F ilt /~Pn:> - \\(D1
EVALUATION OF THE
FLUIDIZED BED
COMBUSTION PROCESS
Sub m itted to:
Office of Air Programs
Environmental Protection Agency
Contract No. CPA 70.9
By:
Westinghouse Research Laboratories
Pittsburgh, Pennsylvania
VOLUME m APPENDICES
EPA LIBRARY SERVICES RTP NC
804 ! ~TJ) = 116 i
TECHNICAL DOCUMENT COLLECTION
-------
EVALUATION OF THE FLUIDIZED BED COMBUSTION PROCESS
SUMMARY REPORT
Contract'No. CPA 70-9
November 15, 1969 - November 15, 1971
Prepared for
Office of Air Programs
Environmental Protection Agency
Research Triangle Park,
. North Carolina 27711
Project Officer:
P. P. Turner
By
Westinghouse Research Laboratories
Pittsburgh, Pennsylvania 15235
Authors
D. H. Archer, D. L. Keairns
J. R. Hamm, R. A. Newby
W. C. Yang, L. M. Handman
L. Elikan
-------
PREFACE
The results of the evaluation of fluidized bed combustion for
steam/power generation are presented in this three-volume report.
The
report identifies fluidized bed fuel processing systems which should
meet both market requirements and air pollution abatement requirements
and are likely to be cheaper than alternative, conventional systems.
program is recommended for commercializing promising processes.
A
This volume (Volume III) contains the detailed market survey
reports, boiler design reports, pressurized boiler combined cycle power
plant report, and support studies on design and operation prepared by
Westinghouse and its subcontractors.
The scope of the work, technical
evaluation, comparisons, conclusions, and recommendations are contained
in Volumes I and II.
-------
TABLE OF CONTENTS
Volume III
APPENDIX A - Electric Utility Market Survey
APPENDIX B - Industrial Boiler Market Survey
APPENDIX C - Development of Fluidized Bed Combustion Boilers
APPENDIX D - Industrial Boiler Design Report
APPENDIX E - Turndown Techniques for Atmospheric
Fluidized Bed Boilers
APPENDIX F - Dynamics of Atmospheric Fluidized Bed Boilers
APPENDIX G - Optimization of Heat Trap System Cost
APPENDIX H - Pressurized Boiler Design Report
APPENDIX I - Regeneration/Sulfur Recovery System Cost
APPENDIX J - Pressurized Boiler Combined Cycle Plant Report
APPENDIX K - Atmospheric-Pressure Boiler Design Report
APPENDIX L - Boiler Burner for Low Btu Gas
APPENDIX M - Gas Turbine Corrosion, Erosion, and Fouling
APPENDIX N - Stack Gas Cooler Design
Page
A-I
B-1
C-l
D-l
E-1
F-l
G-l
H-l
I-I
J-1
K-1
L-l
M-l
N-l
-------
APPENDIX A
ELECTRIC UTILITY MARKET SURVEY
A-I
-------
TABLE OF CONTENTS
PURPOSE.
. . . .
. . . .
. . . . . .
. . . .
. . . . . . .
SU~MARY. .
. . . .
. . . . . . . .
RECOMMENDATIONS. .
. . . .
. . . . . . . .
. . . . .
FOSSIL STEAM GENERATION MARKET
. . . . . . . . . . . .
. . . . .
Introduction
Annual Fossil Steam Installations
Unit Sizes
Combined Cycle Market Forecast
Boiler Fuel Mix
Operating Characteristics
Expected Life of Units
FOSSIL FUELS FOR UTILITY POWER GENERATION. . . . . . . . . . . .
Fossil Fuel Reserves
Factors Affecting Future Production of Coal
Factors Affecting Future Production of Gas
Factors Affecting Future Production of Residual Fuel Oil
Utilization of Fossil Fuels for Power Generation
PRICE TRENDS OF FOSSIL FUELS FOR POWER GENERATION. . .
. . . . .
Electric Utility Fuel Price Trends
Coal Price Trends
Electric Utility Fuel Oil Price Trends
Natural Gas Price Trends
Nuclear Fuel Cost Projections
ADDENDUM:
UPDATES PROJECTIONS. . . . . . . . . . . . . . . . .
A-3
A-5
A-6
A-9
A-13
A-26
A-40
A-51
-------
PURPOSE
The purpose of this survey is to identify the magnitude,
characteristics, and requirements of the future utility boiler market
as a guide for determining design parameters in the development of the
fluidized bed boiler.
Its scope entails a forecast of the fossil
steam market including combined cycles, a review of the availability
and cost of fuels, and an economic assessment of alternative sulfur
removal systems.
A-5
-------
SUMMARY
Approximately 50% of future annual electric utility generation
additions will require boilers of one form or another.
The market for
fossil steam generation in the United States is expected to show a
constant upward trend of 4 to 5% annual growth rate through 1985,
compared with a total electric utility aunual growth rate of 7%.
The
fossil steam segment will grow mainly on the strength of increasing
intermediate generation requirements as the fossil base-load market is
displaced by nuclear power.
Intermediate additions burning coal,
natural gas, and oil will represent over 80% of the fossil steam market
by 1985.
Two dominant size classes of new fossil units have emerged.
The 700 to 1300 MW size class consists primarily of coal-fired units
in the coal-producing areas, while the other size class, encompassing
all intermediate capacity and some base-load capacity in the 400 to 500 MW
range, wi~l extend toward the smaller sizes when combined cycles come
into greater use.
The advent by 1975 of the packaged combined cycle plant
employing a steam turbine which utilizes the waste heat of two gas
turbines is expected to precipitate the capture of half of the annual
intermediate additions in the mid 1980s.
Up to 90% of the larger gas
turbines may be retrofitted with boilers and steam turbines.
Distillate
A-6
-------
oil, and eventually residual oil, will fuel approximately two-thirds of
the combined cycle installations unless coal gasification becomes
significant during the next decade.
The need for greater reliability and flexibility requires
each utility to determine the operating characteristics best suited to
its particular system's requirements.
Operating problems appear to be
centered in the boiler area due to the lack of design maturity and
operating experience of larger, high-pressure, once-through boilers.
For cyclic operation, utilities generally favor proven, low-pressure,
drum type boilers, while the systems approach to utility economics also
shows a tendency toward units with shorter expected life.
Although a growth in demand for fossil fuels will accompany
the continued growth in the demand for electric energy, a variety of
economic pressures will impede the ability of the coal and gas industries
to meet the rising requirements for these fuels.
Labor problems, new
health and safety regulations, and the lack of new mine capacity will
continue to plague the coal industry and limit production into the
mid 1970s, even though almost unlimited reserves of this natural resource
are available.
The natural gas industry is faced with a diminishing gas
reserve and regulated price levels that make the investment in exploratory
drilling for
new supplies unattractive.
At the same time, the
availability of adequate gas reserves that can be tapped to meet the
nation's gas requirements is questionable.
Oil is the only fossil fuel
abundant enough to meet the electric utility demand adequately; however,
A-7
-------
its use is limited to those markets adjacent to deep waterways unless
transportation by pipeline over considerable distances proves
economically feasible.
In the utilization of fossil fuels for power generation, annual
demand for coal will increase at a declining rate after an upward surge
in the early 1970s as nuclear units are placed in operation following
long delays.
Coal-fired capacity installed in 1985 will equal only
60% of that added in 1970.
Gas-burning steam plants, which will main-
tain a fairly steady rate of installation through the 1970s, will be
limited primarily to gas-producing areas in the South Central United
States, while areas remote to gas fields show a decreasing gas market
share.
As a result of the gas shortage and the difficulty of getting
gas contracts, some utilities in gas-burning states are considering the
installation of oil-fired plants, as well as coal, lignite, and nuclear
plants.
Continued shortages and increased usage of gas may ultimately
result in end-use control, rationing, and restrictions on the use of
gas in boilers.
With the recent influx of low-cost, low-sulfur,
residual oil imports along the Atlan~ic coast, many eastern utilities
have converted their existing coal-fired plants to oil and anticipate
the addition of new oil units, especially in the New England area.
More than half of the annual fossil steam additions in 1985 will be
oil-fired.
A-8
-------
RECOMMENDATIONS
Analysis of fossil steam market trends suggests two courses of
action as the most advantageous in the development of fluidized bed
combustion in electric utility power plants.
The first recommendation is the development of a 600 MW, coal-
fired fluidized bed boiler with steam conditions of approximately
2400 psig/IOOO°F/IOOO°F.
The choice of capacity and steam conditions is
based largely on the ability of a plant with these characteristics to
operate as both intermediate and base-load generation.
Such a plant
would be intended for cyclical operation initially; however, with
advanced technology and proven reliability it could eventually be used
as base capacity.
Sizes smaller than 600 MW would not be as adequate
for base-load generation if load factors of 65 to 80% could be achieved,
since they do not take full advantage of economies of scale.
Poor
performance by conventional 800 MW units installed to date casts doubt
on the successful operation of larger units at this time.
Coal is recommended as the primary fuel for a number of reasons.
In spite of limited coal production caused by new coal-mine health and
safety regulations and an inadequate mine work force, abundant reserves
of coal are available for extraction.
While the coal industry is dom-
estically controlled, the oil market is strongly influenced by foreign
political policy which is subject to erratic and unpredictable fluctuations,
A-9
-------
as demonstrated by the recent unexpected reduction in world crude supply.
The instability of the oil market is in contrast to the long-term contracts
established between utilities and coal companies, who are no longer willing
to supply coal on a short-term contract as they had in the past.
In the more distant future another important aspect of the coal
versus oil question is the effect of world demand on oil availability.
Energy use is increasing at a higher rate in the rest of the world than
in the United States, as evidenced by the higher worldwide per capita
energy consumption rate and the soaring global population.
As more
countries use more of their own fuels at an increasing rate, especially
oil, the United States will be forced to. rely more on domestic fuels, of
which coal is the only one with adequate reserves to meet the future
requirements of the fossil market.
The second recommendation is that the fluidized bed process be
reviewed for its competitiveness with nuclear power as base load genera-
tion after initial operating experience.
In this long-range activity
the feasibility of larger unit sizes -- approximately 1200 MW -- should
be thoroughly examined from a technical and economic standpoint.
A
generation cost of 7.9 mills per kwh is projected for an initial
l200-megawatt nuclear plant for operation in 1980 at a capital cost
upwards of $270 per kw and a fuel cost of 18 cents per million Btu.
To provide power at a comparable cost, the fluidized bed boiler plant
using coal at 45 cents per million Btu will require a capital investment
of approximately $170 per kw; for a minemouth plant with less expensive
A-10
-------
coal at 40 cents per million Btu, a capital cost of $195.per kw will be
competitive with nuclear in 1980.
The fuel cost is an obvious key
factor in determining the competitiveness of these two types of
generation.
However, even with a high coal cost the possibility of
attaining $170 per kw is excellent if economies of scale prove applicable
to the fluid bed concept in larger units.
The likely effects of fluidized bed combustion on the fossil
steam market depend on its degree of success relative other emissions
control devices and on the excalation in fuel prices.
There is little
doubt that pollution regulations will get stricter in the future and
that a workable and economical method of pollution control will be
developed to satisfy these restrictions.
Because of the uncertainty
of the fuel picture, a precise estimate of the fluid bed boiler plant
proliferation in the fossil steam market is extremely speculative.
One
can sa~ however, that if successful it will capture all of the presently
predicted coal-fired additions regardless of fuel price.
If the
divergence in oil and coal prices is less than predicted, as now appears
likely, the fluidized bed process will gain a sizable portion of the
intermediate oil market, especially after 1980, when oil-burning
combined cycle plants were otherwise foreseen to dominate this market.
In the fossil fuel market, this new concept of coal~fired
generation will certainly have a favorable effect on the future of coal
in the United States.
The introduction of the fluidized bed combustion
process will stimulate the demand for coal but will have little effect,
A-II
-------
if any~ on the projected price of coal, since the coal demand already
exceeds production.
The current production shortage stems from the
inability of the coal industry to attract sufficient miners to meet the
demand and its understandable unwillingness to open new mines except on
a long-term basis.
The fluid bed boiler should help to remedy the
situation on both counts.
The fact that the present contract of the
United Mine Workers expires in the near future, combined with the
present overall fuel shortage, gives the UMW a strong bargaining position
for higher wages.
The combination of a better wage P?ckage and the
safer conditions in new mines opened for fluidized bed plants should
attract the necessary manpower in new mines to meet the future production
demands.
At the same time the development of power plants which burn
coal exclusively may prompt utilities to establish new long-term contracts
with coal companies, and may lead them to supply a portion of the capital
necessary for opening new mines.
In any event, the fluidized bed combustion process will
ultimately assure the continued growth of the coal industry in the
United States.
A-12
-------
FOSSIL STEAM GENERATION MARKET
Introduction
In the electric utility industry, generation units are ordered
four to six years prior to scheduled operation.
As a result, the market
for capacity additions through 1975 can be projected with considerable
accuracy.
The forecast of the more speculative market from 1976-85
is based on a number of factors, including trends in annual utility
peak loads as related to the u.s. Gross National Product, in the
generation service mix (base, intermediate, and peaking), in the
availability and price of fuel to utilities, and in power generation
technology.
In areas where quantification by mathematical extrapolation
is not applicable, predictions were based on subjective judgment
seasoned with experience.
In any case, the information presented here
is not to be taken as an edict of what will happen in the future, but
as an indication of our best estimate of what the situation will be,
based on o.ur present knowledge.
Annual Fossil Steam Installations
The fossil steam generation market will continue to grow
between 4 and 5% per year through 1985.
The annual additions to capacity
will average 20 to 25 million kw per year throughout the period.
Figure A-I shows the total and base load annual fossil steam additions
from 1970 through 1985.
The total fossil market shows an upward trend
A-13
-------
Millions
r
32
28
24
20
16
12
8
4
1970
. ...n,.....","-
----".",-,.,-,- -...',
71
u. S. ELEC TRIC UTILITY INDUSTRY
ANNUAL FOSSIL STEAM INST ALLA nONS
1970 - 85
I
'.
1.,-
i
.,
"
.,
,
!
.. - ;--....
. !
-''''. - "i,-'--''''''-~'-~--:
'''-''-.''-''
.n~ - .. ~. .', .
. ! -.."
.1
I
.!..
"
..
. ...---.,.-.. ,-.'
I.
,.
:i
"r'
. ---to .-_..
.,
i..
.;''''::.
"'.- ..-,...--. .
:1:
i.
i
.~.~..:...__.;.:"":':.~'~ .....L..:
-- ' -...."' "'"
. " . ~... --'
,. ;. .
,.,,>u"--'"-." '.- _._.~,.-. "--'
.' . ! .
,.
.!
.,
, .
I:...' .j
./. i
['':''''--i-:-:- I r
....~(TGI.....
'-'-1-" .':'~""'-'''':''':'.
...
.,
72
-, . "'- -.. . - ..~..
,.
. , .
./
i ..
~ L"
! .
.-..-.-.--.-. ..-."
.. . .. . .
,.
i
.,
":
"
...
.". -,- .\. ..._-
..
..
:_-~-;~-_...:_._...~;....- ,~ ..:.'.~ ~
.1
i;
, ,
-."p,..I..
i
. . . ..'
, . ,
... - ..".-,........ .
. . '...'. . .
, ,
.,. .. "":-. -:-:-...
'i.
I. '. i
l' "., ~ .-. . ;
-'!.
,-",-"., ---- .-.--' .,- ..~.O' -.._._._----'...,~,
- .'. " . .
. ,
'I
,
. ,
.--.u,--.-,...""
;. .. . I
~I- _..~.-. - . - i.. .--.. , ". .
, ~'... '\ ' ,;',' ::l~:.
-. T'---T--~T~"""7:-:-: f~~
'.
73
75
76 77
FIGURE A-I
74
A-14
.,
I.
.,
.,.
,
,.
78
:j-
.'
79
80
81
, i
,.
.,
. , .
i
, '
'M" ..... ....-
I
"'4'_-' .~..._.'..
, ~.
., .
82
. ,',.'u_u..'.
83
85
84
-------
over the sixteen-year period with an average increase in'annual additions
of 770 MW over the preceding year.
Installations in the late 1970s
level off as a consequence of overbuying by utilities in the late 1960s
for installations in the early 1970s.
While nuclear power is expected
to supply most of the base load requirements for the nation after 1976,
utilities located in coal-producing areas will add base load fossil
plants representing 10 to 15% of the thermal market.
In Figure A-I
these base fossil steam additions show a marked decline from 1973 to
1979 and then stabilize at approximately 5 million kw through 1985.
Cyclical operation steam plants, including possible combined
cycle plants, are expected to account for 43% of the fossil steam
market in 1975, 78% in 1980, and 82% in 1985.
Steam cycling plants will
represent 40 to 45% of the total thermal market.
This new intermediate
capacity has the characteristics for low or medium load factor operation
and less initial cost than the more efficient base-load capacity.
Unit Sizes
Historically, the unit size distribution for fossil turbines
has been fairly uniform.
However, in the late 1970s and early 1980s,
there will probably be two dominant size classes of fossil units.
One
class will be in the range of 700 to 1300 MW and will grow at the same
rate as the maximum unit size.
The other dominant size class will be
in the 300 to 500 MW range and will be oil-and/or gas-fired, with a
small portion coal-fired, at approximately 2 million KW per year.
A-15
-------
The maximum size fossil turbine-g~nerator has doubled every
five years from the 1950s through the mid 1960s.
However, it appears
that the rate for the mid-1960s through 1985 will be more moderate.
The maximum size of 1300 MW to be installed in 1973 is expected to
remain. the largest fossil unit until possibly 1983, when a 1500 MW unit
can be expected.
This diminishing trend toward larger sizes results
primarily from the decreasing gains from economies of scale and minor
technological improvements.
From the1950s to the early 1960s, the median unit size doubled
every ten years, essentially following the utility load growth.
However,
in the period from 1964 to 1967, the meqian unit size almost doubled
in a three-year period.
This reflects the trend to joint planning
and mergers or anticipated mergers.
The rate of change from 1967 through
1975 is very low, again reflecting the trend to cyclic steam units.
In the size class under 200 MW, the last few years have
demonstrated an electric utility market of 1500 MW per year.
This market
is expected to maintain this level until the advent of combined cycles.
. .
Combined Cycle Market Forecast
A new type of utility power plant -- the packaged combined
cycle plant -- is just emerging, and in fact, is still in the develop-
mental stage.
In these plants as they are now conceived, a gas turbine
exhausts into a boiler which generates steam and feeds a steam turbine.
The plants are usually 50% gas tu~bine power and 50% steam turbine
power, so they vary from combined cycle plants that have been used in
A-16
-------
the past.
In most cases, additional heat must be added between the
gas turbine and the waste heat boiler.
The present Westinghouse combined
cycle plant under development uses two 60 MW gas turbines and one 120 MW
steam turbine for a total plant rating of 240 MW.
These will be installed
to serve as intermediate generation, which has a forecasted annual
capacity factor of 30 to 50%.
The initial combined cycle plants are being designed to burn
natural gas; but developments are already underway to introduce distillate
oils and later residual oils as the fuel for these plants.
Thus,
combined cycle plants can be expected to burn two types of fuels in
the future:
natural gas and oil.
As time progresses, oil will become
the predominant combined cycle fu~l.
The split of the fuel will be on
the order of two-thirds oil-fired and one-third natural-gas-fired.
The market for the combined cycle plant is expected to appear
in about 1975 and 1976, partially because of the development time
required for the equipment in these plants.
Starting from a low level
of 500 to 1000 MW a year, the market will increase to approximately
25 to 50% of the total intermediate generation market.
The actual
magnitude of the market will, of course, depend on the ultimate cost of
these combined cycle plants and the economics that they hold in operation.
Since these two parameters are still estimated on early data at this
time, it is hard to define accurately the likely magnitude of the market.
From an initial plant size of 250 MW, combined cycle units are
expected to grow to approximately 500 MW, corresponding to improved
gas turbine technology and growth of gas turbine unit sizes.
A-17
-------
.~he boilers used in these plants are packaged boil~rs; that is,
shop-assembled and shipped for field erection.
They are designed for
high air flow and for forced circulation of water/steam.
Since the
firing is external to the boiler itself, there are no burners near the
heat transfer surfaces.
The plants presently, under design use one waste
heat boiler for each gas turbine.
The steam conditions are in the area
of 1200 to 1300 pounds pressure per square inch and 900 to 100QoF
temperature.
In addition to packaged combined cycle plants, there is a
market for retrofitting boilers and steam turbines ~o presently installed
gas turbines.
A great many electric utility gas turbines have been
installed in the last few years, and this trend will continue for the
next year or two.
The 25,and 50 MW gas turbines exhaust a great deal
of useful energy to the atmosphere.
In the future, utilities can
logically be expected to add boilers and steam turbines to these gas
turbines to recover and utilize this energy. ,These applications will
be, in all likelihood, only on those gas turbines installed at major
steam plants; that is, it is not expected that waste heat boilers and
steam turbines would be added to gas turbines installed at remote
locations on the system.
Possibly 80 or 90% of the larger gas turbines
ultimately will be converted to combined cycle plants.
These retrofitted combined cycle plants can have many
configurations.
However, as with the packaged model, the most promising
will probably be a waste heat boiler with supplementary firing feeding
A-18
-------
a stearn turbine of approximately the same rating as the gas turbine.
There
will be cases where supplemental firing will not be applied; in these
cases, the stearn turbine rating is approximately one-half of the gas
turbine rating.
In this latter application, a header system could be
installed between several gas turbine waste heat boilers to feed a single
stearn turbine of larger size.
Boiler Fuel Mix
The pattern in boiler fuels for future fossil stearn installations
will change significantly from the trend of the past decade.
During
the 1960s coal was the primary boiler fuel for two-thirds to three-
quarters of all new fossil stearn capacity; gas, for about one-fourth
of new fossil capacity; and oil, for less than one-tenth of new fossil
capacity.
Additions in 1970 reflect this situation, with 75% of fossil
capacity being coal-fired, nearly 25% gas-fired, and less than 1%
oil-fired.
Tables A-I and A-2 show the response of utility buying to the
changing fuel picutre in the United States.
Annual coal-fired installa-
tions will drop to 63% of fossil capacity in 1975, to 34% in 1980, and
to only 25% in 1985.
Oil-fired additions, on the other hand, will climb
to 12% of fossil additions in 1975 to over 50% in 1985, while gas-fired
units will fluctuate between 23 and 31% of fossil capacity through 1985.
Installations in 1980 are expected to show nearly equal proportions for
each type of fossil fuel.
An explanation of the forces behind these trends is contained
in the next section, Fossil Fuels for Utility Power Generation.
A-19
-------
TABLE A-I
ANNUAL FOSSIL STEAM INSTALLATIONS
By Type of Service
1970-1985
YEAR
IN SERVICE TOTAL BASE INTERMEDIATE
1970 16.3 10.1 6.2
1971 18.8 12.4 6.4
1972 21.2 15.9 5.3
1973 20.3 14.5 5.8
1974 19.6 10.7 8.9
1975 22.1 12.7 9.4
1976 18.8 8.0 10.8
1977 19.3 7.6 11.7
1978 20.1 7.3 12.8
1979 17.9 4.8 13.1
1980 20.4 4.5 15.9
1981 22.4 5.1 17.3
1982 23.4 5.4 18.0
1983 25.4 5.1 20.3
1984 27.5 4.5 23.0
1985 28.6 5.2 23.4
Units: Millions KW
A-20
-------
TABLE A-2
ANNUAL FOSSIL STEAM INSTALLATIONS
By Type of Fuel
1970-1985
YEAR
IN SERVICE TOTAL COAL GAS OIL
1970 16.3 12.2 4.0 .1
1971 18.8 12.8 5.3 .7
1972 21.2 13.9 3.6 3.7
1973 20.3 11.9 5.5 2.9
1974 19.6 9.0 7.8 2.8
1975 22.1 13.9 5.6 2.6
1976 18.8 11.2 5.3 2.3
1977 19.3 10.6 5.6 3.1
1978 20.1 10.2 6.6 3.3
1979 17.9 6.7 6.0 5.2
1980 20.4 6.9 6.3 7.2
1981 22.4 7.1 6.9 8.4
1982 23.4 7.6 6.6 9.2
1983 25.4 7.1 6.5 11.8
1984 27.5 6.3 6.5 14.7
1985 28.6 7.3 6.4 14.9
Units: Millions KW
A-21
-------
Operating Characteristics
Future operating characteristics are difficult to specify
explicitly bec~use of variations in utility needs and practices.
However,
several qualifications in this regard can be made.
Electric utilities are conc~rned about the potential difficulties
of keeping generation reliability up, and fuel and maintenance costs
down to tolerable levels.
The operation of generating units can no
longer be scheduled as a matter of simple economic choice but must
rather be treated as a matter of operating flexibility of currently
installed generating units seem to be centered in the boiler area rather
than the turbine generator.
The low maturity factor of larger supercritical and subcritical
once-through boiler installations in some instances has led utilities
to favor proven drum-type boiler designs.
The choice of steam pressure
for these installations is a function of economics and unit size.
Trends in turbine inlet pressure ranges shown in Figure A-2 exhibit a
tendency of fossil steam generation toward greater use as intermediate
capacity and lesser use as base capacity.
It should be kept in mind that boiler component designs for
low capacity factor versus base load operation are not much different.
Cycle comparisons to determine economic choice of throttle pressures
for various lifetime capacity factors indicate that as the capacity
factor on a system increases, higher pressure, lower heat rate cycles
are justified by increased fuel cost savings.
Utilities, however, cannot
A-22
-------
U,S, ELECTRIC
Af'JIJ U A I:-
BY TURB/I'JE
UTIL Il'Y
FOSSIL STEAM
INLET
II\lDUSTRY
INSTALLATIONS
PRG'S5URE'
PCRCl/J7 or M,I~E::.,:"
FOSSIl- STEj\rv',
ADD 1 TJ 9..N.? ._-.._-_._~.- . "''''-''~-'~'-'
.,. i ,.. .: ;::.>: !':"~:~"~~-7:~~'T:~"'::.:,:'iJ:, .,.~,..', T~~.',;-.i: ,,~:-:'~ .!.-"~: --"!'-':'~':::-\,c-:=r""'::"'T:'-~ .!
. i . I . i . . ~ : : . .: .. . 1 '.. J . ; ~ '-". I . ... .
.:.....~ -. --.. '~-:""_" ." ",.. .. . .~:.~. ;.: f. :.._1 .;...~.:.._._.!_.- -._._...l._,__..:........ .:...,..__............"":":.:.':"':..:..
f\.sOV,E:3000 P5,IG,' ",:: ":) ,,! "'" " ' "'-""':'-""-;-""
, ! .. ,
.-. 22.00 3000 PSIG'
.i:1'?9 PSIS
o - 1L',So9 P 51 G
so
.--.
1500
----
70
,- ... ~ ... '.. ..'
M.. . -- "_.~_._.., ..--.
. -. ,-_e.- ,-. .
... """'"''''','''''
,i
roo
;
, "
..,
-._---- ,- .....-.-.-....--.,....-.,.
, '
"""'r".'"
. i...
, '
.. . -."-. '~-""..,.
, ' ,
-"1"
50
,'. ",""-- '," ...,.,...,.. ',\
\ . - --: . , " :.:
. j. \ '
..m\;;!..'i-~ ;,..:!-.......:;. ... ..- _....~'..-....:-
. . ..-.," ... --"1--- : -..-: ,;n.....:...
: !
!
'!'
. .-...... "".- .. ~ -,
... I. -., -
"'~""--""--' '....
...-- -' .~. ." _..
,i
",.!-
- .-.-. - ."--." ".-'
" .
,i
."
40
..._~. _,-n ...~:
: .--. :;. .... ... , : .....:....... :.~ ....;._;-:.:.....~.._.., -...-...." ,......, .....
. '" ,
, ,.. "' ;
.. ~ .. ....,.. 'dO-'"
:1.
"
"
.......
30
20
.-.-..."" .-_.
..'
. I..
"
10
..
. - --,--"'--' - - , .
1 .. ... .
" '
!
.J
i:.",:....
...- .
,-." -
u-..."""""'. "'-- - . ...'.. .:..:...1........ . ----
. ,~- C_<- ;":~c-",-L~~~ '- ~ - - --'-.-- -,-'- - c. -: ~- ~ '- .:.; >,.-' . . ... .- ~. -.. C --
/970
71
73
25
80
8i
78
Figure A-2
INS TALL AT ION
A-23
79
Y::,l\R
7Z.
77
32
74
75
7(;
93
8+
-------
establish a practical operating load factor for a specific installation.
In general, the operating flexibility and particular utilization of a
specific plant is determined by special operating procedures implemented
by advanced control and automation systems.
Operating characteristics quoted by manufacturers -- such as
cold start-up, hot restart, minimum load operating point, operating
criteria (variable versus constant pressure), and rate of load change --
vary substantially among manufacturers.
These performance characteristics
are considered firm only after verification by utility operating
departments.
Many operating problems on large boiler installations reflect
the lack of design maturity and operating experience.
Expected Life of New Installations
Increasing emphasis on evaluations of plant economy and
system planning has brought about a change in philosophy of many
utilities toward units with a shorter expected life than units previously
installed for a similar type of service.
Several advantages inherent
in the tendency toward shorter-life machines make it economically
desirable.
The system becomes more adaptable because the utility can
keep its distribution of installed sizes and generation mix more closely
in line with the optimum distribution corresponding to the utility's
particular load characteristics and system growth.
Capital costs tend
to be lower for shorter-life machines.
Although the capital cost for
two IS-year units is more than that for one 30-year unit, the difference
A-24
-------
is usually off-set by lower operation and maintenance costs and lower
fuel costs (due to better heat rate) in the second 15-year unit compared
to the second fifteen years of operation of the 30-year unit.
Shorter-
life units also permit the utility to take earlier advantage of
technological improvements.
A-25
-------
FOSSIL FUELS FOR UTILITY POWER GENERATION
. .
In 1968, approximately 81% of the kwh generation in the
United States was produced bytheuse of fuel, with the balance produced
primarily by hydro-electric generation and a small amount of geothermal
steam generation.
There are four basic electric utility fuels:
coal,
residual oil, natural gas, and nuclear.
Figures for 1960 and a forecast
of their relative position in 1970 show recent changes in percentage
of capture by fuel:
RELATIVE SHARE OF ELECTRIC UTILITY STEAM GENERATION
(% of Steam Generation)
FUEL 1960 1968 1970
Coal 66.3 61.9 59.7
Gas 26.0 27.6 25.9
Oil 7.6 9.4 9.4
Nuclear .1 1.1 5.0
Fossil Fuel Reserves
Coal Reserves
The coal reserves in the United States are tremendous; the
actual coal underground approximates 1.5 trillion tons.
However, not
all of this is economically recoverable under present-day technology.
Assuming that bituminous coal seams at least 3-1/2 feet thick are
A-26
-------
recoverable, that sub-bituminous coal seams at least 10 feet thick are
recoverable, and that only 50% of the seam is economically recoverable
(because of coal pillars left for roof support), we arrive at a figure
of approximately 265 billion tons of known, economically recoverable
coal in the United States today.
Approximately 70% (based on tonnage)
of these reserves are located west of the Mississippi River.
Based on
caloric value, approximately 45% of the reserves are located west of
the Mississippi River.
Gas Reserves
At the end of 1968, the proved recoverable gas reserve still
in the ground in the United States amounted to 287 trillion cubic feet.
Proven reserves are those reserves in which the field has been definitely
mapped and tested for quantity.
In addition to proven reserves, there
are potential and probable reserves which would add approximately
one-thousand trillion cubic feet to the gas supply in the United States.
However, these reserves are not proper~y identified and quantified and
may not be as extensive as estimated or may not be economically
recoverable.
Therefore, in considering a fuel reserve supply, conservatism
dictates that only the proven reserves be mentioned.
These reserves
can be increased, at greater expense, either by the importation of
1iquified natural gas or by the manufacture of gas from domestic coal
supplies.
Neither of these methods is economically competitive at the
moment with the natural gas production in this country.
However, recent
long-term contracts have been signed for LNG delivery to the East Coast.
The price range (40-55~/MB) prohibits use for powe~ generation.
A-27
-------
Oil Reserves
Because of ,its ease of transportability over water, oil is
truly an international fuel.
Hence, the reserves for the United States,
the balance of the free, world, and the Communist Bloc countries, have
been indicated in the following table.
The proven reserves left in
the United States amount to 31 billion barrels of economically productive
oi1.
An interesting fact to note is that present technology in oil
production allows the recovery of approximately 30% of the oil contained
in oil sands.
Hence, if we take the 85 billion barrels of oil already
produced in this country plus the 31 billion barrels expected to be
produced and consider it as 30% of the total oil in the country. this
would leave an oil reservoir of approximately 385 billion barrels remaining
in the oil-producing strata in the continental United States.
Obviously,
oil-producing companies have spent and are continuing to spend a signi-
ficant research effort to discover methods to increase the yield of oil
from the oil-bearing strata.
However, in assessing fuels at the present
time, we must consider only the economically and technically recoverable
fuel, which leaves the proven reserves at 31 billion barrels in this
country.
The same reasoning applies to the proven reserves for the
balance of the free world and the Communist bloc.
A-28
-------
PROVED RECOVERABLE FOSSIL FUEL RESERVES IN 1968
PROVEN ANNUAL
RESERVES CONSUMPTION
Coal (Tons x 109)
U.S. 265 0.5
Gas (MCF x 109)
U.S. 287 19.9
Oil (bbls x 109)
U.S. 31 4.78
Balance free world 381 7.57
Communist bloc 59 2.08
Prudhoe Bay Field (Est) 20-30
Factors Affecting Future Production of Coal
Unfavorable Factors
Several major factors are a deterrent to the increased
production of coal.
One of the most serious obstacles facing the mining
companies is the lack of manpower.
Not only has productivity per man-day
suffered reverses due to temporary labor unrest, but more important,
the mining companies are having difficulty enticing younger miners and
professional people to work in the mines.
The numbers of mining
engineers recently graduated from the universities have fallen short of
the demand for mining engineers in the mining industry.
More experienced
miners prefer to remain miners or federal inspectors under the Department
of Interior rather than accept jobs as mine foremen.
As a result,
mining companies are suffering shortages in mine management and mining
engineering.
A-29
-------
A second deterrent to production of coal is the capital cost
of opening deep mines.
This cost is currently running between $10 and
$15 per annual ton of capacity.
With the current cost of capital, the
potential shortage of adequately trained personnel and wide fluctuations
in the price of coal make the investment in new mines highly speculative.
A third, more recent deterrent is the strict mine safety
legislation recently passed by the U.S. Congress.
Not only will this
increase the capital cost of the equipment in a min~ but it has the
potential to reduce the output per man-day because of the additional
safety precautions necessary to protect the health of the miners.
This
may be a significant cost increase factor in the production of coal.
A fourth area that will create serious problems in the use of
coal in the utility industry are the potential air pollution require-
ments, particularly those relating to sulfur dioxide emissions.
Most
of the steam coal east of the Mississippi River has 2-1/2% or higher
sulfur, which means that it cannot be burned in conventional electric
utility boilers within the proposed air pollution regulations.
Thus,
the coal either has to be treated to remove the sulfur, or the sulfur
dioxide must be removed from the flue gas.
The alternatives are covered
in another section of this report.
Favorable Factors
There are also several factors favorable to the potential
future production of coal.
Mining processes are continually being
improved through mechanization.
Methods of continuous mining and cutting
A-30
-------
machines, rock dusting apparatus, and gas detection systems are being
improved with new technology.
In addition, the application of long-wall
mining techniques is finding use in certain parts of the coal fields.
This technique, originally developed in Europe, has a moving cutter along
the working face of the mine which may be 600 to 900 feet long.
This
cutter works continuously, with the cut coal conveyed to the mine face
by endless belt conveyors.
The productivity per man-day can be at
least tripled by using this system.
The cost of production is further
reduced because no permanent roof supports are used, and the roof of the
mine is allowed to collapse behind the mining operation.
Perfections
of this technique are expected to produce 200 tons per man-day of effort,
versus the current average of 20 to 25 tons per man-day of effort.
Coal firms are now able to obtain long-term purchasing contracts
from utility companies.
These contracts enable the coal companies to
obtain the capital necessary to open large deep mines.
Previously the
practice has been for most utilities to buy coal on a monthly or annual
basis on the open market, which did not assure a specific coal producer
a continuous market for his coal.
With the use of long-term, life-of-
mine, commitments, they can adequately plan their production, capital,
and manpower to utilize the most efficient production methods.
The last -- and one of the most important -- favorable factors
is the tremendous growth in the use of energy in the United States.
This
growth of energy requirements will tax all types of energy-producing
methods, oil, gas, coal, and nuclear.
Therefore, the coal industry has
an assured growing market for its product over the long term.
A-3l
-------
The following figures compare the present consumption of coal
with the forecasted consumption in 1980.
Note that the use by utilities
has a greater growth rat.e. than the industry as a .whole.. Also note that
the compound annual growthrat.e by utilities is less than the utility
power production growth rate of 7.8% per year.
This is the result of
coal's being replaced by nuclear and oil in future utility planning.
U.S. COAL CONSUMPTION (MILLIONS OF TONS)
1969
1980
Total U.S.
Electric Utility
E.U. % of U.S. Total
571
310
54.0%
793
508
64.0%
ANNUAL COMPOUND GROWTH RATE
1960-69
1970-80
Total U~S.
Electric Utility
4.0%
6.8%
3.3%
5.0%
Factors Affecting Future Production of Gas
Unfavorable Factors
The use of natural gas for various heating applications has
increased rapidly since World Ware II.
Concurrently, the discovery of
new gas reserves in the continental United States continued to increase
until 1968, when the proved reserves actually decreased by 5.6 trillion.
cubic feet because of the continued high United States requirements.
A-32
-------
The FPC has jurisdiction over gas use by virtue of its regulation
of interstate pipelines and is able to control the prices paid for gas
at the well-head.
The gas industry believes that current well-head
prices are too low to encourage new gas discoveries, and new gas
discoveries in 1968 and 1969 indeed have occurred at a lower rate than
in previous years.
All of this makes the outlook for new findings of
natural gas reserves in the United States unfavorable as this point
in time.
There are two main sources of natural gas production:
gas
wells and oil wells.
The economic incentive to do exploratory drilling
for gas fields has been retarded by FPC policy.
However, the production
of gas as a by-product of oil is not ruled by the same economics.
Approximately 6000 SCF of gas is produced with each barrel of crude oil
production in the U.S.
The production rate of crude establishes the
gas production from the source.
Favorable Factors
Gas is a clean-burning fuel.
It reduces or eliminates most
air pollution problems in urban centers and is an excellent fuel for
certain process industries -- such as the glass industry -- and as raw
material in the chemical industry.
In addition, gas is a very convenient
fuel for residential heating and cooking and has gained a strong prefer-
ence as a fuel among consumers.
The industrial market accounts for
48% of gas consumption; the residential market accounts for 36%; and the
utility power generation market accounts for only 16%.
_A~33
-------
Natural gas can be s~pplemented by the importation of liquid
natural gas .and by coal gasification.
However, the present-day economics
of these two sources of gas preclude their use in the electric utility
power generation market.
Hence, one can conclude that gas supplies for
markets other. than electric utilities will be adequately satisfied from
one of several sources, while the supply of gas for power generation will
be limited to natural well-head gas.
The FPC must approve use of natural
gas for boilers if the gas is carried in an interstate pipeline.
The
present policy of the FPC is to discourage the burning of natural gas
under boilers unless other benefits to the public are paramount, such
as reduced air pollution in California.
u.s. GAS CONSUMPTION (TRILLION SCF)
1969 1980 1990
Total u.S. 19.9 30.0 38.5
Electric Utility 3.2 4.2 5.0
E.U. % of Total 15.2% 14% 13%
ANNUAL-COMPOUND GROWTH RATE
1960-69 1970-80 1980-90
Total U.S. 5.2% 3.2% 2.5%
Electric Utility 7.2% 2.5% 1.8%
The.use of gas for power generation accounted for approximately
15% of total natural gas comsumption in 1969; the utility percentage will
A-34
-------
decline slightly through 1990.
However, this forecast is subject to
many factors:
a national policy on energy consumption, FPC price
regulation, and the proving out of the probable gas fields in the
continental U.S.
Any adverse action by these factors will reduce the
utility gas consumption at a faster rate than any other segment of the
gas market.
Factors Affecting Future Production of Residual Fuel Oil
Unfavorable Factors
The production of domestic residual oil is almost non-existent
because the domestic refineries are designed to produce all of the
valuable components of the crude that are available, leaving only the
barest residual.
This is dictated by the economics of the market place
and the price of domestic crude.
However, foreign refineries face a
different problem in that their markets for the different petroleum
products are much more limited.
Hence, they make no effort to "crack"
the crude into other products, and from 40 to 60 percent of the barrel
of crude remains as residual.
Therefore, the only significant source
of residual oil for utility power generation is from foreign sources.
To date the government has restricted the importation of oil, crude or
otherwise, to approximately 12% of domestic production.
However in
District I, the Eastern Seaboard, these restrictions do not apply to
residual which is imported for use as a fuel.
This restriction has also
been temporarily lifted in District V, the West Coast, 50 that low-sulfur
Indonesian residual could be imported to relieve the air pollution
A-35
-------
As of this writing, application ,has: been made
by a mid-western utility for relief so that, they can convert an in-city
problems ,in California.
coal plant to oil for pollution reasons.
However, one of the major
deterrents to the use of residual nationwide is that the cost of
transportation, other than by large sea tankers, is extremely high.
Another factor which will unfavorably influence future costs
is the problem of oil slicks in harbors and along the beaches.
Stricter
safety regulations for tanker operation coupled with international
enforcement will increase the cost of sea transportation of oil.
This
factor cannot yet be quantified, but it will be severe.
Favorable Factors
Several factors tend to make residual an attractive fuel for
utility use.
First, the governments of Venezuela, Libya, Iraq, Iran
and Nigeria are very aggressive in promoting the sale of their crude
through the companies they have licensed to drill for the oil.
Their
major source of government income is the oil royalties obtained, on
production.
Thus today, at least, there is an abundant supply of crude
and/or residual from foreign sources.
Secondly, the 502 air pollution
problem can be alleviated by reducing the amount of sulfur in the fuel
before combustion.
This can be done either by using naturally low-sulfur
African residual or by'desulfurizing the high-sulfur Venezuelan, residual.
Both options are being exercised in the eastern utility fuel market.
A third advantage is the extremely low transportation cost over water.--
as low as 3.l~/million Btu/1000 miles.
A-36
-------
A substantial portion of generation capacity -- approximately
35% -- is required to operate in a cyclic fashion, that is, it must
produce power for the daytime, weekday loads with little or no output
during low load periods.
Large, high-pressure, once-through coal
boilers are not suited for this service.
The utilities are now starting
to procure lower pressure, drum type (400 MW) boilers for this duty.
Oil or gas is much preferred to coal for this service because of ease
of control.
In addition, residual oil, with special restrictions on
sulfur and vanadium, may prove an excellent fuel for gas turbine peaking
service as well as combined cycle intermediate service.
Residual oil
has many advantages as a fuel for power generation, i.e., ease of storage,
economical water transportation, abundant foreign supplies, and relative
ease of start-up and shutdown of boilers.
RESIDUAL FUEL OIL CONSUMPTION
(Thousands barrels/day)
1969 1973 1980
Total U.S. 1800 1923 2123
Electric Utility 480 600 800
E.U. % of Total 26% 34.5% 38.0%
ANNUAL COMPOUND GROWTH RATE
1960-68
1969-80
Total U.S.
Electric Utility
3.5%
10.0%
1.5%
4.6%
A-37
-------
The utility use of residual has been growing at.a faster rate
than the U.S. total .residual market.
In fact, the utility segment of the
residual market is the only segment which shows any growth potential.
Note also that the projected annual growth for utility consumption
, .
declines in 1969-80, reflecting the growth of nuclear power.
Utilization of Fossil Fuels for Power Generation
Changes in the use of coal, gas, and oil in the electric
utility industry, as well as changes in the fuel situation in general,
are caused by factors such as supply, demand, government regulations,
pollution, nuclear power delays, fuel production, and fuel transportation
costs.
The annual demand for coal by the utilities will increase
through 1980, but the rate of growth will decline.
The growth in coal
requirements through 1976 is a result of the delays in scheduled nuclear
plant additions and the need for generating capacity to meet the increasing
demand for electricity in the early and mid-1970s.
The addition of coa1-
fired plants for intermediate generation accounts for the increases
in coal requirements through the end of the decade,. but the commitment
of nuclear plants for base-load generation will reduce the growth rate
of utility coal demand.
The most significant change in the'nation's fossil fuel market
has occurred along the Atlantic coast.
Almost unlimited amounts of
low-cost, low-sulfur residual oil imports have become available to the
utility companies along the East Coast.
Faced with shortages in their
A-38
-------
coal supplies, rising coal prices, and legislation limiting the sulfur
content of their boiler fuels in metropolitan areas, the East Coast
utilities have been a very receptive market for the petroleum companies.
Many have converted their existing coal-fired plants to burning imported
residual oil as the primary boiler fuel, and additional fuel conversions
of existing plants are scheduled.
A number of eastern utilities, apparently
not concerned about a non-domestic, politically-influenced energy source,
are purchasing single-fuel, oil-fired 300 to 500 MW generating units.
All indications are that the petroleum companies will continue to
penetrate the eastern electric utility fuel market successfully.
To 1985, gas is expected to remain the primary fuel for
electric generation in the gas-producing states and contiguous areas,
with most of its growth confined to this area.
The bulk of electric
utility burning gas plants in the future will be added in Louisiana,
Texas, Oklahoma, New Mexico, and Kansas, which produce 90% of the gas
in the continental United States.
In regions far from gas production,
gas is expected to decrease its share of the market, especially after
1975.
Much of the historic growth of gas use has occurred outside the
area where gas is produced.
It is in these regions with high fossil
fuel costs that nuclear and oil power will make the largest gains,
tending to reduce the overall growth of gas use in the utility fuel
market.
As a result of the gas shortage and the difficulty of getting
gas contracts, coal, as well as oil, may penetrate outside its traditional
consuming areas.
This trend is already in evidence; the past few years
have seen new coal-burning plants built in Florida, New Mexico, Texas,
Nevada, and Kansas.
A-39
-------
PRICE TRENDS OF FOSSIL FUELS FOR
POWER GENERATION
ELECTRIC UTIIJTY
IT: :2L
1,)DT(""I~'
~ .. ~....V~
ri\n,~,.ml'"
";-..;."'';'.~..i..,L'v
It c~~ be unequivocally st~ted that the days of cheap, readily
available supplies of fuel for pm'ler generation are over.
Gone are
the days "Then cor::peti tion in the electric utility fuel market is governed
exclusively by price.
rfuile each of the fuels is basically competitive
with the others in the electric utility marketplace, the major factor
influencing the Lla!'1:et price of each is different.
These major factors --
coal
the cost of production,
oil
alternative market opportunities,
gas
government'regulation, and
, ,
I
nuclear
the cost of preparation --
are, hm.;-ever, being !:lutually influenced by artificial, political and
cavir0n;;:-.;rrtw.. <':v:..':..:::.tra.L.-G5 tlia.J" d.J:e: ci.lh:a.~y i'tblHj.~in!l iJlf~ }"1"\";,r:'f:' ~ 8~,,!,~~ly'
and demand relationGhips th~t characterized the electric utility fuel
market in the 1950's and early to ~~d-1960's.
The patterns that have
been formed in the recent :past, along with continuing political and
, . ' ,
environmental pressures, vdll affect the future utility fuel market and
fuel price trends over the next 15 years.
A-40
-------
COAL PRICE TRErIDS
Coal prices in the electric utility fuel market began to
climb in 19S6, fol1o~,[ing alrnost a decade of decline.
The increases in
the price level for cOe,l began over tvlO years prior to the "energy alert"
of 1969 and 1970.
The increases '\-rere due prima.rily to improvements in
coal producti,rity no longer being able to counter rising labor and material
costs.
This rising trend has continued as the labor-intensive coal
industry c:i:j)'.::rj.ences a very unstable labor climate.
Labor unrest has
combined 'id. th the provisions of the 1969 l>1ine Health and Safety Act to
rcducedc8])~;d.ne productivity by 15 to 2010, and conversely increase
cp)erating cocts.
These rising production costs plus rapidly increasing
. .
coal demands rcsult~d in further increases in utility coal prices in
'i9S9 and 1970, but coal industry officials state that those increases
were insufficient.
The continuing effects of the ~line Health and Safety
Act., a nelV three-year contract ,vi th the UNWA, escalation not being offset
by substantial improvement.s in producti vi ty, and attempts by coal
companies to increase their return Ifill result in the continuing rise in
electric utility coal prices.
, A~41
-------
ELECTRIC UTILITY J.<"'UEL OIL PRICE TRENDS
Historically, the fuel oil available for use in electric utility boilers
was the residual waste product of the U~ refineries, representing only 6-7%
of each barrel of refined crude.
Crude oil was considered too valuable to
bUrn directly as a power plant fuel and was instead refined into high-priced
petroleum products.
The residual oil was functionally priced to compete with
coal or gas on a limited basis.
By comparison, foreign refineries permit
residual yield of 40 to 55 percent, and in 1969 the availability of an
apparently unlimited supply of imported, low-cost residual oil was promoted
for power generation in PAD District I.
:
Residual oil became a viable competitor
in the East Coast electric utility fuel market as competition between oil,
companies brought a sharp reduction in the price of imported residual oil --
high-sulfur resid prices bottomed out at 28~/~21BTU
in mid-1969.
HOifever,
as a r~sult of supply and demand pressures, the price begw1 to rise rapidly
in the fall of 1~9.
Newly enacted air pollution regulations and tremors
in the politically volatile African and HidcUe East oil-producing countries
caused further in9reases in ~he market price of residual oil in 1970.
The
supply of oil for the U.S. market was reduced, tanker capacity was over-extended,
JU1d premium prices were being demanded for 101" (1%) sulfur characteristics. .
A return 'to reasonably stable political conditions and an agreement between
. .
the oil companies and the Organization of Petroleum ~hporting Countries (OPEC)
relieved the "shortage" in the world oil supply and tanker capacity, and in
1971 the price of residual oil began returning to a market level more in line
wi th' a balanced supply and -demand condition.
More widespread and re~trictive
environmental regulations, however, continue to bring a premium for low-sulfur
A-42
-------
oil, with 0.3% sulfur content becoming the most stringe~t limit established
for boiler fuels.
This highest quality oil will demand the highest premi\~
price.
It is expected that environmental regulations limiting the sulfur content
of boiler fuels '!>"i11 have a marked impact on the oil industr:{' s re1ation.ship
to the electric utility fuel market.
High-sulfur residual fuel oils '!..ill
find less demand under tightening environmental regulation~ and the price will
be comparable to that of high-sulfur mine-mouth coal.
The lucrative market
for low-sulfur oil has presented the oil refiners with the economic incentive
to begin installing expensive .desulfurization facilities. for producing clean,
heavy distillates from the high- sulfur feedstocl\:s of the Caribbean and }1iddle
East.
The magnitude of the added cost of' desulfurizatiol1 is determined by
4-"',... ,......, ~...- -__.la.........L .. ----.,
_....;- ";'\,......,i,...i.......... --..,.,i......;"~..i.;'" ...i...\";-"-\";..i..
dCG:L:L"E;d. Ci.ild. t,ll(j
(;h(j,r'dc;Lel'il:d~ics of the fE:eilstoc.:h.
used.
'-!bile the current high demand for low-sulfur fuel oil ,'lith a limited
supply available is creating an artifically high differentia~ price beti'Teen
high-and 10~sulfur oil, the differential will become more directly related
to the actual difference in d~sulfurization costs '!Jhen the m~lY new processing
,.
facilities begin operation and the supply of 10iJ-sulfur oil increases.
With the rapidly rising oil prices in the electric utility fuel market
and the high cost of desulfuriza.tion, the oil companies have begun the unprecentcd
marketing of crude in the U.S. directly as an electric utility boiler fuel.
Continuing success of selling crude directly as a boiler fuel is dependent on
the crude having a low sulfur content -- African and Indonesian crude comes
closest to' meeting environm~nta.l sulfur reguJ. -- and the price being.
A-43
-------
high enough that the return on the basic crude is sreater than the net return
from the sale of the petroleum pro~~\'.\:1
refined from that crude~
It is
estimated that this price level on crude is just slightly less than the
market price of resiclual oil of' the sa..TTIC sulfur content since crude has some
safety disadvantages con1p~~:::ed to tl;:.: "equivalent high-quality heavy distillates.
.,.
".
The crude has a low flash charact~yi£tic since the gasoline and naphtha have
not been removed in processing.
Over the long term, the oil industTJ" Hill continue to functionally
price its products in the electr:le utility market place.
Fuel oil prices
will be established, commensurate ~~th the ~arket value of alternative fossil
fuels based upon th~ir heat content, environmental characteristics, convenience,
and availability.
In the 1970's, low (0.3%) sulfur resid and crude will demand
premium prices due
LO l.f!e
irclbtW..ailCc; lie L"v~-~Gll ':;~1i:Pl::,- ~~~ dc:-~nd
fer °101';-- ~t'J.f1~,"
fossil fuels, while in the 1980's it ~dll approach the market value of
. .
natural gas, the most desirable of the fossil boiler fuels.
Fuel oil for
the electric utility market ,,;i th greater sulfur contents\, ~'dll demand less
of a premium but will still co~and a good price due to its value as feedstock
,
for processing into higher quality boiler fuels.
A-44
-------
NATURAL GAS PIUCE TRENDS
Natural gas has gone from being a nuisa.nce bJr-product of domestic
crude oil production to a Dod tion as the premiere of the electric utility
boiler fuels.
The Federal Povrer Co:n:nission, by rcgu1atin[~ the price ",hich
gas producers can charge the {nterst'c1;!:,}.:':sransmission and tEstribution
companies and the resale price to 1c::.:'
-------
NUCLEAR FUEL COST PROJECTIONS
Each of the major categories of ma.s.'1ufa.cturinc; costs for the nuclear fuel
,cycle,
, Uranium
Conversion
U3 08 Rmv 1':,1,t.81'ial
Converts U3 013 to UF6
Enrichment
Increases U ~ Content in TJF6
2':;)
Fabrication
Ha.:uufactul'cs Fuel Assemblies
Reprocessing
Reprocesses the Spent Fuel Assemblies
and Recovers Unused Fue~
can be ana.lyzed to produce a cost breal:d.m..rn ,\rhiC~l ccm the;n be examined for the
effects of cost escalation for the perioj of 1971 to 1985.
Each of these fuel
. cycle cost factors can be apportioned :into perCcl1t3.g.8S for lc..bor, Jnaterial,
ano a firm non-variable cost.
By using the past ten J'co,rs for an historical
base, the index for the labor and material cOr.Jpon811ts of each fuel cycle step
was projected on a straight-line basis.
In addition to J]{:J.the1:atical cost
projections, other economic factors 1-Tere consid'~red in projecting the nuclear
fuel cycle costs.
The supply and dem"md pressU::.'E:S on ura)'l~UYtl prices; the
volume sensitivity, automation, and lerw.'ning-cUl'v:::: cost ilq)rovements in the
fabrication process; the volume dependency of reprocessing costs; and the
governmental restraints on the cost of enrichment were evaluated.
Nuclear fuel costs were calculated for a base load nuclear plant with all
of the fuel cycle components escalated and the cost of enric~~~ent at the legally
established ceiling after escalation.
T'nis most conservative projection shows
that nuclear fuel costs increase slightly from 20.18~/~~mTU
in 1971 to
22 .10~/Ivjl\ffiTU
in 1985.
This increase over the 15-ycar time l)eriod results
from escalation factors in the nuclear fuel cycle beginning to overtake the cost -
volume improvements in the fabrication and fucl rc:covcry components of the cycle.
A-46
-------
YEAR
1968
1969
1970
1971
1972
1973
1974
1975
1976
1977
1978
1979
1980
1985
ELECTRIC UTILITY FUEL PRICE PROJEC'l'IONS 19'71-1985
STEAM COAL
Deep-I.1ined J'.line-Houth
YEAR
~/NHBTU
16.7
17.8
21.3
26.2
30.0
32.0
33.4
34.2
35.3
36.6
37.9
39.2
40.6
48.6
INDEX
100.00
106.58
127.54
156.88
179.61t
191.61
200.00
204.79
211.37
219.16
. 226. 91~
234.73
24-3.11
291.01
Deen Water Port Cont~act Cargos
196U Htgh-::5UIf'ul' I\8sid Price ~.OO
High-Sulfur Resid ' LOvT (1%) Sulfur R~sid 0.3% SQlfur Resid
~/I
-------
CRUDE OIL
Deep Ylater Port Contr:lct Cargos,
1971 High- Sulfur Crude Price = 100.00
High- Sulfur Cru~ LmV' (1%) Sulfur Crude 0.3% Sulfur Crude
YEAR if; / I"MB TU INDEX rf;/l.rj.fBro INDEX rf;/PYJ3TU UIDEX
1968
1959
1970
1971 50.0 100.0 56.0 112 .0 72.5 145.0
1972 51.5 103.0 58.0 116 .0 75.0 150.0
1973 53.0 106.0 59.5 118.0 77.0 154.0
1974 54.5 109.0 ' 61.5 123.0 79.5 159.0
1975 55.5 111. 0 63.5 127.0 82.0 164.0
1976 57.0 114.0 65.5 131.0 84.0 168.0
1977 58.5 117.0 67.0 134.0 86.0 172.0
1978 60.0 120.0 68.5 137.0 87.5 175.0
1979 61.0 122.0 69.5 139.0 88.5 177'.0
1980 62.5 125.0 70.5 141. 0 89.5 179.0
1985 69.5 139.0 76.0 152.0 93.0 i86.0
A-48
-------
NATUTIAL GAS
Electric Utility Price
YEA.~ . ~ /1
-------
Curve 64S771-A
110
100
90
80
70
:::>
I-
~OO
~
~
50
40
30
aJ
10
0
1970 1975
Jet-Kerosene
No.2 Diesel
Natu ral Gas
0.3% 5 Resid
O. 3% 5 Crude
1 % 5 Resid
1 % 5 C rude
High 5 Crude
High 5 Resid
Mine-Mouth Coal
1980
1985
Year
Electric utility fuel price projections 1971-1985 actual dollars
A:.. 50
-------
UPDATED PROJECTIONS
A-51
-------
ELECTRIC UTILITY GE:mRATION ADDITIONS IN GW
r.l~~?3T. St77,:.~~~~:.Y 1~J70-1~'\:.5
1970 1971-1975 1975 1976-1930 1980 1981-1985 1985
TOTAL ADDITIONS TOT..A.L ADDITIONS TOTAL ALDITIO!TS TOT.'\.L
-
EASE LOAD
Coa.l 87.4 10.5 97.9 30.3 128.2 2.1 130.3
Oil 21.1 1.3 22.4 4.9 27.3 27.3
'. . Ga.s . 45.5 3.4 48.9 48.9 48.9
!o~aL Fossil 154.0 15.2 169.2 35.2 204.4 2.1 206.5
Nuclear 5.3 62.1 67.4 70.1 137.5 130.9 268.4
Hydro 25.0 25.0 25.0 25.0
Ht!.' :..:'..!.::::DIA':3
Coal 51.7 30.4 82.1 45.7 127.8 73.7 201.5
Oil 10.4 8.7 19.1 15.2 34.3 5.3 39.6
Ga.s 21.3 12.8 34.1 7.6 41.7 41.7
Total. Fossil 83.4 51.9 135.3 68.5 203.8 79.0 282.8
Nt:.clear 7.6 7.6 26.3 33.9
~Uro 23.6 2.5 26~1 2.5 28.6 2.5 31.1
PEA1\I1;G
In"ter.Comb
& G.T. 21.8 30.9 52.7 11.4 ' 64.1 37.8 101.9
Hydro 7.3 15.1 22.4- 18.2 40.6 15.0 55,6
TOTAL
CA?;CITY 320.4 177.7 489.1 213.5 711.6 293.6 ' 1005.2
A-53
-------
u.~. EL~CTr ,r ' :'01 ' r':;: -: . .:: " . ' /" , I::' r.~~: ;-;~ ',-:.:'- - ..;.J L.:'_c
l~
, ,
. -'..'.'..---,.-" .-- .-..,. _.....
. ""!-.'. . ..- :
...- -... .-, -. .
. ,. -..
p-.
1'/'
I"', :
'. t:~...
14
. .. .
"p' .. .-..-.' -.
---
.;.._.
"
.-'
..,
, ,
- ..;,.: . .. ....;. -'_..~-
I'. .
!~/1
. . .'" .,.~
.. ~. . ~ l~:...
. . I .. ...
.- ,-"-,,,""'.'-----'"
....,..
1C:>7B
198D
1981
INSTALLA,IDN
1981
YEAR
1964
A-54
1%5
1963
1979
-------
IV1ILL10NS
K'"
"
U,S, ELECTRIC.
DISTRIBUTION
BY TLJR8Jr~f
LJTIL ITY
It-1DU~TRY
OF
F"D!>-SIL
STEAM
ADDITIONS
AND 1991- 85
RATtN G
1'37b - 50
I (" I
'1
. ._.,. .-..".- ....- ..-.-..,..--..
. !., "
. . .-._-~... - ,-.' -.---' .--. .- --., -t".
-~...~~..~_.~ --- .-:.-: ... ,"".'" .:-:... -:"'1 __M:-',_- , ---.". .....~--._.~- --'-'-'-'."~ .-.--....,
. . !, ... '.. ',., ; . i ':. '!
"
.. .;'
U!
'-.'."'''' ..
"
,',
"
- -, -. - ...
197~
BO:
"
I
,,'
co
,
,... .
!
I
I
j
I
I
j
i
J
I
I
J
i '
I
I
I
I
lrtJ--LJl
;
i
J
",. .",. 'u" -..- . "
12.
"
8
,I,
,':,','r
, :"', ':' .1, I,
10
. M .-." ~ .......
"
, -::
, '
"
4
..
(
'--=1
-------....
12
.I,"!. ., .'
'3 1 ' "I ': ,':: '
" G i r--~:- - i---'-- -.;--- -----' ! ---,-~-' -- ------
~ I" 'r- ,--.., - - - ",",--\-',-',',",",",-':"-,, ":~,..;.":..,:..--"....,..._:,":"..,, ",I""", ,','
4J """," -. ...-" __..n' .--.. ...."-.. .
III 11 ,:',",:, ',: ',' . ',;,',""" -,. .""",','",."'.-.:,',',.,,,,'"'-, ,'..',i -",._',:~_:'"..::_:-,,~. \:~':' :', :--':i": ,,!~:' ,: : ,I9B I ~ 85,;,.,:, h
"i - ..----..-..---......-.-. :"" ~'~"'---'~__.'M"__' ..u:..':':..._.f.._":'..:.'~,... .........,_J...:....~ ._..-. ;--..---..- ...
j :. ~ .' . j . I . . I : i . . ; : . j : . : : : i .. f '.:
- ;_J; ---""1~. ... -i~~~ .... .:~-: c-4,. :-jh"~; ,~~:- ~,: :. ,l: :..~~-~,:~~:~_i'h;:, :,:,~''''<~_::~~: :~~:,~..,~ ,~~. --.
,H . i:--~. ""u .:..':.; ...-: .. .... - !' ...~ .-- . J' . . U j
-- ~- '--:-j u-r=~=,'!;,r--=I',~:,:!~,-~:;',,-,b-"-i~-~ i: 'u '-.
i', " ,::j" .., ,:~~,.,:,;.._.._:...:I,;...,...,!
-,--. ........ ..'... .....__.1._;...:..-.-.,-...-. m.u::~~~j..:__.~._L_:~~.._~L._.,..~: ....1..- ~.. ..~_...... '.~..... '..
: !.! ' '~:I--::cl:,: ,~,' :ic~";",, ,'.. ' ..
. .._..:...~._":":":' ...i..:..._. ......':'...:...-=_....:....... _: .......... ....._- -.'-
. . I . I' .
" I'
'. . : ...~ -~ :... .: . .. .... . j ..:
4 !, -"-'- i 'j" -.., !..~ ! , ..
i i I I I' !
f t' i i
2. I j -1.., > -, j I ! .'
. I ;, I I [
:'01 . -- , ! ' r
~
10
'8
I
1
....-.,...-- ~.~ _. ~.-
n
'..
I
I
I
..-. .-----.
Q
UNDU?
100
100
,~DO
300
400
500
(DOO TOO
TURBINE
900
RATING IN
8C;O
1000
rv1W
1100
12.00
1300 1400
A-55
150[..
-------
U.S. ELECTRtC
DISTRIBUT I6N
r.jlLlIONS
KW
OF
UTIl.rfY
iNDU~"RY
FOSSIL
STEAM
ADDITIONS
. . . .
.-.": :.-7~: :~~.':: ': ':-1~:.~?~';-~: r~.~-~"::::':-'~"'-':::-:-:::~~~':?'~.-:~7' :r":":~: :.~'.:'-1~?"f:~.:.~ ...-.:-:;:.... ~:~.~ "~':'i ~......:-:~
" . ..' . I' ..,.,. ,. ~ .' . "'" '.., .' ,..: . '" .' ~ . . . . . .:
:',' .,", i..._',:" .f-:.,::' '. ._. ,. ',j..::: .;,':',: :':.~.'. ..
2B
..
2G
"~ . ",,' .' . .-" -, .
2.4
. .
22.
- ...-_. . "'-'~' .
" .. .
. .
.-. . .-. - .. --- .." .
. .. , .. ,.. .
" - ~ ,- . ~.-
.. .
20
,"" '. ..-.,...
16
'" . -, --.-'
.'
IS
'. .-. .. '.~ . ... - - ..," '0' .
. n'.- .'''.-'
14
Q
r'.,!
. I..": .
L,:'!
., . [;::1
. . ' """-' 1::.:.1
'1:. :
, ,
..
. ,....
. L. ~.~.
i,
. : . ~ :
- I: .:.
, '"
I:.: ~
i"
400
500
TURBINE
j' ,"
t~ .'
[:'i:
!.. ~.,
[f,",
.::.<.
,:"",
1:.'..
. j:.:::
'..
, .',-
J": ~ ;.
: .'
t. ..
i:"~ :
!; ":"
J'.''''
!: ~~
(::.:1'
~?,::I. '
.:f:1
j"..
" i:;1 .
: 1.:.,1
;::;~I" . ,
!:..<
i j
:;,'1
I::.'~ I
--.'. 1:'1
!;:"'t
I'>q .
)'..>1
1-::'::1 'IW.'..,',..',..,.,'
. ,",/ IL:.I
.. r ':j !'~":,I
1>/
[.::! . ~. :,~,:,',II
\: .1
:.'i '''. .1
F:..! ::-
'):,)1'" ,I~'-
t}..:. II::"
:.'.1 :.. I
. ..:\' 'r::1
~ ,:'.' !~. . I
, " I
, I
I
"
.' -,'k'.'."4'--"-' ..
: ~., :
. ~ --' _.'
h_'__".'-'"
-, n',' . - .
'... .
TOO
800
1100
900
1000
RATING
IN fV1't1
A-56
- .-..
,.
:!.
. '.. .
-.-.
. P'"
i"
I~: ,:
. I ~;
.. I '
j=.,' .
I
IZOO
/300
-------
APPENDIX B
INDUSTRIAL BOILER MARKET SURVEY
Prepared by Erie City Energy Division
of Zurn Industries, Inc.
AUTHOR:
Warren D. Schwinden
'B-1
-------
TABLE OF CONTENTS
A Study of the Industrial Stationary
Watertube Boiler Market. . . . . . . .
Figures.
Appendix I
Appendix II
Appendix III
Appendix IV
Appendix V
Appendix VI
Appendix VII
Appendix VIII
Appendix IX
Appendix X
. . . .
. . . . . . . . . . .
ABMA Data.
. . . . . . .
. . . . . . .
. . . . . . . . . . . . .
Capaci ty. . .
. . . . . . . . . . . .
Pressure. . . .
. . . . . . . . . . .
Temperature. .
. . . .
Base Fuels. . .
. . . . .
Alternative Fuels.
Firing Method
Markets.
. . . .
Region.
. . . .
. . . .
1970 ABMA Data. .
. . . .
B-3
. . . .
. . . . . .
. . . . . ..
. . . .
. . . . .
. . . . . . .
. . . . . . .
. . . . . .
B-5
B-19
B-41
B-47
B-6l
B-73
B-89
B-99
B-109
B-117
B-131
B-143
-------
A STUDY OF THE INDUSTRIAL STATIONARY WATER TUBE BOILER MARKET
1.
INTRODUCTION.
In an attempt to estimate the possible influence of fluidized-
bed combustion (FBC) technology on the Industrial Stationary Watertube Boiler
Market, a study was performed under NAPCAContract CPA 70-9.
The two-fold ob-
jective of the study was to first determine typical operating parameters for a
prototype design of an industrial FBC unit; the other objective was to measure,
in some manner, the possible areas of application for FBC technology in the
industrial boiler market.
Recognizing the state-of-the-art for this combustion method would probably re-
main in the developmental phase until at least 1973, any discussion of the above
objectives must pertain to the post-1973 market.
Hence, a forecast of the market
relative to technological changes and consumption patterns would be required
prior to any assessment of FBC potential.
CONCLUSIONS. The major results of this report are listed below.
2.
1.
The prototype design should be in the 600 PSIG - 750 F pressure-temperature
class.
The output of the unit should be the maximum possible while still
remaining shipable subject to current railroad restrictions.
This suggests
using a modular approach to unit design for minimization of field installation
costs.
2.
The potential 1980 market for units with outputs exceeding 100,000 lbs. stm/hr.
will be in the neighborhood of 63.5 million pounds of steam.
This is the por-
tion of the industrial boiler market which FBC technology will need to pene-
trate.
B-5
-------
3.
The predominant portion of the industrial boiler market is shifting from
smaller to medium sized units (that is, units with outputs between 100,000
and 250,000 lbs. stm/hr.)
4.
Relative to aggregate capacity sold, the industrial segment is not expanding
as rapidly as the utility'portion of the stationary watertube boiler market.
5.
In the current market, either oil or gas are used as the primary fuel for
80 and 90 percent of the total capacity and units sold, respectively.
The
preferred fuel is gas which is used for 60 and 70 percent of the total capa-
city and units sold, respectively.
6.
The use of bituminous coal as a primary fuel'for units sold in the industrial
boiler market has been rapidly declining.
In the 1969 mar~et, coal firing
accounted for less than 3 and 2 percent of the total capacity and units sold,
respectively.
7.
The use of coal as a primary fuel is generally restricted to larger sized
units with the preferred method of firing being either spreader stoker or
pulverizer.
8.
The major consumers of units with outputs exceeding 100,000 lbs. stm/hr.
appears to be the chemical, paper, and petroleum industries.
9.
Since it is unlikely FBC will be a competitive alternative for gas-fired
units, and the region (Texas, Oklahoma, Arkansas and Louisiana) consuming the
, largest average unit size uses gas as the primary fuel, the domain of FBC
marketability is further restricted.
10.
Unless the availability of oil and gas are severely restricted by either
diminishing supplies or legislation, coal does not 'appear to be asigni-
ficant primary fuel in the future industrial boiler market.
The overall assessment of the future for FBC technology in the industrial station-
ary watertube boiler market, based upon the above conclusions, is not
R_h
-------
very
optimistic.
Although FBC will hopefully aid in the pollution control of
coal fired units, it is doubtful that industrial users can be persuaded to switch
from present oil or gas fired units to ones using FBC methods.
To produce such a
switch, some rather dramatic improvements in either initial investment or opera-
ting costs compared to existing methods would have to be offered.
This appears
rather unlikely for FBC units.
On the other hand, since coal fired units will
always have some area of application in the industrial boiler market, FBC technol-
ogy should be a useful technological advancement.
3.
OUTLINE OF REPORT.
The remaining pages of this report contain a definition of
the source, method of presentation, and limitations of the available historical
statistical data.
Some interpretations of these data will then be offered along
with a discussion of the method used in generating the required long-term fore-
cast.
As a means of obtaining a comparison, an additional forecast is presented using
an independent approach.
Both results are strikingly similar, thus yielding
some degree of confidence in the forecast.
F~llowing the interpretation of the forecast, numerous figures and appendi~es
are presented.
It must be emphasized, while reading this report, constant refer-
ence to these supplemental statistics will be required.
4.
ABMA RECORDED DATA.
The historical data used for this market analysis was ex-
tracted from the 1961 through 1969 annual reports of the American Boiler Manu-
facturers Association (ABMA).
A letter authorizing the use of these data is
included in Appendix I.
Perhaps a definition of the source and type of statistics recorded by the ABMA
will make the data more meaningful.
Each stationary watertube boiler sold by
B-7
-------
member companies (and this includes all of the major and most of the minor equip-
ment manufacturers) is reported to the ABMA listing the following properties:
1.
Purchaser's Standard Industry Classification (SIC) number.
2.
Domestic or export use.
3.
Domestic region (or foreign country) in which unit is installed.
4.
Electric utility or industrial use.
5.
Packaged or field assembled construction.
6.
Steam capacity.
7.
Operating pressure.
8.
Outlet steam temperature.
9.
Primary fuel.
10.
Alternate fuel.
11.
Firing method for solid fuel (if applicable).
It should be noted the above listing only includes those items which affect the
Other properties are reported, such as reheat temperatures,
intended market study.
Also, marine
but this study is meant to exclude boilers intended for utility use.
boilers and hot water units are omitted.
The annual reports of the ABMA group the operating parameters (unit steam capa-
city in thousands of pounds of steam per hour, operating pressure in PSIG, and out~
let steam temperature in degrees Fahrenheit) into discrete intervals.
Likewise,
the other properties are separated into distinct categories.
A definition of these
ABMA defined clusters is included in Appendix I.
It is important to note, however, ABMA is continually redefining these statistical
groups.
limited.
Consequently, the available years with consistent statistics becomes quite
At best, the reported industrial steam data remained consistent within
B-8
-------
the various categories for only a nine year time span.
Indeed, the industrial
steam classification was not tabulated in their annual reports prior to 1961.
The data stated for the entire stationary watertube boiler market from 1937
through 1969, however, were useful statistics.
5.
DESCRIPTIVE STATISTICS.
In performing this study, the available statistics were
analyzed from various viewpoints.
To begin with, Appendix I includes a tabula-
tion of the aggregate capacity sold in the entire stationary watertube boiler
market from 1937 through 1969.
In addition, the industrial boiler market from
1961 through 1969, and its percentage relative to the total demand, is given.
The same data are shown graphically in Figure 1.
Observe this graph is a semi-
logarithmic plot to indicate the natural growth trends.
It is thus clear the
total market is expanding at a faster rate than the industrial demand.
This
observation is an expected one considering the growth of the utility industry
during this time period.
Note the utility industry steam demand is essen-
tially the difference between the total and industrial markets.
Figure 2 is merely an extension of the total market data exhibited in Figure 1
with the exception it is shown on a rectangular grid.
Notice the significant
shift in the level of total demand from 1962 to 1965.
Again the increasing
difference between both markets is apparent.
The historical data for the clusters used by ABMA in reporting their annual
statistics (that is, the ones already mentioned which are relevant to this study)
are presented in Appendices II through IX.
Each category covers the years for
which consistent data were available and are displayed in differente table form.
These tabulations represent both aggregate demand (millions of pounds of steam)
and strength relative to the total demand (expressed as a percentage) for each
category.
And in addition, because the market can be measured with respect to
B-9
-------
."..
either total capacity of total number of units sold, the appendices list the
data accordingly.
6.
INTERPRETATION OF STATISTICS.
Certainly any market study has to begin by looking
at the available historical data.
Likewise, the statistics. should be viewed from
different vantage points.
Thus Figures 3, 4, and 5 separate the data into broad
categories to suggest trends relative to. unit size.
Obviously, the predominant
influence in the past has been exerted by those units with outputs not exceeding
100,000 Lbs./Stm/Hr.
This strength is shifting, however, to the units of medium
size (that is, those units with output between 100,000 and 250,000 lbs. Stm/Hr.)
Page A-5 contains a tabulation of the average unit size for fuels, firing method,
markets, and regions.
Some interesting observations can be made such as the
increasing unit size for both oil and gas firing.
Notice these data, being
average values, are influenced by the quantity of smaller sized units sold in
the market place.
The need for larger sized units in the chemical, paper and petroleum industries,
although intuitively evident, is substantiated by the tabulated data.
Similarly,
the concentration of the chemical and petroleum industries in Region 6 (Texas,
Oklahoma, Arkansas, and Louisiana) is indicated by the marked increase in average
unit size contrasted to the other regions.
When attempting to analyze a set of statistical data, it is always interesting
to look at the corresponding cumulative distributions.
Accordingly, Figure 6
displays the annual distributions for capacity (that is, unit size), pressure,
and temperature.
Several comments regarding the construction of these distributions are in order.
First, the reporting intervals remained consistent during the 1962 through 1969
B-IO
-------
period.
The 1961 distribution (Figure 6-1) on the other handt is includedt but
the different structure is evident.
Indeedt this contrast is most obvious in
the temperature distribution.
The second comment concerns the temperature curves.
ObviouslYt the saturated
portion of the market is not uniformly distributed throughout the saturation
interval (0 to 300 degrees Fahrenheit) as indicated by the graph.
Insteadt the
percentage level at the curve and partition line intersection relates to the
saturated steam demand for that particular year.
FinallYt these distributions are linear segment approximations .over intervals
defined in Appendix I.
In factt Appendices II, III, and IV exhibit the actual
density data used to construct these cumulative distributions.
Some conclusions can be reached from reading these curves.
For example, it
seems in the past units with outputs not exceeding 100,000 Lbs.Stm./Hr. account
for roughly 80 and 50 percent of the units and capacity soldt respectively.
When one looks at the pressure distributionst it becomes apparent 90 and 70
percent of the units and capacity soldt respectivelYt do not exceed 600 PSIG
operating pressure.
Likewiset the significance of saturated units is readily
discernible from the temperature curves (approximately 75 and 50 percent of the
units and capacity sold, respectively).
The span between 1964 and 1967t how-
evert illustrate the period of industrial expansion by showing greater dependence
on superheated units.
Note the most important superheated class is the range
covering 725 to 775 degrees Fahrenheit.
Certainly turbine applications cause this
p'edominant temperature interval.
B-11
-------
Trends exhibited by the density data (relative to percent of aggregate capacity
sold) contained in Appendices 'II, III and IV are shown in Figures 7, 8 and 9, respect-
ively.
These trends will be used later in an attempt to anticipate technological
changes.
7.
LONG RANGE FORECASTING TECHNIQUES.
Whenever one attempts to make a long range
market forecast, he must consider both the economic and technological factors.
For the prevailing economic activity will determine in some manner the level of
demand, but the state of technology limits the available product species.
In forecasting economic conditions, several techniques are in current u~e.
Perhaps the most popular among non-economists is correlating a particular market
with some economic indicator.
To achieve meaningful correlation, however, a rather
large set of market data should be avaiable (most forecasters recommend a minimum
time span of 15 years).
Obtaining the necessary statistics for the indicators.is
no longer an insurmountable problem since several government sources publish
easily accessible data.
To locate long-term projections for these indicators,
on the other hand, is quite a different problem.
Still, some sources are available.
For instance, several institutions maintain econometric models from which they
make long-term projections for many of the common indicators.
Normally the market data itself, however, is the limiting factor.
Indeed, this
market study uses only nine known data points.
Thus it would seem quite foolhardy
to attempt a correlation with some type of indicator (such as the New Plant and
Equipment Expenditures and Corporate Profits data published by the Council of
Economic Advisors in their "Economic Indicators" periodical) especially for long
range forecasting.
Yet this approach would be feasible if one was only interested
in short-term predictions.
For then a constant surveillance of the variance between
predicted and actual values could measure the validity of the correlation.
This
B-12
-------
monitoring is possible since short-term predictions are, in general, repeated
for each new period.
In contrast, the objective of this particular market study
is not to devise some repetitive forecasting procedure.
Rather it is to make a
single reasonably valid estimate of the potential market.
Furthermore, to use a long-range single-point estimate, as would be the case in
short-term predictions, can only result in an erroneous forecast.
The most one
can expect to determine is some interval which will hopefully contain the future
trend.
Moreover, as the forecast period increases, the interval range should
diverge.
Note the distinction made in stating this interval should contain the
expected trend value and not a single-point estimate of the actual demand.
As a
matter of fact, the value of the demand could well exceed the interval boundaries.
We are in essence starting with a set of nine data points originating from 1961.
From this starting point, we are saying if the trend were computed after each
additional year's demand was added to the existing set of data, the interval would
contain the terminal point of the trend line (that is, the trend line value for
the latest recorded year).
8.
BETA DISTRIBUTION.
If one accepts the concept of using trend interval estimates,
the problem then is how to determine the interval range.
This can be achieved
by making optimistic and pessimistic estimates which can be used as the upper and
lower bounds, respectively.
If some value within the interval can be considered a
most likely estimate, a statistical distribution can then be used 'to generate a
statistically expected value.
A probability measure for subinterval forecasts is
then available.
Observe the span of the interval is a measure of the uncertainty
implicit in the forecast.
The Beta distribution is the particular one used over
the forecasted interval; for a discussion of its mathematical properties, see
Vol. 2 of William Feller's An Introduction to Probability Theory and Its Applications.
B-13
-------
In determining the optimistic and pessimistic bounds for the interval, one could
rely on either subjective opinion or objective techniques.
For a new technolo-
gical method, however, subjective numbers would be hard to determine.
Hence,
naive methods (that is, extrapolation of historical data) were used.
Assuming
the greatest expansion of a market would be limited to the law of natural growth,
the optimistic bound would be subject to an exponential function.
Consequently,
a constant ratio between consecutive years characterizes the optimistic estimate.
Since a considerably larger set of data were available for the total stationary
watertube boiler market, the pessimistic constraint was generated (linearly) from
these numbers.
The average industrial steam portion of the total market was then
assumed to be 30 percent of the total demand.
Notice Figure 2 shows a significant
change in demand for the total market between 1962 and 1965.
Yet the trend of the
raw data without any adjustments determined the pessimistic estimate.
Hence, the
pessimistic estimate should indeed be conservative.
For the most likely estimate, it seemed reasonable to use the current trend line
for the industrial steam market.
Observe a linear trend, as used for the pessi-
mistic and most likely values, assumes a constant annual change in the magnitude
of the market, as opposed to a constant proportional change for the optimistic
constraint.
With the interval bounds and the most likely value estimated, a statistically
expected value using the Beta distribution was calculated.
Figure 10 shows this
distribution for the forecasted 1980 interval with both the density and distribu-
tion curves illustrated.
Notice the interval has been transformed to the zero-to-
one range.
This has been done for ease of calculation.
In interpreting the figure,
perhaps the distribution curve is most useful.
For example, one can determine
the median value, the probability of some subinterval estimate, and the skewness of
the distribution.
B-Jh
-------
9.
FORECAST RESULTS.
The trend interval estimates are shown in Figure 11.
For each
year, four points are shown on the graph: optimistic and pessimistic bounds, the
most likely value, and the progression of the statistically expected values indi-
cated by the continuous curve.
A tabulation of the corresponding numbers is pre-
sented in Figure 12.
As previously stated, the noticeable divergence of the in-
terva1 constraints can be interpreted as a measure of the uncertainty implicit
in the forecast.
After the forecast was made, preliminary data became available for the 1970 market.
Therefore, the trend line for the augmented statistics was calculated as a check
on the procedure used.
The resulting trend line terminal point was found to be
in the neighborhood of the midpoint for the subinterval bounded by the pessimistic
and expected values.
Thus the trend line interval forecasting procedure was not
refuted.
Once the future demand for industrial steam was estimated, the changing techno-
logical requirements for the operating parameters (unit capacity, pressure, and
temperature) had to be considered.
To anticipate these differences, the trends
within categories were calculated (see Figures 7, 8 and 9).
Now the major pro-
blem in using .the available data resulted from the statistics being separately
Teported for each property.
Hence, the annual marginal distributions for capa-
city, pressure, and temperature were known, but not the joint distribution.
Un-
fortunately, it is precisely the sequence of annual joint distributions which
would have been most helpful in anticipating pattern changes for these proper-
ties.
Observe a given joint distribution implies knowledge of the demand for
each capacity-pres sure-temperature combination.
Assuming the properties are statistically independent, the joint relationship
is determined by the marginal distributions.
If this is an erroneous assumption,
B-15
-------
however, knowledge of the marginal distributions does not provide adequate in-
formation to generate the joint profile.
Indeed, the capacity-pressure-tempera-
ture properties do not exhibit statistical independence (covariance does not equal
zero which is a necessary,although not -sufficient, condition for statistical in-
dependence).
It was decided, however, to still generate the joint distribution
as an aid in projecting technological change, even though statistical independence
was not characteristic of the capacity, pressure and temperature properties.
Figure 13 shows the joint capacity-pressure distribution for both the historical
and future markets.
It is interesting to note the increasing influence of the
medium range units.
Likewise, the anticipated market growth results in'a shift
from units with very low to very high generating capabilities.
As already noted, the industrial stationary watertube boiler market forecast was
generated using an estimated trend interval procedure.
An additional forecast
was made using an economic indicator approach.
It is important to note this
method is questionable since a definite relationship is difficult to establish
with such a limited set of available data.
The results are merely stated here
for comparison.
The instrumental variables used for the economic indicator were Corporate Profits
Before Taxes and New Plant and Equipment Expenditures data as published by the
Council of Economic Advisors in their periodic.al "Ec~nomic Indicators".
The
response of the .indicator in relation to the actual performance of the industrial
steam market is shown in Figure 14.
Notice the declines for both 1967 and 1970
were anticipated .by the indicator.
The tabulated data displayed in Figure 14 were
generated from adjusted profits and expenditures projections published in the Summer
1970 issue of the Wharton Economic Newsletter. It is interesting to note tabu-
lated data exhibit a less rapid short-term expansion, but the 1980 estimate of 126
B-16
-------
million pounds of steam is essentially coincident with the 127 statistically
expected value for the 1980 trend interval estimate.
10.
INTERPRETATION OF FORECAST.
The motivation for this market forecast was to esti-
mate the potential applications for FBC units.
Limiting the region for FBC ~se
is the general opinion that only units with outputs exceeding 100,000 Lbs. Stm./
Hr. can economically apply this new combustion method.
Since this will amount to
approximately 50 percent of the 1980 industrial steam demand, around 63.5 million
pounds of steam will be the maximum potential FBC market.
Notice, however, this
is almost the level of the current available market for all industrial units.
Indeed, the entire 1980 industrial stationary watertube boiler market is expected
to expand from the current level by an approximate 1.5 factor.
A significant shift to medium-sized units should occur.
Thus the current influence
which smaller sized units exert on the total market will be declining, although the
actual annual quantity sold should be increasing at a slow rate.
The industrial market is not experiencing the same rapid expansion as the utility
sector.
But for FBC applications,the utility industry appears to offer better
market potential because of the demand for larger unit size and fossil fuel usage.
The competition from gas fired units would appear to severely limit FBC usage in
the industrial portion of the stationary watertube boiler market.
Numerous appendices are included with this report.
Thus the known history of
the industrial steam market is presented to allow individual interpretation of
the data.
B-17
-------
--
.--------
TABLE B-1
--.-.-------.--
A B MAD A T A
-.---.-
._----_._-_.~ VERAGE ..UN t ~_.QIJJ.eUJ:-LttL T.~9_US~NPS OE-l..B.S!__S 1.t1~.~ tf~_._)
~-,---'--'.-
--.-------.
..._--_. .
-----_.---- ----~_..-
CATEGORY
1962
1963
1964
1965
--.--.- .--- - -"... -
1966
1967
1968
1969
-..------
...---
---- .
COAL 66.4 80..0. 107.6 116.3 74.4 95.6 128.1' 10.5.0
--.-----.-.OIL ------44.1---46.8.-- .53.9 ---.58.8--'--57.6._.60..3--- 80..4':." 65.8
F GAS 51.7 49.4 60.4 61.7 66.5 62.5 64.2 64.3
'-------'~r- WOOD ..._.__.m_.6.1~5-.'.-100.o. ---91.7"'...-38.5u -.--33.3'--180..0--107.7 121.lJ
E BAGASSE 68.4 86.4 95.0 100.0 10.0..0. 190..0. ~i6~-
L LIQUOR 137.5 212.5291.7 268.4 282.4 175.0. 233.3 '30.0..0
OTIj.E_~____---~-~.!..f5._--'~ _._Q---_Il~.~.__~16~-"l___1..o_8_...L_J2.13._~_2.__-..J} ..5.__~ ~ 5.4
F
~~UL VER 1 ZED- ..~5o.. 0. .___.213.3..- 326 .7.__.. _.330..8. __..250...0._._._150..0 _._'+75.0.
R SPREADER 67.2 96.9 96.7 115.0. 84.4 95.2 113.3
1 UNDERFEED 37.5 25.0. 14.3 18.2 25.0. 166.7 42.8
--N-OVERFEED . ".4o...o.'--6o..O"-i14'.3---So.'-o...--66.f-- 50.0..0.--..'33.3.
G OTHER 46.3 70.8 88.9 142.8 93.8 113.6 71.4
__.350..0.
10.4.3
. --. 2 0. . 0
57.1
91.7
_._-~--_._---
NON-.MfG
CHEMICAL
--.--"L.. PAPER .. - .--...-.
A PETROLEUM
~- FOOD
K METALS
E MISC. MFG.
T TEXT iLES
___!RANSPORT ~ T ION ._.
WOOD
RlJ~BER
40.3 43.9 41.9 44.3 44.8 4.6..!?__.
115.2 10.3.3 97.4 10.3.5 10.1.0. 93.8
.1_56.3 175. O. .131.5 .._.135.7...___155.9 --- 158.2
90.1 124.6 138.5 98.2 112.7 120..0
____63.2.------_._55.9_-- . _.5 8.0. .--. 57. .1- __._.7.0..2__..... 68.4
77.3 131.1 92.1 96.6 78.1 178.9
55.7 47.1 56.8 57.8 71.6 5~~O....
54.3 37.8 44.4 48.9 51.0. 56.2
84..4 _.__..7.8. 0. -- ..... 67.7 .___.64.0._____110..8 ... .103. 7
84.650..0. 59.2 94.4 70.0. 67.6
36_. 9___27..~_..__.~_9 ._2..___~6.1I]_~~.. 6__.__..5.0..0.
--..-----..
1.
R 2
E 3
G 4
___._1_-- ~ --.--.--
o 6
N 7
----8.--'---.
9
~5. 6-
63.5
57.4
91.1
. .52.7
142.0
57.1
64.6
62.5
_._.SS.2 _.
55.1
63.6
61.5
49.4
133.1
So..O
77.8
50..0.
..--- ~S ..6.
44.8
63.7
72.1
50.0.
126.7
47.4
.85.2
44.2
--. 59. 4- - -. .
58.9
7?~~
82.5
71.9.
113.1
46.2
63.6
57.4
55.9
5A.7
78.2
74.4
. 27.4
140..0
52.6
65.8
64.5
--------------..-----..---------.----.-
.----.-
A-S
B-18
----.--.----
------.-.-.--. --
-------
FIGURES
B-19
-------
600 '
, 350
200
td
I
I\J
t-'
,'~'
... ~
~ 100
" ~
I-
fJ)
fJ)
~ 60
to
JI',
III
g
. - ".'.
STATIONARY VolT BOILER MARKET
t-TOT AL
2=INDU5TRIAL
3=PERCENT
, ,"-
. ,..--
35
20
to
\960'
\962'
1 !
,1964
\966'
'19681
YEARS
...-'
Figure 1
.-'... . . .".-.
,
.
"
,,'
,,'
L
!:':
;1'
, '
"
:-:
!-
.UJ
x
~
60 ~
J
<:
I-
o
I-
35 11."
0"
'!-
z
w
U
!r
o W
0..
V,
:J
a
'. ~
o
\970
;1
"
,: (.,; I" ; I I" I I I """ I'" \" I !'j L J ; ii'
-:')" '~j"c;r.>' ,'" i' ; '('i" j-';"'T+ 'r:'!"'I-~;-, ':'t..: ,j..", j" ,: ",
" fI~:'?~i"~ ':t++:'I!:'~:F'~,'~T,~j.{P-i::li:} ',:,T:r"'~'~L~.~': ','
, :~': ~.:eso.oo :, ,I" ~~"I,.J.,., "J"-r'['~f+T.i."'I,~.j ,1.. ,!..~. I
, 0 ';J,~ '. ~J~-t~j~-!~JX~:I::).'~p~~I! ::'ltJ:'l, ..1-..,1 :f,~i.', , ~,: '~:',
.,..,'!',.!', ,.I..I'.':"I,!,.I-.I.'r;';' /"rj'- ,,'!'...I;, ,i
:l.":i',~ "",:~:Lf;ii~:;.,-,,:..-b.l,:~!~r~(T" r.,;,.:,";'< ~ ,!.
J-: _..," t .1. I I . i! :..~ ..L .L..
"~(fc~t~ ..',eeL ',J::IT~!~'-: ': ~'~i:. :: i '
(J}~:~ 11:;' ;!Ij 11:
<~'~~~::: ::': -+'f'!', !' i ; , : '.
,.,....",...,.,., r"".'\"T"-r"-" - ...,'.,.., , '
'i..,,:L:! '~'i"~'i':' I'!: ! ,,:,..J .. ,: :
8 8
, ~ ~ ~
..' ..
Figure 2
-------
PLOT' . CAP t.E lOOK
PLOT 2 . CAP C GT lOOK M.;Q LE 250K )
PLOT 3 . CAP GT 250K
f'lOT 1 " C,,~ LE ICOK
f'lOT 2 .. C/o? C GT lOCK AND LE 250K )
, . PLOT 3 . CN"- GT 250K .
,.
eo
sop
50
80
,~ .,
',~,~ '.
" ;...~
. ..........
70
60
to
Z
11/
U
0:
~ ..0
~ 6Q
IIJ
U
0:
IIJ.
e.
.
, ,
. -.
...0
. .
30
o
1~60 1965 1970 1975
DATA DIST. RELATIVE TO TOTAL CAPACITY SOLO
Figure :3
190C'
;,..----
".'~
.~- .
.. ,~--_.:._---------------:--_.
o . ---I I I I - I r I 1 I I
J960 . J965 .9;(1 1975 1880
OAT A DIST. RELATIVE TO TOTAL NO, OF ll~liTS.50LO
20
10
Figure 4
PLOT I . CAP LE 1001<
. PeOT 2 . Ci\P ( GT !C:)!( AND LE 2501( )
PLOT 3 . CI,P CT 2SCK
-.
01600
::I
o
I
0:
11.1
0..
~500
11.1
t-
o
IL
o
2:;4100
5
o
G..
IL
o
0300
o
z
-<
o
::I
o
.:C
t200
>-
'I-
U
-<
0..
~IOO
./
../-
'/. .
.../.' . ".
.'
.'
..
...c..~--.~--------
. -----
--------------
Figure 5
o
. 1960
1965 1970
AVERACE SIZE OF UNIT SOLO
1975
1980
B-22
-------
. INDUSTRIAL STATIONARY
V'1A TERTUBE BOILER
MARKET
1951 DISTRIBUTION
TOT AL CAPACITY
40,640,000
TOT AL NUMBER
OF UNITS
787
NOTE .
SOL1D LINE REPRESENTS
UNITS O1STR18UTI0N
BROKEN LINE REPRESENTS
. CAPACITY O1STRIBUTI0N
./.-
./
"",_....
".'"
:;-
".
"
./
'"
I
I
I
40 /
I
I
I
I
I
o I
o
80
CAP ACITY
200 400
80
80
B-23
PRESSURE
6 0 1200
/
/
;'
/
/
'"
./
.;
"./
"."
",.
--
SLPERHEATED
TEMPERATURE
400 800
600
1800
1200
FIGURE ..-I
-------
. INDUSTRIAL 5T A TIONARY ,
~A TERTUBE BOILER
MARKET
1962 DISTRIBUTION
TOT AL CAPACITY
43,333,000
TOT AL NUMBER
OF UNITS
877
NOTE
SOLJD LJNE REPRESENTS'
UNJTS D1STR1BUT10N
BROKEN UNE REPRESENTS
'. . CAP ACJTY OJSTR1BUTJON
..........-
--
'"
'" '
",'
,/'" '
./
I
I
I
I
40 /
I
I
I
I
I
o I
o
80
200
400
80
80
o
o
B-24
/'"
,....
I
I
.....
././ .
.""
,/
--.....
SUPERHEATED
TEMPERATURE
400 ,800
600
1800
1200
FIGURE 6-2
-------
INDUSTRIAL STATIONARY
V'JA TERTUBE BOILER
MARKET
1963 DISTRIBUTION
TOTAL CAPACITY
50,535,000
TOT AL NUMBER
OF UNITS
.879
NOTE
SOLID LINE REPRESENTS
UNI rs OJSTRIBUTlON
BROKEN UNE REPRESENTS
. CAPACITY 01STRIBUTION
80
, ....".-_...---
./
. '"
""",'"
","
,'"
/
I
I
I
40 /
I
,
I
I
I
o I
o
CAP ACITY
200 400
80
40
o
o
PRESSURE
6 0 1200
80
./
/
,-
I
I
,,-
'"
....
'"
/'
-'
--
o
o
SUPERHEA TED
TEMPERATURE
400 800
B-25
600
1800
1200
FIGURE' G-3
-------
INDUSTRIAL 5T A TIONARY
~A TERTUBE BOILER
MARKET
1964 DISTRIBUTION
TOTAL CAPACITY
72.348.000 .
TOT AL NUMBER
OF UNITS
1033
NOTE
SOlJO lJNE REPRESENTS
UN1TS OJSTRJBUTJON
BROKEN lJNE REPRESENTS
. CAPACJTY OJSTRJBUTJON
80
CAPACITY
200 400
"
-- "".....
",,-
",,""
",,-
--
",,-
--
/
/
./
. ./
I
I
40 I
J
J
I
J
I
J
o /
o
80
o
80
-
--
"..-
/
I
,....
I
I
'"
","
."","
--'"
o
o
SlPERHEA TED
TEMPERATURE
400 800
B-26
E?OO
1800
1200
FIGURE 6-4
-------
INDUSTRIAL STATIONARY.
V'JA TERTUBE BOILER
MARKET
1965 DISTRIBUTION
TOTAL CAPACITY
76.885,000
TOT AL NUMBER
OF UNITS
1055
NOTE
sauo UNE REPRESENTS
UNJTS DlSTRIBUTI0N
BROKEN LINE REPRESENTS
. CAP ACJTY DlSTRJBUTJON
-
",-
...
-""
...-
/-
./
""
;'
,
./
,
. /'
/
/
,
I
I
I
I
I
. I
. I
. I
o
o
80
40
80
o
o
80
/
I
/
. /
I
I
ISAT
o '/
o
B-27
CAPACITY
200 400
600
PRESSURE
600 1200
1800.
.;'
/
I
J
t'
I
I
//
.""
""
./
--"".
SUPERHEATED
TEMPERATURE
400 800
1200
FI CURE G-6
-------
INDUSTRIAL. ST A TIONARY
~A TERTUBE BOILER
'MARKET
1966 DISTRIBUTION
TOTAL CAPACITY
81,438,000
TOTAL NUMBER
OF UNITS.
1165
NOTE
SOLJD UNE REPRESENTS
UN1TS 0ISTRIBUTI0N
BROKEN UNE REPRESENTS
CAP ACITY DlSTRIBUTI0N
,
80
. CAPACITY
200 400
80
".-
.",,"".
- .
"" .
;'
/
/
/
/
Z .....""
W .....
U /
. ~ ./
40 W I
CL I
. I
I
I
I
I
PRESSURE
6 O' 1200
,0
o
80
./-
I
/
I
I
I
.""
/
./ .
""
./
--.
I
I
/
I
I
/
I
ISAT
SUPERHEA TED
TEMPERATURE
400 . 800
o
o
B-28
600
1800
1200
FIGURE 6-6
-------
INDUSTRIAL 5T A TIONARY
V'JA TERTUBE BOILER
MARKET.
1867 DISTRIBUTION
TOT AL. C.A.P ACITY
57.257.540
TOT AL NUMBER
OF UNITS
839
NOTE .
SOLID LINE REPRESENTS
UNITS O1STRIBUTION
BROKEN LINE REPRESENTS
CAPACITY DISTRIBUTION
80
."
