BOILER DESIGN DEPARTMENT
RAFAKO CFB BOILERS TECHNOLOGY
CFBB TECHNOLOGY AT RAFAKO

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.

Total CFB Boilers capacity (approx. 1755 MWt) contracted by RAFAKO
in Poland:
contract award
-
OFz 45O 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
1993
1994
1998
1998
2010
start-up
1996
1996
1996
2001/2002
2001
2012
CFBB TECHNOLOGY AT RAFAKO - Advantages





"complex" environment protection method, i.e. low
combustion temperatures (800oC - 900oC) result in the
release of low quantities of nitric oxides (lower than 200
mg/Nm3) 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








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:
2
3
1. 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
REQUIRED LIMESTONE GRAIN SIZE
DISTRIBUTION
K211
0,1
1
5
10
LIMESTONE REQUIREMENTS
20
30
40
50
90
%
Moisture content
< 0.1
%
Reactivity index - RI
> 2.5
60
70
Residue [%]
Purity of the limestone (CaCO3 content)
80
85
90
95
96
97
98
98,5
99
99,5
10
20
30
50
100
Grain size d [m]
200 300
700
1000
REFERENCE LIST OF CFB BOILERS
Qty
Boiler
capacity
t/h
Steam
pressure
bar
Temperature
of live/reheat
steam ºC
PP Wachtberg - Germany
1
175
190
535
CHP Köhler - Germany
CHP Gaisburg - Germany
1
1
100
150
136
90
535
500
CHP Pforzheim - Germany
1
90
166
540
PP Emile Huchet - France
PP Berrenrath - Germany
1
2
367
250
155
107
545 / 540
510
PP Goldenberg - Germany
1
400
135
505
lignite
PP Wählitz - Germany
1
150
115
535
lignite
PP Gardanne - France
1
700
193
565 / 565
bituminuous coal
CHP Bielsko II - Poland
1
230
138
540
bituminuous coal
CHP Żerań - Poland
1
450
100
510
bituminuous coal
CHP Tisova - Czech
1
350
116
505
lignite
CHP Polpharma - Poland
2
75
45
455
bituminuous coal
PP Mironowska - Ukraine
1
260
138
540
anthracit
EC Mlada Boleslav - Czech
2
140
125
535
bituminuous coal
PP Red Hills - USA
2
753
203
568 /540
lignite
PP CAN - Turkey
2
462
175 / 38
543 / 542
lignite
PP Siersza - Poland
2
425
161
560 / 560
bituminuous coal
CHP Żerań - Poland
1
450
100
510
bituminuous coal
Customer
Plant Name
Country
Fuel
lignite
bituminuous coal
bituminuous coal
bituminuous coal
Bituminuous coal sludge
lignite
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

Boiler capacity MCR
315 MWt

Steam output
450 t/h

Life steam temperature 510 oC

Life steam pressure
10 MPa

Feed water temp.
205 oC

Boiler efficiency
92.2 %
Fuel: Bituminous coal




Heating Value 22 - 28 MJ/kg
Moisture
8 - 15 %
Ash
7 - 18 %
Sulphur
0.6 - 0.8 %
Boiler OFz-450 “A”, Żerań CHP, Warsaw
Harmful Emissions From the Boiler
(guaranteed and measured values)
36%
Emission [mg/Nm3]
250
67%
83%
16%
Real emission value
vs. guaranteed
200
150
100
50
0
SO2
NOx
CO
HCl
11%
48%
HF
Fly
Ash
Guaranties
Measurements
Boiler OFz-230, Bielsko-Biała CHP
Technical Data

Boiler capacity MCR
177/165 MWt

Steam Output
230 t/h

Life steam temperature 540 oC

Life steam pressure
13.8 MPa

Feed water temp.
158/205 oC

Boiler efficiency
91.2/91 %
Fuel: Bituminous coal

Heating Value17-20.1 MJ/kg

Moisture
10-17 %

Ash
20-30 %

Sulphur
1%
Boiler OFz-230, Bielsko-Biała CHP
Harmful emissions from the boiler
(guaranteed and measured values)
29%
65%
Emission [mg/Nm3]
300
Real emission value
vs. guaranteed
30%
250
200
Guaranties
Measurements
150
100
6%
50
0
SO2
NOx
CO
Fly Ash
2 x OFz-75, Polfa Starogard Gdański
Technical Data

