响,当掺烧比例在5%~15%时,锅炉各系统运行稳定,各参数均在正常范围内,锅炉效率变化基本在0.5%左右,烟气污染物排放满足环保要求,电厂能够正常运行。虽然随着污泥掺烧比例增大,锅炉效率呈下降趋势,且锅炉运行负荷越低,下降幅度越大,但整体上掺烧污泥对锅炉效率的影响较小,同负荷试验工况间最大的锅炉效率降幅小于0.5%。针对NO_(x)、SO_(2)和粉尘3种常规烟气污染物,试验过程可以将CEMS装置提供的数据作为研究依据,分析发现掺烧污泥后排放烟气经过现有净化系统依然能满足燃煤电厂的超低排放要求,不需要进行改造升级。而针对重金属及其化合物和二噁英类2种非常规烟气污染物,虽未配备专门的脱除装置,但试验发现当掺烧比例较低时影响较小,正常处置即可,不会造成二次污染。

CFB锅炉掺烧气化细渣技术研究进展

煤气化渣产量大、存量多,常规的填埋和堆积处理不但占用大量土地资源,而且还存在严重的污染风险和安全隐患。本文介绍了气化细渣的组成、结构和燃烧特性,综述了残碳富集、脱水干化等气化细渣预处理方法的研究进展,从气化细渣的含水率、灰分、掺烧比例及污染物排放情况等方面分析了气化细渣掺烧对循环流化床(CFB)锅炉燃烧的影响,指出CFB锅炉掺烧气化细渣具备显著的环保和经济效益,是气化细渣实现减量化、无害化和资源化利用的主要途径之一。

基于ASME PTC 4的油页岩CFB锅炉效率的改进算法

油页岩属于非常规油气资源,作为常规能源的补充,对改变我国能源结构具有非常重要的战略意义,同时以资源丰富性和开发利用的可行性而被列为21世纪非常重要的接替能源。与常规电厂的燃煤相比,油页岩具有热值低、灰量大且灰分中含有大量CaCO_(3)等特点。虽然我国油页岩蕴藏量十分丰富,居世界第四位且储量仅次于煤炭,但是我国油页岩却几乎未被很好地利用,尤其是在燃烧发电技术方面。针对国外某油页岩循环流化床锅炉,基于ASME PTC 4(LHV)标准,提出了油页岩循环流化床锅炉效率的改进算法,并通过现场试验对该算法进行应用,为后续国内油页岩在发电方面的应用提供参考。结果表明:与同类型燃煤机组相比,油页岩在燃烧过程中灰渣的显热损失明显偏高,达到11.134%;油页岩的灰分质量分数较大、热值较低造成燃料消耗量明显偏高,达到637.56 t/h;灰渣中CaCO_(3)未完全煅烧少吸收的热量作为外来热量进入锅炉,导致计算效率时的外来热量值明显偏高,达到6.008%,锅炉效率达到91.97%的同时产生的大量灰渣可进行综合回收利用,加之油页岩本身资源丰富性和开发可行性,因而在燃烧发电方面具有较高的商业应用价值。