-c:........ - .",,'"
-~
,--
/
/
/ ,
/
",,/
""
J
I
I
J
I
,
I
J
/
o I
o
40
CAP ACITY
200 400
80
o
o
PREqSURE
6 0 1200
80
// .
/
/
r"
I
I
""
, ""
./
./
",
_../"
I
/
/
/
/
/
I
I SAT
SUPERHEA TED
TEMPERATURE
400 800
o
o
B-29
600
1800
1200
~IGlJRE 6-7
-------
INDUSTRIAL 5T A TIONARY
V'JA TERTUBE BOILER
MARKET
1968 DISTRIBUTION
TOTAL CAPACITY
66,991,285
TOTAL NUMBER
OF UNITS
908
NOTE .
SOlJD lJNE REPRESENTS
UNJTS DISTRJBUTJON
BROKEN LlNE REPRESENTS
CAP ACITY OJSTRJBUTI0N
--
-....
". ---...........----
--
/' .
./ ' .
,
I
/
/
/
/'
i
J
I
I
I
I
J
I
o /
o
80
40
80
o
o
80
o
o
B~'30
CAPACITY
200 400
PRESSURE
6 0 1 00 I
....-
I
I
,....
I
I
....
.-
./
./
.....""
--
Sl...f'ERHEA TED
TEMPERATURE
400 800
600
1800
1200
FIGURE: G-g
-------
INDUSTRIAL STATIONARY
V'JA TERTUBE BOILER
MARKET
1969 DISTRIBUTION
TOTAL CAPACITY
78,003,935
TOT AL NUMBER
OF UNITS
1043
"
NOTE
SOLID UNE REPRESENTS
UNITS D1STRIBUTION
BROKEN UNE REPRESENTS
. CAP ACITY DISTRIBUTION
80
--
~ ,.------""
",---'"
./
./
./
./
I
I
I
I
/
I
I
I
I
I
I
I
o J
.0 '
40
CAP ACITY
200 400
80
o
o
PRESSURE.
6 0 1200
80
./-
/'
.-
I
I
I
/
"",."
.-
-""
-
SUPERHEA TED
TEMPERATURE
400 800
B-31
600
1800
1200
FIGURE G-~J
-------
90 0 - 25 KLB PER HOUR
60 I-
ffi
. u
ffi
Q.
30
D
960
------
..
" - w
1964 ISGG
19GB
}970
1962
90 51 - 100 KLB PER HOUR
60 ~
W
u
n:
w
0..
30
o
960
w
..
. v :
.
-
"
..
1964
1962
. 1966
196B
90 151 - 250 KLB PER HOUR
60 ~
W
U
tr
W
0..
30
o
960
~
..
~
. -
..
..
II
1968
1962
~966
196"1
90 26 - 50 KLB PER HOUR
60 .~
W
U
tr
W
0..
30
o
960
"--,.-
-
"
w
..
..
..
1962
. ."
"
1962
. SS4
..
196"1
..
"
196"1
90 351+ KLB PER HOUR
60 ~
w
u
~
W
0..
30
eo. .......
o
960
~.
~
1962
~96-4 1966
Figure 7.
---+-1
. ~9GO 197~
1966
90 101 - 150 KLB PER HOUR
60 ~..
W
U
tr
W
0..
30 .
1970
o
960
1970
..
..
1966
. .
~
..
~9Ga I.
90 251 - 350. KLB PER HOUR
60 I-
z .
UI "
U
"
W
0...
30
o
. .
",
.
1970
960
A
I
1966
..
B-32.
j"
"
..
1968
1970
~
I .1
19GU
11970
-------
90 0-149 PSIG
90 150-249 PSIG
L " "
~ .. ..
0 0
960 1962 1864 1966 1968 1970 960
,
:
.'
II A II V
..
GO ... (;0 ...
z. z
UI UI
U U
0: 0:
UI UI
0. 0.
30 30
1862
1966 I
.}
1 ~,t"! (1
---
..
-- --'" --
... -_._-,--_.~,
1964
h68'
90 250-599 PSIG
$0 600-849, PSIG I
(;0 ~
UI
u
ffi
0.
60' ....
Z
UI
U
0:
UI
0.
. '
30
30
-
..
60
..
..
"
"
"
V
..
..
-
A
..
o
960
1962
1964
1966
1968
1970
o
960
.1962
19~~66
196H
1970
'850-1249 PSIG
90 .
.. ,
90 1250-l799 PSI,?
. .
60 ...
, Z
UI
U
0:
UI
0.
60 ~
IU
U
0:
UI
0.
'. '
" .
30
"
30
o
. ,
..
" A "
--..
1862 1964 1966 1968
960
1970
'0 - t
eGO
\962 i
..
t ~----+-,,-~'-~--i~..
1964 1966 ISGU 1970
.Figure 8
B-33
-------
90 SATURATED STEAM
90 STEAM TEMP. 300-524 DEG~ F.
'.
60 ~
IIJ
U
ffi
0..
.
---
.
60 ~
IIJ
U
a:
UJ
0..'
.
.
-
-
.30
30
,.
-
~
y
.
o
960
1962 .
1964
'1966
1968
o
1970
960
1962
196~ '
1966
1968 ~1!)70
90 STEAM TEMP. 525-624 DEG. F.
90 STEAM TEMP. 625-724 DEG. F.
so -....
Z
IIJ
U
0:
IIJ
0..
I
60 t-
Z
III
U
OC
IIJ
.11.
30
30
o
960 .
,ff
.
~
,-
~
.
.
,1968
1970
o '
960
-..
'. ..
..
y
"
1962
1964
1966
1962
1964
1966
'1968
..
1970
90 STEAM TEMP. 725-774 DEG. F.
60 ~
IIJ
U
0:'
IIJ
0..
,30
~
.
-
o
960.
1962
1964
1966
1968
1970
Figure 9-1
B-34 ,
-------
00 STEAM TEMP. 775-824 OEG. F.
GO ~
UJ
U
iii:
111
n.
30
o
. 960
1962 .
..
1 I
1964
.'
..
~966 ~
I
1968
90 STEAM TEMP. 825-874 DEG. F.
GO I-
z.
UJ
U
tr
111
on.
,30
.. ~
~ A
o - .. "
I
1970 960 1962 1964 1966 1960
1970
90 STEAM TEMP. 8?5-924 OEG. F.
[;0 ~
UJ
U
Ir:
III
n.
30, .
00
960
)I ,.
}SG2 I
0'
. .
. ..
I I
1964
00
..
"\966 1-)968 I
90 STEAM TEMP. 925+ DEG. F.
60 ~
UJ
U
iii:
UJ
n.
30
..
I
1970
o
1962
'" 1
1968
Y966 I
I I
1964
1970
960
, Figure 9- 2
B-35
-------
tJj
I
W
~
tl!:'~!: '!:~! !:'!I:::T':-'::'~:;~r:: Ii', :lI~ 'I:; :1:1 ::118"1'11:11'1"1"''1'1::' :'T'
j:,:@~'I'~ :~n:i::iiili',!:::,,:(,~~: ;:I~:' '::~ci.!,::H:C!~:~
~'I;;::"'::~' ..:.-:.;,1,,,.,...:,.:-1'- ...".:. '-"p':"'d" ....Ki"J."",-,":'['l'''''':;;' .
W:I ~.J:: ~oo :'; ':'1> i :::I':~:;H<::;.::; :;':<;' :~Hl{,<;:'>!d+t~
1-' ._1.... -.1.-. ....-... -....,.. -.1.-,1-+" ..-. ..1-. "''1'''' ...\._1. ..1---'''''''''''''--
8:"r:E~' .'(:I~rII:j:'.'!':'!:,!]fr:~f.~7r-~r-4-~
'~=m"'L_' :.:... . --:,,1 "'H~-2~. t.......... C~,..... .'.'':.:,... -....,. ..,. .~., .-f._.....:..
~a:..;... .~I~:. :.L:I.i~tL~JI :~~ :~~~Sbr:~Hi~.:.'iTL.li:
.0. I"', I""" '.,' . .:1. ... --, --''''''''f .,,,.. . . I.,
~~'~7r';SC?' '7.;: ..; :::' .':: :-1:,17 '::;;':1': . ~~~:7':~~?:';:::;) ~
-... . -..--I .-1. ....n.......,.. --T--...I..-I-...... ,..-1.- ('. '1-"" r- I.. .,.
~~ :::.. I ~+~~t-+~.td f~2~rl~~f::::'t -+:~:I~'~'~>~~~: ':.~~ .
;m'1-'-~'-""" ..::. "",. ..::.: ""--:':H:~'1 ""cr-- :.ij.:::, . 1:..1 _t. 1:-..,.- -,.t.-
~r' ~. '~fr5 <> :~~'.::r::Fhr: +,.L.1f:.::' +~'kt-h{:'; ::.i~
~.!lJ.:J::.. ""'0' ':".:;.1....' 'C';:'':'''L'':':'I''''IJ.!L.! :-:8;1... '::;"1' :+~;; .:.ti;;;J.;"t,.
'-F.r:'!:.: I'.: I. '" r .., .. ... ..~... "'1'" I.. . ... ,. . I.. .
':'"'~f '~~;-'~'h'r~ :~:.,~~,~ ::~ -7+!:':;::~~~:'~~'-++
,'ItI. I.. ..., .. "1' '" . " ........., ":1:' I .., , ". I. I" , . i
.._oj"-i"-l": ~ -...:- r' Q '. .::. .:p,::I::: :.: D.,-.. ...;--,::';. . . . '.;;" '.. .-'-r': . .
:w~"+~i:~ ..+-L ..!~tj.:.~.:~.J.-+I~I:H:j~i~+ -!~~LL::.;:. :::, '.
,en .._,.";~_:~.'- . ~J.. ...::,. ;"'~+-'I::"\.":'I:_:[':r'-'-i"""" !. ... ,.. . ":'r':"'"
~t~~~~~=~~=j~:'j¥j~fr~~stt~j:t~t~
.~.....I--I-"'- -'1".1 . -1---r-L..-1--T" Q :-.,...1..-,... ..,-.,.....,-...-
1-<:- ::':,.: :.i::~ :; :;I!~<:.:i:./:.~~*~ i:++.:..-i~T-:~.-!,-'.;:.:2-~
.tJ...;,;.:.!,..I.:; .-':.... ,. ,'".. -.;...;-1.:..+. I:. .,.. 4..,., :~"'::I :l ..1.. ".".""" .'
n ; :jo.~ ~. ;~~~;tfTI :~~\;~r'h~H ~;I.:'T:'r 1:-+::.; 3~:
q~"' '""l-":tr' - f-,tJ"'r'~1 -'u.--.,
~j~f -;J':tiJ-:~XI}]iilr~~lr~+~JfF
-- "-"ri" .,...1. ...1...-..(.." '1,..L,..I....j... 1'1... .... . .
~;'::; r:r'oo .:.~ : . 1 ':" .:~: :': :', ": :,. ::,'~ ~. I ;:: :.
L -:1"-1".:1 ..8... . .,j..;:: iii ." .~.._::. ~"'I': Gkl.. ~..j''''''II''@ ",. 8.. .-
1;i; ',:: ::'.:':. :i,~ :::'oi 6. i:: 0 :;, 6.!::Q~~~:Q_L~Q....L.~,LL.:
~~.~; 'i;';':~~,'['~,1"!': ~i~!~~:i'~~
~'-' . ..C9).(X).. "-~i'-'-':';'-~- -~LT' -t.-r-,-- -''----r-'-:'-~'-''
U: Lb./.t.. "-I:~+-.' f+~.j:: . iL:lt~,;;".H.::. .. I: I.i .::,'. LJ.U... i
~:'" i~.'~. :T:~::'";:t.~. 4 '~h!fi:: I:: m:.' ~i~:'~'~~+-+;'r
b: ,,+,1 J.:. ';'f:+++I'-I'~: ''':T' ...r,-. -j';:-... j'" ...1_..1.::.; -I....... T
~fl~t.~f':'.l~~i,~:~iilbr;~F~Ft' :i-b~JLJ£t
~~~:.cdJ.?o. :.;:9':~fS: ~:::J-:]~~: ,>' P1<.: Y;+-+j: 1-1++4'
'25 ,-.~..: I "t.... I r-:h:t'''J.-,:...::I..,./... .,=-t.,. .:.~..:.'....I.... '1"...1_.";'.~. j
i~ :::i'~~, '.~:Hb'lil:R++! ~:,::.I.,lJl-; ::i4Li;i
~rn+~q;:~: ;:~~r:t~;I:':::'~12IS~ '::: :+t~J.*I-+~"~+:~r~f- ,.
+-J7::.:!.::.I....., ',' '+').'::I:;~"'::'~::' '~~"T"r.'" .,;;, :+"i;:::I:""':;;I-,,"':~I.,~:!.,.. .
=~j~1~;~'~i:Hf+I,)~/,~P:~li~r ~::f:~:ri~t~f: ~~:. ..+~..,
~: ., '."..: : '''.':' '"71:"'1" .t"l..+ -'1"': .:- t"':I~" .."",,, .-.t:-:-I.- .... . --,.... .. r-
~-+.1li~:~.. ""'~':::I:.:::;h~":~I'" -:;, ~4:: i:': ~:.'."+ .~.,.. '~~.". .
-O--T.j...,.. -;1-+:+..,-......._1_...+- .._I.... ....... ..'.- ..,. ....
3-8~~~::r:::P+~: ~+1~'PfB- 2::> .+~. .~~-~ .': ..~:. .r'
,. . :.-1,,'--1 --'1':: . ;:.s;;,,::,"j:- J"'.j... '.'...;: .-t-....t... ., ...---. :.... ..... .
~~::::;:i~.dJ. ;+~!-l~:::2 ,~.'. ~.~. .': :..~~- -+~ .~ .+. ..+.
::U'::.j.'. .1..: L. .::u. ,; '... ... . .1... .;.... ...,... -.+ . . +.' --.':..
JD:tWED:+, ';i~t.~. .~:-~:+ :"::';.::::01:;;'1 .:~ :};;. ~~
m: :1~+~r~t~tb ~~fFIBJ:~I£t-tI:~!;;~~br.-dE+
* :~;+~~~. :~:G;i-:i+S:-:!~:~::~: ~< ~~,hl:"I:~l:..f.+~+-tt.+:+
.". ;'i.;.I-,'... - ..-.......x ..-+.1......1-1 'Th. "'.-1...-1 "'j . ~... ....1...,1'
~~~l~aJ:~ .~:b*1~',::;:1+;7 ::/~. .~;~~ I"+~-+I-,>~"!'~):
ri:n';:.J..+ 'I..:. ..:.~.. ""1''''--'1'''' '::-1': .:.:::: ... ~':"i"'+";":'I-I...:I"';;,,+
f;~8~~i-b.~.~. ';:T.' .:::: ".:,,:,'.,:: ". :.:. .:~.. . I'" ':"0; '.';, : .
7:'i ;':7 ~ . ~1:;lI :'l~'::LT:;,',T' )"~:::r:-~:J. T ~ ::, ~..:t:~::I: ~
. .1. ..' . .. I~' L-;i:.;.~..,,~l~...:L=;- . ~~~~-8
YEARS---~-~----(INOUS WT 8LR WKT)
. .
X=(1/92)~E-(87/92)
Figure 10
Figure 11
-------
INDUSTRIAL STATIONARY WATERTUBE BOILER MARKET
LONG-RANGE FORECAST RESULTS
USING TREND INTERVAL PROCEDURE
TREND LINE ESTIMATES
Most Statistically
Pessimistic Likely Optimistic Expected
Year Estimate Estimate Estimate Value
1970 70 83 .87 82
1971 72 87 94 86
1972 73 91 101 90
1973 75 95 108 94
1974 77 99 116 98
1975 79 103 125 103
1976 80 107 134 107
1977 82 112 144 112
1978 84 116 155 117
1979 86 120 166 122
1980 87 124 179 127
1981 89 128 192 132
1982 91 132 206 137
1983 93 136 221 143
1984 94 140 237 149
1985 96 144 255 154
NOTE:
Figures are for aggregate demand in millions of pounds of steam
B-37
Figure 12
-------
, " a-~c/..:,r;'''''~5/';-t.~.::.«y"-::,-:: (,RJ:/~...)
. . . I/.~~ /f/f;0/~" If ::' ':
. 1(\ r.':t. I f:" I OJ I rv ~~/. ",
. . . . . '. 1\\()/~{~«19~~O/:~&?I-' '.' .
C/?~~~/.;r-rll.6'5'p~E/Io«R)/\),;/\l, v/ '"/ {)/'V" '
. rO---'2S~-;-O---'---I'!~'~:;'::7::-::-::;;;:'i;~-~~~t ' .
L2 w,~c~ - ~a OO~ --~i;~.~i~-ic;:~:':~~."r~;~ ---
'I~~ooo - I000-;;cT[ J:;:j~~?2;;~~-fL. _r~~:
I /01. 0 t) c; - /.:: 0 /") ..., .- . .tr",:". ':..' ,,~::- ".;" I
I . ~-' /' / - ~:; ~,~ ,., - E~:::4:~~~~f::(.~f;:~:;~~~~~~'~:';!-
I /.:;J~ vO::; - -'...,~ (J:.JO , ~~«.-,~ ~:.....::;;.-.-(-::.~.:~:;,>_.]
1-"-:-- - -,. - :"'''-it.~,:".:::~ -~-'~-=-. "-~ ,
I 25,~Oa() -.::-~~o~O ..~:--:;.:~i
I .s';j~.-?~o ~~ O//L~,e ! I, \-
-.--
i
I
! " 0 - 2.5; c;;co
.?~, 000 - 50; coo---~s::)~,>~-:r~-:~":'l
- " . ;~~:'_:.::..~,~:-.:-::-.~",.. _..,:;.~,~ :'--:;:':~-.
I' :;il, 000 - /00, 000 'iikw:,,:;::':i;:c;C::'-":O;;:
/0'" OCiO -/5c2,. 000. ,~:~:;~~!)~:]~, --
/, 2.,- . '~7.J~ "'.~ ::~;..:"":,.~:,~~,--:,"~-':'~~~.~:;l".
I 5~ CJoo - =' C"ODC >', ~"'7-,.:,,~ ,-:' '.;"',:-.': "~~'>-~:>" '
...:; .". ',-.:-. """"""..~'.",." ,.".~~~
I 25~()Oo-35qcOD ,.. i '
I 3S/~ooo f' Ol/t.:-z'
()'- 25,000 I!'!
2G~ooo - 5~ 000 ~[J~~~>.r:::f~1---r.-'-J:<
. '. ~ '. .'" ''''.,..'''J-:~'._..-;:..~.....~'''''''''.
5~ 009 - loa 000 _t\(~'{jf~':_:~::::~~s-~~.~~:~~:t~:L:;:~~~;j
'//)/000 -/500""--;::) g".. ,.,::',",:-j. : :
..., / I '-- '. -:- .,.._~S~'~;~~:~-:;:,J~,-,,:, ."~:"
/ 5/I"':/')o ~)~-o.. 000 "~:'" '-'.:~., --,"-: --._,..'7,:""""""";-.." ::"~ .
z;;,:o ~ 3;; 000 -~f:T:;:=t"-T':"i" .
- .---J - ----r-.... .
3$~ 000 ~'.Of/cK:. . ~~~~~'t~r~;TJB1 . J Jf~~
" B-38
CCJ~$I#eLJ
Jle7o/2/C' ~L..
, '£),4rA
I?G2 Tl-J"ea/708
t'.sJl/lPEL>. AR E/J /fh:LVPP$
,&"£041 50% 7d 70 % .P~
~T~~ frJA.eK6/)
P,eELJICT.£D ,.t:O..e
Ir75
5/1'APFtJ A-<,:;!J
80 % OF /07/11.
It/c/.lI{)~s.
1'4/j~~I!'T h
,o~eDlcr.!;.o ~..e.
/~80
fH~£)££) ~~S4 /N~U~e
~:;: % ~I:-li;/JI.. 1t7~~ItEr
Figure 13
-------
1970
1971
1972
1973
1974
1975
1976
1977
1978
1979
1980
" . -, '......... ..-. -- ...
-"'."','---.'."-----'" ..- ...... "---."'-"""0
; ~~~~~~~~ ::~ :~~ ~~.~~::i~~:~~=~~ ~~~~~~~~~~~~~
:::.;J :;:.:=~:: :::-::=::. . ---_n__.'._'-". .--__n-.,-_....---;..' ...h..___-_...
:::m - :;::-;:50.00 . ._;:::::.:::::::.-:::::::::::.::.:-~;:::::::~:::::-:::::::: ::::;::~:::
'.'," 't-. -..-' ..-. "" . :. :"~~~~~'~::?~~-i'~::~:;~7:::::::~:::::'~.~f:~~::::::-:=~::.:::
:r tf) . . .:::::~::~:::~'::-==~:;:::;::7::i:==::::-~:::::~:::':::::::::=:::~:=
.:.:~.-:..:.. -~~ =:-:.~:'.:::::==::' :~::?-:::=::::;::!~-::::::~~~:=::E:-: :::::::. :::::7:':~~:
=-::t:=~=-. ~_'.:~8._:. _:..':::-_.....-.~._~::-..::_~._~_.~._--~---':---~~_. ~-~:':~...~ .:...':-....~:' -..:~:_--~:~.:_~_.:_-:-.-oo~:.~~_.~.~:::-_:.'-~_:-:.:_. .. -- . -. --.. --- - ... n.- ---. -. ..- - -- -.. - -- ..- - n. -. n moo - --.. - - - .
- ~~~~i~~m~~~~l~i~m~~~~t:-0J~{~~~T~~~~~i:\m~itmm~mijt
:; ~:~~~:..~3:~_:.::;~~~~=::=;:.~:::-:::~~-:.::.::::~~:f=;~:.:::::'::::7:':: ::::
:::::: :; ::::=-~:: ~::::.::- ::=~: ::::::- ===..-::: ::.:::::: ::.: ::~-=::::;::::,:~:: i::::::::: ::::'=:::~: r:
~:';-::-.~.-::t.t._::~=:-:=--~:-:;_'_-20~7~r.~.oo-:~~. ............----t---------.---..-.......-....----------- -" "..'-.. -. -'-
.:::.:.::-::: ::::::: - :::::.-:::::::::::::=-=::::::::::::: ::::::=::::::::.:-: ::: ~ :::::-c:- .: :::::::::-
. ".. ,- "'.-". ...-..... -,"'.'" ...-----.--..----.-----.-.---...----.-.'" ...0.- .........
:t:.=..: -,--....- .0.-_---... ~. ': .: :.;: =--::..;::.;.:::::.:.:;:::: ::'::::::':==--:-:'::;::::':::-":.:::::::::.:'::::'::": -:::::;:: -: :;. :.: ::::::::
=:~~r~.=-=-~_.-'._----=-..:--:-.-_:.:.=,;-..-:-~:-_.__.. ... --.........-.. ----..----.---..---- ----..-.....
-...- . .: :..:::::::..==:=1:::.:.~::::::::::.=:::::=':;:::.=::::: ~~=====::~:!.: :..:~:.: :-::::: ::::.:::::
_. ...' -_.-- -.. '. " -: :::::-::::;::..-":"'-::;::::--:':::'::::::::"'~:::::~'::=":::=:=--==:'::~~::':::; :-::::::::::.: :::::..:!.:
~:-~:'f~-::-;::-_---~:- -.'-_.:-.:~--:-.o:... -:..:._~_:f!J..._-.-..~_:_.: .: :::: :; :::::'::::3: :::==:=:=::::::= ==::.: ::'::::::':':'=:-":=:-==:=:::::7==::::-:.. ..:::-:::
+- - ~~~~~i~~~~~~=:£~~~i~~~~;~~f:::=~~~~~~~~~f;~i~~~~:::::~r~~~~'~~~:::~ .
- .- r : ::-:~::=:::~::~~::::~:::~:~=~:~:f:::::=~-=-:"::~:~~~:: ';:':':::.::: ::~: .:::.:.l~
illl.!~-ic~~i~~]~cilt~_~1~=_1
FORECAST
ECONOMIC INDICATOR
TREND INTERVAL
Predicted
67
70
._.75
81
88
95
103
110
116
122
126
StatisHcally
Expected
82
86
90
94
98
103
107
112
- 117
122
127
.~
B-39
Figure 14
-------
APPENDIX I
ABMA DATA
B-41
-------
~
AMI;:RICAN BOILER MANUFACTURERS ASSOCIATION
1180 RAYMOND BOULEVARD
NEWARK. NEW JERSEY 07102
TEL: AREA 201: 623.80.40
November 25, 1970
Mr. R. N. Mosher
Erie City Energy Division
1422 East Avenue
Erie, Pa.
Subject:
ABMA Policy - Distribution of Watertube Statistics to
Federal Agencies
Dear Russ:
This letter wi II confirm our telephone conversation today regarding
Association policy on the distribution of watertube statistics to agencies
of the federa I government. .
It has long been a policy of the Watertube Section to make avai lable its
statistics to any agency of the federal government which has a need for
this information. This policy applies, of course, to our distributi~n of
these statistics from this office. Certainly it applies equally to the use
of ABMA statistics by Watertube Section members in any work with the
federa I government, which requires the use of this data.
Therefore, I feel it is entirely appropriate for you to quote the Association
as the source for the project you described to me over the telephone to me
this morn ing . .
Best regards.
Sincere Iy ,
/~7JCtktl-
V~illiam B. Marx
Manager
WBM:kw
B-43
-------
---.
AMERICAN BOILER MANUFACTURERS ASSOCIATION (ABMA)
STATIONARY WATERTUBE BOILER MARKET
Industrial Percentage of In-
Year Market (1) Market (1) dustria1 to Total
1937 44.2
1938 24.6
1939 53.6
1940 79.8
1941 108.1
1942 112.9
1943 40.8
1944 36.6
1945 89.3
1946 136.5
1947 128.1
1948 111.3
1949 60.1
1950 180.5
1951 191. 9
1952 119.3
1953 77.8
1954 75.8
1955 160.i
1956 224.6
1957 125.1
1958 61.2
1959 124.1
1960 116.4
1961 140.5 40.64 28.925
1962 120.6 43.33 35.928
1963 162.3 50.54 31.137
1964 209.0 72.35 34.616
1965 250.1 76.88 30.742
1966 249.9 81. 44 32.588
1967 259.8 57.26 22.039
1968 262.1 67.00 25.559
1969 281. 5 78.00 27.710
NOTE:
1. Figures are in millions of pounds of steam per hour
(aggregate output sold).
B-44
-------
AMERICAN BOILER MANUFACTURERS ASSOCIATION (ABMA) .
INDUSTRIAL STATIONARY WATERTUBE BOILER MARKET
GROUPING InTERVALS DEFINED FOR ABMA DESCRIPTIVE STATISTICS
CATEGORY
CAPACITY PRESSURE TEMPERATURE
GT LTE . .GTE LT GTE LT
-
1 0 25 0 50 Saturated
2 25 50 50 150 300 425
3 50 100 150 250 425 475
4 100 150 250 350 475 525
5 150 200 350 450 525 625
6 200 250 450 600 . 625 675
7 250 300 600 850 675 725
8 300 350 850 1250 725 775
9 350 400 1250 1450 775 825
10 400 450 1450 825 875
11 450 500 875 925
12 500 925 1025 .
13 1025
NOTE:
1. LT denotes "Less Than"
2. LTE denotes "Less Than or Equal to"
3. GT denotes "Greater Than"
4. GTE denotes "Greater Than.or Equal to"
5. ABMA data summarizes each category interval for
number of units and steam output
Capacity is in thousands of pounds of steam per hour
Pressure is in PSIG.
Temperature is in degrees Fahrenheit
6.
7.
8.
B-45
-------
AMERICAN BOILER MANUFACTURERS ASSOCIATION (ABMA)
iNDUSTRIAl. STATIONARY WATERTUBE BOILER MARKET
CATEGORIES DEFINED FOR ABMA DESCRIPTIVE STATISTICS
BASE FUEL FIRING METHOD
. FOR SOLID FUELS
1. BITUMINOUS COAL PULVERIZED
2. OIL SPREADER
3. GAS UNDERFEED
4. WOOD OVERFEED
5. BAGASSE OTHER
6. BLACK LIQUOR
7. OTHER
NOTE: THE SAME CATEGORIES EXIST FOR ALTERNATE FUELS
MARKET
1. NON-MANUFACTURING
2. CHEMICAL
3. PAPER
4. PETROLEUM
5. FOOD
6. METALS
7. MISCELLANEOUS MANUFACTURING
8. TEXTILES
9. TRANSPORTATION
10. WOOD
11. RUBBER
12. TOBACCO
CONSTRUCTION
PACKAGED (SHOP ASSEMBLED)
FIELD ERECTED
B-46
-------
APPENDIX II
CAPACITY
B-47
-------
E R I E C I T Y ENE R G Y D I v.
l URN I N D U S T R I E S. I N C.
INDUSTRIA~ WATERTUBE BOILERS. DISTRIBUTION AS TO SIZE Of UNIT 0-25 UNIT CAP.
YEAR CAP. TOTA~ DY1 DY2 DY3 PERCENT DY1 DY2 DY3
1962 6.~0 43.3 14.32
-0.30 -2.64
1963 5.90 !>O.!I -0.20 11.611 -1.58
-0.50 1.30 -4.21 6el3
1964 5.40 72.3 1.10 7.47 4.!>5
0.60 -1.90 0.3:; -5.56
1965 6.00 76.9 -0.60 7.110 -1.01
-0.20 -Ci.40 -0.6b 2.24
1966 5.80 81.4 -1.20 7013 1.23
-1.40 Z.tlO 0.5:> -Z.60
1967 4.40 57.3 1.60 7.6b -1.37
0.20 -2.00 -0.81 0.96
tP 1968 4.60 67.0 -0.40 6.87 -0.41
I -0.20 -1.22
~
\0 1969 4.40 78.0 5.64
YEAR UI'. ITS TOTA~ DYI DY2 DY3 PERCl::NT DYI DY2 DY3
1962 348.00 877.0' 39.68
-10.00 -1.Z3
1963 3:;6.ClO 879.0 -36.00 38.45 -11096
-46.00 112.00 -10.1~ 21.4U
1964 292.00 1033.0' 76.00 2110 27 12.44
30.00 -129.00 Z.25 -19.55
1965 322.00 1055.0 -53.00 30.52 -7.11
-23.00 9.00 -4.86 13.95
1966 299.00 1165.0 -44.00 25.67 6.84
-61.00 11".00 1.99 -10.60
1967 232.00 839.0 10.00 27.65 -3.16
3.00 -11.00 -1.77 2.37
1968 235.00 908.0 -1.00 25.88 -1.39
2.00 -3.16
1969 237.00 1043.0 - 22.72
NOTE** DY1 . fIRST DIffERENCE
DY2 . SECOND DIFFERENCE'
DY3 . THIRD DIFF~RENCE
-------
1
J
,
5
6
7
8 E R I E C I T Y E N I:: R G Y 0 I V.
9 l. URN I N D U S T R I E S. J N C.
10
11 INOUSTRIA~ WATERTU~E BOILERS. DISTRI8UTION AS TO SIZE OF UNIT 26-!l1J UNIT CAP.
12
13 VEAR CAP. TOTAL DVl DVZ 0'1" PERCENT 0'1'1 OV2 DY3
14
15 1962 10.60 43.3 24.41:1
16 -0.60 -4.60
17 1963 10.00 ~O.~ 3.50 19.80 2.72
\8 2.90 -6.80 -1.96 -2.3~
19 1964 12.90 72.3 -3.30 17.84 0.37
2~ -0.40 5.1:10 -1.59 2.9U
21 1965 12.50 76.9 2.50 . 16.25 3.27
12 2.10 -8.70 1.60 -4.56
23 1966 14.60 81.4 -(1820 17.94 -1.29
2. -4. 10 9.80 0.39 -2.4'1/
2S tJj 1967 10.~O 57.3 ,.60 18.32 -3.79
;'~ I -e.5Ci 0.20 -3.40 9.31
27 \J1 lS6B 10.00 67.0 ,.80 14.93 S.!l3
0
!8 3.30 20lJ
11 1969 13.30 78.0' 17.05
10
II
'2
YEAR UNITS TOTAL. D'1'1 0.,.2 OY3 PERCENT l>'1'1 DV2 DY3 .
.
:s 1962 2B7.00 877.0 32.13
16 -26.00 -3.03
1'1163 261.00 879.0 105.00 29.6'11 6.25
'. 79.00 -201).00 ~.2, -11.68
" 1964 340.00 1033.0 -95.00 32.91 -5.42
ij -16.00 177.00 -2.20 10.39
" 1965 324.00 1055.0 82.00 30.71 4.97
'1 66.00 . -261.00 2.77 -8.19
'- 1966 390.00 1165.0 -179.00 33.48 -3.23
.. -113.00 277.00 -0.46 -0.47
., 1'167 277.00 839.0 98.00 33.02 -3.70
61 -15.00 -z.oo -4.16 11.89
71 1968 262.00 908.0 96.00 28.85 8.19
~ 81.00 4.03
1969 343.00 1043.0 32.89
~I t\oTEtttf DYl . FIRST DIFFERE/liCE
DY2 II SECO/liD DIFFERE~CE
DV3 . THIR~ DJFFERENCE
:\
-I
-------
5
6
7
E R I E C I T Y E N ERG Y D I v.
9 Z URN I N.D U S T R I E S. I N C.
10
II INDUSTRIAL WATERTUBE BOILERS. DISTRIaUTION AS TO SIZE OF UNIT 51-100 UNIT CAP.
12 .".
I] YEAR CAP. TOTAL DY1 DY2 DY3 PERCENT DY1 DYZ DY3
I.
15 1962 12.50 43.3 211.87
16 1.20 -1.74
" 1963 13.70 50.5 6.10 27013 3.66
18 7.30 -15.50 1.92 -10.04
19] 1964 21.00 72.3 -9.40 29.05 -6.39
:'\: . -2.10 13.10 -4.47 "." 11.46
~, 1965 18.90 76.9 3.70 24.5B 5.08
n 1.60 -10.50 0.61 -4.16"
2] 1966 2q.50 81.4 -6.80 25.18 0.91
}.: -5.20 15.10 1.5;l -1.67
,"
2\ 1967 15.30 57.3 8.30 26.70 -C.76
26 3.10 -11.80 0.70 -4.39
27 b:;I 1968 18.40 67.0 -3.50 27.46 -5.15
I
28 VI -0.40 -4.39
I-'
29 1969 18.00 78.0 23.08
]0
]1
31
J) yEAR UNITS TOTAL DY1 DY2 DY3 PERCENT DYl DY2 DY3
].
35 1962 173.00 877.0 19.73
30 8.00 " 0.87
H 1963 "1 81 . 00 879.0 76.00 20.59 4.20
Jd 114.0U -179.00 ~.Vb -1l.~9
]9 1964 265.CO 1033.0 -103.00 25.65 -7.40
.0 -19.00 151.00 -2.34 10.02
., 1965 246.CO 1055.0 48.00 23.32 2.62
.1 29.00 -152.00 0.29 -2.68
.3 1966 275.00 1165.0 -104.00 23.61 -0.05
.. -75.00 225.00 0.23 3.U8
.5 1967 200.00 839.0 121.0U 23.84 3.02
40 40.00 -170',00 3.25 -10.07
.71 1968 246.00 908.0 -49.00 27.09 -7.05
481 -3.00 -3.79
4~ 1969 243.00 1043.0 23.30
50
51
52 NOTE** DYI . FIRST DIFFERENCE
53 DY2 & SECOND DIFFERENCE
5. CY3 . THIRD DIFFERENCE
55
50
-------
2
3
.
/)
7
8 E R I E C I T Y ENE R G Y 0 I V.
9 l URN I i~ D U S T R I E S. I N C.
10
II I~DUSTRIAL WATERTU~E BOILERS. DISTRIBUTION AS. TO SIZE OF UNIT 101-150 UNIT CAP.
12
13 YEAR CAP. TOTAL. DYl DY2 DY3 PERCENT OY1 OY2 DY)
I.
15 1962 2.90 43.3 6.7CJ
16 2.80 4.5<,1
17 1963 5.70 50.5 -1.00 11.2'1 -5.50
18 1.80 -0.(,/0 -(,0.<;1 6.t/4
19 1964 7.50 72.3 -1.00 10.37 1.33
.c 0.80 3.50 0.42 1.70
21 1965 8.30 76.9 2.50 10.79 3.04
22 3.30 -13.60 3.46 -14.11
23 1966 11.60 81.4 -11.10 14.25 -11.Cl8
:. -7.80 21.90 -7.62 22.21
25 ' 1967 3-80 57.3 10.eo 6.63 11.14
3.0C -8.90 3.52 -9.80
27 ttI 1968 6.80 67.0 1.90 10.15 1.33
28 I 4.90 4.a~
29 VI 1969 11.70 78.0 ' 15.00
30 I\)
31
32
33 YEAR UNITS TOTAL DY1 OY2 OY3 PERCENT CY1 OY2 DY3,
3.
J5 1962 24.00 877.0 2.74
36 20.00 2.27
37 1963 44.00 e79.0 -3.00 5.01 '-1.37
38 17.00 -11.00 0.9u 0.CJ3
39 1964 61.00 1033.0 -14.00 5.91 -0.74
.0 3.00 37.00 0.10 2.24
II 1905 64.00 1055.0 23.00 6.07 1.50
.2 26.00 -107.00 1.60 -7.07
.J 1966 9C.OO 1165.0 -84.00 7.73 -5.57
.. -58.00 167.00 -3.91 11.94
'5 1967 32.00 839.0 83.00 3.81 6.37
'6 25.00 -66.00 2.46 -~.62
.7 1968 57.00 908.0 17.00 6.28 0.75
.e 42.00 3.21
.9 1969 99.00 1043.0 9.49
5;)
51
H NOTE.. DY1'. FIRST DIFFERENCE
53 DY2 . SECO~D DIFFERENCE
5' DY) . THIRD DIFFERE~CE
55
56
-------
. 2
]
~
7
81 E R I E C I T Y E N ERG v 0 I v.
,I
101 1. URN I N 0 U S T R I ~ S. I N C.
II INOUSTRIA~ WATERTubE bOl~ERS. 01STR1BUT[ON A5 TO SIZ.E OF UNIT 1!:11-200 UNIT CAP.
12
I] YEAR CAP. TOTAL OVI DY2 DY3 PERCE/la OY1 OY2 OY3
"I
IS 1962 3010. 43.3 7.16
16 -0.20 -1.42
.7 1963 2.S0 50.5 2.80 5.74 3.28
;8 2.60 -5.70 l.bo -5.99
;9 1964 5.50 7203 -2.90 7.61 -2.71
-0.30 9.30 -0.115 10.67
" 1965 5.20 76.9 6.40 6.76 7.97
>21 6.10 -14.90 7.12 -13.44
'] 1966 11.30 81.4 -8.50 13.118 -5.47
'. -2.40 12.70 1.6~ 4.26
!S 1967 8.90 57.3 4.20 15.53 -1.21
~6 1.80 -7.60 0.44 -3.53
.1 tD 1968 10.70 67.0 -3.40 15.97 -4.74
'8 I .-1.60 -4.3U
VI
9 LA> 1969 9.10 78.0 11.67
0
2
] YEAR UNITS TOTAL DY1 OY2 OY3 PERCENT Dy1 DY2 OY3
S 1962 11.00 871.0 1.94
6 -1.00 -0.12
7' 1963 16.00 879.0 14.00 1.82 1.11
13.00 -29.1>0 0.99 -2.34
9 1964 29.00 1033.0 -15.00 2.81 -1.24
I) -2.00 49.00 -0.2~ 3.99
1965 27..00 1055.0 34.00 2.56 2.75
32.00 -72.00 2. ~H -4.01
1966 59.00 1165.0 -38.00 5.06 -1.25
-6.00 54.00 1.25 0.62
1961 53.CO 839.0 16.00 ()t 32 -0.63
6 10.00 -.32.00 0.62 -1.46
1968 63.00 908.0 -16.00 6.94 -2.09
-6.00 -1.47
1969 57.00 1043.0 5.47
}I
;1 NOTE** DVl . FIRST DIFFERE~CE
:/ DY2 . SECO~D DIFFERENCE.
DY3 . THIRD DIFFERENCE
~ I
-------
2
3
.
5
6
7
8 E R I E C I T Y ENE R G Y D I v.
9 1 URN I N D U S T R I E S. I N C.
10
II INDUSTRIAL ~ATERTUBF. BOILERS. DISTRlaUTION AS TO SIZE OF UNIT ZOl-2>0 UNIT CAP.
12
13 YEAR CAP. TOTAL DYl DY2 00 PERCENT DYl DY2 DY3
"
15 1962 3.50 43.3 8.08
16 -1.00 -3.13
17 1963 2.50 50.5 0.40 4.95 0.81
18 . -0.60 3.UO -2.3l ~.OO
19 1964 1.90 72.3 3.40 2.63 5.81
20 2.80 -7.70 3.41t -11.47
21 1965 4.70 76.9 -4.30 6ell -~.66 ,
22 ';'1.~0 . 7.90 -2.1u 1J .16
2] 1966 3.20 tll.4 3.60 3.93 7.50
2. 2.10 -6.40 >.32 -1>.20
25 1967 5.30 57.3 -2.80. 9.25 -7.70
26 -0.70 4.50. -2.38 .10.40
27 1968 4.60 67.0 . 1.70 6.87 2.70
29 t::I:I 1.00 0.31
I
79 V1 1969 5.60 7e.0 7.18
30 +::-
31
32
33 YEAR UNITS TOTAL Oyl DY2 OY3 PERCENT Drl DY2 DY3
3.
3~ 1962 15.00 877.0 1.71
3t -4.00 -0.46
37 1963 11.00 879.0 1.00 1.25 -Ci.02
38 -3.0~ 14.\)0 -O.4d 1.62
j. 1964 8.00 1033.0 l!hOO 0.77 1.60
.~ 12.00 -33.00 1.12 -3.41
41 1965 20.00 1055.0 -18.00 1.90 -1.82
'2 -6.00 33.00 -0.69 4.05
.3 1966 14.00 1165.0 15.00 1.20 .,. 2.23
.. 9.00 -28.00 1.>4 -4.42
.~ 1967 23.CO 839.0 -13.00 2.74 -2.19
.~ -4.00 22.00 -0.6> 3.0>
'7 1968 19.00 908.0 9.00 2.U9 0.86
'2 5.00 0.21
.? 1969 24.00 1043.0 2.30
!,Ij
\1
52 NOTE** DY1.. FIRST OIFFERE:-lCE
53 OY2 . SECO~D DIFFERENCE
5. DY3 . THI~D DIFFERENCE
!5
~t
-------
6
7
8 E R I E C' I T Y ENE R G Y D I V.
9 I. URN I N D U S T R I E S. I N C.
10
II INDUSTRIAL wATERTU8E eOILERS. DISTRIBUTION AS TO SIZE OF UNIT 251-300 UNIT CAP.
12
IJ YEAR CAP. TOTAL DY1 DY2 DY3 PERCENT on DY2 DY3
..
IS 1962 1.20 43.3 2.77
10 1.70 2.97
17 1963 2.90 50.5 -2.00 5.74 -5.12
13 -0.30 3.40 -2015 8.48
'" 1964 2.60 72.3 1.40 3.60 3.36
i", 1.10 -1.00 1.22 -3.00
]; 1965 3.70 76.9 0.40 4.&1 0.36
]~ 1.50 -6.60 1.5t1 -7.45
~J 1966 5.20 81.4 -6.20 6.3~ -7.09
24 -4.70 12010 -5.52 14.27
2~ 1967 0.50 57.3 5.90 0.S7 7.18
b:t
:b I 1.20 -3.60 1.66 -4.72
]7 VI 1968 1.70 67.0 2.30 2.54 2.46
VI
"8 3.50 4.13
2- 1969 5.20 78.0 6.67
JO
., I
32
J) YEAR UNITS TOTAL DYI OY2 OY3 PERCENT DYI OY2 OY3 .
J4
JS 1962 4.00 877.0 0.46
JO 6.00 0.6iS
F 1963 10.00 879.0 -7.00 1.14 -0.95
3d -1.00 12.00 -0.27 1.~B
J.9 1964 9.00 1033.0 5.00 0.87 0.63
4~ 4.00 -4.00 0.36 -0.68
.. 1965 13.00 1055.0 1.00 1.23 -0.05
42 5.00 -22.00 0.31 -1.57
4) 1966 18.00 1165.0 -21.00 1.55 -1.62
44 -16.00 41.00 -1.31 3.35
4S 1967 2.00 839.0 20.00 0.24 1.73
4~ 4.00 -12.00 0.42 -1.09
47 1968 6.00 908.0 8.00 0.66 0.64
48 12.00 1.06
.. 1969 18.00 1043.0 1.73
5C
51
52 NOTE**. DY1 . FIRST DIFFERE~CE
53 DY2 . SECOND DIFFERE~CE
54' DY3 . THIRD DIFFERENCE
5S
561
-------
2
J
4 .
5
6
7
8 E R J E C J T Y E N ERG Y D J V.
9 l. URN J N D U S T R J E S. I N C.
10
II INDUSTRIAL WATERTU~E BOJLERS. DJSTRIBUTION A~ TO SIZE OF UNIT 301-3~0 UNIT CAP.
12
\3 YEAR CAP. TOTAl. DY1 DY2 on PERCENT OY1 OY2 DV'
14
15 1962 2~00 43.3 4.t»2
16 1.00 1.32
17 1963 3.00 50.5 -2.30 5.94 -4.91
18 .-1.30 7.20 .;-3. ~9 13.04
19 1964 1.70 72.3 4.90 2.35 8.13
20 3.60 -12.40 4.54 -17.84
21 1965 5.30 76.9 -7.50 6.89 -9.71
2. -3.90 12.00 -5017 1t».66
23 1966 1.40 61.4 4.50 .1.72 '6.94
20 0.60 -5.80 1.77 -1tJ.26
25 1967 2.00 57.3 -1.30 3.49 -3.32
2~ -0.70 1.70 -1.~~ 4.21
. 27 tJj 1968 1.30 67.0 0.40 1.94 0.89
28 I -0.30 -0.66
VI
29 0'. 1969 1.00 7e.o 1.28
3C
31
32
33 YEAR UNITS TOTAl. DY1 DY2 OY3 PERCE,..T DY1 DY2 DY)
30
35 1962 6.00 877.0 0.68
36 3.00 0.34
J7 . 1963 .9.00 079.0 -7.00 1.02 -0.88
" -4.00 22.00 -O.~4 2.45
39 1964 5.00 1033.0 15.00 0.48 1.57
00 11.00 -38.00 1.03 -~.78
., 1965 16.00 10SS.0 -23.00 1.52 -2.21
42 -12.00 37.00 -1.17 3.75
03 1966 4.00 1165.0 14.00 0.34 1.55
04 2.00 -18.00 . 0.37 -2.19
o~ I ' 1967 6.00 839.0 -4.00 0.72 -0.65
.~. -2.00 5.00 . -0.27 0.77
07 1968 4.00 908.0 1.00 0.44 0.12
.a -1.00 -0.15
09 1969 3.00 1043.0 0.29
5C
51
52 NOTE-. DYl . FJRST DJFFEREr\CE
53 DY2 . SECOND DIFFERE~CE
54 DY3 . THIRO DIFFERENCE
5S
56,
-------
. I
. 2
. ..3
. .
~
6
7
8 E R I E C I T Y ENE R G Y 0 I v.
9 Z URN I N 0 U S T R I E S. I N C.
10
II INDUSTRIA~ WATERTUBE BOI~ERS. DISTRIBUTION AS TO SIZE OF UNIT 3~1-4UO UNIT CAP.
12
13 YEAR CAP. TOTAL OYl OY2 DY3 PERCENT OYl OY2 on
I.
13 1962 1.10 43.3 2.54
16 0.50 0.63
11 1963 1.60 50.5 0.20 3.17 -0.62
18 0.70 -1.30 0.01 -0.11
19 1964 2.30 72.3 -1010 3.18 -0.72
1~ I -0.40 0.80 -0.71 (J.44
,; I 196~ 1.90 76.9 -0.30 2.47 -0.29
1:! -0.70 0.90 -l.vu 1.73
1! 1966 1.20 81.4 0.60 1.47 1.44
2' -0.10 -0.00 (j.4~ -1.42
2~ 1967 1.10 ~7.3 0.60 1.92 0.02
2t CI.50 0.00 0.47 0.58
" 1968 1.60 67.0 0.60 2.39 0.61
:9 tJj 1.10 1.07
I
29 VI 1969 2.70 78.0 3.46
~(. ~
)1
)2
J) YEAR Ur-.ITS TOTAL . DY1 DY2 DY3 PERCENT Dvl DY2 DY3
~I
1962 3.00 877.0 0.34
I
)61 1.00 0.11
)11 1963 4.00 879.0 1.00 0..46 0.01
38 I 2.00 -4.00 0.13 -0.25
)" 1964 6.00 1033.0 -3.00 O.~8 -0.23
'01 -1.00 2.00 -0.11 0.12
.' 1965 5.00 105~.O -1.00 0.47 -0.11
., -2.00 3.00 -0.22 U.43
'3 1966 3.00 1165.0 2.00 0.26 0.32
u 0.00 -1.00 0.10 -U.33
.~ 1967 3.00 839.0 1.00 0.36 -0.02
.~ 1.00 1.00 0.06 U.16
.; 1968 4.00 908.0 2.00 0.44 0.1~
'8 3.00 0.23
" 1969 7.CO 104:!.0 0.67
sc I
SI
511 NoTE-- DY1- FIRST DIFFERENCE
53 I DV2 - SECOND DIFFERE~CE
5' DY3 - THIRO DIFFERE~CE
HI
56
-------
A
S
6
7
8 E R I E C I T Y ENE R G Y D I v.
9 l. URN I N D U S T R I E S. I N C.
10
II INDUSTRIAL WATERfuBE BOILERS. DISTRIBUTION AS TO SIl.E OF UNIT 401-4~0 UNIT CAP.
12
13 YEAR CAP. TOTAL DYI OY2 DY3 PERCENT DVI OV2 OY3
,IA
15 1962 0.00 43.3 0.00
16 0.40 0.1<;
17 1963 0.40 50.5 2.20 0.79 2.57
18 2.60 -6.10 3.36 -7.86
10 .1964 3.00 72.3 -3.90 4015 -~.30
)1) -1.30 5.70 -1.9" 1.73
21 1965 1.70 76.9 1.80 2.21 2.43
22 .0.50 -2.80 0.4'J -2.66
23 1966 2.20 81.4 "!'1.00 2.70 -0.23
2A -0.50 0.20 0.26 -2.41
25 tx:I 1967 1.10 51.3 -0.80 2.~7 -2.63
26 I -1.30 2.60 -2.37 5.56
27 VI 1968 0.40 67.0 1.80 ' 0.60 2.93
(»
28 0.50 0.56
2'1 1969 0.90 78.0 1.15
JO
31
J2
33 YEAR UNITS TOTAL DVI DY2 DY3 PERCENT Drl DY2 OY3
3A
3S 1962 0.00 877.0 O.liO
36 ' 1.00 0.11
31 1963 1.00 879.0 5.00 .0.11 0.45
38 6.00 -14.00 0.56 -1.31
3; 1964 7.00 1~33.0 -9.00 0.68 -0.86
40 -3.00 13.00 -C.3U 1.21
41 1965 4.00 1055.0 4.00 0~38 0.35
A2 1.00 -6.00 O.O~ -U.35
43 1966 5.00 1165.0 -2.00 0.43 -0.00
00 -1.00 0.00 0.05 -0.41
05 1967 4.00 839.0 -2.00 0.48 -0.41
o~ -3.00 6.00 -0.37 0.86
A71 1,968 1.00 ~08.0 4.00 0.11 0.45
ASI 1.00 O.Cij
Aql i969 2.00 1043.0 0.19
3~,
31'
.~I NOTE... DYI . FIRST DIFFERENCE
DY2 . SECO~D DIFFERENCE
DY3 . THIRD DIFFERE~CE
s!t!
5e i
-------
:1
E R I E C I T Y ENE R c; Y D I V.
9 l URN I N D U S T R I E S, I N C.
10
II INDuSTRIAL WATERTUBE HOlLERS, DISTRI~UTI0N AS TO SIlE OF UfljlT 4!)1-!)iJO UNIT CAP.
12
I] YEAR CAP. TOTAL Dvl DY2 DV3 PERCENT uvl DY2 DV3
'0
IS 1962 0.00 43.3 0.00
16 0.90 1.711
17 1963 0.90 50.!) 0.20 1.7~ -0.80
18 lalO -0.30 0.91S V.Y!)
'9' 1964 2.00 72.3 -0.10 2.77 0.1!)
7~ 1.00 -2.!)0 1.13 -).47
71 1965 3.00 76.9 -2.60 3.90 -3.32
n -1.60 5.30 -2.11S Sollt
2] 1966 1.40 81.4 2.70 1.72 It.tl2
20 1.10 -4.30 2.64 -8.tS5
2S 1967 2.50 57.3 -1.60 4.36 -4.02
.s -0.50 1.60 -1.3Ci 4.31t
Z7 td 1968 2.00 67.0 0.00 l.'' 0.32
I
78 V1 -0.50 -1.06
1" \0 1969 1.50 78.0 1.92
IC
JI
12
IJ YEAR UNITS TOTAL DVl DY2 DV3 PERCENT OY1 OY2 OY3
10
IS 1962 0.(;0 877.0 0.00
16 2.00 0.23
11 1963 2.00 879.0 0.00 0.23 -0.07
18 2.00 O.vO Oal6 0.09
I~ 1964 4.00 1033.U. 0.00 0.39 0.02
.0 2.00 -5.00 Oal8 -u.51
" 1965 6.00 1055.0 -5.00 0.57 -0.49
.2 -3.00 10.iJO -0.31 1.11t
.] 1966 3.00 ' 1165.0 5.00 0.26 0.65
2.00 -8.00 0.34 -1.14
. 1967 5.00 839.0 -3.00 0.1)0 -0.1t9
~, -1.OJ 3.00 -0.16 0.50
:1 1968 4.00 908.0 0.00 0.41t 0.00
-1.00 -0 . 15
9 1969 3.00 1043.0 0.29
c
1
2 NOTC-.. DY1 . FIRSt. DIFFEREhCE
3 DY2 . S~CC~D DIFFERE~CE
:1 OV3 . THIRD DIFFERE~CE
-------
2
3
.
5
6
1
8 E R I E C I T Y ENE R G Y D I V.
9 Z URN I N D U S T R I E S. I N C.
10
II INDUSTRIAL WATERTueE BOILERS. DISTRIBUTION AS TO SIZE OF UNIT 500 + UNIT CAP.
12
13 YEAR CAP. TOTAL DY1 DY2 DY3 PERCENT Ov1 DV2 DY3
..
u 1962 0.00 43.3 0.00
16 1.20 2.38
11 1963 1.20 ' 50.5 4.20 2.38 4.38
18 5.40 -10.40 6.7:;' -12.71
19 . 1964 6.60 72.3 -6.20 '1.13 -&.34
20 -0.80 4.20 -1.59 6.07
21 1965 5.80 76.9 -2.00 7.54 -2.2.7
22 -2..80 .2.90 -3.tl6 4.36
23 1966 3.00 81.4 0.90 3.69 2.09
2. -1.90 4.70 -1.77 4.92
2~ 1967 1.10 57.3 5.60 1.92 7.01
2e td 3.70 -9.50 5.24 -13.52
I
21 0\ 1968 4.80 67.0 ~3.90 7..16 -6.51
28 0 -0.20 -1.27
29 1969 4.60 78.0 5.90
30
31
32
33 VEAR UNITS TOTAL DV1 DY2 OY3 PERCENT DY1 DY2 DY)
3.
35 1962 0.00 877.0 0.00
36 2.00 0.2::1
31 1963 2.00 879.0 3.00 0.23 0.22
38 5.00 -7.00 0~4!1 -v.59
3; 1964 7.00 1033.0 -4.00 0.68 -0.37
.0 1.00 0.00 0.08 -0.04
.. 1965 8.00 1055.0 -4.00 0.76 -0.41
'2 -3.0C 4.00 -0.3) 0.:;'5
'3 1966 5.00 1165.0 0.00 0.4) 0.14
.. -3.00 8.00 -0.1'1 0.59
.~ 1967 2.00 839.0 8.00 0.24 0.72
..., 5.00 -13.00 0.53 -1.36
AT 1968 7.00 908.0 -5.00 0.77 -0.63
.e 0.00 -O.lU
.~I 1969 7.00 1043.0 0.67
50
51
52 NOTE** Dvl.. FIRST DI~FERENCE
SJ DY2 . SECCND DIFFERE~CE
5' DY3 . THIRD DIFFERENCE
ss I
5..:
.
-------
APPENDIX III
PRESSURE
B-61
-------
2
3
E R I E C I T Y ENE R G Y D I V.
0 l URN I N 0 U S T /{ I E S. I N C.
IJ
II INDUSTRIA~ WAT~RTU~E BOI~ERS. DISTRldUTION AS TO OPERATING PRESSURE 0-109 PSIG
12
IJ YEAR CAP. TOTA~. OY1 OY2 DY3 P~:r.(CENT l)Y1 DY2 DY3
,.
I
IS 1962 0.20 103.3 0.46
Ie 0.00 -0.07
17 1963 0.20 50.5 0.10 0.40 0.08
I~ 0010 -0.30 O.OO! -U.26
~ 9 1964 (;.30 72.3 -0.20 0.101 -0.17
'Jr. -0.10 0030 -0.1~ \).31
]1 1965 0.20 76.9 0.10 0.26 0.14
n/ 0.00 -1,).20 -0.01 -U.20
;J 1966 0.20 81.4 -0.10 0.25 -0.06
2. -0.10 0.30 -0.07 U.25
IS 1967 0.10 57.3 0.20 0.17 0.20
1/. 0010 -0.30 0012 -U.36
27 .C:J 1968 0.20 66.9 . -0.10 u.30 -0.17
.5 I 0.00 -0.04
10 0\ 1969 0.20 78.U 0.26
w
. IQ
)I
n
13 YEAR UI\ITS TOTAL. DY1 DY2 Dn PERCENT DY1 DY2 DU.
I.
IS 1962 11.00 877.0 1.25
IS 5.00 0 .!iI1
I" 1963 16.CO 879.0 -6.00 1.82 -0.93
::1 -1.00 -1.UO -0.37 0.51
1964 15.00 1033.0 -7.00 1.45 -0.42
IC. -8.00 18.00 -0.79 1.40
II 1965 7.00 1055.0 11.00 0.66 0.98
II 3.00 -17.UO u.1~ -1.20.
13 1966 1(;.00 1165.0 -6.00 0.1:16 -0.22
14 -3.00 130 00 -1,).02 \).62
I~ 1967 7.00 839.0 7.00 0.113 0.40
,e 4.0e -8.UO 0.3& -0.65
I~ 1969 11.00 908.0 -1.00 1.21 -0.25
18 3.00 0.13
10' 1969 14.00 1043.0 1.34
.0
.1 NOTE** OY1 . FIRST DIFFERENCE.
'c I DY2 . SECO~~ OIFFERE~CE
~I DY3 . THIRD DIFFERENCE
-------
I
2
~
.
5
&
7
I E R I E C I T Y ENE R G Y 0 I v.
" l. URN I N 0 U S T R I E S. I N C~.
0 .
1 INDUSTRIAL WAT£RTUBE BOILERS. DISTRIBUTION AS TO OPERATING PRdsURE ~0-149 J.lSIG
2
3 YEAR CAP. TOTAL. DYI OY2 DY3 PERCENT. DYI tlY2 on
1962 .9.80 43.3 22.63
-0.60 -4.41
1963 9.20 50.5 2.40 18.22 1.41
1.80 -3.00 -3.0U 2.24
1964 11.00 72.3 -0.60 15.21 3.65
1.20 2.80 0.65 -1.00
1965 12.20 76.9 2.20 lS.1j6 2.65
3.40 -10.20 3030 -~.92
1966 15.60 81.4 -8.00 lY~16 -3.27
-4.60 13.20 O.O~ 1.38
1967 11.00 57.3 5.20 lCJ.20 -1.89'
0.60 -3.30 -1.86 4.49
tJj 1968 11.60 66.9 1.90 17.34 2.60
I 2.50 0.7'4
0'\
1 +:- 1969 14.10 78.0 18.08
)
YEAR UNITS TOTAL DYI OY2 on PERCENT DYI OY2 DY3
\ 1962 358.00 877.0 40.82
~ -17.00 -2.03
I 1963 341.00 879.0 22.00 38.79 -3.27
! 5.00 26.00 -5.30 12.\10
1 1964 346.00 1033.0 48.00 . 33.49 9.62
) 53.00 -41.00 4.33 -12.37
1965 399.00 1055.0 7.00 37.82 -2.75
'60.00 -201.00 1.511 0.50
1966 459.00 1165.0 -194.00 39.40 -2.24
-134.00 317.00 . .-0.60 "1.2~
1967 325.00 839.0 123.00 38.74 -3.49
. -1.1.00 -59.00 -4.10 8.2~
1968 314.00 90S'.0 64.00 34.58 4.76
.53.00 0.61
~I 1969 367.00 1043.0 35.19
NOTE.- OYl . FIRST DIFFERENCE
~I DY2 . SECOND DIFFERE~CE
OY3 . THIRD DIFFERENCE
-------
I
2
3
.
7
8 E R I E C I T Y ENE R G Y 0 I v.
l URN I N 0 U S T R I E S. I N C.
0
INDUSTRIAL WATERTUUE ~OILERS. DISTRIBUTION AS TO OPERATING PRS. 150-24CJ PSIG
YEAR CAP. TOTAL' DY1 DY2 DY3 PERCENT DY! DY2 DY3
1962 12.80 43.3 29.56
3.10 1.92
1963 15.90 50.5 1.30 31.49 - 5 . 33.
4.40 -6.70 -3.41 5.7~
1964 20.30 72.3 -5.40 28.~8 0.43
-1.00 8.50 -2.9~ .3.74
1965 19.30 76.9 3.10 2~.10 4.17
2.10 -11.20 1.19 -4.78
1966 21.40 81.4 -8.10 26.2Y -U.61
-6.00 17.20 0.59 ".80
1967 15.40 57.3 9.10 2tu tj6 0.19
3.10 -8.40 O.7~ -".U3
tD 1968 18.50 66.9 0.70 27.6!) 0.16
I 3.60 0.94
~
\.n 1969 22.30 76.0 28.59
YEAR UNITS TOTAL DY1 DY2 on PERCENT DY1 DY2 on
1962 304.00 811.0 34.66
28.00 3.11
1963 332.00 879.0 22.00 37.77 -3.90
50.00 -128.00 -0.79 -1.39
1964 382.00 1033.0 -106.00 36.98 -5.29
-56.00 202.00 -6.08 11.88
1965 326.00 1055.0 96.00 30.YO 6.60
40.00 -226.00 0.52 -!).63
1966 366.00 11(,5.0 -130.00 H.lt2 0.96
-90.00 262.00 1.48 -0.32
1967 276.00 839.0 132.0U 32.90 0.65
42.00 -153.00 2.13 -5.29
1966 318.00 908.0 -21.00 35.02 -4.65
21.00 -2.52
1969 339.00 1043.0 32.50
NoTE.'. DY1.- FIRST DIFFERENCE.
DY2 - SECOND DIFFERENCE
on - THIRD DIFFERE~CE
-------
E R I E C I T Y E.N ERG Y D I V.
l. URN I N D U S T R I E S. I N C.
INDUSTRIA~ WATERTUBE BOIL.ERS. DISTRIBUTION AS TO OPERATING PRS. 2~0-349 PSIG
YEAR CAP. TOTA~ DYI . DY2 DY3 PERCENT DYI DY2 Dn
. 1962 .3.10 43.3 7.16
0.40 -0.2J
1963 3.50 50.5 2.90 6.~3 2.70
3.30 -6.80 2.47 -fh!j2
1964 6.80 72.3 . -3.90 9.41 -3.82 .
-0.60 6.90 -1.34 7.e:.6
1965 6.20 76.9 3.00 8.U6 3.85
2.40 . -9.00 2.~u -11.19
. ,1966 8.60 81.4 -6.00 10.57 -4.34
-3.60 12.60 -1.84 9.41
1967 !j.OO ~7.3 6.60 8.73 5.07
3.00 -8.10 3.2~ -8.08
t:x:t 1968 8.00 66.9 -1.50 11.~6 -3.01
I 1.50 0.22
0\
. 0\ 1969 9.50 78.0 12.18
YEAR U~ITS TOTAL. DYI OY2 OY3 PERCENT D)'l OY2 Dn
1962 69.00 877.0 7.87
-16.00 -1.84
1963 53.00 879.0 65.00 6.03 5.68
49.00 -112.00 3.114 -9.54
1964 102.00 1033.0 -47.0U 9.ts7 -).1!6
2.00 55.00 -0.02 3.80
1965. 104.00 1055.0 8.00 9.86 -0.06
10.00 -54.00 -0.07 -".36 .
1966 11.4.00 1165.0 -46.00 9.79 -0.42
-36.00 '106.00 -0.49 2.84
1967 76.00 839.0 60.00 9.30 2.43
24.00 -46.00 1.94 -2.17
1968 102.00 908.0 14..00 11.23 0.25
38.00 2.19
1969 140.00 1043.0 13.42
NOTE-- DY1 . FIRST DIFFERENCE.
DY2 . SECOND DIFFE~EhCE
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y 0 I v.
l URN I N D U S T R I E S, I N C.
INDUSTRIAL WATERTUBE bOILERS, DISTRIBUTION AS TO OPERATING P~S. )50-44'11 PSIG
YEAR CAP. TOTAL DY1 DY2 DY3 PERCENT DY1 OY2 DY3
1962 .3.10 43.3 7016
0.80 O.:>tI
1963 3.90 50.5 0.20 7.72 -1.51
1.00 -1.50 -0.9~ 1.66
1964 4.90 72.3 -1.30 6.78 0.15
-Q.30 0.20 -0.8(,) -1.40
1965 4.60 76.9 -1.10 5.98 -1.26
-1.40 4.90 -2.0:> Y.1~
1966 3.20 81.4 3.80 3.93 7.89
2.40 -7.60 5.84 -17.23
1967 5.60 57.3 -3.80 9.77 -9.34
-1.40 4.50 -3.5v 11.04
b:I 1968 4.20 66.9 0.70 6.28 1.70
I -0.70 -1.7'7
0\
~ 1969 3.50 78.0 4.49
YEAR UNITS TOTAL, DY1 OY2 OY3 PERCENT OY1 DV2 on
1962 47.00 e77.0 5.36
-11.00 -1.26
1963 36.00 e79.0 27.00 4.10 2.20
16.00 -52.00 0.94 -4.10
1964 52.<,10 1033.0 -25.00 5.03 -1.CJO
-9.00 27.00 -0.96 1.87
1965 43.00 1055.0 2.00 4.08 -0.03
-7.00 14.00 -0.'J9 3.29
1966 36.00 1165.0 16.00 3.09 3.26
9.00 -27.00 2.27 -6.16
1967 45.00 839.0 -11.00 5.36 -2.90
-2.00 3.00 -0.63 1.96
1968 43.00 908.0 -8.00 4.74 -0.94
-10.00 -1.57
1969 33000 1043.0 3.16
NoTE** DY1 . FIRST DIFFERENCE
OY2 . SECOND DIFFERE~CE
OY3 . THIRD DIFFERENCE
-------
E R I E C I T Y E,... ERG Y D I V.
l URN I N D U S T R I E S. I N C.
INDUSTRIAL WATERTU~E BOH.ERS. OISTHIBUTION AS TO OPERATI~G PHS. 4~O-~99 PSIG
YEAR CAP. TOTAL OY1 DY2 DY3 PERC~NT OYl DY2 on
1962 2.90 43.3 6.70
'" ~'.... 1.30 1.62
1963 4.20 ~0.5 -2.90 1'1.32 -6.34
-1.60 5.00 -4.72 11.~O
1964 2.60 72.3 2.10 '3.60 ~.16
0.50 -0.80 0.44 -3.60
1965 3.10 76.9 1.30 4.03 1.55
1.80 -5.10 1.99 -4.50
1966 4.90 81.4 -3.80 6.02 -2.95
-2.00 6.90 -O.Y6 4.82
1967 2.90 57.3 3.10 5.06 1.88
1.10 -3.60 0.92 -2.88
1968 4.00 66~9 -0.50 5.'18, -1.00
tx1 0.60 -0.01:1
I 196.9 I.. 60 78.0 5.90
0\
CD
YEAR UNITS TOTAL OY1 DY2 DY3 PERCENT DYl OY2 OY3
1962 24.00 877.0 2.74
2.00 0.22
1963 26.00 879.0 -4.00 2.96 -0.86
-2.00 15.00 -0.63 2.30
1964 24.00 1033.0 11.00 2.32 1.44
9.00 -18.00 0.8U -2.37
1965 33.00 10';5.0 -7.00 3.13 -0.93
2.00 '-5.00 -0.12 1.0.3
1966 35.00 1165.0 -12.00 3.00 0.10
-10.00' 29.00 -0.02 0.47
1967 25.00 839.0 17.00 2.98 0.57
7.00 -21.00 C.~4 -1.28
1968 32.\J0 908.0 -4.00 3.52 ' -0.11
3.00 -0.11
1Y69 35.00 1043.0 3.36
NOTE** OYl . FIRST DIFFERENCE
OY2 . SECC~D DIFFERENCE
DY3 . THIRD DIFFERENCE
-------
. E R I E C I T Y ENE R G Y D I v.
Z URN I N 0 U S T R I E S, I N C.
INDUSTRIAL NATERTuBE ~OILERS, DISTRIBUTION AS TO OPERATING PRS. 600-849 '-SIG
YEAR CAP. TOTAL DYl DY2 DY3 PERCENT DV1 OY2 OY3
1<;62 7.70 43.3 17.78
1.60 0.63
1963 9.30 50.5 -0.40 18.42 -4.53
1.Z0 2.40 -3.8!11 11.71
1964 10.50 72.3 Z.OO 14.!!Z 7.19
3.20 -2.80 3. 2 !II -B.!!l
1965 13.70 76.9 -0.80 17. b2 -1.33
2.40 -9.10 1.96 -~.4()
1966 16.10 b1.4 -9.90 19.7tt -6.73
-7.50 18.70 -4.77 11.29
1967 8.60 57.3 8.80 15.01 4.56
1.30 -5.40 -0.21 -0.4]
If 1968 9.90 66.9 3.40 14.110 4.13
0\ 4.70 3.92
\0 1969 14.60 78.0 18.72
YEAR U.\nS TOTAL OY1 OY2 OY3 PERCENT Dv1 OY2 DY3
1962 49.00 877.0 ~.59
11.00 1.24
1963 60.00 A79.0 0.00 6.tt3 -1.19
11.00 8.00 0.0' 2.80
1964 71.00 1033.0 8.00 6.b7 1.61
19.00 -12.00 1.66 -2.79
1965 90.00 1055.0 -4.00 8.53 -1.18
15.00 -62.00 0.40 -1.88
1966 10~.00 1165.0 -66.00 9.01 -3.06
-51.00 124.00 -2.~1I 5.92
1967 54.00 839.0 sa.ce 6.44 2.86
7.00 -45.00 0.21i -2.09
1968 61.00 908.0 13.00 6.72 C.77
20.00 1.05
1969 81.00 1043.0 7.77
NoTE** DY1 . FIRST DIFFERENCE
DY2 . SECCND DIFFERENCE
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y 0 I V.
l URN I N D U S T R I E S. I N C.
INDUSTRIAL WATERTUBE BOILE~S. DISTRIBUTION AS TO OPERATING PRS. 850-1249 PSIG
YEAR CAP. TOTAL DY1 DY2 DY3 PERCENT DY1 OY2 OY3
1962 2.70 43.3 6.24
-0.10 -1.09
1963 2.60 50.5 5.60 5.15 7.14
5.50 -5.':.10 6.0~ -7.10
1964 8.10 72.3 -0.30 11.20 0.04
5.20 -9.70 . 6.0':.1 -12.\18
1965 13.30 76.9 -10.00 17.30 -12.94
-4.80 11.80 -b.8~ lb.9~
1966 &.50 81.4 1.80 10.44 6.01
-3.00 2.90 -0.84 -4.00
1967 5.50 57.3 4.70 9.60 2.01
1.70 -7.50 1.16 -6.11
b:I 1966 7.20 66.9 -2.80 10.76 -4.11
I -1.10 -2.94
~
0 1969 6etO 78.0 7.82
YEAR urn T S TOTAL ' CY1 OY2 OY3 PE~CENT OY1 DY2 CY3
1962 12.00 877.0 1.37
-1.00 -0.12
1963 11.00 679.0 20.00 1.25 1.77
19.00 -25.00 1.6~ -".16
1964 30.00 1033.0 -5.00 2.90 -0.39
14.00 -20.00 1.27 -2.22
1965 44.00 1055.0 -25.00 4.17 -2.60
-11.00 24.00 -1.34 3.61.
1966 33.00 1165.0 -1.00 2.1:13 1.01
-12.00 12.00 -0.33 -0.98
1967 21.00 839.0 11. CO 2.50 0,,03
-1.00 -5.00 -0.30 0.47
1968 20.00 908.0 6.00 2.20 0.49
5.00 0.19
1969 25.00 1043.0 2.40
NOTE** . DY1 . FIRST DIFFERENCE
. DY2 . SECOND DIFFERENCE
DY] . THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y 0 I V.
l URN I N D U S T ~ I E S. I N C.
INDUSTRIAL WATERTUBE BOILERS. IJISTRIBUTION AS TO OPERATING P~S. 1250-1449 PSIG
YEAR CAP. TOTAL. DY1 DY2 DY3 PERCENT DYl DY2 DY3
1962 0.50 43.3 1.1!1
0.60 1.02
1963 1.10 50.5 1.90 2.111 1.18
2.50 -!l.10 2.1I1J -o.!>1
1964 3-60 12.3 -3.80 i.. 98 -4.19
-1.30 5.10 -1.9Y 7.3~
1';65 2.30 16.9 1.90 2.';'; 2.56
0.60 -2.90 0.:)1 -2.33
1966 2.90 81.4 -1.00 3.!l6 0.23
-0.40 -0.40 0.8101 -4.3!>
1961 le50 51.3 -1.40 4.36 -4.12
-1.80 4.70 -3.32 V.21
tt:I 1968 0.70 .66.9 '. 3.30 1.05 5.09
I
-.:j 1.50 1.71
I-' 1969 2.20 18.0 .0:.82
YE.AR urll T 5 TOTAL. OYl DY2 DY3 PE~CENT DY1 DY2 DY3
1962 2.00 811.0 0.23
1.00 0.1.L
1963 3.00 819.0 2.00 0.34 0.13
3.00 -1.00 0.24 -~.57
1964 6.00 1033.0 -5.00 O.~II -0.44
-2.00 10.00 -0.21.1 0.60
1965 4.00 1055.0 5.00 0.38 0.42
3.00 -9.00 0.22 -O.!>3
1966 1.00 1165.0 -4.00 0.60 -0.11
-1.00 1.00 0.11 -U.50
1961 6.CO 839.0 -3.00 0.12 -0.61
-4.00 10.0U -0.4'i 1.36
1968 2.00 908.0 1.00 0.22 0.75
3.00 0.26
1969 5.00 1043.0 0.48
NOTE** .DY1 . FIRST DIFFERENCE
DY2 . SECO~D DIFFERE~CE
DY3 . THIRD DIFFERENCE
-------
E R I E C.I T Y ENE R G Y 0 I v.
l. URN I N 0 U S T R I E S. I N C.
INDUSTRIA~ WAT~RTU8E BOILERS. DISTRIBUTION AS TO OPERATING PMS. 1450-1799 PSIG
YEAR CAP. TOTA~. DY1 DY2 DY3 PERCENJ DY1 OY2 DY3
1962 0.30 43.3 0.69
0.30 0.5'"
1963 0.60 50.5 3.50 1.1'1 4.40
3.80 -9.60 4.9IJ -12.65
1964 I.. 40 72.3 -6.10 6.09 -8.25
-2.30 6.30 -3. 3~ tie H8
1965 2.10 76.9 0.20 2.73 0.62 .
-2.10 2.40 -2.73 2.98
1966 0.00 81.4 2.60 O.IJO 3.60
0.50 -0.90 0.87 -1.31
1967 0.50 57.3 1.70 0.117 2.29
2.20 -5.60 3.16 -8.21
1968 2.70 66.9 -3.90 4.04 -5.92
tJj -1.70 -2.n
I
~ 1969 1.00 78.0 1.28
I\)
YEAR ur~ I Hi TOTAi. DY1 DY2 DY3 PERCENT DY1 DY2 OY3
1962 1.00 877.0 0.11
0.00 -0.00
1963 1.00 979.0 4.00 0.11 0.37
4.00 -8.UO U.37 -0.75
1964 5.00 1033.0 -4.00 0~48 -0.38
0.00 -1.00 -0.01 -U.OH
1965 5.00 1055.0 -5.00 0.47 -0.46
-5.00 12.0U -0.47 1.18
1966 0.00 1165.0 7.00 0.00 O.7~
2.00 -6.\J0 0.24 -U.64
1967 2.00 839.0 . 1.00 0.24. 0.07
3.00 -5.00 0.31 -o.s~
1968 5.00 908.0 -4.00 0.55 -0.48
-1.00 -0.17
1969 4.00 1043.0 0'-38
NOTE** DY1 . FIRST DIFFERENCE
DY2 . SECOND DIFFERENCE
DY3 . THIRD DIFFERENCE
-------
APPENDIX IV
TEMPERATURE
B-73
-------
E R I E C I T Y ENE R G Y 0 I v.
l URN I N 0 U S T R I E S. I N C.
INOUSTRIAL ~AT~RTU~E BOIl~RS. DISTHItHJUON A~ TO STlAM TE~P~RATURE SAT
YEAR CAP. TOTAL OY1 DY2 Dn PERCENT OY1 L>Y2 DY)
1962 2~.50 43.3 5th89
1.6v -5.23
1963 27.10 50.5 5.30 53.66 -1.41
6.90 -11.30 -6.0" b.40
1964 34.00 7203 -6.00 47.03 4..,9
0.90 9.40 -1.64 -(J.5~
1965 34.90 76.9 3.40 45.~U 4.42
4.30 -19.70 2.77 -7.d~
1966 39.20 81.4 -16.30 48.10 -3.46
-12.00 37.40 -;).b~ 1U.66
1967 27.20 57.3 21.10 47.47 7.40
9.10 .; -25.10 6.71. -1~.21
td 1968 36.30 67.0 -4.CO 54.18 -7.&1
I 5.10 -1.10
-.:.1
VI 1969 41.40 78.0 53.li8
YEAR UNITS TOTAL DY1 DY2 L>Y3 PERCENT !.IY1 OY2 DY)
1'162 727.00 877.0 "2.90
-22.0(; -2."9
1963 705.~0 879.0 113.00 "0.20 -C;.46
'11.00 -212.00 -3ol~ 1.24
196~ 796.00 1033.0 -99.00 17.06 0.18
-e.oo 209.00 -Z 03 7 ;'.2'11
1965 788.00 1055.0 110.00 14.69 4.07
102.00 -496.00 1.70 -9.94
1966 890.00 1165.0 -386.00 16.39 -5.!!7
-264. '-)0 775.00 -4.17 10.11
1967 606.:;0 839.0 389.00 72.23 11j.24
105.00 -398.00 6.0b -17.2~
1968 711.00 908.0 -9.00 78.30 -1.01
96.00 -0.93
1969 807.00 1043.0 77.37
NoT.;*- DY1 . FIRST DIFFE.RENCE
ovZ . SECOND DIFFER~~CE
on . THIRD DIFF~RENCE
-------
E R I E C I T Y ENE R G Y D I v.
Z URN 1 N 0 U S T R I E S. 1 u c.
JNDUSTRJA~ WATERTU6E BOILEkS. DISTRl ~UTlON A~ TO ~TEAM TEt-:Pl;ttA TIJRE. 3...tJ-"24 -- F
YEAR CAP. TOTAL. DY1 DY2 DY3 PERCI:::NT i)Y1 DY2 DY3
1962 0.30 43.3 0.69
0.40 0.69
19,.,3 0.70 ~O.S -0.70 1.39 -1.~3
-0.30 1.~0 -O.tI) 0!.33
1964 0.40 72.3 0.30 O.~~ ".tlO
O.OU 0.70 -0.C3 '-'."3
1965 0.40 76.9 1.00 0.52 1.23
1.0(j -1.80 1.2(,) -1.3t.
1966 1.40 81.4 -0.80 1.72 -0.13
0.20 0.30 1.07 -1.tlC
1967 1.60 57.3 -0.50 2.79 -1.'12
-0.30 1.60 -O.C~ 3.53
OJ 19,.,8 1.30 67.U 1.10 1.~1.o 1.60
I 0.80 0.7~
~
0\ 1969 2.10 78.0 2.69
YEAR . Uj~ 1 T S TOTA~ DY1 DY2 DY3 PE~CENT DY1 DY2 DY3
1962 8.00 877.0 0.91
7.00 O.7Y
1963 15.00 879.0 -15.00 1.71 -1.82
-8.00 25.00 -1.03 3.03
1964 7.00 1033.U 10.00 0.68 1.20
2.00 1.00 C.11S -O.!4
196~ 9.00 10~!:>.0 11.00 0.85 0.66
13.00 -21.00 1.~.. -U.l:iti
1966 22.00 1165.0 -10.00 1.89 0.06
3.00 8.00 i.c,'i -1.2t.
1967 25.00 839.0 -2.00 2.98 -1.21
. .1.00 15.00 -Uel~ 2.30
1'168 26.00 908.0 13.00 2.tlb 1.tl9
.14.00 0.97
1969 1.00.00 101.03.0 3.81.0
NOTE..' DY1 . FIRST DIFFERE~CE
DY2 . SECO~D DIFFEHE~CI:::
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y D I v.
~ URN I N D U S T R I E S. 1 N C.
INDUSTRIAL WAT~RTU~E BOILii:RS. DISTRI~UTION AS TO STEAM TEMPERATURE ,-,5-414 -- F
YEAR CAP. TOTAL DY1 DYZ DY3 PERCENT OY1 DY2 DY)
1962 0.90 43.3 2.08
-0.20 -v.eY
19"'3 0.70 50.5 1.50 1.30,,1 2.CJ7
1.30 -3.20 1.)0 -10.14
1'0164 2.00 7Z.3 -1.10 2.17 -2.07
-0.40 2.40 -0.t>9 ;'.(.;0
19"'5 1.60 16.9 0.70 2.08 V.94
0.30 -1.20 0.2:1 -U.56
1'>166 1.90 81.4 -O.~O 2.:33 v.3~
-C.2C 0.40 0.6;J -1.1:1'"
1967 1.70 51.3 -0.10 2.0;7 -1.!!1
-0.30 0.1:10 -0.00 2.61
trI 1968 1.40 67.0 0.70 Z.O'J 1.10
I 0.40 0.22
~
~ 19!>9 1.80 78.0 Z.31
YEAI( U~.r T 5 TOTAL DY1 ' DY2 DY3 PERCENT DY1 \)Y2 OY3
1962 D.CO 877.0 1.48
-Z.OO -0.23
1963 11.00 879.0 18.00 1.25 1.59
16.00 -39.00 1.30 -3,.48
1964 27.00 1033.0 -21.00 2.61 -1.89
-5.00 21.00 -0.!!3 1.79
1965 22.00 1055.0 0.00 2.09 -0.10
-5.00 3.00 -"."'3 1.u~
1966 17.00 1165.0 3.00 1.46 CI.95
-2.00 -2.00 0033 -1.!!;'
1967 15.CO 839.0 1.00 1.79 -Cl.57
-1.0(, -3.00 -0.2~ 0.33
1968 1'-.CO 908.0 -2.00 1.54 -0.24
-3.00 -0.4'01
1969 11.00 1043.0 1.05
NOTE** DY1 . FIRST DIFFERENCE
DYZ . SECOi~D D I FFEREilCE
DY3 . THIR~ DIFFERENCE
-------
E R I E C I T Y E: ii E R G Y D I v.
l URN I N D U S T R I E S. I i~ C.
INDUSTRIAL WATERTUBE bOILERS. DISTkl~UT10~ AS TO STEAM TEMP~RATUj{E 4 H-~24 -- F
YEAR CAP. TOTAL DVl DY2 DY3 PERCENT JVl DV2 DV3
1962 1.60 43.3 4.1~
C.l0 -0.3'11
1"'63 1.90 50.5 0.20 3.76 -0.32
".30 O.Oll -v.7~ 1.~1
1964 2.20 72.3 0.20 3.v4 1.1..,
0.50 -0.30 c.47 -l.:i!b
1965 2.70 76.9 -0. 10 J.51 -'".17
0.40 -2.20 i).:'U -1.64
1966 3.10 81.4 -2.3'0 3.81 -2.01
-1.90 4.3U -1.71 3.57
1967 1.20 57.3 ' 2.00 2.U9 1.!l6
~. 0.10 -2.00 -v.1) -1.~!I
191>8 1.30 ~7.0 -0.00 1.'114 O.Ul
tV 0.10 -0. 1 ~
,
~ 1969 1.40, 1,8.0 1.79
(»
VEAR- Ui.I T 5 TOTAL DY1 DY2 DY3 PERCI::NT OV1 DY2 DY3
1962 23.00 877.0 2.62
0.00 -0.01
1963 23.00 879.0 3.00 2.62 -0.('9
3.00 -4.00 -i,j. 1 \J i.le 3 3
1964 26.00 1033.0 -1.00 2.52 0.24
2.00 3.00 0-14 -U.20
191>5 28.00 1055.0 2.00 2.6~ -U.lI4
4,OV -23.\.10 V.O'i -1.01
1966 32.00 1165.0 -21.00 2.75 -1.05
-17.:>0 36.00 -0.<,;6 1.6~
1967 15.00 839.0 15.00 1.79 0.60
-2.00 -9.UO -0.3" .."',O~
1968 13.00 908.0 6.00 1,43 0.55
4.00 0.20 "
1969 17.00 1043.0 1,63
NOTE** DVl '. FIRST DIFFERENCE
DV2 . SECOND DIFFERENCE
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y E ~ E R G Y D I V~
l. URN I N D U S T H I E S. I I"~ c.
INDUSTRIAL. WATERTUBE BOILERS. DISTRIBUTION AS TO Sa.AM TE":PEHATURE ~25-624 -- F
YEAR CAP. TOTAL DYI OY2 DY3 PEI~CE N T ~Y1 DY2 DY)
1962 2.40 43.3 5.54
0.90 0....'.1'
191>3 3.30 50.5 -0.30 6.53 -2.13
0.60 -O.~O -1.14 2.()'II
1964 3.90 72.3 -0.80 5. 3 !.I ".56
-0.20 2010 -0.511 1.11
1965 3.70 76.9 1.30 4.&1 1.67
1.10 -2.20 I.Cy lI.""
1966 4.80 81.4 -0.90 5.!.IO 1.74
0.20 c.eo 2'03 -5.6."
1967 5.00 57.3 -0.10 8.73 -3.94
0.1" -1.10 -101.1. l.~7
tt1 1968 5.10 67.0 -1.20 7.61 -1.37
I -1.IC -2.41;1
-...:j 196q 4.00 78.0 ~ol3
\0
YEAR ur, ITS TOTAL OYI OY2 DY3 PERCENT OYI I)Y2 OY3
1962 25.00 817.0 2.tl5
4.0C 0.45
1963. 29.00 H79.0 5.00 3030 -0.07
9.00 -5.00 ~.30 ~.47
1964 3 !.!o C. 0 1033.0' 0.00 3.68 0.40
9.00 -17.00 0.711 -2.28
196'; 47.00 1055.0 -17.00 4.45 -1.B8
-8.00 32.1,)0 -1.11 5.13
1966 39.00 1165.0 15.00 3.35 3.24
7.0i) -24.00 2.14 -1:1.01
1967 46.00 839.0 -9.00 5.48 -2.77
-2.00 4.00 -0.64 2.11
1968 44.00 908.0 -5.00 4.85 -0.66
-7.00 -1.3iJ
1969 37.00 1043.0 3.55
NOTE-- DYI . FIRST D I FFERE:,CE
OY2 . SECO:.::> DIFFERENCE
DY3 . THIRO DIFF~RENCE
-------
E R J E C J T Y E N E R G Y 0 1 v.
l. URN J N 0 U S T R J E S. J N C.
JNDUSTRJA~ ~ATERTUBE (jOJ~EHS. DJSTRJBUTJON AS TO S TEA,.1 TEfv'PERATURE 62~-671o -- F
Y1::AR . CAP. TCTA~ DY1 DYZ DY3 PEHCE",T [)Yl DYZ Dn
196Z 1.JO " 43.3 3 ..00
0.00 . ~c. 4 ~
1963 1.30 50.5 0.30 2.~7 0.07
0.30 0.70 -iJ.;j6 1.ti~
19610 1.60 7Z.3 1.00 2.21 1.92
1.3(; -1.Z0 1.5b -Z.3~
IIJh5 2.')0 76.9 -0.20 3.77 "!'\J.42
1.10 -3.30 1.14 -2.U~
1966 4.00 81.4 -3. ~o 4.91 -3.26
-2.40 5.30 -Z.12 4.1J9
1'167 1.60 57.3 1.80 2.79 ".82
-0.,60 -0.20 -1.3;) le~~
19613 1.00 67.0 1.60 1.49 2.37
b:I 1.00 1.e7
I
(» 1969 2.00 78.0 2.56
0
YEAR U,\ ITS TOTA~ DY1 DY2 DY3 PERCENT DY1 DY2 DY3
1962 15.00 877.0 1.71
-5.00 -C.~1
1963' l~.OO /i79.0 11.00 1.14 0.'18
, 6. CO 1.00 0.41 :U.28
1964 16.0,0 1033~0 12.00 1.55 1.26
18.00 -3C.00 1.67 -:h 24
1965 34.00 105s.a -le.oc 3.ZZ -1.98
c.oo -1.00 -0.3v 1.l!)
1966 34.~0 1165.0 -19.00 2.92 -(h8)
-19.00 33.00 -1.13 1.27
1967 u.OO 839.0 14.00 1.79 C.44
-5.00 -6.00 -0.69 0.3\/
1968 1C;.00 908~O 8.00 1010 ti. 83,
3.00 0.15
1969 13.00 .1043.0 1.25
r.oTEtttt DY1 . Fl~ST'DlFFERE~CE
DY2 . SECOh~ DlfFEREhCE
DY3 . THJRO DJFfERENC~
-------
E R I E
l U R ~
C I T YEN ERG Y
J ~ D U S T R J E S.
D I V.
J N C.
YEAR
INDUSTRIA~ wATE~TU6E BOI~ER~. DISTRIBUTIO~ AS TO STEAM TEYPERATURE b7~-724
l)Y2
1962
1963
1964
1965
1<;66
1967.
b:I
I
CO
I-'
196/1
196q
YEAR
1'J62
1'..163
1964
1965
19&6
1967
1968
1'169
CAP.
1.10
2.30
2.00
2030
1.50
1.10
1.50
4.00
U:-'lTS
15.CO
11. CO
12.00
15.CO
16.00
7.00
9.(;0
22.00
TOTA~
43.3
50.5
72.3
76.9
81.4
57.3
67.0
7e.o
TOTA~
877.0
1\79.0
1033.0
1055.0
1165.0
839.0
9CJ!!.0
1043.0
DY1
1.20
-0.30
0.30
-0.80
-0.40
0.4v
2.~O
DYl
-4.00
1.0e
3.00
1.00
-9.00
2.00
13.00
DY2
-1.~0
0.60
-1.10
0.40
0.80
..
2.10
DY2
5.00
2.00
-2.00
-10.00
11.00
11.00
r..OTE**
oY1 . FIRST DIFFERENCE
DY2 . SECONJ DIFFERE~CE
DY3 ..THIR~ DIFFERE~CE
DY)
2.10
-1.70
1.50
0.40
1.)0
DY)
-3.\)0
-4.00
-fj.oo
21.00
0.00
PEkCE~T
2.~4
4.55
2.77
2.-»9
1.b4
1.'12
2.24
5.13
PERCENT
1.71
1.2~
1.16
1.42
1.37
0.83
0.9<,/
2.11
&.>Y1
2.01
-1.7'J
(1022
-1.1~
O.Ob
0032
2.tI'J
OYl
-0.46
-0."'1
0.2£1
-0.C5
-0.54
0010
1012
-- F
-3.tjO
2.(;1
-1.37
1.;:3
0.24
2.57
DY2
0.37
0.35
-0.31
-1.1.49
0.70
0."6
DY3
~.1S2
-3.3<;
2.ou
-(j.'itj
l.33
on
-u.Ci2
-U.66
-v.111
1019
1.i.27
-------
E R I E C I T Y E N E R G Y D I v.
l. URN I N D U S T R I E S. I N C.
INDUSTRIAL. WATERTUBE tlOIL.ERS. DISTRIBUTION AS TO STlAM TEMPERATURE 7l5-774 -- F
,YEAR CAP. TOTAL. DV1 DV2 DY3 PERCENT OV1 OY2 DV3
1962 ~.80 43.3 13.3'J
1.eo 1.65
1963 7.60 50.5 0.70 15.0~ -2.73
2.5J -2.90 -l.~d 3.37
1964 1~.10 72.3 -2.20 13.'117 0.63
0.30 2.80 -".4~ u.17
1965 10.40 76.9 0.60 13.~2 O.t!C
0.90 -5.10 0.3~ -1.61
1966 11.3C 81.4 -4.50 13.Hb -(;.110
-3.60 9.20 -0.4,+ 2 34.00 877.0 3.118
17.00 1.9~
19h3 51.00 879.0 2.00 5.80 -C.<;5
19.00 -35.00 O.'i7 -1.4."
1%4 7\;.CJO 1033.0 -33.00 6.78 -2.44
-14.00 57.00 -1.47 4.27
196"- 56.CO 10~5.0 24.00 5.31 1.83
10.00 -6C.CJO 0.36 -3.U8
1966 66.\,)0 1165.0 -36.00 5.67 -1.25
-2".00 75.\)0 -0.9v 3.2l
1967 40.00 839.0 39.00 4.77 1.97
13.00 -40.00 1.07 -2.64
1968 53.00 908.0 -1.00 5.84 -0.67
12.00 0.40
1969 65.00 1043.0 6.23
~OTE.* . DV 1 . FIRST DIFFERENCE
DY2 . SECO~D DIFFER[NC~
DV3 . THIRD DIFFERENCE
-------
E R I E C I T Y E N E R G Y D I v.
t. U R N I N D U S T R I !;; S. I N C.
INDUSTRIAL. 'NATERTUBE BOILERS. DISTRIBUTION AS TO S TEA,\j T E;.'oPE~A TURI:: 7H-b24 -- F
YEAR CAP. TOTAL. DY1 DY2 DY3 PERCENT OY1 DY2 DY)
1962 0.40 43.3 0..,,2
0.50 O.de.
19b3 0.90 50. !I -0.70 1.78 -1.b7
-C.20 3.40 -"'01 !1.bd
1964 ".70 72.) 2.70 lJ.Y7 4.u1
2.50 -4.40 3ol't -()...~
1Y65 3.20 76.9 -1.70 4.16 -2.44
0.8u -2.9C C.7;, -2.t'1i
1966 4.00 81.4 ~4.60 4.91 -5.32
-3.80 9.20 -4.!l6 11.v3
19b7 C.2C 57.3 4.60 0.3!1 5.71
0.80 0 -5.20 1.14 -b.JJ1
1966 1.00 67.0 -0.60 1.49 -1.10
td 0.20 0.05
I 1969 1.20 76.0 1.54
ex>
YEAR UI,I TS .TOTAL !:oY1 DY2 DY3 PERCI::NT ;;Yl DY2 DY3
1962 1.vO 877.0 0.11
6.00 0.61j
1963 7.(;0 879.0 -11.00 O.tI:) -1.29
: -5.00 24.00 -O.6U 2.b4
1964 2.00 1033.0 13.00 0.1'>1 1.3b
8.00 -11.00 0.75 -1.34
1965 10.00 10!J5.0 2.00 0.95 0.01
10.00 -:;1.1,)0 (;077 -~.3d
1966 2C.00 1165.0 -29.00 1.72 -2.37
-19.00 52.00 -1.bU 4.40
1967 1.00 839.0 23.00 0.12 2.03
4.00 -.27.00 0.43 -~.53
196? 5.00 908.0 -4.00 0.55 -0.50
~.OO -0.C7
1969 5.VO 1043.0 0.48
r..OTE** OY1 . FIRST DIFFERENCE
DY2 . SECC:ID DIFFERE:ICE
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y E N E R G Y 0 I v.
l U R tl I N D U S T R I l: S. I N C.
I~OUSTRIAL WATERTuHE BOILERS. DISTRI~\JTIO~ A:; TO ST~AM TE~PERATURE d25-~71t -- F
YEAR CAP. TOTAL DY1 DY2 DY; PERCENT [;Y1 DY2 !JY3
1962 1.70 43.3 3.<;3
1.1.40 0.2~
1963 2.10 5r1.5 2~8C 4.16 2.':114
3.20 -2.UO 3.11 -~.3Cj
1964 ~,30 72.3. 0.00 7.33 C.55
3.20 -£,.10 3.141 -~.4~
1Y65 8.50 16.9 -6.10 11.05 -7.'10
-2.90. 6.50 -4.11 1U.61.1
1966 5.60 tl1.4 0.40 6.U8 2.70
-2.50 5.vO -1.41 2.31
1961 3.10 57.3 5.40 ~.41 5.01
2.9C -10.90 3.!:I:I -13.16
txI 1968 6.(;0 61.0 -5.50 8.'16 -8.14
I -2.60 -4.00
ex>
+:"" 1969 3.40 78.0 4.36
YEAR UIliITS TOTAL OYI DY2 DY3 PERCENT. (;Y1 DY2 DY3
1962 8.00 871.0 0.Y1
1.00 0.11
1963 9.00 !l79.0 10.00 1.U2 0.80
11.00 -9.00 u.c;l -U.62
1964 20.00 1033.0. 1.00 1.94 0.18
12.00 -28.00 1.10 -2.86
1905 32.00 1055.0 . -27.00 3.03 -2.67
-15.00 38.00 -1.5"1 4.34.
1966 17.00 1165.0 11.00 1.46 1.66
-4.00 -7.00 0.1.19 -1.87
1':1161 13.00 831).1) 4.1.10 1.55 -0.21
0.00 -1.00 -0 . 1l 0.4'3
1968 B.CO 908.0 3.00 1.43 0.22
3.00 0.10
1':1169 1£..00 1043.0 1.53
~.OTE** , DY1 . FIRST DIFFERENCE
DY2 . SECOND DIFFEqE~CE
OY3 . THIRD DIFFERENCE
-------
E R I E C I T Y E N E R G Y D I v.
/. U R N I N D U S T R I E S, I N C.
H:t;uS TR I AL WATERTUBE ~OIlI::HS, DISTRIOUTIOi\; AS TO SHAM H:.i" PI:.RA TUfiT !;V1 !JV2 OY3
1962 1.40 43.3 3.2;:'
0.30 Oel3
1963 1.10 ~O.!> 1.80 3.37 1.16
2.10 -4.!1C1 1.t!\oI -4.14
1964 3.20 72."3 -2.10 5.26 -2.<;8
-0.60 3.vO -1.~'i ;).48
1<;65 3.20" 16.9 0.30 4el6 0.50
-C.30 1.20 -C.b\J 3.7(,;
1966 2.90 81.4 1.~0 ~.56 4.1<;
1.2\j -5.60 3.~<; -B.l:)
1967 4.10 51.3 -4.10 1.16 -11.'16
-2.90 1."80 -5.3b 1).0,.
tJj 196e 1.20 61.0 3.10 1.19 6.14
J 0.80 0.11
CP 1<;69 2.uO 18.0 2.56
V1
VEAR UNITS TOTAL. !)Vl DY2 DV3 PERCENT L)Vl DV2 C;V3
" 1962 ~.vo 811.0 0.51
1.00 0.11
19~3 6.00 819.0 5.00 0.611 0.37
6.00 -13.UO 0.40 -1.06
11/64 12.00 1033.0 -8.00 1016 -".69
-2.00 9.00 -':'.21 0.13
1965 l~.OO 1055.0 1.00 0.95 0.04
=1.00 2.00 -i).lo 0.011
1966 9.00 1165.0 3.00 0.11 0.11
2.00 -13.00 w.:)" -i.l3
1961 11.(,;0 83Q.O -10.00 1.31 -1.~2
-11.00 20.00 -v.90 2.6~
196H 3.(;0 908.0 10.00 0.33 1.13
2.00 0.1!1
1969 5.00 " 1043.0 0.48
,',OTE*. DYl c FIRST DIFFERENCE
DY2 . SECOi':D DIFFERENCE
DVJ c THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y D I v.