Boiler capacity MCR
60,2
MWt

Steam Output
75
t/h

Life steam temperature 455
oC

Life steam pressure
4.5
MPa

Feed water temp.
105

Boiler efficiency
91.5 %
oC
Fuel: Bituminous coal

Heating Value16,5-19 MJ/kg

Moisture
15-21
%

Ash
25-32
%

Sulphur
1,4
%
2 x OFz-75, Polfa Starogard Gdański
Harmful emissions from the boiler
(guaranteed and measured values)
400
Emission [mg/Nm3]
Real emission value
vs. guaranteed
75%
350
40%
50%
300
250
Guaranties
Measurements
200
150
100
50
0
SO2
NOx
CO
2 x Boiler OFz-425 , Siersza PP
Technical Data
 Boiler capacity MCR
338.5 MWt
 Life steam output
425
t/h
oC
 Life steam temp. (40-100%)
560
 Life steam pressure
16.1
MPa
 Reheated steam output
371
t/h
 Reheated steam temp. (50-100%) 350/560oC
 Reheated steam pressure
3.7/3.5 MPa
oC
 Flue gas outlet temp. (at MCR) 135
 Efficiency (coal - 16.7 MJ/kg )
91.0
%
2 x Boilers OFz-425, Siersza PP
Fuel: Bituminous coal

Heating value 16.7
MJ/kg

Ash
20.6
%

Moisture
21.7
%

Sulphur
2.4
%

Volatile matter 36.6
%
Emission Guaranties

SO2 337.5
mg/Nm3

NOx 307.8
mg/Nm3

CO
mg/Nm3
250
for normal, dry conditions with O2
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)
Emission [mg/Nm3] (Ca/S
x100)
(Fly Ash g/Nm3)
85%
Real emission value
vs. guaranteed
55%
350
15%
300
80%
250
200
Guaranties
Measurements
150
100
50%
50
0
SO2
Ca/S
NOx
CO
Fly Ash
Boiler OFz-450 “B”, Żerań CHP, Warsaw
Technical Data

Boiler capacity MCR
315 MWt

Steam output
450 t/h

Life steam temperature
510 oC

Life steam pressure
10 MPa

Feed water temperature
205 oC

Boiler efficiency
92%
Fuel: Bituminous coal
 Heating Value



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)
Emission [mg/Nm3]
75%
200
180
160
140
120
100
80
60
40
20
0
60%
50%
Real emission value
vs. guaranteed
Guaranties
Measurements
SO2
NOx
CO
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
16,7
26
21,7
18,1
21
20,6
21,8
16,4
30
18
17
25
20
15
16,4
10
2,4
Siersza
PP
(design)
14,8
10
1,6
0,8
Siersza
PP
Żerań "A"
(present)
CHP
moisture [%]
0,8
1
Żerań "B"
CHP
LHV [MJ/kg]
ash [%]
1,4
Bielsko
CHP
sulphur [%]
Polfa CHP
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

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
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 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

Optimisation of cyclone separators
shape

Improved bed ash extraction system

Improved start-up system of the
boiler

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

abandoning of fly-ash recirculation system

abandoning of ash mill with auxiliaries and mill ash vessel

abandoning of ash separator and hot ash scraped conveyor

implementation of main screw ash extractor
Improved start-up system of the boiler:

abandoning of oil lances

better flame control

better burner nozzle adjustment

improved protection of burner tips
Boiler Construction Optimisation
Target: Simplification of Installation
Boiler Construction Optimisation
Target: Simplification of Installation
Operational Experience With Circulating Fluid Bed Technology In Poland
Summary

Participation and supervision of Supplier at erection and
commissioning of the boiler

Co-operation with the Client during boiler operation

Adaptation of specific construction measures needed for the
coal fired in CFB

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