TIPS TO IMPROVE AVAILABILITY & EFFICIENCY OF YOUR ATMOSPHERIC

BUBBLING FLUIDISED BED COMBUSTION BOILERS

By K.K.PARTHIBAN, Boiler Consultant
Venus Energy Audit System
Email ID:parthi2006@gmail.com / venus.energy@gmail.com


The fluidized bed combustion technology has been now well accepted by the users across the country
for different solid fuels. There are installations for mixed fuel firing & even gaseous / liquid fuels co-
firing. Across the country there are lot of engineers and boiler operators who have learnt this
technology. Yet the technical tips of FBC operation may not have reached all. This is a sincere effort
to throw more light to the behavior of FBC to the benefit of boiler users.

A BRUSH UP ON FUNDAMENTALS

WHAT IS FLUIDISED BED?

When air or gas is passed through an inert bed of solid particles such as sand supported on a perforated
plate, the air, initially, will seek a path of least resistance and pass upward through the sand. With
further increase in the velocity, the air starts bubbling through the bed and the particles attain a state of
high turbulence. Under such conditions, the bed assumes the appearance of a fluid and exhibits the
properties associated with a fluid and hence the name 'Fluidised Bed'.

MECHANISM OF FLUIDISED BED COMBUSTION

If the sand, in a fluidised state, is heated to the ignition temperature of the fuel and the fuel is injected
continuously into the bed, the fuel will burn rapidly and the bed attains a uniform temperature due to
effective mixing. This, in short, is fluidised bed combustion.

While it is essential that temperature of bed should be at least equal to ignition temperature of fuel and
it should never be allowed to approach ash fusion temperature (1050C to 1150C) to avoid melting of
ash. This is achieved by extracting heat from the bed by through evaporator tubes immersed in the
bed.

If velocity is too low, fluidisation will not occur, and if the gas velocity becomes too high, the particles
will be entrained in the gas stream and lost. Hence, to sustain stable operation of the bed, it must be
ensured that gas velocity is maintained between minimum fluidisation velocity and particle
entrainment velocity.

DESIGN OF FLUIDISED BED

Based on the boiler heat duty, the amount of fuel to be burnt is decided. Based on chemical constituent
of fuel, the air required for combustion is calculated. As the combustion takes place in the bed all the
heat is released within the bed. The heat is extracted out of the bed by the leaving flue gases and the
bed evaporator tubes. The bed cross sectional area is fixed based on the fluidisation velocity which
will not exceed 2.8m/s. Once the bed coil area and bed cross sectional area is decided it is clear
turndown becomes difficult. Because lower the heat release rate, lower will be the bed temperature.
Hence by reducing the bed height, the bed HTA immersed in bed is reduced. Thus the bed temperature
is still ensured for steady fuel combustion. Additionally compartmentalisation is done to ensure the
minimum fluidization is achieved. The fuel feed and air feed are turned off in the slumped bed.

OVERBED AND UNDERBED FUEL FEEDING ARRANGEMENTS

Any time underbed feeding is superior in terms of combustion efficiency. Underbed is best suited for
fuels which have higher carbon content, such as Australian & African coals. The excess air
requirement is more in Overbed feeding arrangements. In overbed feeding arrangement elutriation
losses would be more. Hence underbed is preferred by many boiler buyers.
FINE TUNING THE FLUIDISED BED COMBUSTION BOILERS

The design of Fluidised bed combustion boiler has lot to do with the fuel type and the fuel conditions.
The fuel itself may change since the purchase of the boiler. A design based on certain fuel / fuel
combinations is not at its optimum when it comes to other fuels. This is specifically true when the
boiler is changed from agro fuels to coal. Similarly change in operating loads may also warrant fine
tuning of the boiler operational parameters. There are cases where the boiler is specifically oversized
considering the future expansion. In such a case the bed area and bed coil area may have to be covered
up until the steam requirement increases. The air requirement and flue gas to be handled becomes less.
Use of VFD / use of smaller capacity fans would benefit the user in terms of power saving and
operational efficiency. Like this there are lot of possibilities for a review of the original design to
present operating conditions.

TIPS FOR IMPROVEMENT IN OPERATIONS / MODIFICATIONS FOR IMPROVEMENT

In the following pages the tips are explained with illustrations as necessary. The tips are based in the
operational experience of several make of FBC boilers in India. Some of the tips would certainly
benefit some boiler users. There is always a solution born to every problem experienced. In the
continual improvement of the design / Operation of the FBC boilers there is always scope for
additions to this list.


