Z. U ~ rl I ~ D U S T R I E S. I N C.
INDUSTRIAL. ~AT~RTUBE'HOIL.~~S. DISTRIt;UTIO,.., AS TO ST~A/J, THIPERAT..JRE 9<::5-1024-- F
YEAR CAP. TOTAL. DYl DY2 OY3 PE/{CENT DYl uY2 [;,Y3
1962 0.70 43.3 1.62
0.20 0.11
1963 0.90 50.5 5.20 1.76 fu77
5.40 -13.60 6.9J -lb.3d
1964 6.30 72.3 -6.60 8.11 -11.01
-3.20 10.!10 -4.61) 14.48
1965 3.10 76.9 1.90 4.03 2.86
-1.30 O.OCl -l.b..! 1.1.93
1966 1.t:O 61.4 1.90 2.21 3.80
0.60 -2.90 1.90 -6.9&
1967 2.40 57.3 -1.00 4.1'1 -3.1tJ
t:D -0.40 . 1.60 -1.2\i 4.4d
I 1968 2.00 67.0 0.60 2.99 1.30
ex:>
0\ C.4C 0.09
1 'J 69 2.40 76.0 3.08
YEAR UhITS TOTAL. DY1 DY2 OY3 PERCENT UY1 DY2 DY3
1962 2.00 877.0 0.23
0'.00 -O.C/v
1963 2.00 679.0 5.00 0.23 C.45
5.00 -13. au U.4~ -1.20
1964 7.CO 1033.0 -8.00 0.66 -"'.15
-3.00 10.UO -0.3i.1 0.93
1965 4.00 1055.0 ,.00 ' 0.38 ,','0.16
-l.CO -3.00 -0.12 -1./.19
1966 3.00 1165.0 -1.00 0.26 :~..o. 0,
-2.00 5.00 -0.14 v.31
1961 1.(,;0 839.0 4.00 0.12 C.)!1
2.00 -4.\)0 O.Zl -1./.41
1968 3.00 908.0 0.00 0.33 -o.()o
,2.00 Ool~
1969 5.00 1043.0 0.48
"OTE** CY1 . FIRST DI FFEREiKE'
DYZ . SECO~D DIFFERENCE
DY3 . THIRD DIFFERE~CE
-------
E R I E C I T Y E 0'1 E R G Y 0 I v.
l U R ,~ I N D U S T R I E S. I N C.
I:'-iDuSTIHAL. WATERTUI::t: bOIL.E~S. DISTklbUTION A~ T;j STEAM TEJI.'PE~ATUkE l",Z~ + -- F
YEAR CAP. TOTAL. DYI DYZ DY3 "'EHCENT !JYl UY2 DO
1<]62 (ielO 43.3, 0.23
-O.lv -0.2:;
19!>3 0.00 50.5 0.10 0.00 0.23
O.Ou -0.10 O.:';v -u.23
1'J64 CI.iJO 72.3 O.Ou u.uo O.UU
. 1,).0u u.uu u.\.:v v.uo
1'.165 0.00 76.9 0.00 li.UU O.UO
0.01,) 0.10 o.tlu u.17
19b6 0.(,,0 !!1.4 (;.10 O.uu C.17
0.10 -C.IJ liol"i -"'.2;;)
1%7 OelO 57.3 .0.00 0.17 -0.05
O.lv -0':;0 0.1~ -v. :;"
h68 C.20 67.U -0030 0.3(.1 -0.42
tII -0.20 '-o.:;\,;
I
co 1 9 ()Cjl 0.00 7A.0 0.00
-.:J
YEAR U... ITS TOTAL DYI DYZ DY3 PERCENT DY1 OY2 OY)
1'162 l.vO 877.U 0.11
-1.00 -0.11
1<]63 U.CG 879.u 1.00 o.o\) C.ll
0.00 -1. vO 0.',) -U.11
1'1164 .:>.00 1033.0. O.Ov 0.00 0.00
0.0,) O.UO O.u... U.i.lO
1965 C.OO 1055.0 0.00 O.'UO 0.00
0.0" 4.00 O.Uv (".41f
1966 0.(,0 I1b5.0 4.00 0.00 (;.4&
4.00 -8.00 O.4t1 -V.'J'J
1'J67 4.UO ':13').0 -4.00 0.4!! -0.51
0.00 0.00 -u.e.. v.11
1'J6A 4.UO 9uB.0 -4.00 0.44 -U.40
-4.00 -0.4'+
1969 O.uO 1043.0 0.00
NoTE** DYI . FIRST DIFF(kEi~CE
DY2 . SECOND DIFFt:REi~CE
DY3 . THIRD DIFFEREt\CE
-------
APPENDIX V
BASE FUELS
B-89
-------
E R I E C I T Y E 1'1 E E G Y 0 I v.
l U R N I N 0 U S T ~ I t. ,!). I N C.
INDUSTRIAl. ~ATEIHU~E aOIL.I::RS. DISTRI8UTION AS TO BASI:: FUeL.S - 8 I TU.~: l"OU5 CvAL
VEAR CAP. TOTAL DV1 DY2 DV3 PfRCEIXT vvl OY2 DYJ
1<,/62 7.30 43.3 1t..llb
2.70 2.';"
1963 10.1.10 50.5 1.40 19.tlO -3.24
4.10 -7.~O -O.3~ -\1.22
1CJ64 14.10 72.3 -6.10 19.!:I0 -j...7
-2.:>0 1.tlO -~.77 -1.;;1
196~ 12'.10 76.9 -4.30 15.73 -4.04
-6.3iJ 9010 -d.t..l 1).03
1..,66 5.80 tll.4 4.80 7.13 b. 01 FFEREr,CE
DY3 D THIRD DIFFERENCE'
-------
E R I E C I T Y E t. E R G Y D I v.
t. U R r; I N D U S T R I E S. I N C.
INDUSTRIAL 'tiATERTU~E ElOIL.EHS. DISTRldUTION AS TO BASE FUI:.L.5 - OIL
.YEAH CAP. TOTAL. DY1 DY2 DY3 PEHCENT DY1 OY2 DY3
l'i6l 26.10 .43.3 bO.2ij
-13.80 -;'!J.9~
1963 12.30 50.5 17,.50 24.36 33.6CJ
3.7v -19.80 -2.23 -;,u.CJ7
1964 '16."0 72.3 -2.30 22.13 2.72
1.4~ 2.10 ".~iJ -J.JU
1'i65 17.'-0 76.9 -0.20 22.63 -iJ.27
1.2U -b.20 U.Zl -l.CJli
lSobe) H.60 .81.4 -6.'-0 l2.8!J -3.18
-7.20 19.ih) -2.9;) "'.!jl
1<;67 11.40 57.3 11.40 l''i. "'0 6.34
4.20 -17.90 3.3'1 -1~.1J6
tP 11J68 1~.60 67.0 -6.50 23.28 -9.62
I -2.30 -6.23
\0 1969 13.30 7E1.0 17.0~
I\)
Yt;;A~ u.dT5 TOrAL OYl DY2 DY3 PEHCENT DY1 DY2 DY3
1962 ~92.00 877.0 67.50
-329.00 -37.!Jd
1%3 263.00 879.0 363.0p 2':1."'2 36.41
34.CC -3 DIFFEREi\CE
DO . THlqD DIFFERENCE
-------
E R I E C J T Y E I't E R G Y D J v.
l U R N I N !) U S T R I I; S. I r.. C.
INOUSTRIAL ",AT£RTU~E BOILERS. ;) I S TlH au T I O~I AS TO BASE FUt:LS - GAS
YEAR CAP. TOTAL DYI DY2 DY) PERCEtliT L)Yl DV2 DV3
1962 ~4.20 43.:J ~5.ij'J
-4.00 -15.b'7
1'J63 20.20 50.5 13.40 40.VU 16.!!3
'i.40 -17.80 \i.9.. -D.72
196" 29.60 72.3 -4.40 40.94 :J.11
5.uU 10.00 ".J~ ;'.31
1965 34.60 76.9 5.6;) 44.9
-------
E R I E C I T Y E N E R G Y D I v.
l U R N I N D U S T i< I E S. I N C.
Ir-.DuSTRIAL ~iA T£RTU~E BOILERS. DISTRJOUTION A:" Tv BASE FUELS - I\'vvD
YEAR CAV. TOTAL DY1 DY2 DY3 PE~CE::o\T OY1 OY2 DY)
1962 0.80 43.3 1.tI~
-0.10 -U.4b
1963 0.70 ~O.5 0.50 1.39 0.60
0.4u -1.50 0.14 -1.bO
1964 1.10 72.3 -1.00 1.52 -1.01
-0.60 1.20 -1.1.1:17 i.35
196~ (;.~O 76.9 C.2t; 0.65 CI.34
-0.4v 1.\010 -\;.5:; J..b~
1966 ColO 81.4 1.20 0.12 1.'iij
0.8(.; -1.50 1.4~ -2.<,;0
1'167 0.90 57.3 -0.30 1.51 -'1.'>13
0.50 C.70 0.5, 1.27
1'ihR 1.40 67.0 0.41.1 2.09 C.34
td 0.90 O.Ob
I 1969 2.30 78.0 2.95
'"
.J:-
YEAR UidTS . TOT AL DV1 DY2 l>V3 PERCENT vY1 UY2 Dn
1962 13.00 !H1.0 1.4M
-6.00 -0.6'»'
1963 1.CO A79.0 11.00 0.110 1.05'.
5.00 -15.vtl 0.3.' . -1.3~
1964 12.00 1033.0 -4.00 1016 -v.29
1.00 -7.00 0.01 . -(j~75
1'>165 13.00 .1055.0 -11.00 1.23 -1.05
-10.00 23.00 -0.97 2.3b
1966 3.00 1165.0 12.00 0.26 1.31
z.ou -6.uO 0.3" -u.tl2
1967 5.00 f\39.0 6.0;;; O.bu O.~O
8.00 -8.00 O.tj'+ -v."',,
"1968 13.00 908.0 -2.00 h43 -U.45
6.00 0.3'>'
1969 19.00 1043.0 1.82
NOTE** DY1 . FIRST DIFFEI\Ei,CE
. DY2 .. SECOND DIFFERENCE
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y E r. E R G Y D I v.
I. U R N 1 ~I [) U S T R 1 E Sf 1 N C.
I:IIDUSTfUAL. 'liATERTUBE t30ILf.!.23
-Cl.2C 0.70 -\.1.2:> 1.."'2
1967 0.00 57.3 0.50 o.uo 0.6'1
0.3(; 0.20 0.4~ U.08
1968 C.30 67.0 0.70 0.45 0.77
tD 1.00 1.2 34.00 -1.7:' 2.'11
1965 2.00 1055.0 18.00 uo1CJ 1.73
O.JCI -lO.OCl -0.(;, -1.88
1966 2.\>0 1165.0 -2.00 u017 -0.15
-2.00 7.0,,;{) -\.1.17 "'.bb
1967 o.co 83<;.0 5.00 U.I.IO 0.50
3.00 -5.00 0.3J -CJ.5~
1968 3.00 9011.0 o.co 0.33 -0.0<;
3.00 0.24
1969 6.00 1043.0 0.58
NOTE** DYl II FIRST DIFFERE;\ICE
'DY2 II SECO\D DI FFEREt.CE,
DY3 II THIRD DIFFERENCE
-------
E R I E .c I T Y E ii t:: R u Y D I v.
lUR,\ I t4 D U 5 T ~ I E S. I /II C.
l~DUSTRIAL. wATERTUBE bOIL.ERS. DlST~loUTION A:;' Tv BASI; Fu~L.S - ~L.ACI<. L.IQUUI<
YEAR CAP. TOTAL DY1 DY2 DY3 PEHCEi\T DY1 DY2 DY3
1962 1.10 43.3 2.~4
2.30 4.1'>1
1963 3.40 50.5 -2.20 6.73 -6.(;8
0.10 3.70 -1.bo:i <;.77
1964 3.50 72.3 1.~O 4.84 3.66
1.60 -3.40 1. "/y -0.21
1965 5.1(' 76.9 -1.90 6.63 -2.~3
-C.3~ -1.90 -0.14 -1.41
1966 4.80 81.4 -3.80 5.<;0 -3.~4
-4.10 9.3U -4.bb hl.~3
1967 0.70 57.3 5.50 1.22 6.59
1.40 -5.40 1.91 -1.\)2
1\168 2.10 67.0 0.10 3.13 -C.43
1.~0 . 1.4CS .
tJj 1969 3.60 78.0 4.62
I
\0
0'\
YEAQ U~. 1 T S TOTAL DY1 DY2 DY3 PERCENT Dv 1 l)Y2 DY3
1962 e.co A77.0 0.'>11
8.0u 0.91
1963 16.00 879.0 -12.00 1.82 -1. ~7
. -4.0u 23.\J0 -0.66 2.86
1964 12.00 1033.0 11.0U 1.16 1.30
1.:)0 -20.vO v.b4 -2.28
1965 19.00 105!:i.O -9.0C 1.80 -0.98
-2.00 -2.00 -«.i. 34 "'.34
1966 17.<.;0 1165.0 -11.UO 1.46 -1.1.64
-13.UO 29.(,;(" -v. ':.1o ~.14
1~67 4.(1) 839.0 18.00 0.48 1.~0
5.00 -20.00 u.!:ii -1.85
1963 Si.vO 9CIt!. 0 -2.00 0.\19 -0.36
3.00 0.1e.
1969 1.2.00 1043.0 1015
,,,orE** DY1 . FIRST DIFFEREt-.CE
DY2 . S~CO~D DIFFERE~CE
DY3 . THIRD DIFFERE~CE
-------
E R I E C I T Y E N ERG Y D I v.
l URN I N D U S T R I t: 5, I /It C.
INDUSTRIAL WATERTUBE f:jOILt;:I~S, DISTRI~UTION AS TO BASE FUELS - OTHER
YEA~ CAP. TOTAL DY1 DY2 DY3 PERCENT DYl OYZ 0'1'3
1962 5.30 43.3 12.24
-3.30 -d.20
1<}63 2.00 50.~ 7.30 ~."'6 12.62
4.00 -10.~0 4.3'+ -16.1:1
1964 6.UO 72.3 -3.00 tI.3u -3.5~
1.0v 1.70 o./iU 1. tH~
1965 7.00 76.9 -1.30 YolO -1.6"
-0.30 -0.10 -u.61 ~.C4
1966 6.70 81.4 -1.40 tI.23 1.37
-1.70 2.uO O.~" -4.77
1967 5.00 57.3 0.60 8.73 -3.40
-1.10 4.20 -2.<;1 1u.23
1968 3.90 67.0 4.80 5.82 6.b)
3.70 . 3.92
t:d
I 1Y69 7.60 78.0 Y.74
\0
-4
YcAR ur.d T 5 TOTAL OY1 DY2 DY) PERCENT L>Y 1 UY2 0'1')
1962 77.QO B77.0 8.78
-40.00 -4.~7
1963 37.(;0 P.79.0 74.00 4.21 7.23
34.00 -119.00 2.6u -11.08
1964 71.00 10:;3.0 -45.00 6.67 -3.85
-11.00 58.00 ~1.1'J 4.67
1965 6:).00 1055.0 13.00 5.69 O,6Z
2.00 -:38.00 -0.37 -1.13
1
-------
APPENDIX VI
ALTERNATIVE FUELS
B-99
-------
E R I E C I T Y ENE R G Y D 1 v.
Z URN I N D U S T R I E S, I N C.
INDUSTRIAL WATERTUbE BOILERS, DISTRI~UTION AS TO ALT. FUELS - B ITUM I NOUS CuAL
YEAR CAP. TOTAL DY1 DY2 DY3 PERCENT UYl DY2 on
1963 0.40 50.5 0.79
0.00 -u. 24
1964 C.40. 7203 -0.20 0.5~ -1,).05
-0.20 O.~O -0.29 v.46
1965 0.20 76.9 0.30 0.2(. 0.40
".lC -O.bU (Jell -u.71J
1966 0.30 81.4 -0.30 0.37 -0.30
-0.20 0.60 -0.19 CJ.62
1967 0010 57.3 0.30 0017 C.32
0.10 -O.~Q 0.12 -1J.bl
td 1968 0.20 67.0 -0.20 U.3U -U.29
I -0.10 -0.17
f-I 1969 C.10 7i3.CJ 0.13
0
f-I
YEAR U,'UTS TOTAL DY1 DY2 DY3 PERCENT LJY1 DYZ DY3
1963 6.00 879.0 O.bt!
-4.00 -0.4'01
1964 2.00 1033.0 .7.00 O.lY 0.71
3.00 -13.00 0.21; -1.35
1965 5.00 1055.U ~6.00 0.47 -0.58
-3.00 9.00 -0.3U u.lJ~
1966 2.00 11650U 3.00 ' 0.17 0.37
0.00 -3.00 o.c -, -U.4~
1967 2.00 839.0 0.00 0.24 -0.08
0.00 1.00 -u.Oi 0.17
1968 2.00 908.0 1.00 0.22 0.09
1.00 0.07
1969 3.00 1043.0 0.29
ttOTE** DY1 = FIRST DIFFERENCE
DY2 . SECOND DI FFE.RENCE
DY3 .. THIRD DIFFERENCE
-------
E R I E C I T Y E f'4 ERG Y 0 I v.
l. URN I N D U S T R I E S. I N C.
INOUSTRIA~ WATERTUBE 80 I LE,RS. DISTRIBUTION AS TO A~T. FUE~S - OIL
YEAR CAP. TOTAL DY1 OY2 OY3 PEHCEf'4T OYl DY2 OY3
1963 11.40 50.5 34.46
3.30 -S.84!
1964 20.10 12.3 3.30 28.63 12.69
6.60 -10.70 6.8"/ -22.51
1965 21.30 76.9 -7.40 35.50 -9.82
-0.80 6.00 -2.9~ 22.61
1966 2£,.50 81.4 -1.40 ~2.56 12.80
-2.20 8.90 9.85 -2lJ.88
1967 24.30 51.3 7.50 42.41 -0.08
~.30 -2.40 1.77 1:;.41
td 196/1 29.60 67.0 5.10 . 44.1ij 5.33
I
I-' 10.40 7.1u
0 1969 4~hOO 18.0 ~1.28
I\)
YEAR Uf\ITS TOTAL DY1 DY2 DY3 PERCENT DY! DY2 OY3
1963 321.00 e19.0 36.52
45.00 -1."9
1964 ~66.00 1033.0 28.00 35.43 7.27
13.00 -41.00 6ale -12.23
1965 439.00 1055.0 -13.00 41.61 -4.~6
60.00 -115.00 1.22 12.21:f
1966 4<)9.00 1165.v -128.00 42.1:f3 7.32
-68.00 261.00 ij.54 -12.60
1967 431.00 839.0 133.00 51.31 -5.28
65.00 -100.00 3.2~ 4.35
1966 496.QO 909.0 33.00 54.63 -0.93
96.00 2.33
1969 594.00 1043.0 56.95
NoTE** DY1. FIRST DIFFERENCE
DY2 D SECO~u DIfFERE~CE
DY3 = THIRD DIFfERENCE
-------
E R I E C I T Y ENE R G Y D 1 v.
l URN I N D U S T R I E S. I N C.
INDUSTRIAL WATERTU~E EIOILERS. OISTRItiUTIOf\; AS TO ALT. FUELS - GAS
YEAR CAP. TOTAL DY1 DYZ DY3 PEHCEI'.T DYl OY2 OY3
1963 8.10 50.5 16.0'+
1.30 -:;.04
1964 9.40 72.3 1.90 13.VO 6.42
3.20 -,.60 ~.30 -11 d3
1965 12.60 76.9 -3.70 16.38 -4.90
-0.50 -3.40 -1.~~ -0.59
1966 12.10 81.4 -7.10 14.66 -5.4~
-7.60 15.10 -7.01 11.'i6
1967 4.50 57.3 8.00 7.85 {H47
0.40 -4.70 -0.54 -2.22
1961:\ 4.90 67.0 3.30 7.31 4.25
td 3.70 3.71
I
~ 1969 8.60 78.0 11.03
0
LV
YEAR UNITS TCTAL DY1 DY2 DY3 PE~CENT OVl DYZ DY3
1963 101.00 R79.0 11.4\1
12.00 -0.5~
196'+ 113.00 10:;3.0 -3.00 10.94 1;18
9.00 -7.00 0.62 ':2.98
1965 122.00 1055.0 -10.00 11.56 -1.80
-1.00 =61.00 -1-lti -1.57
1966 121.00 11b5.0 -71.00 10.39 -3.37
-72.CO 144.00 -4.5~ 1.58
1967 49.00 839.0 73.00 5.84 4.21
1.00 -60.00 -0.33 -3.25
'1968 50.00 908.0 13.00 5.51 O.'i6
14.00 0.63
1969 64.00 1043.0 6.14
NOTE** DY1 D FIRST DIFFE~ENCE
DY2 D SECOND DIFFERENCE
DY3 = THIRD DIFFERENCE
-------
E R I E C I T Y E I'll ERG Y 0 I v.
l URN I N 0 U S T R I E S, 1 N C.
INDUSTRIA~WATERTU~E BOIL.ERS, DISTRIBUTION A~ TO A~T. FUELS - WOOD
YEAR CAP. TeTAL DY1 DY2 DY3 PERCEt-.T i.)Yl DY2 DY3
1963 0.60 5e.s 1.11j
-0.40 -0.91
1964 0.20. 72.) 1.90 0.21:1 2.65
1.50 -3.40 1.9~ -4+.'10
1965 1.70 76.9 -1.50 2-21 -2.0b
0.00 0.00 -0.12 0.44
1966 1.70 81.4 -1.50 z.o? -1.62
-1.50 3.10 -1.74+ 3.4b
1967 0.20 57.3 1.60 U.35 1.&4
0.11J -1.90 v.l0 -l.2b
1968 0.30 67.0 -0.30 U~45 -0.42
a1 -0.20 -0.32
I 1969 0.10 79.0 0.13
......
0
+:-
YEAR UN ITS TOTA~ DY1 OV2 DV3 PERCENT DVl Dv2 DY3
1963. 4.00 879.0 0.46
z.oo 0.1~
1964 6.00 ~033.0 -1.00 0.58 -0.U4
1.00 -3.00 a.Ob -0.30
1965 7.00 1055.0 -4.00 0.66 -0.40
-3.00 5.00 -U.3C: U.02.
1966 4.00 1165.U 1.90 0.34 ' 0.22
-2.00 1.UO -0.1U -0. 13
1967 2.00 839.0 2.00 0.24 0.09
0.00 -2.00 -0.02 -0.10
11j68 2.00 908.0 0.00 u.22 -0.01
0.00 -0.03
1969 2.00 1043.0 u.19
NoTE** DY1 . FIRST DIFFERENCE
DY2 . SECOND DIFFERENCE
DV3 D THIRD DIFFERENCE
-------
E R I E C I T Y E N E R G Y D I v.
Z U R N I N D U S T R I E S, I N C.
INDUSTRIAL ~'IATERTUUE BOILE.RS, DISTRIBUTION A~ TO ALT. FUELS - BAGASSE
YEAR CAP. TOTAL DY1 DY2 DY3 PE~CENT Oyl DY2 DY3
1963 OalO 50.5 0.20
-0.10 ";'0.2v
1964 0.00 72.3 0.10 0.00 1.1.20
O.JO -0.10 0.01) -0.20
1'.,165 0.00 76.9 0.00 0.00 0.00
0.00 0.00 0.(,;1,) u.oo
1966 0.00 81.4 0.00 o.vo 0.00
0.00 (i.OO 0.0.., 0.1.10
1967 0.00 51.3 0.00 0.00 0.00
0.00 0.1)0 o.eu 0.00
tP 1968 0.00 67.0 0.00 o.vo u.oo
I
~ 0.00 o.c~
0
VI 1969 e.CiO 78.0 0.00
YEAR UN ITS TOTAL DY1 DY2 DY3 PEHCENT DY1 I)Y2 DY3
1963 2.00 879.0 0.23
-2.00 -0.2~
1964 0.00 10;:'3.0 2.00 0.00 u.23
0.00 -2.00 o.ou -O.2~
1965 (;.00 1055.0 0.00 (J.OO 0.00
O.Ou 0.1,)0 u.u.., 0.00
1966 0.00 1165.0 0.00 0.(.10 '-i.lIO
0.00 0.0(; U.vu "'.00
1967 0.00 839.0 0.00 0.(.10 0.00
0.00 0.00 o.ou 0.00
1968 0.00 908.0 0.00 0.00 0.00
0.00 0.01.1
1969 0.00 1043.0 0.00
NoTE** DY1 = FIRST DIFFERENCE
DY2 D SECOND DIFFERENCE
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y E N ERG Y 0 I v.
i. URN I N 0 U S T R I E S, I N C.
INDUSTRIA~ WATER TUBE BOILERS, OISTRIBUTION AS TU A~T. FUE~S - B~ACK. ~laUOR
YEAR CAP. TOTAL on DY2 DY3 PERCENT [lY1 OY2 OY3
1963 0.00 SO.5 o.ou
0.00 O.(;U
1964 0.00 72.3 0.00 o.()o 0.00
0.00 0.00 u.00 0.00
1965 0.00 76.9 0.00 0.00 0.00
0.00 O.iJO O.Ov o.uo
1966 c.oo 81.4 0.00 O.CJO 0.00
0.00 (;.10 0.00 0.1~
1967 0.00 S7.3 0.10 0.00 0.15
b:I 0.10 -0.30 0.1~ -0.4!)
I 1968 0.10 67.0 -0.20 0.15 -0.30
I-' -0.10 -0.15
0
Q\ 1969 0.00 7B.0 0.00
YEAR ur~ ITS TOTA~ DY1 . DY2 DY3 PERCE,...T OY1 IJY2 DY3
1963 0.00 879.0 0.00
0.00 c.uu
1964 0.00 1033.0 0.00 0.00 0.00
0.00 0.00 c.cu 0.00
1965 0.00 10S5.o 0.00 0.00 (i.00
0.00 0.00 0.00 v.uu
1966 O.UO 1165.0 0.00 0.00 0.00
0.00 1.00 o.ou U.11
1967 0.00 839.0 1.00 0.00 . 0.11
1.00 -3.00 0.11 -0.33
1968 1.00 9(;8.0 -2.00 0.11 -0.22
-1.00 -0.11
1969 0.00 1043.0 O.CJO
NoTE** DY1 . FIRST DIFFERE""CE
DY2 a SECOND DIFFERE~CE
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y D I v.
l. URN I N D U S T R I E S, I N C.
INDUSTRIAL. 'iJA TERTuaE BOIlE~S, DISTRIBUTIOh A~ TO AL.T. FUEL.S - OTHER
YEAR CAP. TOTAL. DYl DY2 DY3 PERCENT OY1 DY2 DY3
1963 2.20 50.!; 4.36
1.80 1.10
1964 4.00 72.3 -1.30 !;.53 -0.86
0.50 4.70 0.32 ~.u1
1965 4.50 . 76.9 3.40 5.e5 4.15
3.90 -13.~0 4.47 -1~.10
1966 6.40 . e 1.4 -10.10 10.32 -10.~5
-6.2e 15.20 -6.41; 1~.2:i1
1967 2.20 57.3 5.10 3.84 4.28
-1.10 -4.20 -2.20 -2.57
t:D 1968 1.10 67.0 0.90 1.64 1.71
I -0.20 -0.4<;
...... 1969 0.90 78.0 1.15
0
~
YEAR Ut\lTs TOTAL DYl DYZ DY3 PERCENT DY1 DY2 DY3
1963 19.00 879.0 2d6
14.00 1.0~
1964 33.00 1033.0 -25.00 3.19 -2.14
-11.00 62.00 -1.11 5.29
1965 22.00 1055.0 37.00 2.09 3.14
26.00 -96.00 2.03 -7.51
1966 48.00 116~.0 -59.00 4.12 . -4.37
-33.00 87.00' -2.33 6.01
1967 15.00 A39.0 28.00 1.79 1.65
-5.00 -24.00 -0.69 -1.20
1968 10.09 908.0 4.00 1dO 0.45
-1.00 -0.24
1969 9.CO 1043.0 0.b6
NoTE** DY1 " FIRST DIFFERENCE
DY2 .. SECOND DIFFERENCE
Dn .. THIRD DIFFERENCE
-------
APPENDIX VII
FIRING METHOD
B-I09
-------
E R 1 E C 1 T Y t:: :'i E R G Y D 1 v.
l U R N 1 N l> U S T ~ 1 E S. 1 ~ C.
1r..l>uSTRIAL. '"A TERTUBE BOIll:.r
-------
E R 1 E C 1 T Y t:: N E R G Y D I v.
l URN I N D U 5 T R I E S. I N C.
INDUSTRIAL WATfRTU~E BOILl::RS. DISTRIBUTIOr. A~ TO FIRING ~e:THOD - SPRI;;AOI:.R
YEAR CAP. TOTAL l)Y1 DY2 DY3 PE~CENT IJY1 UY2 DY3
19h1 4..99 1.0..6 12.2\1
-0.49 -1..""
1962 4.50 43.3 2.29 10.~y 3....8
. 1.80 .,,:,1.~Y2 DY3 PEI-0 -3...1' . ~.tl3
1965 60.CO 10~5.0 16.00 ~.69 1.30
-15.00 -25.00 -1.112 -U.b3
.1966 45.00 1165.0 -9.00 3.116 0.46
-24.00 27.00 -1.3b li.O"
1967 .21.00 R39.0 18.00 2.50 C.:;'1
-6.0v -4.00 -U."~ u....u
1'168 15.(,;;0 9U8.0 14.01> 1.6~ ' 1.40
8.00 U.:I:I
1969 23.00 1043.0 2.21
NOT E.- DY1 . F I,~S T OIFFERENCI;. DY2 . SECOI'\IJ 1>1 FFI:.~~NCI:. l)Y) . THIHIJ l)IFFE~I:.t.CI:.
-------
t:: R I E C I T Y E~ E R G Y D I v.
L. U R N I N CJ U S T ~ I E S. 1 :-. C.
INDUSTRIAL. 'NATt:;RTUI:!!:: 801L.I:I-Y3 PERCENT DYl !JY2 DY3
1~61 37.00 787.0 4.70
-21.00 -2.t!~
1962 16.00 877.0 25.00 1.tl2 3.33
4.00 -35.U(,i (,i. 4:;' -4.1U
1963 lO.liO' 879.0 -10.00 2.2t1 -1.37
-6.00 13.00 -0.:;, 1.<;ti
l'i64 14.00 1033.0 3.00 1.:16 Ioi.bl
-3.00 1.iJO -0.31 -v.31
1965 11.00 1055.0 4.00 1.04 0.30
1.0v -14.iJC -v.~l -(,i.";b
1966 12.CO 1165.0 -10.CO 1.03 -U.66
-9.00 23.00 -U.<.ol 1.7~
1967 3.00 839.0 13.00 0.3b 1.09
4.00 -23.0C O.4~ -2.17
1':i6'3 7.00 90A.O -10.00 0.77 -1.09
-6.00 -0.60
1OTE.- DYl " FIRST IJIFFERENCl: DY2 .. SECOND DIFF~RE~C!:: DY3 a T~IH~ ~IFFE~t~C~
-------
E R I E C I T Y E f'. E R u Y D I v.
l U R i\ 1 N 0 U S T t{ I l S. I.~ C.
INDUSTHIAL 'ifATERTUBE BOILERS. OISTklBUTION AS TiJ FIKINu 'oIl:, Tt1UD - UVEkFEEO
YEAR CAP. TOTAL DYI DY2 OY3 PE~ClNT OYl OY2 on
1961 1."'76 40.6 4.33
-0.36 -1.1iJ
19hZ 1.40 43.3 1.06 3.2J l.Cl3
.0.70 -3.06 O.y~ -u.~U
1 '}63 2.10 50.~ -2.CO 4.10 -J.':I~
. -1.3U 3.70 -;;.v:' ".4fj
1964 :0.80 72.3 h70 1.11 3.!>1
0.4U -2.10 \J . ...~ -4.1b
1965 . 1.20 76.9 -1.00 1.!>b -1.2b
-O.bU 1.50 -O.cS~ 2.24
1966 0.60 81..4 0.50 0.14 (.It 1.09
I 0.30 o. ;, O'
~ 196'i 0.40 711.0 0_51
~
..".
YEAR Uid T ~ TOTAL DY1 OYZ DY3 PE~CENT uvl DY2 DYJ
1961 47.00 71:S7.0 !>.o;1
-12.00 -1.lid
1C;62 35.UO 877.0 12.CU 3.'ic} 1.'117
O.OIJ -40.vO -0.1.11 -!>.27
1963 35.\.10 R79.0 -28.00 3.98 -3.)0
-28.00 73.~U -3.3..: d.20
1'Jt64 7.00 1033.0 45.00 O.bb 4.'il0
17.CV -77.\)0 1.t-v -tl.UU
1965 24.CO 1055.0 -32.00 2.27 -3.10
-l!>.OU )9.0u -1.~v ).9!1
1966 9.00 1165.0 7.00 0.7"1 V.d5
-8.00 3.~O -U.b:l c...U2
1967 1.00 839.0 10.00 0.12 0.66
2.00 -8.UO 0.21 -v. 74
1 '} 6ij 3.00 908.0 2.0U 0.33 U.13'
4.0U 0.)4
1969 7.00 1043.0 0.67
NOTE** OYl . FlttST OIFFEkENCf DY2 . SECOI~L> OIFFlRE::NCt;. un . THINO OIFFE~t;.~Ci
-------
E R I E C 1 T Y I:. '" E R G Y D I V.
I. U R N I N D U S T R I E S. I N C.
INDUSTRIAL ,.;AH:,RTUEiE t:lOILI::./{S. ::> IS T;{ II:).JT 101\1 A~ TU FIRING r--ETI1UD - OTttc:.R
YEAR CAP. TOTAL DYl OY2 UY3 PEHCENT UYl UY2 un
12 2.~0 43.3 -2.40 ,,:>.77 -~.9b
-o.~v 3.10 -2.4.1. 'r. i2
1963 1.70 50.!! 0.70 ~.37 1.~~
-0.10 -1.20 -1.1:1 -1."1
1964 1. (,0 72.3 -o.~o 2.21 v.24
-G.6v 1.60 -u.'J~ 1.21
1'765 1.00 76.9 1.10 1.~1.I 1.45
0.50 -0.61.1 0.,4 u.~i
1 0 4.36 -~.39
ttJ -1.!i0 4.10 ';'2.1:1'/ ti.17
, I 1'i6~ 1.<;0 66.9 1.60 1.49 2.78
..... 0.10 -0.00
.....
V1 1"'69 1.10 78.0 1.41
YEA~ Ul',1 TS TOTAL DY1 DY2 DY) PERCENT I)Yl DY2 DY)
1961 25.00 7t17.0 3.18
2<).00 2.'10
11,;62 54.00, 877.0 -!i9.00 6.16 -6.41
-30.00 83.UU -3.4;' tI.tI~
11,;63 24.CJO 879.0 24.00 2.73 2.44
-6.00 -29.UO -o.y"" -Z.~3
1964 1thuO 1033.0 -5.00 1.74 -0.09
-11.00 25.01.1 -1.00 1.blS
1965 7.00 11J55.0 20.00 0.66 1.79
9.0U -23.01.1 ".71' , -1 . 2'~
19b6 16.00 1165.0 -3.1.10 1.37 0.~4
6.01.1 -11.00 1.2t1 -2.tJ7
1967 22.00 R39.0 -14.1.10 2.62 -2.33
-8.0U 2U.iJO -1.uo ;).02
1IFFERE~Cl un .. Trill
-------
APPENDIX VIII
MARKETS
B-117
-------
E R I E C I T Y ENE R G Y 0 I v.
l. URN 1 N 0 U S T R 1 E S. 1 N C.
INDUSTRIAL \oiATERTUBE BOILERS. DISTRIBUTION AS TO ~ARIC.ETS NON-r-~FG
YEAR CAP. TOTAL DY1 DY2 DY3 PERCI::NT :>Y1 OY2 OY3
1964 1!1.40 72.3 21.30
0.20 -1.01
1965 15.60 76.9 .1.20 20.29 1.61
1.40 -5.70 0.6U 1.16
1966 17.00 81.4 -4.50 20.88 2.78
-3.10 7.40 3.37 -Y.96
1967 13.90 57.3 2.90 24.26 -7.18
-0.20 2.40 -3.61 14.65
1968 13.70 67.0 5.30 20.45 7.47
5.10 3.6!i
1969 18.80 78.0 24.10
b:I
I
I--'
I--'
\0 YEAR U1\ITS TOTAl. OYl OY2 on PERCENT OY1 OY2 OY3
1964 382.00 1033.0 . 36.Y8
-27.00 -3.33
196!i 355.00 1055.0 78.00 33.65 4.53
51.00 -221.00 1.20 -3.16
1966 406.00 1165.0 -143.00 34.85 1.38
-92.00 227.00 2.!:I& -7.68
1967 314.00 839~O 84.00 37.43 -6.30
-8.00 22.00 -3.73 1!i.06
1968 306.00 908.0 106.00 33.70 8.76
98.00 5.03
1969 404.00 1043.0 38.73
NoTE..1t OY1 . FIRST DIFFERENCE
OY2 . SECOND DIFFERENCE
DY) . THIRD DIFFERENCE
-------
E R I E C I T V ENE R G V 0 I V.
l URN I N 0 U S T R I E S, I N C.
INDUSTRIAL WATERTU~E BOILERS. DISTRI~UTION AS TO MARKETS CHEMICAL
YEAR CAP. TOTAL OYl DY2 DV3 PERCENT Dvl DV2 Dn
1964 15..20 72.3 21.02
0.60 -O.loij
1965 15.80 76.9 -1.40 20.55 -1.64
-0.80 -1.10 -2.1, !».7~
1966 15.00 81.4 -2.50 lij.43 4.11
-3.30 4.50 1;.99 -11.00
1967 11.70 57.3 2.00 lO.42 -6.89
-1.30 3.90 ..4.9tj U.49
1968 10.40 67.0 5.90 15.52 8.60
4.60 3.71
1969 15.00 78.0 19.23
td
I
I-' VEAR utI! T S TOTAl. DVI DV2 DV3 PERCENT Dv1 OV2 DY3
f\)
0
1964 132.00 1033.0 12..78
21.00 1.72
1965 153.00 1055.0 -20.00 14.50 -3.01
1.00 -22.00 -1.2a 4.54
1966 154.00 1165.0 -42.00 13.22 1.53
-41.00 73.00 0.25 -3.91
1967 113.C;0 839.0 31.00 13,47 -2.37
-10.00 36.00 -2.12 8.~0
1968 103.00 90e .0. 67.00 11.34 6.12
57,00 4.00
1969 160.00 1043.0 15.34
~OTE** DV1. FIRST DIFFERENCE
DY2 . SECONJ DIFFERENCE
DY3 . THIRD DIFfERENCE
-------
E R I E C I T Y ENE R G 'I' 0 I V.
Z URN I N D U 5 T R I E S. I N C.
INOUSTRIA~ WATERTUBE BOI~~RS. DISTRIBUTION AS TO t-1ARKETS PAPER
YEAR CAP. TOTA~ 0'1'1 0'1'2 DY3 PERCENT OY1 0'1'2 0'1'3
1964 11.10 72.3 1!1.35
2.20 1.94
1965 13.30 76.9 -3.40 17.30 -4.37
-1.20 0.10 -2.43 5.20
1966 12.10 81.4 -3.30 14.86. 0.83
-4.50 9.40 -1.60 1.24
1967 7.60 57.3 6.10 13.26 2.07
1.60 -4.40 0.47 -~.Z40
1968 9.20 67.0 1.70 13.73 1.83
3.30 2.29
1969 12.50 78.0 16.03
'" I.
td YEAR U;'\I T S TOTAL DY1 DY2 0'1'3 PERCENT Dvl DY2 0'1'3
,
f-'
f\) 1964 71.00 1033.0 6.87
f-'
5.00 0.33
1965 76.00 1055.0 11.00 7.20 0.36
16.00 -63.00 0.6'1 -2.211
1966 92.00 1165.0 -52.00 7.'10 -1.92
-36.00 91.00 -1.22 2.96
1967 56.00 839.0 39.00 6.67 1.05
3.00 -22.00 -(l.1b 0.21
1968 59.00 908.0 17.00 6.50 1.25
20.00 1.08
1969 79.00 1043.0 7.57
NOTE-- 0'1'1. FIRST DIFFERENCE
0'1'2 . SECO~D DIFFERENCE
0'1'3 . THIRD DIFFERENCE
-------
E R I E C I' T Y ENE R G Y D I V.
Z.U R N I N D U S T R I E S. I N C.
INDUSTRIAL WATERTUBE fiOILERS. DISTRIBUTION AS TO ~ARI(ETS PETRULEUM
YEAR CAP. TOTAL DY1 DY2 DY3 PERCENT DYl DY2 OY)
1964 6.40 72.3 1:'-65
0.70 0.3d
1965 7.10 76.9 3.00 9.23 3.65
3.70 -12.10 4.C4 -11.53
1966 10.80 81.4 p -9.10 13.27 -7.88
-5.40 15.30 -3.Cl4 11. 5~
1967 5.40 57.3 6.20 9.42 3.67
0.80 -S.40 -0.17 -2.76
1968 ,6.20 67.0 0.80 9.25 0.92
1.60 0.7!»
1969 7.80 78.0 10.V\)
td
I
I-'
I\) YEAR U.'IJTS TOTAL DYl DV2 Dn PERCENT DV1 DY2 DU
I\)
1964 ,71. CO 1033.0 6.87
-14.00 '-1.47
1965 57.00 1055.0 35.00 5.40 2.76
21.00 -79.00 1.29 -4.20
1966 78.00 11(.5.0 -44.00 6.70 -1.43
-23.00 67.00 -0.14 1.07
1967 55.00 8 39 . 0 23.00 6.56 -0.36
0.00 -13.00 -0.5v 1.03
1968 S5.0Q 908.0 10.00 6.06 0.67
10.00., 0.17
1969 65.00 1043.0 6.'23
NOTE** DY1 . FIRST DIFFERE~CE
DY2 . ~ECOND DIFFE~ENCE
DY) . THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y D I v.
l. URN I N D U S T R I E S. I N C.
INDUSTRIA~ WATERTUBE BOI~ERS. DISTRIBUTION A~ TO MARKETS FOOD
YEAR CAP. TOTAl. DYI DY2 DY3 PERCENT DYI DY2 DY3
1964 7.90 72.3 10.93
-0.30 -1.04
1965 7.60 76.9 0.30 9.81:1 O.~O
0.00 -1.90 -O.~~ 1.18
1966 7.60 81.4 -1.60 9.34 1.68
-1.60 5.20' 1.13 -1.35
1967 6.00 57.3 3.60. 10.47 C.33
2.00 -8.20 1.47 -6.b2
1968 8.00 67.0 -4.60 11.94 -6.49
-2.60 -5.02
1969 5.40 78.0 6.92
td
I
I-'
I\)
w YEAR Uf. ITS' TOTAl. DYI DY2 DY3 PERCEI'.T Dyl DY2 DY)
1964 125.00 1033.0 12.10
11.00 0.7'J
1965 136.00 1055.0 -16.00 12.89 -2.44
-S.OC -6.00 -1.6~ 5.23
1966 131.00 1165.0 -22.00 11.24 2.80
-27.00 59.00 1015 -3.79
1967 104.00 839.0 37.00 12.40 -C. 99.
10.00 -82.00 0.16 -4.15
1968 114.00 908.0 -45.00 12.56 -5.110
-35.00 -4.9d
1969 79.00 1043.0 7.57
NOTE** DYI . FIRST DIFFERE~CE
DY2 . SECO~D DIFFERENCE
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y 0 I v.
z- URN I NO U S T R I E S. I N C.
INDUSTRIAL WATERTUBE BOILERS. DISTRIBUTION AS TO ~'ARKETS METALS
YEAR' CAP. TOTAL DY1 DY2 DY3 PERCENT DY1 DY2 Dn
1964 3.40 72.3 4.70
2.50 2.97
1965 5.90 76.9 -2.60 7.67 -3.52
-0.10 -0.30 -0.5~ 1.62
1966 5.80 81.4 -2.90 7.13 -1.69
-3.00 5.60 -2.24 2.78
1967 2.80 57.3 2.70 4.89 1,.08
-0.30 -1.50 -1.16 CI.70
1968 '2.50 67-.0 1.20 3.73 1.78
0.90 0.()3
1969 3.40 78.0 4.36
tII .
I
I--' YEAR UNITS TOTAL DY1 DY2 DY3 PERCENT- DY1 OY2 DY3
f\)
.t::""
1964 44.00 1033.0 4.2&
1.00 0.01
1965 45.00 1055.q 17.00 4.27, 1.14
16.00 -69.00 1.14 -4.23
1966 63.00 1165.0 -52.00 5.41 -3.09
-34.00 89.00 -1.9~' 5.11
1967 29.00 839.0 37.00 3.46 2.02
'3.00 -53.00 0.07 -3.79
1968 32.00 908.0 -16.00 3.52 -1.77
-13.00 -1.70
1969 19.00 1043.0 .1.82
NOTE.- DY1. FIRST DIFFERENCE
DY2 . SECOND DIFFERENCE
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y 0 I V.
I. URN I N 0 U S T R I E S, I N C.
INDUSTRIAL WATERTU8E BOILERS, DISTRIBUTION AS TO MARKETS MI.SC. MFG
YEAR CAP. TOTAL OY1 DY2 DY3 PERCENT DY1 DY2 on
1964 3.40 72.3 4.70
-0.10 -0.41
1965 3.30 76.9 1.40 4.29 1.77
1.30 -4.70 1.36 -4.24
1966 4.60 81.4 -3.30 5.65 -2.47
-2.00 8.50 -1.11 7.71
1967 2.60 57.3 5.20 4.54 5.23
3.20 -9.70 4.12 -12.24
1968 5.60 67.0 -4.50 8.66 -7.01
-1.30 -2.69
tJj 1969 '.. 50 78.0 5.77
I
......
I\)
VI
YEAR UI~ IT S TOTAL OY1 OY2 on PERCENT DY1 DY2 on
1964 61.00 1033.0 5.91
9.00 0.73
1965 70.00 1055.0 2.00 6.64 -0.41
11.0;) -49.00 0.32 -1.49
1966 81.00 1165.0 -47.00 6.115 -1.91
-36.00 119.00 -1.5'1/. 7.05
1967 45.00 839.0 72.00 5.36 5.15
36.00 -110.00 3.56 -10.05
1968 81.00 90e.o -38.00 8.92 -4.90
-2.00 -1.35
1969 79.00 1043.0 7.57
NoTE** DY1. FIRST DIFFERENCE
DY2 . SECOND DIFFERENCE
OY3 . THIRD DIFFERENCE
-------
E R I E C I T 'f ENE R G Y 0 1 v.
1. \.! R N INOU S T R I E S. I N C.
INDUSTRIAL WATERTUBE BOILERS. DISTRIBUTION AS TO MARKETS TEXTILES
YEAR CAP. TOTAL OYI OY2 OY3 PERCENT DYI OY2 OY3
1964 2.~0 72.3 3.46
0.30 O.lti
1965 2.80 76.9 0.10 3.64 0.11
0.40 -1.~0 0.29 -0.49
1966 3.20 81.4 -1.40 3.9"3 -0.38
-1.00 2.70 -0.09 0.37
1961 2.20 57.3 1.30 3.84 -0.02
0.30 -0.50 -0.11 1.01
1968 2.50 67.0 0.60 3.73 0.99
1.10 . 0.88
1969 3.60 78.0 4.62"
tJj .
J
.,...
I\) YEAR utXITS TOTAL. OYI OY2 DY3 PERCENT DYI OY2 DY3
0\
1964 46.00 1033.0 4.45
28.00 2.56 "
1965 74.00 1055.0 -30.00 7.01 "" -3.40 .
-2.00 5.00 -0.83 3.41
1966 72.00 1165.0 -25.00 6.18 " 0.U2
-27.00 56.00 -0.82 0.83
1967 45.00 839.0 31.00 5.36 0.85
4.00 -20.00 0.03 -0.14
1968 49.00 908.0 11.00 ~.4(). 0.71
l~.OO 0.74
1969 64.00 1043.0 6.14
NOTE** OY1 . FIRST DIFFERENCE
DY2 . SECOND DtFFERENCE"
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y D I v.
Z URN I N 0 U S T R I E S. I N C.
INOUSTRIA~ WATERTUBE BOl~~RS. DISTRIBUTION AS TO MARKETS TRANSPuHTATlON
YEAR CAP. TOTA~ OY1 OY2 OY3 PEHCENT DY 1 DY2 :; DY3
1964 3.80 72.3 5.26
-0.60 -1.09
1965 3.20 76.9 -0.50 4.16 -0.49
-1.10 1010 -1.51i 2.21S
1966 2.10 81.4 0.60 2.58 1.79
-0.50 2.40 0.21 1.32
1967 1.60 57.3 3.00 2.79 3.11
2.5J -6.80 3.33 -8.97
1968 4.10 67.0 -3.80 6.12 -5.86
-1.30 -2.53
1969 2.80 78.0 3.59
OJ
I
f...I
(\) YEAR VI', 1 T S TOTA~ OYI DY2 OY3 PERCENT DYl DY2 Dn
--4
1964 45.00 1033.0 4.36
-4.00 -0.47
1965 41.00 1055.0 -6.00 3.89 -0.76
-10.00 10.UO -1.23 2.30
1966 31.00 1165.0 4.00 2.66 1.54
-6.00 14.00 0.32 -0.77
1967 25.00 839.0 18.00 2.98 U.78
12.00 -40.00 1.1U -3.36
1968 37.00 908.0. -22.00 4.U7 -2.58
-10.00 -1.49
1969 27.00 1043.0 2.59
NOTE** OYl . FIRST DIFFERE~CE
DY2 . SECOND DIFFE~ENCE
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y 0 I V.
l. URN I N 0 U S T R I E S. I N C.
INDUSTRIAL WATER TUBE BOILERS. DISTRIBUTION AS TO 'J.ARKETS WOOD
YEAR CAP. TOTAL DY1 DY2 DY3 PERCENT DY1 DYZ DY3
1964 2.20 72.3 3.04
-0.90 -1.35
- 1965 1.30 76.9 1.20 1.69 1.63
0.30 -1.40 CI.2Ci -
-------
E R I E C I T Y ENE R G Y 0 I V.
l. URN I N O:U S T R I E S. I N C.
INOUSTRIA~ WATERTu~E BOI~ERS. DISTRIBUTJON AS TO l>1ARKETS RUBBER
YEAR CAP. TOTA~ DY1 DY2 DY3 PERCENT OY1 OY2 on
1964 0..90 72.3 1.24
-0.30 -0.46
1965 0.60 76.9 1.30 0.71:1 1.65
1.00 -2.50 1.1'1 -2.36
1966 1.60 81.4 -1.20 1.97 -0 . 71
-0.20 2.00 0.4/:j 0.77
1967 1.40 57.3 0.80 2.44 0.06
0.60 -1.90 0.54 -1.67
1968 2.00 67.0 -1.10 2.'19 -1.60
-0.50 -1.06
1969 1.50 7a.o 1.92
txJ
I YEAR UI'.ITS OV1
I-' TOTA~ OVI OY2 OY3 PERCENT OY2 OY3
f\)
\0
1964 25.00 1033.0 2.42
-9.00 -0.9U
1965 16.00 1055.0 20.00 1.52 1.70
11. OJ -,a.uo 0.8iJ -1.2~
1966 27.00 1165.0 -8.00 2.32 U.46
3.00 11.00 1.26 -1.33
1967 30.00 839.0 3.00 3.58 -0.87
6.00 -15.00 0.39 -(), 61
1968 36.00 908.0. -12.00 3.96 -1.108
-6.00 -1.09
1969 30.00 1043.0 2.88
NOTE** DYl. FJRST DIFFERENCE
OY2 . SECOND DIFFERENCE
OY3 . THIRD DIFFERENCE
-------
APPENDIX IX
REGION
B-131
-------
tD
I
'f-'
W
W
. ~I
~:1
-eo
c~O
=~~
O~m
;I~~
-< VI
::'O~»
rn~r-
~i. ~
~.
>-
~
o
Z
»
::0
-<.
c;:I
.0
r=~
m
::'0
VI
-------
E R I E C I T V E I~ E R G V 0 I v.
t U.R" I N 0 U 5 T ~ I E 5. I ~ c.
INDUSTRIAl. ":A TERTUBE dOll.ERSt DISTkIDUT10~. BY ~f.G I Ot~ - 1
YEAR CAP. TOTAl. Dv1 DY2 DY3 PE~CE~T DY1 OY2 uY3
1965 2.10 76.9. 2.73
1.bC l.d1
196b 3.70 81.4 -3.30 4.~~ -2.67
-1.7U !;).lO -1.\.10 ~.72
1967 2.C.O ~7.3 1.90 3.49 ;J.b!»
0.2u -U.!»CJ -v.ll ".~~
196'1 2.20 67.0 1.40 3.28 1.60
1.60 1.~7
1'169 3.80 711.U 4.&7
YEA~ UI. ITS TUTAL DYl i)V2 UY3 PERCENT I,)Y~ DY2 !:IY)
txI
I 1965 46.00 10!;)5.0 4.36
......
W 21.:.>0 1. 3 'Ii
.+=, 1966 67.00 116~.(J -~2.00 ~.75 -2.8~
.- 3 1. C: 0 &4.;,)0 -1.4Co 4.1fJ
1'767 36.1,;0 839.0 32.00 4.2~ 1.24
1.00 -2.00 -~.2l 1.42
196d 37.00 90a.u 30.00 4.(17. ,2 .b~
31.00 2..."
1969 6(;.00 1043.0 b.!;IZ.
NOTE.. DYI . FIRST DIFFEREj~CE
DYZ . SECO~D DIFFERENCE
DY3 . THIRD l>IFFlRE~CE
-------
E ~ J E C J T Y (:: ,. E R.C; 'I' I> J v.
L. U R /II I ,'II D u S T I{ I E S. J /II C.
JNUuSTRJAL. i\ATt.RTU~(:: BOlll:.~S. L)ISTIo(I~UTJOj\j 6'1' REGICr. - 2
YEA~ CAP. TOTAL DY1 UY2 i)Y3 PERCENT CY1 DY2 DY)
1965 1~.30 76.9 19.<;(,;
-1.80 -:h)!
1'166 13.50 b1.4 -3.9C '16.51:1 C.:;4
-5.71. 13.40 -1.. ~ 7 b.JJ
1767 7.80 5703 9.50 B.61 6.07
3.B\) -11.10 J.7" -l".iJU
196R 11.60 67.0 -1.60 17.31 -;".32
2.Z0 0.)0
1969 13.80 7B.0 17.t;,9
b:1 YEAR 1.1;.1 T5 TOTAL Dv1 DYZ DY~ PERCEi'oT on Uv2 DO
I 0
~ 1965 241.(;() 1C!i!).O 2l.tj4
w
Vl 4.00 -1.01
1966 24~.00 116!i.0 -75,CO 21.03 1.~2
-71,lil.l 1t.9.1,)0 -0.2'1 -(J.Zl
1967 174.00 839.0 94,OU 20.74 1.25
23.00 -79.VO 0.9b -1.37
1968 197.tJO 90/:!.U 15.01,) 21.70 -U.12
3e.oo Q.c)"
1969 2~5.00 1043.0 22.53
:-tOTE-. DY1 . FIRST DIFFI::REI\CE
DY2 . St.CO~:D Dl FFEREI..CE
DY:; . THIRD DIFFEREI\CE
-------
E R I E C I T Y ( /'i E R (j Y D I v.
l U R N ~ N D U S T R I I:. $- I ~ c.
INDU~TRIAI. WArERTUI:IE BOILI:.t<$. DIST~ltiUTICN BY REG_ON - )
YEA~ CAP, TOTAL DY1 DV2 OV3 PEH(EI'. T 0:> V 1 DY2 on
1'J65 12.40 16.'J . 16.12
3. 5Q . ),41
1'J66 15.90 tn.4 -li.70 1'01'53 -4.27
-5.?O lli.iJO ..0.06 b.~4
1967 1(,,7Q 57.) 9.30 18.67 '..2t1
4.10 -8.:'0 ).4~ -4.~Z
1961:1 14;eo 67.0 0.60 1 fFE;REj~~E
DY2 . SECOND C I FFERE,';CE
DY") . THIRO DIFFE,RE.Nq
-------
f R I E C I T Y E I~ E R G Y D I v.
1 U R N I '" D U S T R 1 E S. 1 N C.
1:-'IJUSTRlAL \o:ATERTu~E bO I URS. DISTRlcUTION BV Rt:uIO~1 - 4
VEAR ::AP. TOTIIl DY1 DY2 DY3 PERCENT DV1 l>Y2 DV)
1'16~ 14.30 76.'1 1H.bU
-3.6v -~.Io;)
1966 1C.7(1 81.4 2.20 13.14 b.~4
-1.4v 3.10 :;.(;'1 -o.l~
1'167 '1.30 57.3 5.:10 16.23 '-.39
3.9u -12.20 ~. 4.' -lv.4t1
196f! 13020 67.0 -6.90 1'J.70 -11,).10
-3.0C -b.oC!
1969 1u.20 78.0 13.08
tD Y£AR UldTS TOTAL DV1 DY2 DY3 PERCENT i)vl I)V2 DY3
I
~
w 1965 157.UO 10~~.O 14.08
~ 17.VO v.v:"
19b6 1710.00 11b5.0 -62.0U 14.'14 U.:;....
-45.00 13a.vC 0.4.. 1.42
1967 12S1.0f) B39.0 76.00 1~.38 l.tH
31.00 -13\J.UC 2.2~ -b.~4
1<;68 16v.CO 9vf!.0 -54.00 17.62 -b.73
-23.0U -4.47
1969 137.CO 104).0 13.14
,..OTE** DYl . FIRST DIFFERENCE
DY2,. SECOM) DIHERE~ICE
DY3 . ThIRD DIFFERE~CE
-------
E R 1 E C 1 T Y E r. E R G Y D 1 V.
l. URN 1 N D U S T R 1 E S. 1 N C.
INDU5TRIA~ ~ATERTU~E ~OlLE~S. L>lSTt(luUTlOr. ~Y HEGIO.\ - !I
YEAR CAP. TOTAL DY1 DY2 OY3 PERCENT [)y 1 [)Y2 DY3'"
196!1 4.80 76.':1 6.24t
-0.30 -(,.71
1':16~ 4.50 tl1.4 -1.20 !I.!l3 ","2
-1.!l0 3.tH;' -1.1.2':11 ~. -'0
1961 3.00 !l7.3 2.6u ~.'21t. 1.111
1.11:1 -6.10 0.1j" -o.I.IU
1~69 1..10 67.0 -3.50 6.12 -4.62
-2. (.0 -3.94
1969 1.70 7e.o 2.18
tJj YEA~ U~lTS TOTAL DY1 DY2 DY3 PE~CE"'T OY1 UY2 [)Y3
. 0
I-' 1965 91.(,0 1055.0 8.63
w
ex> 0.00 -0.01
1'#66 91.00 116~.(J -31.00 7.61 0..1.5
-:n.oo S9.tJO -o.u~ -...37
1967 ~o.oo 839.0 28.00 7.15 -C.21
-3.00 -~o.vO -0'07 u.7~
1~68 57.00 90P.u 8.00 6.28 0.51t
5.00 -0.3;)
1"'69 . 62.00 10lt3.CJ ~.~4
NoTE-- CY1 . FIRST DIFFEREI1CE
DY2 . SECO~J OIFFERE~CE
CY3 . THIRJ DIFF(RlNCE
-------
E R I E C 1 T Y E N E R G Y D 1 v.
l URN I N 0 U S T R I I:: S. I t'i C.
INOUSTRIAL. \tIA.TERTU~E BOIL.ERS. DISTHlI3UT[O~ BY R~GIO~ - 0
YEAR CAP. TIJTAL. DY1 DY2 DY3 PERCt::f'.T DY 1 OY2 DY3
1965 15.20 76.9 1'1.77
1.30 \.1.:1..
1966 H,.'50 81.4 -6.40 2u.27 -v.l1b
-5.10 11.30 -(;.31 -1.~2
1967 11.40 57.3 4.90 1'1.'.;0 -2.80
-0.2i) -1.20 -3.1d b.ll
196A li.20 67.0 3.70 16.72 5.31
3.50 2.D
1969 14.70 78.0 HI. 65
tJj YEAR ur. ITS TOTAL :,)Y1 OY.2 I.JO ~ERC~NT ~Y1 LiY2 uYJ
I
I-'
w 1965 101.(;0 1055.0 10.14
\0
17.00 v.5v
1966 124.(;0 1165.i./ -51.00 10.64 -\;.42
-34.00 94.0v O.Co u.~l
1'161 9C.OO 839.0 43.00 10.73 Ci.tJ9
9.00 -46.00 0.10 -1.10
1':; 6 8 99.00 90e.O -3.00 10.90 -1.01
6.00 -0.84
1969 105.00 1043.0 10.07
NOTE** CYl.. FIRST DIFFERENCE
DYZ a SECO~D DIFFERENCE
DY3 . THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y D I v.
l. URN I N D U S T R I E S. 1 N C.
INDUSTRIA~ WATERTUBE BOIL.E~S. DISTRIBUTION BY HI::GION - 7
YEAR CAP. TOTAL. DYl DY2 DY3 PERCENT DY1 DY2 DY3
1965 1.60 76.f.J 2.Uij
-0.40 -0.61
1966 1.20 61.4 0.10 1.47 0.70
-0.30 -0.10 0.10 -1.47
1967 0.90 57.3 -O.OU 1.57. -U.77
-0.30 0.70 -O.6d 1.&3
1968 0.60 67.0 0.70 0."'0 1.06
0.40 0.39
b:I 1969 1.00 78.0 1.28 .
I
I-J
~
0
YEAR Ut\ITS TOTAL. DY1 DY2 DY3 PERCENT. L>Y1 DY2 DY::S
1965 28.00 1055.0 2.65
-4.00 -O.5'i
1966. 24.CtO 116!).0 -1.00 2.06 C.tW
-5.00 0.00 0.2U -1.84
1967 19.00 839.0 -1.00 2.26 -1.04
.-6. ou 13.00 -\.i.b3 2.26
1968 13.00 908.0 12.00 1.43 1.22
6.00 0.3'"
1969 19.00 1043.0 1.62
r-.OTE** DY1 II FIRST DIFFERENCE
DY2 II SECOND OIFFERENCE
DY3 II THIRC DIFFERENCE
-------
E R I E C I T Y ENE R G Y D I v.
l URN I N D U oS T R I E S. I N C.
INDUSTRIAL WATERTUBE BOILERS. DISTRIBUTION BY Rf;,GION - ~
YEAR CAP. TOTAL. DY1 DY2 L>Y3 PERCENT DY1 DY2 DY3
1'165 3.10 76.9 4.03
-0.30 -O.~Y
1966 2.80 81.4 -0.20 3.44 1.17
-0.50 O.~O 0.,7 -2.62
1967 2.30 57.3 0.30 4.01 -1.45
-0.20 0.30 -0.8 b. 2.40
196A 2.10 67.0 0.60 3.13 0.95
0.40 0.07
1969 2.50 78.0 3.21
td
I
I-'
..j::'"
I-' YEAR ur, ITS TOTAL. DY1 DY2 DY3 PERCENT DYl OY2 DY3
1965 48.00 1055.0 4.55
-12.00 -1.46
1966 36.CiO 1165.0 3.00 3.09 1.5Y
-9.00 12.00 0.13 -1.30
191:17 27.00 839.0 15.00 3.22 CI.29
6.00 -16.00 0.42 -0.70
1<;68 33.00 908.0 -1.00 3.63 -0.41
5.00 0.01
1969 38..00 1043.0 3.64
NOTE** DY1 I: FIRST DIFFERE,'KE
DY2 a SECOND DIFFERENCE
DY3 = THIRD DIFFERENCE
-------
E R I E C I T Y ENE R G Y 0 I v.
l URN I N 0 U S T R I E S, I N C.
INDUSTRIA~ WATERTu~E 60 I L.'ERS, OISTRIi:iUTION BY Rt;GION - 9
YEA~ CAP. TOTAL. OY1 OY2 DY3 PERCENT UYl OY2 OY3
1965 3.50 76.9 4.!)~
, 0.20 -0.01
1966 3.70 81.4 -2.00 4.55 -1.22
-1.80 4.60 -1.23 3.17
1967 1.90 57.3 2.60 3.32 1.94
0.'80 -2.10 0.71 -1.56
1968 2.70 67.0 0.50 . 4.03 0.38
1.30 1.10
, 1969 4.00 78.0 . 5.13
t;;d
I
~ YEAR UldTS TOTAL. DY1 OY2 OY3 PERCENT OY1 OY2 DY3
.::-
r\)
1965 56.00 1055.0 5.31
18.00 h04
1966 74.CO 1165.0 -49.00 6.35 -2.27
-31.00 84.00 -1~2~ ~.5!)
1967 43.00 ~39.0 35.00 ~r. 13 1.28
4.00 -24.00 a.os -0.56
1968 47.00 908.0 11.00 5.18 0.72
l~.OO 0.77
1969 62.00 1043.0 5.94
NOTE** DYl -,FIRST DIFFEReNCE
OY2 . SECOND DIFFERENCE
DY3 a THIRD DIFFERENCE
-------
APPENDIX X
1970 ABMA DATA
B-143
-------
DOMESTIC SALES OF STATIONARY WATERTUBE GENERATORS
STATE DISTRIBUTION
Industrial Tvee Utilitv Tyee I
Percen t STATE Percent
U\'it$ Capaci ~-I Toto I (lndf CODE Units Capacity' Total (Util)2
-
17 1471 2.47 Alaoama 0 0 .00
2 135 .23 Alaska 0 0 .00
3 580 .98 Arizona 0 0 .00
5 405 ..68 Arkansas 0 0 .00
22 1181 1.99 Cal. 8 2720 1.14
16 897 1.51 Colo. 2 3487 1.46
7 444 .75 Conn. 1 4320 1.81
3 730 1.23 Del. 2, 3981 1.67
1 40 .07 D. 0.. 0 0 .00
12 1354 2.28 Florida 4 11732 4.92
22 2532 4.26 Ga. 11 13608 5.70
2 96 .16 Hawaii 1 963 .40
2 283 .48 Idaho 0 0 .00
79 6817 11.47 Ill. 2 4349 1.82
21 935 1.57 Indiana 4 10190 4.27
e 607 1.02 Iowa 4 706 .30
7 213 .36 Kansas 6 1820 .76
17 885 1.49 Kentucky 1 1900 1.11
17 2522 4.24 La. 4 9935 4.16
10 717 1.21 Maine 0' 0 .00
29 2796 4.70 Maryland 1 4600 1.93
24 1163 1.96 Mass. 3 4450 1.87
29 1474 2.48 Mich. 1 200 .08
12 916 1.54 Minn. 1 4985 2.09
4 . 153 .26 Miss. 1 5312 2.23
~ ~,. ,78 M 1 ~~-~,~; 2 1!430 3.53
2 -560 .94 Montana 1 2520 1.06
2 175 .29 Nebraska 0 0 .00
1 40 .07 Nevada 0 0 .00
2 65 .11 N.H. 1 2992 1.25
24 1139 1.92 N. J. 1 2850 1.19
0 0 .00 N.M. 0 0 .00
61 3627 6.10 N. Y. 32 27670 11.60
31 1732 2.91 No.Carol. 1 50 .02
2 40 .07 No. Dak. 1 3075 1.29
.. 21 1121 1.89 Ohio 2 251 .11
5 470 .79 Okla. 2 7030 2.95
14 ,775 1.30 Oregon 0 0 .00
62 4451 7.49 Penna. 6 27962 11.72
3 120 .20 Rd. Is I. 0 0 .00
17 1044 1.76 So. Carol. 2 200 .08
7 . 212 .36 So. Dak. 0 0 .00
18 1397 2.35 Tenn. 2 80 .03,
56 6656 11.20 Texas 16 43435 18.21
11 576 .97 Utah 1 3300 1.38
2 80 .13 Vermont 0 0 .00
19 1365 2.30 Virginia 1 5841 2.45
22 1:305 2.20 Wash. 0 0 .00
10 842 1042 W. Virginia 3 675 .28
25 1208 2.03 Wis. 1 3800 1.59
0 0 .00 Wyoming 2 7960 3.34
6 182 .31 Puer. Ric. 0 0 .00
3 " 450 .76 Vir. Isles 1 420 .18
0 0 .00 Pac. Isles 0 0 .00
Note 1: Million lbshlr
Note 2: Domestic Only
B-145
-------
INDUSTRIAL STATIONARY
. ~A TERTUBE BOILER
MARKET
1970 DISTRIBUTION
..
'. .
TOT AL CAPACITY
68,359.000
TOTAL NUMBER
OF UNITS
861
NOTE
SOLID LINE REPRESENTS
UNITS DISTRIBUTION
BROKEN LINE REPRESENTS
CAPACITY DISTRIBUTION
.. .
80
". .' .
CAPACITY
I I ,_.~ ..--f
200 . . 400
-
--
-
/
/
/
/
I- . /~
Z /
W /'
u /
. ~-' I
.40 W J
Q..I
I
J
I
I
J
8D
o
o
PRESSURE
600' 1200
80
I-
Z
W
U /
40 f5 -/
(L I
/
I
I
/
I' SA T
o
o
. B-146
/
/--
I
I
.,.,.'"
",
'"
./
--"
SUPER <;EAT ED
TEMPERATURE
. .. 1---1 I.
400 800
600
. .
1800
,-I
1'>'(.:0
1._'-'
F'1 :~' .'....r:- ~ -1":
-------
1970 SALES OF INDUSTRIAL TYPE WATERTU'BE STEAM GENERATORS
.. --
, DISTRIBUTION AS TO SIZE OF UNIT
Unit Capacity
Number of Un i ts thousand Ib hr
166 ~~ -1 1 0 - 25 3.4
263 f L - ') 26 - 50 10.0
.I ,
234-=r';' ~I ~ 51 - 100 17.1
121 /~ 101 - 150 16.3
I
39 151 - 200 7.4
10 201 - 250 2.3
251 - 300
301 - 350 1.7
351 - 400 1.2
401 - 450 1.8
6 451 - 500 3.0
500 + 2.9
Totol Number of Units - 861
Total Capocity 68,359
- thousand Ib/hr
B-14,
-------
1970 SALES OF INDUSTRIAL TYPE WATERTUBE STEAM GENERATORS
-
DISTRIBUTION AS TO OPERATING PRESSURE
Operating Pressure
Toto I COPJci ty
8
Number of Units psia (m i I lion Ih/hr)
4- 0 - 49 .0.1
290 /1. 50 - 149 /4 - 10.9
323 II. 150 - 249 ll.
8
250 - 349
27 350 - 449 3.3 .
39 450 - 599 6.1
21.0
ij.3
1..6
66
"600 - 849
II.
--
17
850 - 1249
3.8
5
1250 - 1449
2.6
0.8
o 1800 - 2399 0
Total Number of Units - 861
" Total Capocity - 68,359 thousand Ib/hr
B-148
-------
Number of Units
692-
62
. 1970 SALES OF INDUSTRIAL TYPE WATERTUBE STEAM GENERATORS
DISTRIBUTION AS TO STEAM TEMPERATURE
/
26
29
Steam Temperature
.de rees F
Sot
4 300 - 424 0.7
12 425 - 474 1.6
9
475 - 524
525 - 624 I
::: ~ ::4 r- 1.3 ? n
:: - ~;: I - . ~
o 775 - 824 I 0 .
825 - 874 ~ 0.9
1'>
....
9
0.8
o
1 025+
o
Total Number of Units - 861
Total Capacity - 68,359 thousand Ib/hr
B-149
/,(
3.7
4.0
II.
Total Capacity
38.3
11.4
3.6
-------
1970 SALES OF INDUSTRIAL TYPE WATERTUBE STEAM GENERATORS
- .-
DISTRIBUTION AS TO. FUELS AND FIRING METHOD
Number of Units Base Fuel
15 Bituminous
Coal
231 /1. Oil
578 / / / Gas
-
7 Wood _1.0
3 Bagasse 0.3
9 Black
liquor
0 Turbine 0
Exhaust Gas
5 Other 0.9
Waste Heat
0 Lignite 0
13 Other
Total Number of Units - 861
Firing Method
N umber of Un i ts for Solid Fuels
Pu Iverized 0.4
14
7
2
Total Number of Units - 24
Spreader
Underfeed
0.01
Overfeed
Other
0.7
. Toto I Copac i ty - 3335 thousand Ib/hr
B-150
2.4
/ L-
I.
If
.
': .'~..,;.,., 'v,.'
3.9
17.9
-1II'.7L..uo.:
39.3
-
2.7
Total Capacity - 68,359 thousand Ib/hr
1.7
-------
1970 SALES OF INDUSTRIAL TYPE WATER TUBE STEAM GENERATORS
DISTRIBUTION AS TO FUELS AND FIRING METHOD
Alternate Total Capacity
Number of Units Fuels (million Ib r
o Bituminous 0
Coal
476 1/ 1 Oil ~ 32.4
101 / Gas . / 9.6
.
Wood 0.1
0 Bagasse 0
0 Black 0
Liquor
0 Turbine 0
Exhaust Gas
1 Other 0.5
Waste Heat
8 2.1
Other
Total Number of Units - 587
Total Capacity - 44,637
thousand Ib/hr
B-151
-------
1970 SALES OF INDUSTRIAL TYPE WATERTUBE STEAM GENERATORS
DISTRIBUTION AS TO MARKETS. ,---- -
Number of Units
Morket Cate or
64 Elec. Uti!. 8.6
(Non-Gen. )
84 Chem ica I 8.4
39 Paper 8.0
55 - Petroleum 7.4
119 Non-Mfg 6.9
101 Schools 5.8
76 Food 5.1
139 Medi ca I -.. 4.7
58 Mis. Mfg. 4.7
35 Metals 4.1
44 Texti les 2.1 .
Transportation
Rubber w', .
16 Wood
Total Number of Units - 861 .
Total Capacity - 68,359 - thousand Ib/hr
Note 1: This section includes all industrial type units, steam and hot water, packaged and field
"assembled, regardless of use.
Note 2: Schools includes schools and colleges; medital includes hosptials, medical centers
and related facilities. These categories were formerly included in the Non-Mfg. group.
B-152' .
-------
APPENDIX C
DEVELOPMENT OF FLUIDIZED BED COMBUSTION BOILERS
C-l
-------
DEVELOPMENT OF FLUIDIZED BED BOILERS
Several boiler systems have been built, tested, or proposed
which incorporate fluidized bed combustion.
A brief listing of these
systems is presented to gain an understanding of what concepts have been
considered. The list is not necessarily complete and no attempt was
made to present all fluidized bed combustion processes which may be
applicable to fluidized bed boilers with sulfur removal.
Pope, Evans, and Robbins
A packaged industrial fluidized bed boiler of capacity
250,000 lb/hr steam has been developed and is shown schematically in
Figure C-l. The design is based on modular units 18" x 12' assembled
together with water walls dividing the units. High efficiency is obtained
by using a carbon burn-up cell to react unburned carbon. The nominal
operating conditions projected are primary bed temperature l600°F, carbon
burnup cell bed temperature 2000°F, gas velocity of 12-14 fps, bed
height of 12-20 inches, and coal crushed to minus 3/4 inch. Sulfur
dioxide emissions would be controlled by injecting fine limestone (per-
haps 100 mesh).
The modular concept has been extended to a utility
boiler design concept.
A new shippable unit of capacity 300,000 lb/hr steam with
modified design(9) is shown in Figure C-2. The modules or cells run parallel
to the steam drum and connect to a single carbon burnup cell. Flue gas
passes straight up through the convection section and economizer, both
located in the freeboard.
Primary superheater is arranged to serve as
baffle screens above the bed.
The bed operating conditions are essen-
tially the same as the earlier design.
C-3
-------
...AIN SUA" HUDER
SUPERIt(AT£R,
~,,-
PRIMARY OUST
tOLLltTOj'
~
$T£AII
DRUN
I
I I
,
I I
I'
I'
I
I
- - - - - - - - - - - -, -, - --
I I
I,
I I
i I
i (
I I
'"'''AllY
801I.£R
CElL
v
PLENUM
/"~'"""
.. COAL rEEDER
Overall Dimensions:
12 ft wide x 16 ft high x 40 ft long
Figure C-l - Schematic fluidized-bed boiler incorporating
a carnon burn-up cell
c-4
TO
S[COt~~t~y
OUST
roLLE£.c;!'
\
AIR F'!1[HEATfR
8[D 1[I.\P[.'.1UR[
-CONTROL tOI.L
FLYASH It.J~CTlOU AIR
-------
".",.--~,..... ,.\."''':- "rt
.',4- ,
~.
r. D ..': Hc.Alkl!
COli!. r'(EOCn
-~:'r
------, ,~L- -. -----,
'rf~,\~~_"M' -
I . -- ' - -, -'. I ."':'--. EC:~OMIZc.R
~! ,,', ' " I! , ". 11
'~,' .'-' .~~ 'r COA~ SUPPLY TUSE
\ h~r-01
"- _4~;,"<~~~l~~: 111 i ",
)\.\\~',:)~~~-~ll-~!' 11-~~~vEcT,oN BA~"(
j \:1 \\\;,\~~\\\ J\! i,\ I:! 1;1': \\ :\11 \ II
~J: !j.i: IllllL~i p,! 't ~ Ii.
[jIJr~ij 1 ~''''c.''" .~, """
~+-~ h ~c=:J~_SU;>ERHEATER
CL-JPl M f- ~l~o--SuPERHEATER OUTLET HEAOCR
~L,r=I- I ' ~
"'" "'0 "" ;::>-!I, "..J 1......,1...,..
,------' --' ---
i
I~
I'
i'l
I
I
i
I I
III
III
~
J
I
LOWER HEADERS
FIGURE C-2 - End View, Coal-Fired Fluidized Bed Utility
Boiler, Factory-Assembled
C-5
-------
"502 acceptor process", where the 502 is absorbed in the pri-
mary bed and regenerated in the carbon burnup cell, was conceived. The
continuous absorption-regeneration is accomplished by recirculation of
limestone beds between the primary bed and carbon burnup cell through
the provided openings.
Esso Research & Engineering
Esso R&E have proposed an operating concept for a fluid bed
boiler with sulfur removal.
The fluid bed combustor would be operated
with a bed of "large" limestone particles and pulverized coal would be
pneumatically fed to the bed.
The ash from the coal would be entrained
from the system, leaving a bed composed essentially of limestone.
reacted limestone would be removed from the bed, regenerated, and
The
recycled back to the combustor.
Initial experiments were performed in a 3" diameter coal com-
bustor and a 2" diameter limestone regenerator.
The fluidizing velocities
used were 3 ft/sec and 2 ft/sec respectively. The bed temperature was
l600°F in the combustor and 2000°F in the regenerator.
CRE- NCB
The NCB has undertaken an extensive program to provide a
series of fluidized bed boiler designs.
These include
. a 220,000 lb/hr, 20 MW, water tube boiler. Preece, Cardew and
Rider (PCR) have produced preliminary designs for this atmos-
pheric pressure boiler shown in Figures C-3 and C-4. The design is
later changed, as shown in Figure C-5, with 1" tubes of length
60'-80' running horizontally back and forth in the direction of
the larger dimension of boiler. Overall boiler dimensions are
14' x 40' x 16' with active bed area 400 ft2. The bed is divided
into three beds and a carbon burnup cell. The fluidizing velo-
vity is 8 ft/sec and coal particle size is -1/8". The design is
for installation at Grimethorpe to serve as a demonstration plant.
c-6
-------
---- -- -
Primary
Superheater
I .
I
!pt~~~;;
'".,,,'1'11
"~:U~~:n:l
111'1111.""
,.::111:I!'UI
~I,~....I
}'.:::~.'
,,,"( ---
,.,
'//
111.'//:
h
--~=.JL -
[J
---- -.-
------=
-------
I «
40 ft.
,/
",._-- -- - ,-
-"----~-
Secondary
Superheater
FIGURE C-3 - PCR Design of 20MW Water Tube Boiler (Side View)
) I
C-7
-------
o
I
ex>
r -_., I
. I
-~~.. ilrtj~4:!;
. . iia~.~;1(1
r;;:j ..'1 :
1~?~-4) 0/ ~,. ~_. I
i ;ll~I'~ .I'!~'\'W 111' ill ij, ~r:rrrtri
'dl'i iiji':,I'i"j:(,j;!: !1""W;/11 !/Iv:'c~-~\:
1 !)ii!ij:,\!! .!!Ii%;i;lli~j~~r~:, '11{,li!!;; :1:'
i", j. I!"I!!.'" ::,li'!:i':)oI:JH ",111.1,1,
: " II, i ,! I Ii! ' .! I', J I' 1,1': ,;t.tl!J:I' "1,1
i::IT- ,If,I'''II,,,I'iol: '::':
II'; iijjJjIJJi\1~~~U~~::;f0~
, . - I . It';~n~",:rift . ' -
,~-;: -----r~,t') ~ . ~--..- -.
~ ;~';;~~i{:"'< ~1 ~t; £...
).. .1
I c
14 ft
I I
Primary Cyclone
Particulate
(+ 75 micron)
Return to Bed
"-
Economiser II
Economiser I
FIGURE C-4 - PCR Design of 20MW Water Tube Boiler (Front View)
To Lj ungs trom-
type Air
Preheater and
Secondary
Cyclones
-------
Dwg. 6162A23
P ri mary
Superheater
Screen to Drop Out
Large Particles
Open Grate of Tubes
Dust Collection
Water Wall
(") 16 ft
I
\0
Evr Secondary
Superheater
3 2 1 CBC
~ 40 ft ~ 14 ft Deep
Fig. C-5 -PCR des ign of 20MW atmospheric pressu re boiler-Gri methorpe plant
-------
. a 120 MW atmospheric pressure utility boiler. PCR have also
carried out a design study of this utility boiler which has been
sectionalized to allow shop fabrication. The conceptual design
is shown in Figure C-6 with overall dimensions. The total active
bed area is 2212 ft3. The heat transfer surfaces are provided
by 1.5" tubes in 3.5" spacings. The design study was carried
out to uncover design and operating problems and to investigate
the economics of a small-scale utility boiler.
. a 500 MW atmospheric pressure utility boiler. An early concep-
tual design is shown in Figure C-7(1). The nominal operating condi-
tions selected include a fluidizing velocity of 2 ft/sec, coal
crushed to -1/16", and bed temperature near 800°C.
~ a 660MW atmospheric pressure utility boiler. The conceptual
designs by International Combustion, Babcock & Wilcox, Foster
Wheeler, and PCR are shown in Figures C-8 through C-ll. Inter-
national Combustion proposes a battery of 12 units. (Figure C-8) each
capable of 55 MW. Superheater and evaporator tubes are located
in the fluidized bed. Babcock and Wilcox proposes a boiler con-
taining 15 fluidized beds of 90 ft x 20 ft (Figure C-9). Air flows
in parallel through each of the beds at 3 ft/sec. Beds operate
at 780-900°C. Of the 15 beds, 9 are superheaters, 3 are reheat-
ers, 2 are evaporators, 1 is combined evaporator-reheater.
Foster Wheeler proposes an arrangement of 6 fluidized"beds, each
66 ft wide (Figure C-lO). Air flows in parallel through each of the
beds at 3.5 ft/sec. Bed temperature is 850°C. The bed depth is
2.5 ft. The coal is fed to the beds at 850 points. The evapora-
tor and primary superheater surface is provided by horizontal
tubes in the beds. The top bed serves as a carbon burnup cell.
Reheater and secondary superheater surfaces are located in the
gas stream leaving the boiler. PCR extends its 120 MW atmospheric
design concept to a 660 MW utility boiler installation. The
design consists of 40' x 16' x 14' modules with 2 evaporator beds,
C-IO
-------
P=j~~~3
fiImary-Sup'er':
---ireatEr---
f
I
55 it
Reheat beds
Evaporation beds
.-..-----"
..---------------
Q
.:, ' : '. h j't 'i~;"\'~{?:i.";
) I
38 ft
.'
14 t it Reheat Bed Evaporator 14tft
Bed
i- Secondary i-
Super-
14 t it heater I Evaporator
Reheat Bed 14tft
-t I Bed i-
I- 25 ft ~I I.... 14 ft ->-1 1- 38 ft -I
FIGURE C-6 - PCR Conceptual Design of a 120MW Atmospheric Utility Boiler
C-ll
-------
"IA."
".--
- ...
..
.-
- ~. :'"~"'"
"""
I
I '0'
11'
!
,
I
!
\.. ~
.... i'I
,_F 7~-:J'
,-=:=0' ~\
"""" ~;:-~t=:.~:F-',
-", E=:='=:;.:::::::f'1
\.~-'""-o:=f\
\. ~'.i -:=:f\
\.E:'-~'
, F'-=:-:::/'.:o:..-::f)
~=::'S11
\~:-:;~:~~~.::J\ .'-
---"-~ ,as eM
OIA~~A,""'A TIC AI!~AH'I"III!
SIIO.,,:HG A:~ AN' GAS FtO'" 'UHS
., \lCAlI
(OA~ '''0 -ft,
COAt. '''0 filUOC.' ...----.
COlt( 'C" ,"'''' 01 IIOS) "':'----
-,
; I:
. ------ ~.\
"
"
- -
-.
. ,
--
o
I
f-I
f\)
~ 'J"
-l"
\ IE)
,
-------
1
,--...
....
. ". . .:: .: .., ~
. ',;:.
53 ft
Rcheater
"
1
l5tt
ft-+-I'
I+- 16 ft-+-I+-16
FIGURE C-8 - Conceptual Design by International Combustion
for a 660MW Atmospheric Utility Boiler
C-13
-------
Fresh Air --
" '- '.
~
~
.~
. , '
9
~
~
,
. i 20 ft-1
10 Beds
. Flue
Gases
r
".
~
I I
~ 20 ft....
I I
5 Beds
FIGURE C-g - Conceptual Design by Babcock & Wilcox
for a 660MW Atmospheric Utility Boiler
c-14
~ Fresh Air
-------
-j 0 0 0 0 0 ~ Final
I Reheat
L 3 Final
o 0 0 o. 0 Superheat
~ - I Primary
.-..====i Rehea ter
140 ft 0 C
0 0 0 0
\Air 0 0 0 0
I
< 66 ft ><: 66 ft >-
o
o
o
FIGURE C-10 - Conceptual Design by Foster Wheeler for
a 660MW Atmospheric Utility Boiler
C-15
-------
2 reheater beds, and 1 superheater bed. The overall dimensions
are 90' (depth) x l20'(width) x 100' (height), (Figure C-ll).
BCURA Industrial Shell Boiler
BCURA is developing a fluid bed coal-fired packaged shell
boiler to compete with oil-fired units at capacities up to 50,000 lb
steam/hr. A prototype of the shell boiler is 'shown in Fi'gure C-l'2,.
proj ec ted oper,ating ,conditions are gas velocities ,of 10-14 fps, bed
depth of about 2 ft" 'and coal crushed to minus 1/4 in. Theprototype
is 3 ft diameter and has a capacity of 8000 lb steam/hr feeding 1000 Ib
coal/hr. The heat transfer tubes are set at an angle of 1'0° ,to allow
The
for natural circulation of the water.
will be ex,tracted in the bed.
About 50% of the heat release
BCURAHfgh'Pressure Boiler
BCURA proposes a high-pressure fluid bed boiler.
The fluid
bed is operated at 15 to 25 atm, 800°C, and the energy in the gases
from the bed is recovered in a gas turbine (Figure C-13). Lower capital
cost through boiler size reduction and increased cycle efficiency are
projected advantages over an atmospheric fluid bed boiler.
'The proposed
system would convert approximately 70% of the coal energy to steam.
experimental apparatus, shown in Figure C-14 has been constructed at
An
BCURA to burn 1000 lb coal/hr at 5 atmospheres.
Conceptual design of a 140 MW pressurized boiler is shown in
Figure C-15. The detailed design will be carried out by John Thompson Ltd.
The boiler is contained within a pressure cylinder 14 ft in diameter and
100 ft long. Active bed area is 900 ft2. Air is fed at 8 atm. with
fluidizing velocity of 2 ft/sec. Coal is fed at 136 feed points with
coal particle size - 1/16". One-inch tubes at 3" spacings are used for
heat transfer surface in the bed.
total power.
Gas turbine generates ~ 12% of the
c-16
-------
(")
.
I-'
......
T
16'
1
~
Reheater
40'
T
lOa'
1
~
Superheater
~
40'
~I
~
Fig. C-ll -Conceptual design by PCR for A600MW atmospheric utility boiler
. Evaporator
Dwg. 6162A24
40'
~I
-------
s~ ~.AM
Cl.TlE'
r\ .. i
----~'Am-C£"c----~. ."E' ,",n,
GAS ..;J )
EXIT/
(\
~
/
ACCESS
:'Sf-'
WEIR
'-'-A l FEe)
FIGURE C-12 PROTOlYPE BCURA INDUSTRIAL FLUID-BED SHELL BOILER
C-18
-------
'Uborh
2t1t1K
r--,
r --, 1-
, i ...-!
~' ~I
2 (It>or ! '
" ,.. '.' ..
. lrMl);
Int~rcOOI~~ ;1114.7bor
I. : ()7:1 "
I r F"Iuid-b...d
-....
150 bar ~""'> I <:'> bOll~"
. 564 K I <- I,
~ 1<--- """"""9K
.---. -I. _n.- ---.:.>.
;>:> 9 Mr: 28 ,.bar 1104 5 bar:
Bl1K I 1',441< 1~1I1< I
t . t ('>
. I I <'
. I I I 1.0 DO'1 -> Economls~r
~ I I 538K ~
&1, iKj I
~ . +
~. . :c IJObor
1Z0MW I 493K
-6-6J
o 04 bar T I
304 K L.-l~-o-- ..-
Cond~"s~r Pump F~~d h~t~r.s(6)
/ .
"
). 1 hnr
79J K
8=
2\OMW
1 02 bar
G-IIK
-Gas c~l~
--- Steam cycle
FIGURE C-13-ScHEMATIC DIAGRAM FOR CQ'v1BINED-
CYCLE POWER GENERATION
C-19
-------
Turbin~ l>lod~ Sl"f'"cim~ns
and tnrg~t 'IJ~~S .. - .. -
..
Combustion gases
leave at 800'C.-.:-
First stage cy(lont>
dust collector
Tubes
absorbing
GO - 70".
01 coal heat
Pressure
casing
Coal bUrns in
----- lIuidised bed
of ash
/coal
. Air
-
Gatm
Air
distributor
FIGUREc~14~HEMATIC DIAGRAM OF PRESSURIZED
FLU ID- BED CQ'YffiUSTOR
C-20
-------
f
"",'
14 ft
ASh! F1~~~ized,
Res r- '
voi
t
10 ft
I
'f .
v
~ 10 ft _.~
FIGURE C-15 - Conceptual Design of BCURA 140MW
High-Pressure Utility Boiler
C-21
-------
Ignifluid Boiler
Albert Godel's Ignifluid boiler was developed by modifying
the air supply system of the travelling-grate furnace to create a fluid
bed on the grate(2,3). The grate is divided into sections to control
fluidization. A sketch of the design is shown in Figure C-16.
particle size is < 20 mm and the gas velocity is near 10 fps.
The coal
The
Ign~fluid boiler is capable of burning a wide range of coals by using
the discovery that the ash of essentially all coals agglomerates near
1000°C. The fluid bed is operated between 1000 and 1200°C. Ash parti-
cles increase in size, sink through the bed onto the grate, and are
carried out of the bed on the moving grate. Partial combustion occurs
in the bed and secondary air (approximately 50%) is supplied above the
bed to complete the combustion.
Particulates are reinjected into the
bed.
A 60 MW unit has been built and a 275 MW unit is projected for
Northeastern Pennsylvania by UGI.
Godel's Stacked Fluid Bed Boiler
A. A. Godel has also proposed a stacked fluid bed boiler(4).
The bottom fluid bed would be an Ignifluid unit.
Water walls are pro-
posed, but no heat transfer tubes are incorporated in the first bed.
A secondary fluid bed is located above the primary furnace.
This bed
would contain granulated refractory and heat, transfer surface and would
operate near 850°C.
Unburned carbon particles carried by the gas from
the first bed would be combusted in the second bed.
Above the second
bed, a third and fourth bed are provided with heat exchange tubes for
steam reheat and an economizer.
Lurgi
Lurgi has a "Turbulent Layer Process" which they recommend for
combustion of low-grade fuels. The heat of combustion is utilized for
the production of steam.
A schematic of the process is shown in Figure C-17.
C-22
-------
. . ., :' :il ;;j:li,/;::il ~:!!':::?"im!0r~:~ .1!.:g(~;~~I-\;~~IR
" I I I ! I: , ~ ! !: ' : : I : , . . 1 , : , I ~ ! I I : . I > ; I . I! : ~. .if ,or
.' ! ! ! I ; , ' i ' ' , . ! ; : . . ! ; . I . : ; . , ' I ! . I I .! I I ; ~ ' : . I ~ II
: i . , ,,1,1 , I , . ,i':': '.,, I ,I" I : I I : . , ' : I "I ' :' j
,.. , . ,;:; I I I , , , III ' : ' , . , , ': ' I , . ; , ' r ' ; , Iii' I ' : '/1 '
COAL, 'i'j" I' :" ',;III;:';!II'iji: il::: 'f ;'1/',:
~i~il~I,;\j!IJ:1!I:P~!:::!IH;,HiI ii!lj', io'! A/ AIR JET
,-" ~ 'I i I d ! ~ 'I 'I 'I . ! ! ", :: ~ , "I! i ' '1'1 : : ,1'1 i 11111 J I ! : : : : ! .:L_;...., ~/.~--.,-~' .
I',c;-.:~.,...I U; .:' I, '. ,I -:.:..wJ .iJ:..u:..: au 'l.!..Ld::-':L~~~'.~~,/-~::.;~".';',~','
'J~~}~~'--'~-' -.., ,- ,,/ ;:"1
. ,~'....~:":'':-:.~~., "...~:.." "~.
',\\'...",.:-,"".:~' ,"'. "'"" ~~.....4 ",' .,"; ,I
I \', ".' ,',-, ,."" """",'''','',' '.' ,.. ...,...",...,,~..,.. \ 1....-" ,4 'J
t !;g:::\{Y//.~~,:':'::':.,:":,~~:.~:~r}~:~~;~:~~~:~["~:\ ~',~ ~\\!;i'..,i ::
~~~::':::::/:<:~~~:~~~~1"{\" i- -; \ ~-~~ - ~r(-jr..tl :'l,:~l t"
" . ...' \ j-"' _.J ~. t. 1'- \> .\.
.... I I .... I' "I ... "I '
",......."~~. \ C:/;-'~~;I-~~I~-;'('I . Ii :,:) ~~?,
,.."" -' ,: ...1 I I I.
(f)" "...,...,' " '[;.)';0 I! ! / U) / J / U ,~
......, '. ~- ~. 'I P
PRIMARV t,\R . '\ I ~
~y
ASI.lES
./'
FIGUREc-16-IGNIFLUID BOILER COMBUSTION SECTION
C-23
.."..
-------
I
II
Ii
L":.
.
, ~
~~--~-~-
10
---._-
(')
I
I'\)
+:'"
""2
"
~=---
"
..,.:,.,,:':'~,~~~~-.'~'~2~~_~;~~,.:~.~~~:-'~--,.c.~~;:.._, ,'., ..,. . . .
, . . ."'" ...-:. ~ " , .". . " :- 1 Contro~ room 3 Air blower
. 't' l, '.11 '!'r' .I""'''~y'.~''' . "'.' " ": '. ," "
! ... '. .. ~\ ~ ,,"\.-' :.-,! ;;;;;~ :r"-;.';: t . :..~. '~'. ...~',. ~.~,: '~:.: '''""..:' '2 Ttt,b0'lOf1o,ator .A..4 fe~diflg dc"icQ . . .
.:."-.~.,...~~\ "t.;! ~~.""f".""~".~..'~_'\.."..,:~~.:"'~\.! ",.":.~I''''''''' ..I.... .."1'," .:...~" .,,'
. .
.. .,
." .. . .
. . . ' ,
. - '.' -., '-' ...' ...... ',-.'- -_:-. . .-..:-."'.... .--.--.-""'" ~: ........' ..... ....--.a.._-._..
5 Turbulent layer furnace:, " "7- Steam boiler 9 H:mdl'j~9 equipment';~ '.-
6 C~ol;:~q, e~emen~s. ,~"'~ tll3oil~ ~rwr": "~ E1eftt~'p,rcc:ipi'ato'. '>:;-- .
FIGUREc-17-WRGI ''TURBULENT lAVER PROCESS"
-------
The turbulent layer furnace (fluidized bed) is cylindrical with an
enlarged upper section which serves as a secondary combustion chamber.
The lower part of the furnace contains a grate of refractory material
with openings through which the fluidizing air enters.
material is discharged at the bottom of the furnace.
The burned
Esso Petroleum Co., Ltd.
Esso Ltd. Research Center has considered the desulfurization
of fuel oil in fluidized beds of lime particles when the combustion is
complete and when it is partial.
One concept being considered places a
fluidized bed gasifier at the bottom of a boiler.
Fuel is partially
burned in the bed and combustion is completed in burners above the
refractory cyclones as depicted in Figure C-18.
steam turbine plant is shown in Figure C-19.
A combined gas turbine-
Stratton
J. F. O. Stratton(5) presented a spouting fluid bed boiler
system in 1928. Coal < 6 mm can be fed to the unit. Gas velocities
range from ~40 fps at the base to 10-15 fps in the furnace. The bed
operated near 2000°F in order to agglomerate the ash which would be
removed after falling through the grate.
The cross section of a furnace
and boiler system installed at a U. S. Gypsum Co. paper mill is shown
in Figure C-20.
The unit handled 5000 lb of crushed coal per hour.
Institute for Fuel Research, Czechoslovakia
Laboratory and semi-production units have been operated.
The
concept is presented in Figure C-2i. Temperatures in the fluid bed were
maintained between 900 and 950°C without agglomeration. Unburned combus-
tion gases and particles from the fluid bed are burned in a second com-
bustion space such as a cyclone furnace.
furnace were from 1000 to l200°C.
Temperatures in the cyclone
C-25
-------
c. :..~. 3.
8a.Lr:::~ C~:.:\./::,~~.:C.~
?~ ri :-
; ;:.\.J !! i
;'''{jltf1;'!\ ~ ~ :
&:1"'1"'1' '; "
Jj'~";::' !
d I: . I'
-<,' 1 I
I ,
I .
,I I I '
i: I: I I
i I I: i !
" I: I i
:! G"S II i M:'IN AIR I ;,
IGNITLFh~,= C:'lir:~;:i'S-.L1 SL;P?LY !
I F.'~'::J'=J~
FLUiOIS;;:O £;::0 . I .~,!/ M i":~..! I 1, . . I
GASIF:f.t\ I :J:JLII \!-'-;-CY;'LO~ES ::--= .-
FU':l.::,:..I:::';'\'~'~'-':-FUEL : i GA5IFI.....:.~
'" I;;' --,..".-"-, '. , I -=--.:... BLOW,i1
.' ! i~ III -I r .
STf.RT-Vt'i II i I I I
DUfiNEHS-;.-- ! ! GAS I FH::i:
I!: A:F; SUP?...'{ I
. ---LL- i I
of
, I
I,
. I
: I
:
FIGUREc~l~SSO LTD. FLUID BED BOILER FOR FUEL OIL
"'.
c-26
-------
I
,
'-1
I
G.L'.S .~lJ::;ul ~:::/STEA:,:
CYC~::
I
i
I
I I
I
(
CI$i,;LPHI,E
SOLUTION
). ! . ~ I II' U!..,RA :
r1 I I 1J7l] CYCLONe: I
! Id i, r\ ~i I !
j.. i I!I! I~ :
I 11-.-L'!.19":~ i ' II
"'~_J"-'''~''J -"~~OILER -U--S
(('t' C:_'~'::>' ) I LJ I O~
I 1;5UO:~vLtT~0'~~;-FUZL ~ ~ I
I II . ~/: I I
9 'r H-..J~ i .
