Circulating fluidized bed power plants offer improved technology for burning low-grade coals

Introduction The 150 MW circulating fluidized bed (CFB) power plant described in this article is the product of recent Bechtel experience in the industrial power and steam market, where the economic feasibility of fluidized bed projects has been proven. The ability of CFB boilers to burn low grade fuels makes it possible to burn low ranking coals or coal wastes. These include anthracite culm, coal mine rejects, and coal wash-plant-waste slurries. This article also addresses the impact of fuel characteristics on plant design. This includes solids handling, steam generation, sulfur capture, and auxiliary load requirements. The uncertain economic environment in which utilities must now operate has shifted the industry's interest away from large, base-loaded generating units to small, more versatile installations. Utilities now consider purchasing new generating capacity in smaller increments and staging its deployment to correspond with demand increases. In this way, they lower their risk in the increasingly hazardous art of long-range load forecasting. This strategy has many advantages. Multiple, smaller units have inherently greater turndown capability and better availability than a single larger unit of the same size. In addition, the smaller units will each have better cycling capability. And, with CFB combustion, the smaller units will have greater fuel flexibility. General plant description The 150 MW powerplant described here is a grassroots CFB unit. Fluidized bed technology differs from conventional combustion techniques. With CFB, solid fuel, together with inert material such as sand, gypsum, limestone, or ash from the fuel, is kept suspended in the combustion chamber. This is done by using the action of the fluidizing air distributed below the bed. Fluidization promotes the turbulent mixing conditions required for good combustion. The turbulence causes the entire mass of solids to behave like a liquid. The result is improved mixing. This allows heat to be generated at a lower and more uniformly distributed temperature that is below the ash fusion temperature of most coals. The fluidizing mechanism offers several other advantages over conventional combustion. There is less volatilization of alkali compounds, which cause deposits on boiler tube surfaces. And there is less sensitivity to the quantity and nature of the ash in the fuel. The low combustion temperatures prevent vitrification of the ash particles and minimize problems associated with furnace slagging. The ability to select from many fuels is one of the major advantages of CFB combustor technology. Fuels that can be burned in CFB plants to produce steam and electricity include: low grade coals with high ash or sulfur, lignite, peat, wood and pulp products, biomass, refuse, anthracite culm, petroleum coke, and oil shales. The plant's turbine cycle uses superheated steam at 12.4 MPa (1800 psi) and 538°C (1000°F), with single reheat to 538°C (1000°F). Two high pressure and three low pressure, closed, feedwater heaters are furnished. So is a deaerator, which is an open, direct-contact heater. The CFB plant exceeds EPA's New Source Performance Standards (NSPS) for air emissions. The design limits sulfur dioxide (SO,) emissions to 0.25 kg/GJ (0.6 lb per million Btu). SO2 reduction occurs in the combustor by reac-