TIP 1 Measure and maintain adequate Distributor plate drop

The quality of fluidisation should be good ensuring there are no defluidised zones. This can not be
ensured by visual means. The distributor plate pressure drop becomes a vital factor to ensure this.
When the DP drop is less than 75 mmWC, the coarse particles begin to settle down at the bed bottom.
In an ideal case, DP drop should be 1/3 rd of bed height. Defluidization or settlement of coarse
particles will not be visible from top of the bed, as the fine bed material would continue to fluidise.
Settling of coarse particles can also damage bed coils. This leads to localised erosion of bed tubes.
This can happen even in overfed FBC boilers. Providing studs does not help. Bed coil erosion
continues. See figure 1.

P1
P2 AIRBOX
AIRBOX
FOR EROSION HERE
BED COIL PRONE
SETTLED BED DUE
TO LESS DP DROP
FIG 1: WHEN DP DROP IS LESS BED COARSE PARTICES SETTLE AT BOTTOM OF BED
DP DROP =P2-P1



TIP 2 Check bed coil pitch for studded bed coils

Studs can increase protection against gross erosion but not localised erosion. Studs decrease the
clearance between adjacent bed coils. Spacing of coils is to be specially addressed if studding is opted
for. The Increased fluidisation velocity at narrow clearances decreases the life of the bed coils.



TIP 3- Consider reduction of bed size

When the steam demand is less, the bed area becomes oversized. Maintaining a minimum pressure
drop for fluidisation would be difficult. The boiler operators continue to maintain high excess air level
to avoid bed slumping. In many process boilers this is the case due to oversized boiler (planned
considering future steam requirement) See figure 2. It is necessary to reduce the bed area by blocking
nozzles and by construction of refractory walls.


230.0 NEW REFRACTORY WALL
NOZZLES ARE REMOVED AND
PLUGS ARE FITTED TO DP PLATE
IN THIS AREA
FIGURE 2. BED AREA REDUCTION TO SUIT THE REDUCED STEAM GENERATION REQUIREMENT



TIP 4 - Inadequate instrumentation

Some manufacturers do not provide draft gauges
/ manometers for indication of bed pressure. In
such cases, the operators do not get an idea on
bed height. Knowing air box pressure alone
does not tell what the bed height is. It may be
possible that fluidising air is more and the bed
height is less. More fluidising air leads to excess
air operation. This affects the bed coil life. See
figure 3.




TIP 5 - Care of idle bed

At times it may be necessary to reduce the steam production rate. This is done by slumping
compartments. Continued operation of slumped bed may result in shallow bed height in the operating
compartment and leads to defluidization. This happens particularly when bed size is smaller. The bed
height in operating bed becomes less when it spills to adjacent slumped compartment. See figure 4. It
becomes necessary to alternately activate the slumped bed to bring the bed height back to normal.
There are other reasons as well. See the further tips.
FIG 3: BED HEIGHT & AIRBOX INSTRUMENTATION
IDLE
DG
BED
AIRBOX
DG

COMPARTMENT I COMPARTMENT II COMPARTMENT III
AIR
BED MATERIAL / FUEL SPILLS FROM
FLUIDISING COMPARTMENT
FIGURE 4. BED MATERIAL SPILLAGE TO IDLE COMPARTMENT


TIP 6 Provide additional drain points

Heavy stones and heavy ash particles keep accumulating at the bottom of bed. Larger beds need more
ash drain points in order to ensure coarse ash particles, which settle at the bottom can be effectively
removed. If drain points are inadequate or if all the available drain points are not used, small clinkers
would form and grow big. The ash draining will be effective in open bottom fluidised beds. The ash
draining must be kept partially opened to allow gradual discharge of ash from the bed. This way it is
found to remove most of the coarse particles that settle at the bottom.

In overbed feeding arrangement coarser particles would settle near fuel feed points. Provide additional
ash drain points at these locations to remove the stones / heavy particles.

TIP 7- Care for idle bed

Slumping of the bed is done to meet the steam demand. It is not correct to keep same compartment
under slumped condition. In the slumped bed heat transfer to bed coil becomes less. The circulation of
water ceases. This may result in high pH corrosion / caustic gouging/ settling of iron oxides /
corrosion products in such bed coils, depending on boiler water chemistry. See figure 5, for
appearance of tube inside on a caustic gouging failure.

FIGURE 5. CAUSTIC GOUGING ATTACK IN IDLE COMPARTMENT
A
A
A
A
TUBE SECTION AA



TIP -8 Use Optimum primary air pressure

Primary air fans are required for underfeed system. The PA fans are selected with 15% - 25 % flow
margins. It is necessary to keep the PA header pressure as low as possible so that the suction effect is
just the minimum at the throat. The air leakage from the feeder must be taken as a guide. Higher PA
header pressure leads to more air flow through the fuel feed points. Higher air flow would erode the
bed coils faster. It addition venturi erosion would be faster.