AIR + FUC:Li I If,TM:T~~.G ~ ! "
, aURNt:R ,.,,'),,--<"
-"'CYCL" "., < Cv.... I'i::'.) ..OR
"... I;. ~..~ ("?' "O-rt .
,.. ""',. Co f
,
FIGUREC-l9-Esso LTD. CO'1BINED CYCLE FLUID BED BOILER SYSTEM
C-27
-------
,
, .
,
I
I
I
.
i
,.
FIGUREc-2o- SPOUTED BED BOILER SYSTEM PRESENTED
BY J. F. O. STRATTON
C-28
-------
. . .- .' ." "1
. I
v;~..~.
~~ ~ - ~
Go S "'1') ..:..-==-~. --- .~~
m I' Fuel N
P . ~ feed
~ " J[(i~l~j .
t -\~ I jl}T :10"1
Se:cOI1~:Fj i . ..1 - .
,.- air _k 1..-
1 J _r:~~'i. [ .
, -]'~ Ir-
A h .' \\ . . - =Q:) - FI u I d i:l t: d
~ ~ -----
r:::lilo~ar ;~I }r- -: £,oi.1b'.J!.1.or
pr~irory->-/ r[ .
Cyclol1t:
E.£r:::.!> u s 1. ° r
Figure C-2l - Institute of fuel research fluid
bed combustion system
C-29
-------
Moscow Power Institute
A two-stage furnace for a steam boiler was developed by the
Moscow Power Institute.
A fluid bed unit was combined with the combus-
tion chamber of the steam boiler (Figure C-22). Combustible gas and par-
ticles escaping from the fluid bed would be burned in the combustion
chamber.
Any coarse particles would fallout of the combustion chamber
an~ complete combustion in the ash pit.
Stouff
Stouff(6) proposed an agglomerating bed as a means for burning
untreated coal fines. Coal is introduced into the cone~shaped bed at
, ,
any level and the'air is injected at the base of the cone. A diagram of
the boiler system is shown in Figure C-23. Carryover from the bed is large,
and excessive losses are avoided by recycling fines back to the bed.
Yokoyama
bed system
Coal sized
Okaniwa and Suzuki(7) have proposed a p.f.-dilute phase fluid
forbur!ling low-grade coals available in Japan (Figure C-24).
less than 18 mesh is fired through the p.f. burners along the
water walls. Particles too large .to ,burn in the gas fall into the
fluidized bed in the cone-shaped bottom of the boiler. Approximately
80% of the air is blown upwards through the base of the bed. The tem-
perature in the fluid bed is 1550 -1650°F and the temperature at the
burners is near 2000-2200°F.
Additional Concepts
Novotny(8) describ~s early spouting beds which were proposed
for fluid bed combustion. A. A."Shershniev constructed a spouted bed
system in 1927 for the combustion of peat. Two beds were located adja-
cent to each other such that particles could be blown from the first bed
C-30
-------
Dwg. 861A447
Coal
Air
/
Fig. C-22- Two-stage fu rnace forstea m boi ler
C-3l
-------
COAl FEED
HOPHR
ASH PIT
At;D
AIR COX
..,..
/
/
FIGURE Q-23-STOUFF FLUID BED BOILER SYSTEM
C-32
-------
~I'
II I
U
L
..
CfJ
x
o
Co:
n.
D.
.c;
.
FIGUREc-24 - YOKOYM"A EXPERIMENTAL FLUID BED BOILER SYSTEM
C-33
-------
and thus the second bed helped to extend the residence time of fuel
particles in the combustion chamber. Szikla-Rosinek also developed a
spouting bed design. The design is complex and did not find practical
application. A spouting bed design" by K. Stousse is reported which
attempts to solve the problem of unburned carbon by a two-stage furnace
with recirculation of the fines to the fluid bed.
patents.
Several additional concepts have been proposed in ,recent
A list of patents which cover' proposed fluidized bed boiler
concepts is presented in Table C-1.
C-34
-------
Patent t\o.
2,842,102
2,976,853
2,983,259
2,997,031
3,C48,153
3,101,697
(")
I
W
\Jl
3,119,378
3,431,892
3,387,590
2,884,373
2,884,303
2,973,251
2,997,286
3,119,379
3,355,249
3,276,203
TABLE C-1
STATE-OF-THE-ART U. S. PATENT SEARCH:
Date
Patented
--~
7/8/58
3/28/61
5/9/61
8/22/61
8/7 /62
8/27/63
1/28/64
3/11/69
6/11/68
I'; 28/ 59
4/28/59
2/28/61
8/22/61
1/28/64
11/28/67
10/4/66
FLUIJ BED COMBUSTION AND COAL GASIFICATION
Title
Steam Generation
Steam Generation
Method & Apparatus of Steam Generation
Method of Heating and Generating Steam
Vapor Generator
Steam Generation
Steam Generation
Process and Apparatus for Combustion
and Heat Recovery in Fluidized Be1s
System for Regulating the Total Heat
Input in a Burning Fluidized Bed Heat
Exchanger or Boiler
Method and Apparatus for Heating Fluids
Inventor
H. J. B1askowski
A. T. Hunter,
R. C. Patterson,
E. C. Lewis
E. C. White
R. C. Ulmer
R. F. Abrahamsen
A. T. Hunter
L. J. Marshall
A. A. .Gode1
J. W. Bishop
Heat Transfer Apparatus
High Temp. Burning of Carbonaceous Fuels W. J. Metrailer
B. E. Bailey
Fluid Bed Furnace and Process
Apparatus for Combusticn of Fuels
Producing Hydrogen and Power
Top Heat Fower Cycles
M. B. Leland,
T. S. Sprague
G. Friese
M. P. Sweeney
A. M. Squires
A. H. Squires
Assignor To
Combustion Eng. Inc.
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
CIPA (in Switzerland)
U.S.A.
Esso R&E
Esso R&E
Babcock & Wilcox
Meta1lgesel1schaft
Aktiengesellschaft
(Germany)
M. P. Sweeney
A. H. Squires
A. H. Squires
-------
Patent No.
Re 24;328
3,004,839
2,607,666
2,665,200
(")
I
W
0'\
2,671,015
2,674,524
2,686,113
2,689,787
Date
P<,tented-
6/11/57
10/17/61
8/19/52
1/5/54
3/2/54
4/6/54
8/10/54
9/21/54
2,694,623 11/16/54
2,700,592
2,700,599
2.705.672
2,729,552
2,741,549
2,776,879
2,794,725
1/25(55
1/25/55
4/5/55
1/3/56
4/10/56
1/8/57
6/4/57
TABLE C-l, continued
Title
Conversion of Hydrocarbonaceous Fuels
into Synthesis Gas
Gasification of Carbonaceous Fuels
Apparatus for Treating Carbonaceous
Solids
Process for the Gasification of Solid
Carbonaceous Materials
Gasification' -of Carbonaceous Materials
Process for the Preparation of CO & HZ
Process of Promoting Chemical Reactions
Volatile Fuel Production and Apparatus
Therefor
Process for Enrichment of Water Gas
Method of Carrying Out Endothermic
Reactions Under Fluidizing Conditions
Gasification of Solid Carbonaceous
Materials
Manufacture of Water Gas
Process of Contacting Gasiform Car-
bonaceous Solids
Conversion of Carbonaceous Solids into
Volatile Products
Gasification of Solid Carbonaceous Fuel
Manufacture of Gas Mixtures Containing
CO and H2
Inventor
L. J. Montclair,
L. P.' Gaucher
E. L. Tornquist
H. Z. Martin
M. Kwauk
R. J. Morley
P. W. ,Garbo
W. W. Odell
H. J. Ozorzaly,
C. W. Tyson
A. B. Welty,
S. B. Sweetser
T. D. Heath
J. C. Kalbach
E. Gorin
K. J.Nelson,
E. J. Gornowski
F. R. Russell
W. Grumz
:W. G. Scharmann
Assignor To
The Texas Company
Northern Ill. Gas Co.
Standard Oil
HRI
ICI (England)
HRI
W. W. Odell
Standard Oil
Standard Oil
Dorr Company
HRI
Consolidation Coal Co.
Esso R&E
Esso R&E
HRI
Esso R&E ,"
-------
Pat.:ent No.
Date
Patented
2.866,696
12/30/58
2,868,631
2,906,608
1/13/59
9/29/59
2,911,293 11/3/59
2,985,515 5/23/61
3,086,853 4/23/63
3,311,460 3/28/67
. "
(1
I
LA)
-..j
3,322,521 5/30/67
2,l.40,940 5/4/48
3,454,382 7/8/69
3,433,859 3/18/69
3,226,212 12/28/65
3,034,776
5/15/62
TABLE C-l, continued
Title
Process for the Gasification of Granu-
lated Fluidized Bed of Carbonaceous
Material, Over Moving, Sloping, Horizon-
tal, Continuous Grate
Gasification Process
Apparatus for Dense Phase Fluidization
Production of Gas
Fluidized Solids Contacting S~:stem
Method of Gasifying Combustible Mater-
ial in a Fluidized Bed
Method for Gasification of Carbonaceous
Materials
Process & Apparatus for the Gasifica-
tion of Ash-Containing Fuel
Gas Producer
Two-Stage Type Gas Producer
Inventor
A. Godel
H. N. Woebcke
L. J. R. Jequier
Van de Putte
P. S. Viles
D. L. HcKinley
A. P.. L. Brand-
berg
H. H. Stotter,
G. B. Farkas,
P. G. Keith
R. G. Cockerham
A. L. Galusha
G. H. Hamilton
Process for the Preparation of Hardened, T. E. Barr
Dense Heat Transfer Medium
Apparatus for the Production of Combus-
tible Gases From Solid Carbonaceous
Haterials
Rotary Furnace
T. E. Barr
Hannenberger,
et al.
Assignor To
CIPA
HRI
Inventors
Esso R&E
Union Carbide Corp.
S1:ledish Co.
HRI
The Gas Council
(England)
McDowell-Wellman
McDowell-Wellman
McDowell-Wellman
McDowell-Wellman
Lurgi
-------
REFERENCES
1.
Physics Departmental Memorandum No: 152, National Coal Board, Coal
Research Establishment.
2.
Gode1, A. A.; French Patent No. 1,092,540.
3.
Proceedings of the First International Conference on Fluidized Bed
Combustion, NAPCA, Oxford, Ohio (Nov. 1968).
4.' Gode1, A. A.; U. S. Patent 3,431,892.
5.
Stratton, J. F. 0.; Power 68, 486 (Sept. 1928).
6.
Stouff, M. 1.; Paper presented at the "Journees de 1a Combustion
des Combustibles et pu1verises", (1957).
7 .
Keiji, O. and J. Suzuki; J. Fuel Soc., Japan, 38, 429 (i959).
8.
Novotny, P.; Monograph No. 14, Institute For Fuel Research.
9.
Ehrlich, S., E. B. Robison, J. S. Gordon, J. W. Bishop,; paper pre-
sented at AIChE 69th National Meeting, Cincinnati, Ohio (1971).
C-38
-------
APPENDIX D
INDUSTRIAL BOILER DESIGN REPORT
Prepared by Erie City Energy Division,
Zurn Industries, Inc.
Authors
Robert V. Seibel
Richard E. Winschel
D-l
-------
STUDY OF FLUIDIZED BED COMBUSTION
- - INDUSTRIAL STEAM GENERATOR APPLICATION - -
INDEX
Abstract -------------------
Introduction ----------------------------
General Discussion -------------------
Fuel System --------~--------~.
Limestone System -----------------
Steam Generator ~---------------------
Fluidized Bed Combustion Chamber ------
Carbon Burnup Cell --------------
Superheater -------------------------
Conv~ction Pass -----------------------
Water Circulation System ------------
Economizer ---------------------------
Primary Ash Collector -------------------
Ash Handling System ---------------
Controls and Instruments ----------
Combustion Control -------------------
Feedwater Flow Control -------- M
Steam Teaperature Control ---------
Electrostatic Precipitator -------------
Wet Scrubber - Slurry Dewatering ----------
.Dry Solids System -----------------
Wet Scrubber System
----------~---
Economic Factors of the Two Systems -----
Conclusions
--------------~----------~--
D-3
PAGE
D-5
D-6
D-8
D-9
D-13
D-13
D-13
D-17
D-18
D-20
D-20
D-21
D-22
D-22
D-23
D-23
D-25
D-25
D-26
D-26
D-27
D-29
D-29
D-32
-------
Abstract:
Fluidized Bed Combustion studies were continued by applying latest
state of the art knowledge to develop a useful industrial steam
generator.
A study of the market (reported previously) pointed'
out the useful capacity, steam pressure, and, steam temperature.
A commercial design was developed from an understanding of user's
requisites and economic factors.
Fuel handling and steam generator
design was held constant in the development of two different systems
to control atmospheric emission.
A sample proposal in response to
an assumed specification was developed.
It was concluded that the
cost factors appear competitive for coal burning applications when
compared to present techniques.
D-5
-------
Introduction:
Fluidized Bed Combustion techniques have been studied for some time both
in the United States and in foreign countries.
The investigations were not,
however, extensions of fluidized bed processin~ which has had a long history
of commercial chemical processing applications.
At the outset, the studies
in the United States were to develop smaller size, less expensive coal fired
steam generators.
The public feeling about environmental factors lead to
the study of control of pollution control.
Now controlling the emission of
combustion products such as sulfur oxides and oxides of nitrogen appears to
be the more valid reason for studying fluidized bed combustion techniques
in the United States.
Pilot plant and laboratory studies formed the base of the development.
No
commercial sized units for pollution control were or are readily available
since investment costs are prohibitive.
Industrial steam generator users rely
on high availability, low maintenance, and proven designs for new or
replacement units.
Capital investment for "non-profit making" equipment, that
is not fully proven and without nearly full size pilot units is no~ done.
Whether further development would prove f~itful was a question left to be
answered by someone other than the users.
Government authorities sponsored
this and other studies where the worth of further pilot studies is being developed
by using the background data already available and by looking into the future
at steam generator markets.
This study, only a part of a much broader one, was then to produce a commercial
design for the industrial steam generator markets.
Economic factors would be
developed and, also, as areas of further development would be made more clear,
development costs could be outli~ed and pollution control effects could be
pointed out.
D-6
-------
Erie City Energy Division of Zurn IndustrieR was authorized as a sub-contractor
to Westinghouse to utilize information sources about the steam generator
markets and to develop markets prediction as to a useful size steam generator
for future markets.
From the market information, a commercial design for a
steam generator would be developed, using a procedure whereby the state of art
would be defined by Westinghouse and integrated into commercial designs.
Economic considerations such as capital costs, optimum design, and operating
costs would be developed parallel with the technical design.
Work would be
done by Erie City Marketing Computer and Engineering Forces.
The following is a report on the work that was done to produce a steam
generator design that tests the market and the sellability of a Fluidized
, Bed Combustion Steam Generator for industrial' application.
It is assumed that throughout this report the reader bas an intimate
knowledge of fludized bed technique and terminology.
D-7
-------
GENERAL DISCUSSION
------------------
As the work with fluidized bed combustion steam generators progressed two systems
began to emerge. . Both systems were designed to consume coal at the same combustion
conditions, but each was different from the other in regard to the control of
atmospheric emission of sulfur oxide gas.
The steam generator, nevertheless,
remained the same in both cases.
It is important to bring this out at this point
since references will be made to each system throughout the report.
'One system utilizes lime, calcium oxide, to absorb sulfur dioxide formed in the
combustion reaction as soon as the sulfur component in the fuel is oxidized.
This is the "Dry solids" system.
The term comes from the fact that the reacted
calcium oxide is taken out of contact with the flue gas in a dry state as a
powder.
The other system, designed to have equivalent performance in the control
of sulfur emissions, is called the wet scrubber system.
In this system limestone
is calcined in the fluidized bed and is mixed with water to form a slurry which
contacts the flue gas.
The limestone slurry has an affinity for sulfur oxide
gases and they are removed from the flue gas.
Although in both systems, the same
steam generator is used, there are fundamental differences in the auxiliary
~quipment needed for the system.
These differences are discussed in more
detail later.
The market survey and study of the technical aspects points to a steam generation
capacity of 250,OOOU/hr. of steam at a steam pressure of 600 PSIG, and steam
temperature of 7500 F.
There appears to be a growing demand for units like this
and in 1980 that demand will approach 40% of the industrial steam generator
market.
Refer to Appendix XII.
These steam conditions of temperature and pressure
imply a steam generator where steam will be used to generate power in a turbo
generator.
The steam after expansion to a lower pressure, normally
150 PSIG. is made available to the process
D-8
-------
applications such as heatinR.
In other cases, when processing power requirements
are high, the auxiliary equip~ent drivers may be turbines exhausting to the
process steam header.
With those conditions in mind and using hi~h sulfur coal
as the basic fuel, work was centered eround finding the most economical arrangement
of steam generator components, and the auxiliary equipment needed to complement
the steam generator system.
All significant components were subjected to individual
study.
These are as follows:
- Fuel System
- Limestone Feed System
-Steam Generator, including the superheater and saturated sections
- Economizer
- Primary ash collector
-Ash handling systems
-Controls and instrumentation
-Electrostatic precipitator
-Wet scrubber and Limestone Slurry Dewatering System
In addition to this, the system considerations such as heat and material balances
were developed.
Cost data -were developed as the design was produced.
This report will be divided according to the system components mentioned above.
Under each section will be a discussion of the design parameters, goals for the
designs and what appeared to be the best arrangement according to the combination
of "State of the Art" and present economic factors.
Appendices covering specialized
areas of study are attached.
FUEL SYSTEM
In recountin~ the design work on the whole project, the most difficult problems
that must be solved in developing Fluidized Bed Combustion steamge~er~tors 1s
that
involved with materials handling.
. .. .
This includes theprepciration, the handling,
and the inject~on of coal and limestone.
D-9
-------
In all fuel feeding systems, several factors are vital and must be accounted for.
These are:
---Control of the fuel feed rate.
- Constant and preferably negligible time transients from inlet to
the discharge of the system.
-Wear resistance and easy maintenance.
~-Negllglble power requirements.
... . .
All of the above must be solved in the design for Fluidized Bed Combustion
Steam Generators.
Some of the problems presented by the fluidized bed combustion are well known in
utility practice.
For example, overcoming the pressure interface of 40 to 50
inches water gauge to allow injection of coal into the fluidized bed combustion
chamber.
Direct firing of pulverized coal and both the indirect and direct-fired
cyclone furnaces utilize the head of coal feeding from the bunker to prevent
significant loss of pressurizing air admitted to the fuel feeding equipment.
Also, handling coal crushed to 4 mesh size as with indirect fired cyclone furnaces,
in bunkers, bulk conveyors, and rate feeders has been well developed through
experience in utility practice.
Commercial specialized equipment to do this job
i8 readily available.
In fact, rate feeders have been developed that lend
themselves to precise gravimetric rate control. Refer to Appendix IX.
The one relatively unique problem presented by the present thinking about fuel
feeding is the multiplicity of fuel feed points.
For example, in thinking of
an atmospheric fluidized bed boiler for 250,000U/hr. steam capacity, approximately
400 sq. ft. of grid area will be required.
If fuel injection must be made at
the rate of one point for 10 square feet of grid area, there would have to be 40
separate feed points.
This does not
in itself present a problem since fuel piping
and bed injection techniques are not particularly restrictive.
The most difficult
problem in this, is the requirement of dividing one stream of the fuel into 40
D-IO
-------
uniform divisions.
(It would be quickly seen that there would be little relief
if 40 fuel rate feeders were considered not only because of cost, but also, since
exact parallel control that is required would be an impractical case.)
To include present practice and available equipment with a suggestion to handle
new areas certain assumptions were made:
-Coal would be prepared in a bulk-type crusher upstream of the bunker
in an indirect system, 100% less than 1/4~'sizlng was anticipated.
.- One fuel rate feeder would be used.
-The air pressure interface would be made at the bunker with sealin~ air
fed to the fuel rate-feeder.
-There would be four sections of the bed arranged so that one section
could be shut off, independently.
-There would be eight injection points in each of the four bed sections.
Air would transport the coal underneath the grid to the injection point.
-The coal injector nozzles would be removable for repair and replacement
even with the boiler remaining in service. (But with that bed section
shut down.!. .
To develop these ideas, arrangement drawings were made of the coal handling and
boiler system.
In the fuel system, after delivery to the plant, the coal is
crushed at the rate of 2 to 3 times the firing rate and passed to' a single surge
bunker feeding the boiler.
Bunker capacity would be set to handle several hours
firing to allow efficient crusher and conveyor operation, and, to allow adequate
periods of maintenance for the coal crusher and handling equipment without
interrupting boiler operation.
From the bunker, coal is fed to the system usin~ a sin~le belt-type, ~ravimetric
controlled rate feeder.
From the rate feeder, the coal enters a two stage splittin~
system.
In the first stage, the single coal stream is geometrically divided into
four streams each of which can be shutoff for load control or for downstream
D-ll
-------
maintenance.
Each of the four streams would feed a separate section of the bed.
In the second stage, coal is split into several more streams,
In the final design,
for a maximum of 10 sq. ft. per injector point, there would be 8 streams leaving
the second stage splitter.
From the second stage splitter coal drops into an air-swept horizontal pipe which
carries the coal underneath the grid to the injection point.
For' the second stage
splitter or distributor, it was proposed to have a vibrating table feeder to
distribute the coal stream from the first sta~e splitter over the width of a
symmetrical geocetric shape with eight outlets.
At the injection point location, a special grid casting receives the nozzle at the
end of the air transport pipe.
The nozzle is arran~ed so that a compressed air aspirator allows the removal of
individual nozzles while the steam generator remains in service.
This can be done
by reducing the steam generator load to where one bed section may be taken out
of service.
There was some concern about
wear and a jet effect from injecting the coal air
stream into the bed.
The first nozzles proposed utilized a vane principal to
'direct the coal air steam normal to the axis of the nozzle which was horizontal.
It was thought that wear and jet effects could reduce the effectiveness of
this design.
The final design proposes to have the nozzles inclined at a 30° slope
,into the fluidized bed chamber with. a "straight-in" nozzle design.
Several study drawings were made of the coal feeding system (see drawin~ reference
list in Appendix X.)
Drawing FBB-28, in the figures section, pertains to the
final design and gives an outline of the fuel system including the component parts.
D-12
-------
LI~ffiSTONE FEEDER
As noted on the drawing FBB- 28 the limestone feeder was selected as a vari-
able amplitude vibrating table feeder.
The limestone hopper is a pressure seal type
similar to the coal bunker.
The limestone will dischar~e at the dischar~e
end of the coal rate feeder where it mixes with the coal flowing to the fluidized
bed.
In both the dry solids and the wet systems, the limestone feed rate is not
changed instantaneously with the fuel feed rate. Instead,limestone feed is adjusted
to optimize sulfur oxide gas removal. In both systems, either dry solids or wet
scrubber, an increased limestone feed rate will reduce the sulfur dioxide con-
centration in the stack gas.
STEAM GENERATOR
The steam generator design is more easily visualized if it is considered to be
of four components:
-The fluidized bed combustion chamber.
-The carbon burn up cell.
-The superheater.
- The convection pass.
(For reference the four steam generator components are shown on drawings FBB-19
and 20 attached).
STEAM GENERATOR - FLUIDIZED BED COMBUSTION Cl~ER
At the outset of the study, two different fluid bed chamber desi~ns looked
attractive.
Each was developed to preliminary sizing where there would be equivalent
bed temperatures for the 250,OOOD/hr. steam generator.
The two were differentiated
by the arrangement of heating surface submerged in the fluid bed.
They were:
a vertical tube design; and, a horizontal tube design. (The horizontal tube configu-
ration is indicated on the figures attached. Study drawings FBB-i, 3, 4 and 6
presenting an outline of the vertical tube configuration. These study drawings are
not presented in this report.) .
D-13
-------
Although the functional characteristics of the vertical tube design were questioned.
not enough direct information was available to eliminate it as a valid concept.
On the other hand. experimental data have been gathered on the horizcntal tube
designs and there is confidence that full scale performance would be predictable.
In that the two designs had different construction it was decided to submit them to
pricing competition.
Each of the desi~ns for the fluidized bed chamber provided for
shop assembly of two separate
fundamental components - - the fluid bed chamber
and the boiler convection zone.
In both cases. the two parts would be mated in the
field with a minimum of butt-welded pipe connections.
For the price competition for each design. the fluid bed chamber costs were
compared on an equal basis:
-Insulation and lagging were not included.
-The fluid bed grid was not Made a part of the cost.
-Air flow chambers and material handling systems were not considered.
-Field assembly costs were considered to be equal in both cases and
were not included.
-Assembly costs to produce sub-assembly of tube arrangements were included.
On this basis. it was revealed that the horizontal tube design would have a
very much lower selling price.
Price data showed the following comparative figures on the basis above:
Equivalent Selling Price:
Vertical Tube Design
Horizontal Tube Design
Material - - - - - -
- - - - -
- - - -
1.46
1.0
Labor (fabrication & assembly)
- - - -
2.29
1.0
Total selling price (weighted a8
to the total cost of labor &
material)
2.04
1.0
D-14
-------
(The portion of the total steam ~enerator included in the above was found to.be
about 20% of the total price.)
Wei~hts of material for each desi~n were found
to be equivalent with 117,000 pounds for the vertical tube and 102.000 pounds for
the horizontal tube design.
The number of welds required for the vertical tube was
found to be 2.900 and only 770 for the horizontal tube design.
The latter factor,
proved to be the cause of the cost differential.
It was concluded by this analysis, that the horizontal submerged tube design
would offer the better economic choice even though the above data do,not reflect
all of the compensating differences between the two designs.
The horizontal
tube design requires a recirculating pump to provide adequate water flow to cool
the tubes submerged in the bed.
Also, since there is no freeboard heating surface
in the horizontal tube design, there would be more surface required in the boiler
convection pass.
From the s~uciy of prices, then,it is felt that the vcrtic~l tube desig~ should be
largely eliminated from our work in preparing data concerning an atmospheric
fluidized bed combustion steam ~enerator design.
A factor in this decision was
plainly. the fact that development work was concentrated on the horizontal tube
designs.
As the bed design emerge~ utilizing the horizontal tube design, the design parameters
of the bed were brought into better focus.
To summarize, the desi~n factors are:
-Grid heat release rate - - 1 x 106 Btu per hr. per sq. ft.
-Bed Depth - - 30 in (expanded)
-Bed temperature - - 1650 F in fuel bed - - 2000° F in carbon Burnup cell
-Heat transfer coefficient - - 50 BTU/hr. sq. ft. F
-Free volume space underneath the submerged surface
-10% excess combustion air flow through fuel bed
-50% excess combustion air flow through the carbon burnup cell
D-lS
-------
-Application of a particle splash screen
-Tube arrangements that minimize lane effects
To meet these criteria it appeared that the submerged horizontal tube surface
must be composed of small diameter (1") tubes.
Also, forced circulation to cool
the submerged surface will be required.
All materials of construction for
the saturated heat absorbing surfaces and seals are carbon steel types.
Erie City Energy Division drawing FBB-19 attached, shows an arrangement of
submerged surface, and particle splash screen using 1" diameter tubing.
The
spacing shown is to allow straight tubes where the 1" tubes penetrate the combustion
chamber wall.
The number of submerged tubes and splash screen tubes shown in
FBB-19 are the maximum obtainable.
Using parameters now assumed valid, there is a
slight excess heat absorbing surface.
As more becomes known about the bed heat
transfer, the surface may be adjusted to provide operation as desired.
The fluidizing grid design and selection is a subject that still has not been
well defined.
The "State of the Art" designs all utilize nozzles which direct
the fluidizing air either parallel to or against the ~rid plate.
While these
are not particularly restrictive mechanical problems, it is felt that castings with
cored holes would be more economical and would provide for longer service life.
In working toward a commercial design som~ casting designs were developed and are
available for review (refer to the study drawing listing in Appendix X.)
Even
though nozzles may be required, it was contemplated they would be applied to
castings which would be contoured to closely fit the fluidized bed floor tubes.
These castings would be bolted providing cooling in addition to the affect of the
fluidizing air flow.
One facet of the fuel injection point spacing shown on FBB-20 in the fuel burning
grid is the clearance from one transport pipe to the next.
The arrangement shown
is to allow all n~zzles to enter from one side of steam generator.
D-lt1
-------
STEAM GENERATOR - CARBON BURN UP CELL
On drawinr, FBB-20 attached, there is a sectional view through each component of the
steam generator.
In the case of the carbon burn up cell, it should be noted that
the ~as is collected at one end of the combUGtion chamber and directed through the
carbon burn up cell where carhon rich ash is injected and burned with a combustion
air stream that is part of the combustion air stream.
Some heat transfer surface is in-
stalled in the carbon burn up cell to control the bed temperature.
The location of the carbon burn up cell whether up stream or downstream of
the primary dust collector is a matter of much discussion, and review.
In
the case of the designs presented, here it was felt that the boiler design should
take precedence.
It is seen upon close review that the bed temperature control is
part of the boiler steam ~enerating circuits.
To place the refining
system
upstream of the primary collector requires the separation of the boiler circuits.
This could very likely lead to having a third boiler component and would at
least lead to higher equipment costs.
There is, of course, the likelihood of insufficient oxidation of unburned carbon
in the arranp,ement selected which is a "once through" system. It is thought that the
.arrangement selected is also better since recycling of ash is not a feature.
It
must be realized that comprehensive data do
not exist to outline the carbon burn-
up cell location and operation.
At this time it is felt that both higher fluid bed
temperatures and higher relative air flows are returned to achieve the desired results.
Bcd temperatures are thought to be 1900 t02000°F. with 50% excess combustion air
supplied to the carbon refiring system.
The need for turndown led to sectionalizing the carbon burn up cell into four
sections which would generally be operated parallel to the fuel burning bed
sections.
Ash would be air transported to the carbon burn-up cell and injected
D-17
-------
similar to the fuel.
Combustion air and ash injection would be operated in
parallel for each carbon burn-up cell segment.
In addition, equipment and
instrumentation would be installed to bias air flow to allow temperature control.
Increased air flow will lower the bed temperature.
STEAM GENERATOR - SUPERHEATER
----
For the capacity, steam pressure and temperature conditions selected, the
superheater heat absorption represents only 15% of the heat output in the steam.
It should be noted that this is less than the single bed section capacity of
25% of the total fuel burning capacity.
This fact and that economical design
does not allow fuel modulation of a single bed section, led to the decision
to utilize a "conventional" superheater design.
In the utility Fluidized Bed Combustion Steam Generator, a unit of the fuel
burning bed can be large enough to have individual control of firing rate and,
thus, be devoting the possible heat absorption to superheating, a constant final
steam temperature can be obtained.
Superheater tube excessive metal temperature
protection and start-up problems are easily handled when an entire bed unit can
be used for superheating.
The industrial steam generator case is more restrictive
b~cause of size and heat input.
To follow conventional superheater design for the industrial boiler application,
no superheater surface is included in the bed.
It is arranged so that the flue
gas from the fuel burning beds is gathered together and passed through the
superheater and "boiler bank" or convection pass.
It is anticipated that the superheated steam temperature would be "uncontrolled".
This is to say that it is designed for full load conditions with no means to
D-18
-------
"trim" or control steam temperature.
There would be no need for special means
to protect against exceeding the superheater tube metal temperature capability
since there would be little or no disparity between steam flow and heat absorption.
The superheater would be arranged with vertical headers outside the outer wall
of the convection zone.
Tubes would be arranged to have counterflow steam to
flue gas with the tubes passing back and forth normal to gas flow.
Drawing FBB20
attached, depicts this arrangement of superheater surface.
To balance the factors of heat absorbing surface, physical limitations and
pressure drop, 2-1/2" O.D. tubing was chosen.
A vertical spacing normal to gas
flow of 6-1/2" was used.
A parallel or back spacing of 4" was used.
The two
basic design parameters which are the full load superheater pressure drop
(27 PSI) and also the metal temperature consideration, will allow the use of
carbon steel tubing.
The flue gas temperature levels in the superheater section dictate that the
largest component of heat absorption is convection with only a slight radiant
characteristics.
.In such an arrangement of superheater, it is commonly seen
that the steam temperature is directly related to load.
Part of this effect is
the increase of the initial gas temperature.
Advantageously, the fluidized
bed steam generator riffers some means to control this characteristic over the
load range.
By selecting bed sections either closer to, (or farther away,)
from the superheater, it is possible to affect the superheater inlet gas
temperature and to adjust the steam temperature accordingly.
In regard to turndown, if excess air is used for bed temperature control, the
steam temperature will be effected.
If excess air is increased. the steam
D-19
-------
temperature will increase.
A de-superheater in the boiler system to reject heat
from the stream will be needed in this case.
Unlike utility hoiler practice,
however, the steam temperature trimming system would not be desi~ned to extend
the control range of steam temperature but only to adjust the unbalanced or
transient operation.
The convectional type. superheater would:
reduce boiler design pressure since
some means to protect superheater tube metals if they were located in the bed
is not needed; it would provide for easy startup; and it would allow greater
safety of the materials at lower loads.
In light of these factors, it is the
better choice for the industrial steam generator applications.
~~~~EN~RATOR - CONVECTION PASS
To recover heat from the flue g~s to a level where only one heat trap is needed,
the flue gases leaving the superheater are passea through the convective section
of the steam generator.
In convection zone, 2!! tubes are arrangeu on 4-1/2"
spaces.
They are part of the steamgeneratinr, heat absorption.
STEAM GENERATOR - WATER CIRCULATION SYSTEM
1\1 the steam generator, a circulating pump is applied to supply flo~
through the heating surface that is submerged in the fluid bed.
The walls of
the fluidized bed combustion chamber and. all other surfaces are cooled by
"natural circulation" water recirculation.
Drawing FBB-J2 attached shows a
schematic view of the circulation system.
No valves are used to parallel flow
through various circuits.
Circulation requirements and parallel path pressure drops are adjusted to
maintain safe operation under all operation conditions.
For the proposed
design, this has been studied by introducing elements 'of pressure drop, such
8S, "underdrllling" the header entries for tubes, selecting pipe sizes t~ intro-
duce or to eliminate pressure drop influences.
For example, in "un'.~rdrilling"
D-20
-------
a header the diameter of the hole that is drilled through the counter bore
that receives the tube in the header is less than the internal diameter
of the tube.
An orifice results.
Since the system resistance is not great, pipe sizing to insure equal
distribution must be done carefully.
Also, piping links must create a good
distribution system.
ECONOMIZER
----
A study of heat traps was made comparing tubular and regenerative air heaters
and, bare tube and extended surface tube economizers.
By cost comparisons
it would found that the extended surface economizer was found to be most
economical.
(The results are inline with the present steam generator
equipment purchasing practices.)
Although some work on Fluidized Bed Combustion alludes to the necessity
of two heat traps, it developed through Erie City work that there is sufficient
convection surface in the steam generating system to obtain high thermal
efficiency.
As a result of this finding one heat trap is the economic choice.
See Appendix XI for a discussion of the heat trap application.
D-21
-------
PRIMARY ASH COLLECTOR:
------ -------
To obtain the maximum thermal efficiency by reducing unburned combustibles to low
-ends it is necessary to refire carbon rich ash that is elutriated from the fuel
burning bed sections.
The system chosen to do this is a cluster of cyclone dust
collectors downstream of the fuel burning fluidized bed sections.
The cyclones
are arranged to .handle all flue gas from the bed.
They are refractory lined and
internally insulated.
Collection efficiency will be 90% of the ash, carried out
of the fuel burning beds.
Sectionalizing dampers will be required to maintain
collection at reduced loads.
Ash removed from the gas stream 1s transported to the carbon burn-up cell where in
another flu1d bed the carbon 1s refired at relatively high rates of combustion air
and at bed temperatures higher than the fuel burning sections.
It is anticipated that the amount of ash will be related to 'load.
Because of this
the carbon burn-up is compartmented to allow shut down of sections for turndown.
Shown on the schemati~ drawings FBB-30 and 31, hoppers are linked in series to the
ash transport system allowing independent operation of the dust collector sections
and carbon burnup cell.
ASH HANDLING SYSTEMS:
-_._---------
There are two fundamental ash handling systems.
One for carbon rich ash receiving
ash and carbon from 'the primary cyclone collector and the other transferring ash from
the bed sections and from an ash pickup point underneath the superheater.
In the cast::
of the dry solids system. the electrostatic precipitator ash is also discharged to
the ash system.
In all cases a pneumatic ash handling system is contemplated.
The system would be
pressurized and the ash feeders would be lock hopper types to feed across the
pressure interface.
The lock hopper feeders offer an advanta~e in that feed rate
can be adjusted to compensate for operational adjustments.
Lock Hoppers and 8sh feeders are available and are proven equipment. ,See Appendix
IX for information.
D-22
-------
CONTROLS AND INSTRUMENTATION:
There are three basic divisions within the overall control system for the fluidized
bed combustion boiler.
The combustion controls. the feedwater flow control and
steam temperature control.
The basic principles of the control system are the same
for the ftuiclized bed combustion unit as for any sub-critical recirculating type boiler.
Nomenclature and the detailed control loops are slightly different in the case of the
Fluidized bed system. however.
The following will outline the functional aspects of the three different divisions
of the control system (Reference drawing FBB-27).
INSTRUMENTS & CONTROLS - COMBUSTION CONTROL SYSTEM
The fuel burning fluidized bed is sectionalized to allow shutting down one or more
sections for turndown and for on-line maintenance purposes.
The air flow to each
section may be modulated independently of other sections.
Fuel flow, however. is
s~H t eq1.1~ll;. to e:!ch opcr~ting section and may hot be biased to one bed section.
Combustion air is fed to a common plenum by the forced draft fan with the plenum air
pressure being maintained by the inlet vanes.
Combustion air flow to each bed
section and to each section of the carbon burn-up cell i8 controlled by individual
dampers.
Flow to each section is measured and totalized.
Bed temperature is measured in each bed and carbon burn-up cell section.
Bed
temperature is a factor in the air flow control and also is a limit in starting up
and shutting down individual bed sections.
Steam header pressure is the load sensitive control element used to initiate fuel
feed.
D-23
-------
In reference to the functional control schematic, it is seen that the plenum chamber
pressure transmitter signal is compared to a summed si~nal or~~inating from other
control functions representin~ air pressure demand.
The output signal from the error
computer is sent to a proportional plus reset controller to a hand-auto station and to
the forced draft fan vane positioner.
The fuel. feed signal is developed by comparing the header pressure signal to a
set point.
The error signal is sent through a proportional plus reset controller
to the boiler master hand-auto station to a multiplier receiving a signal from
the fuel air ratio setter to the fuel feeder hand-auto station to the fuel feeder
speed controller.
Multiple control loops are required for the air flow control system.
One loop is
shown on the schematic drawing and is typical for all bed and carbon burn up cell
sections.
In an air flow loop the air flow signal is compared to a demand signal irem the
master and from bed temperature.
The master signal is modified by a multiplier
indicating the number of bed sections in service.
(The multiplier is required to
indicate the extent of fuel splitting--to cite an example, for the same fuel feed
at 50% load 2 or 3 bed sections may receive the fuel.
A different air flow
relationship to master signal is required in each case).
The bed temperature
signal is converted to pneumatic and compared to a set point. The error is sent to
a proportional plus reset controller where the output is alarmed and sent to a
summing relay along with the master signal.
When there is an error between the air demand and actual air flow the error signal
is sent to the proportional plus reset controller. the-air flow hand-auto station.
and to the damper drive positioner.
D-24
-------
For alarm purposes, if there is a si~nificant difference between the master and air
flow signal, an alarm will be signalled.
For bed starting up a sub-loop including a transfer switch and time delay volume
chamber is used to control the rate of air flow introduction and bed fluidization.
The system schematic shows that the output to the final error computer is limited
by a rate system initiated from the transfer switch.
The two demand signals for the plenum chamber pressure control system are developed
from the master signal air flow multiplier and the output to the damper drives.
To
compensate quickly for a change in the number of operating beds, the master
air flow multiplier output enters the summing relay.
Also, the highest air flow damper
signal is sent through a proportional reset controller to the same summing relay.
By using the highest damper signal sufficient plenum pressure is obtained to have
sufficient air flow capability to each bed section.
FEEDWATER FLOW CONTROL SYSTEM
The feedwater flow control or steam drum level control is a three element type.
Feedwater and steam flow signals are compared.
If a difference occurs, a signal
is sent to a rate response system and to the feedwater flow control.
The steam
drum level is compared to a set point.
If a difference exists, a signal is set
through a summing relay to the feedwater control system.
The signal from the flow and
from the level is compared and sent to a proportional reset controller to the feed-
water hand-auto station 'and then on to the flow control valve positioner.
STEAM TEMPERATURE CONTROL SYSTEM:
In light of varying bed operating conditions and extending the load range of
constant superheater steam temperature a spray attemperator will be used.
D-25
-------
The principal signal will be the steam flow in a two element system.
The
outlet steam temperature signal is converted to pneumatic and compared to a set
point.
The error signal is sent through a proportional plus reset controller and
summed with the steam flow si~nal.
The. combined si~nal is passed throu~h the
attemperator hand-auto station to the spray flow control valve.
ELECTROSTATIC PRECIPITATOR:
In the dry solids system particulare emission is controlled by an electrostatic
precipitator.
It is designed for low sulfur gas conditions and will have greater
than 99% collection efficiency.
See Appendix 1X for information.
WET SCRUBBER-SLURRY DEWATERING:
In the wet scrubber system, the contacting stages scrub the flue gas free from
particulates.
At the same time, sulfur oxide gases are absorbed by the limestone
slurry passed through the scrubber.
See Appendix IX for more information.
The wet scrubber also requires a slurry dewatering sYRtem.
This includes a thickener
and a vacuum filter and a material handling system.
Drawing FBB-36 presents a
schematic view of the equipment required.
DISCUSSION OF THE TWO SYSTEMS
The arrangement drawing, FBB-23, is useful in establishing the floor space and
volume required for the dry solids system. It should be noted that all components
shown are on bottom supported from the grade elevation.
Drawing FBB-34 shows the heat and material balance for the dry solids system.
Appendix VI presents the relationship used to establish the materi~ balance.
D-26
-------
DRY SOLIDS SYSTEM:
-------
At the outset of this study of fluidized bed combustion application, the
principal means to control sulfur dioxide emission was thought to be one
where the fuel was burned in an environment of calcined limestone.
As soon
as the sulfur was oxidized it would be absorbed by sulfation of the limestone.
At the bed temperature of 1650° F. this reaction was feasible although the
kinetics require several times the stoichimetric amount of limestone.
In
fact, at the rate of 6 times the amount of sulfur in the coal, the amount of
limestone required is nearly equivalent to the coal feed.
This amount of ash, for the purposes of this study, is said to be "once-through".
That is, fresh limestone is fed continuously to control the sulfur emission.
After it has reacted with sulfur in the bed and has been removed from the system,
it is discarded.
Some work is contemplated to develop regeneration techniques
but the effects of limestone regeneration were not considered in this study.
For discussion purposes, three drawings attached describe the dry solids
system.
Drawing FBB-30 shows a flow diagram pointing out the components parts
and a schematic system for auxiliary equipment.
Drawing FBB-23 presents an
arrangement of the equipment showing front, side and plan views.
Drawing FBB-34 presents a heat and material balance for the dry solids system.
To describe the various components and their function it is seen that all
steam generator components and auxiliary equipment are shown on FBB-30.
On this
drawing it is seen that coal is crushed to the firing size, transferred to a
surge hopper where it is metered into the fluid bed chamber along with the
D-27
-------
limestone which is rate fed into the system.
Combustion air is forced through
the fluidized bed grid to burn the coal.
Flue gas passes through the primary
dust collector.
The flue gas is then cooled with superheater, convection pass
and economizer prior to final particulate removal in the electrostatic
precipitator.
Carbon rich ash removed in the primary cyclones is burned
in the carbon burn-up cell.
Limestone which has collected sulfur from
the coal is extracted from the bed and sent to the ash silo.
This same ash
handling system receives ash from the hoppers under the superheater and
from the electrostatic precipitator.
All components required are shown on
this drawing including valves, dampers, etc.
D-28
-------
WET SCRUBBER SYSTEM
As work progressed in this study, it became apparent that the control of and the
feeding and material handling problems with the dry
solids system could be somewhat alleviated if there was more efficient use of
the limestone feed.
To do this, it -is proposed to calcine the limestone i~ the
bed and then transfer it and make a lime slurry for a stack gas scrubber.
This
system requires
20% more than the stoichimetric amount of limestone.
Enough energy would be expended in the sulfur gas absorption system to remove
particulates along with the absorption of sulfur gases.
- -
Drawing FBB-31 presents a schematic flow diagram for the wet scrubber system show-
ing the component parts.
Since the fuel feeding system and the steam generator
remains the same in both systems, only that equipment for the wet scrubber is
shown in arrangement view on drawing FBB-29.
In addition to the contacting
stages of the wet scrubber FBB-29, drawing FBB-36 shows the components for the
slurry dewatering system.
A heat and material balance diagram for the wet
scrubber system is shown on drawing FBB-35.
ECONOMIC FACTORS OF THE TWO SYSTEMS
It was brought out that two different systems apparently could emerge from further
development work.
The systems could be made to have equivalent stack emissions.
If this is true, what is the relative merit of one versus the other?
Comparisons were made as to the cost and power requirements.
In both these com-
parisons, the dry solids system is the better.
See Appendix I for cost compari-
son.
Appendix VIII shows power requirements.
D-29
-------
The heat and material balance indicate a favorable efficiency for wet scrubber
system.
However, in reviewing capital costs, it is seen that the dry solids
system is estimated to have appreciable less first cost.
The dry solids system
cost appears to be $6.10 per pound per hour of steam generating capacity.
The
wet scrubber system is estimated to be $7.40 or about 20% more.
Moreover, the
operating power requirements (a factor in how much energy conversion is avai1-
able for use) greatly favors the dry solids system.
For the dry solids system, it is estimated that the auxiliary power represents
0.86% of the output; for the wet scrubber 1.21%.
In totalizing the higher efficiency and higher operating costs for the wet
scrubber system and comparing this to the lower first cost but lower efficiency
of the dry solids system, it appears that the operating cost of the wet scrubber
would be about $45,000 pe= year less.
This then converts to about a 7 year pay-
off of the higher capital cost.
To the industrial steam generator user, the dry solids system would be favored
as the economic choice and in a very important factor of flexibility of opera-
tion.
The coal; that was chosen is a restrictive case because of the high
sulfur values.
It is-likely that sulfur values will vary.
If this happens,
and if the variation is in the direction of lesser sulfur, the amount of
limestone used will be reduced and the economic factors become even more favor-
able.
It is soon seen that the dry solids system has the capability of react-
ing to any sulfur variation in the fuel at the minimum expense.
An important consideration for the dry solids system is the stigma against
visible stack discharge.
The wet scrubber system will produce flue gas satur-
ated with water vapor.
A constant plume will be observed at the stack unless
reheating is introduced adding another negative economic factor.
For example,
D-30
-------
reheating the stack 1000 F. will require nearly 10 million BTU per hour which
more than offsets the hi~her efficiency savings of the wet scrubber system.
In this case, that could be no recovery of the additional first cost, due to
the lesser fuel flow.
Tabulating this information shows the following:
DRY SOLIDS SYSTEM
WET SCRUBBER
---------
----- --
S,stem Efficiency, as pounds
of coal burned per hour
(Wot including stack gas reheating)
~6,650
25,900
Capital Costs, dollars/pound of
steam generated
6.10
7.40
Auxiliary Power Requirements, as
% of output
0.86
1.21
Material Handlin~:
Limestone, flow, pounds/hr.
Ash Flow from system,
pounds/hour
21,450
4,200
!.6,050
17,30<1,
Stack Condition (without reheating)
~~~ed vapC!!. p1um~
Colorless
Stack Gas Reheating
Heat flow, BTU/Hr.
~required
10 x 106
In taking the above factors into account, it appears that the Dry Solids
System is the better choice, economically.
The one drawback not yet
rationalized is the re~eneration of the spent line and its effect of limestone
consumption.
If regeneration is developed and used, there would be another
factor favoring the Dry Solids System.
D-31
-------
CONCLUSIONS:
-------
From the study of Fluidized Bed Combustion Steam Generator design and market
factors for industrial applications, it is concluded that:
1.
A useful industrial steam generator for future markets will be one to
generate 250,OOO#/Hr. of steam at 600 PSIG and 7500 F. (See Appendix
XII) .
2.
In designir.g a unit to meet the future markets, complete shop assembly
cannot be achieved because of configuration and size requirements.
Modular ,construction is feasible where components are assembled in
shippable modules which are joined at the site.
3.
Design problem areas are not serious enough to warrant fundamental
or basic research. All problems noted .are of a nature where pilot
size units will allow development of the design criteria. Problem
areas are:
a.
Fuel handling - stream splitting - and coal injection - distribution
within bed - introduction of fuel at lighting off
b.
Fluidizing grid design - cooling factors and air flow requirements
- erosion
c.
Heat transfer relationships of the 'submerged surface in the bed
- design parameters - relationship to erosion - turndown - correlation
, to variables for unique design
d.
Heat transfer and reaction kinetics in the carbon burnup cell -
design parameters
e.
Convection zone - erosion factors - ash deposition - cleanability
f.
Ash handling system - operating temperature factors - effective feed
rate control - oxidation of carbon rich ash
4.
Steam generator and auxiliary design can be along the lines of current
practice where units are self-supporting off grade minimizing structural
components and installation time.
5.
The dry solids system design provides greater flexibility in economy
since it can adjust to actual fuel criteria easier than the wet scrubber
system. For example, the limestone feed rate is ~ore easily adjusted
to sulfur in the coal. . . .
6.
Operation of the Fluidized Bed Combustion Steam Generators is more
complicated and exacting than present coal firing systems. Safety of
operation, however, should not be a problem and no more severe than
present techniques.
D-32
-------
CONCLUSI
-------
INDEX TO FIGURES
DRAWING NO.
FBB-19
FBB-20
FBB-23
FBB-27
FBB-28
FBB-29
FBB-30
FBB-3l
FBB-32
FBB-33
FBB-34
FBB-35
FBB-36
D-35
TITLE
Boiler Arrangement
Boiler Sections
Proposed Arrangement
Control System Schematic
Fuel System
Wet. Scrubber Arrangement
System Schematic-Electro Static Precipitator
System Schematic - Wet Scrubber
System Schematic (Feedwater-Steam)
Bed Material Discharge Station
Heat and Material Balance-Dry Solids System
Heat and Material Balance-Wet Scrubber
System
Slurry Dewatering System
-------
--
r~~>
~: I, , \
~! Im:I~, 'I
.,1 II,
~ 'i '
, II"
! ii, :, .!'
.1
"
I
~- ~/~
,o~ ""
.J- '
<&c//c/\/ :-......Rv
-- Zc:;A./C!'
c::;;- o/£cr/D-"
I'
~
~
<:'
, \
~I
, ~ , '
'~
~
~.~
~~.
"', "."t' . =
... '\ ,'" ......
~'- '.~
,', ~: -
. ,""',"
'~<"-"";: ,
{'
'/",
...?',
~j7
t;/
"'./"- .
/" ~.
/Jr'
i
...
(
~
~
"
~
'.,,;
.~
~
\
I
- .,../:' (
':;vP.:f",e #EA'...!"~..e
Et.cvAT/dA/ S
5cc:/i:1N'''''~ . -- -
. ~"NS''# ~"";::""':";,:~'"
11 .6...AT'-'WtC 4."..,-- <""""'"
t"" .;-.N~':-""""'"
(,; .
lj' ~I""
,-
,eD'" .0
. ~
,,/'
"
(p"
\
I
~ -.NJ ,,''1'I...''~'''' ;;;..: I";::"':'
~ R~.'.s'~ .:rJ- .-. ".','..' ~ ",... "11 ( '. ..
11 3! ~::~:Sl'~~:~. ~...- .;...-...~.r. ~~.A..
,
".
".
j
/
.// ..0'
~
".
,
:.~
/'
/
:"(,y'-
. ..e" 0
./ ;.,r- ,0'
/
'-'
,
, /'. , "..
", /./ .~'P"I' // ~-:"'. "-'x:
. ( "- '/ -'....; " "'~
/- I / ' ,/- " '" "
./7/ r:)-, . / _/ " / / , ,,- ,
'0 ,/:.- '- : I '/ // "
".p " .' " ("./ I' '-,
r ,0 ,4#, .' / ~ i I '1 z ./ . . ../ .. ' .,~
' , ".,' ,/ :-----' Y."". // > I' ---s" ,,/
\ ,.. ./ "y' ./
~. I '. q..';O . - , -C. r ~~'> /,~,' ./ / . , r- - ~
"/ -" , / ,
<0 ,.,J':/<'" /~;,j~, ':~~;",,> ~~~ /' /'~, ~ '
,', ,', ' -"1: / , ' / .
...-- " '/ , / / '/
/ ",,/' ,''/' , ,';:;:; I
/, ' " " .' 1'/I~" ,~' 0 .' ,V /
" ", .' /"",,-~., ,"', ,
'''- ~ / ,/'~, V- ,; ,/ // I ,
' "-"-, - :--. "1
c'? ,,~/>J ~ "",:~ ' !
~\~ ' F\< ,,/<,,<" , II I" ';J
~.;;; , ''y'. '1' ./
' " ;:';; . " ,.'" /
' . '''''-' ,/ ',,7'
0/ ;::~ II -<:- " " ,I /.'
.,,:!," : I iH ,,11111'" - '- ~ ,,{/ : I -<' ') ",y,
,I.o""IJ<,,';:1' ,;~',iL:, L'l;-~~," '!~~~~I I.~~ ;..,' ~/ ,..1:,
\~'/Jll"Iffi!,,'" '-;', .',,:'. /
'~~",' "-'>:~"3"::L ~;~tltl8'~~ .,/I!, ;.:;/ ...--
""-"" ~~-,.!~;,/;> bJ ,./
' ~.~. -':'~ "'~' . ';> 't" ~,"
I 'J I~~c""i,"; ,.~ ';/, /,
" /~'''''1~'''~:,: ~," ",/ ,~.".:' /'
! ' "....\:), '>'~;:".,:k~ Y;' I ,;--" ," //
:;:,~I . 'j .,. ',": ~ I ''1' I /
,,'~' ", '-~~~~C"~' /">., /p ,/././
'> -'" ~ ' -c, /
; ;'~<.~<'~) ~ :", . ~. y
~~~r~. ~ /",., ."
... ~ c,. ~~//
"I, I I "
,/
,""
/~ ...~
;/
"... /"
/.3'--
, 0"
.1-1'
"Ct ,~
,j ,..'"
.Z ..."
j'~' /
~
1-
1
I,
~)~
'6\
/) I
'"
r-
I
...'
/
.;
//
/'
/
cg
1"/
//
/'
/
/
,/
""..
..e./
po)
"I
"
,,#
C
;"
/
--
~
,-'
c ..:)
//
."......... .....
~ 8......... ......" "V.
~ ".':"CI:: ..... .. ..It..
. . tS4""'AI'T
. 4/~~,e A-!: ~ ~,. ~MI'''
-------
~I
r :~1
~: ~:
~I'o
..~
~;;,
'"
,
---
~r--
:...
...
.<>
...
."
~
~
"
.,
i~
"
~.
...
....
'"
- -J=-c
~ -:!.!!. Z):'~-I ~
4-
40:0
/q:o-
/0'0'
-.-
z:t;." z:(;." f-,j ~ Z:~. 2-(# ?c;. -f-e;.'
--t ~ ~ --"7! _-% -~ -
; -1 - I 'I I -
c ! :' ,c 2 eX c ;ij c X I e 3 e:'l- e] -
f~: ~-~~- - -~ -- ~Lllr~rn- -~ -
-- -t- I " + I
:iJ-; - i~; ----~ :_:~Cl' :<;c ~c jZC[ l!.c :'1el -~ ~-~
... ,-+ u~...;",-~,tl~"".[.~l{,~,:-,'
-..-. -.... ~..._.~.. -..WOo."...""-... .
I:.J'
r:~'
L
iL..
-t;
i, I
II i
! i
I'
Ii,
I
~j
CJ
~
c:li cr/] ct;J
-- --f--' -. -t--
I- -
-~-L- --
- ut~c ~- r-
r--:-~ -:- t
--
--I-
~.--..---....-~................
........... .
...... .
~.... .
... .
.. .
...... .
........ . .' .
!!t:!i~~ :
m:F'. : : ::: . .1. :
;::::.... .. .,.. 1 ..
+------..-.........e.--...... -.~..._'-...-. .-
4:5 5P$ ...- ..:
.5..::;;:'
LI!-(!.tt~~~o --=.---
I
\.,
/0:0
..
...(,"CI..."
.'J...
. .. .....
'.p'p"
.. ....
. . . . ...+
. .. -...,.
:.~~:t:~:
,."....,.+td..
.' ': -!-.;"."
. . ...-. ...y.......+
..' .++-;.
. . :--t~
. ;"'';'','
. .. . +io:-'Z,"
...... .. '¥~?.+~~
- . ~ . - --M. . - - M -. --. - . . - -. ...;:.r. ,.
C......,c" c-
'V4'S)
'.
!-, ~.ili. ITllf rm rr1l. ~ i ~
I , I"j" II I
I I I
I ',I, I : I
I . I '" I I ,
.' i ; :. I I I
, . " J ',. V I .J '. u ! ) II ~ '
1"---""----- -/ ---- \....-/ <
, , , ,- "~ !;f
--.1
1 . .J
~,,-,.:-~". ,"!~.J"..---
(~
--- ':....2.~!':.":'~-
!..zL
1:J~
_!/L 1::':"'- ..:'
I'r;,'
-;/s..:tP-,S" 4", ',-.:5
~~""~.vJ!I_.:£"'b'~)
.:;. 0 5p.$
(h" ,,'iJ(: €
GO.:;--, 40-=--
~~4~~)
Pc.~A./
5€c T/OA./
. ........ "".............~.,... -+-...;.....,.....+ "!' ..-!'-":-.....-I'++
-y' -+-
. +
- '.of-
-. -.
- - ---0---- - ------ - -
. .: :_~ :L{'~~: h~~~~~:::-::::~:~::~:;:-;::;~ ;~;; -::
"..O?';.~';,.~, - ~-::. - -. - -:-0' ";' -:;.
~- - -- -
-;r ..~~
"t -~.!.
--, ---L-
.:J.:CT/OA/ A-A
-I
/c;:o -J
,rv~t kN/~ LIED $;;"..,,,,.../ (r,."UIt)
.. "--=T~~.~.~r'''F''~
. 0- ----+-~l---
c! C~I 'c~
-"""~
~
----+--- - -- ~
c:Ki }.
- -+- ~
- f- -1 .
-L-l
: ~e j
t
-- ~
..
--
~c
Z c I
!lie
~
I
,
,~-_._,-.'..~-.7-
-
:
.
:
j - .. ----;:u- , ! ; ---r ], ,..
~ ;. ~ I:" >;
f-;-!-i- -r--+-i' .~
~-,~q;:'"::, ~JC"- :
t -~ ,":--t~-r ~"'t A I ~
~ 'j 1 ~,--- '"
!.J..,. , ,:oJ, 'ho. &-1.._,
.' ,,-?
.6 :5.;1"3 ~ /-~ : /C' 0 . /: :;~,.;J.$)
CA'e~4N' ~~;rIV.'" C~€,
.+
+
r
1
~
I,
,I
I'
II
:1
II
I, I
'1
!, -j-
I,
~.-y---
~
--';'::-"":~"""""'-1=J-
---~'" ire
r
tr
-~~[-
a.
~
~
-:tl
, 1
L
I'
~
.,
"
L
5~ -
J 7
3 ....~.
r II ,1 I
I I
, I ,
~~
~
..e~di C-C
D-39
-4:!"~ ~~-,;,-. :i "€-'
--~~
I I ! I i I: 1 : I I
II_~
. I I I,
0- ~ ! I !'
'i '/' I~'
I '. ~
'. I I'. .,1 , '" "
~
. ------
;., /6"-- <'F 4"'~
~
~-
, 0
~ .......... I"."'.""'..' .....
~ ..~ CIT., ......, enI.
...a, ..... ..... .-...
~ft
. ,
O/~£z. $£~';"'N.#
AV/&J,. Ie iSTl1
SCALL 0IIII JttQT TO SCALI[ -
eWG. ~ /~.8-zo Ptcv: A
-------
--
A .Ib.. 1.1 .~. ~
: Ir-:;::.. ~ I
/'
~-
. /(',"'0"
-~"
I
1 -
..
-'- '"
...- -----.-
~~ <2----
, "
'"
._,
.->-------.--.
L n-
''''I: -b~ Ih
I; I
:1
~
----- , I
'»
~I
,
'-.L -I
~
- -- -=t.-
~-::.f ."~-~"~ ....~-- _---/-~-'K/_"..,I-
:i,
j 1
.,1'.:; 0
--='L,.,......" ;//~J-V
C'#CT.eC - ~.r4T"C
~~c:,--,r4fl1A:.
,....- - '.
;"
I
, i
I
--, II
i (1-
\
\
-.
~--~
I
I!
, ,
. ------.
------- ..
(. '---
t~ql
-_J ~--~-
\
\
''L
~ .
I +
-ri-
-----
i
, -
/
-.\
, ) ''''.- - - 1
!"f1I--~l.._. ,cl,~~ i
- 1, ~ ':
I ' ,
:.! T~_n
/~ 0
-- ----.---
fl- =f " ~"~~<,, -
, !
C~
- c-L---
r-1
. ~ t'''e-- ~.'''.''
.. ... fn"r=J--1
"""- -_D q, . -. .. )
.. . ... ... - .~ j
, /
- - -. -4
"
_\,~
-
.---,
I'
1
t
~
'\'
\.,
i I
~
~
rn_- _u_- -
I ' ..
. .:'1 ,..:"'-'-,1 r
h I
. ,
"
,-- /'_'L
i
-r-
..J
F...ec:::l--r
C~~#"-'9r/"N
t-~ ,.. l
"","'"
f
IS' ~
I
~
I i
I 7'~"
.j...-..
l r
,
I)
i\
1 i-
i
I---
I !
€I
I
~
~
~"J:}~ E"V4'/D......,
D-41
'i-'-~'[
t~ ;l\ r .'
l '
t!b'NdAI
-------
~_I"C:,c
.1'~AQAI C::;~r,.-.",,:
~.'-'b.!.rl- .....<..
.
~#.s.I/
"''''''''V''''~ / Av r#
'000-'-
¥
PT'
I
K+S]
~
---- - .c....",
/.v"r o/'AN'~S
c:;.,.vl..rt:!~
#
.5"~",~
-~",~~,e
I I
,PT
~~.::
. 1
t :
.~ .J
, ;
~ ~I
"I ~.
,f' ~
i~;-"7'o!'''f,,"':
- -----
:- ~. "'",£e :!'....-
-;:-~~~.-.::..;.,,,",,~
'c~P:s --
-'>:ir,....,""''-
L.'''''.;--'~<
#'<$""
_fbU rfl?
L
I
8
s
I
i
I
o
3~D
Ale ':;Hh-7Pr~
- C;.A#~..rd,e
..:::... C);I-78v~T/!J.~~/VTef?,--t.~-,w
- ~
".e~- :If..Fe
~,I ..."",-
...o;;e.ps
--
----1
~liL
-~"',,,~'~eA'''v,e£ I
I
,~ I
I
I
I
I
I
I
I
I
I
I
I
I
!
CJ~D
-'.? :.;..g-~
FT
~'!!..2?"!I4
";4! ~,,~
- -.i."'J;;'~"~L
~
~ P'C~4~1li!.
J i1l
'.-..::-;~"L~""-.",,~,,, 'A.
,:,-,r~,.
T o'l
--;p.......~ e,..?
.1~rr....-
,..::J7.
-- -
. ,./~ ,T/PlE
I/N/T.s
/i'D#¥.4rEIIl. :-'-"
-~.........5- r:#~
;-T~''''' c...:;--
-~",,,,,~"',r"~.e
I-
f '
~~ "\
!, ~
\j. ,
\-,,~1 :
[ff
FT
~f,.1¥4,
--~ _. ------.
~
o
,~,:-~...r£~ ~L~W
::;'_14?e.. ",J...~
r---
m
/~Fl.J ':':V',Nr~~-:: -~~~-
D-43
~ ~
~P'."': J
~ I
I
ctJ
;r£--- D.titv,.,., ,E...~,
-~.........{..... ~TEe
r.
C~';~~':::I~
,j" ~I""r
M~-.IH
~
"i
~
':
!
.:\
...:---.. o-~;I'.eAT&!..e ';sPlrA,..- J..t#1'l'At.
~"'--
..;:-",..... ..e"DL 1/"."" ~
::;TEHA7
7lm~.e",rv.e#
CO,..,.TeO~s
.
~ 8"'''''' I"'.U.~"I... .....
~ ...,. CIT" ....".~ DIV.
...., ....- ..... .....
~'GOO(
,CD-net:U Snrr." SC"""M"'''/C
~ A"",I),z!"O tV. ""I. .3rv y
,
SCALE: 01"'- ,,"OT TO SCALE -
DWG-~/dL:J' (:'7 REV.
-------
, ""'-S""'~', O~"
,., ""'''''''''4i'tA(
'ON 'D.MG
LAMi!~
~
6",,,,,..cI..r """"...
C"DA'C:
C6'v"",N'~D
CN<".I:
-------
"ON"'''''
II ~'I r'~~4rM(#''''''''' "'",-.#. ;:'7
.'''''''''''''''''' ,..,.
. ""
-r J.B -<-,.~
~c'-,~
\!
" ,
'-,
'I
/\"'
-------
----
-I ~:'~~'~'.~:.<~~~;~+~'- ~ ~ ~ :., .,"-
'H,#AI'",,.,,,c.
-. 4i.t;WEA:
~,6 O'''~'!!! -.
..~. -, ...,ro:
~IIN. $"~'~A"-
,j.""...4.1 """~I'
- ,-.,,,.r,~,.,
A,,,, D;'~~~~.
I
- - ...--J
C~-"'I!.r"iJ"'"
~,. a..~~
( 1?.4"'''~'';J H:6...!!rL
:$~" "" ""~""!L
I
I
'.~'
"
!MN........c""" I
lJ"ST CtU"~Toe
I I
. I , ' .1,"
:fI-- ;,
. I ' I
I I
~
,~
I
... C "'~!'>I -t",c.. ~$~ I
; --~
,PN£V''''AT/~
j ASH H~---;'"
I L:"_c_~~
..-.
w.
~ ......... ................ ....
~ .... CITY."."''' .'"'.
........ .-.. "'-...
--
~"
. .
-----
5y~r£A'1 ..sC'H'MA"~
l";1(i~nr" .~,.",-,IIC ~c,~rD.
;C"~u~~a'" 'D 4.~(,.e $'*"'D
D-49
SCALE.
01" NOT TO SCALI[ -
CD ,.,....~ REV. A
DWG NO.
-------
-
~,;f8!IM"M
", ~ JJ'l'/~
~
"'-v,",
~,.....
.JIIJLdI.I
~""'I< Cf'4...~N"
0J1W~.."" $L;~ ~",. --
~-ii'~-,~
I
-.1..-
,'1' '
If,.c INJHr.1l
S ~"r:. ""
I
I
':«.'
" '
IMN..-AWK"" I
f',r CQO{"c7
'J,' ',J/
. I ' ,'~',
I
."Q-
~
~~~I
~v-P""
11# J'\M.r
Fl_II,"
IN -..J
FifN#N".
4161 AI... ~
c.-.,,,,-'"
RhC ~AM""S
-!.b j, r.tt;#./
.N'.."".c""-~!!L ~.)
~,~y
J
C--Iv'''."., /1~A ,P~'NVM
r-u
--~
.s'C.,.,<, S",.,
;oM" SCMI/I.'"
.D ~ t,/,.,n,
::~3' ~rA41
W" .sc.~IA
'4~ V-~r
C~.'r",A,/
.4!_~:7A~"LS
~
SlcIIIJJIJ ~r...,
wlr :SCAv,M6'.c.
c;-~ (/"",r
FCON'-'I#A?
.
If
,
I
o
-~I
I
I
..>~:'.
~II-'"
~
'so'
c..,.--
~,"
<:'1..
~/~~' .:1r~
AIr .$C'lvJJIIIM
A- I.hoT
111
{/¥A~t Si.IN.~"'"
, S-""o/."..?~",-n
,
I
/" C,lI~t1N'. CI,cM ~S'" I
; - -
""-,,
CK'~N' AI~
SII"AI"T~
> ---£.->~
$'..-111' F(QW
ClfI--r6.11. "..."'"
~.
~
,fU1r1 V'-
IotMJrIt. ~...
~.
$~
5tv~IlY TIlb¥IIt::.
i
;::~~~~
~......Y ~~.
~
.5t."~,,., ~~
Fi4 'IA~
~
o
dT.
;#r".IJp",,'11
V.4C ,,(/10'1
~
v~v"...
TA,..,~
~ -*,11} HA3"
DIS,...A4.
~ ........ IN.V"""...--'
~ 811tt8 CITV ......, ....
--._._".-Ao
y r~,.,
ItII""',C
'11 itJI4I"" ,
. /-I-'~""''-' .--.........-...
*"""""""""'''''---~'-''''''''' 1f'1l
z'
D-51
KALL 0.. NOT T08CAU
owo."": /"(1/1. ~I -,
,.;;
r
-------
--
/~ ~~A7bC
"
1--f :::J
C\
, "- :---J r-v
-------
.ON .E>MC
,
'----
8-.. --
L-u
J-t ~Vr"
, I
I
/ ------
I I --- - -
I \
I
~f.
~ t
HI
"
" 1 . -'- I
-- =r-L-
- - -IT:- --
-lJ~
--~~-- -~
I
I
-~l
-C:-Oh7,P..eeSStFD .4/£ &..-9.oc..e.
~--
Io.
~--
1.
G..e/.C> L/Ne 7
t --
&~--
I
/
---- ~'
(LOCK #"),.Pc~)
;;$11 r€EP£/e
?O PA//FVA?AT/C
4~h' ~1I'9""'D~/"'6
SFoSTeM
57EI9/Y7 Z);2,()M
A
c::i?1f-'1'p.A!!~r$tFD A/,e .J€ TS
~
M~NUI'9t. 5'/D£ ~rE
.5/'/u,r.o~,.c
n
I I
,
/ II () I D. TII8i
rZ"o,a
~ \
7US#
I I
C(,M'pR~S.J'~P 19/.f? J£T~
5ccT/oN A~A
/11,#JA/v,41. ..;it 106 GI1TF
.5h'(/,r-o~,.c
NUMBER
DRAWN BY
,6tu,
ORDER NO.
: /2'0 7(1
.
SCALE.
DWG. NO.
DATE
~ . /- 7/
DIM. NOT TO SCALE --.,.,
/-:88- 33 REV.
SIZE
TYPE
~ ZU"N INDU8T".I.., INC.
~ ERIE CITY ENERGY DIV.
ERIE, PA. 18812 U.8.A.
CHECKED BY
APPROVED BY
PRODUCT CODE
: fil/IP/ZEP i5ED /l?Are,e/H~
. ....:S:T."t9 r '/4:1 "'"
:",cZV/P/Z€,o LJE~ .8~.h!eA2:
.:;-,~py
ZJ/S't:'N~~E
D-55
-------
(' ~ '1"
~)
--, , ',1M
MY
~4 AM ..
~"'4
2~'YNf
~., 4U~~
~S.~"2r
..
~ D8eoIr
""'A/
~
-
...,.,,8«7- (t:...
9.$,/,,- ~
CAiC/NAn~
"'''''0 .sVtl.'Ar/~
'" ",,"liniN'
bMI#T-"
Zl..hl)f'~
40"
80.,
;.t.~.EI
............ .'...'...'... ........... .....
-
~
~
---
I
I
j
Rwa/U
/~:so-r
I~. ~ ""..,..
-
$t:1'/DS
",,.l,.,4<6' c-
AN" c..... ASI(
lo,rDD~~
.3,~'6~ c::.~
/~.9$~ ""'11.
, 11' "",*,'1"" --) ~"'- ~".".
11.2,1#. ~ I/",.MC_. ....-r.......
,w_.(~- "I" ;lOw s.~ 0,,6 I~
8o~ ---
Mw
--
50(/0:1
Z~~.yM c:A
2r'::::
ilillillilil!I!I!lililililillillil!I!I~
;~~:;:;:;
:::S/tI.o:::::
~:::::::::::::::::::
.:.:.:.:.:.:.:.:.:.:
~
26ai#_~"
~
~i# ....
u..i#N~
~4D h,.
4o~
,quE tSiH
1S6D"
2.' IIM'-
I
,&"u., ~,H
~ 44() ~~
~$O 'I'
0.7 ,..oM!.
I
-
I~--
p~" SMIDS
Io.t()()~ GO.O
Z Zf8O'/~ ~
i~7()1M GO. :JGIt
470"'V~~
1?~1f.t "~L
~.F
~.7",O. "''''/A
~ £leY l)/s~s"'t.
-
...
""
~ .""H .N."."'''.... .....
~ 8"IR CITY .NR".Y DlV.
..... .A. 1..1. V. 8. A.
lID.
~
~,..
~
~
~a.
"EV.
'AfZ,Q4#D C~ sn-y
NMr.,.~~
J}IY S~ oS. c:-----
D-57
-------
sA
317,,:)00,*,
...,
S6.. IW ....
~
~
.,
~ De8Cr
~
;
--
j,MI,IfINI
~-~~
. 4'"
1--
:-
~
II
~,,.,It,.t;il,#~
... c-_L ASH
Jlft) ~ ~
"'-M~4-
Zr;,z~rM-
R_~s
~.C4.4 Z648S1'-r
.$D" 2Z ~ .
Moo II,~"
1a>W" !JI4.45O f:W
/$''''' <).(J ""Mo
~<#. .
o.~
--
19,,,.,,, CAKI
v..- o.n-.u$1N
A- Z"S"IM
GL!.<'# .-,--
Go C'Ir /II~ ~
HIe> ~I~ ~
7d'A4 AI.~S"'''''''
".,"'~ 4n-/.4C
~ !"~.::,:-
~- 618$
/(i,~C1"
$Z./ ""'..
--
~i~jl:JI
:::'~I/II","::::
~: r All/It:. .~:::
~:;:::::::::::.:::::::*~~;;
--
--I
-- $H,,,, K#- D"",,-
.
Mw, ., ,."..,.....,g-.J
.4.J "". ~
,........ iW
I
--
'~1fI tS#~
~
I&~ N<-.
F'IM t$'#J
1070.'-
H.D IN'. MJ.
~
/~ '4., ~M
F~~1
.sr4:4N.c
~
~,
1t:..DA>/-
~
-
40.~
---
--
40~
~-Vi ,--
: rA'K~'.c.:~: I
~::~
~ ."'.... IN."'."'.'... ,....
~ 8"18 CITY 8N....., DIY.
...., ...... ,..'. Y. 8...
"/"Lv/"",z£o ~p c::;..-I""'- g.,ol'
'£Ar4N1J ~A!/"'I I!!!ItNANC'
"""T Sc.cv. I'S,.
D-59
-------
.ON.!)MC
~
~
~)..
~ ~
, ~
~ ~
~'c)
50L /.os ~CJ/Y7
~v/.o/zEpBEP
r----~-- -...---~
~ ,.cL(/~ ~T
/"f~~T ki £CtJ,N'dM/Zc-;e
..............................,.. .
f:::::::::::;;;::;:;;:::::::::::::::J
oS e-,;:>,II;..e ~ TtJ..e
. ..... .
............... ....
!: !:"::!:!:: ,::,:::!::.::! :!: ~!!::!:!:!:;
:I:::::::rt:n:::j:~::::::::
~}~~'tI,R.e ~}}~~
t:::::51j/:{:::::t
SLv££Y PumP
'.
~
. .
I. ". AL8AN&N8
CO..."CIAL 8Lua. ...8.~"
~
~
~
~
~
~
~~{{{{{{{{{)f~t~{)((}(}}({
.. ._._._._.~.~._._._..,~.
::! :::":':::: ::!:::: :::::::::!:::::::::::!::'!!:!:::::::::!!:::::!:!:~!!!!!:!:!! ::::!'
:::::::::::5i«:ky'" rJlic;c'Nijk:::~::::::::
::::::::r:::nnn::::L~':'Y1.ff:nnn:::\:::
.'.""".'''''''.'.''''''''. ...,..,..,....~..:...-:....,..,......,. ."""'.'."""'-;'.~. .
!!!!!!lijl:!IIII:]!IIII]IIIIIIIII]II~
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ u ~ / ~ ~ ~ ~ ~ ~ ~ ~ H /~ ~ ~'mm? u /? /? n u ~ / ~ ~ ~
:~;}f4}j)){)){{))})\1@~ft
.5iv,e,ey Ro.w CON/7ed(.
V~t.i/~ (P;,vCH TYPe)
PETE£SON
ZJ,S,e - lJ..etlh7
8EI.T ~~TE£.
........ .
............... .
............... .
............... .
............... .
............... .
............... .
............... .
............... .
............... .
............... .
............... .
............... .
... ..........
........ .
....... .
. .........
............... .
............... .
............... .
............... .
............... .
............... .
............... .
......... .
...,.., .
....... .
:~~ifkAff~~
':::::::'7i-~M~ ':::
.:::::~: . .':'.'. ~ ~ : :::
.5t./MP Pd/YJP
NUMBER
SIZE
TYPE
DRAWN BY
. £. E. '//\/scIlEL
ORDER NO.
/2070
.
, , SCALE.
CHECKED BY
APPROVED BY
PRODUCT CODE
DATE
~-2S /97/
DIM. NOT TO SCALI;
~
DWG. NO: ":88-.3~
REV.
5Lv"e,ey ~~ k'ET x,ef./48C:"e
'-pcJL YcLEcT.eot./TE
RoccVLI'9Nr
/="/L T~/-IT€
EETt/k'N
~
.
// ~ TE"e c::::-;;;9.A::""~
~;V' JY~ Yt::/"e
G.eI'9DG L/M
Fit. TEI'9TE ?t//1?P
~
.NDU8T....., INC.
CITY ENERGY DIV.
ZU"N
ERIE
.\
ERIE, PA. 1se12
U.S.A.
. WET ..sc~t/BLJc,e. - SL.(/A;~Y
ZJEJ-v/~TE,e/"vG 5Y5T€/II?. -
:nv/o/z~o BE~Bt::J/t.e~ ~i/Z;'-'-
-------
III.
VII
VIII
XII.
XIII
INDEX APPENDICES
I.
Cost Comparison for FBC, etc.
II.
Control System Equipment List
Operating Instructions for Fluidized Bed
IV.
Sample Proposal Data Forms
V.
Fuel Analysis
VI.
Material Balance Relationships
Discussion of Turndown Parameters
Summary of Draft Losses and Power Requirements and review
of Steam Generator Recirculating Pump Performance
IX.
Auxiliary Equipment Vendor Data
X.
List of all Study Drawings
XI.
Study of. Heat Traps
Study of Market.Factors
Shipping Information
D-63
-------
APPENDIX I
D-65
-------
COMPARISON'OF INSTALLED COSTS.
FOR EQUIVALENT CAPACITY, FIELD ERECTED,
STEAM GENERATORS FIRING
DIFFERENT FUELS
Steam Generator
(See detailed
description)
"A"
"B"
"C"
"D"
Fuel & FirinR
Technique
Installed Cost
for boiler system,
$
Gas or Oil Coal fired, Coal fired,
firing spreader fluidized
stoker bed combus-
tion.
Low sulfur Not Dry solids Wet Scrubber
fuel furnished system system
610,000** 1,375,000 1,524,000 1,852,000
520,000
502 emission control
Installed cost for
502 control system,
add, $
Installed cost
total for equivalent
emission to atmosphere, $
610,000
1 ,0:)2,000
1,895,000
1,5:!4.000
Cost per unit
Steam ~eneration, $/I/hr.
for equivalent stack
emission
2.44
7.57
6.10
7.40
.
Costs are based on experience with similar steam Reneratin~ units escalated to
current prices. Estimated factory and installation prices are used for FBC
Steam Generators.
** If the steam generator is shop assembled, the installed cost will be reduced
16%.
D-67
-------
DESCRIPTION OF THE FOUR DIFFERENT STEAM GENERATORS USED IN CAPITAL COST AND OPERATING
COST CO~~ARISONS
Steam Generator "A":
Erie City Ener!'tv Division. Field Erected. "Keystone" Steam Generator
Operating Conditions:
Steam Flow - 250.0001/hr.
Steam Pressure - 600 psi~
Steam Temperature - 7500 F.
Feedwater Temperature 250F
Stack Temperature - 300F
Boiler Efficiency - 82.2%
System resistance - 11.8 in wg.
. (Pressurized operation)
Fuels:
Natural Gas - 12 Oil
Terminal connections are:
inlets to: economizer. fuel train and stack
outlets from: superheater
Equipment Furnishea:
Burners - ECED circular burners .
Boiler - bo~tam supported - no preassembly.
Superheater
Economizer - extended surface
Flues. Ducts and D~pers (not including stack)
Supporting Steel
Soot Blowers
Combustion and Feedwater Control Systems
Refractory and Insulation
Piping for: boiler fuel system, connection between economizer
and boiler and trim piping
Services Furnished:
Erection supervision
Erection labor
Start-Up Service
D-68
-------
STEAM GENERATOR DESCRIPTIONS (CONTINUED)
Steam Generator "B"
Erie City Ener~y Division, Field Erected "Cross Drum" Steam Generator
Operating
Conditions:
Steam Flow - 250,000
Steam Pressure - 600 psi~
Steam Temperature - 750F ,
Feedwater Temperature -250F
Stack temperature - 400F
Boiler ~fficiency - 85%
System air resistance draft
(Balanced draft)
loss - 12.4 in wg.
Fuels burned:
Bituminous coal
(Sized to no more than 30% throu~h 4 mesh screen)
Terminals are:
outlets from: ash handlin~ system and superheater
inlets to: economizer, stoker feeders and stack
Equipment Furnish~d:
Forced dra~t and induced draft fans and drives
Stoker - Detroit roto grate - spreader stoker
Boiler - no preassembly - top supported
Superheater
Economizer - bare tube
Boiler columns and top grid steel
Soot blowers
Combustion and feedwater controls
Refractory and insulation
Mechanical collector
Electrostatic precipitator
Flues, ducts and dampers (not including stack.)
Ash handlin~ system
Piping for: connection between economizer and boiler
and trim piping
Services Furnished:
Erection su~ervision
Erection labor
Start-up service
D-69
-------
STEAM GENERATOR DESCRIPTIONS (Continued)
Steam Generator "c"
Erie City Ener~y Divi~, Modular, Fluidized Bed Combustion, Steam Generator usin~
Dry Solids SO, Control.
Operating Conditions:
Steam Flow - 250,000l!hr.
Steam Pressure - 600 psi~
Steam Temperature- 750F
Feedwater Temperature - 250F
Stack Temperature - 350F
Boiler Efficiency - 85.4%
System Resistance - 43.4 in ~.
(pressurized operation)
Fuel:
Bituminous coal - - 100% through 4 mesh
Terminals are:
inlets to: economizer, coal feeder, limestone
feeder and stack
outlets from: ash silo, superheater
Equipment Furnished:
Forced draft fan and drive
Coal feeding system including rate feeder, spl1tterand injectors
Limestone feeder
Boiler - bottom supported pre-assembled into two modules
Superheater
Economizer - extended surface
Supports for mechanical collector economizer and precipitator
Combustion and feedwater controls
Refractory and insulation
Mechanical collector
Electro static precipitator
Plue, ducts and dampers (not including stack)
Ash handlin~ system and silo
Pipin~ for: Boiler fuel system, between economizer and boiler
and trim pipin~.
Services Furnished:
Erection Supervision
Erection Labor
D-70
-------
STEAM GENERATOR DESCRIPTION (Continued)
Steam Generator "D"
Erie City En~ Division Modular, Fluidized Bed Combustion Stemm Generator
usin~ ! ~ scrubber - particulate and SO, removal system
Operating Conditions:
Steam flow - 250,OOOI/hr.
Steam pressure - 600 psig
Steam temperature - 750F
Feedwater temperature - 250F
Stack temperature - l32F (Saturated
Boiler efficiency - 85.8%
System resistance - 58.8 in ~.
(Pressurized operation)
with water vapor)
Fuel:
Bituminous coal - 100% through 4 mesh
Terminals are:
inlets to: economizer, coal feeder,
linestone feeder and stack
outlets from: vacu~ filter and superheater
Equipment Furnished:
Forced draft fan and drive
Coal feeding system including rate feeder, splitters and
injectors
Limestone feeder
Boiler - bottom supported (pre-assembled into two modules)
Superheater
Economizer - extended surface
Supports for mechanical collector, economizer and precipitator
.Combustion, feedwater and scrubber controls
Refractory and insulation
Mechanical collector
2 stage wet scrubber with slurry tank and pumps
Flues, ducts and dampers (not including stack)
Pneumatic transport ash handling system
Slurry and ash dewatering system
Piping for:
Boiler fuel system~ between economizer and boiler trim
pipin~ and scrubber system convections.
Services Furnished:
Erection supervision
Erection labor
D-71
-------
COMPARISON OF APPROXIMATE INSTALLED COSTS FOR
EQUIVALENT CAPACITY, FLUIDIZED BED COMBUSTION STEAM GENERATORS,
(SHIPPED AS TWO SHOP ASSEMBLED MODULES)
WET SCRUBBER SYSTEM
COMPONENT
Crusher
Fuel system(not including
bunkers, and system upstream
of bunker s)
Forced Draft Fan
Fuel System Sealing
Fan & Heater System
Steam Generator System
Recirculating Pump & Economizer
Ash System for Slurry System
for Carbon Burnup
Mechanical Dust Collector
Wet Scrubber System
Controls
Dewatering
Wet Scrubber System
Approximate Cost ---------------
APPROX IMATE APPROXIMATE
EQUIPMENT COST ~ INSTALLATION COST $ TarAL $
18,000 Not Included 18,000
74,000 25,000 99,000
54,000 5,000 59,000
12 , 000 10,000 22,000
753,000 95,000 848,000
100,000 50,000 150,000
30,000 15,000 45,000
300,000 100,000 400,000
61,000 30,000 91,000
80.000 40.000 120.000
1,482,000 -------------- 370,000 ------- 1,852,000
D-72
-------
DRY SOLIDS SYSTEM
CHANGE THE WET SCRUBBER SYSTEM BY:
REMOVING:
Forced Draft Fan
Ash System
Wet Scrubber
Dewatering
AND. BY ADD ING :
Forced Draft Fan
Ash Handling System
Electric Static Precipitator
Adjust Wet Scrubber Price
to obtain Dry Solids Price
Dry Solids System
Approximate Costs
APPROXIMATE
EQUIPMENT COST $
54,000
100,000
300,000
80.000
534,000
35, 000
170,000
76.000
281,000
(-)
253,000
1,229,000
D-73
APPROXIMATE
INSTALLATION COST $
TarAL ~
5,000
50,000
100,000
40.000
59,000
150,000
400,000
1201000
195,000
729,000
5,000 40,000
85,000 255,000
30.000 106.000
120,000 401,000
(-)
(-)
328,000
75,000
295,000
1,524,000
-------
COMPARISON APPROXIMATE INSTALLED COSTS FOR EQUIVALENr
FLUIDIZED BED COMBUSTION STEAM GENERATORS
A)
For shop assembly into two modules
joined together on site
B)
For field assembly of fluidized bed
section - shop assembly of convection
zone. (design parameters as in A above)
C)
For field assembly of fluidized bed
section - shop assembly of convection
zone (bed velocity designed to 8 ft
per see rather than 15 ft/sec)
D-74
Approximate Equipment
and Installation Costs
$848,000
$973,000
$1,470,000
Relative
Cost
1.0
1.15
1.74
-------
APPENDIX 2
D-75
-------
WESTINGHOUSE RESEARCH & DEVELOPHENT CENTER
~.'
.PITTSBURGH, PENNSYLVMUA
CONTROLS AND INSTRUMENTS FOR A FLUIDIZED BED BOILER
DETAILED TABULATION OF EQUIPMENT
CID PROPOSAL 41-71-04-209
D-77
-------
Quantity
Description
Reference
Item I - Combustion. Controls
Drawing SK-I
Group A - Equipment for Flush Panel Mounting
8
Manual Control Stations
PB-l29-331
1 - F.D. Fan Inlet Vanes
1 - Coal Feeder
1 - Boiler Master
4 - Fluidized Bed Air Damper
1 - Carbon Cell Air Damper
1
Fuel-Air Ratio Adjuster
Group B - Equipment for Rear Panel or Rack Hounting
23
Ratio Totalizers
1 - Duct Pressure Set Point Computer
4 -Fluidized Bed Air Flow Set Point Computers
4 - Fluidized Bed Air Flow Controllers
1 - Fluidized Bed Da~per Opening Limiter
4 - Bed Temperature Limiters
3 - Multiplying Relays
1 - Carbon Cell Temperature Controller
1 - Carbon Cell Air Flow Set Point Computer
1 - Carbon Cell Air Flow Controller
4 - Air Flow Summa tors
4
High Signal Selectors
8
Solenoid Valves
8
Needle Check Valves
8
Needle Valves
5
Volume Chambers
4
Differential Pressure Switches
5
Bcd Temperature Transmitters
5
Electro-Pneumatic Converters
.5
Pressure Switches
n-7A
-------
Quantity
Description
1
Set of Relay Logic
Necessary Air Supply Accessories
0('.
Group C - Equipment for Field Mounting
15
Bed Temperature Thermocouples
1
F.D. Duct Pressure Controller - CAM
Loaded D-33 Regulator
5
Air Flow Trnasmitters - Type D-33
Flow Signal Transmitters -
1
Steam Header Pressure Controller - Type
"F" Master Sender
1
F.D. Fan Inlet Vanes Operator - 6" x 10"
Pneumatic Power Positioner w/Dust Cover &
Manual Operator
5
Bed Air Damper Operators -. 4" x 5" Power
Positioners ~!Dust Cover: ~3nual Oper~to~
& Limit Switches
6
Simple Linkage Struts
Necessary Air Supply Accessories
D-79
Ref~rcncc
-------
Quantity
Description
Item II - Fcedwater Controls
Drawing SK-2
'...
Group A -Equipment 'for Flush Panel Mounting
1
Manual Control Station
Group B - Equipment for Rear Panel or Rack Mounting
3
Ratio Totalizers
1 - Drum Level Corrector
1 - Feedwater Flow Computer
1 - Feedwater Flow Controller
2
Pressure Switches - Mercoid Model DA-33
for High & Low Drum Level
Group C - Equipment: for Field Houuting
1
Steam Flow Transmitter - Ring Balance Model
3008-R80-HT-IG
1
12" Chrome Molys Weld-In Type Flow
Nozzle w/Holding Ring & Pins
1
Feedwater Flow Transmitter - Ring Balance
Model 3008-R88-HT-IG
1
4" Stainless Steel Weld-In Type Flow
Nozzle w/Holding Ring & Pins
1
Drum Level Transmitter - Type FRB-R80
w/One Charge of Sealing Fluid, Equalizing
Manifold Condensate Reservoir and Suppression
Weight
1
Feedwater Control Valve - Fisher Type 667ED
w/4" - 60011 Flanged Carbon Steel Body and
Positioner .
Necessary Air Supply Accessories
D-80
Reference
-------
Quantity
Description
Reference
Item III - Steam Temperature Controls
Drawing SK-3
v
Group A - Equipment for Flush Panel Mounting
1
Manual Control Station
Group B - Equipment for Rear Panel or Rack Mounting
:3
Ratio Totalizers
1 - Characterizing Relay
1 - Steam Temperature Error Computer
1 - Steam Temperature Controller
1
Temperature Transmitter
1
Electro-Pneumatic Converter
Group C - Equipment for Field Mounting
1
Thermocouple Assembly
1
Spray Control Valve - Fisher Type 667DBQ
w/2" - l500t! Carbon Steel Body and Valve
Positioner
D-81
-------
Quantity
Description
""
Item IV - Panel Instruments
3
. Miniature Pneumatic Strip Chart Recorders
1 - Steam Flow - Air Flow
1~ Steam Pressure - Steam Temperature
1 - Feedwatcr Flow - Drum Level
'1
Miniature Electronic One Pen Strip
Chart Recorder - To Record Oxygen
1
Miniature Electronic Three Pen Strip
Chart Recorder - To Record Bed Temperature
w/Alarms
'1
.aniature Electronic Two Pen Strip Chart
Recorder - To Record Bed Temperature
w/Alarms
2
Integrator Counters
1 - Steam Flow
1 - Feedwater Flow
2
Pressure Gauges - 8-1/2" - Ashcroft Type
1377A
1 - Steam Pressure
1 -Feedwater Pressure
1
Three Point Draft Gauge - To Indicate
The Following:
A - F.D. Duct Pressure
B - Furnace Pressure
c- Boiler Outlet Pressure
1
15 Point Annunciator - Scam De Line,
Sequence AF Arranged 3 High X 5 Wide w/
Flasher, Alarm Horn & Two Pushbuttons
For The Following Functions:
"
1 - Drum Level "Hi"
1 - Drum Level "Lo"
5 - Bed Temperature "Hi"
5 - Bed Temperature "Lo"
1 - Steam Pressure "Hi" .
1 - Steam Temperature "Hi".
, 1 - Feedwater Pressure "Lo"
D-82
Reference
-------
Quantity.
Description
Item V - Miscellaneous Equipment
2
~xessure Switches - Mercoid Model DA-33
~ 1 - Steam Pressure
1 - Feedwater Pressure
2
Pressure Transmitters
1 - Steam Header
1 - Feedwater Pressure
Reference
Oxygen Analyzer - Westinghouse "Probe In Stack"
Type w/Probe, Shield, Temperature Controller &
Amplifier
1
Air Sets
D-83
-------
Quantity
Item VI
. Description
1
Instrument Panel
. Control Panel Assembly to be 7 '-0" .
I\~gh, 3 '-8" Wide & 2 '-0" Deep
Construction: Panel to be U Shaped of
3/16" Steel Plate Suitably Braced to
Form a Rigid Structure. To be fitted
wlTop and Rear Covers and Rear Access
Doors of 1/8" Steel Plate.
Finish:
Hammertone Gray
Piping & Wiring: Terminal Piping & Wiring
(#14 AWG Thermoplastic Stranded) for panel
mounted equipment included in this quotation
811 piping and wiring performed in an "open"
shop. .
'.
D-84
Reference
.
-------
Quantity
Description
Item VII - Relay Rack
1
Relay Rack Ass emb 1y to be 7' -6" high,
7'-0" long and 2'-0" deer.
Construction: Panel to be U Shaped of
3/16" steel plate suitably braced to
form a rigid structure. To be fitted
with top and rear covers and rear
access doors of 1/8" steel plate.
Finish:
Hammertone Gray
Piping & Wiring: Terminal Piping & Wiring
(014 AWG thermoplastic stranded) for panel
mounted equipment included in this quotation
all piping and wiring performed in an "open"
shop.
D-85
Reference
-------
APPENDIX 3
D-87
-------
FLUIDIZED BED COMBUSTION STEAM GENERATOR
OPERATING PROCEDURES
Description of Unit
For the steam generator and auxiliary equipment for either the dry solids or the
wet scrubber system, the steam generator operating procedures are much the same
and are generally described below. Flue gas cleanup equipment will have slightly
different operating procedures and those special procedures are included.
There are four principal modes of operation:
Shutting down; and, Emergency operation.
Starting up; On-line operation;
Starting Up
As with any steam generator, the starting up procedures must provide adequate protec-
tion for the superheater tube sections and for the steam generator water cooled cir-
cuits. To do this, the principal fuel, coal, is not fired until the stearn generator.
is raised to the steam system pressure and is in service. Natural gas is used to raise
the boiler pressure and to establish a low rate of steam generation. Natural gas is
fired through a circular burner at one end of the fluidized bed combustion chamber.
The start up burning rating is only a fraction of the stearn generator capacity.
Firing Natural Gas
Prior to firing the startup burner; the boiler is filled to the normal water level in
the steam drum and the boiler water recirculation pump is started. The normal water
amount of bed material (limestone) is transferred into the fluid bed chamber. The
ash conveying equipment is put into operation as soon as fluidization begins. Because
of condensation at low firing rates when the equipment is cool, ash must not be allowed
to reside in any hoppers. Sufficient coal and limestone should be transferred to the
bunker to form a pressure seal at the rate feeder inlets prior to fluid~zing.
Prior to firing the dry solids system, the electro-static precipitator fields should
be energized and rapper operation begun.
Prior to firing with the .wet scrubber system, scrubbers, the slurry tank and the
thickner should be filled to normal levels. All transfer .pumps, and the scrubber
inlet spray recirculating pumps should be starte~ .
Prior to firing in either system, the sealing air fan should be started and the
forced draft fan should be started and dampers opened to deliver air to the
start-up burner only.
The start up burner is lit and the firing rate should be modulated to hold the gas
temperature entering the superheater below lOOOF and/or to have a rate of pressure
raising not exceeding lOOF saturation temperature change per hour.
After the steam generator has reached steam system pressure and is delivering stearn
to the system, the start up burner firing rate should be increased to maximum.
D-89
-------
Firing Coal
When the start-up burner is firing at the maximum rate coal firing may be begun but
prior to firing coal, the sealing air steam coil air heater should be put into service
the speed control circuits of the coal feeder and the other material feeders should
be made ready to operate. The combustion air control damper is opened for the bed
section to be started to achieve fluidization and then set to the minimum firing rate
air flow. A bed temperature of 800°F must be obtained to insure ignition of the coal
feed. If sufficient bed temperature is not obtained from the start-up burner, addi-
tional fuel gas is injected beneath the bed through the coal injector nozzles.
Wnen tOe oea section fluidized bed temperature is adequate, coal feed is begun At th~
minimum firing rate to one bed section. As firing is stabilized, the start-up burner
may be shut down.
If greater steam flows are required, more fuel bed sections should be put into service
by fluidizing the adjacent bed section, heating to 800°F and then beginning the coal
feed. Certain operating parameter permissives and rate controllers are included in
the control system to provide safety and uniformity in idle bed starting up conditions.
As bed sections are fluidized while beginning to fire coal, some bed material will
begin to be elutriated and will appear at the carbori-burn-up cell and the ash disposal
points. In either the dry solids or the wet scrubber system, lime stone feed should
begin with coal firing to maintain the.bed level.
Carbon-burn~up cell operation, also, should begin with coal firing. The first carbon-
burn-up cell section should be started up by injecting air and by opening the cyclone
dust collector ash line to that section. As more oed sections are put into service,
with greater coal firing, additional sections of the carbon-burn-up cell should be
started.
As firing conditions become stabilized operatio" of the sulfur gas emission control
system must be optimized. In the drv solids system, the limestone feed rate should
be adjusted to achieve the desired stack gas S02 concentration. As the limestone feed
rate is increased, more bed material may have to be extracted from the bed by in- .
creasing the feed rate of ash feeders extracting bed material. The fluid bed pres-
sure drop is a measure of the bed level. In the wet scrubber system, the lime-
stone feed rate should be increased to decrease the sulfur gas concentration of the
stack. By doing this, more lime can be transferred to the slurry tank increasing
the slurry flow through the scrubber. .
On Line Operation
As the steam generator is operated to meet steam system requirements, several parameters
should be monitore~. These are:
Excess air - to obtain the most efficient operation, the excess air should be
controlled to as low level as possible without increasing the amount of unburned
coal or the amount of combustibles in the flue gas.
Bed Temperature - Bed temperatures in the four active beds and in each carbon
burn up cell section can be used to detect uneven combustion rates within the
bed. The exact cause of uneven bed temperatures requires analysis of all opera-
ting factors.
D-90
-------
Flue Gas Temperatures Leaving the Boiler and Leaving the Economizer - Flue gas
temperatures are a guide to the effectiveness of the heat transfer surface.
The need to operate soot blowers may be indicated by rising flue gas temperatures.
Superheater Outlet Temperature - In the proposed design there will be'terminal
spray attemperator to control the steam temperature. Steam temperature leaving
the superheater and leaving the attemperator should be observed.