TIP 9 Care for shutting PA damper in idle bed

In underbed feeding arrangements there is no physical partition above the distributor plate. When a
compartment is slumped for load control, particularly for longer duration, it is necessary to close the
PA damper in slumped compartments. Leaving the primary air full open in idle compartment would
lead to bed coil erosion. It is the tendency of many operators to leave open the PA line dampers, for
the fear of line choking. The bed material is continuously thrown at bed coil.

COMPARTMENT I COMPARTMENT II COMPARTMENT III
AIR
FIGURE 6. FUEL LINE AIR ERODING AWAY BED COIL IN IDLE COMPARTMENT
FUEL LINE



TIP 10 Replace the Worn-out venturi / mixing nozzles promptly

In underfeed arrangement the fuel is fed from bottom of the bed. As the pressure at the feed point
inside the bed is 400 -500 mmWC, high pressure PA fan with mixing nozzles are used to transport the
fuel inside. The air jet velocity at the throat of the mixing nozzle is of the order of 100 130 m/s. The
fuel particles are accelerated at the mixing chamber and the diffuser ensures the gradual return to
normal line velocity. The diffuser erodes over a period (1-2 year). As the pressure drop of mixing
nozzle increases more and more air is required for generating suction at the throat. Naturally the
erosion rate of bed coil will be more inside the bed.

TIP 11- Care to use the air vent valve in idle compartment

Slumping of a compartment is necessary to take care of load reduction and while start up of the
combustor. There can be clinker formation if the fuel spillage is present in the idle compartment. In
certain boilers, the fuel feed point may be close to the border of the adjacent compartment. For the
clinker to take place there should be air flow in the idle compartment. The compartment dampers may
not be leak proof. For this reason, automatic air vent valves are provided in compartment air box, to
enable venting the passing air from compartment damper. If the valves are to be manually operated,
the same must be done. Needless to say, that the leaky damper will have to be attended.

COMPARTMENT I COMPARTMENT II COMPARTMENT III
AIR
FIGURE 7 : FUEL SPILLAGE AND LEAKAGE AIR IN IDLE COMPARTMENT CAUSING CLINKERS
CLINKER ON TOP OF BED
LEAKAGE AIR LEAKAGE AIR
S S
S
VENT



TIP 12-Avoid continued operation with troubled bed

A fluidised bed may get clinkered when there are disturbances in boiler operation. For example when
there is no coal in bunker, the operator momentarily reduces the air flow in order to reduce the bed
quenching. At this time, it is likely the bed defludises at some zones. The average particle size is
always high compared to start up bed material and hence defluidization chances are more when the air
flow is reduced. Once the bed is known to have clinkered, steps are to be taken for immediate
removal. This may be possible by increasing the drain rate from the clinkered bed. A bed clinkering
can be figured out from the differences between the bottom and top bed temperature readings.

TIP 13- Ensure proper fuel particle size

Improper fuel sizing affects the bed particle size. Improper screen cloth sizing, coarse particle
separation in bunker, worn out crusher hammers can lead to oversized fuel particles. Oversized fuel
particles are found to accumulate near the fuel feed points leading to defluidization. The air jets
upwards once this happens. Bed coils erode locally above the fuel feed point at this time. See figure 8.


AIR
FIGURE 8 : COARSE PARTICLES SETTLING AROUND FUEL NOZZLE AND PA J ET HITTING BED COIL



TIP 14 - Attend to Loose air nozzles

Some manufacturers adopt push fit nozzles over the distributor plate. Further a castable refractory is
laid over the plate. The castable gets broken during service due to thermal expansion. This leads to
leakage at the air nozzle base itself. Such leakages lead to not only bypassing of more air from such
locations, but also lead to defluidised zones. This can happen near bed ash drain points.



TIP 15 -Leaky compartment dampers

Leaky compartment dampers lead
to partial fluidisation. Spilled fuel
from adjacent operating
compartment would lead to clinker
formation and further growth.
Dampers will need replacement.
Butterfly dampers with proper
seals would be the ideal choice to
solve the clinker problem. In
ordinary flap type damper sealing
strips would help bring down the
leakage. See the figure 9, for the
detail of sealing strip which prove
useful.



TIP 16- Improper setting of Power cylinder of compartment dampers

Compartment dampers are to
be set for closed conditions.
At times it is found that the
dampers do not close inside
where as the power cylinder
closes fully at the outside.
See figure 10, which points
out the defect, which is faced
in many cases.