Feedwater-Steam Flow - The steam and feedwater flow should be in a definite re-
lationship. If this varies, the reason should be explained. Normally feedwater
flow will exceed the steam flow due to blowdown. Any change from normal would
indicate a malfunction of the system such as a tube leak.
Grid Air Resistances - For all fluidized bed sections including the fuel beds
and carbon burn-up sections, monitoring the grid air flow resistance is a guide
to the proper distribution of fuel and air to the beds. An increase could
indicate pluggage. Bed and grid air resistance is a guide to the proper oFer~tion
of the ash extraction and ash handling equipment.
Coal Feeder and Fuel System Temperature - Sealing and transport air is pre-
heated to prevent condensation and to enhance drying in the coal system. Too
low temperatures should be avoided and high temperatures cQuld indicate coal
"hanging up" and oxidizing in the system. -
On Line Maintenance:
Fuel System - Normal on line maintenance of the fuel system will be greasing the
coal feeder and other movi~g parts and ~he replacement of wear parts such as the
coal injection nozzles.
In regard to the- coal injection nozzles, compressed air aspirators allow the nozzles
to be removed from the bed when one section is shut down. The primary coal splitter
is adjusted to allow the desired one of the four discharge pipes to Qe shut-off. Coal
flow to that section and also air flow is shut off. Nozzle isolating valves are
closed to isolate air flow and the coal and air lines are removed. Compressed air
is opened on the nozzle aspirator and a nozzle is removed and replaced by a spare.
The procedure is repeated for each of the eight nozzles in the bed section. After
nozzle replacement, the bed section can then be returned to service. Replacement
of eight nozzles with spare nozzles will take less than 4 hours.
Water and Steam-System - The services of a competent feedwater consultant should
be obtained to recommend and to supervise a comprehensive program of internal and
external feedwater treatment. Prior to initial operation, the boiler should be
chemically cleaned internally. Routine internal cleaning may be required after
internals of operation. During operation, boiler water analysis and feedwater quality
must be checked frequently.
Ash Handling System - The Fluidiz~d Bed combustion steam generator requires continuous
operation of the ash handling systems. Roqtine lubrication and checking of the ash
feeders, blower, valves, and electrical system are requisites to good operation.
Instruments and Controls - Instrument lines should be blown out frequently, water
columns blown down, and instrument and control cleaning should be done routinely.
D-91
-------
Shutting Down:
Removing one bed from .service - For load reductions or for removing the unit from
operation, one fuel burning bed section should be shut .down at a time.
To shut down a bed section, the fuel to a bed section should be shut of~ by closing
the valve at the primary splitter. Simultaneous compensation should be made in the
fuel and air flows to the other bed s~ctions .to maintain stable steam generation.
The bed temperature will drop upon the loss. of fuel input. When the bed temperature
is less than lOOOF, the combustion air flow to that bed section should be shut down.
At the same time, the operation of the ash feeder for that bed section should be
stopped. Operation of the carbon-burn-up cell should be monitored to observe whether
adjustment of the number ash injection nozzles should be made.
If the steam generator is to be taken out of service; starting up ptocedures should be
reversed.. The coal bunker level should.be lowered and the fuel beds should be removed
from service, leaving only the bed section nearest the start-up burner operating.
The start up burner should be ignited prior to shutting down the last bed section..
When coal feed is shut off and as the bed material. cools, it may be expedient to
transfer it to the ash handling system.
In the case of the dry solids system, the beds should be fluidized and the bed ash
feeders started. Eventually all bed materials will be extracted to the ash silo.
The start-up burner should be kept in service at this time to maintain the steam
generator well above flue gas condensation temperatures.
The bed ash feeders should.. be maintained in service in the wet scrubber system to
empty the bed. In wet scrubber system, the bed will be lost to th~ slurrv t~nk and
thickner. (The ash dewatering system ml'lY :r!C\t }-op. 1"nut clo','T! until li~e ar.~ li:",e-sulfur:
precipitates have been reduced to low levels.)
When the bed'material has been removed, the startup burner may be shut off removing
the steam generator from service. The steam generator may be cooled by continuing.
to operate the forced draft fan and the recirculating pump. Venting steam will also
help reduce the boiler pressure. The cooling rate should be limited so that there
are no undue thermal stresses. A cooling rate of IOOF per hour,the same as the
heating rate should be followed.. ,
The recirculating pump should be kept running until the steam generator is cooled to
below 200F and is, ready for draining. As long as the recirculating pump is operating,
the steam drum water level should be maintained. ' ,
Emergency Operations
There are several principal emergency conditions where definite operating steps should
be followed to minimize the chance of damage:
L088 of combustion air flow -
A loss of combustion air flow should trip all fuel feed to the steam generator including
the secondary splitter vibrator. The sealing air. fan should remain in'service along
with the ash system blowers. The electrical sequencing system for ash feeders should
be tripped. The boiler recirculation pump should remain in service and the water level
in the steam drum should be maintained. The superheater vent should be opened as soon
D-92
-------
as the boiler pressure drops below the line pressure.
~~~~-~~_Il~!.!.E!!..!edrcula tion ~ump -
Loss of the boiler recirculation requires that the fuel air flow be stopped
immediately. The seal air fan should continue to operate along .with ash handlin~
and the ~as cleanup equipment. The steam drum water level should be maintained.
As the boiler pressure drops below the line pressure, the superheater vents
should be opened.
It is thoup,ht that there is enou~h thermal circulation capahi1ity to protect the
submerged tubes if the fuel feed were tripped and residual combustibles are
burned up.
Loss of Fuel Feed -
---
The loss of fuel feed is not in itself an emer~ency condition since the forced
draft fan and other equipment may continue to operate. Danger exists when the
condition is corrected and when the fuel flow is re-established. If the bed
temperature were less than the normal ignition conditions, a normal, section by
section, start up should be undertaken. Care in this case should be taken to
prevent superheater damage due to "over firing" upon restarting.
Loss of Steam Drum Water Level - .
-----------
The sudden loss of steam drum water level is usually due to the loss of the feed-
water system but it could be caused by a tube failure. In any case, fuel feed
should be stopped immediately and the steam generator cooled as rapidly as possible.
The forced draft fan should be kept running. The boiler recirculating pump
operation should be watched closely. At any indication of cavitation in the
recirculating pump, such as rapidly varying pump motor current, the pump should
be shut do~. .
To restore the steam generator to opera!ion after the drum level has dropped to
"an unknown point, it should be taken out of service. Drum level should be
restored by feeding water at a low rate (5 to 10% of the maximum steam flow).
The steam generator can then be restarted utilizing the normal procedure where
natural gas is "P1red prior to firing coal.
Tube Leak -
------
If there is an unexplained disparity where feedwater flow exceeds steam flow,
a tube leak may have occurred. Tube leaks are likely to cause extensive damage
if operation continues. The steam generator should be shut do~ as soon as
possible if a leak is detected.
Any tube leak should be considered a serious situation. Minor leaks may not
force an immediate 6utage, however, a tube failure may necessitate tripping
the steam generator because of the inability to maintain the steam drum water
level.
Loss of Bed Fluidization -
-------.----.--
If there is a sudden rise or a sudden loss "of forced draft fan pressure, it
may indicate the loss of fluidization over the grid. P1uggage may be
D-93
-------
responsible for the rise in pressure losses (increasing forced draft fan
pressure) or a blow through in a bed section could cause, a loss of fluidization
and less resistance. Both conditions should be treated as an emergency
and the unit should be shut down until the situation can be explained and
corrected.
, .
A loss of fluidization due to bed behavior will leave the grid exposed to high
temperatures because of continued burning. Also, where bed temperature
control is lose, there may be clinkering and pluggage of the grid.
D-94
-------
APPENDIX 4
D-95
-------
Proposal
Form 1018
2M-a-69
r'.---..~.,.~
"'~;"'"
,(' rEl,~J.JI.L;; ),
('--""''''',,;"7
~~,.~ U V .
"'" tNERGV OIV. .
L' 'U~.~-_..-
~-_..,_....
STEAM GENERATING SYSTEMS' ENERGY RECOVERY SYSTEMS
POLLUTION CONTROL SYSTEMS
1422 EAST AVENUE
ERIE. PA.. U. S. A. 16503 . TELEPHONE (814) 452-6421
PRO POSAL-CO NTRACT
NO.
DATE
TO.
Sample Proposal
For and in consideration of the hereinafter named amount,
The ERIE CITY ENERGY DIV., ZURN INDUSTRIES, INC. (hereinafter called the COMPANY) proposes to furnish to
the PURCHASER, in accordance with the following specifications and general conditions, the machinery, material
and/or equipment (hereinafter referred to as "equipment") and/or services described below:
A steam generator system utilizing fluidized bed combustion and one of two
different techniques to control stack emissions.
In either case, the steam generator will be designed to produce 250,000 pounds
of steam per hour at 750F and 600 psig when supplied with 250 F feedwater.
Fuels
will be bituminous coal, with natural gas for starting up only.
The steam generator will be adapted to utilize either:
Dry limestone solids absorption to control sulfur dioxide emission and an
electrostatic precipitator to control particulate emission, or,
Wet limestone slurry scrubbing to control both sulfur dioxide and part i-
culate emission.
Reference Drawings:
. ECED Drawings
Dry Solids system: FBB-23 and FBB-30
Wet scrubber::
FBB-29 and FBB-3l
ERIE CITY - PROPOSAL- CONTRACT
D-97
-------
SAMPLE,PRqPOSAL
INDEX TO EQUIPMENT DATA AND DESCRIPTIONS
Item
General Descriptions:
Trim List
Fuel System:
Limestone Feeder
Fans:
Steam Generator:
Economizer
Centrifugal Dust Separator
Ash Handling Systems:
,.
Controls and Instrument.ation
Predicted Performance:
Description of Operation:
Electrostatic Precipitator
Wet Scrubber:
Steam Generator
Dry Solids System
Wet Scrubber System
Crusher
Feeders
Fuel Splitters
Fuel Injectors
Start-Up Burner
Forced Draft Fan
Seal Air Fan and Steam Co~l Air
Heater
. .
Fluidized Bed Chamber
Carbon Burn Up Cell
Superheater . .
Convection Zone
Ash Pick Up Points
Carbon Burn Up Cell
Dry Solids Sys tern .
Wet Scrubber System
Dry Solids System
Wet Scrubber System
Operating Techniques
Operating Power Requirements
Scrubber Stages
Slurry Dewatering System
D-98
Page No.
See Appendix &
Report
Pa~es 3-4
See Appendix &
Report
"
"
"
"
"
"
-------
ITEM
QUANTITY
1
1
2
1
3
1
4 1
5 2
6 2
7 2
8 1
9 1
10 1
11 6
12 1
Issue No.1
April 15, 1971
ERIE CITY ENERGY DIVISION
ZrRN INDUSTRIES INC.
ERIE. Pr::NNSYLVANIA
STEAH TR IM LIST
FOR
FLUIDIZED BED BOILER PROPOSAL
EQUIPHENT
Safety valve - Consolidated #1811 set @ 665#
6001IR.F. flanged inlet, 2-1/2" - l50#R.F. flanged
outlet. Suitable for outdoor installation. For
superheater.
Safety valve - Consolidated #1811 set @ 700#
60011 R.F. flanged inlet, 2-1/2" - 15011 R.F. flanged
outlet. Suitable for outdoor installation. For boiler.
Safety valve - Consolidated #1811 set @ 710#
600# R.F. flanged inlet, Y' - 150# R.F. flanged outlet.
Suitable for outdoor installation. For boiler
Water column - Reliance WM-900-C8-EA16R with high and
low whistle alarm and fuel cutout 1 ph, 60 cy., 110 V.
Sets gage valves - Reliance SG-860 with chains and pulls.
Mica protected flat glass insert - 12-1/2" visibility
Reliance FG-909
Direct vision hood and illuminator assy. - Reliance
FG-890, each consisting of one FG-90 illuminator and
one FG-890 direct vision hood. 1 ph., 60 cy., 110 V.
Aux. low water cutoff - Reliance EA-100S levalarm 1 ph.,
60 cy., 110 V.
Steam gauge - Ashcroft 111079-D, 0-150011 range, 6" dial
1/2" male back conn. flush mounted.
Feedwater regulating valve - 3" Fisher 600# Std. R. F.
flanged ends.
Soot blowers - Diamond Model G9B vertical type, manually
operated.
Superheater thermometer, Duro industrial thermometer 9"
scale, 2000 - 9500 F. range, straight form with 304
stainless steel well~
D-99
-------
ITEM
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Issue No.1
April 15, 1971
QUANT ITY
EQUIPrnmr
1
Superheater test well - Duro, stainless steel
type 304
1
Water column drain valve - 3/4" Edward 1/848
2
Water gauge drain va1ve- 3/8" Edward 1/838
1
Steam gauge shut-off valve, 1/2" Edward 1/152
1
Steam gauge test conn. - 1/2" Edward 1/848
2
Drum level transmitter shut-off valves - 1"
Edward 1/848
2
Drum level transmitter drain valves - 1/2"
Edward f/848
1.
Blow-off unit - 2" Edward Tandem f/64l-643 -
600#R.F. flanged
1
Chemical feed shut-off valve 3/4" Ed~vard #848
1
Cont. B. D.. shut C!Jff valve - 1" Edward f/848
1
Superheater drain valve - 1" Edward /1848
1
Superheater vent and drain valve - 1-1/2" Edward 11848
1
Superheater supply pipe vent valve - 1" Edward f!848
2
Soot b1ewer drain valve - 3/4" Edward #848
1
Soot blower main header shut off valve - 2" ?owell
#6033 600# R. F. flanged with chain and guide
Feedwater stop valve, 4" Powe 11 fig. 6031 600f! R.F.
flanged
1
1
Feedwater check valve - 4" Powell figure 6061 600f!
R.F. flanged
2
Feedwater regulator isolation valves - 3" Powell 6003,
600# R.F. flanged
1
Feedwater regulator by-pass valve - 4" Powell 603L
600# R. F. flanged.
D-IOO
-------
APPENDIX 115
D-IOI
-------
SA.'!PLE:
OHIO PITTSBURGH NO.8 SEAM COAL
(Source of data:
USBM. Pittsburp.h. Pa.)
Run of Mine - As Received
PROXIt~TE ANALYSIS (wt %):
ULTIMATE ANALYSIS (wt %):
GROSS HEATING VALUE:
NET HF.ATI~G VALUE:
ASH M-1ALYSIS (wt %):
FUSIBILITY OF ASH:
~.
PARTICLE DENSITY:
GRINDABILITY (HardJ!rove):
FREE S~~LLING INDEX
Moisture
Volatile Hatter
Fixed Carbon
Ash
Moisture
C
H
o
N
S
Ash
13000 Btu/lb.
12500 Btu/lb.
Si02 45.3
A1203 21.2
Fe203 27.3
Ti02 1.0
P205 0.11
Cao 1.9
MJ!O 0.6
Na20 0.2
K20 1.8
3.3
39.5
48.7
8.5
100.0
3.3
71.2
5.0
6.4
1.3
4.3
8.5
100.0
0.7
100.1
Initial Deformation T~perature
Softeninp T~perature
Fluid Temperature
S03
Coal - - ~1.4 gm/cc
Ash - - "" 2.8 p.,m/cc
50 - 60
5-5.5
D-I03
- - 20800F
- - 2230°F
- - 2420°F
-------
APPENDIX 116
D-I05
-------
DRY SOLIDS SYSTEM - MATERIAL BALANCE RELATIONSHIPS
Unhl1rnpd rarbon loss:
Assume:
- 90% of carbon to primary collector is refired in carbon burnup cell.
- 90% combustion efficiency in carbon burn up cell
Therefore:
(1-0.81)
0.0712
10,000
x
14,300
=
193 Btu 1055
10,000 Btu input
Particulate Carryover to Primary Collector:
Assume:
-13% of carbon fired is passed on to primary collector
~ll ash in fuel is passed on to primary collector
-3% of limestone feed as calcium sulfate
Therefore:
0.13 x O. 712 x
0.085 x 10.000 =
13,000
10,000
13,000
..
0.0712 # carbon/lO,OOOBtu input
0.0652 # ash/lO,OOO Btu in
0.03 x 18.75 x 0.0331 x 136
100
Dust to primary collector
0.0253# CaS04/l0,000 Btu in
0.1617# solids/10,000Btu in.
=
D-107
-------
T.;mp~tnnp fppli to flu; Ii; 7.pd bed :.
Assume 6 times stoichimetric amount
or
6 x 100 x 4.3 x 10,000
32 100 13,000
1 *
x-
.0.97
0.64# Limestone/10,OOO BTU In
0.62# CaC03/10,000 Btu In.
Limestone Reactions in fluidized bed (based on sulfur in fuel):
Calcium sulfat~ produced:
0.9 x 136
32
Calcium oxide produced:
=
3.82
(6.0-0.9) x.2.£
32
=
8.92
Carbon dioxide:
6 x 44
32
8.25
Sulfur dioxige unreacted
0.1 x g
32
=
0.2
To find the reaction products as listed above, multiply th~ factors
by the sulfur in the fuel for the fuel used in design fuel, there
is 0.033#/10,000 BTU Input (0.033#/10,000 3tu).
,
* Limestone contains 97% CALCIUM CARBONATE for simplification~
D-IOB
-------
Solids extracted from the Bed:
Assume:
Carbon is negligible
Calcium oxide from limestone.
Calcium sulfate that is not elutriated to primary collector
Therefore:
8.92 x 0.0331
(3.82 - 0.03 x 18.75 x 136 ) x
100 )
Heat Loss due to chemical reactions:
Sulfation of lime
(exothermic)
3.82
x 3 x 106 Btu
ton calcium sulfate
=
0.295# Calcium oxide/10,000 Btu Input
0.0331
0.100# calcium sulfate
10,000 Btu Input
=
x
0.033
10,000
190 Btu/10,000 Btu Input
=
Calcina tion
of limestone (endothermic)
18.75 x 1.5 x 106 Btu
ton calcium carbonate
Heat 1055
x
0.033
10,000
465 Btu/10,000 Btu In.
----------------------------
=
275 Btu/10,000 Btu In.
D-I09
-------
WET SCRUBBER SYSTEM - MATERIAL BALANCE RELATIONSHIPS
Limestone Reactions in Fluidized Bed (Based on sulfur in fuel):
Calcium sulfate produced:
0.9 x 1.2 x 136
6 32
=
0.765
Calcium oxide produced
(1.2
0.9 .L12.
6.0)
56
32
=
1. 785
Carbon dioxide produced
1. 2 x 44
32
=
1.65
To find weight flo\vsof the reaction products multiply the factors abcve
by the sulfur in the fuel. For the design fuel there is 0.033#/10,000
BTU input.
Limestone. Feed:
Assume 1;2 .x stoichiometric
Therefore:
1.2
x
100
32
x
0.033
10,000
.-
0.124#/10,000 Btu Input
D-110
-------
Carryover to Primary Collector:
Assume:
13% of Carbon fired
All ash in fuel
3% of limestone feed as calcium sulfate
Therefore:
0.13 x 0.712 x 10,000 = 0.0712 # carbon/10,000 Btu in.
13 , 000
0.085 x 10,000 0.0652 # ash/10,000 Btu in.
13 , 000
0.03 0.124 136 0.0505 # calcium sulfate/10,000
x x 100 Btu in.
Solids to Slurry Tank
Assume:
Carbon is negligible
All calcium oxide unreacted in bed
Calcium sulfate not elutriated to primary collector
Heat loss due to chemical reactions:
Sulfation of calcium oxide (exothermic)
0.765 x 0.033 x 3 x 106 Btu
10,000 2000# calcium sulfate
_. 38 Btu
10,000 Btu Input
Calcination of calcium carbonate (endothermic)
3.75 x 0.033 x 1.5 x 106 Btu
10,000 2000# calcium oxide
=
93 Btu
10,000 Btu input
Heat LoS's
=
55 Btu/10,000 Btu input
D-lll
-------
Dewatered Slnrrv tn ni~nn~al~
Unburned carbon
193.
10,000
Coal ash:
Calcium sulfate:
Calcium Carbonate:
x
1
14,300
=
0.0135/1/10,000 Btu in.
0.0652/1/10,000 Btu In.
0.126/1/10,000 Btu In.
0.0331/1/19,000 Btu In.
. . Total (dry)
, 0.2378/1/10,000 Btu In.
D-1l2
-------
APPENDIX 117
D-1l3
-------
FLUIDIZED BED COMBUSTION STUDY
INDUSTRIAL STEAM GENERATOR DESIGN
. STUDY OF TURNDOWN PARAMTERS
One of the fluidized bed design features will be the requirement for sec-
tiona1ized beds to facilitate turndo~~. Sectiona1izing the bed to allow
partial shutdown appears to be a requisite because of the narrow range or
possible bed operating temperatures. A range of 1400 to 1650 F. is antici-
pated at this time. It is believed that below 1400 F, the combustion in the
bed will become unstable. Above 1650 F, limestone absorption of sulfur gases
may be reduced.
Sectiona1izing the bed is a feasible way to handle the turndown requirements,
however, an increased number of sections will complicate fuel feeding systems,
air ducting, and the combustion control systems. Other means may have to be
used to control or to smooth bed temperature fluctuations. Adjusting the
expanded bed depth by transferring bed material in and out of the fluid bed
chamber is one method. Adjusting the excess air in the chamber is another
method.
In a bed arrangement where the particle splash screen is said to help control
bed temperature, a prediction of how expanded bed depth relates to bed temper-
ature is not available. As a result, at this time, it is not reasonable to
predict how effective lowering bed depth will be.
If a constant heat transfer cvefficient is assumed, it is possible to develop
a relationship of excess air and reduced heat input to bed temperature.
On Figure #1, curve #1 represents the effect of load reduction on bed temper-
ature with a constant heat transfer coefficient. As is seen 1400 F. is ob-
tained at about 70% load.
Curve #2 on figure #1 represents a means o~ turndown minimizing bed temperature
fluctuations without passing through a minimum of 70% load on one bed section.
A minimum load of 17.5% overall is indicated. The scheme shows that as the
unit load is reduced one section at a time is taken out of service. It assumes
uniform loading of the operating sections.
Curve #3 on figure #1 is another demonstration of the range of bed section
loading over the unit load range. In this example, 4 sections are proposed
with one section having been partitioned to two halves which can operate
separately. A minimum rating of 70% is adhered to; but slightly more than
100% rating is seen to make a continuous operation sequence from the minimum
of 17.5% unit load.
From these data it tecomes apparent that sectiona1izing alone is a difficult
way to produce turndown.
Figure #2 shows two effects of increasing excess air at a constant load.
The bed temperature is reduced by the "cooling" effect of increased air
flow. On the other hand, the volume flow increases significantly. The
simplifying assumption of a constant heat transfer coefficient in this
case does not seem valid. Because the bed particle size-consist will
change with volume flow, it appears likely that the heat transfer coeffi-
cient will vary. It may be, for example, that the negative slope of the
D-1l5
-------
bed temperature curVe would increase in a more negative direction to produce
a sharper temperature change.
Drawn from other experience, it is felt it is not a practical consideration
to program the combustion control to have a load indexed step change flue gas
analysis. Therefore, bed temperature control by means of excess air control,
is not practical.
Conclusions at this point in the study of fluidized bed combustion steam
generator turndown would be:
Sectionalizing, alone, is not adequate to provide smooth control over
the unit load range.
Excess air control is not a practical means to smooth bed temperature
variations in sectionalizing.
Expanded bed depth change appearS to be a valid way to smooth bed
temperature control but the effects cannot be predicted sufficiently
at this time.
D-1l6
-------
~
o
~
~
~
::>
~
~
o
N
~
o
w
~
Q
H
::>
~
~
o
Co:)
Z
H
E-<
~
100
90
80
~~ 70
HO
E-<~
~~
W~ 60
0..::>
O~
U)~
zo
o
HN
E-<
t.J ~
~ &J 100
o~
HO
~~
Co:) >< 90
~~
Co:) 0
~ ~ 80
E-
70
60
-- FLUID BED COMBUSTION --
STUDY OF TURNUOWN P~T~RS
. .-..--.--.. ._~--_... .~. I..-..--~ --- . .-....---..1.. - ---_.. ~ --
"-----
. . ,
, .
100
. ,
. .
- ,,"-' ..~. .-- .....' '.....-. ...' --'-'-'---- -_.
-- . . ""'-'.-h ..,.- - - .
90
.. - .-. ."..
.--.---- -
-- --. -~- ----
80
'. --. .- ..... . -. -. . -- .
60
'.._.in_.L.:.i ._~: _:CURVE NO. 1..___- ..;
.- _._-~__.~~I ~_L__~~~ ~BASED ON: __,i.. --.
'. . .; .. : ,: : : t i: :. .: : . 10% EXCESS AIR.
--:- -.n ..._-~_.__. '''''' ','T:-:--:-:-'-: ". (:--::--:--.n__;, :::U=50=CONSTANT . 'n-
---- --.--.--.,. ---- -- . -.--.. ..-----~._u._._. '---'-'- "'-'- '--
, . . ,
....-.--... ..._.~ .
1300
1400
1500
1600
1700
1800
FLUIu BED TEMP~kATuRE, F.
. .' -'-:---:-~---:-I-:----'-I-'h-"- T---"'" 7n------/._-~/-~_.- .
.'---: ...'.,_., - /- I j -/~_....:-./
".... .. --- ..
-ffJ . ."/-:/~?~-;?~~-;::v~~~;.E~_~-=~
t..; , I : / - ~-r'---'/:," ~/ . /: . .' BASED' ON: .
-. ... :' / -.: / --)1- '/~ --- j/ :; /.:- :.n_~- EIGHT EQUAL' GRID ... ....
. -'- -~_._--. ._-~--~..__:'._--:._-:-n~:-:-.~-:tt:-:--';'~SECTI?NS ~-;_..
, . . . . '. . . -_4_'_--:':_~_'! ...-' - .' t ,4' .. .:..'
-.- --.."- . "
-- :-:~ -~T---:--!'--'-' -~~; -- :.~-. _II ..-- -"- I
. - -. ~. . -.-.. . ..
; : ~ I
-- .:_. .----- 4.J . -- - --I . -----:-- -
. L,tt: . . I
~
oCJ.
- .-.. c:
o
"'-t
'4.J
(.J
r.r
(1/
c:f
.. -.-. . - ---
. i - :. ./: :! -j ~
I'''' .. . .. / i
- ---!~-::~.~/;:~~-~~(: :~:'--:.. /' i
..--; ------:-:-:1 -.. . ~..-
'. . . I ,.
. - -... ... --..-
.J
""W . h_.- .---
. BASED ON: n-
- 1 ,.~:-~------) ---.._---.~/ FOUR EQUAL SECTIONS
..' , . : I - :. .. I.'. - -." / ..... WITH ONE PARTITIONED
: no_! -- ,I _--_..'n. ~/....~~~:-~.__/_-_...._. TOn THO HALVES-
I Ii'
10
20
30 40 50 60 70 80
OVERALL UNIT LOAD, % OF FULL LOAD
D-1l7
90
100
FIGURE NO.1
ECED
ZURN IND-
1-71
-------
o
o
o
~...-i
o
H
~
~
~H:~
5~
O~
>~
tJ)~
-------
APPENDIX #8
D-1l9
-------
SU!'[;~ArtY OF DRAFT LOSSES
CO:.!PO:;:'::;l'
AIR RES 1ST A:':CE
mtY SOLIDS. SYSTE:.t
OR
DRAFT LOSS, IN. WG
WET SCRUDBER, SYSTEM
Forced Draft Ducts -------------
Fluidized Bed Chamber:
~ection Dampers --------------
Perforated Plate -------------
Grid -------------------------
Bed -------------------------- 20.0
Mechanical Collector -----------
Carbon Burn-Up Cell (Thru Flow)-
Superheater --------------------
Convection Section -------------
Economizer
---------------------
Economizer Flues ---------------
Precipitator
-------------------
Precipitator Flues -------------
Wet Scrubber
-------------------
Scrubber Flues -----------------
TOTAL -------------------------- 43.3
0.2
0.5
1.0
5.0
5.0
0.5
2.6
5.6
2.0
0.2
0.5
0.2
D-121
---------------------------
---------------------------
---------------------------
---------------------------
---------------------------
---------------------------
---------------------------
---------------------------
---------------------------
---------------------------
---------------------------
---------------------------
---------------------------
---------------------------
---------------------------
0.2
0.5
1.0
5.0
20.0
5.0
0.5
2.6
5.6
2.0
0.2
16.0
0.2
--------------------------- 58.8
-------
COMPARISON OF POWER REOUIREMENTS *
FOR EOUIVALENT CAPACITY. FIELD ERECTED.
STEAM GENERATORS FIRING
DIFFERENT FUELS
Steam Generator
(See detailed
description) in
Appendix I
"A"
Gas or 011
Fired
liB"
CoalFired
spreader
stoker
tIC II
Coaf-Fired
Bed
Dry Solids
System
liD"
Fluidized
Combus ticn
Wet
Scrubber
Forced Draft Fan, HP 326 84 700 950
Irtduced Draft Fan, HP 341
Recirculating Pump, HP 200 200
Coal Crusher, HP 60 60
Slurry Pumps, HP 150
Total Power
Requirements, HP 326 425 960 1360
Power Requirements,
% of output ** 0.29 0.37 0.86 1.21
* Only major operating horsepower requirements are shown for the different systems.
** "''here a horsepower hour is 2544 Btu and output is 289 millionBtu per hour.
D-122
-------
REVIEIoJ OF STEAI1 GENERATORS
RECIRCULATING PUMP CHARACTERISTICS
To point out the recirculating pump requirements and the system character-
istics, graphical solutions were used. For each section of the recirculating
pump system including suction, discharge and distribution piping upstream of
the heating surface and the collecting and connecting lines to the steam drum
were calculated. In this a constant heat absorption for submerged tubing,
which is the "worst" or highest case was assumed. Curves were developed
showing resistance to flow versus flow for steaming and non-steaming tubes
within the bed sections. This data was then combined to show resistance
to flow versus overall flow for five different cases from out of service
conditions to full load (four sections operating).
The intersections of a "supposed" pump characteristic with these curves
determines the operating points.
It may be developed that a non-steaming section will act as a bypass of the
steaming section. The lowest flow in a steaming section will occur when
three sections are not fired and one bed section is.
The operating point is determined by the intersections outlined above and
can be used to determine flow through the non-steaming and steaming sections.
Total flow and head can be used to find the pump power.
Curve #1 shows the plots of the system resistance and the pump curve selected.
From the intersection of the pump curve, it is noted that:
PRESSURE DROP TOTAL FLOW, PUMP
CASE PUMP HEAD, FT WATER GPH HORSEPOWER
All sections out 21.5 12,900 137.5
One section fired 23.5 12,600 147
Two sections fired 25.5 12,250 155
Three sections fired 27.5 12,000 163
Four sections fired 30.0 11,600 172
Using this in relation to the resistance of a steaming circuit, it is
developed that:
CASE
FLOW/TUBE, #/HR.
(Unfired Section)
STEAM QUALITY LVG. BED, %
STM BY HEIGHT
One section fired
Two sections fired
Three sections fired
Four sections fired
2450
2600
2750
3000
5.70
5.3
4.9
4.3
D-123
-------
It is concluded by this analysis that valving or modulatin~ flow
control is not necessary to insure adequate circulation of tubes
1n the fluidized bed. 'The remainder of the steam generator is
cooled by natural circulation.
An overall circulation rate of
. 15 to I for the natural circulation sections is obtainable and would
be valid design point.
D-124
-------
tT
. .
~ :..
i~
t\.
~
'"
~
\;
"
\.
I;'
(;-'
"
(\'
\:
\~
~
C>
.'/ .~,
t
I.
I
l,"J
Ct ,"...'"
..#.'
. .
....; .
/- II
" )
. . .
,
::-,.,
... ..?
20
10
p
.;)
,"..
----."- ,
. ..~.. .... . --.""
-- ..- . -'-~'''' .
.'.'- ,..".-...
- - . . ----- -
.-- ".---"".'
~r~"" -'7',"'.,..
fJ' r..:t I' .~..: .,.; I
l:'''~'':;-I ;,: r,':;'fiV C$
..-. ~_.- . - .---.
.,.
. ,. .
.--_. ..-..- -.-----.
- ---_._._-~ -..
.-._. --.- - -. '.
..-. -- - - - - ._--," -----
- ..- ...
.-.-- -_.. "."
.. -.- ~._-_.__.
. .-.. -, - . .
"-~"---" ..
. -_.._._--- ...
i .
:...._.; .--.- 1 .._-~.
. j.-,
, ,I : .J
A
I
5
G
/C';/. ./
'- .:? ;-.'V I.
/ 0 ~ ~Jt:/M? ~,../O('//2!
,
D-125
-------
APPENDIX IX
D-127
-------
C2!J
JEFFREY
1 &r1
} '1 ~ (,:.) '~I. "':,)
{ -v '- l;J
, .
&~ r C1... U
,'. !1 ,"t '"1""1' I
-' \ U ~ l.\d~1
~~de~vv ttDn.n-u:V
~~~['lrnm~u~uunu~s
DIN1ENSIONS
SPECDr=~CA T!ONS
WEIGrrrS
"
1 '
I
,I
I
! .
'1-
'1'
I
I
~-
... -. '. -,"
~, 'r-o- '_'~-l'
. i; " ~,' . ; .. . j - ;, -. '", :'1"
-~l,;t.';~:;;;-.I"'r:II~~~. t ~,
I. .,':I~
..........1 . ." '. --" -._- . ;,--.tI
11'--. '-.&. ,t...1
-1
"-J
!
,
~-"-''';:'-:'':':::::~~':::~=.'''7.' 2776K
A hinged cover provides easy access to the metal
trap.
"
:.J
" ~'/1
r' u ~ ~ . v ~: ,: i
~ \ ,...,.- . : J--I' ,
\. ..i....~., ,,_::' ,{. ~. " " .
.-. I' ...."\',. "",' ..
: it ~-- ,,' !,~~) < <"" ~~:"~~l' , f
", ..,f,/." ,';/ I'.',,~, -
: l",.J_----"':"': ,:.:.:,
;:. . \ -,:-1;1' ( :.',
----~- - \ .'
. - "--'; "
~------. -
2756K ---
'ype 45AB Crusher. This rugged single direction
unit incorporates the improvements and experience
of over 73 years of designing, manufacturing and
marketing Hammermills.
G
_. - ,,-,--.". ._,-- _0" --
,_I: ~E"':~,~~::li:\-
,-:-:n i~- ,~~~~~~i 1':"':
; f ,. ",-liT:!,' d
, - rl'~""'-:.""I....,-:-rq .
:.:-~.. ~ ---'--'''':''':'''-~--I'''''''''''-'~ .. ~
,-,., ...~.~- ',. .,--
~j; '. " 'tr
,;\ ' ,,'-:A
~ - -.,.---- ,I - '. .' ...- '---' -, L:....-
A rigid all steel base
provides the mounting
tor the welded rei n-
forced screen bars be-
low the rotor.
2816K
View of the base show-
ing the heavy duty
rotor mounted on an
alloy st,,;;;1 shaft and
supported by spherical
roller bearings.
t~~?-.....:o.;""'j" ()
:=C': ~'~I}~~I~ r.',~'/. ~ l:'",--
.' -;.uuj.,j_.I81,;~' ':
,1j':,~
. ") ~ .c.:- ~.7
! . - . ~ , .,.
"" ,'- . ../
;" --... ."",
"-.- .
.. "...' ''''':..j - ,/
2746K
,~rl' ..
t ~
~ I
j I
,-'
=-~'1\ ' ) ~
------J t .
L..j
I ~ .
J
'~~~"'~r p
f. )i i~. .
;'
.----
.---..-
; I )
.:. - ---'-,- !
i
I I
- 1-.
-- ---- .--
2726K
View of rear side of pivoted breaker plate with
cover r£:mo'/ed,
--- --. -
0/~\ ~ -~'--'~L\ '~~~J -
i \. ...... ,", -,-
~/. ".,,~~~~=,==~~, .
:/ il!:'~~,/';;LJ,\/""-'Lr(:r/-I' :-1i,.,_.\~~~,:~ ~,'...,'" '. \',
," I ,~ -~ I ~L.j . " . " ~
..... ~ f, .- -'. 1 ...J . "'"' j \ .. .
, f. ' : -... ., ~ I J" ~ -' ! ,\'
;~r--1T4-"-~ H";~"1:J r-,! ~'r J.''"~ t!
,r I ir.j \J IJ ',ltH I r,JLU;: n.! )'
\.,.., ~... t.""":. ~,-:J U ~ I.J ft."J 1.....1 ,-i.' I,'" I --
=-_-;1
...
o
e
o
2786K '
View baking into top of Harnme:rmill shov.ing rotor
-------
r:::N °a
I I s-
f .- ''''''-'-1 ,M ,
. .. ., t.
....,....J j , ;
pA Lll I .iJ- .
F nr-i- .-:c-r- .
-., If 'l I, :;1 \\.'-V.J) I '
L \1'::;:-;-': . ''':.~' ,~ ,~~ I
\~, I:':::::: \=:: c:;:j! ~
LL-LG-LG-1LJ J~J i H~~ LM
-R
I
11
,A-j-Ai
R-
K
K
. ,
c:=
~
','
~
c=:I
"
c:::;,
I Dimensions in InChes
Unit I ~.~ ('I~p.nina I ~h,ft ! ! Weight
~Ile -o;a:-r -Ke-YSe.;( in
A B C E F G H J K L M N a p Q R* LOS.
D K.'.'I,
44AB 16~4 18~~ 11 \z 4V2 11,4x5iJ 21 30 1]3;~ 23:2 2 4' J' 101:; 3 2m 2-1'. 271'2 20112 60 8,000
~ .,4 :J.~
45"8 20~~ 18\"2 11\2 ,4~':! l\~ x ~a' 21 30 2H:i 23h 2 45~~ 10\:: 3 2H4 25;;; 27V2 201,2 68 9,100
55AB 21~8 201,2 143.i< 5=¥4 11/2 x ~.:. 28 35 227/8 30Y2 53 131,'a 3 261;2 323.4 32 33 70 15,000
56A£3 2-3.' 20;:2 14~d 53/ H:zx:J;; 28 35 22~8 30,'2 S3 13 3 26V2 3-" 32 33 86 17,000
o,~ ,4 ':~4
S7AB 32 201/2 14308 6~!t Ilf2 x ~ 28 351/4 3H:i 301,.2 631/4 171/4 3V4 261;2 33;~ 32 24 101 23,000
S8AB 371'4 201'2 ' .." 63' !1;2X:J4 28 35\CI 37 30;'2 7312 171,.4 3114 26¥2 331,.4 32 24 112 26,000
J.t+-:a .4
"!"'S
..;;-C;
*Space required 10 remove hammer pins (one side only),
""- -
SPECIFICATIONS:
Type AS Hammermills are of extra heavy construction.
They are oesigned to handle large, heavy feed at high
c<:pt:ciiy ra~es 2:HI to produce acceptable end products
for today's complch markets.
Units are of all steel rigid box construction.
Units me furni:::hed with an integral metal trap and
self-aligning rolier uearings.
Replaceable liners are drilled and tapped, with bolts
inserted from outside of unit, to prevent wCJring 2way
of llC:t heads or nuts.
D-130
-------
STD C K
EQUIPMENT COMPANY
731 HANNA BUILDING - 12161 621-3054
CLEVELAND.OHIO 44115
REPLY TO:
PITTSBURGH OFFICE
3730 POPLAR AVE.
CA'5TLE SHANNON BOROUGH
PITTSBURGH. PA. '5234
14121 343-8599
June 2. 197J
Ert e City I ron ~Iorks
150~-1520 Ea~t Avp..
Eric. Pcr.n~ylv~~ia
Attention:
~Ir. R. Winche11
SUBJECT:
S-(-Ca. Gi'avi~':etric Feeder for
Unknow~ Customer
S-E-Co. Rcf. ~a. E-4656
Gentlemen:
In reply to your recent ~uotation request. we propo$e the following:
!THI I
--
$-E-Co. Gravim~tric Feeder.
A d~tailed description of the Gravimetric feeder follows:
General description and principle of operation are described In
the attar:hed Buitetin :'~. 198.
The advantages to be gained through the utilization of Gravimetric
Feeders are.outlined in the attached reprint of "Combustion Control
Utilizing Gravimetric Feeding of Coal" by Ralph M. Hardgrove.
Capacity of each feeder Is 29,000 Ibs. per hour of coal weighing
approximately 50 lbs. per cu. ft. This Is based on the capacity re-
quirements stated in your Inquiry.
The distance from center line of inlet to center line of discharge of
feeder outlet hopper is 710". Inlet opening is 24" inside diameter.
The $-E-(o. Gravimetric Feeder is designed and built to discharge
exactly 100 Ibs. of coal per revolution of the head shaft. Head shaft
speed and correspondingly the coal feed rate. are determined by an
accur~tely controllable. variable speed drive.
Feeder body is designed to withstand a static Internal pressure of
50 psi in accordance \'/ith the explosion requirements of the Uational
Fire Prevention Association Code 60. Atl portions of the feeder in
Specialists in Bunker to Pulverizer and Bunker to Stoker Equipment Cont i nued. . . . . . . .
D-131
-------
STOCK EQUIPMENT COMPANY
June 2. 1971
Erie City Iron
':lorks
Re:
S-E-Co. Reference No~ E-4656
Page: 2
contact with the normat flow of coat are stainless steel or rubber.
Dull's-eyes and lights are incorporated into the feeder body for in-
spection of the interior. Each bullis-eye and light has a special
fitting for washing the interior gtass 3urface to keep it ctean. One
separate window washer mount~d on a cart is provided for the entire
group of feeders as a portable source of water for the cleaning
ope rat ion.
The rubber feed belt wit I be three ply, molded construction to keep
siftin~ dust and dripping water from the fe~der to an absolute minimum~
The belt design features a rubber curb atong each side to confine
~Disture and d~st. It has a V-belt guide section on the inside to
insu~e accurate tracking of the belt. ~aximum operating temperaturi
of the belt iz 175°F.
The feed belt is removable through the access door provided at either
end of the feeder. The boit wi11 be carried on closely spac~d idlers
~/ith ~nt~-fdction bearings. The tail pulley is m::;unter::l in conven-
tional take-ups which include protected adjustin~ screws which are
also used for tracking the belt. The adjustment is made from outside
the hColiS i ng.
The feeder is driven tl/iough a speciuJJy designed helical and worm
gear reducer by a 1-1/2 H.P. magnetic slip clutch variable speed motor.
Thp. variable feed rate is accomplished by the use of the magnetic slip
clutch with its trdnsistor control. This controller includes a tacho-
meter feedback network and a DC power supply for the field of the mag-
netic slip clutch. It provides a close speed control with rapid and
accurate response to the combustion control signal. A minimum speed
adjustment is provided such that if the input signals fall below a
certain point, then the feeder will operate at the set minimum speed.
The feeder is equipped with a drag type cleanout conveyor to remove
dust accumulations from the bottom of the feeder body through the
outlet. The cleanout conveyor consists of a specially desi~ned
malleable iron chain with stainless steel pins, manufactured by the
Stock Equipment Company. Cleanout conveyor runs on 1/4" thick stain-
less steel pan. A separate 1/4 H.P. motor and gear reducer arc em-
ployed to drive the clcanout conveyor. As the amount of the dust
accumulation is extremely small, a timer is furnished to operate the
cleanout conveyor for a preset period of time, usually 5 minutes for
each hour of feeder running time. .
For calibration purposes, 2 twenty-five pound field test weights are
furnished.
. All bearing~ are
through pressure
equipped for pr~ssure
shell, suitable seals
~
D-132
lubrication. Where shafts pass
against the internal air pressure
Cont I nued. . . .
-------
STOCK EQUIPMENT COMPANY
Jun"3 2, 1971
Erie City Iron ~orks
Re: .~_E_-f5~,' Refer~nc~ NO.._,E-~656 _... ~aq~: 3-
are pre-vi c!cd. To prevent dust 'from ent~rj ng the we i gh 1 ever compa,rt-
ffi~nt, this comp~rtment i~ pres3wrized.
Purchaser ~~y prcvide a ~0~rce of c'c~n ~colin~ air and seal ing
~ir at suitable prC55tl:"C: \,,.;,ich may be t~kcn off at the discharge of
the for!:o::d d,aft f~r;s. :;:-:, err. requ:reci arc sl:~ht1y more than the'
1055 thro:Jsh t!1e c:ea! ieg ~:;: ir:tc th.:!,dot~':1SpOllt, ~o that the f10\'l
of air cmd ccn~:r~q~'(:;;1tly, the dU$t c:t the 01Jtlet .witt be toward the
f~~~er di~~r~rge and into the mi11. .
A 5epar~te fr~~ st~nding e1~ctr!c~1 equ!p~Ent c~binet is provided
for e3ch fp.~~er. Construction is NE~~ 12. :t contains circuit
~!'eC\k~r. :n~f:::>; !:t::)rtei~ fr,;" th!'l :~.":n f'l'<';d"3r driv~ and the cleClr.!')ut
roon'/ey',;' ,~"'ive, cC'ntro1 \':,l:'""~:t7: "..;.~,1sfor!1i~r, re1ays, timer for ~he
cor;tro~ ~. t~a ~1c~n-o~~ CGnv~yor. an~ ths v2ri~b?2 speed cor.tr01 '
for the ~a9ne~ic slip clutch.
The feeder~ ~re pr::>vid~~ wit~ ~ cOI~uit entry ~~X having :erminals
ro; i,~uk!n0 th;-, i;.~c~ssary ~1'?ctrkai conn~r.li~., to ~;{terna! POWC-f
supp!y end control wirc5. Feedsr in:Er~a! ~~ring, from motors ~nd
jn~!;:1in21::~g lights 4;0 their ter:n:fI<'Il i:,~~cks: i$ by S-[-Co. Each
feed~~ hE'$ <3:1 i~tegrai conuol p.s~'::i ...:il.::, OJ "C~I ibrc1te-Lor:al Run-Off-
Rel!Y>tell sel~ct').. s','it~h an~ 1::{l.In-~lai:.; ~i~oi: i. ishts. A larse tacho-
r.:~tei ir.d:c~i:r::- to indic~t0 i~::C of ,;;0c:1 feerl in p::1":"Ids per hour and
t.::t~} co;') 1 int:::,;rC'Jtc..- or C0:'nter to i...d;(':dtP. the f',,;mc!s of coal fed
over ~ period ;:)f time, are iu:-nishcd .3$ sep:.!r<'lte items for mounting
~n purchas~r's bo:1er contro1 pan~l.
Each unit is e1~ip~ed with pulsers which wi!1 give one pulse for
eVe~' 100 Ib:.. cf coal ferl to both a~ !ntegrator and a data logger.
In the event pur~haser de~ires to have arldit!~na1 pu1ses for data
10gging purposp.s for sn~11er units of coal, such pulses can be pro-
vided. '
Two S-E-Co. Padd1e Type Coa1 Stoppage A!arm $witches are furnished
as an integral part of each feeder.
One paddle switch is insta11ed at the discharge of the feeder to
step the feeder in the event f100ding occurs in the hopper or the
clcwnspout to the mi1l. ,Stopping the feeder reduces the amount of
, coa1 within the system which must be removed in order to c'lear the
stoppage, anrl it also' prevents damage to the feed belts.
The second paddie switch is 10cated over the
dication of loss of coa1 flow to the feed2r.
used in the internal circuitry of the fe~de~
improper calibration.
feed belt to give in-
This switch is a1so
to prevent cccidental
Continued....
D-133
-------
STDCK EQUIPMENT CDMPANY
I .
June 2, 1971
~_L~ _C_i.~y~!~f! \.forks
6. )
Re: 5-E-Co. Reference No. E-4656
Page: 4
Features of the 5-E-Co. Gravimetric Feeder are:
I.)
Assures reliable coal flow because the coal is brought down
to the belt through C) flov/ paSS'ige 24" in diameter. This large
inlet provides good coal flO\'/ c?nditions even with fine, wet,
sticky coal. The 2'~" I.!idth of c?al stream is maintained through'
th~ entire feeder with no obstructions projecting into the coal
stre3m at any point.
2. )
Has a very un i form rate of feed beca~lse the rubber be I t d i s-
charges coal at a fairly smooth rate ever the head pulley.
). )
H<.1s pi"Oj)er coal fIOl'/condit!o:1s to :i1ake aCClirate weighing
pos$i~le. Accurate wzi~1hillg (:.':."'! be achieved only if rapid,
sporg~:c fluctuations in the ~ffective coal density resulting
fro~ unevenness of th~ coal stre~m are avoid~d. The 5-(-Co.
Gr~vi~etric Feeder provides the requisite high and very n~arly
con$tant filling cf the discharge area because the co-~fficient
nf friction between the rubber bait and ,the coal is large, be-
c::luse t:,~ width ,of co.:!! on the belt is 21;" and nowhere restricted
and because the coal depth is approximately 4-1/VI.
4. )
Is highlyrelieJ.ble becau5~ it em~:ovs a heavy duty, molded
endless belt, features rugged construction throughout and is
designed with careful attention to every detail.
5. )
Requires lew maintenance because the endless belt lasts many
years barring severe accident, because all surfaces normally
in contact with the flow of coal are mAde of stainless steel or
rubber, and because the unit is designed for easy and quick
dis-assembly and re-assembly. .
Has variable speed magnetic slip clutch drive which gives very
clos~ feed rate control with a rapid and accurate response to
the combustion control siqnal.
APPROXIHATE WE I GIH-----------------7 ,425 I bs.
As additional equipment, we offer:
ITEM 2
Electric Tachometer Generator.
The tachometer generator is suggested to provide a feedback signal
from the feeder to combustion control. .
Continued....
D-134
-------
t::I
.
......
LU
VI
iUlSIO\..l PULLt~
-- ---
CLEAlJ OU1 COt-tVE~02-
..
P~\)\)l.E. 1'!PE
~l
c:.TO?Pf.GE
. IIl~~. ~rT"
,0 Po.t.'i~'T
P\.UGG~GE.
bE.l..'W "om R
?!..OU MIIIIIMU/+? t ~EEOE,e IIt/L.eT TO t NOP,PE~ O(/rU~T
'L
5+(0. GRA.\JIMt.,(R\C.
H.cOc~
STOCr. EOU\PI<\~NT co
.eEVA5£O ",J(,-u
.ch"h.5~O /-~-'s-
CU'JtL"'\.j~
O~\O
l B 3300
-------
STOCK EQUIPMENT COMPANY
June 2, 1971
ErIe City Iron Works
Re: S-E-Co. Reference No. E-4656
Page: 5
The generator is a General E1ectric D.C. Unit, Mode1 GE 5BC46AB 1590,
50 V/1000 RPM steady state, long time drift with 1.n megohm resis-
tance 1oad, .05%/24 hour period.
The generator wou1d be mounted on the belt drive reducer, and driven
at motor speed.
APPROXIMATE WEIGHT-~-----------------35 lbs.
F. O. B. point, terms, de1ivery and other conditions of sale are as out-
lined In Form 260, which is page 6 of thi. proposal.
D-136
-------
810 C K
EqUIPMENT CD.
HRNNR BLDG. CLEVELRND,O.
D~131
-------
- - ' S' E C' ~GRAVIMETRIC . ,,'
'~7 ~ THE STDRYDF . ~~~. "D-~-' -FEEDER;";~',' '-,'7,
,- '. . '''',~' ," ~
. - ,~". .. _: ~ ~ ~~' '. ,~,ti---, ~.. .~:-~:.'".,.~ .....'~, ,"
- --.....,;
"'- , ~
. ,
.. .- '....
.....'
--.- ......~.
.'-" : "C:
S-E-Co. GRAVIMETRIC FEEDERS are de-
signed to feed coal by weight, instead of by volume,
to pulverizers and cyclone burners. Since feeding by
weight is more accurate, these feeders enable more
precise control of fuel-air ratio. They also make it pos-
sible to divide the total coal flow equally among the
several firing units of a single boiler.
The S-E-Co. Gravimetric Feeder is designed to dis-
charge exactly 100 pounds of coal for each turn of the
head shaft. Head shaft speed is equivalent, therefore,
to the rate of coal feed and can be expressed as
pounds of coal per minute or pounds of coal per hour
as desired. Total turns of the feeder head shaft times
100 equals total pounds of coal fed during any given
period. Instruments can be provided to indicate coal
flow feed rate and total coal burned.
The feeder body is a cylindrical housing designed to
meet the National Fire Protection Association Code
No. 60 for withstanding an explosion pressure of 50
p.s.i. Normal internal working pressure is slightly
above or below atmospheric.
Each feeder is driven by a variable speed motor. The
control for that motor balances the speed of its out-
put shaft against an electrical voltage furnished by
the combustion control. This assures a coal feed rate
that corresponds exactly to the requirements of the
combustion control.
Fig. 1 below shows cross-section of entire feeder.
Fig. I
CLEAN OUT CONVEYOR
, -.r"
..- .:- -' ~ ~'~ -::-?:~~ - ~.: -=-
"
THEORY OF DESIGN. The operating
S-E-Co. Gravimetric Feeders follows:
.........~
l:::.
I. R. .1
theory of
Fig. 2
Fig. 2 represents a beam resting on two supports at a
distance" l " apart. If ten units of weight were uni-
formly spaced along the length of the beam, then the
load carried at each support would be five units.
!........~........~
I- £ .1. U. rl
Fig. 3
If the beam were made twice as long, as shown in
Fig. 3, and three supports provided at a distance"l"
apart, and if ten units of weight were applied to each
span, then the amount of load carried by the outside
supports would be five units, but the central support
would carry ten units of weight. This is true provided
that the supports are either in a dead level plane or
the beam is non-continuous or flexible over the center
support.
~F~"
2: ):"
Now if a short length of belt conveyor is supported by
three rollers in a level plane, as shown in Fig. 4, and
-- CALIBRATION MOTOR
PADDLE TYPE
COAL
STOPPAGE
ALARM swnCH
6'-8~ 4. INLET TO t DISCHARGE
-.If
I'
Ii
Copyright 196" by Stock Equipment Co.
D-138
-------
if the belt is loaded uniformly with coal, then the
center roller will carry one half the load and the end
rollers will carry one quarter of the load each.
O.W.-
BAl. -
U.W.-
t
POISE
Fig. S
The load on the weighing roller can be balanced
with a simple lever scale such as diagramed in Fig. 5.
The poise can be moved out or in so that the lever
system comes to balance, and the actual weight on
the weighing roller determined. If for anyone setting
of the poise the weight on the weighing roller is
greater than the correct amount, then the weigh
lever will indicate "overweight." Conversely, if it is
less, the weigh lever will indicate "underweight."
O.W.-
BAl.
U.W.-
Fig. 6
The weight on the weigh lever should always be
constant. Therefore, it is necessary to vary the depth
of the coal on the belt as the weight per cubic foot
of the coal varies. This can be accomplished rather
simply as shown in Fig. 6. The leveling bar is
operated through a gear reducer so that it can be
CALIBRATION
Calibration of the S-E-Co. Gravimetric Feeder is
very simple. The poise or movable weight on
the weigh lever is moved out or in by means of
the calibration motor and a screw. A selector
switch allows the operation of this motor to be
controlled by the "overweight" and "under-
weight" contacts.
If a 50 pound test weight is hung on the weigh-
ing roller (25 pounds at each end) and if the
unit is operated for a short period without coal
on the belt, the calibration motor will be
actuated through the "overweight" and "under-
weight" contacts so as to move the poise to a
position of balance. This simple method of
calibration is indicated in Fig. 8. No tare adjust-
ment is required because the method of calibra-
tion automatically takes into consideration the
tare weight of the belt.
raised or lowered by means of a motor. In the event
of an "underweight" condition, the operator pushes
a button to operate the motor and raise the leveling
bar. For "overweight" the operator pushes the
button to lower the leveling bar and thus reduce the
weight.
Fig. 7
However, since the weight per cubic foot of coal is
continually changing, the operator would have to
watch the balance indicator at all times. The job
can be done automatically by means of "overweight"
and "underweight" contacts to control the leveling
bar motor. This is all shown in Fig. 7.
In the S-E-Co. Gravimetric Feeder, the length of the
weigh span is equivalent to the belt advance for one
turn of the head pulley. The normal weight of coal
on the belt in the weigh span is equal to 100 pounds.
Therefore, the weight on the weighing roller is
normally 50 pounds.
Should this weight be greater than 50 pounds, the
"overweight" contact closes, operating the motor
driven leveling bar to decrease the volume of coal
and thus bring the weight down to 50 pounds. On
the other hand, if the weight is less than 50 pounds,
then the "underweight" contact is made and the
leveling bar motor will operate to increase the
volume of coal and thereby bring the weight back
up to 50 pounds.
O.W.-
BAl.-
U.W.-
TEST
WEIGHT
Fig. 8
D-139
-------
.
I
J.~
----
---'
,.
..
_.~~
"
,
.' itI'" ,~.
~ .
,.
to
',~
.
-----
- -
(tgp) (L~) .j~
~..
I
[
S-E-Co. LONG CENTER
GRA VIMETRIC FEEDER
Shown at the left in the above picture are
three drives. The upper drive is for the
distributor, which is standard for cyclone
burner applications. The distributor as-
sures uniform discharge of coal off the feed
belt when the coal is fine and wet.
In the middle is the variable speed feeder
drive, with an auxiliary tachometer gen-
erator installed at the extreme left. A cen-
trifugal switch to signal machine operation
can also be installed here. The auxiliary
tachometer generator and centrifugal
switch are extra price items.
The lower drive is for the cleanout conveyor.
At the right is located the coal inlet, weigh-
ing compartment with bull's-eyes, and
purge air connection.
S-E-Co. GRAVIMETRIC FEEDER
At the left is the weigh compartment with
right side doors open. The lower door
shows tension roll complete with height
gauge and weighing roller with test weight
attached thereto. The upper door shows
weigh lever, leveling bar actuator and bail.
Box for storing test weights is also shown.
I D-140
-------
...."~o:."'\
.~-~~~ -~~ U~"""'.
-.\ .J~I- , ~ \
~.-jL1-~w:~~
~'
TYPES-SIZES-
CAPACITIES
Stock Equipment Company produces a
complete line of gravimetric feeders. The
standard S-E-Co. Gravimetric Feeder has a
length of 6'-8" between center line of inlet
and center line of discharge. The standard
feeder is illustrated on the cover of this
bulletin. Longer center line lengths can
be furnished as required by specific
applications.
S-E-Co. Gravimetric Feeders are built for
any desired capacity up to 100 tons per
hour. The capacity, which is determined
by the maximum head shaft rpm, is
matched to purchaser's requirements.
The above feeders are built for a 24"
width of coal on the belt.
S-E-Co. GRAVIMETRIC FEEDER
At the right is the weigh compartment with
left side doors open. The lower door shows
left end of tension roll. The upper door
shows leveling bar actuator, leveling bar
height gauge, weigh lever, weight calibra-
tion motor, poise, and magnetic "over-
weight" or "underweight" mercury switch
assemblies.
. IL.:.... - '~-' '~._-~ -- ~...~.. :
D-141
I !j~.'~
H~'
klr
. ...-
.. f'I
ICI '
~ I
~
/\
'"
n
-------
..
,.'
"'::;.: ~. ... -': ""
. ,,'~.~ /'t;'
.. ,. ,iJ.F . ..... ".',
'. . ~., .;).. to!'
.[ -:" <.;
-.: l&- \~... f.::. . ~:~: v.
<;; ~, "
It '."
,Ii.>
.,..... .
: .... ~.
~~
. ,
.
I f' ,Ifi., I"~ r;J"""'lr'7'';'''/'''I'''J''''''f'''I'''lf~'''I,j'I't'I'V''1"il'hf"'lilll'i"'I'~"II'I'I"'I'~'iT"I"fII';'"1"'I",,'iiVT'-''I'ltl''i~i;1'''I'I~~I'I'1''~'t'1'~1~;I'''rl'I"Ik:"~tt'1~~lr~\,1'\'ltiI11' 1 '1i \ -
Frozen Coal-Pyrites-Wood
S-E-Co. Gravimetric Feeders have an extraordinary
ability to pass occasional pieces of frozen coal or
foreign objects without difficulty. The full 24"
width of coal on the belt is just one of the design
features contributing to this ability. The endless
belt is another. At the same time these feeders are
also able to handle fine, wet, sticky coal with no
trouble. The photographs above show lumps of
frozen coal, balls of pyrites, and a piece of wood
that have successfully passed through S-E-Co. Feeders.
D-142
-------
.----.-----
CHANGING BELT ON 6'-8"
GRA VIMETRIC FEEDER
10:00 a.m. Ready to start belt change with new belt
and tools available to three men.
10:15 a.m. Tension pulley being removed. Belt
scraper removed.
10:29 a.m. Weigh roller removed. Head pulley being
removed.
10:36 a.m. Weigh span rollers being removed.
10:53 a.m. Self clenning tail pulley removed.
11 :00 a.m. Slide pan and belt being removed.
11 :07 a.m. New belt ready to install.
11 :21 a.m. New belt and slide pan in place. Tail
pulley being installed.
11 :40 a.m. Weigh span rollers being installed.
11 :53 a.m. Head pulley instalJed, tension pulley
being installed.
12:08 p.m. Weigh roller being installed. Tail pulley
being adjusted.
12:21 p.m. Belt installation complete.
For an experienced crew with a new
feeder
TOTAL TIME 2 HOURS, 21 MINUTES
An inexperienced crew will require somewhat great-
er time than that indicated, especially if the feeder
has been in service.
-
-
-------
FEATURES
BELT
The S-E-Co. endless rubber belt has an integrally
molded high curb on each side to retain coal on the
belt and to eliminate the need of metal side skirts or
troughing of the belt over the weighing section. The
belt also has an integrally molded V section which
engages a V groove in the pulleys. Three plies of
duck with a 78" top cover and }f;;" bottom cover are
used in the belt.
SKIRT BARS AND INLET
At the stainless steel inlet to the belt, vertical stainless
steel skirts are employed for coal inlet control. These
skirts have a clear horizontal spacing of 24" and can
be adjusted vertically for proper belt clearance.
PULLEYS AND SUPPORT ROLLERS
Head and tail pulleys are heavy castings, turned flat
and having a V groove for the belt to assure positive
tracking. The tail pulley is of self-cleaning construc-
tion, eliminating the need of a belt scraper on the in-
side of the belt. Supporting roHers are designed to al-
Iowa small amount of adjustment in the horizontal
plane to assist with tracking. All bearings are pro-
tected against the high humidity and dusty atmos-
phere existing inside the feeders by suitable grease
seals and also have a grease flushing feature for in-
creased protection.
BELT SCRAPERS
A scraper is provided for the outside surface of the
belt. It is located above the feeder discharge so that
any coal removed falls out the discharge opening and
does not accumulate.
CLEANOUT CONVEYOR
S-E-Co. Gravimetric Feeders are furnished with
cleanout conveyors to remove accumulated dust
from the bottom of the housing. This conveyor em-
ploys special malleable iron flights with stainless steel
pins. The bottom strand operates in a stainless steel
trough which prevents corrosion damage to the bot-
tom of the feeder housing. The conveyor needs to be
operated only a few minutes each hour.
DRIVE
S-E-Co. Gravimetric Feeders are driven by an AC in-
duction motor through a magnetic slip clutch to a
specially designed helical and worm gear reducer.
The speed control unit receives a feed back signal
from a tachometer generator on the clutch output
shalt to provide accurate feed rate regulation. Since
the S-E-Co. Gravimetric Feeder feeds the coal by
carrying it, the motor power required is unusually
low, typically I to l~ H.P. In addition, all bearings are
anti-friction. Because no excess horsepower is re-
quired to overcome friction, the wear of feeder parts
is at a minimum.
BODY
The cylindrical feeder housing is constructed of >iff
thick mild steel plate. Steel plate ~" thick is used
where there are large openings in the housing and
where machine work is required. The entire feeder
or head end of long center designs is machined as a
unit on a horizontal boring mill to assure accurate
alignment of the head shalt and ease of realignment
upon reassembly. Bull's-eyes and lights are provided
at both inlet and discharge ends to enable visual in-
spection of the interior while in operation. The lights
are wired internally, the leads being brought to
junction box underneath the main drive motor.
ALARMS
Two paddle type coal alarm switches are provided.
One, located over the feed belt, gives positive indica-
tion of loss of coal flow to the feeder. The other is lo-
cated near the discharge to stop the feeder in the
event of a coal pluggage at the mill or cyclone burner.
SERVICE
Because the S-E-Co. Gravimetric Feeder uses an end-
less rubber belt, very little operating attention is re-
quired. The belt take-ups and adjustments for track-
ing the belt are operated from outside the machine.
All greasing is also accomplished from the outside.
OPTIONAL ACCESSORIES
Pneumatic Speed Transmitter
Electric Tachometer Generator
Coal Feed Rate Indicators and Recorders
Slow Speed Centrifugal Switch
Pulser for Remote Indication of Weight of
Coal Feed
Temperature Safety Switch
Coal Valves and Coal Scales
Downspouts and Hoppers
Plastic Metallic Gasket for Flange
Connections
STOCK
EQUIPMENT COMPANY
.
CLEVELAND, OHIO 44115
731 HANNA BLDG.
Form No. 198 2.5M 7/69
D-144
Printed in U.S.A.
-------
.??LF;:,T!D~! - This n!:~ed, compact. medium capacity
re::!cr is lIs~.d r~::"Jr;l:i ~C~ fe~din; r;~::~c::'ial to belts, screens,
e:e'.'':>~Grs, 7;,inc;il~.~ ;;-:ills. b3tching 3nj cO:1tinuous scales, and
for ptVpor~:onin5' varioLis materials,
C;'\P~C:TY - V2~i'?s wit~, the materiels. and conditiC'ns under
\'-,hieh tI:e'\' ,)(<:? 1;~::idJcd. \'ihen fee~::ig silica sand or simil3r
materil!S '::0i;;lolns lO::>:.'cu. ft., th:s-f2?der will handle up
to 175 T?r-i \'ii',en Gp2r~:lcd \'/ith the ~an on a 10" do'::n-slojJe.
Feeder c3~acjtjcs iHe pr.:'portional to t~ie width of the deck.
COtJTi:OL - \Vhe:1 the feeder is operated from either 50 or
60 hertz alternating current, an SCRf.., rectifier set is fur-
nished with the feeder, Capacity may be instantly varied from
near zero to, m~x.irnum by..~imp.!x turning. th~ calibrated con-
trol pot ();1 LI1e ::"',...,0,,,1 r::':C::ii,cr, ',:r~S;2 v~::;lr~o. the f(:(,G'2r maj
be controlled, and at;tomatically regulated, from a 10-50 ma
DC signal.
PO',':ER U711T :,iOUNTI:lG-The feeder is normally furnished
with the po'::er unit rT.Junted be!c''"1 deck, but can be ar-
rang€d \'/::h the power unit above deck,
DEC:
-------
df!!{~"i"
It .::;:::.:.;!.~
... ;rOo :..
, ",. 0; .
.:U\vf~:"
I Norblo'l
!llUJt C6nbd Jj;do'J1M/
BUELL ENGINEERING COl\IPANY, INC.
253 NORTH FOURTH STREET. LEBANON. PENNSYLVANIA 17042
AREA CODE 717 272-2001
CABLE BUELENC. LEBANON, PA.
TELEX B4\2-332
April 21, 1971
Erie City Energy Division
Zurn Industries
.Erie, Pennsylvania 16500
Attention:
Mr. Bob Seibel
Project Engineer
Subject:
BUELL Proposal No: 71L-19073
Electrostatic Precipitator
Fluid Bed Boiler
Gentlemen:
Attached is our proposal for an electrostatic precipitator in
accordance with our telephone conversat~on. Due to the fact
that this project is a proposal for a new steam generating
process for the NAPCA of the United States Federal Government,
our price as quoted will apply on a one-time only basis. It
is our desire to participate in this project and our price
reflects this desire. We trust that you will treat this matter
in this light.
The drawing that
pitator that has
dimensions shown
reduced by 9".
is included with this proposal is of a preci-
one more gas passage than that quoted. The
for the width of the precipitator should be
Should you have any questions or comments concerning our offering,
do not hesitate to contact us.
Very truly yours,
BUELL ENGINEERING COMPANY, INC.
~.c;:.~
L. F. Rettenmaier
Sales Engineer,
Lebanon District
LFR: sw
(2)
Encl:
flldtw.(f (/;Jtt. ..Cfi'Jti'eM -IJ. r0'Ct;t~J: !/Z'JiJU'J,j,
D-146
-------
2J~ Clmbot cSjplOlIlJ/
BUELL ENGINEERING COl\IPANY, INC.
253 NORTH rOURTH STREET. LEBANON. PENNSYLVANIA 17042
AREA COOE 717 272.2001
CABLE BUELENC. LEBANON, PA.
TELEX 642-332
April 21, 1971
BUELL Proposal No: 71L-19073
Subject: Electrostatic Precipitator
Fluid Bed Boiler
Erie City Energy Division
Zurn Industries
Erie, Pennsylvania 16500
Attention:
Mr. Bob Seibel
Project Engineer
Gentlemen:
BUELL ENGINEERING COMPANY, INC. proposes to furnish, in accordance
with the conditions outlined under NORMAL OPERATING CONDITIONS,
dust collection equipment and certain s~ecific auxiliaries as here-
inafter itemized and described. The items of equipment and services
are listed. Details will be in accordance with referenced drawings,
specifications, data sheets, interpretations and conditions.
Numbered items constitute the limits of this proposal.
NORMAL OPERATING CONDITIONS
Application
Fluid Bed Boiler
Gas
Flue
Boiler Capacity - #Gas/Hr.
298,000
250,000
Boiler Capacity - #Steam/Hr.
Quantity - ACFM
97,500
350
Temperature - of.
Moisture - % by Volume
5.3
Coal Analysis
Proximate
Ash
Sulphur
8.5
4.3
9/ldkll1 Clut !ll'Jt/UiJo- ~. ~J(!~~J: gz'JI/leJJ-
D-147
-------
BUELL Proposal No: 71L-19073
-2-
April 21, 1971
NORMAL OPERATING CONDITIONS (C9nt'd)
Dust
Grains/CF - Inlet at Conditions
Assume 2 to 4
99.5
+ 15
400
Volts Phase Cycle
440 3 60
Desired Efficiency
Mechanical Design Conditions
Pressure - Inches W.G.
Temperature - of.
Required Power Supply
EQUIPMENT AND SERVICES OFFERED
Item 1
One (1) BUELL Model BA1.lx23K333-2P Modular Electro-
static Precipitator, arranged as a one (1) chamber,
one (1) cell per chamber wide, nine (9) bus section
long unit. Electrically, the precipitator is three
(3) fields. The precipitator, therefore, contains
~ine (9) independent, isolatable bus sections. The
precipitator is also equipped with Safety Key Inter-
locks to prevent acc~ss during energization. For
energization three (3) High Voltage, Silicon Rectifier,
. Electrical Sets are furnished. The model number of the
sets is SIPP-SCR-35-11-45, each rated at 35 KVA, 550 MA,
45 KV. The High Voltage is distributed as full wave.
Each set is complete with ANACOMP controls and high voltage
bus-ducts to the extent as shown on referenced drawings.
Item 2
Four (4) Sets of Contract and Customer Data.
Item 3
Services of an Operating and/or Erection Supervisor.
DELIVERIES
Drawings for approval will be submitted four (4) to six (6) weeks
after order. Equipment deliveries will initiate six (6) to seven (7)
months after approval of drawings and settlement of details.
REFERENCED DRAHINGS
Precipitator
NL-874
D-148
-------
BUELL Proposal No: 71L-19073
-3-
April 21, 1971
REFERENCED SPECIFICATIONS
General Conditions
Warranties and Guarantees
GC-l
SC-l
MODULAR PRECIPITATOR
SPECIFICATION BOOK
Modular Electric Precipitator
Safety Key Interlock System
Field Engineering & Contractual Data
High Voltage Power Supply
ANACOMP - Automatic Voltage Control
Vibrator Intensity Control
Section I
Section I
Section I
Section II
Section II
Section II
PERFORMANCE
Based upon the conditions outlined under NORMAL OPERATING CONDITIONS
and with those instructions as issued by our operating supervisor,
the draft loss through the Electrostatic Precipitator, when measured
as a difference of static pressure between the inlet and outlet
flanges of the collector, is guaranteed not to exceed 0.3"W.G.
Based on a maximum of 15% of unburned combustibles in the fly ash
entering the precipitator. The collector is guaranteed to ccllect
99.5% by weight of the suspended solids contained in the gases
entering the collector. An outlet loading of .02 grains per cubic
foot or les5 shall constitute fulfillment of our guarantee.
EQUIPMENT AND SERVICES NOT FURNISHED
The following equipment and services are specifically not furnished
under the terms of this proposal:
Connecting Flues
Fans, Fan Motors and Drives
Dampers
Supporting Steel, Groutings and Foundations
Railings, Ladders and Walkways
Dust Disposal System
Hopper Valves and Vibrators
Thermal Insulation and Clips
Flashings
Power Supply to Control Cabinets
Low Voltage Wiring
Permanent Lighting
Safety Key Interlocks on Precipitator Bolted Access
Safety Key Interlocks on Precipitator Bolted Hopper
Grounding Leads and Subterranean Plant Grounds
Erection, Welding Rod and Field Painting
Openings
Doors
D-149
-------
BUELL Proposal No: 71L-19073-
-4-
April 21) 1971
PRICES
Item 1
& 2.,.......................................... ."$
76)000.00
(SEVENTY SIX THOUSAND DOLLARS)
I t em 3................................................ $
100.00
(ONE HUNDRED DOLLARS) Per Day Per Man for every day
away from Lebanon) Pennsylvania plus living and
traveling expenses.
TERMS
The equipment prices are F.O.B. place of manufacture, suitably
prepared for domestiq shipment.
The terms of payment on the equipment are as follows: 10% upon
acceptance of Approval Drawings; 85% upon shipment; and 5% on
acceptance of equipment, but in no case later than 120 days from
date of final shipment. .
The above equipment prices are firm provided order is placed within
sixty (60) days and shipment of equipment is within one (I) year of
date of proposal.. . .
This offer is subject to acceptancew:tthtn si.:xty (601. days and the
attached GENERAL CONDITIONS, GC...1 and WARRANTIES AND GUARANTEES, SC-l.
Very truly yours~
BUELL ENGINEERING COMPANY, INC.
~sr.~
L. F. Rettenmaier
Sales Engineer
Lebanon District
LFR:sw
(2)
D-150
-------
BUELL ENGINEERING COMPANY, INC.
BID EVALUATION FORM
for
ELECTROSTATIC PRECIPITATORS
FLUID BED BOILER
PROPOSAL NO.
71L-19073
OPERATING AND PERFORMANCE DATA: (See Proposal for Complete
Volume CFM @ operating Conditions
Temperature - of. @ operating conditions
Inlet loading. grains/cf @ operating conditions
Dust Bulk Density
Guaranteed Efficiency -'- Percent
Guaranteed Outlet Loading - gr./act. cu. ft.
Pressure Drop Across Precipitator
including gas distribution devices
Gas Velocity - ft./sec.
Treatment Time-Seconds
Qualifications)
PRECIPITATOR ARRANGEMENT, MODEL NO: BA1.lx23K333-2P
Number of Precipitators
Chambers (number) /Precipitator
Fields (number and length) /Precipitator
Cells (number) /Precipitator
Bus sections (number) /Precipitator
Casing Material and Thickness (inches)
Casing Design Pressure (" W.C.)
(Check one: Positive Ci or Negative J:J)
Number of Hoppers/Precipitator
Hopper Material and Thickness (inches)
Minimum Hopper Valley Angle
Total Hopper Capacity (cubic feet)/Precipitator
Hopper Accessories Oist each separately)
Insulator Compartment Material and
Thickness (inches)
Penthouse Material and Thickness (inches)
Number of Insulator Compartments/Precipitator
Surface Area (sq. ft.)/Precipitator
Roof
Shell
Hoppers
Others
D-151
DATE: April 21, 1971
97,500
300
2-4
99.5
.02
0.3
3.14
8.6
1
1
3 @ 9'
1
9
3/16"
Mild Steel
15
2
3/16"
55
3,547
i'lild Steel
3/1611 Mild Steel
12
510
3,050
1,390
-------
BUELL ENGINEERING COMPANY, INC.
2
PROPOSAL. NO. 71L-19073
Precipitator Internal Gas Distribution Devices
Types
Quantity and Location/Precipitator
Material and Thickness
Number and Type Rappers
Number, Type and Size of. Access Doors/Precipitator
Roof
Shell
Hopper
Insulator Compartments
Other
COLLEC'fL.'lG SYSTEM - PER PRECIPITATOR
Number of Gas Passages
Spacing of Gas Passages (inches).
Collecting Surface Material and Thickness
Collecting Surface Effective Length (feet)
Collecting Surface Effective Height (feet)
Total Collecting Surface Area
Maximum Collecting Surface Area Rapped at
any Instant (square feet)
Type Collecting Surface Rappers
Number of Collecting Surface. Rappers
per Precipitator
mGH VOLTAGE SYSTEM
Discharge Electrode - Type, Material and
Thickness (inches)
Total Lineal Feet of Effective Discharge
Electrode per Precipitator
Type Discharge Electrode Rappers .
Total Number of Discharge Electrode Rappers
per Precipitator
HIGH VOLTAGE ELEC'fRlCAL SET
Type Transformer Rectifier
Number Transformer Rectifiers
Size Transformer Rectifier
Voltage Rating KV (DC) Avg.
(For pure resistive loads)
Current Rating MilIiamps (DC) Avg.
(For pure resistive loads)
Number of Transformer Rectifier Control Cabinets
Construction of Transformer Rectifier
Control Cabinets
NEMA
. .
D-152
DATE:
April 21, 1971
BUELL Vertical
Adjustable
25 @ Inlet
12 Gauge Hild
Channels
Steel
4 - 1'-8" X 3'-0"
2 - 1'-8" Dia.
3 - 1'-8" x 3'-0"
Ducts - 2 - 1'-8" x 3'-0"
23
9
18 Gauge Mild Steel
27
30
37,260
2,050
BUELL Electro-Magnetic
18
Hi Carbon -
.105 Dia.
24,840
Straight Wire
BUELL Electro-Magnetic
9
Silicon
3
35 KVA
45
Diode
550
3
Nema III & V
V & XII
-------
BUELL ENGINEERING COMPANY. INC.
3
PROPOSAL NO.
711-19073
DATE: April 21~ 1971
Transformer Rectifier Insulation Fluid
Wave Form of High Voltage
Number and Type High Voltage Switches
Key Interlocks (Yes -No)
Control Cabinets
Transformer Rectifiers
Access Doors
Type Transformer Rectifier Controls
Maximum Ambient Temperature for
Transformer Rectifier - 'C
Maximum Ambient Temperature for Transformer
Rectifier Control Cabinets - 'C
Power Consumption KV A/Precipitator
I. Transformer-rectifier
2. Rappers
3. Insulator heaters and blowers
4. Hopper heaters
S. Lights
6. Other
Oil
Full
3 - Air Switch
Yes
Yes
Yes
Yes
Solid State Anacomp
40
40
105
2
"
Total
107
Total connected load KV A/Precipitator
Power Distribution
122
Individu:ll bretlkcrs e~;h contra! c:lb!n~t
Yes
No
Central distribution panel
OTHER AUXILIARY EQUIPMENT OR SERVICES
Heat Insulation - Type & Thickness
Weather Enclosure - (Roof and/or Hopper, type)
Inlet and outlet Transitions - Material and Thickness
Access Facilities - Type & Location
Insulator Compartment Blower System (number)
Model Study
Startu~ Training-Testing Supervision
Erection Supervision
WEIGHTS
Total Precipitator Weight Including Electrical
Equipment but Excluding Dust Load
199~000
DRAWINGS:
Layout
Precipitator
Other
D-153
-------
1'1f~,-'; ..
b ,:~~:::::; Ie i'
:~re' b ~
,;.jn ,it
~ .
I Norblo"1
~t.d ~7dilot ¥emP
BUELL E'NGINEERING COMPANY, INC.
253 NORTH FOURTH STREET' LEBANON. PENNSYLVANIA 17042 .
AREA CODE 717 272-2001
CABLE BUELENC. LEBANON, PI'..
TELEX B042-332
May 13, 1971
Subject:
~lli~~ITWJElID ./'1... 8
,,'~\ '( 1 '7 1971 I"_A. ,-9 '
, 'U ".- 1~""'L',~t .-
~,~. .., <./... ,-";f.\
ENGINEERING DEPJ[~; /:. 'f,;'CZ1 ~.
Mr. Bob Seibel ERIE CITY ENERGY DIVI~jrt~';(;~::QO {9~ ' '~
Proj ect Engineer' ~\ "".'J;',('.:"'" ~..,. ,
-';';"~a" .....
. . '''''A "-t ~
BUELL Proposal No: 71L.,..19073 ,~v~
Electrostatic Precipitator "~'.,'/G \,
Fluid Bed Boiler
Erie City Energy Division
Zurn Industries
Erie, Pennsylvania 16500
Attention:
Gentlemen:
We advise you as follows concerning the several questions raised
during our telephone conversation.
The effect on the performance of the precipitator in regard to
the sulphur carried over in the limestone and fly ash will, in our
opinion, have little or no influence on performance.
Precipitator efficiency versus particle size is a consideration in
precipitator design, but is not as important when the particle size
range is evenly distributed. When there is a high concentration on
low and sub-micron particles this must be allowed for in the design.
When precipitators are designed for a fly ash application, without
any other introduced dust, i.e. limestone, the norm is to guarantee
performance on the basis of a maximum of 15% unburned combustibles'
in the ash. As the amount of unburned combustibles increases over
the 15%, it is our practice to also change our,sizing criteria to
allow for the higher carbon content of the ash. On this application,
it is difficult to predict this effect because of the mixture of dust
presented to the precipitator. Frankly, we do not know this effect
as we have no experience in this application.
YldkW1' (kt !JZ/,k/leJJ- -!;} ~'{i~~J. ~/J{/{e.»
D-154
-------
Erie City Energy Div.
-2-
May 13, 1971
We feel we have conservatively sized the precipitator that we
have quoted and have considered it more on the basis of the lime-
stone content than the fly ash which we feel, as stated before, is
the more difficult dust to separate. The real question is whether
the combination of limestone and fly ash presents conditions which
may be better or worse. We have always felt that the more conserva-
tive approach was the preferred one.
Very truly yours,
BUELL ENGINEERING COMPANY, INC.
~.c:t. ~
L. F. Rettenmaier
Sales Engineer
Lebanon District
LFR: sw
cc: New York Office
D-155
-------
.-- ~. --. ,". .' - :. -,' . I
--.".-...... .r. J ....r-:
,t',']
, (=
I"'
I~
1-
~": ' ~
:'~ . ,
1".1 ,
j r f
:1 f
t
I
i
" '';','\ I
.: .: ., ,.
" I ., ,', ;. t
";-"',1 ',,; ~ ~
'. <, ~,) II
; i ;:; : ~ r,
" I ", ;\
, .', '.,\ .
. .. - j .. ; :.~ ~:': ~
~ '. o"t ~, l'
~ t '
" .: i '. ,~ ",,' t
~': '\ (
. 'I
"'> .,,' ~ ,'-
:'.' : ,", ~:,
:, '..A "
. I .. ': .: \ r.
; ~,~ \' : :'; :) ':~'I
°f.'''- -Z_.. ~
"
:'~~,'I
':':," t i
" ;
~~'I
.-
n
1,;) ,
~..
~l
;';}
:'
o .
. ,
" t
()
!.)
,.
-~~
. ,
'. I
.
t::1
I
f-'
VI
~
\,':\
" "
" ,
, ..... .' .., .-... ~
"~-' .--"-".'-'-'-""'--""""""'---.'-"""---_-"'_--'r' .---......-...
,.
r:" '-,-- -.- - ,- -- --1
I ... r,'~' ;,<:',..~."A '-'...- .... ~.I
J '.." .,,-;"1...- "".,w.", 'C"~\~ ""'-.~I
, ~ I
I I
" 'I i~,:..--~-=....-,~.',J
I i \ , . Ii
" , ,!
!I 'j.""'" ~
~ ~
I ;1' , . , ~ I
~' ,i I
~' ,: " " ~ I
. ~; : ',. . ~ I
I :~._/~=~:<.~~..4~Y-';'7~;,:.,~!
I j! 51;,.,.: J ',d I:
:1 '----"'--" -- , ~
1 ;i ",
i .;.;.-::-=<=,:::,..,..."...".:.-::..""'-::-_=~:: "!
,
-.......- ~-~.-.~ r
;
. ..' , .
. " .
" '
n..",
I
i
I
I
!
I '
I
!
i
i
I
I
I
I
I
I
I
I
i
,
. !
I
! '/o'ity ~ /rJ;/~w
...... .....--'."" .......--.,... - --. ..........
1
\ i
\1
~~i..
"
, ;
j
t
..or.... -.........--...""..,,,........., --
<-~ .. f.~~.'''':' . ~ ',~. ;:..:. ~.:.~:C .. !--~
--.--.
.......,_........_-~ "
I -;--. "J ~o-r
I ",\~"
I ; "
...J-- ,'- !~'
I :!.~,'
I ',~ t ,
".. . ..T'~ I I
. I, I I
Ii I I : j ","
I! 'I~ I ',"
!I .' ~'~ I "
jl ':,'
I' :r.:.1
II I~' j{~"
.", 1'1 l~'!~",
I ..;,,1... :\;\
I' r~ i ~ .I,h
. II ", I I'
, III tY I"I~~
. i ,I i, ! t
H' 1 I' ~'
'. .-. t , !'
I' ,.', t
I /~ i
, -,. _..t ~;\
,
I
) r :, f
I J~,I
Iii I~ ,. :,'
.' " I I. i~
! i! ! ' I ! i
! I' j' . I' j
j ,~_L__..__- >t . ,.~..._,,,~-~, !._~"._-,t,..._- L
I ,::?"-2t;,"'! . /6'- ~.~... I 6'''-;;;~'';
:-..~ - - _.....--~_..__., .. - ...--..---- ----,.-... ...-.... . _..~
<..." .........,..
-.................-' .~_.....-_.-...---..._._.--.,_._""'-
, 0
..................- .......-.,
, .
, '
" ,
"
-.-'
,- -, - _._-
I
,
, .
,I
" I
I
I
J
.-- --'---
7:;7'. ':to
, .
oS p",; ~...I:'
.;::::~ ""-/ ,;;.
~1,!?
, .
r
I :',:
o ,
. ,
"
Ii
I
Ii
,I
11
or -~- Ii .
, Ii
I I
I .: .
I ii
: 11
I ,I
, I:
I ;
I '1
:v.. I
t,O
j'",
i.~ . \
i'
i"
I '
r\ ~
i t
I
.
-##. ----.......,....
0'
~..
I '
, t.
:'-4
: .
. " '. . .
, .
,
, .
. ) " IAJLL.--r...," ,....--' .
1:'
o '.
"
. '
, .
o
~J
, .
I
I .
, '
,/'
"
, ,
. :' .
"
.'
3 ~."'- ".. ') .... J /,' ...: ~"~~
.,----. . . . ., . ...-. .....- _.... ..... .",:, ,
.. ,.-. .<....._",.......: ~--_..-......... ....-....r'--........--.
-------
A NEW CONCEPT IN AIR POLLUTION CONTROL. . .
DUSTRAXTORS@
....
-.
-
J..-
--
- -
D-157
-------
:D
DUSTRAXTOR
.
.
.
, . I
UN I Ql
-
-
-
~
1. Cleans large volumes of gas. . . yet requires
minimum space.
2. High efficiency dust removal with moderate draft
loss.
3. Operates solely on air movement. No moving parts
except fan. no spray nozzles to plug. no packing to
be cleaned or replaced. and no recycle pumps
required.
~i"."
."... .
4. Recirculating water system with
very little water discharge required.
5. Available with stainless
steel. fiberglass and rubber-
lined collector elements for
high temperature and cor-
rosive applications.
,
6. Custom design. Your
exact requirements in a
variety of sizes and arrange-
ments.
!
7. Fully shop-assembled for
easy installation.
8. Successfully removes gaseous contaminants. . .
chemical reactants can be added directly to inte-
gral recycle hopper.
HOW IT OPERATES
Dust-laden gases enter the unit and sweep over the
surface of the scrubbing medium and underneath
the base of collecting tubes which are suspended
from an overhead tube sheet. The velocity of the gas
passing beneath the tubes and across the inlet
bonnets inspirates the scrubbing medium from the
surface of the bonnets upward into the collecting
tubes. Each inlet bonnet imparts a cyclonic. spinning
action to the gas mixture. The shearing action of the
gas atomizes the water into a dense spray as the
gases continue up the tubes. As the gases are dis-
charged from the tubes. they are directed against a
curved deflector which acts as an entrainment sep-
arator by forcing the liquid downward onto the tube
2
G 1970 Zurn Industries. Inc.
Reg. TM.
Pat's and Pat's Pend.
D-158
-------
OPERATING PRINCIPLE
Gas Outlet
/
r
-+
)
Discharge Plenum
;r3
4 ~?\
"'...~./:~- ,;Y/- ~~~
\::> II ~
-+
----- - - - -- ---
------
---
Slurry Drain
shee: :he cleaned gases flow around the deflector
a:1d c:Jntinue upward through the collector discharge
plenum and the clean gas outlet. The scrubbing medi-
um is returned to the hopper through a sealed down-
comer. The Zurn "Dustraxtor" operates equally well
with induced draft and forced draft systems. The fan
(8
1
I mpaction of the dust particles into
the scrubbing medium as the high
velocity gases pass through the slot
between the inlet bonnets and the
collecting tubes.
2 Cyclonic sPinning and mixing of gas
and liquid droplets within the collect-
ing tube.
3
Impingement of gases and water
upon the flooded surface of the
scrubbing medium deflector.
4 Scrubbing of the gas as it passes
through a curtain of liquid being dis-
charged from the scrubbing medium
deflector.
may be placed on the top of the unit or remotely
located. Capacities range from 1.200 to 72.000
cubic feet of saturated gas per minute in single unit
construction. Multiple units are used for larger gas
volume requirements.
D-159
3
-------
:D
.
A~
TOOL
DUSTRAXTOR
.
:W
TYPICAL DUSTRAXTOR in a coal mining opera-
tion used for removing coal dust from coal crushers.
screens. and conveyor system transfer points. This
factory-assembled unit has a solids ejector type
hopper. The induced draft fan and the stack are
mounted on top of the Dustraxtor.
4
.
Zurn Industries. Inc. has emerged in recent years as a
"Total Environmental Control" company dedicated to
solving the complex problems of air, land, water, and
noise pollution. and in the process, preserving nature's
ecological balance. By continually expanding its
scientific - engineering - technological base. Zurn
has created a team of technical experts capable of
analyzing and researching your specific problems. . .
then designing and installing the proper contro: system
to assure proper emission quality. Whether your
control program is related to industrial. municipal. or
urban complexes, Zurn total environmental control
capabilities. utilizing our proven systems concept. are
your best assurance of cleaner, clearer, more healthful
environment for years to come.
The combination of the facilities, products and man-
power of Cia rage, Swartwout and Fly Ash Arrestor has
brought together in the Zurn Air Systems Division a
broad range of air pollution control capabilities. The
Zurn "Total System" concept implies a thorough
analysis and understanding of each air pollution prob-
lem and a complete solution based on custom-fabri-
cated components properly engineered and sized to do
the job efficiently. Zurn Air Systems manufactures all
the elements of the Dustraxtor wet scrubber system -
fan, damper. ducts, and structural supports. stack and
complete shop-assembled scrubber units.
The efficiency of a Dustraxtor scrubbing system is
dependent on actual inlet conditions and on the pres-
sure drop across the scrubbing unit. The main influenc-
ing factors are: dust loading in the gas. dust particle
size. and the wetting characteristics of the dust. In
general. based on a variety of existing installations. a
Dustraxtor. when correctly applied to an air pollution
control problem will provide efficiencies in excess of
95 percent. Dustraxtor systems have also been highly
successful in the collection of fumes. atomized mists.
and the absorption of soluble gases. Exceptional re-
sults have been obtained in the absorption of sulphur
dioxide (S02) by adding chemical reactants such as
sodium and calcium to the scrubbing medium. The
Dustraxtor's integral hopper and automatic recycling
action provide the necessary time and contact for the
absorption process to take place.
Zurn Air Systems engineers are continually developing
new applications for this unique air pollution control
system. Dustraxtors in series are economically utilized
to achieve very high collection efficiencies, and
Dustraxtors in conjunction with other types of systems
are solving many serious air cleaning problems.
D-160
-------
FOR AIR POLLUTION CONTROL
.
Zurn Dustraxtor medium-energy wet scrubber systems
are essentially self-contained: and, to the extent
practical for shipment. fully factory-assembled, The
only moving part required for effective operation is a
fan, This fan can be positioned in the system either
before the scrubber or after with equal efficiency, Pro-
vision is conveniently made on top of the Dustraxtor
for placement of an induced draft fan as shown in the
photo on page 4. However, the fan may also be placed
in a remote location without affecting operating
efficiency.
In keeping with the "Total System" concept Zurn Air
Systems has developed and manufactured an induced
draft fan that is ideally suited for Dustraxtor applica-
tions, On smaller units that are suitably sized for ship-
ment. the inclusion of this fan makes available com-'
pletely "packaged" systems. The special fan as illus-
trated above is the Zurn Air Systems Model 3400R B
which is a radial-blade design for large volumes and
medium pressures. It is available in all sizes and widths
necessary to complement the Dustraxtor system. For
higher temperature and corrosive applications special
materials and coatings are available,
D-161
Where circumstances warrant in unusual air pollution
control situations, Zurn Air Systems has available test
models (see below) which can be temporarily installed
to determine actual Dustraxtor efficiency. Zurn Air
Systems as part of their "Total System" concept will
pretest inlet and exit conditions for proper application
and sizing of a Dustraxtor system.
COKE AND COAL: Handling, processing, coal pulverizers,
discharge following dry collectors, dryers, belt transfers.
ORE PROCESSI NG: Crushers, screens, transfer points
and dryers.
KILNS: Lime kilns, rotary dryers.
FERTI LlZER: Dryers. mixers, baggers. transfers. convey-
ors, coolers, screens and pulverizers.
PAINT: Pigment mixers, spray chambers.
OIL MIST: Machining. sprays, asphalt felt coating.
ACID MIST: Pickling and plating.
CLA Y: Rotary Dryers. Baggers.
LINT: Buffing, paper slitters. doctor blades.
FOUNDRY: Sandblast rooms. shotblast. electric melting
furnaces. shakeouts, core ovens, sand handling.
RU BBER: Roll grinding. mixers, tire grinding and buffing
talc dust.
ROCK PRODUCTS AND MINING: Asphalt plants, aggre-
gate dryers.
INCINERATORS: Spray cooling chamber must precede
Dustraxtor.
STEAM GENERATION SYSTEMS: Power boilers, re-
covery boilers or furnaces (Salt Cake).
GASEOUS CONTAMINANTS: 502, N02, etc. . . , chem-
ical reactants are added to scrubbing medium,
5
-------
.
DUSTRAXTOR SPECIAL DES
3N
Dustraxtors are of heavy-duty construction in shop-
assembled u nits. Standard materials of construction
include mild steel. stainless steel. and a variety of
linings. Where corrosive conditions or high tempera-
Three basic arrangements are illustrated below. The
selection depends on the availability of water, method
of liquid disposal and the characteristics of the dust
when wet. I n cases where soluble dust or gases are
collected, concentrations may be raised to a level
tures exist. recommendations will be made by Zurn
Air Systems, Fans, dampers, stacks, support structures
or other special accessories necessary for the "Total
System" will be included.
sufficient to return to process. Flat-bottom arrange-
ments are for periodic cleanout. The hopper provides
for a continuous drain out of the system. Solids ejectors
are discussed on page 7.
FLAT
HOPPER
FLAT WITH SOLIDS EJECTOR
The liquid level within the Dustraxtor is controlled externally by a sealed
adjustable weir as .shown at the right (For a detailed view see page 3).
The weir is connected to both the inlet and discharge plenum chambers
and thus senses the pressure drop across the unit. The level of the
scrubbing medium determines the pressure drop across the unit and the
adjustable weir determines the level of the scrubbing medium. Clean
liquid entering the unit passes beneath the overflow weir, assuring that
only clean water will be discharged from the weir.
Dustraxtor capacities range from 1,200 to 72,000
saturated cubic feet of gas per minute in single
unit construction. The capacity is determined by
c:::::.
the number of collecting tubes within the unit.
A fundamental design parameter is a volumetric
capacity of 1,200 CFM per tube, saturated.
~
~
DOUBLE WIDTH (Short Lengthl
DOUBLE WIDTH (Long Lengthl
SINGLE WIDTH
6
D-162
-------
FEATURES AND APPLICATIONS
.
Special construction features may be provided
where unusual conditions exist such as floating
dusts. lint. or heavy. fast-settling dusts. By re-
circulating the liquid externally by gravity through
weirs or dewatering screens the collected ma-
terial may be removed. examined. or reprocessed
without disturbing the operation of the collector.
See illustration to the right.
The solids ejector as shown to the right is a
mechanical drag assembly for the removal of
collected dust. It is used in connection with the
flat-bottom arrangement described on page 6.
The mechanical drag assembly prevents any
caking of dust within the hopper that might other-
wise clog a hopper-type bottom. The dust is
scooped out of the hopper by an endless drag
chain for disposal outside the Dustraxtor system.
In the illustration on page 4 the collected coal
dust is dumped on a conveyor system and taken
to a separate operation for useful by-product
applications.
l
~-
, - ) ~w"'''''
m~- p """
~
I I
SEPARATE
SOLIDS REMOVAL
--~--
-rj -~ - - I
/
~
DUSTRAXTOR ACCEPTANCE
Here are some of the companies utilizing Dustraxtors for effective air pollution control:
American Cast Iron Pipe Co.
Armour Agricultural Chemical Co.
Armstrong Rubber Co.
Cannon Mills. Inc.
Coastal Chemical Co.
Continental Can Co.
Hershey Foods Corporation
Monsanto Chemical Co.
Molybdenum Corporation
of America
Minnesota Mining & Mfg. Co.
National Phosphate Corporation
Pollock Paper Company
Reynolds Metal Co.
Sears. Roebuck & Company
Stauffer Chemical Company
Tennessee Valley Authority
U.S. Pipe & Foundry Co.
United States Steel Corporation
Vermiculite of Hawaii
Vulcan Materials Co.
West Virginia Pulp and Paper Co.
Woodward Iron Company
D-163
7
-------
~
~ A
~A-1
DUSTRAXTOR SPEC
:ICATIONS
APPROXIMATE DIMENSIONS (Not for Construction) - Dimensions Shown in Inches
HOPPER
r-A1 rBI
~
DUSTRAXTOR
f-F-.,
~J ALTERNATE
[8J 1 OUTLET
C
1
~B---1
ALTERNATE ARRANGEMENTS
I 11
~B---11
FLAT
IAi IBI
~t7\ll
EJECTOR
MEMBER
IGCI
IImDJlJI GAS ClEANING II "'111111811"
Member Air MovIng and Conditioning Association, Inc.
SIZE FAN CFM A B C D E F
1 21.0B 1,200 36'/. 13'/. 1013/. 42 60 13
2 4.0 2.400 36'/. 26'/. 1013/. 42 60 26'/.
3 4.5 3,600 36'/. 39'/. 1053/. 42 60 39
4 5.0 4,800 36'/. 52'/. 1093/. 50 60 39
5 5.5 6,000 36'/. 65'/. 112 'h 56 60 42
6 5.5 7,200 36'/. 78'/. 112 'h 60 60 44
8 5.5 9,600 72'/. 52'/. 112'h 60 72 46
10 6.0 12,000 72'/. 65'/. 116'/. 60 72 48
12 6.0 14.400 72'/. 78'/. 116'/. 60 72 56
14 6.5 16,800 96'/. 91'/. 1193/. 72 72 65
16 6.5 19,200 96'/. 104'/. 1193/. 72 84 75
18 7.0 21,600 96'/. 117'/. 123 84 84 85
20 7.0 24,000 96'/. 130'/. 123 96 84 95
22 8.0 26.400 96'/. 143'/. 130% 96 84 105
24 8.0 28,800 96'/. 156'/. 130% 60 84 115
26 8.5 31,200 100'/. 182'/. 134'/. 60 84 125
28 8.5 33,600 100'/. 182'/. 134'/. 72 84 136
30 9.0 36,000 100'/. 195'/. 137% 72 96 145
32 9.0 38.400 100'/. 208'/. 137 'Ie 79 96 153
34 9.5 40,800 104 221'/. 143'5/'6 79 96 165
36 10.0 43,200 104 234'/, 1 483/8 84 96 180
38 10.0 45,600 104 247'/. 1483/8 84 96 188
40 11.0 48,000 106 260'/. 160% 96 96 197
42 11.0 50.400 106 273'/. 160% 96 96 207
Zurn Air Systems was created by combining the resources of
three well-known companies in the air moving, air controlling
and air cleaning fields: Clarage Fan Company of Kalamazoo,
Michigan; Swartwout, Inc. of Kokomo, Indiana; and Fly Ash
Arrestor Corporation of Birmingham, Alabama. The new integrated
division provides a one-source engineering and supply center for
all air quality control. air moving and handling needs, coupled
with supplemental benefits of enhanced dependability, broader
selectivity and on-time delivery over a wide range of product capa-
bilities. To request additional information merely contact any of
the three locations indicated below.
ZURN INDUSTRIES,
AIR SYSTEMS, DIV.
INC.
ONE CLARAGE PLACE
KALAMAZOO, MI. 49001
(616) 349-1541
1000 N. TOUBY PIKE
KOKOMO, IN. 46901
(3171459-5151
BOX 1 BB3
BIRMINGHAM, AL. 35201
(205) 252-2181
D-l54
BULLETIN WS 6200-300 7.5M 2/70
-------
I'
Sheet 78-A
".," --. '. ..~ ,'"
Boiler
Class VEM
Circulating Pumps
~c~t"t;r,t.fi,_":,~ \;"}. ~'V ~~o '
~~~. ~"~,~~Jg .',
~ 6'~~' - . .' "_A.o'h..~""""~'YA" ~.8::d,;,
t
II"GEHSOLL.R:\;\"D CIa"" YF.~r 1'11111(1" are
,'crtical, "ingle.stage IInit,; with "ingle."uction
impcllt'r and d()u!llt~.volute ca"in~. The entire
assembly, incillding 1'11111(1 and drivcr, is arranged
for mOllnling on the hoil\'r piping. the "Iwtion
and discharge nozzles !Icing welded in po,.;ition.
This arrangell1ent permit:; free movcml"nt of the
pump when operating at high temperatllre,.; . . .
prevents sIres,.; and strain on hoth the hoiler piping
and pump.
APPUC\ TIO\'
Cia,.;,.; YE\r 1'111111'''; art' de,.;igned for lI~e with
high.pre";"lIre controlled cirl'ulation Imilcrs that re.
quire an efTil'ient, rllg~c41 plllllp for this severe ;;erv.
ice. VE.\I IIlIits arc so con,.;tructed that they can
be dismanlbl and re.asselllhit'd in the field with a
minimllm of down time.
GENERAL CO\'~TRl'CTIO\'
Casing is made of ca,.;t carbon steel to AS\lE
specs. Its double.volute dto,.;ign eliminatcs radial
thrust at off.peak capacitit',.;. Stainless inlay is
provided at the ga,;kct fit. Welding neck nozzles of
sufficient size provide reasonable velocities.
Casing Cm'er is of forged carbon steel with
stainlcss inlay at gasket fib. It is drilled for the
necessary injection, hleed.off and cooling water
con nee tions.
Pressure Bolting of heat treated alloy stecl is
accessible for easy rcmoval with an impart wrench.
Removal of pressurc bolting nuts allows complete
pumping elemcnt to be relllm'cd from the casing
without disturbing """tion anll Iliseharge pieing
or. ba"ic pUlllp alignmellt.
Sluffing Box Extt~"sion of one pil"ce cast
chrome.moly steel. pro\'ides adequate packing
depth with integral cooling jacket. The "mother.
ing type gla'141 is malIc of stainless steel.
Pressures: to 2900 I,,,i.
IIl'atl,,: 100 10 175 fl.
Capacities: .1000 to B,OOO !:I'III.
Sizes: 10, 12, U, 16 in.
Temperatures: up 10 and aho\'c 6:>0°F.
"
~
~
L
f
~ l--~T '
~
\.
t
i
\''-'/1-'--- -'.'
fI:::.,~ ~'-""'!'7,C
,.,;;;\ . . :;: ::. .
-('" ";'~~'r" I .'
~ '~""f.:~'J
( (>~(~;- )
~'~~..""
~'.~
,
~.~ ~t
.+ > ~
(' '
, -"1
.~- :-1
. ,
t.. .-~ /'
~:~
\ :.
I
, ;.-.
VE:\I Pump less driver.
L
Shaft is made of heat.treated high.strength.
corrosion.resistant material. It is of the rigid
cantilever type operating below first critical speed.
entirely supported by external hearings. Align-
ment is not influenced by casing distortion duc to
temperature or pressures.
Impeller of chrome-moly steel is of the single.
suction type. Renewable impeller and casing wcar.
ing rings of adequate clearance are provided. 1m.
peller is keyed to the shaft and sel'ured b~' ,.;tainless
steel lock nuts. Allitydraulic pas,.;age,; are smoothly
finished.
Scaling Arralll!cmelll. Boilcr fccd water in.
jection is used to prevent high tcmperature boiler
water from entering the pressure breakdown de.
vice. A throttle bushing and sleeve is used to redul'c
to a minimum the amount of injel'tion watcr enter.
ing pump. In addition, a floating seal pf(~ssure
breakdown device is located between the injeetion
point and the stuffing box. tl1us kloeping the qnan-
tity of injcction wattor rcquired to a minimum.
D-165
Form 100W.7S78.,I\
2.E8
-------
,~,"
\:~L~ --- f~
~LJ
i I~
~~~,~
. ystem.
VE:\Ilubricauon s
(
~
~
~
:.:::: :::-;1::51: ~::':~-====::':'~:::"':=-: ::~i
1: '"OL" Ii
~ 'T,'\: J I,
,-, i -:i,', ~~~, ~'~f: ;1' '. ' " 'cf
~rr-. ~~i---I~' ,:~ I
~~'-I- 'If! r~!
.' ~" ",
:: L...r,.,,' ~;'
:: ri.L.~=lJ~Y ~Ib.
" ~''\ - "
:n~, ti.~ ~: ~.-
}i.L--"" ':
~_u;[..~, :,', :,~, :_,-~', ~i, -::~1TI,:~, f..l!L-
~::':-:'~b*::~- ,..1..;:., "r ~
:: ~~-1~ '--'1 /
~ -- :;-,J~j,; ~~_\~=:~;,i :, '. //
,,--~::;_., -'.' J' ~ " . ...-.
'\ ' : :'-.,.-:~~ "~::f'~1"'':,.*~b~;.';
'::~~~~~~.,;:.,,':,r;;':~::-l: -, i~',:/-::":~it,,~tD-, --,
- --~ ;_'..n", !:%P~,;" ~~~~"';;1 - 'I .,
.- ''F , ' ',;. if.' "~"'~" .!,
;'-':-;~:'---:---,-;'::. "-~~~~\:1~;:~\ i :' Ii
. '. "TT"~,L~-\~~"I i
,--- "", ,:, '" -- ;- .-~ '~~~~~ I I I
" ,_-.:'-~t~;,:; [~~, " ~,~\~ Iii!
' ",' ~::::::,.«! ~wr ~~~~ 11'1 'I
',',. I " /. " '7 ,J' ~~" ,
')\", \U; ,r.~",,,, i II i
,'~ ,.'"'~ ~ '""""'1~%\)Jt,...L~"
' : l','f(:~<~"~~\ ~,~= . -- =-I~~ ~ .-..
"I --~'~~,- ~
".. ,-, ,'" ;;",~ I
, --"
',-" section.
cros".
VEM pump)
~
~
Section 7
.J Sh.tt 78."",
f.ck ...
I
--
".'.".'...1.-.
D-166
_0._'-
-------
'~~:I
(Ri I , c
~: ~.\.~' J.
-----, - -tr. '
t, 8" "I'~ :s
-, 'CP' -'. "
J Ii ~" ,.- ~ ~ :'~l;;-:;: ';. '
\-; ~ 11[~' - ,.
, j' ",. '" '_...~)
~.' "'i~ ,.,,,0;- ~.
i.. . ~
~~~' ' ..
,./ ~ ;.J .~".-"~~~'~..)r.;!..
---~..--r .
~..~'~...~.
--
., \0.
. .....
~ ;:~~~..-:u
..~ -
-
- ~',
T'.~ ...."
,
~ t,....,,~.' .......: - '-. -.: po-
, '~"~~3"-' -~',' . ~
""~--~i\:P_~'
-------
UNITED
DESIGN AND PRINCIPLE OF OPERATION
The NUV A FEEDER System consists essentially of
four basic units-
1. The pressure NUV A FEEDER attached directly to
the dust collector hopper which automatically feeds
the dry, free-flowing fly ash into the conveyor system.
2. The conveyor pipe line with required fittings that
connects to the outlet of the pressure feeder and
extends to the final delivery point.
3. A positive displacement motor-driven blower to
create the air flow in the conveyor pipe line.
4. Venting of storage bin. This is accomplished with
a bag filter or vent returning to precipitator. The
latter results in a closed circuit installation.
PRESSURE NUVAFEEDER
The principle of operation of a suction conveyor
and a pressure conveyor is essentially the same.
In both cases, higher pressure at the inlet end of
a transport pipe conveys air and material through
the pipe to the lower pressure area.
In the suction conveyor, a vacuum exhauster re-
duces the air pressure at thp. discharge end. In a
pressure conveyor, a pressure blower builds up the
pressure at the inlet end.
The inherent advantages of the pressure conveyor
are-
The conveying medium passes through the blower
as clean air before it reaches the transport pipe
where the material is introduced. This eliminates the
problem of erosion on the pressure blower.
The pressure system by compressing the air uses a
denser medium with which to convey the material.
This considerably improves the efficiency and capac-
ity of the pressure system.
The power available to a vacuum conveyor is limited
to atmospheric pressure. The power available for a
pressure system is unlimited except for practical
considerations.
4
It is a single stage system that conveys the dry fly
ash directly from the hopper and delivers it to its
disposal point without any intermediate transfer
point.
The chief problem in the development of a pressure
conveyor for handling exceedingly abrasive ma-
terial is the design of the unit which will feed this
material against the conveying pressure into the
transport line.
Rotary vane feeders, sometimes called air lock
feeders, have been extensively tried in various
forms and all have failed because of the impossi-
bility of maintaining close clearances so .the unit
will function.
Pressure tanks which are in sequence filled with
material, sealed off and blown with high air pres-
sure into the conveyor line are in use. These units
take large headroom, high pressure storage vessels
and operate at exceedingly high velocities through
certain sections of the system. This causes exces-
sive wear and what is commonly called slugging
shocks which make the conveyor line difficult to
support.
Screw type feeders are used where a compacting
screw solidifies the material to the point where the
pressure in the conveyor wmnot blow back through
the screw. These are successful with certain fine
materials but are subject to high maintenance if
exceedingly abrasive material is handled. The ad-
ditional power used by the compacting screw is
excessive, amounting to a fourth to a half of the
total power used. Compressed air at relatively high
pressure is also required. As a result, these con-
veyors are inefficient as far as power consumption
is concerned. (continued on page 6)
D-168
-------
TWIN DIFFUSER
FEEDER
\ /
1 /
DRY DUST COLLECTOR HDPPER
/
)
'"
\
AIR CYLINDER OPERATED
ORIFICED DISCHARGE GATES
FLUIDIZING STONE
HYDROVEYOR' PNEUMATIC CONVEYOR
FOR STANDBY DISPOSAL OF FLY ASH
TO FILL AREA
ORIFICED DISCHARGE GATE
AIR CYLINDER
ORIFICED DISCHARGE
GATE
REMOVABLE
FLUIDIZING UNIT
The pressure NUV A FEEDER is
basically an air lock. It has an upper
and lower storage compartment,
each equipped with an orificed air-
tight discharge gate and fluidizing
stone.
NUVA FEEDER POSITIVE PRESSURE
PNEUMATIC CONVEYOR TO ULTIMATE
DISPOSAL POINT
Figure 3.
The operation of the
NUVA FEEDER is as follows:
With the upper discharge gate open and the lower gate closed, material flows into
the storage chamber for approximately one-half of a cycle.
For the other one-half of the operating cycle, the upper gate is closed, the lower
gate opened, and material is discharged into the conveyor line.
The cycle automatically keeps repeating. A continuous flow of material into the
conveyor line can be accomplished by the use of two or more feeders.
D-169
5
-------
UNITED
-
DESIGN AND PRINCIPLE
OF OPERATION
(continued from page 4)
The United Conveyor Corporation has been work-
ing on this problem for many years. The following
requirements were realized:
For efficient operation, material must be delivered
to the conveyor at a relatively accurate rate and
means must be provided to control this rate. This
allows the power requirement to be accurately cal-
culated and permits the conveyor to operate within
these power calculations.
In order to obtain a smooth and nearly uniform rate
of feeding, more than one pressure feeder is used.
This provides for a half cycle of conveying and a
half cycle for charging of the pressure feeders so
that in all cases full capacity will be fed to the con-
veyor line.
The development of recent years of the fluidizing
of finely divided material so that it will flow more
like a fluid than like a solid, has revealed that a
fine material properly fluidized will discharge from
the opening at an exceedingly uniform rate. This
allows us to make a feeder by the use of small ori-
fice openings which will not avalanche and flood
the charging hopper or the conveyor line. This is
the basic discovery that has made the United pres-
sure conveyor both unique and practical.
Another advantage of this method is that in using
a small orifice we also are able to use a small gate
to control the feed. This small gate is easy to main-
tain airtight compared to the large diameter open-
ings required in conventional types of air locks.
In addition to using this means of controlling the
feed, the openings are designed a little larger than
required for maximum feed and a full load con-
trol is added which operates from the pressure in
the transport line. Under given conditions, if the
amount of material fed to the transport line is in-
creased, the required pressure to move this through
the conveyor line is increased. Taking advantage
of this fact, our NUV A FEEDERS are arranged so
that if the pressure exceeds a predetermined pres-
sure, the feeding gate on the unit delivering material
to the line is momentarily closed until the pressure
drops to the desired full load capacity.
These are the conceptions which have enabled us
to develop a compact unit to give uniform and
high capacity delivery to a transport line at an
exceedingly economical use of power.
r~-
~
~.
t f
! ~
t
f
-------
~ .'-181.. -., I.
o
u~ (j uv
~ ~(I~ "
~ 'l5
o -: ~
u <3
-
Figure 4.
Fully controlled conveying obtained through the
UNITED NUV A TROL@ cabinet designed for automatic
and remote control operation of the NUV A FEEDER
System.
NUV A FEEDER Fly Ash Conveyor System serving
precipitator hoppers. Note the motor driven blower
supplying the air flow to the conveyor system.
Figure 5.
I D-l71
...\1
~
m
I
Figure 6.
Fly ashes are conveyed directly and in a single opera-
tion from dust collector hoppers to an elevated stor-
age bin located in the yard of the Power Station. Dry
unloading is provided for sale of fly ash. Alternatively,
a UNITED Rotary Unloader is used for conditioning
fly ash hauled away from the plant by trucks without
creating a dust nuisance.
7
-------
UNITED
PRESSURE AND VACUUM
RELIEF VALVE
POWER OPERATED
GATES
AUTOMATIC OPERATING
BAG FILTER
,,--------
/
~-
I
-
MOTOR DRIVEN
EXHAUST FAN
+
VENT PIPE TO
PRECIPITATOR INLET
(ALTERNATE)
UNITED ROTARY UNLOADER
FLY ASH CONDITIONER
HYDROVEYORo
FLY ASH STORAGE BIN
The diagrammatic layout illustrated on
these pages shows the versatility of the
NUV A FEEDER Fly Ash and Dust Han-
dling System as follows:
WATER SUPPLY TO
HYDROVEYOR SLURRY
MIXING UNIT
Fly ashes are conveyed directly to the
furnace for refiring, thus permitting fuel
recovery if combustible is present or the
fly ashes can be melted in the slagging
furnace so that only disintegrated slag
is produced.
DRY UNLOADING
SPOUT
EMERGENCY
OVERFLOW DRAI/I
t
Fly ashes can be conveyed to a storage
bin for ultimate disposal in dry or con-
ditioned state to railroad cars or trucks.
~
System is adaptable for direct conveying
of slurried fly ash to fill ground area
located several thousand feet from the
power station.
SLUICE DISCHARGE PIPE LINE
TO FILL AREA
CONVEYOR PIPE LINE
DURITE@ wear resisting alloy fittings with extra heavy wearing backs to withstand
concentrated wear that occurs at the bends are used throughout the system. NUV ALOY@
wear resisting alloy is used in the conveyor pipe between the various fittings.
~)
8
D-172
-------
CONVEYOR FROM
NUVA EEDERS
-
DISTRIBUTING TANK
GATES
DISCHARGE PIPES
TO FURNACE
t
~
.
PRESSURE
NUVA FEEDERS
CONVEYOR
Figure 7.
A\
V
POSITIVE DISPLACEMENT BLOWER
The machinery requirements for the NUV A FEEDER positive pressure system are relatively
simple. The entire system is operated by a positive displacement blower located near
the dust collector hoppers which supplies the conveying air as well as the fluidizing air
for the feeders.
D-l73
9
. - ---
-------
UNITED
Basic Components for UNITED NUVA
Engineered for the Heaviest
Many basic and specially designed components have been developed by
UNITED engineers for pneumatic and hydraulic conveyors handling fly ash,
dust and similar abrasive materials. Illustrated on pages 10 and 11 are a
few of the components used in sevt;!ral thousand installations furnished by
Custom engineered NUV A TROL control cabi-
net designed for automatic and/or remote con- t-
,,,, 0:''''1;0" . - C C
(t~ -..- "'"'" '0
~ / NUVALOY
Figure 1;. Figure 13. and DURITE
45° elbow with extra heavy re- 45° long radius solid elbow- wear-resisting
movablswearbackand handhole. designed extra heavy in area of alloy pipe with
15°, 22);.° and 30° elbows also concentrated wear. 15°, 22);.° standard flange
available and 30° elbows also available couplings
Figure 8.
Bag filter
iQ"
.. . ~. ~t!
Figure 11.
Figure 14.
Totally enclosed conveyor gate,
manually or air power operated
10
,
- IICII
I) .
~ IIi!5m
~
~ ~~ ~
- -
. . Co ..
, ~~ ,
II:1II II:1II
Figure 9.
~ ~
~~:
... -'
.
Figure 15.
Figure 16.
Figure 17. )
90° elbow with extra.
heavy removable
wearbacks and hand-
hole
45° lateral with extra
heavy removable wear-
back
45° solid type lateral-
designed extra heavy
in area of concentrated
wear
D-174
-------
FEEDER Pneumatic Conveyor
buty Requirements
:f)
UNITED in over 48 years of experience in this field.
AU fittings are DURITE iron castings. DURITE is a special wear-resisting,
uniformly dense and close-grained aHoy metal particularly suitable for han-
dling abrasive materials.
J~
',.,
Figure 19.
Figure 18.
Tee-solid type-de-
signed extra heavy in
area of concentrated
wear
Tee with extra heavy
removable wearback
'4
~~
Motor-driven blower to supply
conveying air to NUV A FEEDER
system
\. Figure 24.
~ 900 long radius solid elbow
-designed extra heavy in
area of concentrated wear
Figure 20.
Handhole section
Figure 23.
Expansion joint
HYDROVEYOR air han-
dling unit mixes fly ash
and water for discharge
D-175
~."'f-'.j
...~ ;
. ~
. .
J,..
(r;~'-
,
.,
- .-----
\.
.
~
~
.
-------
Figure 27.
NUV A FEEDER pneumatic fly ash conveyor pipeline as it comes from the generating station
DELIVERING DRY FLY ASH ONE AND ONE-HALF
MILES BY PIPE LINE TO TURN A
WASTE PRODUCT INTO A PROFIT
In 1961, a well known cement company decided to
build a cement product plant about 11h miles away
from an electric generating station. The availability
of fly ash was one of the factors influencing the
selection of this site by the cement company. They
could use fly ash as a substitute argillaceous com-
ponent of the raw mix. The power company had
the fly ash, a waste product, being sluiced to fill
areas which were rapidly filling up.
PROBLEM
How to get approximately 400 tons a day of dry
fly ash from the power plant to a bin on the
cement company property 11h miles away?
SOLUTION
Convey it directly from the dust collectors to the
storage bin in a single-stage pneumatic pipeline
system illustrated on pages 12, 13 and 14.
Initially, several different schemes were investi-
gated, all involving rehandling the material once
or twice. A conventional approach was to convey
from the dust collectors to an intermediate storage
or transfer bin with a relatively short pneumatic
system and then, either truck the material from that
point to the cement plant or install a second pneu-
matic system. Trucking involves manpower and a
problem of transferring material from trucks to bin
at the cement plant. This expensive equipment, with
weatherproof roads, requires maintenance which
had to be considered in addition to providing means
for eliminating dust nuisance at each transfer point.
A two-stage pneumatic system meant extra equip-
ment and extra expense.
No one, to our knowledge, had ever conveyed fly
ash or similar material such a great distance in a
single-stage pipeline system before, but based on
experience with several long systems in success-
ful operation, UNITED knew it could be done.
When the idea was presented, the cement and
power companies readily accepted it because of
the obvious operating advantages and savings.
J
Figure 28.
1 Y, mile long NUVA FEEDER fly ash conveyor from power plant dust collector hoppers.
Note the cement plant in the distant background.
-------
:f'
~~
t)
BOILER No.6
BOILER No.5
BOILER No.4
BOILER No.3
BOILER No.2
MOTOR OPERATED POSITIVE EIGHT DUST COLLECTOR NUVA FEEDER UNDER
PRESSURE BLOWER ~ HOPPERS AT EACH BOILER DUST COLLECTOR HOPPERS STACK
~. fAI /\ ~ ~ 0
- -I - -1 'I ~ SUPPLY -i "'---Y" 00" "~ C~~~~Y~~ri~~SM '/ - ,1
I: / '1 y / t, L l~ - 1
- -----,------:1;----.:.. --' --::.:-------------_:t:_~______n- _:L_-----------=--------7-~
". '""" '0 CO',,'O. A" .U,...., '0 CO.,,,O, I
850 FEET ~
NUVA FEEDER POSITIVE PRESSURE
CONVEYOR TO CEMENT PLANT
The principles employed in the design of the
highly successful NUV A FEEDER pressure
feeder were used by UNITED engineers to de-
velop a high pressure feeder required for long
distance conveying. Once the method of feed-
ing from dust collector hoppers at negative
pressure to the conveyor line under relatively
high pressure was perfected. only the selec-
tion of proper size pipe line and positive pres-
sure blower remained.
The diagrammatic layout shows the system
employed. A pressure NUV A FEEDER is in-
stalled under each of the dust collector hop-
pers of the boilers being served. The fly ash
conveyor pipeline connects each group of
feeders through the main header leading to
the cement plant.
Figure 30.
I-
IIJ
IIJ
...
0
0
...
,..
><
0
II:
Q.
Q. ~
«
NUVA FEEDER pneu-
matic fly ash conveyor
with HYDROVEYOR sys-
tem in background
FLY ASH STORAGE BIN
AT CEMENT PLANT
Figure 29.
The existing HYDROVEYOR pneumatic fly ash con-
veyors originally installed for conveying fly ash to
the fill area were left in place for use any time the
cement plant does not require all of the fly ash
being produced by the boilers. Special by-pass
gates. illustrated in figures 3.30and 31. at each dust
collector hopper permit discharge of fly ash into
either the pressurized transport system for delivery
to the cement plant or into a combination pneu-
matic vacuum and sluice type HYDROVEYOR sys-
tem to the fill area.
The capacity of this system is approximately 35
tons of fly ash per hour with a power consumption
of approximately 13 KW per ton.
-------
14
UNITED
Two of the forty NUVA FEEDERS installed in this
plant
- ...
t
Figure 32.
Typical arrangement of positive displacement blower
with silencer supplying conveying air to NUVA
FEEDER pneumatic conveyor
FLY ASH STORAGE BIN
AT CEMENT PLANT
.
Figure 33.
Discharge end of the fly ash conveyor at the
cement plant fly ash storage bin
-------
NUVAFlOW FLUIDIZED I' /'
CONVEYORS ~ /'
NUVA FEEDERS
-- - --.
/ "-
// "
// -..,
\'" "'--",
I :::=::\ "'--"
I I::::::'-:::=::::., ,........... \.
I 1 ~ ~ ~-..
I I I ':::::. -=:::" BAG FilTER'\.
I I I k \ ~-..
I I I I --- =:: ~ ~. '\
I I I I f -- ( >: /)
I I I I I'-'~" i; .1-;::-;::-/1
I I I I I ~ -- J-~ I
I I 1 1--=--1 I
: I I STORAGE SilOS I 1 I I
\ I I I I I I I
" - -~ I I I I I I
~ I I I I I
'---1 I I I I
\ 1 I I I I
"- --1 I I I I
~ I I I I
"- -1 1 I
\ 1 I /
-- - -~ I- - --
\ I
'- ---/
Figure 34.
The system illustrated above, furnished for a large midwestern
cement company, is used to unload fly ash from hopper railroad
cars and convey it to a storage bin at the rate of 120 tons per hour.
Conveyor utilizes two NUV A FEEDERS which alternately feed
material into the conveyor pipe line resulting in a continuous flow
of material to the bin.
I
I
I.
I
I
I
Two NUV A FEEDERS fur-
nished for plant illustrated
above, to give 120 tons per
hour capacity.
j
j
Figure 35.
15
--- . - ---
-------
--
UNITED
.~ . .' . .
-----
l5 lS
--
.' .' . CQ) .
".~.l5~~
.
c
II
..
Six NUV A FEEDER pneumatic systems conveying fly ashes
approximately 1600 feet directly from dust collector hoppers
to elevated storage bin or slurry tank. Figure 37 shows the
NUV A FEEDERS installed below the dust collector hoppers
and Figure 38 is a view of the routing of the various conveyor
pipelines to the storage bin. Total steam generating ca-
pacity in this plant is approximately 16,000,000 Ibs. per hour.
..
~
.
Figure 36.
Separate UNITED NUV A TROL control cabinets furnished
for each boiler for automatic operation of fly ash and dust
removal system
16
D-180
-------
-.
.-"..
I' '.
I
...
r
~~)
~
-..", -
~
~f
~. iL -
7'.1 ~" : ~~
':~ .:.:._~;
--:: :; ~:::~;
~#! J..",.::...~
---;IIi:.&--
'::'>~~'-:"
:A.
,"
t -
~...~ "),
-.!,. ~J~~
,/ '-'-~
,,-
-,.
Figure 38.
"
.
",
.
D-181
~
-------
~- -.....-
UNITED
..
D-182
This NUVA FEEDER System is one of six pneu-
matic conveyors furnished for a large Central
Station Power Plant with a total capacity of ap-
proximately 8,000,000 Ibs. of steam per hour.
. Figure 40.
Close-up view of NUV A FEEDER air lock with
motor-driven blower supplying the air to the con-
veying system.
Figure 41. .
Typical arrangement of NUV A FEEDER conveyor,
Figure 41, distributing fly ash to three points for
refiring into the furnace.
:;.-:
- -
-------
..
~
J..,
:1
'~
'" "e -l~.
.... .~ ;
~ ,,') .
~
I
I
D-183
19
-------
---
..-= ~
. ~.
~-
UNITED
Motor-driven blower with standby blower supplying
conveying air to NUV A FEEDER System.
Figure 42..
.
Typical installation 01 NUV A FEEDERS connected
directly to the Ily ash collector hoppers.
Figure 44. .
NUV A FEEDER positive pressure pneumatic con-
veyor discharges to distributing tank for refiring fly
ash to furnace burners, or coal feed pipelines
20
D-184
-
-------
~~. :t:':"
~.
L-
-,",
tat:~ ~'
~;,_-:-
...--~
"..~.:...:.'
~_L
.,i..,~."."'" -~ .
,
. "
'I...
.... .
""":".:.~~-'~':---;'
I - I ---::"--1 ---~' .-;
. .~"'" "" ~! -1'- "
Figure 45,
,
NUV A FEEDER conveyors discharge to a
Two b"
1650 ton fly ash storage In
-
Figure 46, .
f'lt t Pe dust co 1-
Automatic operating bag I er y,
lector located on roof of storage bin.
-------
I
UNITED
In this central station NUV A FEEDER pneumatic systems serve two
steam generators with a total capacity of 8,000,000 pounds per hour.
f
i
Figure 47.
NUV A FEEDER systems installed under electrostatic precipitators operate at a
total capacity 01 120 tons 01 dry Ily ash per hour.
22
D-186
-------
REMOVABLE FLUIDIZING
STONE
--------
AIR SUPPLY
, \
, I)
UNITED NUVAFLOW'
FLUIDIZING UNITS
..
D-187
Figure 48.
UNITED DISCHARGE
EQUIPMENT FOR
DRY FLY ASH
COLLECTOR HOPPERS
Frequently, dry fly ash is of such char-
acter that it arches and hangs up in the
collector hoppers. To obtain maximum
capacity for the pneumatic conveyor,
UNITED engineers developed two
methods to assist in overcoming this dif-
ficulty.
Upper photo. Figure 48, on this page
shows the UNITED patented vibrating
discharger. The vibrating mechanism lo-
cated outside the hopper is connected
to a vertically hung plate inside the dust
collector hopper. The vibrating plate
breaks down arching and results in a con-
tinuous gravity flow of dry fly ash to the
conveyor system.
An alternate design is illustrated in the
model photo. Figure 49. UNITED flui-
dizing units located inside the dust col-
lector hoppers introduce low pressure
compressed air in sufficient quantity to
aerate the dry fly ash, thus causing dry
material to flow freely and by gravity.
The operation of the above equipment is
automatically controlled by the UNITED
NUV A TROL. generally a part of the con-
veying system.
Figure 49.
23
-------
Figure 51.
...
"
~
UNITED
UNITED RESEARCH
AND DEVELOPMENT
FACILITIES
UNITED POLICY-to meet the needs of industry.
A never-ending program of research and constant
development of new equipment to give a high de-
gree of efficiency and economy. Full scale equip-
ment installed in our laboratory (partially pictured
on this page) is used extensively to obtain engineer-
ing data for developing a wide range of conveyor
systems, components and their application.
Figure 50.
t,'
! 1
i .
I I
...
,
~~
r I
,
-' .l"~.J... .
~'"
t.;f~""
..~. '"
~. ..'~.- ''''.',;' ''fI...''. . ."'.:~
; I '.,;:J "
-.../ t. - -}J"" ...
~.., ;j."
~t:. ."
.~.~ II:; r~
~ i "" .::
tr ..~'}, ,:,,:,'
Nuva Feeder Bulletin
No.4NF-68A
UNITED CONVEYOR CORPORATION
6505 NORTH RIDGE BOULEVARD, CHICAGO, ILLINOIS 60626 U.S.A.
PHONE (AREA 3121 761-4100
D-188
Printed in U.S.A.
-------
APPENDIX X
D-189
-------
LIST OF ALL STUDY DRAWINGS
Drawing No.
Title
FBB-I
Horizontal Section Thru Boiler
FBB-2
Bid Development
FBB-3
Sectional Elevation (Natural Circulation)
FB B-4
Grid Development
FBB-5
Sectional Elevation (Forced Circulation)
FBB-6
Sectional Elevation
FBB-7
Horizontal Sections Thru Boiler (Forced Circulation)
FBB-8
Bed Heating Surface Development
FBB-9
Load Dimensions
FBB-IO
Section Elevation
FBB-ll
System Schematic (Fuel)
FBB-12
Tube Arrangement at Coal and Limstone Feed Pipes
FBB-13
Fuel Grid Development
FBB-14
Fuel Distributor Arrangement
FBB-15
Grid Arrangement for Fuel and Limestone Injection
FBB-16
Combustion Air Distribution Arrangement
FBB-17
Combustion Air Flows Control Schematic
FBB-18
Expanded Bed Heating Surface and Screen Tube Arrange-
ment
FBB-19
Boiler Arrangement
FBB-20
Boiler Sections
FBB-21
Expanded Bed Heating Surface and Bed Screen Tubes
with Coal ahd Limestone Feeds
FBB-22
Economizer Development
FBB-23
Proposed Arrangement
FBB-24
Proposed Fuel System
FBB-25
Proposed Insulation and Wall Construction
D-191
-------
Drawing No.
Title
FBB-26
Prime Fuel Splitter
FBB-27
Control System Schematic
FBB-28
Fuel System Development
FBB-29
Wet Scrubber Arrangement
FEB-3D
System Schematic (Electro-static precipitator)
FBB-3l
System Schematic (Two Stage Wet Scrubber)
FBB-32
System Schematic (Feedwater/Steam)
FBB-33
Fluidized Bed Material Discharge Station
FBB-34
Heat .and Material Balance - Dry Solids System
FBB-35
Heat and Material Balance - Wet Scrubber System
FBB-36
Wet Scrubber Slurry - Dewatering System
D-192
-------
APPENDIX XI
D-193
-------
STUDY OF HEAT TRAP - DESIGN & COST
In order to compliment the design work and boiler pricing data we obtained
heat trap price data for our proposed 2S0,000U/Hr. design.
With the design of the boiler and convection pass, we were able to obtain
sufficient boiler heating surface to reduce the heat trap heat load to about
25 million BTU/Hr. in order to achieve a stack gas temperature of 3500 F.
In determining the relative costs of different heat traps, four (4) types
were defined and considered. The selections are as follows:
BARE TUBE ECONOMIZER
A bare tube economizer would be a convection type unit where there are 2"
tubes at 3-1/2" spaces perpendicular to flow and 4" spaces parallel to flow.
Flue gas and water flow are arranged for counter flow. An inlet gas velo-
city of 100 ft./sec. was selected to peak the overall heat transfer coef-
ficient. For an inlet gas temperature of 6720 F. and an outlet of 350" F.
and a 1000 F. water temperature rise from 2500 to 3500 F., it was found
that 7400 square feet of heating surface was required.
EXTENDED SURFACE ECOKOMIZER
An extended surface economizer considers a convection type unit similar to
the bare tube economizer, with multiple parallel circuits arranged for
counter flow gas to water. The gas side heating surface, however, is in-
creased by applying continuous spiral fins 0.135" thick, 3/4" high at a
pitch to have 2 fins per inch lineal run of tubing. It is common to have
pipe sizes used on commercially available finned tubing. In this case,
1-1/2" pipe was considered and the tubes are arranged in a 4-1/2" square
pitch.
At the temperature conditions, as the first case above, 12,700 square feet
of gas side surface w~s found necessary. This surface included fin surface.
TUBULAR AIR HEATER
The tubular air heater that was considered is a counter flow type, with gas
inside the tubes, air outside. 2-1/2" tubes on a 3" triangular pitch was
considered. An outlet air temperature of 5150 F. was found using 1200 F.
inlet air temperature and the 24.9 million BTU/Hr. heat load. The higher
air inlet temperature was a corrosion consideration, and would be a result
of forced draft fan compression and a steam coil air heater.
Under thc above conditions, 32,600 square feet of heating surface was found
necessary.
D-195
-------
REGENERATIVE AlP HEATER
The operating conditions were submitted to Air Preheater Company for estima-
tion of a regenerative air heater, rotating heating element type, using
counterflow and patented heating surface configuration. A vertical shaft
type rotor was specified - a c1eanabi1ity consideration. Predicted perfor-
mance was in line with the above conditions.
Outlet gas temperature corrected for air leakage was somewhat lower. Approx-
imately 10% leakage from the high pressure air side to lower pressure gas side
was predicted; .
For the four cases above, the comparitive estimated prices were developed
maximum shop assembly was assumed.
ECONOMIZERS
AIR HEATERS
240
100
TUBULAR REGENERATIVE
37,000 32,000
150 130
105 103
BARE TUBE
EXTEN~ED SURFACE
Estimated cost
Comparison of
cost - %
Comparison of
effect on
total cost - %
60,000
25,000
115
100
D-196
-------
APPE!\1HX XII
D-l97
-------
SUMMARY OF INDUSTRIAL STEAM GENERATOR
MARKET PROJECTIONS
Table #1 is an outline of technical classifications in capacity, steam
pressure and steam temperature that was used to determine data in order
to extrapolate and predict future markets.
Figure #1 is an outline showing the fraction of the market for different
classifications of capacity projected for 1975 and for 1980.
Figure #2 is an outline showing ~he fraction of the market for different
classifications of operating pressure.
Figure #3 shows the market fractions for different steam temperatures.
D-199
-------
Cf../J.5.:/IF/wjrlCNJ "p [;E.,;.;.v I'/JMHdE1!.5
11./ (/II':> T,(:"II.lL. C:O/I..E.L.. /-/l;r/J
C/7//j~/TY,
I/:Jvu~' OF ':;/"6'/;/1'1 p{.Itr.'~.l
C¥C.L'/,t/",14 l.lt:\i.~
r.:d..,.
T".,." E. \
i",',)\.,
o ~ 2.5,000
U,Cr:;~. so, COO
51, oCJ\)~/oo, O[>()
lOt, PtlO - ISv, ~
ISI.CiO~-2So, :/..K;
251, coo -S':;"Cf. 0':;.:.,
3So. 000 f (/v~k.
c. -H.t
1.50 - 2.J-i
2..L;O. Sir
6(1~- 6'41'
6'>0- IUi
/250- 1717
..:;'",;N"!,I'llf If:,,!£, .? "',-7.111
ffIHi:A.',J/I'4.~ F
.;i9 rt/.(/J'" C".P
300 - 524
$1 $- 624-
62.> - 7U-
7;5'. 77-1-
71;'- 8;.4-
91$- 5/1-
B7S"- qi--/-
1J.$ f CI/ck..
P,eOJEc.rELJ 1>t,J7;1!/6'J,r/o.A/ ",/?i7'/N
FV rvt€ £ IN/)I/.>TIf!/A1.. !JOhEl: 114RJ:ET.5'--
S,rE,Itfl, .q E/YE/.'/iT/Ntf ":/)/'nC,ry,
J'-7:,.l: if 75" !
I
rt'J~ 1981> i
, : ~
26, ~o - ~qax> =:-: ::::=.::.:::::;r! i
i : j I
54"oCJ-/()~t'()O ~:'2"~ <::'~~'.:-:?~=-'- ":':1 !
,
14:"'" /Sqo:>o l: :=:~::,:Jj I 'I , I
~~C~ -a I -, .
;> .. ~ ".XJQ : :.: '-:':"-'-~c . :":-:-;-,;:.,,, '-::-:--:-:--:~~7:'~:'::-':-C'~' ~:-:--:""'":---:-:-?J I
~tc,,~ - 3f; «0 ~'" :"-r~-T--'C------cr"'---~
351.()X) to;;,,!"/:. ::''',.:..<.::.,'''::'~:~:'::Ti I ! I
-,
al''/C/fY
PO.:,lA.;:b . :.'o[I.'''1/'..Z/.'-v.t!.
o - u; uo
'---11
----''""7.1
...,:...;......,;..1
- -! \('
nl\vKt.
\
o
5" 10 IS" ~ 2S 30 $5" ~o
Ff/lcrNJ/t/ OF Tor//L. ST€,I)/1
ilENE)! /Jr/Nq C,IJ//lc/TY .50k-LJ / GJ,b
D-200
45"
. £(.fCD
'Z.Ji~\i\
-------
p~o .JE.:.reb I)/JTA.'/ldT/o/.I ~tlJrIl/A./.
F'iJri/l£" I/.I/;y.;;rk//JL &;C>/~£t: JvM£);:E7.f
OPE£.lJrt/A; ,P~E$.5 v-t:c
o - /4-9
O/E£/Jrl-l.-y'- f>,l~;:;;i/Lc, I'..~/.-i.
1$0 - 21/
1.~0 - N9
600' 91-7
....\~ J~-1.
r tt i\t
8.)0' I/. -Fi
/250 - 17 ti
..."_.. -_..>.,,..~,,,::.~ ;.,.e. };~r i I I I
. I! ii i
.;~;"i;:::~/~?;';'-::'.;;f.;;~~ i i I
()
5 10
F/:~cr;ol./
,,£I.lE£~?lI.I;
OF TOT/l1. $TcQH
C/l/'/'IC/ ry .fo~.(i,.o1O
.Jo
I
I
I I
I
I 1-'"
I
35 4<) 4S
15"
20
25
PfOJceJ£l. (j/.Jr;:l!vl"l~ I.(J/TIINJ Fi/TVl:li
l~bi/>rI!IIIL 801tc,l H.9.eKCr...f
.$(/Pc~IIE/Nc/) $TC/.JII TE/'/FE:C/)'-';/U
TEH~I""I:'f.'.t.I, F .
,~ "'0/2 /980 i
. ,
t
I
,
I
.,
I
I
I
;-.-:-£:.::~~~
. j
I
i
j
I
I
I
!
.,'~:;::.:~;? ,
.-'-'-~:. !
t-:-~.:.~:.~ .~.~ {~:7:: ~:,:~
o C 1(1 IS' ':'0 ,!$ ,;."0 JS'
r'121l.::.r;(:),,-, OF rt:>T/)':' ..;-Tc!F/,)/-I
qcF./O:/,J rlA/,: ';;?"/I.:t,y .fO':'~, %
D-201
I
I
I
-
I i.
I
I
I
i
I
,
I
I
I
I
I
I
i
I
I
I
I
40
-M""
t. (£\)
L\) R\-\
-------
APPENDIX XIII
D-203
-------
SHIPPING CONFIGURATIONS
To develop optimum costs, it is
modules as possible to minimize
is also the field assembly time
is contemplated.
necessary to shop assemble as large
field costs. An important advantage
which is much less when shop assembly
For each large module shipped by rail individual rail clearances are
developed for the most favorable routing to the destination. In the
case of a very large Erie City Keystone Boiler for the Tennessee Valley
Authority, page #1, represents the railroad 'response to a shipping
clearance request. Figure #1 is a sectional dimension view of the
clearance that must be adhered to.
D-205
-------
}.{r. C:. \'J. Sher::nan
Trc:!.zrs..c 1:=':1:::;-:1"
Erie City Iron \'lorks
Erie, p c:u:s~r 1 \",:).ni a
Dear 1-:1'.
Sher!"~'t1:
*
- " : -;-.,'-
\ .
. .
'r'~.
L. ':". .:} .
. ,-----~J . .
:1idth
8 F-r:-6 In.
9 Ft. 9 In.
12 Ft. 2 In.
J3 Ft. 0 In.
J3 Ft. 0 In.
10 Ft. 6 In.
Co
.
~
\'. .. '..
. .
PENN CENT1=lAL
.; -.-..
. .
\.
".
..~. ."
- --
..
707/GCJ
1324 \lest Tbird street
Clevola"lQ, Ohio 44113
January 31, 1969
File:
9-EG-9320
of a
land
phase refer to :.our Januar-f7th request
5:10:::> .A:;s::::~ld 30iler to the l'Cnnessee Valley
City, ?~r:.~cs~ee.
for rcil c:leara.nce
;"uthori. ty, Cur:.ber-
.r'1e ha.va cleared the hand.lin~ of a din.~nsiona.l ~t..ip::J.ent frO::!.
Eric, Perms~'lva.!1i.a to. the a::,mre desttndion !'Quted: PC/?! - Tol'3do,-
lrM - 31o~.ir.:.:t:)n - G:.2:0 :... nUr:.'cold - .L::U. 'The shi.:p,.'.cnt" net'ilCi;ht of
'?r;'mn -:'"1""""'ri,, :~."~:?ri~"":'" ';'(') '7'("'", :;~ ';'oot 6 T1"\r-~, -Pl..,-!- """st ""f"lt. ;"'~'rQ
--""J.-'" - ;;;-'_O'.-----J -----"'- ---. -'II ... --.... ~-" '- -......--- ----, - ---- ,....-e-
a. co:::bint3d center of [;!"a.'.rity excecdin,g 98 Inches. The 1o=:.ded ci.i:::cn-,
sions ~3t not e7.cc~d:-
.,-, ...
. ". ... t .
,- .
'.
, .
..
rdg
cc: FreiGht A~ent
penn ~cntral COCPMY
Erie, ?cnns~: 1vani~
. Hcis;-ht. AT:!'.
19 Ft. 9 In.
18 Ft. 6 In.
17,Ft. 3 In.
15. Ft. 9 In.
4 Fh 3 In.
3 Ft. 5 In.
Yours truly,
PENU C£~':7?_AL CCJI~A;rY
cp.L¥J@
B. L. Strohl p-
General SucerinteI::t;:nt-TranSDortation
- .
CL)?(T: t
1/IY/70
(~
"t.,.;,,j L."
D-206
-------
1
I
I
I
/3 ~o "
/2 '-z"
9!911
"" I "
Q-Q
II .I.~:',':~.I:':': ,"'i;:j:;+,,! I
II L:-I...' ,..tt:I:1::tt-,--..:..c..1!:L,.:--,-,-, ':L1:...:.....w..lJ~,
~$' !'~~~ ,:', :~:ti:;:: .' I::: i., ~:
1/.w:r::ti-1"i"r-r'~;-"'--"'T!' I ' , " :",; ,,',-,-'-rl., , 1:
:'~).i:LG~';+:-r-'~~~~~
+'+1..-;-":+......llli,', '-
ilit!:1,:;':,L~, I, ,,:::,,,-jj~~-iJ+i+,,':: ~, : rD,"~ ',~~
.-,,;:::::;2l:'~: .. ~-:#;
+H- ~" ..,.....-. .~- "11 . . .,", "
',. ,-hI... ,,:. I ,'-r-~:;:':; ~~.'-t++11
'~~ Ji[; ~:~~~i~
,,' H#~.':": ;_-:imiIt~~: ,'i: i :4+h~:i
~~~~~:~
, " ' , ' :.J..t, ,~, ;- ,-;--l+W--'-Ht
r
I
1
1
~ I
~
'.
':l)
"
~ -r--,
~
"
~
.
.
\,
" I
\~ \
"
~I \91
, . ! -" I
~I ~I~
.....,
t\"
..........
,H-4-t-r~ '.' i J , i
,,' ,:""
i:
.. , ' H+H+
, ' ~.~. t+~-H-t-:
'of
~
++
:-1
., "+
, , ' , ' .. " ' "I
1 ~~."I :~~"-~:~ ~;-;~;~~_~7~__~~~.,.;J
~~
~p ,,~ C"/i,.(.?
~I
~I
ToP ~;::- R/flt..s
/O~G"
C:CL//[:"/Z.:O £r:lJ C:?/t.6C
,,:-,::j-'i/<:? .V
'0 I'" CJltY8TALI:NI:" co."e"C'AL 8LU8, ..18, PA.
PR 9540-170
-------
APPENDIX E
TURNDOWN TECHNIQUES FOR ATMOSPHERIC FLUIDIZED BED BOILER~
ABSTRACT
A comprehensive analysis of applicable turn-down techniques
for an atmospheric fluidized bed boiler is described. The techniques
for altering the bed temperature, the heat transfer coefficient, and the
heat transfer surface in the bed are discussed. The effectiveness of
different techniques are evaluated.
The bed operating conditions, such
a~ bed temperature, excess air, coal feed rate, before and after turn-
down are presented and compared.
The most economical and convenient turn-down technique is that
of changing air and coal feed simultaneously and maintaining the excess
air constant. To increase the turn-down ratio, the fluid bed can be
shut down by sections.
E-l
-------
A comprehensive analysis of applicable turn-down techniques
for an atmospheric fluidized bed boiler is described. Although the
analysis of the industrial fluidized bed boiler is used as illustration
here, the analysis is general and applicable to both utility and
industrial fluid bed boilers.
Load change in a fluidized bed boiler constitutes two
additive parts: the contribution from the heat transfer in the bed
and that in the convection section, including the heat traps.
The
change of heat transfer in the convection section is caused primarily
by change in the heat transfer coefficient due to change in gas flow
rate and gas temperature and can be easily evaluated once the flow rate
and temperature are known.
The change of heat transfer in the bed,
however, involves three main parameters: the heat transfer surface in
the bed, the heat transfer coefficient, and the bed temperature,
assuming the water-side conditions are the same. Techniques which are
capable of changing one variable or a combination of them will be
effective in turn-down. Since the magnitude of the contribution from
the convection section depends on different boiler designs, this
general turn-down discussion will be confined to change of heat
transfer in fluidized beds alone. The effect of the convection section
is additive and can be determined once the design of the boiler is
finalized.
The applicability of different turn-down techniques is
evaluated by turning the bed from its original operating conditions
at 1650°F bed temperature and 10% excess air down to 1400°F bed tem-
perature and the appropriate percentage of excess air.
E-3
-------
TECHNIQUES FOR ALTERING THE BED TEMPERATURE
The techniques available for altering the bed temperature
and achieving the turn-down effect are:
(a)
(b)
decreasing the air preheat temperature,
decreasing both air and coal feed rate and
maintaining the same percentage of excess air,
(c)
increasing percent excess air by decreasing the
coal feed and maintaining air flow constant,
(d)
increasing percent excess air by increasing air
feed and keeping coal feed constant,
, l
, (e),
(f)
combination of (a) and (b); (a)' and (c); (a) and (d),
recirculation of 'flue gas.
The percentage of total heat input transferred in the bed for
every pound of coal burned is plotted against the bed temperature in'
Figure E-l for different degrees of air preheat and at different
percentages of excess air based on the adiabatic flame temperature of
the flue gas, assuming the heat capacity of the flue gas to be' constant
in the temperature range considered. We will call these lines the
equilibrium lines at their respective operating conditions. Hence if
the bed temperature and air and coal input conditions are known, the
total heat transferred in the bed can be determined from Figure E-i.
The percentage turn-d~wn achievable for e~ch technique can thus be
quantitatively determined.
ing the operating conditions
the bed temperature l650°F.
these can be analyzed in the
The procedure is illustrated by consider-
before turn-down to be 10% excess air and
Normal operating conditions other than
same way.
E-4
-------
~
-
"@
en
c: 100
"@
s....
s....
Q)
-
In
c: 80
1'0
s....
I-
-
:::J
c.
c:
-
.- 60
:B
tJ:j ::I:
I
\.Jl 1'0
-
0
I-
-
0 40
Q)
C'I
1'0
-
c:
Q)
u
s....
Q)
a... 20
. 0
o
Curve 641624-8
. No Ai r Preheat
. 10%, No = 10% Excess Ai r wit h No Ai r Preheat
- - - With Air Preheat
10%, 700 = 10% Excess Air with 700OJ: Air Preheat
--- Flue Gas Recirculation
40%, R = 40% Flue Gas Recirculation
'.
"
10%, 700
10%, No
-, 30%, No
20%, R
50%, No
40%, R
1500
1000
Bed T emperatu re, OJ:
Fig. E -I-Effectiveness in turn-down ,by diff~rent turn-down techniques
. \
2000
-------
(a)
Turn-down by Decreasing the Air Preheat Temperature
With air preheated and with the fluidized bed serving as an
evaporator, the heat transferred in the bed before turndown is
(~ + X ) + CpF(TA - TB)]Yb
s
~Sb(Tb - Ts) = [Hc f
s
where
hb
Sb
Tb
T
s
H
c
F
X
s
f
s
C =
P
TA =
TB =
Yb =
(1)
=
heat transfer coefficient in the bed before turn-down,
Btu/ft2-hr-oF
=
total heat transfer area in the bed before turn-down,
ft2
=
bed temperature before turn-downoF
temperature of the saturated steam, of
=
heat of combustion of fuel, Btu/lb
total air flow rate, Ib/hr
excess air before turn-down, %
=
stoichiometric air requirement for each pound of
fuel burned
average heat capacity of air, Btu/lb-oF
air preheat temperature, of
base temperature, of
percentage of total heat input transferred in the
bed before turn-down, %
The heat transferred in the bed after decreasing the air-preheat
temperature from TA to TB is
where
h
.a
F
haSa(T - Ts) = Hc fs(l + Xs) y
(2)
heat transfer coefficient in the bed after turn-down,
Btu/ft2-hr-oF
E-6
-------
S
a
=
2
total heat transfer area in the bed after turn-down, ft
bed temperature after turn-down, of
T
=
y
=
percentage of totaLheat input transferred in the
bed after turn-down, % .
In the case of the atmospheric industrial boiler, the following conditions
are assumed:
T = l650°F ; T = 489°F ; X = 10%
b s s
T = 7000F ; T = 800F ; C = 0.24 Btu/lb-oF
A B P
H = 12500 Btu/lb ; f = 10.04 lb air/lb coal burned.
c s
The total heat input transferred in the bed before turndown, Yb' can be
read off from Figure E-l to be 61%.
Dividing Eq. (2) by Eq. (1), we have
h S (T - T )
a a s
Y = 0.69 . hbSb . (1650 - Ts)
(3)
For the time being, assume ha = hb and bed depth is constant; i.e.,
Sa = Sb' Equation (3) is a straight line passing (y = 0, T - Ts)
(Y = 0.69, T = 1650), and we shall call this line an operating line.
The total reduction of heat transfer in the bed by decreasing the
air preheat temperature from 700°F (point N in Figure E-l) to no air
preheat (point a obtained from Eq. (3)) is 14% calculated from
Eqs. (1) and (2). After turn-down the new bed temperature is l490°F,
from Figure E-l. If the bed temperature is to be decreased to l400°F
after turn-down,y can be obtained from Eq. (7) (see Section (e)) to
be 0.59 (point e in Figure E-l).
This gives an air input condition of
20% excess air without preheat from Figure E-l. In other words, l490°F
is the lowest bed temperature obtainable under the specified condition.
Any attempt to lower the bed temperature further requires other
techniques such as increasing the excess air with decreasing coal feed.
E-7
-------
(b)
Turn-down by Decreasing Both the Air and Coal Feed Rate
and Maintaining .theSame Percentage of Exce'ss Air
Operating condition before turn-down:
bed temperature:
1650°F
air preheat:
excess air:
none
10%
percentage heat transferred in the bed (from Figure E-1):
55%
Operating line:
h S
Y = 0.55 . ~
hbSb
Fb
. - .
F
a
(T - T )
s
(1650 - T )
s
(4)
where
Example:
Fa' Fb = total air flow rate after an4 before turn-down
respectively.
(assuming again ha = ~; Sa = Sb)
If air flow rate and the corresponding coal flow rate is to
be decreased by 25% after turn-down, then Eq.
(4) becomes
1 (T - Ts)
Y = 0.55 x 0.75 x (1650 - T ) ,
s
a straight line passing (y = 0, T = T ) and (y = 0.733, T = 1650°F).
s
The intersection with the equilibrium line of 10% excess air with no
air preheat is point b' in'Figure E-l. The turn-down achieved is
0.55 - 0.75 x 0.61 = 16.82%
0.55
and the bed temperature after turn-down is 1450°F.
If the bed temperature is to be reduced to l400°F after
turn-down, Eq. (4) becomes
E-8
-------
Fb (1400 - 489)
y = 0.55 . F . (1650 - 489) .
a
(5)
From Figure E-l
y = 0.622
Combining the two equations we have
Fb/F a = 1. 44
or
F/Fb = 0.695.
Since the percentage excess air is constant before and after turn-down
the total coal and air feed needed to bring the bed temperature from
1650°F down to 1400°F, a reduction of heat transfer in the bed of
21.5%, is 69.5% of their original feed.
The maximum percentage turn-down achievable by this technique
is determined by the lowest bed temperature allowable based on
considerations of coal combustion efficiency and S02 removal efficiency
by limestone or dolomite.
(c)
Turn-down by Increasing Percent Excess Air by
Decreasing the Coal Feed and Maintaining Air Flow Constant
Operating condition before turn-down:
bed temperature:
l650°F
air preheat:
excess air:
none
10%
percent heat transfer in the bed (from Figure E-l):
55%
Operating line:
y = 0.55 . (1 + x)
1.10
h S
a a
. -.
hbSb
(T - T )
s
(1650 - T )
s
(6)
where
x = percent excess air after turn-down.
E-9
-------
Examples:
(assuming h = h- . S = Sb)
a -D ' a
If x = 0.5, i.e., after turn-down the bed is operated at
50% excess air, then the operating line becomes
(T - T )
s
Y = 0.75 (1650 - T )
s
a straight line passing (y = 0, T = T ) and (y = 0.75, T = 1650°F).
s
The operating line intersects with the equilibrium line for 50% excess
air and nO air preheat at c'.
The turn-down obtained is about
1 - 1.10 = 0.267 = 26.7%.
1.50
The bed temperature after turn-down is 1330°F, from Figure E-l.
If the bed temperature after turn-down is 1400°F, Eq.
(6)
becomes
y = 0.55.' (1 + x) . (1400 - 489)
1.1 (1650 - 489) '.
(7)
For every x there is a corresponding y. The correct x and y can be
found by trial and error between Eq. (7) and Figure E-i. Here the
excess air required after turn-down is found to be 40%, and the coal feed
is 78.5% of the original rate.
The maximum percentage turn-down achievable by this scheme
depends also on the lowest allowable bed temperature after turn-down.
(d)
Turn-down by Increasing Percent Excess Air by
Increasing of Air Feed and Keeping the Coal Feed Constant
Operating condition before turn-down:
Same as outlined in (c).
E-IO
-------
Operating line:
h S (T - T )
a a s
y = 0.55 . hbSb . (1650 - Ts)
(8)
Examples:
the points of intersection after turn-down are d" and d' for
their respective operating conditions.
The percentage turn-down and
the bed temperature after turn-down are 6.4%, 1580°F; li.8%, 1510°F
respectively.
If the temperature after turn-down is 1400°F, Eq. (8) becomes
y = 0.55 . (1400 - 489) = 0.432.
(1650 - 489)
From Figure E-l, the excess air required after turn-down is found to be
~ 75% by extrapolation.
The maximum percentage turn-down obtainable
through this scheme depends on the maximum fluidizing velocity allowable
after turn-down based on the solid elutriation consideration.
(e)
Turn-down Through Combination of (a) & (b);
(a) & (c), (a) & (d)
Considering here only the case of a combination of (a) & (c),
the operating lines for cases of (a) & (b); (a) & (d) can be obtained
through the same analysis.
Operating conditions before turn-doWn:
bed temperature:
1650°F
air preheat:
excess air:
700°F
10%
percentage heat transferred in the bed (from Figure E-l):
Operating line:
61%
h S (T - T )
[(1 + x) a a s
y = 0.61' (1.10) + 0.12(1 + x)] . hS' (1650 - T) .
b b s
(9)
E-ll
-------
Examples:
the point of intersection after turn-down are e" and eHl for
their respective operating conditions.
The percentage turn-down and
the bed temperature after turn-down are 26.4%, l335°F; 37.4%, l2l5°F
respectively.
The final operating conditions for turn-down to l400°F bed
temperature was found to be 20% excess air for the (a) & (c) combinat~on
scheme an~ 35% excess air for the (a) & (4) combination scheme.
(f)
Turn-down Through Recirculation of Flue Gas
The equilibrium lines for 20% and 40% of total f~qe gas
circulation were also' included in Figure E-l, assuming the flue gas
temperature to be 350°F. Flue gas recirculation has the combined effects
of air preheat (due to the sensiqle heat carried by the flue gas) and
increasing excess air and keeping the coal feed constant (due
to the increased flow caused'by flue gas recirculation). The operating
line is similar to the one for turn-down through scheme (d). Combination
of this scheme with techniques (b), (c), and (d) can also be obtained
by the same analysis.
The turn-down' techt;liques available" their 'corresponding percentage
turn-down, and their final operating conditions by 'decreasing the bed
temperature from l650°F to l400°F'are summarized in Table E-l assuming
ha = ~ and Sa = Sb' Note that mode (a) turn-down alone cannot achieve
bed temperature lower than l490°F for the chosen conditions. Mode (b)
offers the most efficient means of turn-down, because the lowest coal
feed is needed and the lowest flue gas heat loss is experienced.
It should
be therefore employed as the primary scheme for turn-down whenever possible.
If the fluidized bed serves as a superheater or reheater
instead of an evaporator, the operating line for each turn-down technique
can be obtained through the same analysis.
These are presented in
Tab Ie E-2.
E-12
-------
TABLE E-l
EFFECTIVENESS OF TURN-DOWN BY DIFFERENT TECHNIQUES*
(Fluidized Bed Serves As An Evaporator)
Coal Feed
Conditions Before & Bed Temperature Degree of Turn- (Arbitrary Unit) Excess Air (%)
.
After Turn-down Mode of After Turn-down down in Bed Before After Before After
(.Refer to Fig. E-1) Turn-down (OF) (%) Turn-down Turn-down Turn-down Turn-down
AI -r a (a) 1490 14.0 1.0 1.0 10 10
.A -rb (b) 1400** 21.5 1.0 0.695 10 10
A -r c (c) 1400 21.5 1.0 0.785 10 40
A -r d (d) 1400 21.5 1.0 1.0 10 75
AI -r e (a) & (c) 1400 21.5 1.0 0.915 10 20
combination
AI -r el (a) & (d) 1400 21.5 1.0 1.0 10 35
combination
tzj A -r d (d) & (f) 1400 21.5 1.0 1.0 10 60% Flue
I
I-' combination Gas Recir-
w
cu1ation
* Operating conditions before turn-down are 10% excess air, 1650°F bed temperature,
without air preheat or with 700°F air preheat wherever is applicable.
**1400°F is by no means the lowest bed temperature allowable. It is used here just
as an example for purpose of illustration.
-------
TABLE E-2
EQUATIONS FOR OPERATING LINE OF DIFFERENT TURN-DOWN TECHNIQUES
WHEN FLUIDIZED BED SERVES AS A SUPERHEATER OR REHEATER**
Mode of
Turn-Down
. Operating. Line
l1;/Ra
(a)
Y = 0.69 . G*
0.69/y
(b)
Fb
Y = 0.55 . p- . G
a
0.55 Fb/Y . Fa
(c) .
Y = 0.55 . (1 + x) . G
1.10
0.55.(1 + x)/1.10.y
(d)
Y = 0.55 . G-
0.55/y
(a)&(b) combination
Fb
Y = 0.69 p- . G
a
0.69 Fb/Y'. Fa
(a)&(c) combination
- . (1 + x)
Y - 0.61 [ 1.10 +
0.12(1 + x)JG
Y = 0.69 . G
0.61[(li:l~) +
0.;1.2(1 + x)]/Y
0.69/y
(a)&(d) .combination
h S
*G = ~ .
hbSb
(1650-Tl)
,In (1650-T )
2
(T-Tl)
In (T-T )
2
** .
Operating conditions before turn-down are 10% excess air,
1650°F bed temperature. without air preheat or with 700°F
air p.reheat wherever applfcabte. .
E-14
-------
Where
Tl
inlet temperature of steam into the superheater or
reheater
TZ
outlet temperature of&eam out from the superheater
or reheater
~, Ra
steam flow rate in lb/hr before and after turn-down
res pe c ti vely .
When the fluidized bed serves multiple function, i.e.,
for both evaporator and superheater or reheater. the operating lines
for techniques (b). (c). and (d) were evaluated and shown to be:
Technique (b)
r
x (Tb-T ) + x
e s s
(TZ-Tl)
(Tb -Tl)
In (T -T )
b Z
(TZ-Tl)
(1650-Tl)
In (1650-T )
Z
(10)
ha Fb
Y = 0.55 . -- . -- .
~ Fa
x (1650-T ) + x
e s s
L
Technique (c)
y = 0.55 . (l+x)
1.10
h
a
. -- .
hb
x (1650-T ) + x
e s s
(TZ-Tl)
(Tb -Tl)
In (T -T )
b Z
(TZ-Tl)
(1650-Tl)
In (1650-T )
Z
(11)
x (T -T ) + x .
e b s s
E-15
-------
Technique (d)
x (Tb-T ) + x
e s s
(T2-T 1)
(Tb-Tl)
In (T -T )
b 2
(T2-Tl)
(1650-Tl)
In (1650-T )
2
(12)
h
y = 0.55 . ~ .
x (1650-T ) + x'
e s s
assuming the total heat transfer surface is constant,
, \',
i. e. ,
the, b,ed
depth is constant, where
x ,x
e s
=
fraction of total heat transfer surface in the bed for
evaporation and superheating functions respectively.
The operating lines for other turn-down techniques can be
readily obtained through the same analysis.
,TECHNIQUES FOR ALTERING THE HEAT TRANSFER
COEFFICIENTS AND/OR HEAT TRANSFER SURFACE
The analysis presented above and the operating lines obtained
(Eqs. (3) through (12» are general since both the change of heat
transfer coefficient and heat transfer surface before and after turn-down
are considered, although
S = S. In fact, it is
a . b . .
three parameters without
the illustrations are based on ha = hb and
almost impossible just to change one of the
. . . . .
altering the other two, since
the heat transfer coefficient depends on both the bed temperature and
the fluidizing velocity.
A change of gas and/or fuel flow rate will
automatically change the heat transfer coefficient in addition to the
bed temperature. So most of the techniques discussed can still be applied
here with the same operating lines derived, but with ha ~ hb and Sa ~ Sb'
E-16
-------
(g)
Turn-down by Slumping Part of the Bed or
Completely Shutting One Section of the Bed
This is actually technique (b) carried out to the extreme.
When air and fuel feed rate decrease more and more, the bed becomes
de-fluidized and slumped, and both the heat transfer coefficient and total
heat transfer surface in the bed decrease until the complete section is
finally shut off.
To find out the percentage turn-down achievable by
this scheme, the operating line for technique (b) (Eq. (4) is applicable.
(h)
Turn-down Changing the Bed Depth
Through Adjustable Bed Weir Height
This will change the bed depth and thus change the total heat
transfer surface in the bed. However, due to the high heat transfer
coefficient for the surface just above the fluidized bed, this turn-down
scheme applied alone may not give the effective turn-down desired.
Nevertheless, this scheme can be applied in conjunction with techni-
ques (a) through (f) described above. The operating lines derived
(Eq. (3) through (12» are still applicable in calculating the percentage
turn-down.
E-17
-------
APPENDIX F
DYNAMICS OF ATMOSPHERIC FLUIDIZED BED BOILER
ABSTRACT
The dynamic behavior of atmospheric fluidized bed boilers was
analyzed mathematically to give some insight into the design and
operational problems which might be encountered.
Response time for ignition from a neighboring bed was quanti-
tatively estimated using the atmospheric industrial fluidized bed
boiler design as an illustration.
Burners for start-up and restart
during load swing were also sized, based on a load response rate of
lO%/min.
To achieve this response rate, the total thermal capacity of
the burners is close to 50% of total boiler capacity.
start-up and restart were also reviewed and discussed.
Methods for
Rate of bed temperature change and residual steam generation
in a fluidized bed after shut-down were also mathematically analyzed.
Three cases were studied:
turning off the bed by 1) stopping the coal
and air feed simultaneously; 2) stopping only the coal feed and keeping
the bed fluidized; 3) stopping the coal feed and maintaining the
fluidization with solid recirculation. from the neighboring operating
bed.
F-l
-------
DYNAMICS OF ATMOSPHERIC FLUIDIZED BED BOILER
Knowledge of the dynamic change of bed temperature during
start-up and shut-down of fluidized beds is important for sizing the
burners and devising the light-off system and control scheme.
With a
requirement of turning the beds on and off to provide load swing, the
fast response of the bed temperature change becomes more critical. In
the absence of actual pilot plant data, the dynamic behavior of fluidized
beds was analyzed mathematically to give some insight into the problems
which might be encountered.
The analysis for the atmospheric industrial
fluidized bed boiler will be used as an illustration.
RESPONSE TIME FOR IGNITION FROM NEIGHBORING BED
There are several methods to ignite the idle beds either for
cold start-up, hot start-up, or load swing. The two most common methods
are: 1) providing an individual burner for each bed; .2) providing a
burner for only one bed and igniting the other beds by solid circulation
from the operating bed.
To use the first method, large burners have
to be provided for each bed to accommodate the fast load swing because
the burners are estimated to have only approximately 30%-50% efficiency
(see discussion in next section).
Hence the latter method is always
preferred if the bed ignition can be accomplished fast enough for the
desired load change.
To analyze the latter method, now consider two beds:
Bed 1
is operating at full load with a bed temperature of l650°F, and Bed 2
is in idle with a bed temperature of either 80°F (for cold start-up)
or 489°F (for hot start-up). At time t = 0, the idle bed will be
F-3
-------
fluidized at a minimum fluidizing velocity and be heated by solid cir-
culation from the neighboring operating bed. At the instance of
fluidization, the bed temperature of Bed 2 will rise due to the hot
solid circulated from Bed 1, and the bed temperature of Bed 1 will
drop due to heat loss to Bed 2, unless the firing rate is increased
at the same time.
Mathematically, the bed temperature change in both
beds can be expressed as
Bed 1:
H - h A(T - T )
. lIs
. dTl
.F1CPa(TI-TB) - WCPs(Tl, - T2) =WBCps~
(1)
Bed 2:
dT2
WCPs (Tl .,. T2) - h2A(T2 -TS)- F2CPa(T2 - IB) = WBCPsdt
(2)
where.
A = total heat transfer surface in the bed, ft2
Cp
a
Cp
s
Fl,F2 =
H '=
hl,h2
Tl,T2 = bed temperature of Beds 1 and 2, of
T = saturated water temperature, of''
s
TB = base' temperature, of
WB = total weight of bed materials, lb
W = rate of ~olid 6irculation, lb/hr
= heat capacity of air, Btu/lb-mole-oF
= heat capacity of bed mate~ial, Btu/lb~oF
total air flow rate in Beds 1 and 2, lb-mole/hr
total heat' supplied to Bed 1 by burning coal, Btu/hr
heat transfer coefficients in Beds 1 and 2, Btu/hr-ft2_0F
knowledge
ately, in
Equations (1) and (2) ar€ coupled. To solve the equations,
of the relationship between Tl and T2 is necessary. Fortun-
the actual operation it is' advantageous to keep the operating
bed temperature, T. , constant to .assure stability of operation, to
1
facilitate contr.ol, and to . shorten the light-off time of Bed 2 by main-
taining the possible maximum ,bed temperature .difference between the
F-4
-------
two beds.
With the operating bed temperature, T1' kept constant, Eq. (1)
becomes
H = h1A(T1 - Ts) + F1CPa(T1 - TB) + WCPs(T1 - T2)
(3)
and Eq. (2) can be integrated to give
WBCps
t =
k2
(k1 - k2To)
In (k1 - k2T2)
(4)
k1 k1 k2t
T = -- + (T - --) exp (- W Cp )
2 k2 0 k2 B s
(5)
where
k1 = WCPsTl + h2ATs + F2CPaTB
(6)
k2 = WCPs + h2A + F2CPa
(7)
To = the bed temperature of Bed 2, T2' at the instance of fluidization
(t = 0).
When Bed 1 is operating alone, the total heat input through coal feeding
to maintain a constant bed temperature, T , is
1
Ho = h1A(T1 - Ts) + FoCPa(T1 - TB).
(8)
At the instance of starting solid recirculation, the firing rate of Bed 1
has to be increased as shown in Eq. (3) to maintain the constant bed
temperature.
The additional heat required is expressed as
F-5
-------
~H = H - H
o
= (Fl - Fo) CPa(Tl - TB) + WCPs(Tl - TZ)'
(9)
Substituting Eq. (5) into Eq. (9) we have
kl k kZt
6H = (F - Fo)CPa(Tl - TB) + WCp {T - -- + [-1 - T ]exp(- W C)}, (10)
1 s 1 kZ kZ 0 B Ps
k
Physically, kl is always larger than
time independ~nt and gives a solution
kl
T. When -- =
o kZ
at equilibr~um
T , Eq. (10) becomes
o
condition where
"
WCp (Tl - T ) = hZA(T - T ) + FZCp (T
s 0 0 s a 0
-TB) .
(11)
Theoretically, Bed Z can be ignited in as short a time as desired by
increasing simultaneously the firing rate in Bed 1 and ,the solid circu-
lation rate.
In actual practice, an increase of firing rate through
increase of coal input requires a proportional increase of air.
With
the bed area constant, an increase of firing ,rate'necessitates an increase
of fluidizing velocity which in turn determines the carbon carry-over
and CO loss.
With the maximum firing rate restricted, the solid circu-
. ,
, " . .
lation rate has to be controlled, i. e. , 'the opening between the t~vo beds has
to be determined, in order to maintain the bed temperature, Tl' constant.
Note that ~H is, largest at t'= 0 and decreases progressively when the
bed temperature, TZ' increases. 'Thus the design should be carried out
based on ~H at t = O.
For example, to provide a lO%/min load swing capability for
the industrial fluidized bed boiler, a boiler module which constitutes
25% of the total load has to be brought to full operation in Z.5 minutes.
, ,
This represents the most pessimistic case and thus the minimum time
" '
F-6
-------
limit.
Assuming the bed temperature required for self-sustained com-
bustion in a fluidized bed is 700-800°F, the time required to increase
the bed temperature from 800°F to 1650°F is estimated to be ~2.5
minutes from PER and British experiences~1,2] That gives no time at
all to heat the bed from 489°F to 800°F.
In actual operation, however,
we can fire the operating beds at >1650°F, say 1700°F or 1800°F, to
meet part of the load swing requirement.
In this way we can relax the
time constant from 2.5 minutes to about 5 minutes or even longer.
Assume now we have 2.5 minutes to heat the bed from 489°F to 700°F
(case 1) or 800°F (case 2) before coal injection into the bed.
The
solid circulation rate required from the operating bed at 1650°F can
4
be found by trial. and error from Eq. 4. to be W = 12.0 x 10 1b/hr.
Assuming solid circulation rate of 1 x 104 1b/hr ft2,[3,4] an
opening between adjacent beds of 12 ft2 is required. The amount of
increase in the coal feeding rate required can be found from Eq. 10
and is presented in Figure F-1 for both case 1 and case 2. At the
moment Bed 2 is fluidized, a step increase of coal feed to Bed 1 to 145%
(case 1) and 168% (case 2) of the original coal rate is required to
maintain the bed temperature constant.
Increasing the bed temperature
of Bed 2 during this heat-up period will decrease the coal feed require-
ment to Bed 1 as shown in Figure F-1. Increase in coal feed necessitates
increase in air flow proportionally. During this heating-up period,
Bed 1 is thus required to operate at up to 18 ft/sec (case 1) and
21 ft/sec (case 2) for a period of 2.5 minutes.
Increase in carbon
carryover due to increase in fluidizing velocity during this period
is probably small, although more experimental studies must be performed
to confirm it.
The bed temperature change and the steam production
of Bed 2 during this period is also presented in Figure F-2 (here the
gas-side heat transfer coefficient in the minimally fluidized bed is
2
taken to be h2 = 20 Btu/ft -hr-OF).
The effectiveness of using solid recirculation between beds
for hot restart as described requires further experimental verification.
The foreseeable problems are:
F-7
-------
150
"C
co
o
....J
-
:J
u..
'0 140
~
0)'
.-
co
c:::
C'1
.: 130
"C
0)
0)
u..
co
o
U
. , -
. ""
Cur~e 643555-B
170
160
".' '.
Case 1
120
110
100
o
1 2
. -
TimeAfter the Neighboring Bed is Fluidized, min
Rg. F-I-Coal requirement in bed 1 during ignition of the neighboring bed
3
F-8
-------
Curve 643554-8
7
800
8
~ 6 700
~
-
u
ra
c..
ra
U
c: 5
0
:::: Ll-
ra 0
~
Q) a)
c: ~
Q) ::J
c..=> -
E 4 600 ra
~
ra Q)
Q) c..
- E
VI Q)
I-
::J "0
LI- Q)
- 3 CO
o
Q)
C"
ra
-
c:
Q)
u
~
Q) 2 500
0...
1
o
o
1 2
Ti me After FI uidization, mi n
400
3
Fig. F -2-Rate of bed temperature change & steam generation in bed 2 during heating-
up period
F-9
-------
1) St~bili~y of bed ,temperature. At the .momentof fl~igizing
Bed 2, toe stability of bed temperature in Bed 1 is of concern. Will
the bed temperature fluctuation be short-lived or persistent and last
over the period of restart?
Will this temperature fluctuation be
detrimental to overall control stability?
2)
Temperature gradient.
An extreme temperature gradient
, .
may exist in both beds during restart, especially in Bed 2 which is '
only minimally fluidized. For small beds, the problem is not serious.
However, when the bed area becomes lar&er, the problem may increase
in dimensions.
What are the size limitations beyond which this scheme
will no longer provide the 'beneficial and possible way for restart?
Sizing the Burners for ~tart-up and Restart During Load Swing
Sizing the burners for initial start-up is less important
than sizing the burners for restart, because there is no stringent
time limit for initial start-up of a boiler.
However, the~e is a
strict time response requirement for restart of a bed fa meet the
designed rate of load response of a boiler. . . The size, of the burner
required to meet this load response can be estimated from the following
energy balance equation in the bed:
'.
. dT
H - hA(T - Ts) - FCp (T - Ta) = W Cp --.
a B s dt
(12)
Note that no solid circulation from the neighboring bed is assumed.
One idled module of the boiler system is assumed to be kept
hot at all times by recirculation of saturated water through the
immersed tubes from the steam drum, in the case of an atmospheric
industrial boiler, or' from ~ flash tank at" ~lOOO psi (saturated water
, temperature 545,OF),in the. case of an atmospheric u~i1ity botler. When
restarting an idle bed, only minimum fluidizing velocity is provided
(~l ft/sec) to minimize the heat transferred to the immersed tubes
(assume h = 20 Btu/ft2-hr-OF).
F-IO
-------
Integrating Eq. 12 gives
H =
FCp Ta {[Ex] -I} + FCp {T - Ts[Ex]} -hA(Ts - T)
a . a
1 - [Ex]
(13)
where
Ex = exp [ -
t(hA + FCp )
a
~ C ].
B Ps
From Eq. 13 the theoretical heat requirement to heat the bed
to a specified temperature in a finite time limit can be estimated.
The heat required to heat the bed to 800°F for both atmospheric
industrial and utility boilers is presented in Figure F-3 for different
response times. For example, to heat the bed of the industrial boiler
from 489°F to 800°F in 2.5 minutes, corresponding to 10%/min load
6
response, the theoretical heat requirement is 29.0 x 10 Btu/hr, from
Figure F-3. However, the burners may have low efficiencies. From
analysis of the data collected by PERI and the British2 using Eq. 13,
the actual burner efficiency during start-up is found to be about 30%
to 50% depending on the position of burners in the bed. Assuming the
6 .
burner has 50% efficiency, then a burner of size of 58 x 10 Btu/hr
is required for each individual bed to give the stated load response.
The burners required (assuming only three are needed) are thus almost
equivalent to 50% of the total boiler capacity.
Hence, it would be
more economical to use solid circulation between beds for restart
purposes.
Similar analysis can also be done for the atmospheric
utility boiler.
F-ll
-------
70
-0
10 60
.-
x
....
.t::.
-
-:::J
- - .
co 50
'<1
I
'"
.... .
(1)
c
.....
-' :::J
:co_. .
g40
....
u..
:-
C
.(1)
E
(1)
.: 30
:::J
g.
0::
-
. ro
(1)
-:::I:
20
10
o
o
\
\
\
'\ .
\ .'
\-
\
\
\.
'\
. ,,-. -
"-
"-
..............
----
---- --- ---- .
--- ~------- ."
---
t--oo
Curve 643552-B
Atmospheric Utility
160 ft2
24,OOOIb
750° F
2032 ft2
Atmospheric I ndu strial
100 ft2
12,500 Ib
None
564 ft2
Bed Area
Bed Weight
Air Preheat
Heat Transfer Area
in Bed
Water Temp. in Tubes
Heat Trarjsfer Coeff.
At MinimumFI uidization
545°F
20 Btu/ft2-hr-oF
489°F
20 Btu/ft2-hr-oF
Symbol
----
------
t -'00
5
10
15
20
Response Time, min
Fig. F-3 -Theoretical heat requirement in heating the bed to 800°F
-------
The single factor which is responsible for the large burners
required for start-up and restart is the heat transfer from the bed
to the immersed water tubes in the bed.
Any means which can reduce
this heat transfer during start up will be helpful, e.g., keeping the
water temperature in the tube essentially equal to the bed temperature
by close looping the water circulation circuitry during start-up.
Alternative methods for start-up and restart besides the
solid circulation scheme discussed in the last section are summarized
below:
A.
Methods for Restart
(1)
Use Gas Burners:
Gas burners can be directed on the bed surface to heat up the
bed. Disadvantages are a) low burner efficiency, b) tube screen imme-
diately above the bed has to be removed.
plate.
Gas burners can be put between the tube bundles and distributor
Disadvantages are a) space limitation - some tubes may have to
. be removed from the bed, b) there may be some danger of impinging high-
temperature gas flame on the water tubes.
External gas burners -- combust the gas in a separate. burner
and inject the high-temperature gas into the bed. Disadvantages are
a) the arrangement might be more expensive, b) low efficiency - if
the high-temperature gas cannot be distributed through the distributor
plate because of temperature limitation.
(2)
Solids Handling:
Heat up initially using shallow bed in order to reduce burner
size.
Control of bed level may be difficult.
Utilize high-temperature regenerated limestone to assist in
heating the bed.
This requires flexibility in the solids flow control
system for the regenerator and may require a high-temperature surge tank.
F-13
-------
B.
Methods for Initial Start Up'
.. .
. . . .
Methods for initial start up are less restricted because the
response time limitation is relaxed.
In addition to the methods dis~
cussed above, some other methods can also be used.
(1)
Use preheat air and auxiliary burner.
Disac;lvantages. are
a) separate burners outside boiler, are needed for preheatin~ the air,
b) long response time.
(2) Pass gas into the bed (through separate pipes or coal.
feeding port) and ignite above the bed. Disadvantages are a) low
burner efficiency, b) tube screen immediately above the bed has to be
removed, c) danger of having high-temperature gas flame around water
tubes in the bed.
Rate of Bed Temperature Change and Residual S'team Generation in a
Fluidized Bed after Shut~down
An operating fluidized bed can be turned off by (1) stopping
the coal and air feed simultaneously or (2) stopping only the coal feed
and still keeping the bed fluidized.
In both "of these cases, the bed
eventually will. drop off ~to the equilibrium ambient temperature and
cease generation of steam.., .In t;he case. where sO,lid circulatio~ from
the neighboring operating bed is possible," the residual ste,am genera-
tion. will never cease but only leve,l of.f after equilibrium condi ti.ons
are reached.
These three cases are analyzed below.
Case (1)
When a fluidized bed is turned off for turn-down purposes by
stopping the coal and air feec;l, the bed becomes de fluidized immediately;
however, the water in the tubes is kept running to prevent the overheating
F-14
-------
of the tubes in the bed and thus continuously draws heat from the bed.
Before the bed temperature is cooled down to the water temperature in
the tube. the turned-off bed will continue to generate steam at a rate
dependent on the cooling rate of the bed temperature.
To estimate the rate
Figure F-4.
of bed temperature change. the following model is employed. as shown in
In the industrial boiler. I-inch water tubes are staggered in
the bed with 6-inch horizontal spacing and 3-inch vertical spacing.
If
imaginary cylinders of 3-inch diameter are slipped over each tube. as shown
in Figure F-4. analysis of the bed volume encompassed by a single cylinder
would be a reasonable approximation for the behavior of the total bed.
Energy balance within a single cylinder results in the follow-
ing partial differential equation
a 2T + 1. l'!. = ..e.9.E. . l'!.
ar2 r ar k at
(14)
with boundary conditions
where
r = R
i
for t > 0
T = T
s
r = R
o
aT
- = 0
ar
for t > 0
t = 0
T = To
for R. < r < R
~ - 0
r:
radial coordinate
outside radius of water tube
R. :
~
R :
o
radius of the imaginary cylinder
time variable; t=o is the time the bed is turned off
t;
T :
s
T :
o
p:
saturated water temperature
bed temperature during shut-down
density of the.bed
heat capacity of the bed
Cp:
k:
heat conductivity of the bed.
F-15
-------
Dwg. 2944A76
. .
. .
. (-:~ 1" Tu~es .
. /--- t ~ )--1 .
/\", /( \
( @ ) I~\\ . .
" / ( ~R'-.~/.
~~'" . "(.UI. J o~~
( ) \>--/ ( .
\ )/ ""(.
\ ~ ) "---
.~~/ ..
3"
,
6"
Fig. F-4-Model for estimating dynamics of Industrial
. . Fluidized Bed Boiler
F-16.
-------
The solution of Eqs. (14) and (15) is
T - T
s
T - T
o s
n=oo
R. R.
[JO(R1 an) Yo(~ an) - Jo(~ an) YO(R1 an)]
o 0 0 0
Ri
Jo(R n)
o 2
[ J (a) ]
1 n
- 1
kaZt
n
. exp[- ----z]
pC R
P 0
(16)
= ~ L
n=l
With a 's the roots of
n
R. R.
Jl (an) YO(R1 an) - JO(R1 an) Yl (an) = O.
o 0
(17)
Here the J 's and Y 's are the Bessel Function of 1st and 2nd kind. The
n n
first two roots, al and aZ' of Eq. (17) were determined graphically to
be 1.877 and 6.3 respectively. The temperature change with time at
r = R was calculated and plotted in Figure F-5 for the .industrial boiler
o ' 3
where T = 489°F' T = l650°F' R. = 0.5"; R = 1.5"; p = 45 lb/ft ;
s ' 0 ' 1 0
Cp = 0.24 l~~~F; k = 0.377 Btu/hr-ft-oF.
The value of heat conductivity, k, used here is obtained from
fitting actual PER experimental data by assuming that the model of
heat transfer from a semi-infinite slab to surroundings at uniform tempera-
ture is applicable.
It is interesting to note that the k value used
here is approximately the average heat conductivity of air and limestone.
From Figure F-5 the bed temperature at r = R is found to decrease from
o
l650°F to half of its value 825°F in 11.5 minutes and to 617°F in
20 minutes.
The average temperature change can be evaluated by defining
IRo 2~r .
R.
1
liT . dr
liT = (T - T ) =
s
~(RZ - R~)
o 1
; liT = T - T .
s
(18)
F-17
-------
-
en
l-
I
o
.1- .
.;:::: .
-en
I- .
I 0.5
. I-
'>j
I
~
00
10-
o
o
0'
~
0'
Curve 642036-B
n - T ) In - T ) at r = R
. s 0 s 0
Q-'Q or n - T )/ n - T ) .
fo .s . 0 s
o
o
5
10
t, min
15.
LU
Fig. F-5 -Change of bed temperature & bed sen sible heat after shut-down
-------
Substituting Eq. (16) into (18) and integrating, we have
liT
:;
T
o
- T
s
(19)
Ri
21T (R)
o
R2
i
(1 - -)
R2
o
n=oo
~.
Ri Ri Ri. Ri
[Yo(R CLn)Jl (R CLn) - Jo(R CLn)Yl (R CLn)]
o 0 0 0
R. .
J (R1 CL )
o 0 n 2
CLn{[ Jl(CLn) ] - I}
exp(-
kCL2
n
2 t) .
pCpR
o
n=l
Total sensible heat available from the bed material at t = 0 is
Q = V p Cp(T - T )
o 0 s
(20)
and total sensible heat remained in the bed at time t after shut-off is
Qt = V P Cp liT
(21)
or
Qt
-=
Qo
liT
(T - T ) .
o s
(22)
Equations (19) and (22) were also calculated and plotted for the
industrial boiler in Figure F-5. The result shows that the overall
sensible heat of the bed material is reduced by half in 7 minutes.
The
average bed temperature as defined in Eq. (18) is also plotted as
Curve 1 in Figure F-6. When the heat conductivity is assumed to be
0.2 Btu/ft-hr-OF instead of 0.377 Btu/ft-hr-OF, the time required to cool
the bed to a given temperature is shown in Figure F-8.
conductivity is not overwhelming.
The effect of heat
F-19
-------
'>j
I
N
a
u.
o
(1)
~
:::::J
ro 1200
~
~
E
(1)'
I-
"C
~ 1000
(1)
r:TI
ra
~
(1)
>
«
Cur"~ 643557-6
1800
1600
Curve
1
2
3
Type of Operation
Shut Off Coal & Air Flow Simultaneously
Shut Off Coal Only; Fluidizing Air On
Shut Off Coal Only;
Fluidizing Air On With Solid
Recirculation From Neighboring
Ope rat! ng Bed At 16500F .
1400
3
800
600
489
400
o
5
10
Time After Bed Shut-Off, min
15
20
Rg. F-6 -Change of bed temperature after shut-down
-------
100
>-
-
u
(1J
c..
(1J
u
-
::J
-
-
0
~
c::
0
:0=
(1J
L. 50
":1 Q)
I c::
N Q)
I-' <..::>
E
(1J
Q)
-
V)
(1J
-
c::
Q)
L.
Q)
-
-
c
0
o
Curve 643555-B
Curve
1
2
3
Type of Operation
Shut Off Coal & Air Flow Simultaneously
Shut Off Coal Only; Fluidizing Air On
Shut Off Coal Only;
Fluidizing Air On With Solid
Recirculation From Neighboring
Operating Bed At 1650°F
3
5
10
Time After Bed Shut-Off, min
15
20
Fig. F -7 -Residual steam generation after bed sh ut-off
-------
~
I
N
N
u..
°
OJ'
L.
" ~ 1200
L.
OJ
c..
.E
OJ
I-
"0
~ 1000
~
"'
. L.
OJ
>
«
1800
1600
1400
800
600
489
400
o
Curve 1
, " Curve 2
KEY
k = O. 377
k= 0; 200
I
---------
20
Curve 643553-6
".,
Btu/ft-hr-OF
Btu/ft-hr-oF
40
Time After Bed Shut-Off, min
80
60
Fig. F-8 -Change of bed temperature after bed is sl umped
-------
Note that the equations derived are general and can
be applied to other fluidized bed configurations with different tube
arrangements, bed material, and steam conditions for both atmospheric
or pressurized boiler designs.
Case (2)
When the operating fluidized bed is turned off by stopping
the coal feed only, the bed remains fully fluidized. The rate of
bed temperature change can be expressed by the following equation:
dT
hA(T - Ts) + F CPa(T - Ta) = - WBCps dt .
(23)
Integrating Eq. (23) gives
k3 k3 k4t
T = -- + [T - --] exp[- W C ]
k4 0 k4 B Ps
(24)
where
k3 = hATs + FCPaTa
(25)
k4 = hA + FCPa'
(26)
The bed temperature change after shut-down expressed by Eq. (24)
is evaluated for the industrial boiler and shown as Curve 2 in Figure F-6.
The corresponding residual steam generation rate is also shown as
Curve 2 in Figure F-7.
Case (3)
When solid circulation from the neighboring operating bed
at
l650°F
is possible, the bed temperature change after shut-down
can be expressed as in Eq. (5). Both the rate of bed temperature change
and residual steam generation are shown in Figures F-6 and F-7 as Curve 3.
F-23
-------
It is interesting to note that although the average bed
temperature in Case 1 decreases less rapidly compared to. that in
Case 2 (Figure F-6), the reduction in residual steam generation is
actually larger in the first 3 minutes after bed shut-down,as shown
in Figure F-7.
The reason is that in Case 1 the average bed temperature
results from integration as defined in Eq. (18) while the total heat.
transferred from the bed to the water tubes depe~ds on the temperature
gradient at r = R.. For an industrial boiler generating steam at a
. . ~ '.' ..
rate of 250,000 lb/hr, average steam generation in each bed at full
load is 1042 Ib/min.
When cooled down from l650°F to 489°F the total
sensible heat of bed material is capable of generating 4800 lb of
. .
steam.
The cooling rate of bed temperature determines the rate of
residual steam generation after bed shut-off.
At the instance of
defluidization, the temperature of the solid layer' immediately outside
the water tubes drops off rapidly; however, the rate of heat tr~nsfer
levels off after the first few minutes because of slow heat conduction
through solid layers of bed material.
After bed shut-off the steam
generation capacity of the bed is halved in one minute.
The further
reduction in steam generation is more gradual; after 5 minutes, the
bed is still generating 30% of full steam capacity.
Theoretically, at t = ~ the bed temperature will be in
equilibrium with the water tube temperature, i.e., the saturated'water
temper~tu:~, 489°F.
Thus, it is logical to ,keep the saturated water
continuously running in the tubes to maintain the bed temperature
essentially at ~89°F for fast light-off of the bed during load swing.
For an expected long idle period of the bed, the scheme is, of course,
not justifiable because of the pumping cost.
The same scheme (running the saturated water in the tubes).
can also be used to heat up the bed for cold start-up.
The rate of bed
temperature ch~nge was calculated for the industrial boiler case as
shown in Figure F-9.
W,ithout fluid,izing, the bed can be heated up from
80°F to 440°F in 20 minutes.
, F..;24
-------
Curve 642037-8
1.0
o
l-
I
"1
I
N
\.n
VI
~ 0.5
I~
o
o
5
10
t, min
15
20
Fig. F- 9-Change of bed temperature during cold start by passing saturated water through heat transfer tubes in the bed
-------
In Case 2, the steam generation decreases to zero after
14.5 minutes.
From there on, heat transfer reverses the direction
from water tubes at 489°F to the bed for heating the incoming fluidizing
air at 80°F.
The bed temperature finally levels off at 408°F.
For Case 3, the final bed temperature is 10110F with a
residual steam generation 'rate of 32% of full capacity due to solid
recirculation from the neighboring operating bed at l650°F.
To provide a 10%/min load change during turn-down, a bed of
25% total boiler capacity has to be reduced from 100% load, to 0% load
in 2.5 minutes. Clearly the response of the three methods considered
is not fast enough to ,provide the load reduction (Figure F-7). However,
by shutting down the designated bed before it reaches the lowest allowable
operating bed temperature, further reduction of temperature in the
remaining operating beds can reduce the load further and attain the
load response required.
Highley, of the National Coal Board, England, has analyzed the
5
same problem of rates of cooling the slumped and fluidized beds of
ash by steam tubes (equivalent to Case 1 and Case 2 in our discussion
here). Altho~gh his analysis of Case 2 shows results consistent with
those of the present analysis, his result in Case 1 gives about 10 times
longer for the time required to cool the bed temperature to a designated
temperature.
In other words,
his calculation of cooling rates is
under-estimated by a factor of 10 if his data are used in Eqs. (16) and
(19). The discrepancy comes primarily from his assumption that the
tubes are surrounded by an infinite bed, while the present analysis takes
into consideration the geometrical limitations of different tube
arrangements in the bed,arid thus is inherently a better model in
predicting the cooling rate of a slumped bed.
The general analytical
solutions in close form as in Eqs. (16), (17), and (19) are more
accurate and convenient to use.
F-26
-------
REFERENCES
1.
"Development of Coal-Fired Fluidized-Bed Boilers," Interim
Report to Office of Coal Research, U. S. Dept. of Interior, by
Pope, Evans and Robbins (1969).
2.
Smale, A. W., "Investigation of Start-Up Techniques for Fluidized
Combustion Using a One Foot Fluidized Bed Combustor," Fluidized
Combustion Section Rept. No. 41, Coal Research Establishment,
National Coal Board, England (1969).
3.
"Study of Characterization and Control of Air Pollutants from a
Fluidized-Bed Combustion Unit," Monthly Progress Rept. No.9
(June 1970), prepared under Contract No. CPA 70-10 for NAPCA by
Pope, Evans and Robbins.
4.
Ehrlich, S., Robison, E. B., Gordon, J. S., and Bishop, J. W.,
"The Fluid Bed Boiler and Its Applicability to Pollution Control,"
Paper No.8, Presented in AIChE 69th National Meeting,
Cincinnati, Ohio (May 1971).
5.
Highley, J., "Rates of Cooling of Slumped and Fluidized Beds of
Ash by Stearn Tubes," Fluidized Combustion Section Rept. No. 13,
Coal Research Establishment, National Coal Board, England (1968).
F-27
-------
APPENDIX G
OPTIMIZATION OF HEAT TRAP SYSTEM COST
ABSTRACT
Two methods, one graphic and one analytical, were presented
for determining the optimum air preheat temperature and for optimizing
the cost of the heat trap system, including economizer and air preheater.
The calculation is sensitive to the relative unit cost of
economizer and air preheater.
For a 300 MW atmospheric design with
operating conditions similar to those outlined in the 14th Monthly
Progress Report, the optimum air preheat temperature (which minimizes
the total cost of the heat trap system) was found to be 560°F.
G-l
-------
OPTIMIZATION OF HEAT TRAP SYSTEM
For considerations of economy, means of recovering part of
the flue gas energy before the stack are necessary in a steam generating
uni t.
To accomplish this, either the economizer or the air preheater
or both are usually used.
When both the economizer and the air preheater
are employed, there is an optimum distribution of heat load between
economizer and air preheater which minimizes the total cost of the heat
recovery apparatuses.
In the case of a fluidized bed boiler, additional
heat transfer surface has to be provided in the bed to transfer the
sensible heat carried by the preheated air to maintain a constant bed
temperature.
To be rigorous, the cost of this additional surface
required in the bed has to be included in the determination of the
optimum air preheat temperature.
Consider the heat recovery system as shown in Figure G-l,
where:
Tb
T.
1
= flue gas inlet temperature to economizer
= flue gas outlet temperature from economizer
or inlet temperature to air preheater
T
o
= flue gas outlet temperature from air preheater
(stack gas temperature)
= air inlet and outlet temperature to air
T ., T
a1 ao
T ., T
W1 wo
Wf'W ,W
a w
preheater
= water inlet and outlet temperature to economizer
= mass flow rate of flue gas, air, and water
respectively
---
C C C = average heat capacity over the temperature range
pf' pa' pw
considered for flue gas, air, and water
respectively.
G-3
-------
-
Tb'. Wt' Cpt
CJ
I
......
- .
T W' C
wo' W' pw
T
D~/g. 2945A38
I
- - -
Economizer Air
Preheater
- - -
-
T "W C .
WI' w' pw'
-
Tao' ~a,Cpa
" .
Fig. G-I-Flue gas heat recovery system
-
To' Wf; Cpt'
. -
T ", W , C
al a pa
-------
are fixed, and the air preheat temperature, T ,
ao
optimization. The unknown temperatures T. and T can be expressed in
~ wo
terms o~ a single variable, T , by following energy balances.
ao
In the actual design, the temperatures Tb' T , T ., and T .
o a~ w~
is to be found by
Heat balance at air preheater:
Wf . Cpf . (Ti - To) = Wa . Cpa' (Tao - Tai)
(1)
or
W
+2
Wf
C
.~
Cpf
(T - T )
ao ai
(2)
T. = T
~ 0
Heat balance at economizer:
Wf . Cpf . (Tb - Ti) = Ww . Cpw
. (T
wo
- T )
wi
(3 )
or
Wf C W C
T = T +- ' --rl (T b - To) a .~ (T - T )
wo wi W - W ao ai
w C w C
pw pw
(4)
Heat load at air preheater:
Wf . Cpf . (Ti - To) = Wa . Cpa' (Tao - Tai)
(1)
Heat load at economizer:
Wf . Cpf . (Tb - Ti) = Wf . Cpf
(Tb - TO) - Wa . C . (T - T .) (5)
pa ao a~
G-5
-------
LMTD (logarithmic mean temperature difference) in air preheater:
(T. - T )-
1. ao'.
(T.
Q.n . 1.
(T
o
(T - T .)
o a1.
T )
. ao
- T )
ai
LMTD in economizer:
(T -
b
T ) - (T. - T .)
wo 1. W1.
(Tb - T )
wo
Q.n (T. - T .)
1. W1.
= ( 1
Wf'Cpf
1_)
W .C
w pw
(T
. ao
=
,W.' C
- T .). (~ . ~
a1. Wf' C''
pf
(T. - T )
1. ao
Q.n(T ':"T .)
o a1.
- 1)
[Wf ..Cpf (Tb - T ) - W ~" (T' - T .)]
o a pa ao a1.
(Tb -. T ).
. wo
in (T. :- T .)
1. W1.
(6)
(7)
The total cost o~tbe hea~'reco,very system, after considerable
simplification, can be expressed as:
(T. - T )
1. ao
(T - T .)
C = C . in 0 a1.
T A
h ( 1
A.
Wf.Cpf
1
+ C .
E
)
W .C
a pa
+ C .
B
W
a
. C . (T - T .)
pa ao a1.
hB . (TB - TS)
(Tb" - T )
wo
nn (T. - T .)
1<. 1. W1.
h . ( 1
E
Wf Cpf
1 -)
W . C
w pw
where
CA,CE,CB = the unit cost of heat transfer surface in air preheater,
economizer, and bed, respectively.