TIP -17 Leaky distributor plates

PARTITION WALL
LEAKAGE
FIGURE 11: LEAKAGE BETWEEN SUPPORT FRAME AND DP PLATE
Some manufacturers adopt removable distributor
plate design. This is adopted for ease of approach
during bed coil maintenance. The leakage
between distributor plate and supporting frame
would lead to local fluidisation and keeps making
clinkers. When the air bypasses at some place it is
natural at some other location, the bed has settled.
See figure 11. If the erection is improper this
could be a serious matter disturbing the fluidised
bed operation.


















TIP -18 Replace all failed air nozzles at one go

Air nozzles may be made from cast iron /
stainless steel. The nozzles begin to oxidise at
the top where it receives radiation and
convection heat. Over a period the top opens
up. Now the air jets from top hitting the coils
above. Some experience cracking of air
nozzles along the top row of nozzles. Failed
air nozzles allow more air flow and hence the
air flow through the good ones would come
down (Preferential flow through least
resistance path). This leads to defluidised
zones.

CRACKED NOZZLES OXIDISED TOPS
FIGURE 12: FAILED AIR NOZZLES DISTURB FLUIDISATION
AND CAUSE BED COIL EROSION





TIP 19 Do not Operate the boiler with choked PA lines

Primary air lines choke up when oversized fuel is fed or when compartment damper is opened before
operating PA damper. Due to this the fuel nozzles get distorted. In running boiler no one can guess
what the extent of distortion is. The fuel nozzle cap is distorted the fuel-air mixture may target the bed
coil and lead to premature failure. Distorted nozzles are to be replaced immediately. SS fuel nozzles
offer better protection when it comes to bed coil life.



TIP 20 -Reduce the chances for start up clinkers

Fluidised beds may be started compartment by compartment. When the first compartment is started
one must ensure that there is a good mount of bed material to prevent the fuel spillage to adjacent
compartment. The PA pressure should be bare minimum. Excess PA pressure spills more fuel to
adjacent compartment. The PA pressure requirement will be less, since the bed height will be less
during start up. When the fuel spill is more a border clinker is likely to form. Excess mixing air flow
also leads to more spillage. It is necessary to keep the PA air line dampers of adjacent compartments
in close condition.



TIP 21- More PA and less fluidizing air

By virtue of design / operating load, bed material settles along the wall side. This leads to throwing of
bed material along the wall to the coils. This happens where fuel feed points are close to wall. When
the frequent load turn downs are expected the bed plate pressure drop has to be designed for ensuring a
minimum bed plate pressure drop of 75 mmWC. Operating at lesser P would lead to pockets of
defluidised zones.




TIP 23 -Bed coil to fuel nozzle clearance

The designer has to ensure a minimum clearance of 150 mm from fuel nozzle cap top to bed coil to
safeguard the bed coil against erosion. At times due to faulty erection the clearance may be less
leading to premature bed coil failure.



TIP 24 Check the adequacy of instrumentation of fluidised bed

In the absence of bed temperature indications and air box pressure, bed pressure, operation of the
fluidised bed is risky. When such instruments are compromised, no one can vouch that the bed is
perfectly OK at all places. It may be possible to assess from the bed material drained from ash drain
pipe. But the same will not be proper for bigger beds. Failed thermocouples, burnt compensating
cables, defective temperature indicators are to be replaced at the earliest opportunity to prevent bed
coil erosion.



TIP 25- Review Oversized fuel feeders

In some cases, it is likely that the feeders are over sized. A feeder designed for agro fuel becomes
oversized when it comes to changing over to coal. The fuel feeders are to be replaced with a smaller
one or additional speed reduction mechanism needs to be added. For a small rpm change the feeder
may be dumping excess fuel. The clinker formation possibility is increased due to this. In the recent
years many boiler users have started using high GCV imported coal. This may also lead to excess fuel
dumping for a small rpm change.


TIP 26- Change the bed coil configuration while replacement

The pitch of the bed coil is a factor for
erosion potential. At least one tube gap
must be adopted while selecting the
pitch. This is a reason for bend erosion
in closely pitched hairpin type bed coils.
Staggered bed coils would ensure
sufficient gap between coils and thus
fluidisation becomes more uniform at
entire bed. Cross bed tubes are found to
be better than the hairpin coils. While
planning for replacement of bed coils,
consider improvement of bed coil
configurations. There are many
possibilities for better configurations
considering ease of replacement.





CONCLUSION

I hope the readers would agree some of the suggestions made here are applicable to their installations.
Suggestions are welcome from the readers.