G-6
(8)
-------
hA,hE,hB = heat transfer coefficient in air preheater, economizer, and
bed respectively
TB
TS
= bed temperature
= saturated water temperature.
The optimum air preheat temperature, T ,can be found by
ao
setting
dCT
~=o.
ao
(9)
Since the heat transfer coefficient and LMTD in the bed are
much higher than in the air preheater) while the unit cost of heat
transfer surface is slightly higher, the cost of additional
heat transfer surface required in the bed for absorbing the sensible
heat of the preheated air is estimated to be about 10% of the cost of the
air preheater.
Hence, for mathematical convenience the third term in
Equation (8) was neglected and its cost was combined with the cost of the
air preheater by increasing the unit cost of the air preheater 10%.
Substituting Equations (2) and (4) into Equation (8) and carrying out
the mathematical manipulation for Equation (9), we found that the optimum air
preheat temperature can be parametrically expressed in the following
equation:
G-7
-------
, ,
(T - T .) =
ao a1.
(Tb - T .) W C ,h ACE
W1. [~,. ~ (- -
2 Wa C hECA
pa
1)
Wf C f
+ - ---E.!.
W-
, a C
pa
hACE
(1-- .
hECA
W C
W 'T\W
-~)
W -
a C
pa
Wf
- 2-
W
a
C
. -.2f
C
pa
(T - T .)
o W1.
(Tb - T .)
W1.
]
(Tb ~ T.) W ,C hACE Wf Cpf hACE W C 2
W1. { [~ '~ (1 W pw 1) ]
+ --) + (- -
2 - , hECA - hECA
,- W C W C W C
a pa a pa a pa
h A CE W f
+ 4 he' W'
E A a
C W C",,,
~~~
C WaC
, pa, pa
: (T . - T .) , Wf' C f
[ W1. a 1. ---E.!.
(T - T .) + W '-
b "W1. a ,C
. -, pa
, (T - T .) 1/2
o W1.]}
(TbTwi)
(10)
Using:
CE = $3.S0/ft2
CA,= $l.S/ft2;
2
hE = 20 Btu/ft -hr-oF ;
, 2
h = 10 Btu/ft -hr-oF'
A ' ,
and the 600 MW atmospheric power plant, design described in the Seventh
Monthly Progress Report, we found the optimum air preheat temperature to
be 433°F. With other design and operating conditions, the optimum air
preheat temperature can be readily determined by Equation (10).
G-8
-------
C>
I
'"
-
Wf Cpf
Q)
~ W C
~ W pw
Q)
a.
E
Q)
I-
Tb
(Tb-TO)
T .
WI
To
T.
al
00
Q)
:c
rc:I
-
rc:I
....
Q)
a.
o
-
o
2:
c
o
Sf
0::
(Tb' Wf Cp, (Tb -To))
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I (TWi' Wf Cp, (Tb-To))
I
----~
I
I
I
I
- - - -1 Total Heat Load
Tb
T
wo
T.
I
Air
Preheater
Curve 642086-6
Q)
.0
rc:I
-
rc:I
....
Q)
a.
o
-
o
2:
C
.~
Sf
0::
-
W, Cp' (Tb -TO)
Fig. G-2 -Temperature difference & heat load distribution for air preheater & economizer
T
o
Economizer
T .
al
T. T
WI ao
--I------------------~
-------
A graphic method can be used instead of the analytical method
described above to find the optimum air preheat. tempeniture.
The total
cost of the economizer, air preheater, and the additional heat trans-
fer surface in the bed can be plotted against the air preheat tempera-
ture, T ; the air preheat temperature which gives the lowest total
.;1.0
cost is the optimum one.
To facilitate the calculation, the tempera-
ture change of T., T , and T were plotted at different air preheater
1. ao wo'
heat loads in Figure G-Z. The total heat transfer surface required
. .
for the economizer and air preheater can. be readily calculated from
the temperature differences shown where
tlTlA = T
i
- T .
ao'
. tlTZA = To
T "
a1.
tiTlE = Tb - Two;
tlTZE = T. - T .'
1. W1.
Physically
in Figure G-Z)
in Figure G-Z.
. .
impossible situations where T ,
. W1.
and T > T; (to the right of
ao 1.
The graph can easilY,be constructed for an actual
> T, (to the left of point B
1. .'
point A) are also shown
case,
for example the 600 MW atmosph~ric.design outlined in the Seventh
Monthly Progress Report, as shoWn in Figure G-3. The graphic method
gives an optimum air preheat temperature of -450°F (Figure G-4) compared
to 433°F from the analyt~cal method.
The resulting cost of the air
preheater,is comparabl~ to the cost cited for utility boilers in the
Tenth Monthly Progress Report.
For the 300 MW atmospheric design presented in the 14th
Monthly Progress Report, the optimum air preheat temperature was found
to be 560°F, by ,the analytical method (Equation (10».
G-10
-------
800
u...
0
(U-
'-
::J
..... 600
(Q
'" '-
I (U
~ c..
~ E
(U
I-
400
1250
1200
Tb
Curve 594821-8
--------------------
1000
Air
Preheater
Tb
Two
Economizer
T . T
WI ao
200
T Minimum
wo T
wo
-------
Curve 642087-B
1.4
0.2
. .
1.2
-0
I
S 1.0
X Total Cost
~
Q)
u
ro
-
~ 0.8
V"I
~
Q)
c;) -
VI
I c::
.....
N ro Economizer
~ 0.6
..... Cost
ro
Q)
:::r::
-
0
.....
VI
80.4
Cost of Ai r Preheater &
Additional Heat Transfer
Surface in the Bed
o
100
200
300
400 500 000
Air Preheat Temperature, OF
700
800
900
1000
Fig. G-4-0etermination of Optimum air preheat temperature
-------
APPENDIX H
PRESSURIZED BOILER DESIGN REPORT
Prepared by Foster Wheeler Corporation,
John Blizard Research Center
Authors:
R.W. Bryers
J.D. Shenker
R.J. Zoschak
H-l
-------
ABSTRACT
A conceptual design was developed for a pressurized fluidized
bed steam generator to be used in a 318 MW combined cycle utility
power plant.
The investigation includes a study of design and cost
for the steam generator, coal handling and feeding equipment, and
particulate removal equipment.
The cost estimates are also extra-
polated to a 636 MW capacity.
H-3
-------
SUMMARY
The preferred concept for the pressurized steam generator is
a once-through steam circuit with a four module boiler.
The pres-
sure vessels are vertically oriented with four stacked fluidized
beds and one carbon burn-up cell in each module.
The heat trans-
fer surface is arranged such that each of the fluidized beds
mainly provides the steam duty for only one steam generating
function (i.e., superheating, reheating, or pre-evaporation).
This arrangement simplifies operation at reduced loads and during
start-up.
Wherever possible the benefits to fluidized bed combustion
that result from a pressurized system are exploited.
The ability
of a pressurized system to operate economically with relatively
large pressure drops was taken advantage of in the design of the
fluidized beds.
The relatively deep beds that are possible in
the pressurized system greatly simplify the coal feeding system
and allow a large amount of the heat transfer surface to be 10-
cated in the fluidized beds where the heat transfer coefficient
is high.
Load reductions are accomplished by lowering the temperature
of the fluidized beds.
Lowering the bed depth was also considered,
but this type of system did not result in operational benefits and
required more complex equipment.
Fuel/air ratios at the various
loads are determined by gas turbine inlet requirements and this
results in high excess air values at reduced loads.
The excess
air values, however, do have the beneficial effect of maintaining
H-5
-------
the design efficiency of the particulate removal equipment over a
wide range of operation.
The mechanical design of the steam generator provides for
maximum use of existing shop technology.
The steam pressure
parts are all of standard design, and the arrangement of the
pressure parts, although different from conventional units, does
not present any major difficulties.
The pressure vessel is used
as a support system for the steam pressure parts besides serving
as a vessel to contain the gas pressure.
The design of the com-
bustion air and flue gas circuits is such that the pressure
vessels is cooled by the combustion air and does not require
internal insulation.
/
H-6
-------
ABSTRACT
SUMMARY
TABLE OF CONTENTS
PAGE
H-3
H-5
TABLE OF CONTENTS
1.
H-7
INTRODUCTION
H-15
2.
SPECIFICATIONS
H-16
2.2
3.
2.1
Fuel Specifications
H-16
Fluidized Bed Boiler Specifications
H-16
2.3
System Specifications
H-16
BOILER DESIGN CONCEPTS
H-28
4.
3.1
Selection of System Parameters
H-28
3.2
Selection of Steam Generator Design Concept
H-29
DETAILED BOILER DESIGN
H-33
5.
6.
4.1 Circulation through the Boiler
H-33
4.2
Energy and Mass Balances
H-37
4.3 Tube Details
H-40
4.4
Coal Feeding
H-4l
4.5
Sorbent Feeding
H-43
4.6 Particulate Removal
H-44
4.7
Carbon Burn-Up Cell
H-46
OPERATION
H-47
5.1
General Problems
H-47
5.2
Start-Up
H-5l
5.3
Load Control
H-57
5.4
Shut-Down
H-59
5.5
Performance
H-6l
STEAM GENERATOR AND ACCESSORY EQUIPMENT COST
H-63
6.1 Capital Costs
H-63
H-7
-------
6.2
6.3
7.
TABLE OF CONTENTS (cont'd)
PAGE
Maintenance and Operating Costs
»-64
Extrapolation of Capital Costs to a 600 MW Plant
H-66
DEVELOPMENT REQUIREMENTS
H-73
APPENDIX
Al.
CANDIDATE CONCEPTS
H-77
Al.l
Al.2
A2.
Determination of the Steam Cycle and Gas
Pressure
H-77
Determination of Optimum Design
H-87
Al. 2 . 1
H-87
Bed Cross-Sectional Shapes
Al. 2 . 2
H-88
Bed Heights
Al.2.3
H-90
Arrangement of Tubes in the Bed
Al.2.4
Number of Vessels and the Arrangement
of Beds in the Vessel
H-93
H-97
ENERGY AND MASS BALANCES
H-10S
A3.
A3.l
TUBE DESIGN INFORMATION
A3.2
A4.
Sizing and Arrangement
H-10S
Mechanical Design
H-lll
MODULE DESIGN
H-117
A4.l
A4.2
A4.3
A4.4
A4.S
A4.6
A4.7
Pressure Vessel
H-1l7
Air Piping
H-1l7
Plenum Chamber and Distributor Plate Design
H-119
Coal Feeding
H-120
Sorbent Feeding and Circulation
H-123
Steam Piping
H-124
Particulate Removal
H-124
H-8
-------
AS.
TABLE OF CONTENTS (cont'd)
PAGE
H-l29
STEAM GENERATOR SUB-SYSTEM DESIGN
H-l29
AS.I
A5.2
AS.3
AS.4
AS.S
AS.6
Steam Generator Module Arrangement
H-133
AS.2.1
Coal Handling System and Limestone Make-Up
H-l33
AS.2.2
AS.2.3
AS.2.4
AS.2.5
Assumptions
Scope
H-135
Equipment
H-142
Cost
H-143
Sorbent
Make~Up, Storage and Feed
H-l46
AS.3.l
Coal Feeding
H-l5l
AS.3.2
AS.3.3
A5.3.4
AS.3.S
Assumptions
H-lSl
Petrocarb System
H-lSl
Literature Survey
H-161
Fire and Explosion in Pneumatic Trans-
port of Coal
H-195
Conclusions
H-199
H-200
Sorbent Circulation System
Gas Piping
H-203
Second Stage Particulate Removal
H-200
H-9
-------
FIGURE
2.1
2.2
2.3
2.4
3.1
3.2
3.3
3.4
4.1
4.2
5.1
5.2
5.3
5.4
6.1
6.2
6.3
Al-l
Al-2
Al-3
Al-4
Al-5
LIST OF FIGURES
PAGE
Coal Size Distribution
H-18
Superficial Velocity
H-19
Schematic Diagram Plant Power Cycle
H-22
Size Distribution of Particles Elutriated from the
Fluidized Beds
H-27
Details of Steam Generator
H-32
Details of Steam Generator
H-32
Details of Steam Generator
H-32
Details of Steam Generator
H-32
Fluidized Bed Steam Generator Flow Circuitry
H-34
Schematic Diagram of Particulate Removal System
H-38
Parallel Pass with Damper Control
H-50
Boiler Start-Up System
H-52
Alternate Ignitor - Scheme "A"
H-54
Alternate Ignitor - Scheme "B"
H-55
Steam Generator Cost versus Plant Size
H-68
Steam Generator Dollars per Kilowatt versus Plant Size
H-69
Cost Increments for Field Erected Four-Module Plants
H-72
Gas Flow versus Steam Flow for Cost Study
H-80
Vessel Diameter versus Gas Flow
H-8l
Effect of. Number of Vessels Selected on Vessel Size
H-82
Schematic Diagram of Vessel Used in Cost Study
. H-84
Vessel Diameter versus Cost
H-85
H-IO
-------
FIGURE
AI-6
Al-7
AI-8
AI-9
A2-1
A2-2
A2-3
A2-4
A3-1
A3-2
A3-3
A3-4
A3-S
A4""1
A4-2
A4-3
A4-4
",t..-5
AS-I
A5-2
LIST OF FIGURES
PAGE
Shell Cost versus Gas Flow
H-86
Annular Bed - Vertical Tube Fluidized Bed Steam
Generator
H-92
Layout of Vertical Tubes in an Annular Bed
H-92
Horizontal Conceptual Design for a Fluidized Bed
Steam Generator
Facing Page
H-94
Mass Balance, Design Load
H-lOO
Mass Balance, 70% Plant Load
H-IOI
Energy Balance, Design Load
H-I02
Energy Balance, 70% Plant Load
H-I03
Tube Configurations in the Fluidized Beds -
Scheme "A"
H-I06
Tube Configurations in the Fluidized Beds -
Scheme "B"
H-I07
Tube Configurations in the Fluidized Beds -
Schemes "B & C"
H-I08
Tube Element Support Assembly
H-1l2
Conventional Tube Bank
H-1l4
Cross-Section of Air Distributor Plate with Bubble
Cap Air Distributors
H-121
Air Distributor Plate Support
H-122
Fractional Efficiency Curve for First Stage Cyclones
H-126
First Stage Cyclone System
Facing Page
H-126
Plot Plan' for Steam Generators and Cyclones
300 MW Combined Cycle Plant Site. Plot Plan
H-130
600 MW Combined Cycle Plot Plan
H-132
H-Il
-------
LIST OF FIGURES
FIGURE
AS-3
300 MW Pressurized Fluidized Bed Steam Generator
Conveyor System
AS-4
300 MW Pressurized Fluidized Bed Steam Generator
Conveyor System
AS-S
Schematic Diagram Coal Handling Plant
AS-6
McNally Flowdryer
AS-7
Typical Installation Diagram of a McNally Flowdryer
AS-8
Limestone Feed System
AS-9 .Coal Handling and Injection System
AS-IO Petrocarb Pressurized Coal Feeding System
AS-II Typical Lock Hopper Arrangement
AS-12 Variation of Coal/Air Ratio with Compression Ratios
at Various Bulk Densities
AS-13 Power Requirements for Different Compression Ratios
and Final Bulk Densities
AS-14 Pneumatic Conveyance of Coal to Feeders
AS-IS Typical Lock Hopper Feed System Used to Feed Coal
Under Pressure to Gas Turbines
AS-16 Reduction in Operating Pressure by Placing Hoppers
in Series
AS-17 Reduction in Power Using Hoppers in Series
AS-18 Schematic Diagram of Dr. Donath's Principle of the
Continuo~s Positive Displacement Pressurizer Emplo~ed
at BCR
AS-l9 Rotary Pumps Proposed by Yellott and Incandescent Heat
Company
AS-20 Multi-Ram Rotary Pump
AS-21 Koppers Gear Type Pressurized Coal Pump
H-12
PAGE
H-136
H-136
H-13 7
H-140
H-l4l
Facing Page H-l46
H-153
H-154
H-163
H-166
H-l66
H-l68
H-169
H-170
H-170
H-172
H-175
H-175
H-177
-------
LIST OF FIGURES
FIGURE
AS-22 Koppers Pressurized Coal Feed System
AS-23 Fuller-Kinyon Screw Feed Pump
AS-24 Diagrammatic Arrangement of a Ram Pump and Its Cycle
AS-2S Effect of Compression Ratio on Final Bulk Density
and Indication of Briquetting Limit
AS-26 Power Requirements - Lock Hopper with Moving Wall
and Positive Displacement Ram Pump
AS-27 H. Koppers Solid Extruder
AS-28 Typical Slurry Feed Cycle
AS-29 Power Requirements for Pressurizing Coal Slurries with
Various Percent Water
AS-30 Peristaltic or Rubber Pump
AS-31 Schematic Arrangement for Local Fluidization
AS-32 Sorbent Circulation System
AS-33 High Temperature Gas Pipe
AS-34 Fractional Efficiency Curve for Second Stage Separators
AS-3S Second Stage Separator
A5~36 Operation of Second Stage Separator
H-13
PAGE
H-177
H-182
H-184
H-186
H-187
H-188
H-191
H-192
H-192
H-196
H-201
H-204
H-207
H-208
H-209
-------
LIST OF TABLES
TABLE
PAGE
2.1
Coal Specifications
H-17
2.2
Bed Parameters at Design Conditions
H-20
2.3
Sorbent Specifications
H-2l.
2.4
Plant Capacity - 300 MWCombined Cycle
H-24
2.5
Steam Cycle Conditions
H-25
2.6
Gas Cycle Conditions
H-26
5.1
Steam Generator Performance
H-62
6.1 Capital Cos ts for 300 MW Combined Cycle Plant
6.2 Capital Costs for 600 MW Combined Cycle Plant
Ah.l Typical Subcritical and Supercritical Steam Cycles
H-65
H-71
H-78
A2-l Fluidized Bed Par~eters - Design Load
H-98
. A2-2 Fluidized Bed Parameters
70% Plant Lcad
H-99
A2-3 Steam Generator Losses Based on 275°F Exit Gas
Temperature
H-l04
A)-I Tube and Header Specifications
H-110
AS-I Operating Cost of McNally Flowdryer
H-193
AS-2 Comparison of C~pital Cost of Coal Handling Equipment
H-145
-
AS-3 S02 Sorbent Analysis Used for Preliminary Fluidized
Bea Boiler Analyses, Weight/Percent as Received
H-146
A5-4 Summary of Estimated Fixed Investment Requirements
H-150
A5-5 Power Requirements for Feeding Coal to 1000 Psi
Gasifier
H-173
.'
H-14
-------
-~
1.0
INTRODUCTION
As subcontractor to Westinghouse on Public Health Service
Contract CPA 70-9 to evaluate the fluidized bed combusti~n
process, it was Foster Wheeler's responsibility to develop concep-
tual designs of two utility boilers at the 300 and 600 MW level
according to specifications provided by Westinghouse.
At the
onset of the program it was decided that development of a pres-
surized boiler as part of a combined cycle and an atmospheric
boiler at the 300 MW level would probably be the most worthwhile
approach.
As work developed and a better feel for the boiler
market was observed, it was found necessary to extrapolate the
data to 600 MW to provide meaningful results.
,
This section of the report which appears in two volumes dis-
cusses the pressurized boiler design and cost estimated at the
318 MW level.
The data is extrapolated to 636 MW to make mean-
ingful comparisons with conventional equipment.
The nominal plant
sizes of 300 MW and 600 MW are used in the text.
The report in-
cludes a presentation of specifications provided by Westinghouse
resulting from a state-of-the-art review and discussion of boiler
design, performance, operation, cost and trade-offs in design
where they apply.
Auxiliary equipment such as coal handling, coal
feeding, and particulate removal were developed and cost estimated
through the courtesy and cooperational efforts of numerous equip-
ment manufacturers.
The results are also presented.
Concepts investigated and discarded are briefly reviewed and
recommendations for future consideration are made.
H-15
-------
2.
SPECIFICATIONS
The plant specifications were supplied by the Westinghouse
Electric Corporation.
2.1
Fuel Specifications
The fuel selected for the fluidized bed steam generator is
Ohio Pittsburg No.8 Seam Coal having the specifications listed
in Table 2.1.' . This coal will be received at the plant by unit
train.' The size of the coal as received is 1-1/2" x O.
This siz-
ing is specified due to coal flow dryer requirements, but no cost
penalty is paid for this sizing.
The size distributions of the
received coal and the coal fed to the steam generators are shown
in Figure 2.1.
2.2
Fluidized Bed Boiler Specifications
2.2.lBed Characteristics,
The range of allowable superficial
velocities can be seen in Figure 2.2.
The allowable superficial
velocities are based on the average particle size in the beds.
Table 2.2 lists the bed temperature, gas side heat transfer co-
efficients, and the combustion efficiencies for the primary beds
and the carbon burn-up cell.
2.2.2
Sorbent Specifications
The sorbent is BCR 1337
dolomite.
The chemical composition and flow rates for the dolomite
are listed in Table 2.3.
The recycled sorbent ranges in size from
500 to 5000 microns with an average size of 2500 microns.
The
make-up sorbent is -1/4". ,
2.3
System Specifications
2.3.1
Power Cycle
A schematic diagram of the combined cycle
plant is shown in Figure 2.3.
Also indicated on this drawing are
the parts of the cycle that Foster Wheeler Corporation investigated.
H-16
-------
TABLE 2.1
OHIO PITTSBURGH NO.8 SEMi COAL
(Source of data:
USB~lt Pit tsburgh t Fa.)
SA:IPLE:
Run of i1ine -
.-
PROXI~IATE ANALYSIS (wt ;;):
J.3 *
39.5
48.i
8.5
~!oisture
Yolatile ~tatter
Fixed r:a.rbon
Ash
100.0
ULTli-tHE A:.1ALYSIS (Ivt %):
(includes moisture) .
71. 2
5.4
9.3
1.3
4.3
8.5
100.0
C
H
°
N
S
Ash
('\.60% organic
GROSS HEATI~G VALUE:
13000 Btu/lb
~ET HEATING VALUE:
12500 F;tu/lb
. ASH ANALYSIS (IVt %):
Si02 45.3
A1203 21. 2
Fe203 27.3
Ti02 1.0.
,P20S 0.11
CaO 1.9
MgO 0.6
Na20 0.2
K20 1.8
S03 0.7
100.1
FUSIBILITY OF ASH:
Initial Deformation Temperature
Softening Temperature
Fluid Temperature
PARTICLE DENSITY:
Coal
Ash
"'1. 4 gm/ cc
"'2.8 gm/cc
GRDrDABILITY (Hardgrove):
50-60
FREE SIJELLI:\G I~DEX:
5-5.5
COST:
$5.50-~.75/ton for "'4% S coal, 13,000 Btu/lb
($6.00/ton cost projected by end of 1970)
*Possible Pick-up in Storage and Handling 6.7%
Givin~' Maximum Total Moisture as Received of 10%
H-17
40% pyritic)
2080°F
2230°F
2420°F
-------
1
1 -
5 -
15
25 r=---
35~
45 F=
55 r--
f-< 1--
~ 65~-
~ 75
>-
I:Q
::x:
I
I-'
():)
t-e
. 85 ,.-
ILl \
~ I
~ ,-
~ 93,-
;-
96 .
98
I
i-'
99 II
r-rIJ -:--;--!r- -- --.--
. i
I I
/
GE ./
/
.... '
(FEED TO BOILER)
KOPPERS REVERSIBLE
HAMMERMILL
CRUSHER
/ "
/
,./
~~Y' //
""~"""-;:/ //
cJ)~7 ~
vC, . -
~//
~~.
~ / RAW COAL
PITTSBURGH
SEAM NO.8
I
~
~
-1
I
-i
I
"1
I
-
v.
!
i
.--
/
i
:
I
-4
I
I
;
--!
,,,
100
1---LL_LLJ____I___-LJ.__LJ.LLl..____.- i
1000 10,000 100,000
PARTICLE SIZE, MICRONS
16 1/8" DIA. 1/2" DIA. 2" DIA.
L__--_._---'.____l___~_____'N.1 .._.- .'. ___1__--_._... ._-----
1/4" DIA 1" DIA.
PARTICLE SIZE, ROUND HOLE SCREENS
LJiliJ
100 60
I
28
I
PARTICLE SIZE, U.S. XESH
"0:1
1-1
~
c:
::0
t%1
N
.
....
1:1
1-1
CJ)
'"'.!
::0
1-1
tII:
c:
>-3
1-1
o
Z
o
...,
n
o
>
t'""
CJ)
.....
N
t%1
>
CJ)
::0
tr.
(')
tr.
.....
<
t:]
o
>
~
'-'
,
-
>
-.:
>-3
.-.
::c
(')
;:0
c:
CJ)
=
......
z
C)
-------
::r::
I
f-'
\0
10,000
........
(/)
r::
o
...
()
.....
e
1,000
c:t:
t>J
Eo<
t>J
~
1-1
o
t>J
....:I
U
1-1
Eo<
~
j:Io
Temperature
Pressure
Solid Density
Gas Density
Gas Viscosity
100
10
0.001
BASIS
17 00 0 F
10 atm
3
125.1b/ft (limestone)
0.189 1b/ft3
0.045 cp
RANGE FOR 6
2500~ PARTICLES
-
10
16
28
en
tLI
N
.....
en
60 ....
tI)
t>J
100 :E
200
0.01
10.0
1.0
ACTUAL GAS VELOCITY (ft/see)
FIGURE 2.2
100
-------
TABLE 2. 2
BED PARAMETERS AT DESIGN CONDITIONS
PRIMARY BEDS
Temperature
Gas Side Heat Transfer
Coefficient in Bed
Gas Side Heat .Transfer
Coefficient in Transition Zone
Elutriated Carbon
CO -
Excess Air
Superficial Velocity
CARBON BURN-UP CELL
Temperature
Gas Side Heat Transfer
Coefficient in Bed
Gas Side Heat Transfer
Coefficient in Transition Zone
Combustion Efficiency
Excess'Air
..,.
Superficial Velocity
H-20
l750°F
2
50 Btu/hr-ft _oF
2
40 Btu/hr-ft _oF
6%
<0.5%, in flue gas
10%
5.6- 9.1 ft/sec
20000F
, 2
50 Btu/hr-ft _oF
2
40 Btu/hr-ft _oF
90%
79%
5.7 ft/sec
-------
TABLE 2.3
ABSORBENT SPECIFICATIONS
BCR 1337 Dolomite
Component % wt As Received
Si02 0.78
A1203 0.15
Fe203 0.25
MgO 45.0
CaO 53.
Ti02 0.02
SrO <0.03
Na20 <0.02
'; K20 <0.1
Mn02 <0.03
'. ,
"
.... . ..' ,
.' "
H-21
-------
Sill.- ~.u ~
R IC 1-\
4"5
Au!...
:s 0 li-b E. u"'(
R~co t.foo\lIl.AToli,
tU~\.
REVISION
A.\fI...
Co""PIt.~S:'OR..
I
i
! J
'. C
'"
, ~
I tJ
\ilL<::. ~N e.lI. ~ i to D I'
:SO~t) ~... 'T '
5Pt.~ -r
:;)O~t:>L""~
COIol\PR.t..:'$0 ~
'TII.. e:.100I c:
--- ------- - ------------
~f'-PS\~~ ~~t..t.\..-t.a:--_.-
1----
.
-l
I
~1l1~"'II..'!
P ",,-~ \('\\\'"..t!
1lE.1'I<> v -. \.
rl..\'IIOI'Z.i.O
~toD
CO"""~u:'TO ....
01L:II~~"u R.,1't.1. It.
<1
2
o
J :
I.
I
I
I
I
t
---------- ~
c . c.
r~ -. --~ --;
s : g
~ 0
--1
I- o.
... 3 ... -
2
.J ~
IJ J
J. ()
0 of)
1/1
.0.
tal .:1
t- .
III
01\ ~ J
4. .( (
1 1 0
v
o...o~..,'"
...e.c.o,",O" ~"(
P"ILI".e:\H"1f
A..~"'QV"I.
j
POY! E.. i..
i u ~O I~t.
--- --I
UPPE.IL
5, "c. "-
Go .0.5
c. 0 0 '-t.1I.
l..O\Nt.1I.
S,"C;'"
Go ~5
COOl.. t. II.
~
WA.5'T E. .50'-ID~
F I~ "'I.
P"'...pc II loA., t
R- to ",,"0 V " L
(,pp, 10"" ,,\,,)
F\C4.2.3
ORDER NO.O-5
,
.1
SC~E~~\\C OI~G~~h\
P l ~- ~ '1-- ? /) '/'oJ ~ a.. < "( C \.. !.
IJJ
t
DRAWN BY:
CHECKED BY:
APPROVED BY:
TN'. 0-....... .. TN. PWO".TY O. TN.
FOSTER WHEELER CORPORATION
110 SO. ORANGE AVE.. UVINGSTON. N.J.
AND IS LaNT WITHOUT CONSIDE"ATION OTHE" THAN THE.
80"ROWE"'S AGREEMENT THAT IT SHAIoL NOT 8E "E.
""ODUCED. CO"IE8. LOtT. 0" DI."OSED 0.. DI"ECTLT 0"
IJ!t.DIAeCTCY NO" USED ..0" ANT "U""OSE OTHE" THAN
THAT "0" WHICH IT IS s"ItCI...CALLY "U"NISHED. THE.
"""A"ATUS SHOWN IN THIt D"AWINO'8 cova"ED 8,. .
"ATENTS.
=1'-0"
t2.D -7i 3-1 \SA
-------
This report deals primarily with the equipment in these areas.
2.3.2
Plant Capacity
The plant capacity is tabulated as
a function of gas turbine inlet temperature and steam cycle load
fraction in Table 2.4.
2.3.3
Cycle Conditions
The steam cycle conditions are
tabulated in Table 2.5 as a function of steam cycle load fraction.
The only parameter in this table that 1s also a function of gas
turbine inlet temperature is the feedwater inlet temperature.
The
values of this parameter listed in the table correspond to the ex-
pected gas turbine inlet temperatures at the specified steam load
fractions.
The gas cycle conditions are listed in Table 2.6 as a function
of steam cycle load fraction and gas turbine inlet temperature.
2.3.4
Particulate Removal Requirements
The first cyclone
stage is required to collect 90% by weight of the particulate in
the gas from the primary beds.
The expected size distribution can
be seen in Figure 2.4.
The second stage cyclone system is required
to collect 97% by weight of the particulate of the combined gas
stream.
This gas stream consists of the gas cleaned by the first
cyclone stage and the gas from the carbon burn-up cell.
It is
also required of the second cyclone stage that all particles great-
er than five microns be collected.
2.3.5
Sulfur Removal Requirements
It is specified that the
flue gas contain less than 5% of the sulfur in the coal.
2.3.6
Turn Down Requirements
It is required that the com-
bined cycle plant have a turn down ratio of four-to-one.
It is
also required that the response rate to load changes be at least
5% of load per minute.
H-23
-------
TABLE 2.4
PLANT CAPACITY 1
300 MW COMBINED CYCLE
Steam Cycle Load Fraction (Ref.) 1.02 1.00 0.8 0.6 0.4
Turbine Inlet Temp. - of 1600
Plant Power - MW 317.7 313.7 271. 7 223.1 162.8
Steam Power -MW 269.2 265.3 223.5 .175.1 114.7
Plant Heat Rate - Btu/kw-hr 8974 8967 8869 .8846 8952
Fuel-Air Ratio 0.0919 0.0907 . 0.0777 0.0636 0.0470
Turbine Inlet Temp. - of 1500
Plant Power - MW 309.8 305.8 263.7 215.3 155.8
Steam Power - MW 268.8 264.8 222.9 174.4 114.7
Plant Heat Rate - Btu/kw-hr 9091 9080 8999 8998 9165
Fuel-Air Ratio 0.0908 0.0895 0.0765 0.0625 0 . 0460
Turbine Inlet Temp. - of 1400
Plant Power - MW 301.8 297.8 255.8 207.5 148.7
Steam Power -.MW 268.1 264.1 222.1 173.6 114.7
Plant Heat Rate - Btu/kw-hr 9211 9202 9134 9161 9392
Fuel-Air Ratio 0.0896 0.0884 0.0753 0.0613 0.0451
1 "
Reference conditions for steam cycle are from Hammond Station, Unit #4,
Georgia Power and Light Company.
H-24
-------
TABLE 2.5
STEAM CYCLE CONDITIONS 1
Steam Cycle Load Fraction (Ref.) 1.02 1.00 0.8 0.6 0.4
Inlet Feedwater Temp. - of 578 576 554 540 536
Main Steam Outlet Temp. - of 1,000 1,000 1,000 1,000 1,000
Main Steam Outlet Press. - psig 2,500 2,486 2,454 2,434 2,410
Main Steam Flow - M Ih/hr 1,727 1,693 1,354 1,016 677
Reheat Inlet Temp. - of 650 632 592 560 530
Reheat Inlet Press. - psig 600 587 465 345 223
Reheat Outlet Temp. - of 1,000 1,000 1,000 1,000 1,000
Reheat Outlet Press. - psig 580 568 450 333 217
Reheat Flow - M Ih/hr 1,644 1,614 1,308 998 677
1 Reference conditions are from Hammond Station, Unit #4, Georgia Power and
Light Company.
H-25
-------
TABLE 2.6
GAS CYCLE CONDITIONS
Steam Load Fraction (Ref.) 1.02 1.00 0.8 0.6 0.4
Turbine Inlet Temp. - of 1600
Air Compressor Outlet Temp~ - of 636 636 632 628 623
Air F1ow*~ 1b/sec 650 650 650 650 650
Fuel-Air Ratio 0.0919 0.0907 0.0776 0.0636 0.0470
Heat to Gas Turbine - M Btu/hr 1,423 1,420 1,385 1,348 1,304
Tllrbine Inlet Temp. - of 1500
Air Compressor Outlet Temp. - of 628 628 624 620 615
Air F1ow* - 1b/sec 650 650 650 650 650
Fuel-Air Ratio 0.0908 0.0895 0.0765 0.0624 0.0461
Heat to Gas Turbine - M Btu/hr 1,284 1,281 1,249 1,215 1,175
Turbine Inlet Temp. - of 1400
Air Compressor Outlet Temp. - of 620 619 616 611 608
Air F1ow* - 1b/sec' 650 650 650 650 650
Fuel-Air Ratio 0.0896 ,0.0884 0.0753 0.0613 0.0451
Heat to Gas Turbine - M Btu/hr 1,148 1,145 1,116 1,084 1,049
* Value given is gas turbine compressor air f19W.
Five percent of compressor
air flow is used for turbine blade cooling and by-passes boiler.
H-26
-------
::r:
I
I\)
---4
~
H
~
5
~
~
. Po<
1
1
1l'm1
-.
-i-
.~
-----T-lT'rrrT-------r-rr
.-.
_._-.;
~
"""""I
i I
99 C~~~-LliliL_._.__J.._J~_.JiliL_.____.J_-__;_._L_L_LL1L ----~
10 100 1000
PAftTICLE SIZE, MICRONS
325 200 100 60 28 16
. --.----._-..0".---- -. . - - 1. - -----L- ...- --.--.- L.- - - 1 . -.. ..--------.-1 - ._. -_._.._---_.~--
5
15
25
35
45
55
65
75
85
93
96
0-
I
98 I
r--
0._---_..'
SIZE DISTRIBUTION OF PARTICLES
ELUTRIATED FROM THE FLUIDIZED BEDS
1
-----. . . -." .
PARTICLE SIZE, U.S. MESH
FIGURE 2.4
-------
3.
BOILER DESIGN CONCEPTS
3.1
Selection of System Parameters
There are two general areas that \have to b~ investigated to
arrive at a design for the 300 MW, pressurized steam generator.
The first area to be considered is the selection of cycle con-
ditions.
The determination of steam cycle parameters and gas
pressure are the major categories in this area of design.
The
choice of steam cycle is basically between the subcritical and
supercritical cycles.
An investigation of steam generator capital
costs indicates that the subcritical boiler is more economical for
all size once-through steam generators.
This is mainly due to the
fact that subcritical steam conditions result in thinner pressure
part walls and lower tube metal temperatures.
Also natural cir-
culation steam generators are more economical then supercritical
once-through steam generators up to 700 MW.
Thermodynamic and
cost analyses of 10 atmosphere combined cycle plants with l60QoF
gas turbine inlet temperature done by Westinghouse have also shown
that there is no advantage in using supercritical steam conditions
at 1000°F steam temperature.
For these reasons subcritical steam
conditions were used for the detailed design.
Since a subcritical cycle was chosen, it was necessary to de-
termine whether a natural circulation or a once-through steam gen-
.erator circuit should be used.
Although the steam conditions
specified in Section 2 are 9ften used with natural circulation
systems in conventional steam generators, the physical restrictions
of a pressurized, fluidized bed design make this system impractical.
These physical restrictions mainly affect the location of evaporator
surface and the steam drum.
The once-through system, on the other
H-28
-------
hand, allows more freedom in the arrangement of the evaporating tube
surface and does not require a steam drum.
Therefore, it was decided
that a once-through system would be better for the pressurized steam
generator application.
The most important gas side parameter to be determined is the
gas pressure.
This parameter primarily affects the pressure vessel
cost, but it also influences the selection of the number of boiler
modules.
An analysis was performed on the effects of gas pressure
on pressure vessel costs.
This analysis showed that although in-
creasing the system pressure does decrease the required vessel di-
ameter for a given gas flow rate, this effect becomes less signifi-
cant as the pressure level increases.
Above 10 atmospheres it
appeared that very little cost saving would be realized by increasing
the pressure level.
It was also anticipated that the cost of auxili-
ary equipment such as coal and sorbent feeding equipment would be
considerably greater at higher pressures.
Consideration of these
factors resulted in the choice of a 10 atmosphere gas pressure.
The selection of system parameters is discussed in more detail in
Appendix 1.
3.2
Selection of Steam Generator Design Concept
Once the steam cycle conditions were selected and the gas
pressure was determined, the second area of design had to be in-
vestigated.
This area of design pertains to the layout of the steam
generator.
The arrangement of steam pressure parts, the size and
shape of the fluidized beds, the arrangement of the beds in the
vessel, and the orientation of the vessel are all aspects of the
design that have to be considered.
These design areas are all in-
H-29
-------
terrelated, and affect many aspects of the process.
For example,
the selection of bed shape can place restrictions on the arrangement
of steam pressure parts.
If beds of annular cross section Bre-
chosen, it becomes impossible to use horizontal, serpentine .tube
banks .in the beds.
Besides affecting. the steam flow, the type of
tube bank in the bed affects the fluidization parameters of the
bed .such as. temperature distribution and particle mixing.
From
this brief example the complexity of choosing an optimum design
can be seen.
Also due to the state-of-the-art of fluidized bed
design, many of the decisions have to be based on engineering
judgment rather than firm experimental data.
A detailed discussion
of how the final steam generator design was selected is presented
in Appendix ,1.
The final design is shown in Figures 3.1, 3.2, 3.3 and 3.4.
Four of these modules are used for a 300 MW combined cycle plant.
.rhis design consists of a vertically oriented pressure vessel with
four, stacked primary beds and one. carbon burn-up cell.
The fluidi-
zed bed cells are rectangular in cross section and are about 20ft.
high.
The actual bed depths are around 12 ft. in the fluidized
state.
The 12 'ft. beds take maximum advantage of the high heat
transfer coefficient in the fluidized beds without causing unreal is-
tic superficial velocities or gas pressure drops.
Horizontal, ser-
pen tine tube banks are used in the beds.
It is felt that this ar-
rangement will give. even fluidization of the beds.
This type of
tube bank design also allows for conventional fabrication tech-
niques and is adaptable to a wide range of tube spacings.
At first glance it may appear that using beds of rectangular
H-30
-------
cross section in a cylindrical vessel is an inefficient use of
space.
It can be seen in Figures 3.1, 3.2 and 3.3, however, that
the void areas between the pressure vessel shell and the finned
tube welded wall enclosure are used quite extensively for trans-
port piping and accessory equipment.
Also, the flat enclosure
wall panels used to form the beds have the advantage of being
fabricated with automatic equipment.
It is not certain that
other wall shapes will be adaptable to fabrication with existing
automatic equipment.
H~31
-------
'"
r;; Dl r1~.
i~
10,
'"
~
'"
~.
At '
/ilK AN1/'16S
'U ~~cr."E"L'
r;; R~N~rrK
< 6i" r Nll1r1fPK-
t. l ,,,-
$, ' ~ ~ {,\ I:::J
,..,., "" t1) ~
10 r- ~ ~
Lu S b CiJ c:::
<: --
"" 'i ~ :t:. ~
,.., "" '\ I'\j
t::> " C\ f'tI
iI) \)
-------
I
I
~~
:::!~
~~
~
~CCTI()N "A -A "
4~r
SECT/ON ''8-8"
Se:CT/ON "C-C"
~....
~~;
s~
"
"
-"
"-
CI
c:::
~
'"
l1J
."
\:)
c:::
~
\.)J
a
C,\ a
~ ~
r;; ~ I"
"'tI f\ ()
...... a ~
,,~ ~
>. CP
't --
~
~
IliJ . II
r," \,
'0 '-'1
,. l,
u, ll\
"i c..:
~ ~
~ I\J
~
~ ~
hi ~
~ S?
cs I\J
~ t;
"""'
'"
'-
I\J
~
'"
~
c:::
"-
~
'"
~
~~
.."
ti
~~
~~
"... .
..~
~~
~t
~~
~~
,11111
..""
.5ECTION ''0 -f)"
~~
~~
~
~s.
;~
~I.>,"
~,~
2, W
5ECT/ON"E-E"
TYp. FORA/R DAMPERS
'i';:,
"'''
~~
::~
~~
~
~'"
;)t~
~~
1Af\
..~
,>;
"''''
...
Lo'
~~
~~
"'1'\
"'~
.!'-"
'"
~
~~
~~
..."
'\.~
"''''
..
~
5ECTION"F -F"
-------
Bep RE-/V/O'f,9t
P,PE -"',
,-
.
...
Ul.lolt/$ ~
S£AL.~ T YP.)
3" CIJ,fL PIP~
(nil.)
Ir4NITOR
e /
I..".. ~
~
r-
~
It:.
H
...
5E.CTlON "C;- c;'
/--- CO,qi Pipe
.I 14/'11 TOR
----..../"---------- ----'
:~
"
.
.~
1\0
DE. TAIL "A-
AIR
IiI'IrlUR
SEe nON "4/- G/'
.5H/IT 01'1' VALVc-
-~---------------
1
I
,
I
\
\
J
-I
I\j
..
......
~
~
$
5£CT/ON "/I-fl"
"
~ ~t
---\-~
"
II
IJEIlO/lfS bP!! Jr.
PR.ESSUR.fZ-=D FLUIDIZED
BED STEAM CdNER.ATOR.
FtJlC.
300 MW COMo/NfD
CYCL..:
P~A/,,'T
,:' 0 U e... (4.) f2. t' Q f.) I R.. E ::J
F/GUR..E3,3
-------
~1
"
PUTF'''''''' Et I"/~~"
PUrPMI'1 EI.. "" "..
I'IATP""Nrcl. 7.3~~
Pr.A"""'.M cl..59;O"
A rl'.,r,
. .5~;,,"
earp'KMcl. 37"0"
f'tAT,6rJIi'H .30:0.
PIATFlIItME(.IS'()"
6L.«J/E t! (. O'D'
+
+
+
.+
ct.£V,4T1oAl
!1 (>.) (:J:J ~
'" 1"1-,
D "I:: ~ '" rt,
c:: \') C) VI VI
r-. VI
""TJ rv I'll ~ 'i \%
fI1
C\ ~ ~ < I~ }:. ~
c:: r-. 1\ () ~
1'> ~ )". c:- ~ \:)
..... <: ~ ~;!:!
..... (')
W c:: ~ ~ ~ S:
J:.. '" ~ 'I.1.t;:)
'" "11 b ~
~ ~ 'i f't\
~ tJ
1\;)
, ,
"\
"
I "
_/
-------
4.
DETAILED BOILER DESIGN
4.1
Circulation through the Boiler
Detailed drawings of the boiler are shown in Figures 3.1, 3.2,
3.3 and 3.4.
Simplified drawings showing the steam side and gas
side flow circuits are shown in Figure 4.1.
The steam circuits
and gas circuits are really an integrated whole as far as the de-
sign and operation of the steam generator is concerned, but they
will be discussed separately here for the sake of clarity.
The steam circuits are of once-through design.
The location of
the tube surface is different from that of a conventional once-
through unit, but the concepts and steam side design criteria
used in this steam generator are typical of conventional units.
In the design presented in this report feedwater enters the steam
generator near the bottom of the module.
The feedwater then flows
upward through the lowest tube bank.
This tube bank has been
labeled a pre-evaporator.
Most of the bank contains sub-cooled
water, but steam starts to form in the uppermost loops of the bank.
At the top of the pre-evaporator tube bank the water steam mixture
is collected in a header and then flows through a transfer pipe to
one of the lower wall headers.
The tube walls are divided into four separate circuits, and
the water steam mixture flows through each of the circuits in
succession.
After each pass through a wall circuit, the mixture
is transported to the bottom of the next circuit through unheated
downcomers.
This results in upward flow in all heated circuits
that contain a water-steam mixture.
Upward flow is highly desirable,
H-33
-------
""'i
:r>,. -
"'"
"';f
111 n
01>- "
,,~ -
--~ 0
NJ>%'
~iilo
~)d"
~~
~
i
.\~ c~p~~s I
REI! E:A "T£R !
- F-~.ez~6IN!..E.T. HDR, !
~'FRcM 14,"", ~T'EA~
iVRe, \Nq: .....
To t4. P. S"£~M 4-0 ..:....
1'UtlB\N!! -
, ~B':UPERUT]~" .-
OViL~1 HDR.
~.-._-
r'--l,1
J~:[ , JI[ J'[ I
! . I
~ r-I - - I
!~llllit i
!
~
~
-<
o
~
:r>
.
'"
.
..
I~ -i
1'1 I ~i
",".i..R "J
SVTWTj
I I =---..:i
-l~1
E"'.:~~~~AMP~~~i_~.I_~!-,;~
E.L.~t;'-"; ~ ! -7
:~:
I il::rdj!
- -.I.
t.°vtE~=:J\
1-=..... ~,]I
--I'll'. DA~1>ER5 d.,
.t~
I ,,'QS'
IJr-
/
/.:~
~<.<;
;;'~~{,,"Ip'"
.,/ <
r - ---
k~~
~ -,1>-1:. EVAPORA"TOR.
b 9 OU"T\.I!I Hb~.
P l' El !5~O"
d <1
~ ~
- .~
-r;.6.c..c'AS OU1\.ET
WAiER WALL CI~CUlTRY
:G.AADI!. Z!L 0'-0" I .__.-
.~?E.1<.HEp.,i'E~
REI-1E"" I 12..CUI,1('y
~ n 0 ~ :-
'I ~ = CIJ) ~~
q~
a : ~ 9 "TI
. < 'TI~..., ~ ~~
~ h
1:""9r-
:... 0 C a~
'" ; i i ~5:o
.. . ..111
~ 0(j\N . ...
.. II, hi ~ ~C7
7OT11rrt .
OJ ~! 0Z0 . ~~
ilii!1 a ~ f ~r'1'(J1 : i ~~ ~
~~I"'I z-
.... 11IZ:
]O~o ~s ~
lit"i J II '<0 00
IUI~r ~ i r
.
, lii'Ii'
-------
because it prevents bouyant forces from separating the water and
steam.
After passing through the last wall circuit, the now almost
saturated steam enters the first superheater bank.
The superheater
duty is accomplished in the two series connected superheater banks.
The steam then leaves the vessel and is transported to the high
pressure turbine.
Steam from the discharge of the high pressure
turbine returns to the boiler module at the bottom of the top tube
bank to be reheated.
The steam leaving this bank is at the final
reheat conditions and is fed to the intermediate pressure turbine
after being combined with the reheat steam from the other modules.
The steam side circulation is more complex during boiler
start-up than in the description presented above.
Under the conditions
of start-up, the steam side circulation is strongly interrelated
with gas side ignition problems and plant steam cycle requirements.
This type of steam generator operation is discussed in Section 5
of the report.
The air and gas flow system can be seen in Figure 4.1.
The
combustion air for the primary beds enters the pressure vessel
and fills in the void volume between the steam generator tube
walls and the pressure vessel shell.
This volume acts as a manifold
to distribute the air among the four primary fluidized beds.
The
flow of air from the void volume to the air plenum chambers located
under each of the beds is regulated by control dampers.
The air then
flows from the plenum chambers through distribution plates to the
fluidized bed cells.
In the four cells coal is combusted in a bed of fluidized
H-35
-------
dolomite.
The tube surface in the fluidized beds and the trans.ition
zones absorbs approximately 80% of the steam cycle duty.
This sit-
uation makes efficient use of the high bed-to-tube heat transfer
coefficient that is expected in .the fluidized bed.
The dolomite
particles in the bed react with oxides of sulfur formed during
the combustion of the coal and remove this pollutant from. the
gas stream.
The actual fluidized bed extends to 2 ft. below the
top of the tube bank.
The top 2 ft. of the tube bank and the
tube free space above the bed .serve as a disengaging zone for
particles elutriated from the bed.
The flue gases leave the primary fluidized bed cells through
tube screens that are located near the top of the cells.
Tube
screens are openings in the enclosure walls that are formed by off-
setting some of the tubes in the wall.
The gases then combine in
a gas passage that, like the cells, is formed by tube walls.
Con-
vection heat transfer between the flue gases and the tube walls
takes place in this passage.
This zone is the last heat transfer
surface in the gas circuit.
Near the middle of the gas passage an
insulated duct carries the gases from this passage, through the shell
wall and to the first cyclone stage.
The carbon burn-up cell has an air-gas circuit that is separ-
ate from that. of the primary fluidized beds.
Combustion air for
the carbon burn-up cell enters the pressure vessel through a duct
located above the primary b~d air. inlet duct.
This duct connects
directly to the air plenum chamber under the carbon burn-up cell.
The flue gases from the carbon burn-up cell are also segregated
from the primary bed flue gases in the module.
These gases do
H-36
-------
reunite with the flue gases from the primary beds after the
primary bed flue gases are cleaned by the first cyclone stage.
A schematic diagram of the flue gas flow streams exterior to
the vessel can be seen in Figure 4.2
4.2
Energy and Mass Balances
The energy and mass balances were calculated for design
load and 70% plant load.
These calculations are based on the
specifications listed in Section 2.
The steam duty requirements
at different loads were taken from Table 2.5.
For the design load
the bed temperatures were fixed at l750°Fand the boiler surface
was designed for this temperature.
At reduced loads the required
bed temperatures were calculated from the steam duty requirement.
Fuel/air ratios were fixed by the overall plant design for each
load.
Once steam duty requirementst bed temperaturet and fuel/air
ratio are establishedt mass flow rates and velocities in the steam
generator can be calculated.
Tables A2-l and A2-2 of Appendix 2
list the flow parameters for each bed.
The mass balances and
flow circuits for airt flue gases and solids are shown in Figures
A2-l and A2-2 for each module.
The energy balances were also calculated for each bed.
Once
the bed temperature was calculatedt the bed was considered as a
control volume and the heat inputs and losses were determined on
a pound of fuel basis.
The difference between the heat inputs
and the heat losses is the energy per pound of fuel that is
transferred to the steam.
The air sensible heat input and the
flue gas loss from the cells varied with the air/fuel ratio and the
bed temperature.
The rest of the heat inputs and losses were assumed
H-37
-------
'2 ~o ~'T "" l
S I. P ... R.A "tl)
\ ~"f ~1~" E
sa.. p A. a-A\~
_hP i...\M/\ a.. '( -
h' ~ t:.D S
'"
C)
-
..J
o
If)
o
",
t-
'0
...
J
'.I
~
\J
FLue; ~~S 4
!.I.U'U..IAoiEO
SO~IOS .
c: A. .... bD ~
e»\) ~~. U?
. c.. 1;. \. \.
FLU~ '" ~s %
tL\I" "-11:\1 to
50ll t) ~
c. .. co.. NO. ...".
f\..ue.G~~ ~O
G.~~ \Ui..~\t-.le.
In
o
J
o
VI
i
\ ..
....
~ ..J ol ~
4 4
- ~ .... ~
4; c(
u i
' I I
.,.j :
SCHtM~1'\C OF ?AR.1\C.ULA1E
CO~l~C~\O~ 5~5~lM
This Drawing i I th. Property of the
FOSTER WHEELER CORPORATION
110 SOUTH ORAMGE AVEMUE
LIVINGSTON. NEW JERSEY
AND I. L.ENT WITHOUT CONSIDERATION OTHER THAN THE 80RROWER'S
AGREEMENT THAT IT SHAI.I. NOT 8E REPROOUCED. COPIEO. L.ENT. OR DIS'
PO.EO 0... OIRECTI.Y OR INDIRECTL.Y NOR USED FOR ANY PURPOSE OTHER
THAN THAT "'OR WHICH IT IS SPEC''''CAL.I.Y FURNISHED. THE APPARATUS
SHOWN IN THE D..AWING 'S COVERED 8'1' PATENTS.
H-38
ORDER NO.
DRAWN BY:
CHECKED BY:
APPROVED BY:
SCALE:
O'5~.\\~Z
j ~ S 20
= ,. -0"
RO.7'4~\'3
r\G..4.2
-------
to be invariant with load on a pound of fuel basis.
The inputs
from the combustion of coal and the Ca-S02 reaction were 13,000
Btu/lb coal and 325 Btu/lb coal respectively.
The radiation,
latent heat of H20, solids sensible heat and unaccounted for
losses were combined into one heat loss term of 797 Btu/lb coal.
Six percent carbon carryover was assumed for the beds.
This re-
suIted in a carbon loss of 624 Btu/lb coal from the primary beds.
Heat transfer above the beds and in the gas passage were calculated
to determine the flue gas temperature decrease in these passages
and hence the final flue gas energy loss from the steam generator.
The car~on burn-up cell is designed to be maintained at
2000°F entirely by the combustion of carbon returned from the first
particulate collection system.
The fuel input to this cell will
therefore decrease as the load of the steam generator is decreased.
When the fuel input to the primary beds is reduced, the bed tem-
perature drops.
In the carbon burn-up cell, however, it was felt
that a temperature drop at reduced loads should be avoided because
it would probably reduce the efficiency of the carbon burn-up process.
For this reason- the carbon burn-up cell was designed for 80% excess
air at rated load.
As the steam generator load is reduced the
excess air to this cell is lowered to keep the bed temperature
at 2000°F.
At 70% load approximately 20% excess air is required
for a bed temperature of 2000°F.
If the excess air is lower than
20%, the carbon burn~up cell may lose efficiency due to insufficient
excess air, so at loads less than 70% the bed level or temperature
will have to be lowered.
Flow diagrams showing the energy inputs
and losses in the cycle can be found in Figures A2-3 and A2-4
of Appendix 2.
H-39
-------
Steam generator efficiency calculations are misleading in
a combined cycle plant, because the high flue gas temperature
leaving the steam generator is not really a loss.
Table A2-3
of Appendix 2 lists the expected steam generator losses based
on a flue gas temperature of 275°F.
This is not a true repre-
sentation of the system, but it gives a means of comparing the
steam generator with conventional units.
4.3
Tube Details
The layout of the tube walls and tube banks can be seen
in Figures 3.1, 3.2 and 3.3.
The tube enclosure walls, tube banks and
the support systems for them are of conventional design.
In
fact, at .first glance the pressure parts very closely resemble
the convection pass of a conventional unit.
The operation of
the unit is, of course, very different from the operation of a
conventional steam generator, but the fabrication of the pressure
parts requires no new machines or new shop technology.
The tube enclosure walls are of monowall construction.
That is, they
aLe panels made. up of straight, vertical tubes with metal fins
welded between the tubes.
The enclosure walls perform other important
functions besides providing heat absorption surface for the
evaporation duty.
They also serve as partition walls to form
various air and gas passages.
Steam or water cooled walls are
very desirable for this purpose, because they do not require
as much maintenance as insulated walls and are not as expensive
.as walls made of high temperature alloy.
Another function of
H-40
-------
vessel.
The coal is transported pneumatically through these
lines directly to the coal inlet nozzles at the fluidiz~d
bed.
The flow through these lines is continuous and they are
calibrated with respect to pressure drop so that the coal flow
can be measured.
4.5
.Sorbent Feeding
There are two areas of design in the sorbent feeding
system.
One area pertains to the location and number of
sorbent inlets and outlets in the fluidized beds.
This aspect
of the system is discussed in Appendix 4.
.The other area of
design is the transporting system that circulates the sorbent
between the steam generator system and the regeneration system.
This part of the system is presented in Appendix 5.
Since the sorbent average residence time is about one
hour, only one inlet pipe and one outlet pipe are provided in
each bed.
The inlet pipe is located about 4 ft. above the air
distributor plate.
The outlet pipe is located about 4 ft. below
the top of the tube bank.
Fresh sorbent is added to the system
to make up for the stone that is expected to be elutriated from
the beds and for the spent stone removed in the regeneration
system.
This sorbent will be fed through the coal feeding system.
No special equipment was required for this, but the equipment
required for the coal feeding was sized considering this additional
flow.
Two types of systems .were considered for the circulation of
sorbent between the steam generator and the sorbent regenerator.
One system that could be used (and which has been selected for the
plant by Westinghouse) would be a lock hopper system similar to the
H-43
-------
coal feeding system designed by Petrocarb.
With this type of system
the possibilities for regenerator locations and uperating pressures
are quite extensive.
An alternate system investigated by Foster
Wheeler would be one which uses static pressure heads of the
sorbent to achieve pressure sealing between different parts of
the circulation system.
A schematic of this type of system is
shown in Figure A5-32 of Appendix 5.
Slide valves are used to
provide some means of control over the flow rate.
These valves
also separate the dense phase transport from the dilute phase
transport.
The operation of this system is described in Appendix 5.
4.6
Particulate Removal
The particulate collection system consists of two stages
of particulate removal equipment.
The flow of gases and solids
in this system is shown schematically in Figure 4.2.
The first
stage of separators is used to minimize the unburned carbon en-
ergy loss by removing 90% of carryover.
Particles collected in
this stage are fed to the carbon burn-up cell through dip legs.
In the carbon burn-up cell the excess air and bed temperature are
kept at relatively high levels to enhance the combustion of the
carbon in the returned solids.
In this manner the carbon energy
loss of the steam generator can be reduced without maintaining
high excess air and temperature levels in the primary beds.
The
first separator stage consists of four Duclone type cyclones
manufactured by the Ducon Company.
These cyclones are housed
in a pressure vessel located adjacent to the boiler module.
The
arrangement of these cyclones in the pressure vessel can be seen
in Figure A4-4 of Appendix 4.
The location of this pressure
vessel and the secondary cyclones can be seen in Figure A4-5 of
H-44
-------
vessel.
The coal is transported pneumatically through these
lines directly to the coal inlet nozzles at the fluidized
bed.
The flow through these lines is continuous and they are
calibrated with respect to pressure drop so that the coal flow
can be measured.
4.5
.Sorbent Feeding
There are two areas of design in the sorbent feeding
system.
One area pertains to the location and number of
sorbent inlets and outlets in the fluidized beds.
This aspect
of the system is discussed in Appendix 4.
.The other area of
design is the transporting system that circulates the sorbent
between the steam generator system and the regeneration system.
This part of the system is presented in Appendix 5.
Since the sorbent average residence time is about one
hour, only one inlet pipe and one outlet pipe are provided in
each bed.
The inlet pipe is located about 4 ft. above the air
distributor plate.
The outlet pipe is located about 4 ft. below
the top of the tube bank.
Fresh sorbent is added to the system
to make up for the stone that is expected to be elutriated from
the beds and for the spent stone removed in the regeneration
system.
This sorbent will be fed through the coal feeding system.
No special equipment was required for this, but the equipment
required for the coal feeding was sized considering this additional
flow.
Two types of systems .were considered for the circulation of
sorbent between the s~eam generator and the sorbent regenerator.
One system that could be used (and which has been selected for the
plant by Westinghouse) would be a lock hopper system similar to the
H-43
-------
coal feeding system designed by Petrocarb.
With this type of system
the possibilities for regenerator locations and uperating pressures
are quite extensive.
An alternate system investigated by Foster
Wheeler would be one which uses static pressure heads of the
sorbent to achieve pressure sealing between different parts of
the circulation system.
A schematic of this type of system is
shown in Figure A5-32 of Appendix 5.
Slide valves are used to
provide some means of control over the flow rate.
These valves
also separate the dense phase transport from the dilute phase
transport.
The oper~tion of this system is described in Appendix 5.
4.6
Particulate Removal
The particulate collection system consists of two stages
of particulate removal equipment.
The flow of gases and solids
in this system is shown schematically in Figure 4.2.
The first
stage of separators is used to minimize the unburned carbon en-
ergy loss by removing 90% of carryover.
Particles collected in
this stage are fed to the carbon burn-up cell through dip legs.
In the carbon burn-up cell the excess air and bed temperature are
kept at relatively high levels to enhance the combustion of the
carbon in the returned solids.
In this manner the carbon energy
loss of the steam generator can be reduced without maintaining
high excess air and temperature levels in the primary beds.
The
first separator stage consists of four Duclone type cyclones
manufactured by the Ducon Company.
These cyclones are housed
in a pressure vessel located adjacent to the boiler module.
The
arrangement of these cyclones in the pressure vessel can be seen
in Figure A4-4 of Appendix 4.
The location of this pressure
vessel and the secondary cyclones can be seen in Figure A4-5 of
H-44
-------
Appendix 4.
A discussion of alternate arrangements for the first
separator stage and the expected collection efficiency can also
be found in this appendix.
The secondary particulate removal stage consists of two
model 1,800 separators manufactured by the Aerodyne Development
Corporation.
This separator can be seen in Figure A5-35 of Ap-
pendix S.
The flue gas from the carbon burn-up cell enters the
upper chamber of the first stage separator pressure vessel.
Here
this gas stream mixes with the cleaned gas from first stage sep-
arators and the combined stream leaves the pressure vessel through
two gas pipes.
Each of these gas pipes enters one of the secondary
separators.
The layout of this equipment is shown in Figure A4-S
of Appendix 4.
The secondary separators were designed for 97% collection ef-
ficiency.
Basically these separators depend on the cyclonic action
of two gas streams to effect particulate removal from the gases.
In the design shown here both of the gas streams are dirty gas.
After entering the separator, the flue gas from the steam generator
is divided into two streams.
One stream enters the bottom of the
inner chamber and rotates as it flows upward.
The other stream
enters at the wall of the inner chamber near the top of the
chamber and flows downward with a rotational motion.
The combined
effect of these two streams provides good efficiency over a range
of particle sizes that extends down to 5 microns.
The operation
and efficiency of this separator is discussed in more detail in
Appendix S.
After leaving the secondary separators, the gases go
directly to the gas turbine.
H-45
-------
4.7
Carbon Burn-up Cell
The location of the carbon burn-up cell can be seen in
Figure 3.1.
This cell is formed by the same tube walls that
form the gas passage and there are no tubes in this fluidized
bed.
Although having tubes in this bed would probably provide
a more even fluidization, there are several problems involved'
that excluded the use of tubes in the bed.
One factor was the
need to keep the bed height approximately the same as the other
fluidized beds.
This keeps the pressure drops across the beds
approximately equal and thereby simplifies ~he gas handling as-
pect of the design.
It was determined that placing tubes in the
bed would require a lower bed height in order to maintain a high
temperature in the carbon burn-up cell.
This is due to the fact
that the carbon input to the bed is fixed by the operation of
the other beds, and it is not desirable to use a supplementary
fuel in this bed.
Also, the possibly unstable operation of this
bed would increase the possibility of tube burn-out if steam
circuits were located in this bed.
The solids that are collected in the first separator stage are
fed to the carbon burn-up cell by four dip legs.
This stream of
solids contains particles of sorbent, ash and carbon.
All of
.
the sorbent and ash from the primary bed is also expected to be
elutriated from the carbon burn-up cell.
The carbon burn-up
cell has a sorbent circulation system which can maintain the bed
height in the cell so that any particles fed to the bed that are
not elutriated will not accumulate in the bed.
This cell is
also supplied with an ignitor to accomplish start-up of the bed
and to provide supplementary heat if it is needed.
H-46
-------
," -
5.
OPERATION
5.1
General Problems
The steam flow circuits of the boilers presented in this
report are very similar to those of typical once-through units.
The modular boiler design and the requirements of fluidized bed
combustion affect the operation of the steam cycle, but the basic
philosophy of once-through operation is not changed.
Overall
steam generator operation depends both on steam side and gas side
requirements and limitations.
Certain requirements of fluidized
bed combustion make the operation of the boiler more difficult
than conventionally fired boilers, but there are also some
aspects of boiler control that benefit from the fluidized bed
design.
One characteristic of fluidized bed combustion is that
there are limitations on the amount of combustion air that can
be fed to each bed.
The superficial velocity in the beds must be
greater than the minimum fluidizing velocity but less than the
terminal velocity for the particles in the bed.
The range of
velocities that are allowable can be seen in Figure 2.2 of Section
2.
The limitations on air flow place restrictions on firing rate,
but other parameters such as bed temperature and air/fuel ratio
can be adjusted to extend the range of operation.
Besides limitations imposed by the fluidization requirements
of the bed, there are also restrictions on operation that are
. .
caused by the heat transfer -characteristics of the bed.
One
characteristic is that the mixing action of the fluidized bed
uniformly distributes any heat added to the bed.
In other words,
there are only small temperature gradients in the bed.
Also the
H-47
-------
bed-to-tube heat transfer coefficient remains nearly constant during
turn down.
I
The overall heat transfer coefficient is reduced slightly
at reduced loads due to a decrease in the steam side heat transfer
coefficient, but the major effect of reducing the heat input during
turn down will be a reduction in bed temperature~
There are, how-
ever, limits to how low the bed temperature can be.
During normal
operation the sulfur removal process requires that the bed tem-
perature be above 1400°F.
During start-up operation, the uniformi-
ty of the temperature in the bed and the high heat transfer co-
efficient make ignition of the coal a problem.
The ignitors must
supply enough heat to overcome the heat transfer to the boiler
tubes and heat the bed up to the ignition point of the coal.
In some aspects of steam generator operation the fluidized
bed design presented in this report has a greater. flexibility
than conventional units.
The separation of steam generator
functions (i.e., superheating, reheating, etc.) into separately
fired beds is highly desirable, since the firing rate and hence
heat input, to each part of the water/steam circuitry can be
separately and positively co~trolled. .
There are several reasons why it is important to have control
over the distribution of heat to th~ water/steam circuitry.
First,
the tube banks are designed for specific locations in the circuit.
If at a certain load the distirbution of heat transfer is such that
water is flowing in tubes d~signed for steam, or vice versa, pres-
sure drop and/or tube metal temp~ratures can be seriously affected.
Also during start-up of a unit, certain tube banks must be pro-
tected from hot gases during these time periods or excessive tube
metal temperatures will result.
H-48
-------
In conventional units all the fuel is combusted in. one furnace
so the distribution of heat transfer to the water/steam circuitry
must be accomplished in a more indirect manner than in the fluidized
bed design presented in this report.
Two methods are used concur-
rently to control the distribution of heat transfer in conventional
units.
One method is to separate the convection pass of the boiler
into two parallel passes.
By means of dampers located in the rela-
tively cool zones of the passes the gas flow distribution between
the two passes can be controlled.
The other means of control that
is used is spraying feedwater into the steam.
If at a certain load
the heat transfer characteristics. of the boiler are such that too
much heat is being absorbed in the superheater elements and not
enough in the economizer and evaporator sections, feedwater is
bypassed around the economizer and evaporator sections and spray-
ed into the superheater circuit.
The spray nozzles are carefully
designed so that the feedwater will mix rapidly with the steam
and evaporate.
This type of operation insures that the tube
banks will have the phase of steam or water flow that they were
designed for.
Figure 5.1 shows a typical layout of the parallel
gas passes.
There are several problems involved with the conventional
means of distributing the heat that can be overcome by separately
fired beds.
It is impractical to have more than two parallel
gas passes in a conventional unit, but the stacked bed design
gives four areas of direct heat input control.
The separate bed
arrangement also provides a better means of keeping hot gases
away from certain tubes during start-up, because in reality, con-
troldampers do not provide 100% shut off and so it is not possible
H-49
-------
PARALLEL PASS WITH DAMPER CONTROL
RADIANT SUPERHEATER
CONVECTION
SUPERHEATER
SUPERHEATER
-j~ f 7- ~
':::::J
REHEATER
DAMPER
CONTROL
FIGURE 5.1
H-50
-------
to completely stop the flow of hot gases to one of the two parallel
convection passes in a conventional unit.
However, leakage of the
control dampers in' the fluidized bed design just results in rela-
tively cool air flowing through the bed.
It is not meant to be implied that conventional means of
distributing heat to the steam cycle are inadequate, because
these systems are used successfully.
It should just be kept
in mind that the obvious operational problems associated with
the fluidized bed process may be balanced by certain favorable
operational features of the process.
5.2
Start-Up
Start-up of the plant is accomplished by putting one module
into operation at a time.
There are two possible start-up situations.
One situation is initial start-up of a cold module.
This type of
start-up would be required for the first module to be put into op-
eration.
The other situation would be start-up of a module with
one or more modules already in operation.
This would occur during
plant start-up and during load changes.
The boiler start-up system is shown in Figure 5.2.
This is
basically a conventional once-through start-up system that is
modified for a modular steam generator design.
To start-up the
initial steam generator module the B, W, P and D valves are opened.
Water flow is then started through the pre-evaporator bed, wall
tubes and first superheater bed, from which it flows to the flash
tank and then to the condenser.
Next the pre-evaporator and first
superheater beds are ignited.
The bed conditions that will be necessary to ignite the
H-51
-------
::x:
I
V1
f\)
"TJ
(')
C
;;C
t"'1
V1
'"
........ TO TURBINE
.........
TURBINE
~ , ~ , ~ , I ~ STOP VALVE
~ II ~ It r. ~--.
i. i. i. . . - - - -- - J
Ii. 'i. YI W24~ Y2 ~ ~ Ys W4" 4 > Y4 "
E
EVAP EVAP EVAP EVAP
. ~ ~ 'B2 ~, ~ ., ~ .,C
81 4) Ss ~B4 TO
4 ~ 4 ~ . CONDENSATE
~ ~~HI ~ ro-: H 2 ~ ~IH3 ~ 8>-i H 4 PUMP.
~ 4
I I I
I I I I ~ ~
) I-.J H--' )1--.1 H-J FROM
7 6 -FEEDWATER
HTR HTR PUMP
CD
o
-
r
ITI
::0
Cj)
-I
J>
::0
-I
I
C
-C
Cj)
-<
Cj)
-I
ITI
3:
W
-------
bed will have to be determined from pilot plant tests.
For this
design it was assumed that during cold start-up the water tem-
perature in both tube banks will be 80°F and that a bed temperature
of 750°F will be necessary for the ignition of coal.
were assumed to have a capacity of 25 x 106 Btu/hr.
The ignitors
Under these
conditions it was estimated that a 3 ft. high bed would be the
maximum that could be brought up to the ignition temperature.
It
was assumed in these calculations, that the ignitor combustion ef-
ficiency of the system shown in Figure 3.3 was 70%.
If this com-
bustion efficiency is not achieved, the ignitor system could be
modified as shown in Figure 5.3 or 5.4.
The system in Figure 5.3
uses a combustion chamber to provide a hot zone that will give the
ignitor fuel a better chance to combust before it is exposed to
the heat sink affects of the fluidized beds.
Another approach
would be to put more ignitors into the beds.
This could be
done as shown in Figure 5.4.
Another possibility rather than
modifying the system would be to maintain only a very small flow
in the tubes during start-up.
If the flow were kept small enough,
the water temperature would increase and reduce the heat loss
to the tubes.
Once coal ignition is established the bed height
can be increased as rapidly as the dolomite feed system will
allow.
Assumming a feed rate of 200 lb/min, it would take
about one hour to raise tbe pre-evaporator and first superheater
beds to full capacity.
As heat is added to the system, valve D is closed and the
heat recovery valve E is opened.
This mode of operation allows
a more rapid heating of the water than would be possible with
H-53
-------
all) IlEMflVA\.
PIPl
\G.~liOa..
~
e>01101o\ puql
&~ U i Of f
~ ~I. Vi.
8J
c. .. co.. NO. ...8.t
.-----------
,/ "..........
/ ,
..//
"
~t.lLOW':>
E)(.°IU4~\ON '5tt\..
(, '( p)
~" c" p.. \. ~ I l' t
(, ~ P. )
....
-c--
.8"
OS" ~5.
- - - .
'-22 '. . r:::-:>
r~
15.
"'-' . \': I?
~w.,.. .. ,It. i G. ~ Ii 0 il-
,""',..
~..."..,
.:J':HZJ:~ 1$.
'-.', _.:'~..
~S. ~
cor'
~
/
,
,
'".
'-..
'.
...... -----.-.-.,
,
"
....
P L
A
).J
-9:~~' :
A.\IZ... OAM?L~
''\.. .JI
co~\. PIPE
\ Ca 104 lit) I...
: .
~
;;-: f
'" '
-1
I:D
.
IJ'
'-,
, ,
,.. .'
. ../
II
II
"
II
t,1
.J
j
11.1"0" CIA.,
.. "
5 ~ c ,. \ 0 ~ P\- A
ALIt..R.~~\l. \GN\TO~
-----5 c~ L M- L"'A -';-" .. --'--'----"" .
O"DE:R NO.
O'S'i'II~t
DRAWN 8Y:
J~
Ij.,1
- --.....----.----.--.
.U_h__-
CHECKED 8Y:
Thla en.wlne I. tho Pro,.rty 01 tho
FOSTII WHIILII COIPOIA TIOM
118 IOU"" 0IIAM81 AftMUI
LIYIItGITOII. M.. J..SIY
AND I. L..NT WITHOUT CON.IO."ATION OTH." THAN THI[ .0""081[""
A."._IENT THAT IT "AL.L. NOT.. ".~"OOuc.o.co~,I[O, L..NT, 0" 0'1-
~O..O 0.. Ol".CTL.Y O"'INO"'.CTL.Y NO" U..O "0'' ANY ~U"~O.I[ OTHII:"
THAN THAT "0'' WHICH IT 'I .~.CI"ICAL.LY "U"MI8HII:O. THI[ A~~A"ATU'
..0- IN TH. DRA"". II CO"II:".O .., ~.TII:NTI.
A"ROVED 8Y:
--...- --..-
SCA LE::
=".0"
----
0-59- 714-G2
F I 6. 5.::1.
H-54
-------
t~ ~- _~~~I~ I
! ' .-.-:-.::---,"11
~~~:~~--D I
I i I L-'-~-"-='~:"~'-l:-l-'
I ~ '-=-~_.J
I ~---_.. - I,
I i I---~- -- . ...
i i ! ,,'. 0" c,~.
I, '-----------. I
II~. ~~-;]. !
I 111 -'='~I-"I
l ; - ._~~~. . I I
: II L=-::~l=l-r ;
I ~ ,--- --~~- . I ;
--C=---~~~~-~ .."\"1 ;
-=r---=-.~~' '.-:.. :
i ~_. _. --.=1
I ( I '.
'ii . j.
.~_.~g--.-:.-::-:-. -~ .. d::---"" ,_u"- -=-=i: ~-:z €.~\..
ORDER NO,
O"9'\\~,
DRAWN 8V:
~~
J~
CHECKED 8V:
A~ROVED 8V:
-- -..,. -. .-
':: ,. - 0"
SCALE:
-
0-59-714-C?3
----...,.-
\'=\6. 5. A
-------
circulation through the condenser.
As heat ~s add~d to'th~ ci~-
cuit a pressure of 2600 psig is maintained in the pre-evaporator
and evaporator circuits by throttling the W valve.
The pressure
in the first superheater and flash tank is kept at 600 psig by
controlling the A, D and E valves.
A steam-water level forms in
the flash tank, and the NandI valves are opened to allow this
steam to warm the second superheater tubes and the subsequent
steam lines.
Next the second superheater bed is ignited.
Ignit-
ing this bed will be considerably easier than the first two beds
because the tubes will be heated by the entering steam.
It is
anticipated that this bed can be ignited with a full capacity of
dolomite.
When the steam enthalpy is sufficient, the turbine can be
warmed and rolled.
The flash tank pressure is then raised to
1000 psig and the steam flow is increased until the load is about
10% of full plant load.
At this point the turbine throttle pres-
sure is raised to the operating value by closing the P and N
valves and opening the V and Y valves.
Subsequent increases in
load are controlled by the turbine governor and accomplished by
increased steam flow.
Start-up of additional modules whether during plant start-up
or load changes is very similar to the start-up of the initial
module, but there are some important differences.
First the feed-
water temperature will be greater than 500°F instead of the 80°F
temperature that is present in the cold start.
With this reduced
heat loss to the water circuit, the pre-evaporator and first sup-
erheater beds need not be ignited at a low dolomite capacity.
This
speeds up the start-up process which is important fo~ load changes.
H-S6
-------
.-
In this start-up situation the flash tank system is used in the
same manner as before, but the I valve cannot be opened until the
steam temperature and pressure match the existing steam turbine
conditions.
Until these conditions are reached, the U valve will
be open and the steam will be sent to the condenser or a high
pressure feedwater heater.
In a conventional once-through steam
generator plant it takes 6-7 hours to reach full load from. a cold
start.
Steam turbine considerations are the main factor in this
time schedule so the extra time required to ignite the fluidized
beds should not be a problem.
5.3
Load Control
A procedure has been devel9ped to change the plant power out-
put to meet system load demands.
It is required that the plant be
capable of a 5% load change per minute and turn down to 25% of full
load.
If the plant is operating at full load and it is desired
to reduce the load, the output of each of the modules will be
reduced simultaneously until 75% load is reached.
At this point
one module will be removed from service, and the load of the re-
maining modules will be increased to maintain 75% plant load.
The
output of the remaining three modules can then be lowered simultan-
eously until 50% plant load is reached.
At 50% plant load the
three individual modules would be operating at 67% of their full
load.
At this point one of the modules would be taken out of
service, and the remaining two modules would be brought up to
full load.
The same procedure will be used as the load is de-
creased further.
The individual module turn down capability is. 50%.
With a four module plant this will provide a smooth load change.
H-57
-------
curve with the above turn down procedure.
The 50% module turn down
limit is dictated by the sulfur removal 'process.
Since load is
reduced by lowering the bed temperature, the low temperature limit
of the sulfur removal process also limits the turn down capability
of the module.
The steam generator parameters for each module at reduced
load can be seen in Tables 2.4 and 2.5 of Section 2 and Tables
A2-l and A2-2 of Appendix 2.
The steam side conditions are based
on the Hammond #4 Station of Georgia Power and Light Company.
The
feedwater inlet temperatures to the steam generator modules differs
from the Hammond #4 temperatures because of the stack gas cooler
in the combined cycle plant.
The gas side parameters are a function
of the heat requirements of the steam cycle and the flow require-
ments of the gas turbine.
The bed levels are not changed during turn
down.
As the feedwater flow rate is reduced, the fuel input to the
various peds is reduced.
This lowers the bed temperature, and there-
by reduces the heat to steam.
The air/fuel ratio is increased
during turn down.
This is necessary both for the fluidization of
the bed and for the efficient use of the gas turbine.
The fuel/air
,ratios for different loads are given in Table 2.4 of Se~tion 2.
The resulting bed superficial velocities can be found in Tables
'A2-l andA2-2.
The gas turbine compressor air rate is constant
so as fuel rate (load) changes the air/fuel ratio must change also.
Fortunately, the superficial velocity remains fairly constant with
load turn down.
The temperatures of individual beds within a
module can be different at low loads.
This is due partially to
changes in heat transfer characteristics of the steam generator
at low loads and partially due to changes 1n the steam cycle
H-')R
-------
conditions.
These changes in the steam cycle conditions include
the proportion of reheat flow and the inlet feedwater temperature.
5.4
Shut-Down
The normal shut-down of a module will be accomplished
by basically the reverse procedure of start-up.
Again there
are two possible situations.
One condition would be
the shut-down of one module while the other modules are in opera-
tion.
The other situation would be the shut-down of the final
module.
In the first case the module load would be reduced until
it is at 50% of the full module steam flow.
At this point the I
valve would be closed and the U valve would open to permit flow
to the condenser.
Fuel flow would be stopped. but fluidizing
air flow will be maintained in the beds in order to purge and
cool the beds.
When the bed has cooled sufficiently to indicated
that it is purged. the air flow can be stopped.
If it were de-
sired to keep the module in a standby condition. feedwater flow
would be continued through the pre-evaporator bed. evaporator
walls and first superheater bank.
This flow would be achieved
by closing the V valve and opening the P valve.
Feedwater would
then flow through these tube circuits and maintain the bed at
approximately 500°F.
If it is not required that the module be
kept in a standby condition. feedwater flow will be stopped by
closing the B valve.
The last module to be removed from service would be shut
down in a different manner.
When the last module is operating
at full load. the steam turbine will be at 25% load.
At this
point the pressure reducing valve W will be throttled and the
H-59
-------
P valve will be controlled in order to ramp the turbine throttle
pressure down to 1000 psi.
At this point the steam turbine
would be removed from service 'and the I valve would :be closed.
From this point on ,the shut-down operation would be the same
as with the previously removed modules.
Several possibilit.ies exist that -would require emergency
.shut-down .of the steam 'generators.
One .possibilitywould be
.the loss of load ona gas -t-urbinewhich would cause a run-away
condi-tion.
If ,this occurred ,the fuel input would be automatically
stopped and a relief valve would open to divert the flow from the
gas turbine.
As the gas turbine slows down" the air flow through
the beds should still be sufficient to purge any volatiles from
the bed.
On the steam side, the I valve would be closed to pro-
tect the steam turbine.
Emergency shut-down due to steam side problems would be
accomplished in the same manner as in conventional units.
The
components of the steam system (1. e., condenser, f lash tank,
feedwater heaters, etc.) are designed on the same basis as a
plant of the same steam flow as the total of the four modules.
This is necessary because only one steam turbine is used for
the four module plant.
One problem of emergency shut-down is
that the fluidized beds will contain a greater amount of heat
than conventional boilers due to the specific heat of the
sorbent.
This same situation, however, does occur to some
degree in conventional units where a highly fouling fuel is
used.
In these units ash attached to the tubes also has a
specific heat that must be dissipated.
In either case, if a cir-
H-60
-------
culation of feedwater flow is maintained, no problem exists.
Even if circulation is stopped on the steam side, however, the
combined effects of air flow through the beds and blow down on
the steam side should prevent any damage to the tubes.
A tube failure in the steam generator would also require
removing a module from service.
This event, however, would not
require an emergency shut-down.
In fact, it would probably take
a relatively long period of time to determine that a tube rupture
had occurred.
An indication of a tube rupture would be a loss
of make-up water.
When this is noticed, the steam generator
would be shut-down in the normal manner.
5.5
Performance
The performance of the steam generator is summarized in
Table 5.1.
The values tabulated are for the total 300 MW plant.
Additional information on performance can be found in Section 2
of the text and Appendix 2.
H-61
-------
TABLE 5.1
STEAM GENERATOR PERFORMANCE SUMMARY
(FOR TOTAL PLANT)
Fuel flow - M lb/hr
Air flow - M lb/hr
Flue gas flow - M lb/hr
Feedwater inlet temperature - of
Feedwater inlet pressure - psig
Main steam outlet temperature - of
Main steam outlet pressure - psig
Main steam flow - M lb/hr
Reheat inlet temperature - of
Reheat inlet pressure - psig
Reheat outlet temperature - of
Reheat outlet pressure - psig
Reheat flow - M lb/hr
Flue gas exit temperature - of
Flue gas pressure drop - psig
Fuel/air ratio
DESIGN LOAD 70% PLANT LOAD
215 154
2,506 2,506
2,705 2,650
578 547
2,824 2,650
1,000 1,000
2,500 2,444
1,727 1,140
650 584
600 405
. 1,000 1,000
580 391
1,644 1,090
1,650 1,400
4.8 4.8
0.0856 0.0615
H-62
-------
6.
STEAM GENERATOR COSTS
6.1
Capital Costs
Cost estimates were obtained for the following pieces of
equipment in the 300 MW plant described in this report.
The
cost estimates include engineering, material, fabrication, profit
and overhead.
Shipping costs to the plant location are not in-
cluded since a plant site was not specified.
6.1.1
Steam Generator Modules
Details of these modules
are shown in Figures 3.1, 3.2, 3.3 and 3.4.
Four modules are
required for a 300 MW plant.
The estimated cost includes piping
in the vessel up to and including the penetrations of the pres-
sure vessel shell.
6.1.2
First Stage Separators and Gas Piping
Details of this
system can be seen in Figures A4-4 and A4-S.
Included in this
cost estimate are the first stage separators, the separator pressure
vessel and all of the gas piping from the steam generator outlet
to the secondary separator inlets.
The cost for this equipment
was estimated for two cases.
In one case the gas piping from the
steam generator to the first stage separator is lined with hard
refractory, but the first stage separator pressure vessel and the
gas piping from it are lined with stainless steel.
In the other
case hard refractory without an alloy liner was used throughout.
6.1.3
Second Stage Separators The second stage separators
can be seen in Figures A4-S and A5-3S.
The cost for these cyclones
includes the pressure vessel and internals.
The pressure vessel
is lined with insulating refractory and an alloy shroud.
H-63
-------
6.1. 4
Coal Handling System
Details o~ this system can
be seen in Figures A5-3 and A5-4.
Costs for this system in-
elude coal conveying, drying, crushing, and storage equip~ent
from the coal train discharge up to but not .inc~uding the surge
bin of the coal pressurizing system.
Structural steel, in-
strumentation, controls and erection are included in this cost
estimate.
6.1.5
Coal Pressurizing and Feeding System
This system
can be seen in FiguresAS-3 and A5-4.
The cost estimates
.include the storage bins, storage injectors, primary injectors,
and the piping and valves between these vessels.
Cost estimates
are also included for the coal feed lines from the primary in-
jectors to the beds and for instrumentation and control of the
entire system.
Table 6.1 lists the cost estimates for the equipment
spec if ied .
6.2
Maintenance and Operating Costs
A quantitative estimate of maintenance and operating costs
is impossible to determine at this stage of development.
As far
as the maintenance of the steam generator modules is concerned,
it is probable that certain repairs will be more time consuming
than in conventional units.
Specifically, the additional problems
in the repair of tube leaks are discuss~d in Appendix 3.
The
significant effect on maintenance cost, however, will depend more
. on the frequency that tube ruptures occur than on the increase in
the cost of repairing them.
The steam generator design presented
in this report may be less prone to tube ruptures than conventional
H-64
-------
TABLE 6.1
CAPITAL COSTS FOR 300 MW COMBINED CYCLE PLANT*
(Shop Assembled)
1.
Steam Generators
$3,856,000
$
500,000
2.
Steam Generators - Erection
$2,110,000
$1,500,000
$1,992,000
$2,500,000
$2,400,000
* The extent of equipment in each item is specified in the text.
3.
First Stage Separators and Gas
Piping
With stainless liner
With hard refractory liner
4.
Second Stage Separators
5.
Coal Handling System
6.
Coal Pressurizing and Feeding System
H-65
-------
units, because the heat absorption rates in the steam Hod water
circuits will be more even.
A major cause of tube ruptures In
conventional units is the uneven heat absorption rates in the
furnace.
Since the fluidized beds should have very even heat
absorption rates, the possibilities of a tube overheating may
be reduced, but it is nearly impossibl~ to estimate the frequency
of tube ruptures even in conventional units.
Another advantage of
the fluidized bed steam generator is that soot blowers and pulverizers
are not required.
These items, which are necessary in conventional
coal fired plants, require a large amount of maintenance.
Other
maintenance of the steam generator such as repairing insulation,
ignitors and dampers should be no more frequent. or expensive than
in conventional units.
The high temperature flue gas piping is not found in con-
ventional steam generators, but experience with this type of
piping in process applications has shown that practically no
maintenance is required.
6.3
Extrapolation of Capital Costs to 600 MW
The capital cost estimates presented in Section 6.1 for a
300 MW plant were extrapolated to obtain cost estimates for a
600 MW plant.
These ,estimates are rough, however, because
detailed designs of the equipment were not develored for the
600 MW plant.
Instead, the equipment was scaled up assuming
that the four-module arrangement will be retained as the plant
size is increased to 600 MW.
The selection of the number of
boiler modules is discussed in Appendix 1.
Basically, it is
felt that the added complexity of plant operation with more
than four modules and the additional costs of auxiliary equipment
H-66
-------
offset the benefits of a fully shop assembled 8t~am generator
module.
Figure 6.1 shows the expected steam g~nerator costs for
different size plants.
One curve assumes that four modules are
used in each plant, but the module size is increased.
The other
curve assumes that the maximum size shop assembled module is
used, but the number of these modules is increased.
It can be
seen from these curves that a five-module shop assembled plant
is approximately the same in cost as a four-module field erected
pl!lOt.
If the costs of auxiliary equipment such as coal handling
and feeding equipment were included, however, the cost of the
five module plant would exceed that of the four module plant.
This is due to the additional number of vessels, hoppers, and
controls that are required as the number of modules is increased.
Over the range of plant sizes shown in Figure 6.1, the
benefits of shop assembly can still be taken advantage of to
some extent, even with four-module plants.
The resulting sizes
are such that individual fluidized bed cells could be assembled
in the shop including the enclosure walls, tube banks, headers
and dampers.
These units could then be shipped to the plant site
for final field assembly of the steam generators.
This work
would consist of welding the cells together and assembling the
pressure vessel.
In conventional field assembled steam genera-
tors the enclosure wall panels, tube banks and headers have to be
shipped separately so there is a larger scope of field work.
Figure 6.2 shows the cost of the extrapolated steam genera-
tors on a dollars per kilowatt basis.
It can be seen that the
dollars per kilwatt cost of the four-module plant levels off at
H-67
-------
$8,000,000
$7,000,000
$6,000,000
. $ 5 ,000 ,000
il
$4,000,000
$3,000,000
$2,000,000
$1,000,000
LIMIT OF CURVE
SINCE DEGREE OF
SHOP FABRICATION
CHANGES BEYOND
THIS, ~ POINT
STEAM GENERATOR ~(Including Erection)
vs
PLANT SIZE
--
Not including equipment
exterior to module
pressure vessel'
, It
L 4 MODULE PL-
,/~ FIELD ASSEMBLED WITH
/' MAXIMUM SHOP
~' FABRICATION
.,. /
. '/
0.
/'
. /
/
/
I
/~
IC
PLANTS CONSISTING OF MULTIPLES
OF LARGEST SHOP ASSEMBLED MODULE
.
o DETAILED DESIGN. POINT
)( CALCULATED EXTRAPOLATION POINTS
100
200
300
400
500
600
PLANT SIZE (MW)
Figure 6.1
-------
14.0
13.0
~
.......
(J)-
.....,
Eo<
CI)
o
u
12.0
11.0
It
,
,
\
\
\
\
,
\
~
PLANTS CONSISTING OF
MULTIPLES OF LARGEST
SHOP ASSEMBLED MODULE
x
vs
STEAM GENERATOR COSTS, $/KW
(Including
PLANT SIZE
-...,.-
~ FOUR MODULE PLANT
~FIELD ASSE}ffiLED WITH
MAXIMUM SHOP FABRICATION
\
)(
LUIIT OF
CURVE SINCE
DEGREE OF SHOP
FABRICATION
" CHANGES BEYOND
. " THIS POINT
Erect10n) x~
. ~x~
Not including equipment exterior to
module pressure vessel.
0DETAILED DESIGN POINT
xCALCULATED EXTRAPOLATION POINTS
100
200
300
PLANT SIZE (MW)
H-69
400
500
600
700
Figure 6.2
-------
about 600 MW.
This is mainly because pressure vessel costs
rise at an increasing rate as plant, and hence module, size is
increased.
Beyond this point it might be beneficial to increase
the number of modules, or to change the basic. design in some
manner.
In order to investigate this, however, another detailed
design would have to be developed for the steam generator and
the auxiliary equipment.
The reason for this is that the cost
of considerable extrapolation has already been used in arriving
at the five-module plant, and the compounded errors that would
result from further extrapolation to larger size modules would
make the results of quentionable value.
The estimated costs for the steam generator and auxiliary
equipment for a 600 MW, four-module plant are tabulated in
Table 6.2.
Except for the structural steel and platform cost,
which was not included in the 300 MW plant cost, the scope of
equipment in Table 6.2 is the same as that in Table 6.1.
It
should be kept in mind, however, that these costs are not based
on a detailed design, but on an extrapolation of the 300 MW
,
plant. Figure 6.3 indicates the proportionate cost of the
different items that make up total steam generator cost and
how these cost items change as the plant size is extrapolated.
H-70
-------
TABLE 6.2
CAPITAL COSTS FOR A 600 MW COMBINED
CYCLE PLANT*
1.
2.
3.
Steam Generators
Steam Generators - Erection
First Stage Separators and Gas Piping
With Stainless Lining
With Hard Refractory Lining
$6s669s000
$ 725s000
$3s560s000
$2s560s000
$3s984s000
$2s750s000
$3s400s000
$
631s000
4.
5.
6.
7.
Second Stage Separators
Coal Handling System
Coal Pressurizing and
Structural Steel and
Steam Generators and
Separators
Feeding System
Platforms for
First Stage
$
303s000
8.
Structural Steel and Platforms for
Steam Generators and First Stage
Separators - Erection
* The extent of equipment in each item is specified in the text.
H-71
-------
8,000,000
7,000,000
6,000,000
5,000,000
'"'
q)-
'-'
~ 4,000,000
o
t.)
3,000,000
2,000,000
1,000,000
I
I
,
(Engineering, Contract!
Reserve, etc.) I
3
COST INCREMENTS FOR
FIELD ERECTED FOUR-HODULE PLANTS
Not including costs exterior
to module pressure vessel
Erection
Pressure 'Parts
(In'eluding Field
Assembly)
.
Shell
(Including Field
Assembly)
Subcontracted and ~-
Contracted Equipment
Drafting
. r Booe
Office
318
100
200
300
400
500
600
H-72
PLANT SIZE (MW)
Figure 6.3
-------
7.
DEVELOPMENT REQUIREMENTS
One of the objectives of this study is to determine what area~
in the plant design require further efforts in research or develop-
mente
Broad areas to be considered are the fluidized bed charac-
teristics, mechanical design problems, and safety aspects.
The steam generator design that was developed in this study
was based on certain bed characteristics.
Some bed characteristics
were quantitative in nature such as the heat transfer coefficient
and the amount of particulate elutriation.
Others were qualitative
such as the uniformity of bed temperature and the absence of fouling
in the bed. The quantitative assumptions need to be more accurately
determined by experiments on beds that are similar to the beds in
the design.
The qualitative assumptions should be validated over
the entire range of possible operation of the beds.
All of these
characteristics influence the design of the steam generator.
The
uniformity of the bed temperature and the value of the heat trans-
fer coefficient influence the selection of tube materials and de-
termine the required amount of tube surface.
Fouling in the bed
would influence the design of the tube bundles, because it would
be very difficult to clean ash deposits off of tubes with the close
tube spacings that are desirable for good fluidization.
It would also be desirable to optimize the coal feed nozzles
and the air distribution nozzles.
This type of an optimization can
only be done experimentally.
Aspects of the air nozzles that re-
quire optimization are the number of nozzles and the shape of the
nozzles.
The effects of the number and location of the coal noz-
zles on carbon burn-odt and bed temperature distribution should
H-73
-------
also be determined.
Certain characteristics of the gas flow after .the fluidized
beds also require further development.
The heig~t and heat trans-
fer coefficient of the transition zone above the bed should be
more accurately determined.
Both of these parameters of the
transition zone could be strongly dependent on bed dimensions,
tube. orientation .and fuel firing rate.
There is also a possibility
of a gas temperature rise above the bed.
This would be due .to a
certain amount of combustion .after the bed.
The extent of this
combustion should be evaluated for. the .type o.f fluidized beds
shown in this design so that convection heat transfer surface
could be located after the beds if it is required.
There are certain mechanical aspects of the design that need
further development.
The possibility of extreme tube vibration
in the beds co~ld influence the selection of tube diameters and
the shape of the beds. A more detailed analysis of the shell
pen~trations then was possible in the sc~pe of this project should
.be undertaken. for all possible operating conditions.
Safety aspects of the system should be analyzed further.
Certain problems relating to safety w~ll require feedback from
experimental tests of the fluidized beds.
The carbon carryover
from the beds and extent of combustion after the beds will affect
the possibilities of fire and explosion in the system.
Other
safety aspects will primarily be concerned with the control
system.
The possibility of a pressure bu~ld-up in the vessel
can easily be taken .care of with safety valves.
A leak in the
.pressure vessel due to other. causes, however, would be more
difficult to handle.
The reaction force caused by a gas leak
H-74
-------
of this type could put a stress on the vessel and also the hot
escaping gas could injure personnel.
Some menns of automatically
determining this type of a leak and depressurizing the vessel
should be developed and incorporated into the control system.
H-75
-------
APPENDIX 1
CANDIDATE CONCEPTS
Al.l
Determination of the Steam Cycle and Gas Pressure
The selection of a fluidized bed combined cycle power plant
design requires the examination of both the steam side and the gas
side of the power cycle.
The steam side parameters are somewhat
fixed by the present market for large, high pressure steam genera-
tors.
Basically, the choice is between two cycle conditions, sub-
critical and supercritical.
Two steam cycles were chosen as being
typical and suitable as a guideline for the fluidized bed study.
The Homer City Station, Unit 2, of the Pennsylvania Electric Com-
pany was used as a basis for the supercritical cycle, and the
Hammond Station, Unit 4, of the Georgia Power and Light Company
was used for the subcritical cycle.
The parameters of both of these
units are listed in Table AI-I.
The subcritical cycle results in
lower boiler costs because of thinner pressure part tube walls
and lower tube metal temperatures.
Thermodynamic and cost analyses
of 10 atmosphere combined cycle plants done by Westinghouse have
also shown that there is no advantage in using supercritical steam
conditions at 1000°F final steam temperature.
The type of steam flow circuit in the boiler also has to
be determined.
Both natural circulation and once-through circuits
were considered.
Although natural circulation systems have char-
acteristics that are beneficial in subcritical steam generators,
the physical restrictions of a pressurized fluidized bed boiler
H-77
-------
TABLE Al-l
TYPICAL SUBCRITICAL AND SUPERCRITICAL
STEAM CYCLES
SUBCRITICAL SUPERCRITICAL
Unit Capacity, MW 500 660
Steam Flow, lb/hr 3,326,000 4,620,000
Steam Pressure, psig 2,486 3,800
Steam Temperature, of 1,000 1,005
Reheat Steam Flow, lb/hr 3,206,500 3,873,000
Reheat Inlet Pressure, psig 452 630
Reheat Inlet Temperature, of 607 588
Reheat Outlet Pressure, psig 581 605
Reheat Outlet Temperature, of 1,000 1,005
Feedwater Inlet Temperature 465 543
Drum Pressure, psig 2,530
H-18
-------
make the use of a natural circulation system impractical.
A
major problem with this type of circuit is the need for a large
steam drum.
This drum would have to be placed on the top of the
steam generator pressure vessel and many downcomers and risers
would have to penetrate the pressure vessel shell.
The gas side parameter that has the greatest effect on
steam generator cost is the gas pressure.
It is desirable to
relate the gas side design to the steam side design so that the
various curves based on gas flow will have more meaning in terms
of boiler size.
This can be accomplished by fixing certain para-
meters.
If the furnace exit temperature, excess air, heating
value of fuel, and steam cycle conditions are established, a
relationship between steam flow and gas flow can be established.
This relationship is shown in Figure Al-I for the subcritical
cycle.
Figure Al-2 is a plot of vessel diameter versus gas flow
with gas pressure and velocity as parameters.
The velocities
that this graph is based on are not the only possible gas velo-
cities, but they serve as a reasonable basis for the study.
It
is obvious from this graph that the rate of reduction in vessel
diameter becomes smaller as the pressure is increased.
At any
gas flow rate the vessel diameter can be changed by changing
the number of vessels in the plant.
The reduction in vessel di-
ameter as a function of the number of vessels can be seen in
Figure Al-3.
It can be seen that with more than 4 or 5 vessels
the effect of increasing the number of vessels on the vessel
diameter becomes less significant.
H-79
-------
GAS FLOW VERSUS STEAK FLOW FOR COST STUDY
12
~I---"----T-
10 -
FURNACE EXIT TEMPERATURE - I700°F
CYCLE CONDITIONS - SUBCRITICAL CYCLE IN TABLE A-I
8 -
\0
0
:::r:: r-!
I )(
CD r-!
a
~ 6 ---
r-!
~
tI)
.~
'-
4 -
COMBINED CYCLE
/
,/
Gas Pressure - 10 ATM
~~
,
2
/
" '/
/ /'
./...."
/" ./,...~'.-'
/'. .'
.....'
/""
~~~~
.........
CONVENTIONAL,
BOILER
Gas Pressure - 1 ATI.!
I
---L~.._--_._......_--_.~.__._-
2 3
-L
4
5
6
Steam Flow lxl06
FIGURE .\1,-1
-------
100
90
80 -_.
10
,...
.u
.....
'-J
~ 60
CII
~ .u
I ~
CD 50
r-o "" --
~ 40 L
r-I
CII
I/)
CI)
CII
==-
30
VESSEL DlAMETERVERSUS GAS FLOW
,-.-----..-.---...,
--l-------T'"
/
/
.// /
../ /
/
20
//
// /"
:/.' ~' -'-
'.' .._'~
- .".'~' /~
iW--:-:-~ .-
~~ --. .' L__'h"'" . .....L.n
1 2
10
---
~_.-
~~-~
,,/' ~.
/ ~
. ~
,....."
1ATM
Dia. Required by Fluid Bed
Vspace= ~5 ft/sec
Dia. Required by Fluid Bed and
Gas Return Line at V a 50 ft/sec
28S
and V a 15 ft/s~c
space
-----
..,........_..--_..~...... .
,..-
. .-.'. .
-;~....
. ..--- - .....-
. .--". -....,----.. ,."., .......-.-.--- .-J_"
---.- .---'- --.-. .-- "". ~~-~...,-_._. - .------..-'
. --..---..--.
L_.. .-. .--
.L. """-'--
3
4
6
GaB Flow 1b/hr x 10
10 ATM
30 ATM
I ._--_......:... .......1
5
6
FIGURE A1-;~
--"'.'''''----''''
-------
EFFECT OF THE NUMBER OF VESSELS SELECTED
ON VESSEL SIZE
en 1.0 r
o-J
rzJ
en
en
~ 0.9
>
~
0
~ 0.8
H
u
. H
....J
p.. ....J 0.7
H ~
E-< en
....J en
~ rzJ
>
~ en 0.5
I\)
0 < ~
~ 0
~ 0.4
A
w A
~ ~
H
;:> H
;:> 0.3
rzJ
~ ~
~ ~
rzJ ~
E-< rzJ
~ E-< 0.2
~ ~
H
A H
A 0.1
~
0 0
E-<
0
H
E-<
~ 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
NUMBER OF VESSELS SELECTED
FIGURE Al-3
-------
It should also be pointed out that other aspects of steam
generator design are adversely affected with more than 4 or 5
modules.
These problems are in the areas of control and .auxiliary
equipment, and it. is not possible to quantitatively assess these
affects without detailed studies.
It is relatively simple, how-
ever, to quantitatively determine the effects of gas pressure,
vessel diameter and vessel height on cost of the pressure vessel.
This can be seen in Figures Al-4, Al-S and Al-6.
Figure Al-4
shows the type of vessel used in the cost study.
It should be
pointed out that if the curves are used to evaluate a multi-vessel
system, the gas flow or steam flow per vessel should be used.
Figure Al-S shows the effect of gas pressure on the vessel cost
for different vessel diameters.
Figure Al-6 summarizes the pres-
sure vessel cost study.
This graph shows the relationship between
cost and gas mass flow.
This graph takes into account both changes
in vessel height and diameter as the gas flow and pressure are
changed.
This is necessary because the tube spacings in the beds
are independent of the system gas pressure.
.Theref are, even
though for a given gas velocity the vessel diameter will decrease
with increasing pressure, the vessel height must be increased to
maintain the required heat transfer surface area.
This curve
is based on the same gas velocities as Figure Al-2 and the type
of vessel shown in Figure Al-4.
It is obvious from the plots in
Figure Al-6 that the pressure vessel cost increases with the
system pressure for a given size plant.
The actual costs are
only applicable for the specific gas velocities that were assumed,
but the trend will be the same for any gas velocity.
The difference
H-83
-------
~r-.~.
'..- 0>-
r ~1\ -- -
-. - -~ ~
Ir .
~ -t] M,\,.
:i t
1 I
b- '0> o. -i-t
" I
:1
II
I."
~...)
,
j
! ~.
-+-: .:- -~-'~:'1
r-~ ..,.~fJ
I~ '~"""-='i~ !
~ ~l~ '
I. i .' " (.
" -f:~-~ -,.
~
I
I
~li -- --1
COMPONENTS
1 - 24" Cas Outlet
4 - 12" Air Inlets
4 - 6" Coal Inlets
2 - 24" Manways
2 - Heads
1 - Shell
1 - Skirt
1 - Base
SCHEMATIC DIAGRAM OF VESSEL USED IN COST STUDY
H-84
:: , .~;:. R : A: - /f
-------
"":'15
....
.....
'""
::r: I-<
I Q.I
()) ....
\Jl ~
nI
..-i
c:a
Q.I
:;:10
{/]
t::
H
20
----L~
20
VESSEL DIAMETER VERSUS COST
l
1-\
Field Erected
t
Shop Fabricated
/
.""
T~---1----'--_.- --r-----,
I
I
i
.,
Pressure = 10 ATM
Pressure = 30 ATM
., ,
40
60
1__---1-~
80 100
J__.. __..-L__L_.J.. -~ '
120 1~0 160
180
COST (103 Dollar8)
FIGURE A1-5
-----
I
~
i
I
i
-------
-T-'--'--"
. -. --r-' -- .-.. -- -,--~..
I I I ,,~~
~ £Qg IN DOLLARS
va
./ /,,0
/ /.~.
'\.c~ .' / /
~~v~ ,/ /' .'
4".j) ,/i'.-
4.~ ~. " /
~. /
-------
in shell costs coupled with the anticipated increase in auxiliary
equipment at pressure levels above 10 atmospheres indicates that
ten atmospheres is probably the optimum pressure level for assumed
gas turbine conditions.
A1.2
Determination of Optimum Design
Many factors have to be considered in choosing an optimum
design for a fluidized bed steam generator.
The requirements of
fluidization, gas side boiler design and steam side boiler design
have to be considered in evaluating any design.
Besides the
technical aspects of the design, the economic aspects of the
different designs must be considered.
As a starting point the fluidized bed parameters can be
divided into four broad categories:
1.
Bed cross-sectional shapes
2.
Be d heigh ts
3.
Arrangements of tubes in beds
4.
Arrangement of beds in the vessel.
Each of these categories will be discussed separately, and
the. effects of the different possibilities in each category on
steam side boiler design, gas side boiler design and economics
will be evaluated.
A1.2.1
Bed cross-sectional shapes
Beds of annular and
rectangular cross section were considered feasible for the pres-
surized design.
Just considering the shape of the bed per se
neither design seems vastly superior .to the other.
At first
glance, the annular shape seems to provide a more efficient use of
space in a cylindrical pressure vessel.
However, if space is re-
quired between the tube walls and the shell for piping or equip-
H-87
-------
ment, fully using vessel space by having an annular bed is no longer
a benefi t .
The fabrication of annular beds may be more cos~ly" than
rectangular beds due to more difficult tube wall fabrication.
None
of the above reasons are sufficient for choosing one bed shape as
superior, but these considerations coupled with the tube arrange-
ment restrictions of each shape infl~enced the final choice.
Al.2.2
Bed heights
Three ranges of bed heights were con-
sidered.
Shallow beds of less than 5 ft., medium beds of 5 ft.
to 15 ft., and deep beds greater than 15 ft. were ,considered
for the design.
Shallow beds were ruled out for several reasons.
First, shallow beds require many more coal injection points than
deeper beds.
In the pressurized design this multiplicity of coal
injection points is a problem for two reasons.
First, space is
at a premium inside the pressure vessel, and the coal injection
lines could take up a significant amount of space in the vessel.
Also the increased number of vessel penetrations caused by the
coal pipes makes the expansion problem more serious.
Shallow
beds also require more stacked beds thana deep bed design.
'The
extra tube banks that result from increase in the number ,of beds
require more headers" transport piping, and accessories such as
air dampers and ignitors.
Shallow beds do have the advantage of
having a lower pressure drop than deeper beds, but in a pres-
surized-combined c:ycle design the pressure drop :across ,the bed
is not the most important design consideration,.
A more important
consideration ista have most of the heat transfer surface in ,the
uniform temperature fluidized bed.
For 'a given upper limit on bed
temperature, this achieves the highest ,possible gas turbine inlet
H-88
-------
temperature because any heat transfer outside the bed will lower the
gas temperature.
It is obvious that this situation can be more
easily attained with deeper beds.
Beds deeper than about 15 ft. also have many problems as-
sociated with them.
Certain problems have to do with how the beds
can be located in the pressure vessels, and how the different boiler
functions (superheat, reheat, etc.) can be distributed among the
steam generator modules.
These problems will be discussed later.
Certain problems, however, result just from the properties of a
very deep bed.
The deeper the bed, the more difficult the ignition
problem becomes.
This is because more dolomite and heat transfer
surface must be brought up to the ignition temperature of the coal.
There is also a problem that results from air to fuel ratio and
fluidization velocity requirements.
The velocity requirements
for fluidization can be seen in Figure 2.2.
This curve gives a
minimum and a maximum air mass flow rate for a given bed temperature.
The fuel input requirement is a function of the amount of heat trans-
fer surface that is located in the bed.
As the bed height is in-
creased the fuel requirement increases, and the air flow requirement
increases.
If the cross-sectional area of the bed is restricted
a bed height will be reached where the air flow requirement will
yield a superficial velocity that is greater than the maximum a1-
10wab1e superficial velocity.
The range of bed cross-sectional
areas that can be achieved is restricted in the pressurized deisgn
due to pressure vessel size limitations.
Also, although pressure
drop across the bed is not critical in the pressurized design,
it is an energy loss, and should be weighed against any benefits
of deep beds.
H-89
-------
Bed depths at the high end of the middle range seem best
suited for the design requirements of the pressurized steam
generator.
These depths coupled with bed cross-sectional areas
that can be reasonably fit into, a pressure vessel result in
allowable 'superficial velocities.
It is felt that the simpli-
city that is derived by having fewer beds of this depth rather
than more shallow beds overrides the disadvantage of increased
pressure drop.
Al.l.3
Arrangement of tubes in the bed
Four types of
tube bundles were considered for the steam generator.
These
were helical tube bundlest horizontal serpentine tube bankst
straight vertical 'tubes and vertical pendant tube elements.
At first glance it seems that helical tube bundles in annular
beds is a good design because of the efficient use of vessel
space that is achieved.
Howevert this design has many inherent
problems in steam side designt construct and maintenance.
In
designing a tube bundle the mass flow rates in the tubes must
be within a certain range of values so that the pressure drop will
be acceptable and the distribution of the flow among the tubes
of a bank should be as even as possible.
In order to fulfill
the first design criteriont it is required to have some flexi-
bility in the number of tubes that can be located in a type of
tube bundle.
Alsot in order to have equal flow distribution and
heat absorption in all the tubes of the bank the tube lengths
. ,
must be approximately equal.
It is difficult to fulfill both
of these design requirements with a helical tube bundle.
In
order to get equal tube lengths in the bundle the number of
H-90
-------
tubes and the pitch of the tubes at a given radius from the center
of the bundle are restricted.
This combined with the limits of
bed cross-sectional area and tube sizes provides severe restrictions
on the steam flow rates tha can be achieved.
It is also felt that
the construction of the tube bundles though not impossible, would
be difficult and costly.
Another type of tube arrangement that could be used with an
annular bed is vertical pendant elements.
A design using this
type of bed is shown in Figure Al-7.
This design provides more
flexibility in the steam side design than helical tube bundles,
but the fluidization characteristics of the bed may not be very
good.
Because of problems with supporting and locating the headers,
the only practical arrangement of the pendant elements in an annular
bed is a radial layout.
This presents problems, however, because
this layout results in uneven spacing of the tubes in the bed.
This characteristic of the bed may result in channeling of the
flow, spouting of the bed, or the development of hot spots in
the bed.
Straight vertical tubes could be placed in either annular
or rectangular beds and the~e is a lot of flexibility in the
tube spacings that can be achieved.
The main problem with verti-
cal tubes is the large amount of headers and transfer pipes that
are required.
The number of individual tubes required to fill a
>bed is much greater with straight vertical tubes than with any of
the other configurations.
This can readily be seen in Figure Al-8.
Arranging these tubes in one pass would result in a very small
steam side velocity in the tubes.
To divide the tubes into a suf-
ficient number of circuits requires a large number of headers and
H-91
-------
'l-'W~\OL ...,\.\,
/
./ I
/ i
/ I
:' -/'I~
'~-"
" o",."ot. 'Hi\.\'
1" Pt.>lO""'T
PlIUJ n"D-D"
t>c.~I.t.: 11" ",'.0'
PlA.t-I Ai "c.-c'
~'''lL: 11'" I~o"
-
-
..
...
,.
o
"0
r
..
4
\J
- ~_...."",
.---.--
-'~~~
:I
..
::
I Lt. "
01
.. II
.. I
" rl
o ..
I. J l-
V "
,.. 01
v "L---- %
..
~ 30'.o.t DI
'--
.1' \M~It)1. "'Ul
,- ou,~,o" w,\.\.
~1". P..LMO "'>11
"A" .I
'-J
,v
r
I"OU'T~IOt "Hl
18 P.L't\'tIOM W''-'-
1" 1>1\101. ...All
P LA IJ '.. T 'B . B'
os c.A.\.., fl.-. ,'. Q'
.---.--
..
c
..
--.--
..
c
.,
c
...
-
-'
~
~
~ D ~ .. ..
.. ~ .
II ~ ..
. .
rI ~ '2 10
oJ .I 0 ..
:; " ... 0
01
~ <; ... -
.. d
.. . %
~ :> ,, -
,. .~ ;. ;"
(1 '70~o..t
--
I-
I
-j
FII;.AI"7
"4
.:c
2.
0-
W
...
If)
-
......
-
/- -+-~~.
,/ I
/
(
-~:~:-:::;'-:
~\ ! )
'~--f-//
......0..
ANNULA.1t ~E.O
vtllilCAL "TUb£'
FLU'O'1.~D !lE.D
SitAM GlWU.to.'t02.
ftI8 ....... .. .. ....... .. ..
. "08ftR~~-
II 11080.~A"" ~"J,.
=::.= -.:=..... ftM~ .r:;;-~""yii
=="=--~""'.un' I ftIIUI
""TPOII--",.~Y"" ft8..
...-.aA'rVII ..... . .. ....- .
.........
D8tA'" 8T1
ClCIICKD) 8'Y:
8CAUO
-1''''
_ft,
O'~9'711- 3\
-------
-----~---~
"-
"
'"
\
\ \
\ \
,\
\
\\\
/
i
.I
./ ,/
\.
"
~.
.--------
.----
.-- -----~--
i
-"
--
DWG. NO.
flG.A.I-e,
IIOTES
I. 80""-=----- -~
-......
&. --.....- C8 n8 - -.
~..". ---=-....- &M-
-*~.. - C8-..
~ -1'1 ~
.('I"S.OIIl
LA.'(OUi Of 'H~"\C.L
TUe.l~ IN AM .
AfjfjULA\l e,tO
0- S ':' 700- '34
=::-e: -- IAn ---
- JI.. '-Z6.70 --
no. ---. . .. "'-'r ., -
- "08ft1ll Wttan8111 c:o.o.u.noH
~ ".-1-.~::;1:~:~~
1,- :~ -:.:: ====:.":-==. ~
-------
large number of transport pipes.
Al.2.4
Number of vessels and arrangement of beds in the
vessel
It was determined that a 12 ft. diameter vessel would
be the optimum size for a 300 MW plant.
This diameter vessel
could be shipped in long sections by rail.
The maximum shipping
length would, of course, depend on the exact location of the pro-
posed plant, but for most locations a 12 ft. diameter vessel could
be shipped as long as 120 feet.
With a 12 ft. diameter vessel
having a length in the range of 120 ft., a 300 MW plant requires
four modules.
Besides the economic benefits of a plant consisting
of shop assembled modules, there are alos operational benefits
that result from a modular design.
One beneficial aspect of a
modular plant is that the turn-down ratio required of each module
is less than would be required from a single steam generator unit.
This mode of operation is discussed in more detail in Section 5
of the report.
Also, plant availability increases with the number
of modules.
A drawback to a modular plant is that as the number
of modules in a plant increases, the problem of distributing the
fuel, air and feedwater flows between the modules becomes more
complex.
Both of these apsects of operation have to be considered
in determining the optimum number of module~ in a plant.
A four module plant is a good compromise between the two
criteria discussed above.
The resulting module turn-down re-
quirements are such that turn-down can be accomplished by reduc-
ing the bed temperature.
If a greater turn-down ratio were re-
quired, the bed depth would have to be lowered to achieve turn-
down.
Lowering the bed depth to change load would require a more
complex dolomite recirculation system and would probably result
H-93
-------
in a slower load response time.
The problem of distribut ion of
the various flows between the boiler modules is nut unrealistic
in a four module plant, so a four module plant is a good design
from an operational point of view.
At 300 MW a four module plant
also has the economic benefit of shop fabrication and assembly
since the resulting modules are 12 ft. in diameter and approximately
120 ft. long.
The arrangement of the fluidized beds in the vessel is
another aspect of the design that must be analyzed.
Basically
there are two possibilities.
One would be a vertically oriented
vessel with stacked fluidized beds and the other would be a hori-
zontally oriented vessel with the fluidized beds located adjacent
to each other.
A horizontal arrangement is shown in Figure Al-9.
There are several drawbacks to a horizontal arrangement.
One
problem is that bed height is severely limited.
The steam genera-
tor in Figure Al-9 was designed with a 12 ft. diameter vessel to
allow shop fabrication and assembly.
The resulting bed height
was only 4 ft. and even with this Iowa bed height the particle
disengaging zone is not as deep as it should be.
Another problem
with the horizontal design is the location of evaporation surface.
Upward flow in vertical tubes is the preferred design for evapora-
tion circuits.
This type of an arrangement prevents problems which
arise from water and steam separation in the evaporation circuit.
In a once-through steam generator evaporator tubes can be oriented
in other positions, but the mass flow in the tubes must be main-
tained at a high rate.
Also, walls of bent tubes are more ex-
pensive to fabricate.
In the horizontal steam generator the
H-94
-------
r-
. o'
I-----~--
i
i
i
i
!
,
i
0/1
""
...!
~!
51
rJ.i
I
I
I
--1-----
8/!
,./i
...:
ji
~!
~I
4----
i
!
I
,1'
.I
...
~
,j
%
.J
II
~
:>
~i
,; 9~t..",,,,, c",,_u I'
. 5"""", ''''''11-
------ 0'''" 'P I..L
5 t , 1 I I) '" .~ - ~. -
o
...
~
~I
-4-
>
tAl
~
0.1
I
I
,
:i!:..
--1--- t£.
~ECi It) "-I 'A.A"
T,(~\t~L'~lL W"LL "l"IIL\.\
-,
1 i:
j I.
I : ~
.11-
!! =::.- --,
I!F.'~
I,!i~ i
1,- i
!I! ;-tt
; I i I
I.
i Ii
II: .
ii~
: Ii
,t- - =
- ,
:il=
Iii
. I
: i i
. t:
i i
Iii
! i i
. ~"! --~.
; : ~ --- : .
""-=,
I
~
- I
I
-
,
B+-
I
€+-
I
--ef--
I
';j
- P L ~_l'-l"t>-D"
.~
---r- -
I .
I
i
I
I
I
I
I
I
I
I
I
I
I
I
:~i \J
.
10' U
\1:
2
<)
l-
V
..J
If)
'j,
. ~t
!
1.
t'Z'..o"
-I
F\G.~\'~
f
I
H05t.l'ZOt4i"l cO"C.t~"\I~l
DE.~\c;, N - rO (l II>. p~~ss II i..\H.O
FLUIOIt.LO btO
$IL""'" CiLNLII...ta."':olZ..
VJ
DItA- ":
CHl:CKKD ":
"_aD":
,.... -. .. - P-'ir .. -
FOSTD WHEa.D COIIPOItATIOH
"0 SOUTH ORANGE AVE.. LtVINGITON. NC-JE"SCY
... 18 ...... WI'I'MOU'I' ~'h08I ~ ftIAtI "...
808I:1tOW8Ir8 A888D1DIT ftlAT 11' -.u.L .or - ....
P808UC88. CWI8D. L81ft'.. ~ OP eeaa:n." -
I"".~Y -- UMD.", AllY ........ 01'II8II TIIAII
"",y .... WI8C88 rT '8 8f18C8'1CAL1,Y"""""". "...
APPA8ATU8 ...... .. ft8 _a-- . COWD8D 8Y
P"-
Ji..
-.....
Q.D-712 -92
-------
walls are relatively short, and so straight upward flow evaporator
sections require many headers and downcomers.
As can be seen in
Figure Al-9, the arrangement of the beds in a horizontal vessel
does not leave much room for the location of headers and downcomers.
Because of these space limitations the tube walls shown in this
design would probably have to be used in spite of the drawbacks
discussed previously.
The flue gas passages in the horizontal
steam generator are also a problem.
If the gases leave the vessel
at one location, there will be gas flow across the top of some of
the beds.
This type of a flow is very likely to cause uneven
fluidization of the bed.
To overcome this it was decided to
have separate gas ducts leaving each bed.
This design will re-
quire a manifold system exterior to the vessel.
A vertically oriented pressure vessel eliminates many of
the problems that are encountered in the horizontal arrangement.
The bed heights are not restricted by the orientation of the
vessel and the resulting shape of the tube walls is more
reasonable for use as evaporating surface.
Also the space that
exists between the fluidized bed cells and the pressure vessel
shell in the vertical design is more adaptable to transfer piping.
After analyzing all the aspects of steam generator design
and operation presented in this appendix, the detailed design for
a 300 MW plant was developed.
This design is shown in Figures 3.1,
3.2, 3.3 and 3.4 of the main report.
A vertically oriented pres-
sure vessel is used with vertically stacked beds.
This layout
allows the use of optimum bed heights and tube orientations.
Four of these modules are used in a 300 MW plant which is the number
that resulted as optimum from the pressure vessel study and the
H-95
-------
operational analysis.
remaining appendices.
This design is discussed in detail- in the
j ,<
H-96
-------
APPENDIX 2
ENERGY AND MASS BALANCES
The energy and mass balances for the steam generators are
summarized in the tables and figures of this appendix.
The
assumptions used and the methods of calculation are discussed
in Section 4.2 of the text.
H-97
-------
TABLE A2-1
FLUIBIZ-ED:BEDP.A:RAMETERS
:DESIGN :LOAD
1(1 .MODULE)
,
i \
.Fuel F.low Air Flow ',F!l:ue ,Gas : :Su,pe,rf i:c ial Bed
'(lbfihr) , \(lb/:hr) ..(!l.:b]ihr) ' 'Me1,oci1ty T-emperature 1
, i
; ;
I I ! 1
p..re 'Ev.aporator ;1.,7,,680 192 iOO .2G6,,:2:00 '9..:0 ! 1 ,75'0 I
, ., ! :
,
j i ,
, I
1st I ;
:Superheater 13,100 14:2,7;00 ' J:53" 7,QO 6..8 1,750 i
!
, ;
, , I
\ i
:2nd I I ;
Superheater 10,740 11'6,,900 ]1:25;900 i, 5.,6 \ 1,750
!
i
:
Reheater : !1.:2 ,390 j 134,.'800 1'4'5,:2:00 :6..14 1,750 ;
; : \
\ i
; ,
CBC 6.,4'941 : 42,.600 44,.7'00 '6.1 :2,000
; ,
,
GAST.EMPERAT,URE LEAVING BOlLE'R2.- 1:65'O'op
1
31.7% 'Carbon
63.3% Ash
5..0% Dolomite
:2
Includes GBCGas
H...:98
-------
TABLE A2-2
FLUIDIZED BED PARAMETERS
70% PLANT LOAD
(1 MODULE)
Fuel Flow Air Flow Flue Gas Superficial Bed
(lb/hr) (lb/hr) (lb/hr) Velocity Temperature
--.--
Pre Evaporator 12,600 199,200 209,200 8.7 1,470
st 8,950 141,200 .148,600 6.3 1,470
1 Superheater
nd 7,370 116,300 122,400 5.2 1,470
2 Superheater
Reheater 9,680 152,200 160,800 7.0 1,530
CBC 4,6501 20,200 21,700 3.2 2,000
GAS TEMPERATURE LEAVING BOILER2 - 1400°F
1
31.2% Carbon
62.1% Ash
6.7% Dolomite
2
Includes CBC Gas
H-99
-------
T
I-'
o
o
Flue Gas
631,800 1b/hr
Solids
7 216 1b/hr
PRIMARY
BEDS
MASS BALANCE
DESIGN LOAD
(ONE MODULE)
1
Solids
6,494
1b/hr
Dolomite
6,308 1b/hr
Air
586,500 1b/hr
Dolomite
4,880 1b/hr
Coal
53,910 1b/hr
1
Carbon
Ash
Dolomite
31.9%
63.4%
4.6%
2
Carbon
Ash
Dolomite
Flue Gas
676,460 1b/hr
Solids
5,350 1b/hr
Flue Gas
44,600 1b/hr
2
Solids
4,630 1b/hr
CBC
Air
42,800 1b/hr
4.5%
89.0%
6.5%
3
Carbon
Ash
Dolomite
8.2%
85.8%
6.0%
Flue Gas
676,460 1b/hr
Solids 160 1b/hr
t
...
3
Solids
5,190 lh/hr
FIGURE A2-1
-------
::G
I
. f-'
o
f-'
1
Solids
640,990 1b/hr
Flue Gas
5,263 1b/hr
PRIMARY
BEDS
Air
608,900 1b/hr
Dolomite
4,880 lb/hr
Coal
38,600 lb/hr
1
Carbon
Ash
Dolomite
Dolomite
6,127 1b/hr
31. 2%
62.1%
6.7%
MASS BALANCE
70% PLANT LOAD
(ONE MODULE)
1
Solids
4,740 lb/hr
2
Carbon
Ash
Dolomite
Flue Gas
662,680 1b/hr
3
Solids
3,780 lb/hr
CBC
Flue Gas
21,685 1b/hr
2
Solids
3,255 lb/hr
Air
20,200 1b/hr
4.3%
86.4%
9.3%
3
Carbon
Ash
Dolomite
Flue Gas
662,680 lb/hr
Solids
114 1b/hr
olids
3,660 lb/hr
7.0%
83.9%
9.1%
FIGURE A2-2
-------
::z::
I
~
o
I\)
1.088g8
42.9xlO Btu/hr
PRIMARY
BEDS
Air Seijsible
BO.BxlO Btu/hr
Flue Gas 256.Oxl06 Btu/hr
6
Carbon 33.9xlO Btu/hr
Carbon6
30.6xlO .Btu/h
Steam 6
448 xlO
Coal
70Oxl06 Btu/hr
ENERGY BALANCE
DESIGN LOAD
(ONE MODULE)
Flue G~8 .
279xlO Btu/hr
Carbon6
6.4xlO Btu/hr
Flue Gas6
22.9 xlO Btu/hr
Carbon6
3.lxlO Btu/hr
Steam
lO.5XI06 Btu/hr
Air Segsible
5.9xlO Btu/hr
Flue Gas6
279.0xlO Btu/hr
Carbon6
O.2xlO Btu/hr
f ~
Carbon6
6.2xlO Btu/hr
FIGURE A2-3
-------
:J:1
I
I-'
o
W
Losses
6
30.4xlO Btu/hr
PRIMARY
BEDS
ENERGY BALANCE
70% PLANT LOAD
Flue Gas6
228.lxlO Btu/hr
Carbon 6
23.9xlO Btu/hr
CarboD
2lxlO Btu/hr
Steam
296xl06 Btu/hr
Air ~ensible
77.4xlO Btu/hr
Coal
50lxl06 Btu/hr
(ONE MODULE)
Flue Gas6
239.6xlO Btu/hr
Solids6
4.6xlO Btu/hr
Flue Ga~
1l.5xlO Btu/hr
Carbon6
2.2xlO Btu/hr
CBC
Air 6
2.7xlO Btu/hr
Steam6
lO.5xlO
Btu/hr
Carbon 6
O.l5xlO Btu/hr
Flue Gas6
239.6xlO Btu/hr
Carbon6
4.5xlO Btu/hr
FIGURE A2-4
-------
TABLE A2-3
STEAM GENERATOR LOSSES BASED ON
275°F EXIT GAS TEMPERATURE
Dry Gas
Hydrogen and Moisture in Fuel
Moisture in Air
Unburned Combustible
Radiation
Sensible Heat of Solids
Unaccounted for Losses and
Manufacturers Margin
TOTAL
H-I04
3.88%
4.14%
0.08%
1.51%
0.15%
0.11%
1. 50%
11. 37%
-------
APPENDIX)
TUBE DESIGN INFORMATION
A3.1
Sizing and Arrangement
One factor that contributed to the choice of a horizontal tube
stacked bed design as optimum was that the tube arrangements and
tube support systems allow for conventional fabrication methods.
Structurally the arrangement of pressure parts is very similar to
the convection pass of conventional boiler.
The tube walls are
supported at the upper headers and allowed to expand downward dur-
ing operation.
The walls in turn support the tube bundles.
The
tubes in the tube bundles can be bent on bending machines, and the
tube walls can be welded into panels by automatic equipment.
The tube bundles consist of serpentine elements spaced across
the width of the fluidized bed.
The configuration of the tubes in
the bed is an important design consideration from the standpoint of
fluidization.
There is still much debate about what tube configu-
ration gives the best fluidization, but the design presented in this
report has the benefit of being quite flexible in this regard.
By
changing the tube spacing on the tube walls and the bend radii of
the serpentine elements, the configuration of the tubes in the bed
could be changed without changing the basic design.
The present
tube configurations are shown in Figure A)-I.
Other possible tube
layouts are shown in Figures A3-2 and A3-3.
The cost difference
between the tube banks in the present design and the alternative
H-I05
-------
-
~'h." -
3'/1."
-
3'/,,"
-
~'/," 1"0,0 Wo.\.\. TU~~~
-
~
/'-,\/
"
1___"...
." ~ 1"""'-
\, !
j
v-
, .q-
,
v-
,
I2-E r\~~1EQ.. iU~E
?J 'h" 3 'h."
~~t-.\~. 5C~f~L"A."
~'I'l.' ~'/i." - "2:' 0.0 >N /l..1..\.
. ,-../'-
~,
1u~t.~
.
~ tt,./
.~./
,,;/
\
,,~
.
J
~.
c1'
,
ti\
--.1.
~
,
::
11'\.
e
I '
P 2...E.' to \j A P 0 ~ ~ i 0 ~ ~ 5 \J P E ~ I'i t A i E. 2-
TU~L ~~~'(,S.
'5C~LML "A"__-
TU~E
THE
CO~F\"u R...~iIONS
FLUIDl!tO ~t05
IN
ORDER NO
O.5~.\\""
DRAWN BY,
jlZ-
3 , i7.
CHECKED BY,
!V)
This Drawing is ,he Property 01 the
FOSTER WHEELER CORPORATION.
110 SOUTH OIANGE AVENUE
LIVINGSTON, NEW JIISlY
AND IS LENT WITHOUT CONSIDERATION OTHER THAN THE BORROWER'S
AGREEMENT THAT IT SHALL NOT 8E RE~RODUCED, COPIED, LENT, OR DIS.
POSED OF DIRECTLY OR INDIRECTLY NOR USED FOR ANY PURPOSE OTHER
THAN THAT FOR WHICH IT IS S~ECIf'ICALLY FURNISHED. THE APPARATUS
SHOWN IN THE DRAWII'fG IS COVERED 8Y PATENTS,
APPROVED BY.
SCALE,
- 1'.0"
0-59-714.3~
~,
~.
;:>RM 2:81S.8Z.C
fie.
A 3 - ,
H-I06
-------
-
.'
~
<,~
'»'
"'/'''''- ., '1.."- "'{'..'_' "'f'z"- '" ,'. ,
'" .. '" .. '"' '" ? '/7. - Z h. '- '2. \ 0 , 0
~
I
j
I~
I
i
I I
~ I
ll\ I I
!
~I
(!!)
l' ~....
:~ :
I~ .~I
i Ii:
I(!)' li~!
I Iii!
~U'II~I II~
! ,I --~J
~
~
~
No.l.l. lu~t.';)
V\
Ih."e.c.
PI2-E..- f:.Y~PO~A"O~ ~ S \,) Pl.'l ~ t./\ i t. ~
--""--
\U~L ~A.NK..5
5Ct-\t-.M.~ ..~"
1U~t.
T~E
CONF\GU~~i\ON5
FL.U\O\ZtD ~t..05
\~
,8)
~.
This Drawing is the Property of the
FOSTER WHEELER CORPORATION
110 SOUTH OIANGE AVENUE
LIVINGSTON, NEW JElSEY
AND 15 LENT WITHOUT CONSIDERATION OTHER THAN THE BOR"OWER'S
AGREEMENT THAT IT SHALL NOT BE RE~RODUCED. CO~IED. LENT. OR D'S,
POSED OF DIRECTLY OR INDIRECTLY NOR USED FOR ANY PURPOSE OTHER
THAN THAT FOR WHICH IT IS SPECIFICALLY FURNISHED THE APPARATUS
SHOWN IN THE DRAWING IS COVERED BY PATENTS.
:JPM Ze!5.6Z.C
H-107
ORDER NO
D-5q'II~1
3'
1., )1
DRAWN BY:
j~
CHECKED BY'
APPROVED BY
SCALE:
1.0'
0-5~-7 \4- 38
F\G
A.~-2
-------
,
:
-;t
~'
-- -'--
-r
..
'l)'
. .ut
8)
FORM 285.82-C
,-
I
~ r
,.,r_O
I
i
I
,
!
"/1" i
...
1..'/.( . 'l'/1. - :
,. -
?'/~ :
-
'Z ,} ..
It -
Z "t" ~
~
\)r
~
,
...
~fjJI..
~.
I'
R...t..HEA1E.~ TU~~ ~~~~-SC~tML"~"
'1 '/1. . '3 '/1".L. ? 'It ''.J.-- ~ i1.l1~ 2 '/1 M ~
~L\o\E..A."f..~
~ ~~ ~. ~ c. ~ l. ¥. l "C'I
iU~t..
TUe,[
T~t
CONFlGU~~TlO~5
FlUI{)\'ZED Bt05
IN
This Drawing is the Property of the
FOSTER WHEELER CORPORATION
110 SOUTH ORANGE AVENUE
LIVINGSTON. NEW JERSEY
AND IS LENT WITHOUT CONSIDERATION OTHER THAN THE BORROWER'S
AGREEMENT THAT IT SHALL NOT BE REPRODUCED. COPIED. LENT. OR 015.
POSED OF DIRECTLY OR INDIRECTLY NOR USED FOR ANY PURPOSE OTHER
THAN THAT FOR WHICH IT IS SPECIFICALLY FURNISHED THE APPARATUS
SHOWN IN THE DRAWING IS COVERED BY PATENT8,
H-108
'l'\o,D''''''~I.L
T\)~l~
/'
.
~
-""
-,
\)
,
£" Q. D. IN A. l '- i u ~ l ~
1
'-l\
,
ORDER NO
()''S~.\I~l
DRAWN BY:
J~
.3
1. 1 \
CHECKED BY:
APPROVED BY:
SCALE:
.. I' - 0"
0-59-714-37
f' <4
A 3 - 3
-------
arrangements would be negligible.
All of the tube bundles consist of 23 serpentine elements
spaced across the bed.
The pre-evaporator and superheater tubes
are 1-1/2" D.D.
The reheater tubes are 2" D.D.
From the stand-
point of fluidization, economy of space could be achieved by us-
ing the smallest diameter tubes possible, but both steam flow
requirements and structural problems had to be considered in
choosing the tube sizes.
For example, if the diameter of the re-
heater tubes was reduced, steam flow requirements would dictate
an increase in the number of tubes in each loop.
It was felt
that in a bed of these dimensions more than four tubes in a loop
would be impractical.
The choice of tube size for the pre-evap-
orator and superheat beds was mostly structural.
It was felt
that the tubes in these beds should not be reduced below 1-1/2"
D.D. due to the possibility of tube vibration in the beds.
A
listing of tubing and header specifications is presented in
Table A3-I.
Also included in this list is the maximum mean metal
temperature for the various tubes.
In each fluidized bed a bed-to-tube heat transfer coefficient
of 50 Btu/hr-ft2_0F was used for the bed proper.
A zone extending
two feet above the bed was considered to be a transition zone be-
tween fluidized bed heat transfer and gas convection.
The mechan-
ism of heat transfer in this zone would mainly be particles that
rise above the relatively dense phase of the bed, transfer heat, and
then fall back into the bed.
Here, a bed-to-tube heat transfer
coefficient of 40 Btu/hr-ft2_0F was assumed and the zone was con-
sidered to be at the same temperature as the bed.
The overall
H-I09
-------
TABLE A3-1
TUBE AND HEADER SPECIFICATIONS
TUBES
DESIGN
SIZE MATERIAL MEAN METAL TEMPERATURE
Water Walls 2" O.D. x 0.280" M.W. SA-213-T22 975
Pre-evaporator 1-1/2" O.D. x 0.150" M.W. SA-210-Al 732
Lower Superheater 1-1/2" O.D. x 0.165" M.W. SA-213-T2 900
Upper Superheater (loops 1-7) 1-1/2" O.D. x 0.318" M.W. SA-213-T22 1058
::I1
I Upper Superheater (loop 8) 1-1/2" O.D. x 0.238" M.W. SA-213-TP304H 1150
I--'
I--'
o Reheater 2" O.D. x 0.186" M.W. SA-213-T22 1122
HEADERS
SIZE MATERIAL
Downcomers 10-3/4" O.D. x 1.00" A.W. SA-106-C
Water Wall Headers 6-5/8" O.D. x 1.00" A.W. SA-106-C
Pre-evaporator Inlet 8-5/6" O.D. x 1.255" A.W. SA-106-C
Pre-evaporator Outlet 16" O.D. x 2.03" A.W. SA-106-C
Lower Superheater Inlet 6-5/8" O.D. x 0.864" A.W. SA-106-C
Lower Superheater Outlet 6-5/8" O.D. x 0.925" A.W. SA-213-Pll
Upper Superheater Inlet 6-5/8" O.D. x 0.925" A.W. SA-213-Pll
Upper Superheater Outlet 8-5/8" O.D. x 2.00" A.W. SA-335-P22
-------
heat transfer coefficients varied throughout the circuits, but the
evaporator, superheater and reheater averaged 47, 4S and 43 Btu/hr-
ft2_0F, respectively. These heat transfer coefficients were chosen
as conservatively low values.
A low heat transfer results in con-
servatively large surface requirements, but this will not necessarily
be the most expensive case.
An increase in the heat transfer co-
efficient or the possibility of very uneven bed temperature could
result in the need for more high grade steel in the uppermost loops
of the superheater and reheater tube bundles.
In the zones of the
steam generator that were not in the fluidized bed, standard formulas
for convection and radiation were used.
A3.2
Mechanical Design
As mentioned previously, the layout of this steam generator
allows for conventional fabrication and support of pressure parts.
A general layout of the steam generator is shown in Figure 3.1.
The
tube walls are supported by structural steel located at the top of
the vessel.
This is accomplished by hangers that' connect the upper
wall headers and the structural steel.
There will be a relatively
large gas pressure drop across the fluidized beds.
Since the hori-
zontal span of the tube walls is short, the tendency of the walls
to bend is much less than on a conventional unit.
To be safe,
however, a tieback support system was used to further stiffen the
walls (see Figure 3.2).
The serpentine tube elements are supported
by the wall tubes.
A detail of this support system is shown in
Figure A3~4.
H-lll
-------
FORM 2BS-62-C
This Drawing is the Property of the
FOSTER WHEElER CORPORATION
110 SOUTH ORANGE AVENUE
LIVINGSTON, NEW JERSEY
AND IS LENT WITHOUT CONSIDERATION OTHER THAN THE BORROWER'S
AGREEMENT THAT IT SHALL NOT BE REPRODUCED. COPIED. LENT. OR DIS-
POSED OF DIRECTLY OR INDIRECTLY NOR USED FOR ANY PURPOSE OTHER
THAN THAT FOR WHICH IT IS SPECIFICALLY FURNISHED. THE APPARATUS
SHOWN IN THE DRAWING 15 COVERED BY PATENTS.
-~.._. -~.-.
[[,:: ~
I
i
//
/
//
.....--........"
I ,
L_l
TUb£.. t.LE..MLN1
~ u. P P 0 R.. i A S ~ ~ M " L ~
H-1l2
A3.8
I
i
I
I
(D
I \
i~ L L M Eo. ~ ,.
!..
1.
'. '..~~.
I
TUe,L
. .
ORDER NO.
0-5 q. II ~ '2
DRAWN BY:
Jl.
3/;/71
CHECKED BY:
APPROVED ey,
SCALE:
~ ".0"
O.5~-7)4.39
rl4
A ~.4
-------
All headers and downcomers are located in areas of the ves-
sel that are not exposed to the hot gases.
The tubes of the tube
banks penetrate the finned tube enclosure walls at the top and
bottom of the banks, and connect to the headers in the gas pass.
The penetrations of the tube walls are sealed to prevent air leak-
age into the beds.
The headers are supported both by the tubes
they are attached to and by the shell.
This can be observed in Fig-
ure 3.2.
The combined flexibility of the expansion joint connection
to the shell and the length of tubing from the header into the bed
allows for differential expansion of the tube walls and the shell.
In areas where the steam ~emperature is significantly higher than
the combustion air temperature the headers are insulated.
Throughout the design of the steam generator, compromises had
to be made between economy of design and ease of maintenance.
In
the resulting design it is felt that all normal repairs could be
made without a major disassembly of the steam generator.
Manholes
provide access to the interior of the shell at several locations
as shown in Figure 3.4.
There is sufficient space between the
tube walls and the shell to permit repair of the pipes and headers
located in this zone.
There are also access doors in the enclosure
walls above each tube bank and in the roof plate of each cell.
These two doors provide access to the upper bed areas, air plenum
chambers and lower bed areas.
The repair of tube leaks in the tube banks is slightly more
difficult in this design than in conventional units.
In the con-
ventional units access spaces are provided at certain locations in
the interior of the tube bundles.
A typical layout of the conven-
tional design is shown in Figure A3-5.
This type of design allows
H-1l3
-------
b.C.C.£.~5
C.A'i'1 Y
---.- ..--
I '11- 111 -, I
-- - .~. ~ _Ud I III
rE~ _--'
~ --. -_----ll
.- -- -- -=-~-~--= ---- .1 i I
~-- ------- --- ----- I:
L~lll1i=-~~r:: III
II ---< - J I
-u--=" : : . -. .._._--~-1----~- : ; "-'-- -'.- i
.. I . --' 1]
\- '-- :::- -i j
! r::- -- --= - - :::' J
L{~:=-~ -- _.~---
lJ: .---- ------ ---11
~ ~.:---=- --- ----_._.~=~ - J I I
~___~n=- - ---- Ijj
E-~ -] --.------ ------r . ---1- - )
,_~~[ -l1 ~---i-!I-:! ! .
.. II J.U i'~
I --- -; . -. .--.- :.. ~-~.~- - -,
r~---- -:--. I.. ---===-~-=--=:~~:~~~'.~ - j jl
~ .. , -- - -. . .. I.
uillttL~ L-:'_.-t-~_:~::~~..-~-J
AC.C.f..~5
C A \I ,"( ~ -----
CON\Jt~l\Ot-.lAL
IJ
c. .. co.. "0. .".8'8
11J~e.
t>~fI,.\~
Thla 0,..1"1 I, the Pro,.", 0' the
FOSTII WHIILII COI'OI. TIOM
118 IOU'" ....... A¥l1tUI
LIVMGSTOI8. NO JIIIIT
A..D .. ~."T WITHOUT C_88D..ATIO.. OTH." THO." THIE .O""OWIE""
A."IE."",T THAT IT 8HA~~ ..OT .. ".""ODUC.D. CO"'.D, ~IE"T. 0" DI"
"OI.D 0" DI".CT~Y OW I"DI".CT~Y "o"uI.a ..0.. ANY I"U""oa. OTHIE"
TH"" THAT ..0.. WHICH IT II l"IECI"'CA~~T "U""I 8H lED, THIE A""A..ATUI
8H0- I" TH. OWA"... II COY.".D .Y ..A.TIENTI.
H-1l4
ORDIER NO.
DRAWN 8Y:
CHECKED 8Y:
A....OVIEC 8Y:
SCA L.IE:
(;'~<\-I\q"2.
j\Z-
+, .
i15i7.
= " .0"
0-59-7\4-55
----
F'~. A3-S
-------
for the removal of a section of tubing by cutting the tube at the
nearest access locations.
The conventional tube bank design is
undesirable in a fluidized bed because the tube-free areas that are
provided for access could cause hot zones in the bed and uneven flu-
idization.
The repair of a tube leak in a fluidized bed tube bank
is technically no different from a repair in a conventional unit,
but it would be more time consuming, because the entire length of
the tube element would have to be removed.
The tube element would
be pulled out of the top of the tube bank in as many sections as
the overhead space requires.
The tube leak would be repaired and
the sections of the tube element would be rewelded as it is lowered
back into the bundle.
A leak in the tube walls would also require the removal of
a section of tubing that is as long as the tube bundle.
This is
because the elevation of a wall tube leak in this area would be
difficult to determine.
Again this causes no technically un-
surmountable problems.
Replacement of entire tube banks or headers would require
a major disassembly of the module. but the need for this type of
maintenance is unlikely.
All anticipated normal maintenance ap-
pears to be feasible.
Many repairs are made more difficult by
the economical use of vessel space and configuration require-
ments for fluidization. but the maintenance requirements do not
seem to be a major drawback of this system.
H-115
-------
APPENDIX 4
MODULE DESIGN
A4.l
Pressure Vessel
The steam generator is housed in a 12 ft. diameter pressure
vessel shown in Figure 3.4.
This diameter was chosen because it
is the maximum diameter that can be shipped in long sections.
Man-
holes are provided at various locations on the vessel to allow
access to the pressure parts and accessory equipment located inside
the vessel.
The shell itself is 1 in. thick and is made of SA 515-70
steel.
The outside of the vessel is insulated with 4 in. of batt
insulation. and the insulation is protected by an aluminum sheet.
Besides maintaining the system gas pressure. the vessel supports
the steam generator pressure parts.
This is done with structural
steel that is attached to the shell near the top of the vessel.
The location of this structural steel can be seen in Figure 3.1.
A4.2
Air Piping
The module air piping can be seen in Figures 3.1 and 3.2.
Air for the primary fluidized beds enters the pressure vessel
through a 42 in. diameter pipe located near the bottom of the
module.
Air entering through this pipe fills the space between
the steam generator tube walls and the pressure vessel shell.
This space serves as a manifold to distribute the combustion air
between the four primary fluidized beds.
The distribution was
accomplished in this manner for several reasons.
One benefit
of having the combustion air fill this entire area is that it
will cool the pressure vessel and the structural steel that
H-117
-------
supports the boiler pressure parts.
In fact, a small amount of this
air will be injected at the top of the vessel in order to prevent
hot air zones from forming th~re.
Also, since the combustion air
is at a higher pressure than the fluidized beds and the subsequent
gas passages, any gas leaks that develop in the finned tube en-
closure walls will result in air leakage into the high temperature
gas zones.
The possibility of leakage in the opposite direction
would be dangerous because an increase in pressure vessel tempera-
ture could cause failure of the vessel.
There are other possible means of accomplishing air distribu-
tion between the fluidized beds, but they have serious drawbacks.
One possibility would be putting air ducts ,inside the pressure
vessel.
This scheme would result in a very crowded module with
maintenance of internal equipment very difficult if not impossible.
External ducts with separate inlets to each bed would be another
possibility, but this would require many penetrations of the pres-
s'ure vessel.
It is desirable to have as few penetrations of the
pressure vessel as possible to minimize thermal expansion problems
between the external piping and the pressure vessel.
The carbon burn-up cell combustion air is kept separate from
the primary bed air.
A 12 in. diameter ~ipe penetra~es the pres-
sure vessel just above the primary air inlet ,pipe, and connects
directly to the carbon purn-up cell plenum chambe!.
A control
damper is located in this air line.
The separation of the, ,primary
bed air supply and the carbon burn-up cell air supply gives' more
flexibility in establishing different conditions in t~e carbon
burn-up cell.
The air flow to the carbon burn-up cell affects
H-1l8
-------
bed temperature, excess air, and superficial velocity.
These para-
meters are quite critical for good carbon burnout so it was felt
that good control of the air supplied to this bed was highly desir-
able.
A4.3
Plenum Chamber and Distributor Plate Design
Each fluidized bed has\an air plenum chamber underneath it.
Figure 3.3 shows a typical air plenum chamber.
The location of the
plenum chambers in the module can be seen in Figure 3.1.
The sNe
walls of the chambers are formed by the same enclosure walls that
form the fluidized bed cells.
Air enters the plenum chambers
through control dampers that are shown in Figures 3.1 and 3.3.
These dampers are located over screen openings in the enclosure
walls.
It was felt that this would be easier to construct than
providing openings in the enclosure walls that would be large
enough to contain a damper.
The dampers are controlled by
drives that are external to the pressure vessel.
The dampers
on each of the plenum chambers are controlled separately so that
the relative distribution of air between the beds can be varied.
Although these dampers are basically control dampers, they should
provide sufficient sealing in the fully closed position to essen-
tially stop the air flow to any bed.
The top and bottom walls of the plenum chamber consist of
steel plates.
The top plate is the fluidized bed air distributor
plate.
The function of this plate is to provide an air flow
pattern that is conductive to good fluidization of the bed.
Basically the air distributor plate is a flat plate with air
nozzles spaced across the surface.
The design of the nozzles,
H-119
-------
the number of nozzles and size of the nozzles will have to be de-
termined by pilot plant tests.
Air distribution plates that are
" .,'" '
now in use will not necessarily be effective in the deep, high
pressure beds of this design.
For the purpose of including a
cost estimate for the distributor plate, "button" nozzles of the
type used by Pope, Evans and Robbins were assumed.
'These nozzles
are shown in Figure A4-l.
In order to allow for differential
thermal expansion between the distributor plate and the enclosure
walls, the distributor plate is not welded to the enclosure walls.
Instead, a scalloped bar is welded to the walls around the perimet-
er of the air plenum chamber and the plate sits on the rim formed
by these bars.
This construction can be seen in Figure A4-2.
The bottom plates of the air plenum chambers are solid plates
that seal the plenum chamber off from the gas passage of the next
lowest cell.
These plates are supported off of the wall tubes in
the same manner as the distributor plates.
The side of the bottom
plate that is in contact with the hot gases is insulated to prevent
warpage of the plate.
A4.4
Coal Feeding
The design and location of the coal feed nozzles can be seen
in Figure 3.3.
Since the fluidized beds in this design are rela-
tively deep, it was felt that four coal feed points spaced around
the perimeter of the bed would be sufficient to give an even dis-
tribution of coal in the bed.
The nozzles are directed into the
bed directions that tend to provide equal distribution of the coal
across the cross sectional area of the bed.
Also a 2 ft. high tube-
free zone is provided above the air distributor plate to mitigate
H-120
-------
.- -..- -
A,. "
/ .' / \
I: \
I \
" . '
, .' : .."~,,.~ I
\ "'.' .,:..." .'./ /
\ I
I
/
,
"
- J - -
/
/
I
-.1- ~\l1\O \-.\ C~~ ~\2.. \)\:)IQ..\~\iIG)Q...$
:6ft "n ~ ft ft fi fh
---:-., " ~ ,F .,
f.' ' /'...,»: ,'..'. '. . .
. -.
\
"
i
I
1
t
I
r
A
;;
'-
o
w
~
c~oss St.C.i\O~ O~ A\~ D\~TR.\~UTO~ PL~\e.
'N \T~ 5Ui10N c.~~ A.\Q.. t)\~i~\~UiOi..~
8J
, Thl. Orowlns I. ,h. Pro,.r'y 01 ,h.
FOSTER WHIELER CORrOR. TIOM
110 IOUTII OIAMIIA..MUI
LIVhIGITOM. MI. JUSI"
ANa \. l..aNT WITHOUT c_.,aa"ATIOM OTHafll THAN THIE 80....0WIE..'.
A....a"''''T THAT IT "'AI..I.. NOT .. ".~"oauc.a. cO~I.a. I...NT, 0" 01.
~o..o O~ al...CTI..V Olt INa'It.CTI..V NOltu..a ~Olt ANV IOOUltlOOO.. OTHIE"
THAN THAT ~o" WHICH IT I. .~.C'~'CAL.I..V ~ufllN''''lEa, THIE AIOO~AltATU.
~o- IN TN. altAWlN. I. coy.".a .V ~ATIENT.,
C... CO.. NO. ..48'8
H-121
t
I
ORDER NO.
DRAWN 8'1':
CHECKED 8'1':
APP"OVED 8'1':
SCAL.E:
~D 7 \ 4-
FIe;, A. 4.-\
o.,~. \\q 1.
~ ~t-~i'.h'
_._-~ _._. - -,_.
= " - 0"
-------
HO~{.~ 'to
~ ~ c. 0 ""'"'0 D~H.
A\~ ~O't! l.~ ~,
A.\Q..
8)
c. .. co.. NO. ...8'8
I
u~ --=r--------"t-~o=r-~
- -~ ..__._.~_. -. ..... ,f -- .-.-_.. . -' , .It '.. :
I,
I
,
O\')11l\~\1 i 0 Q..
PL~lt SI\HP,q..2.S
<;'C.~ll()f'Lt)
'-, \I ? \> J ~ '\ ~ to. ~
II c, "
. -.. -. -= ::-:i'=::'==- :::.r
I'
il
-
7~ 0"
..--.-
'-------"-"-" .
Ii> ~" ;l
I I ~
I ,
" ;.(} I I
i I I,
I r It
~ -=- ~ -= -::~::: i:.: = = = -:- = =- ~ -:-::H- = ::- :.~ :-
II I,
II "
ni, I
I' .'
I
'---- .. I, I
-- I' : \
II n
I, II
I i II
II II
C - - - - -' L .. - - -. .. -= -: -:: d 1=:: = = - .::. ::. - -
'0 - i: -.. II .- - - .. - I I
II : I
;.~ " "11-0 "
II ! I
~~- -~--" U'" -4
~_.~_.._.
, \) [ T ~ \ l " 1:> "
~QiiO~ ?U~\t T'1'P.)
CJ
----.--. --
-- . -.- _._-
0\51 Q...\~U10R.
~uPPoR...\
?Lr\l
Thl. Of..,ln, II tho Prop.rty 01 the
FOSTEI WHIILII COIPOIATION
118 IOU'" HA8t81 AViMUI
LIVhIOITOII. M.. JIIIIY
AND II !.IINT ",THOUT CCINIIOIIRATIO.. OTHIIR THAN TH. .0""0.11""
A."IIIIMIINT THAT IT "'A!.!. NOT .. R.~ROOUCIIO, CO~I.O, !.IINT, 0" 0'8.
~011l0 O~ OIRIICT!." 0" IN!)I"IICT!." NORUIIIO ~OR ANY ~U"~OIIl OTH."
THAN THAT ~O" "HICH IT II I~IICI~ICA!.!." ~URNI"'.D. THt[ "~~A""TU'
IHO- IN THII OR"'''N. II COVIIRIID 8" ~ATIINTI.
H-122
'"
()
I,
I!
I!
It
II
II
II
: i
-, ~-=- -.., ~-::::: ..: --...-:J
II ~ 4-
II
II+- (,
, I
ORDER NO.
~
\.
DRAWN 8Y:
CHECKED 8Y:
APfI.-oVED 8Y:
SCA L.E::
--- --.-
r
~
~
N
~
O'S~.II"Z
jQ... . ~ 7/71
--t-_L
I
--- __L..-
-= " .. 0"
t2..D7\4-1\\
I-d:, A4
. I
i.
-------
the effect of possible flow channeling in the upper zones of the
b~.
The coal is transported pneumatically through the feed pipes
and nozzles.
The problem of differential thermal expansion between the
enclosure walls and the pressure vessel affects the coal feed
pipes in the same way as it affects the gas and steam piping, so
flexible penetration seals were used on the pressure vessel shell.
A4.5
Sorbent Feeding and Circulation
The sorbent feeding and circulation system interior to the
module is relatively simple.
Since the modules are designed to
operate at constant bed depths, there is a certain flexibility in
the location of the inlet and outlet pipes of the dolomite circu-
lation system.
Also the circulated dolomite is a small portion of
the total bed capacity, so only one inlet and one outlet pipe are
provided.
These pipes are separated as much as possible, however,
to prevent any possible bypassing of the regenerated inlet stone
directly to the outlet pipe.
The dolomite circulation inlet pipe
is located 4 ft. above the air distribution plate.
The dolomite
circulacion outlet pipe is located 4 ft. below the top of the tube
bank.
The location of these pipes can be seen in Figures 3.1 and
3.2.
In normal operation the bed height will be kept constant.
During start-up, however, some beds will have to be filled during
operation.
This is accomplished by feeding dolomite into the bed
through the dolomite circulation inlet pipe.
The coal feeding
system also has the capability of feeding dolomite.
The dolomite
fed in this manner, however, will only be used to replenish the
H-123
-------
stone that is elutriated and spent from the bed, because,t~e dolomite
feeding capability of this system is not sufficient for circulation.
It is estimated that 0.5% of the bed dolomite will be elutriated per
hour, and the coal feed system is designed to make-up this amount
of stone Rnd the spent stone.
An outlet pipe is provided at the
very bottom of the bed.
This pipe is normally completely closed off,
but it can be used to empty the bed when necessary.
Sorbent taken from
the bed in this manner will be stored in a surge vessel.
A4.6
Steam, Piping
As with the air and gas ducts, it was desired to keep the
penetrations of the shell by steam piping down to a minimum.
To
achieve this as much steam transfer piping as possible was located
inside the pressure vessel.
These pipes are situated in the free
space between the steam generator enclosure walls and the pressure
vessel shell.
Figures 3.1 and 3.2 show the layout of the transfer
piping.
The only transfer pipes that penetrate the vessel are the
feedwater inlet, superheater outlet, reheater inlet and reheater
outlet.
These pipes are attached to the pressure vessel with bel-
lows type seals to allow for differential expansion of the shell
and the headers.
A4.7
Particulate Removal
A schematic flow diagram of the particulate removal system
is shown in Figure 4.1.
The first separator stage cleans the
flue gases from the primary beds and the solids collected in this
stage are returned to the carbon burn-up cell.
The purpose of this
first particulate removal stage is to increase the efficiency of
the steam generator by minimizing the unburned carbon loss.
It
was assumed that
5% of the bed sorbent per hour, 6% of the carbon
H-124
-------
-
and all of the ash in the coal would be elutriated from the primary
fluidized beds.
The size distribution of these particles can be
seen in Figure 2.3.
The first separator stage returns 90-95% of
these solids to the carbon burn-up cell where optimum conditions
for the combustion of carbon are maintained.
The gas cleaned
by the first separator stage and the gas from the carbon burn-up
cell unite before the second particulate removal stage.
The pur-
pose of the second stage is to clean the gas sufficiently to prevent
damage to the gas turbines.
The efficiency specification of the first particulate removal
stage is somewhat flexible.
Increasing the efficiency of the
cyclones also increases the pressure drop, and the gain in com-
bustion efficiency that results from high collection efficiency
must be weighed against the loss of cycle efficiency that results
from an increased pressure drop.
Four Ducon Company cyclones of
the Duc10ne type, size 4-355 VM 81-/150 were chosen for the first
stage collection.
These cyclones are operated in parallel and
provide a collection efficiency of 90.2% by weight with a 0.7 psi
pressure drop.
A fractional efficiency curve for this cyclone is
shown in Figure A4-3.
It is felt that these conditions will give
optimum plant efficiency.
The arrangement of these cyclones in the pressure vessel
is shown in Figure A4-4.
Figure A4-5 shows the location of the
cyclone pressure vessel in relation to the steam generator.
In
the arrangement shown here the cyclones are exposed to the hot
flue gases both internally and externally.
This requires that
the cyclones be made of relatively expensive steel alloys.
~o
H-125
-------
100
90
80
70
60
50
40
30.
20
10
9.
8'
7
6
5
ESTIMATED FRACTIONAL EFFICIENCY CURVF..L
FOR
'"" - .
DUCON CO. SIZE 335 VM 810 CYCLONE
WITH OUTLET AREAl INLET AREA TO 1 ~ 0
>.
4.1
. ~
u
o
.-I
-------
~ ~5
--.
O\l\l.t1
.
o
_I
~
t"
I
I
I
I
I
I
I
L
REVISION
-5~A.L ~L~\t
\ ~ ~ \) 1...-. '\ ' Q ....
, -----C.e>.c. G,A5 INLLT
;.a--
'rS5YPPOL'
(1j, . L\) eo.
." ~
I \ '"
\ "
I
! .
.- ~ Itt.. ~ Go L ...
./
SLC"T
FL'( .o.:=,,,,, R-E.iljl(,,"-1
TO c;..~. C.
~ tJ ~
P L A.
~
~ L.U ~ G A ~.£ R,p ~
PR...\M"~'( 1bE.D
\ ~T
~1AGt
C'(CLONE. SYS1lM
f L~ 'E.. G J:I.~ FLQ""
- ~~~_~~L '( b_~~
C~CLO~~
\NI..£..\
C"(CI...O~E.
o\J'T\.t.1
THIS DitAWIN8 ,. THII ~"O~.IItTY 0" TN.
if)
FOSTER WHEELER CORPORATION
110 SO. ORANGE AVE., LIVINGSTON, N.J.
AND 15 LENT WITHOUT CON8IDIE..ATION OTHIE.. THAN THIE
80....0WIE..'S AG..IEIEMIENT THAT IT SHALL NOT 81: "IE.
"..ODUCIED.CO"'ED. LENT. 0" DIS"08I:D OP' DI..IECTLY 0..
INDI..IECTL Y NO" USED 1'0" ANY "U""081: OTHI:.. THAN
THAT 1'0" WHICH IT IS S"I:CIP'ICALLY P'U.."18HI:D. THI:
A""A"ATUS SHOWN IN THI: D..AWING IS COYI:..I:D 8Y
"ATI:NTS.
ORDER NO.O-5~.1\ ~"
DRAWN BY:
CHECKED BY:
APPROVED BY:
JIL.
42'11'1 SCALE: y' 4-"
Q.O-713-~7
=1'-0"
F I ~. A 4-4
-------
Nons
t. ......8CIILZ"'---'
-"'1'.
L-
i .. ..'..~
r ---;:__n ~~I~:
r----:--- --
_L-
£€.
/t" "fa.""
a. ~...._-................
~ 8ft1 It8I8CM n.... ~...
-*1IIi88 FCI8:" 0811""-'~
~~.~..--=--~--- ---
~~--r---_---u'.A..
I
I
I
-+~
I
- -+ -- -
!.!' ~ 1~
~- ~.-':~
\.'.~:, .
1!'~9'.
--..
-- -I ~- -
-.~.
- '--'---'-
.
o
-~- ---
c eo c.. G,;.'S hU..!.'
. -
:~-
! ;~- ---
I +--
I
c=-
I
H' --
- 1+- ._-
\'" ~'~'L
c."('~r""L
r ----
~.- ----..-
IJ...""..-
w---
~~--
I
I ~ ~
I
I
I
.. -~-:
I ,
i I
~, ta. "'"
G t.N I.'"''''''
,
I
-~ - -- T
I '
I . .
,+
;
i ::
, .
1----
I
I
I
-+-
I
.'
4 1-
I
/
~
, '
I._I
"i-
r.\.n~i-
-1-
/
i .~ ~:
::1 .
: i
: i
i It
,
!
I
I
I
i
~:
I
! I
I
I
I
I
.'" ..,:.~
/
~~J~~':.~
~
.
. j"'''-
I
! 1
~" ,,'0',
-=-T ~
i
I
4.
, r-I
i~1 / :~.
In~7
'Z"'" ::t"'''',,,! c'(c.",o..,,/
i
i
-I
,
- ~~----
IftftI .." .:
.''11110.'
i-~-
PLOI PLAN
~Tf ~ '" co tl4flt~TO'"
UO ~~~t)$O"'f tQuIP..t~T
f 0 I.. ~ ~oo Wfl ~OIA~\~tt>
c"{c \. t. PI..'" W 'T
~. ...
~, ~
I
I
. I
! I
I .~.
---"* --1
\y
"
I
-~.
-~--
.i
t~
"
/
I
[/
~ 'u..
t2.D-710-\o,"
t\. 0'0"
- I I
=.=.: --
JI. 'II-..
-~-_.-
5 te, \ O!oj °A - A-
PLAN
n. --. .. - "-'" .. -
- "08TE1I WHCD.aIIt ~1'1ON
( .--/-_.:.::.::-..:::-.-==::...-
~ ----..........-....---
1 ---.----.-
1 ::...:. ':"': =--=-..~......:.: ~
- =:"'"--.....-----
FIG- A.4-!)
DWG. NO.
-------
other arrangements are possible.
One would be to place cyclone
forms in a pressure vessel and fill the void areas with refractory.
This would do away with the need for high temperature alloy in the
cyclones and in pressure vessel lining material.
A drawback of
this system is that a separate plenum chamber must be supplied
to ensure even gas distribution to the cyclones.
The design
shown in this report conveniently uses the. cyclone pressure vessel
as a plenum chamber.
. .
Another problem with refractory formed cy-
clones is that if wear occurs, repair of cyclones is impossible.
The second alternate cyclone arrangement would be to line the
interior of the cyclones with refractory and design them to
withstand the system pressure.
In this case also, a separate
plenum chamber would have to. be built, and the refractory lining
requires a relatively large amount of maintenance.
In the design presented in this report, the flue gas from
the carbon burn-up cell enters the top chamber of the first stage
separator pressure vessel.
Here it combines with the gases cleaned
by these cyclones.
Two pipes transport this cOmbined stream from
the chamber to the two secondary separators.
These two secondary
cyclones operate in parallel and their purpose is to clean the
gas sufficiently to protect the gas turbine.
This particulate
collection system is discussed in detail in Appendix 5.
H-127
-------
APPENDIX S
STEAM GENERATOR SUB-SYSTEM DESIGN
AS.l . Steam Generator Module Arrangement
The suggested plot plan for the steam generator modules and
the particulate removal equipment in the 300 MW plant is shown
in Figure A4-S.
An in-line arrangement was chosen for the steam
generator modules.
A square layout was considered, but realistic
location of the large coal feeding and particulate removal equip-
ment was impossible with a square module layout.
The location of
the steam generators and auxiliary equipment with respect to the
total plant layout is shown in Figure AS-I.
Each steam generator module has a coal pressurizing and
feeding system and a particulate removal system.
The limit ing
factor in the module spacing is the layout of the particulate
removal equipment.
A minimum spacing between the particulate
removal systems results in a module spacing of approximately
28 ft.
This spacing should be adequate for all normal maintenance
and repairs.
The coal pressurizing and feeding equipment is 10-
cated in two groups.
Another possible layout would be one in
which each coal feeding system would be located on the center-
line of the steam generator module it serves.
Placing this equip-
ment in two compact groups, however, requires less structural
steel and platform.
Platforms for access to the steam generator modules are
located as shown in Figure A4-S.
Full platforms are located at the
H-129
-------
;'01- OIL Q~
(
@
z-
CD -BOILEll'> @ aAUS- PlAvr
@ TlJRBINE B""" @ COi-~50Ra..RS
G) HE"TE R EI"Y @ ~~1IS
o 5lDAAG.'" BINS @ DEAERATOR
CV .A.DM\NI!I"Q.ATlON 8\.0&. @ ASI-I SILO
<0 PAQT"ULATE ~EMOV"L ~QUI'r. @ WATER STORACo!!:" "}o,N\(5
@ G) 6,.,,5 '\"z.a'~E GreWERATO~S @ U~\tLOll 'T"'NIC.
@ STACK GAS COOL.Erl$ @ UC,1fT Oil UNlO)l.OIHG pUMP
@ HACK @ Cl'A.CU\.AT1NC WA~1l.. INT'A.RE PIPm
@ 'URGE eo'N @ PAl/KING AREA
@ U;CE,VIN S.O RAGE(So,OOO TONS) @ CHlOR'Njl.TlON EOUIPTh\~NT
@ WA"E~ TRE'-TMF.:tiT @ IIAIIIABlE. WEIR S
@ OIESH GENERATOR ~OOhl @ S'HITCH YA~D
@ CONT~OL. ROOM @ CONYEYOQ.S
@ MAC \-lINE. S"O P @) S'IONE 5"ORA~E.
@ T'tANS~ORME.RS
NORTH RIVER
~
SITE PLoT PU\N
o 50 100
0......1 L.-.J
zoo
a......I
>r
~
FIC.\JU A5-1
DWG. NO. RD 710-104
MOTES
I. DO.,-r 8CALL n8 ~
---- (8.'.
.. ~,..,t8D(8I~~".
~ 8'mI AIIPaCM SJMeMD -~
8IYIaTDIS F08 USI (81 ~-
La1'TD 88n :,
.300 M.W- COMBINED
CYCLE. PLJ:>.NT
SITE PLOT PLAN
----"
RD 710 -104
---.
-~
COIff.IG.o-",-n'92
5-4-71
n.Dr--.._~"-
. ~~:"=~~:"':.o"
-....-.--...---...--
----......y..........---
:.~~="E-: ~
-------
elevations of the ignitors, damper drives and cual feed pipes because
these are items that require frequent access.
These platforms ex-
tend for the full length of the four modules so that an elevator
is practical.
Small platforms are located below the main plat-
forms to provide access to the three lower manholes.
A full plat-
form is located near the top manhole.
Access must also be provided for the particulate removal sys-
tem and the coal pressurizing and feeding system.
At several ele-
vations the steam generator platform steel extends to the first
stage cyclones to provide access to this equipment.
It was felt
that permanent ladders would provide sufficient access to the
secondary cyclones.
Platforms are specified at three elevations
in the coal pressurizing and feeding system to provide access to
the valves and storage bin.
The arrangement of the steam generators and auxiliary equip-
ment for the 600 MW plant is shown in Figure A5-2.
The size of this
equipment is approximate since a detailed design was not done on
this plant.
Basically the layout is the same as the 300 MW plant,
but the vessel diameters are increased.
The exception to this is
the secondary cyclones.
Better efficiency was attained by using
four of these cyclones instead of two larger ones.
H-131
-------
i
.I
~.! :.
~---
1
~I
!
!
!
..
N-
.
...
j
- !a'\"-"."
I. ..: "'0'
k:r-\..""(--2~ ------
- ~~::,\ :'~JC:>I~~t.L:':::: .
~
PL.A.N
"",.
-2j
c;......o t
~'.~.
~..."'-.....
-
--~.O~~G."
i
---1-
- --..;
!
I
.~
~.-
I
~'L"~
Co............,.....
_1.1.,":.t--=---
- a..51~6"
:;'*~1
, I
~: j
I
- u.:n=o"
~ I
- tL,..IC:~.
5lC1\ON "A-A"
~10t....,t. 8''''
U..o".o"
"IJ'C1.'
_.1. ""'I
..-an...'nc .a,..
i_.1-S10L."" I-J,q.'"
-".... Ct......
n\llt: Nn
r,,,U~ "'5-2
II01U
'0 DO...IC&I: - ~ .....
--GLY. .
a. ==-~.:;:':.=m~.:
..-..11CIIIS R8 &III: (8 -.-
.
_TI ~
81""10.'
PL01 PU"'~
~1tll.'" Gd.loIllI..'10"'~
OMD At:t:l)SOIl1 lQ.""'t.M1
'0Il. .. '00101-.1 COIA"M_fO
C'(CI..L P~"NT
--
C8U: , 'Z"
RD- 710- ~O
--. .,.
-~
JI... .. , I
--
-~
1118 0.--. II ... =:':-noM
(i;ffi ':7-;;;:"~:~.=
~ :y.;;--::~~.=-~
-------
A5.2
Coal Handling System and Limestone Make-Up
Coal handling for the pressurized boiler includes receiving
the coal, storage, transportation to the surge bins of the in-
jector, drying, sizing and crushing.
McNally Pittsburg developed
the coal handling plant and a price including erection.
A5.2.1
Assumptions
The coal handling plant was designed
on the basis of the following assumptions:
The coal to be used is Ohio Pittsburgh Seam No.8 described
in detail in Table 2.1 of the text.
The size of the coal is 1 1/2" x 0" as delivered.
It was
initially assumed that the coal would be sized to 5" x 0".
How-
ever,
this size coal is much too large for drying in a fluid bed
dryer which appears to be the most economical drying method at
the present time.
According to the Bureau of Mines at Bruceton,
there is no penalty paid for the 1 1/2" x 0" coal as it is a
standard size commonly requested.
Under these circumstances it
was felt justified to revise the specifications.
In addition
to meeting the technical requirements, there appears to be a
savings in cost of power required for crushing the smaller coal
size.
Size distribution of coal crushed to 1 1/2" x 0" at the mine
appears in Figure 2.1 of the body of the report.
Moisture as mined, is 3.3% total and 2.1% inherent.
The
difference is surface moisture.
Moisture as-delivered is 10% total.
This is about 6.7% in
excess of the as-mined coal and represents a typical moisture
pick-up during handling and storage in an eastern steam generat-
H-133
-------
ing plant location.
Moisture required at the boiler feed system is 3.0% total
maximum.
Higher moisture content result in agglomeration in
the surge bins and feed lines.
. Size required at the boiler feed.system is 1/4" x 0".
The
Petrocarb pressurized feed system can handle 1/4" x 0" coal,
however, 1/8" x 0" is preferred.
With the larger sizes the
risk of erosion is greater.
Unfortunately, mills and/or crushers
equipped with classifiers to size the effluent coal stream to 1/8" x
0" are not readily available.
A screening operation which would
scalp sizes greater than 1/8" and return them for further grinding
could be developed, but at great expense.
The 1/4" x 0" coal size
is a compromise that might warr.ant further investigation in the
future.
The Hardgrove grindability index is 60.
The burning rates which affect hopper sizes, conveyor speeds,
etc., were set at 113 tons per hour; 2,712 tons per day and 18,984
tons per week.
Allowance was made for handling of sorbent feed
or sorbent make-up as it was not certain at what point it would
be added to the coal stream.
Storage of the coal is divided into two categories, active
storage to handle short term contingencies such as weekend outages
for maintenance and repair and dead storage to handle long term
outages due to short strikes, delays in shipment, etc.
Active
storage was set at three days or 8,136 tons.
The storage capa-
city of the s110 was rounded off to 12,000 tons.
Dead storage was set at two weeks or 37,968 tons.
It was
rounded off to 50,000 tons of open coal pits.
H-134
-------
I
r--------
The values were selected as typical based on the recommendation
of McNally Pittsburg.
Dead storage requirements are vulnerable to considerable
change according to individual customers' requirements.
Changes
should only affect operating cost and land requirements.
The addit ion-
al cost of coal handling should be marginal.
It was assumed that the coal would be delivered by 10,000
ton unit trains at a rate of 2 per week.
The unloading rate is
2,000 tons per hour and the train would require 5 hours to de-
liver its load.
The dead storage pile would r.quire 49 weeks to fill to a
capacity of 50,000 tons.
A5.2.2
Scope
The system begins with the unloading of
bottom dump rail cars in unit train delivery and continues
through active and dead storage, thermal drying, crushing and
delivery to the coal feeder surge silos by Pet roc arb ahead of
the boiler firing system.
The rail car receiving hopper will have.a minimum of 400
tons capacity to provide storage volume for controlling unload-
ing of moving cars.
Details of the receiving hopper and other
components are illustrated in Figures A5-3 and A5-4.
Their
relationship to other components in the coal handling system
is illustrated in Figure A5-5.
Their relationship to the en-
tire power plant facilities is shown in Figure AS-I.
The coal discharge from the receiving hopper will be con-
trolled by four reciprocating feeders, Fl-A, Fl-B, Fl-C and FI-D, (Fig. A5-5)
H-135
-------
""
-,
t
. L -
I".. """(>"1.0.
1.r:z..-8o ft.. ."'-0
J~11AU"lIOH
Do'" C'~L ~EP
-----
---.-
Fie.'
'c"L-
'C
u
~ .:
o c;
--!~.'~~1a I.
~
10" I ':. .
,;t>;~
OP o.yaA.
---_._..'UO~:""- .
'8L
(
~y--'
=DI:1[Q.. -=-
'.,;
. '
. '.0.
, '.'
-Ot1t5C"TIO'" 0'-
~YUtD--
{.,..o'~o.
--- ------ ~
zJ.....
-.0 10'-0'
OF '5"0 'TOW
SU1l4L fa\M
REY PLAN
IIOTES
I. DO_K&l1I8~
-......
--
. -------------
.+
80:-0'
&. ---..UllDC8I___-
aca::8I8II2 - --=.III ~ -..
.....,.. R8 us C8I ---."
REFERE.NCE OW"S.
T'"'IOO M.W. ....",U1t\U.D FUIIIOrU:D eo
::- Stt"'lro4 G,&Me..a..'tDR (o.w'/5'I!OR.
:'S75Tur-,RT.20'1""r "D110-W .:
1)11I.e.cTIO N OF
t:O"'~' -.0
1.
>.:.~ ST"""
-:C7c.........--=-
. .i
. " PU\DI' &.D KO
"'1''''''' a....It.A1'-.s
-1"~
a,. IU STJiIoGa
C'YC ..as
r
1 O~ 70'0' 1,0. oz,ooo
.2EM SILO.:. .
.''11110.'
300 MW. PRE55VRIZED
.--FLUIDIZED BED STEAM
GENE.R~l'OR CONVEYOR
5YSTEM
'SMT. 10'2.
p.
--'
.RO 1'O-~
---. -.
-~ ilJ....YI>~ ~~ -
(TD:DaYKa -'s-n~*-,
.... --0'5'-11"
"-5-71
DIIt1
-If.' ...:"
------=-- .w,."o.
... ..... III .. ...... .. ..
\IJ ~==~~
--------
=-~::..:..~~=
==~-:-:~=-=-':
=---------
5ECTIOM A-P\,
DWG. NO. RD 710-"0
-------
1'- OIL Q/j
,/
,/
/'
/'
/
,/
/
/
/
/
/
[' " " '- ~~
"-
"-
"'-
'-
0"" 'to'OQ-1..t2.
- 'l.,Ooo TI)N "1\..0
I
"-..--- -- --- -- -
I 10 -0', I
I-~
I
-",-0-1
~l - MINUS
~-I
~::==1"="u".".
:...O~ I
to.'Fl5-0 "TON
~v-.c.,,- &1.,.
I
1.I'"E£0.'I.$ ,r4:1
~tP" c\l
It,
I~O tp,", ~'10' ~
l."'" ~Ll1 C.Ot-l'l.~
'TO ISO 'TON !ol,j e,1\t(
_4IQ'-Q' .-----:-~~
1'-Ffttjl-t(\ F",
0/150 t.f~
~c.M -
SECllON 'C-C ~
o
'';'
J
~
Z"'I';( ';.-S~?Ui.
.c.o.1<\.. COR'O'F.:"YO..,
~'TO""Go~ 61"4S
(TIP.\ -
L.
,I .
"II: I
~t--'--j-
~-= 1~'-,,-
~~~~-
~"),p,~ 10'-0' > ~\)'-o'
--- --
SE.C.TION
G.tu)vND LEVEL E.L.O'-O"
.'TO? OF BIN3 E.1.72~'
E.\..5 z.'.O'
n.4T-o"
2,,"' ~.
I ~T~:~L~~~\::~~oY:
---+- -~~..' - - I
~- -1- 1 --->':"~-'i''''- .>=--~
/
~
B-B
-- t. --
-r
I
~- -, I
ri :uc~~: i
I . I I
L-l__1 I
d- -v~~; I
.EL. M\NU5
51!..~'-
DWG, NO. RD 710-(; \
NOTES
t. 00 IIIOT EM.I TMI5 OU-.
~OIII..Y.
.t. A8HV1ATIOM5 U5UI 0fiI nIIS OU.... ... .
~ 'MTM ..-.:1ICIo8I STAIDUIO -0\8.-
8I£Y1AncIII fOIl U5iIE C* au.W8IIi6-
RE.FE.RENC~ DW/;S.
t. 3cO M w. PQ,E!,uQ.IZED F~tJ'tHZED e£o
Sl'L'or.M c.E.!'!oE.'JVo,.,.O'Q. ~O\o.l"I!.'fOR.
"Y~'TE"" ~1-IT. 10,.2, f'tOlI0-'-D
...,. ,:,
300 MW PRE5SURI ZED
FL\J\DIZlO eEl) 51EI-.M
G.r:NEMTOR CONVEYOR
. .sY51EJ~
- SHT. 20F.Z
'RD 7/0 -"I
=:~:. -n.
.P. 4.1'.7'
c:.-r.- O'5~-II'}Z.
noo...~.-"-"fIf-
WlJ)il F~~:':.=';"~ ,;,"="::"'"
.........-...._.~_.........._. ..."M"'"
-.. -.- ......... -...... -..-
-.....-.. L"-,___""""",.
;~~:.~~ =~;~';;';-.'0:;
-I
-------
::z:
I
.....
W
-'j
DC
~I-
RECLAIM
HOPPER . ---
'\61 400 TON HOPPER / -~~~D~;;~';;:AL . 12.000
1\6~ J;. . DETECTOR TON
Q...- 1/2" x 0 0
r::- - -,=",':> 2000 tph 1 NO 1 SIL
-~J--O:I
>
VI
I
VI
T.I. MAGNET,
£1. 160
~
~
MCNALLY #2
FLOWDRYER
tI)
("')
::c
~
t-i
t-I
("')
t:1
t-I
~
~
E1.210
- ~.o---
- -
----:.----
MILL _.::;::::::::::::-
-._8---- 24" BELT CONV. NO.3
- BELT 150 tph 1/4" x 0 7\-/
SCALE .\ I
No . 2 , r ,'\-- J
, ,- ,
4A and 4B I
24 x 6 SC~R CONVS.,., '." I
El.l70.t -~lJ~WJ1, IJ,-- H !~ !')<:~,
II' I I 75 pa @ 10,1.10_- -! . ,
COAL FEEDER SURGE -~Il.oS BY OTHER., :
DEAD STORAGE
50,000 TONS
//"
E1. 100 '.
-..- ,n :,~~~:;."',.7~'
DUST COLLECTOR
t;=tD
("')
o
>
t""
150 TON SURGE
BIN
2 FEEDERS FA
0/75 tph EACH
~
t""
t-I
Z
C')
"'d
~
Z
t-i
GROUND E1.100'
--
._~---_._.... --.. -- ---- { .
-------
each. feeder nominally rated at 500 tph but capable of delivering 700
tph if one feeder is out of service.
A 54" wide inclined belt conveyor No.1 will transport th~.
coal at the rate of 2000 tph to the silo.
Conveyor No.1 will be
equipped with a tramp metal detector and a belt scale for weighing
and recording coal quantities delivered to the plant site.
A 12.000 ton silo will nominally contain an entire unit train
delivery without exposure to wind blown dust and provide active
storage for plant feed without the use of mobile equipment.
Ex-
cess coal will overflow the silo to an initial pile for placing
in permanent storage.
See Figure AS-5.
During extended periods of no-train delivery. coal will be
recovered from permanent storage through a reclaim hopper and
Feeder No. F2 delivering to Conveyor No.1 for refilling the silo.
Coal will be fed from the 8ilo by seven Feeders No. F3A to
F3G. each rated a maximum of 150 tph and operating in timed se-
quence for uniform drawdown of the s1lo. onto a 24" wide belt
Conveyor No.2.
Conveyor No.2 will be fitted with a tramp iron-
magnet before delivery to the coal dryer.
Details of the magnets
and dust r~covery equipment have not been illustrated.
The McNally Flowdyrer will be'sized to evaporate 12 tons
per hour of water from a feed of 150 tph (dry basis) of 1 1/2" x 0"
coal and delivery a product containing 3% total moisture.
The
dryer will be fueled by pulverized dried coal and will be fitted
with a cyclone dust collector to capture the coarse dusts and a
high energy scrubber to reduce exhaust dust to acceptable limits.
H-138
-------
The Flowdryer releases measureable quantities of particulate
matter and sulfur, probably in the form of "25.
The latter
depends, to a large extent, upon the percent pyrites present
in the fuel.
To overcome these problems, a high-energy wet
scrubber has been included, in recent years, as part of the
Flowdryer package.
No data are available on the exact quantities
of sulfur and particulate matter emitted from the unit.
How-
ever, it would seem reasonable to conclude that, if necessary,
emission could be further reduced by conventional equipment
at a modest price.
If this were not found to be the case, an
alternate means of drying coal would have to be devised.
Ef-
fluent from the scrubber will be disposed to the power plant
ash pond.
The Flowdryer is illustrated in Figure A5-6 and
Figure A5-1.
Coal from the dryer will be crushed to 1/4" x 0" size in
a reversible hammermill and, along with the coarse dust from the
dryer cyclone, delivered via 24" belt Conveyor No.3 to the plant
surge bin.
Conveyor No.3 will be fitted with belt scale No.2
to weigh and record coal quantities to the boilers.
From the 150 ton capacity plant surge bin the coal flow
will be split into two streams each served by a 0 to 15 tph
vibrating Feeder F4A and F4B to its associated coal feeder surge
silo group through scraper Conveyors No. 4A and 4B.
The silo feeding system will be provided with automatic
sequential controls with provisions for operator to over ide to
accommodate unusual operating conditions.
The plant surge bin
H-139
-------
\JJ,
'ji-~
tl
~J '
McNally Flow Dryer
Fig. A5-6
H-140
-------
.\ ,.'::,-....
'-'.,~' .'
',', ,\"
.,
o
2
. 5.T_A~. K
,
/
/
/
/-----
o
~
I
I
/
I
,
,
,
,
,
L~o.
SECONDARY
OUST
COLL[CTOR
~':::==:a
ROTAIIY
VALVLS
TYPICAL INSTALLATION DIAGRAM OF
McNALLY FLOWDRYER
A
FIGURE AS-7
H-141
-------
level will control the feed to the dryer and in" turn the dryer
A5.2.3
surge bin will regulate the silo withdrawal feeders.
The coal handling system will consist of
Equipment
the following equipment, materials and services:
1.
Receiving Hopper
2.
Feeders No. FlA, FIB, FlC and FlD
3.
Chutes
4.
Conveyor No.1
5.
Metal Detector
6.
Belt Scale No.1
7.
Reclaim Hopper
8.
Shut Off Gate
9.
Feeder No. F2
10.
Silo
11.
Feeders No. F3A and F3G
12.
Conveyor No.2
13.
Tramp Iron Magnet
14.
McNally Flowdryer
15.
Mill
16.
Conveyor No.3
17.
Belt Scale No.2
18.
Surge Bin
19.
Feeders No. F4A and F4B
20.
Conveyors No. 4A and 4B
21.
Dust Collecting Equipment
22.
Ventilating and Heating
23.
Control Equipment
24.
Motors and Controls
H-142
-------
25. Structures
26. Foundations
27. Electric Wiring
28. Erection
A 5.2.4
Cost
McNally Pittsburg indicates the cost for the
system described should be about $2,500,000.
The flow dryer
represents about $750,000.
This includes an add it ional 24" bel t
conveyor to accommodate the additional handling required by the
thermal dryer.
The complete system contributes about $8.3/KW
to the overall cost at the 300 MW level.
McNally Pittsburg indicates for an increase in capacity to
handle a burn rate of 226 tons per hour, the conveyor sizes should
stay substantially the same; however, their horsepower would in-
crease and the size of the McNally Flowdryer would have to be
increased.
The probable additional cost for increasing the
system might amount to $250,000 for a total of about $2,750,000.
This
represents about $4.5 KW at the 600 MW level.
McNally Pittsburg reports the following cost analysis for
the flow dryer:
TABLE A5-l
Operations
Cents/ton
Operating Labor
Fuel (Start-up Oil and Coal)
Power
Miscellaneous (Operating Supplies)
Total Operating Costs
.955
3.475
2.140
.105
6.675
Maintenance
Maintenance Labor
Maintenance Supplies
Total Maintenance Costs
Total Cost per ton, of Dried Coal
1. 366
.332
1. 698
8.373
H-143
-------
The operating cost of a McNally Flowdryer is generally about
10 cents per ton.
The figures ~:m t\1e previous page are based on
actual costs at a typical installation over a five month peri0d.
Johnson and Auth (1)* and Lyons and Richardson (2) report that
operating costs of drying ranges from 8 to 1~ cents per ton of
dried coal produced with the majority of dryer~ having costs
of approximately 10 cent,s per ton.
On a basis of per ton of water Femo~ed. op~rating costs range
from $1.00 to $3.00 with the majority of the dryers having , costs
of approximately $1.50 per ton of water removed.
The Bureau of Mines at Bruceton. Pennsylvania (3) report that
drying costs at the mine ran about 15 cents per ton of dry coal or
$2.00 per ton of water removed.
Capital charges based on the cost of the dryer furnace. the dryer.
the duct work. exhaust fan and exhaust stack. for a plant having one
shift operation for a 200 day year. assuming comple,te depreciation in
10 year range from 4 to 12 1/2 cents per ton of dried cpal. or 60
to 188 cents per ton of water removed.
Th~ capital charges for the
McNally Flowdryer come to about 7.1Se/ton of dried coal.
Johnson and Auth (1) indicate that maintenance. a major item rep-
resenting from one-third to one-half of the total operating costs
of drying. could be ,reduced in many cases by (1) coating exhaust
ducts. fan housing and exhaust stack to reduce corrosion; (2)
the use of corrosion and fly ash-resistant fan impellers; (3)
, ' -
the use of stainless steel for exposed steel surfaces such as
*(1)
(2)
(3)
A. J. Johnson and G. M. Auth. "Fuels and Combustion Handbook".
McGraw-Hill. New York. 1951.
Lyons and Richardson, AlME Tech. Pub., 2399, August, 1948.
Communication with Bureau of Mines, Bruceton, Pennsylvania.
H-144
-------
screens; (4) adequate controls to prevent overheating of furnace
dryer inlet ducts; and (5) a well-planned maintenance prograM.
The coal handling plant proposed differs from conventional
practice by virtue of the coal drying requirements and the McNally
Flowdryer.
The costs are comparable as shown in Table A5-2
TABLE A5-2 COMPARISON OF CAPITAL
COST OF COAL HANDLING EQUIPMENT
Plant Size (MW) 100(4) 200(4) 230(4) 246(4) 327(4) 300 600(5) 600
Fluid Fluid
Bed Bed
Coal Handling 1010* 1720 1860 1925 2240 2,500 3,122 2,750
and Storage
$/KW 10.10 8.6 8.1 7.9 6.85 8.35 5.20 4.55
Fuel Burning 760 1295 1400 1450 1685 1800 t 2800
$/KW 7.60 7.4 6.1 5.9 5.15 6.00 4.66
* Values in $1000
t Not reported
Fuel burning equipment generally includes bunkers, feeders,
exhauster mills, burners, conduits and controls.
They have been
included here to be certain appropriate comparisons are made.
Although the drying operations would normally take place in the
mill under coal burning equipment, this operation has been included
as part of the coal handling operation because of its relocation
in the sequence of operation.
(4)
T. V. Rallo and
Domestic Boiler
1969, Fluidized
January 1970
S. J. Jack, Power
house, July 1970.
G. Guarraia, "Technology and Economics for
and Power Plant Designs" F.W. Report, June
Bed Combustion, Monthly Progress Report,
(5)
Systems Planning-Fuels and Energy, Westing-
H-145
-------
A 5.2.5
Sorbent Make-Up Storage and Feed
. The sorbent
feed make-up system which consists of a receiving hopper, en:?losed
storage silo and discharge gallery is illustrated in Figure A5-8.
Orientation with respect to the coal handling system is shown in
Figure AS-l.
This equipment was priced by McNally Pittsb~rg.
.5.1
Assumptions and feed conditions
The sorbent
will have the characteristics outlined below.
Table A5-3 (6)
S02 Sorbent Analysis Used for Preliminary
Fluidized Bed Boiler Analyses
Weight/Percent as Received
Dolomite'
BCR 1337
Component
S102 0.78
A1203 0.15
Fe203 0.25
MgO 45.0
CaO 53.0
TiOZ 0.02
SiZO <0.03
NaZO <0.02
KZO <0.1
MnOZ <0.03
(6)
R. W. Coutant, J. S. McNulty, R. E. Barrett, J. J. Carson,
R. Fischer and E. H. Laugher, "Investigation of the Reactivity
of Limestone and Dolomite for Capturing 80Z from Flue Gas",
August 1968, Battelle Memorial Institute. .
H-146
-------
~-
H '1!
!! - - -- - ---, I
" ,
f I : 0.0.00-: rl..l"'1l~'TOI>IL "'''I(.f...UP
I. Lo~,~~oJ ""
i
\i
f
- 3<." bt'..'T
!I..: ,.i:Q"
..---1
- ----
1._.&0';.0"-
,
If
! I
~--r
L\"'<~T'''t. 5T""-~Gt..
5\ \., 0
---
'I
I- I
~_-=!~. ~'''~
/,i.,. .~.~<..:~:.:~~;;~ .
: ,:;.':.! :~.~.
---~
.I.--
I
50'..0" ""',...
::, !:. C T \ 0 ~ .~-~.
SuQ"c.t.
..".
..,~, LD
'D~co~\. Co"'Ie.'fD~ 'tQ
~1.I~c;.L r:,..... . 'lLQt.1I.
~~P'~LL
..~"
r ';)IL"
L
L:~"
\(..~"( p\.,,, \.j
COA.l.. CO"vL'(t"L
G~I..LI.i..'(
, ----J....-
~--1
c.o....... c.o.........,"t..
F\
A:,- IS
0-5~-'\"'1.
Fig. AS-a
NOT8
,. DO IIIO'T' 8CAL8 TMt8 DItA....
~"""""'OML"
a. .....-v"'T1OM8 U8CD 0IIII .,..... o.A'" AM
. Ao;olllOoU8C&' W"," ......1ttCAIII ""-NOAaD
-........vu.TIOfI8 "OIl U8 CHIlI DaAW8IIQ&-
tLEYAi\O~
OF
L\k\E~TO~E FEEO
PLAIoJ T FO~ 'iHE:
300 ~w ~O\I.E'lS
'AI8 -..-... .. - ........., .. -
'iJ f"08TDI _dUJI COOIPOIOA"""
Ii ItO".OIIAJ8GCAva. ~...&.
::.:l.""=,~.~~.::1:?=
=~-=.::~~~
CHaan:D n,
r2..D 7\ \-IBA
, ......,
~'6.
-------
--
The bed material size will range from 1000-5000 microns with
an average diameter of 2500 microns.
Feed requirements were based on the assumption that 90% of
the S02 would be removed with six times stoichiometric feed ratio.
The heat generated would be 3 x 106 Btu/ton of CaS04 pro-
duced by the reaction' of S02 with CaO at 1900°F.
The recycle rate of the sorbent will be based on the as-
sumption that 3% of the sorbent is elutriated from the bed and
10% of the sorbent is ejected during regeneratio~.
, The sorbent will be received by unit train in covered
car with ~OO ton capacity pre-crushed and dried to 1-2% moist-
ure.
Material with such specifications is not
uncommon.
Covered storage is provided.
The material
would be fed to the coal conveyor after the coal drying and
crus~ing operation just prior to the surge'bin for the feed
injection system.
Storage offers several options.
The incoming material could
be stored either in a storage 5110 or in a combination of silo and
pile storage.
The silo is essential in any event, even if pile stor-
-
age were selected the silo would need to serve the same purpose
as bunkers in the coal feeding operation, that of giving some
leeway in scheduling the workers who reclaim from the storage
pile and move coal to the bunkers.
At feed rates of about 200 tons/day to 400 tons/day for the
300 MW system and 600 MW system respectively, the single silo
system handling "live" and "dead" storage appears to be preferred
over the pile-silo system.
A silo of about 2000 tons capacity
H-147
-------
should handle the system requirements.
The direct feed system
eliminates the need for reclaiming hoppers, reclaiming equipment
and operators, limestone dryers and limestone crushers.
It.
should simplify the delivery of limestone by reducing the fre-
quency of delivery and at the same time handle interruptions in op-
erations that might result from delays in delivery.
TVA indicates
truck capacities would run about 20 tons per car load (5).
Rail
capacities are running about 100 tons per car load.
.5.2
Scope
The sorbent will be received in
covered rail cars with truck unloading as an option.
The material
will be discharged at the receiving hopper which has a capacity
of 100 tons.
Its feeder capacity and conveyor belt were selected
for 20 minute unloading time for a 100 ton car.
The storage silo
holds 2000 tons of limestone equivalent to two weeks'supply.
The
limestone silo differs from the coal silo in that the hopper slope
should be increased to about 6]° to handle the small particle size.
Since the stone is pre-crushed to the size required, it can be
discharged on to the coal conveyor at grade level just after the
Flowdryer.
(5)
- "Sulfur Oxide Removal from Powe~ Plant Stack Gas; Conceptual
Design and Cost Study Sorption by Limestone or Lime Dry Process",
Tennessee Valley Authority, prepared for National Air Pollution
Control PB 178972, 1968.
H-148
-------
Investment
Capital investment for the
300 MW and 600 MW limestone handling plant are listed in Table A5-4.
Comparisons are made with data reported for a dry limestone in-
jection system excluding pulverizing and injecting equipment and
attendent power plant modifications.
Engineering contractors'
fees and contingency allowance have been prorated to compensate
for the exclusions.
Data on the fluid bed limestone handling
plant was provided by McNally Pittsburg.
H-149
-------
T~LE A5-4
SUMMARY OF ESTIMATED FIXED
INVESTMENT REQUIREMENTS
(5)
McNally Pittsburg Diy Limestone Inj ec tion
300(MW) 600 200 1000
1) Yard Improvements 25,000 50,000
2) Limestone Storage and
Handling Facilities
2(a) Concrete Foundations
and Conveyor Tunnel 80,000 180,000
2(b) Receiving Hopper Storage
Silo Conveyor Conveyor
Supports and Bridges, 71 , 000
and Powerhouse Storage 200,000
Sub-total 176,000 430,000
3) Engineering Design* 13,000 23,500
4) Contractor Fees and Overhead* 19,300 34,000
5) Contingency Allowance 13 , 000 -12.-. 000
Total 325,000 325,000 221,300 520,000
* Proportion from Original Estimate to Include Only that Equipment
Listed.
H-150
-------
A5.3
Coal Feeding
The coal feeding system includes all the process equipment
from the surge bins adjacent to the boiler to the inlet coal feed
points at the boiler shell.
This includes surge bins, lock hop-
pers. fuel injectors and pneumatic transport lines.
A state-of-
the-art review indicated the localized fluidized bed feeder and
lock hopper system proposed, by Petrocarb best fit the system
feed requirements of pressurizing to 10 atm., and multipoint in-
jection.
petrocarb developed and priced a system for four module
boilers operation at 300 and 600 MW levels.
AS.3.1
Assumptions
The feed system selected must be
capable of transporting coal from the Ohio Pittsburgh No.8 Seam
sized to 1/4" x 0" with a portion of limestone sized from 1000
to 5000 microns.
The material would be dried to insure non-ag-
glomerating and free flowing conditions.
The system must be capable of transporting the feed about
150 feet to elevations'of about 100 feet.
A total of 80 feed
lines are required serving four boilers each containing five
beds.
Each feed line should be capable of turn down of 30%.
A5.3.2
Petrocarb System
.2.1
Description
The Petrocarb System of coal feeding
was recommended by all of the people consulted on coal feeding (7)
(8) .
Petrocarb also felt pressurized fluid bed combustion was a
(7)
Communication with the Bureau of Mines at Morgantown.
West Virginia.
(8)
Communication with the Bituminous Coal Research at Pittsburgh,
Pennsylvania.
H-151
-------
proper and interesting application of their s~stem.
The Petrocarb System simply consists of a surge bin which
receives the coal and dampens fluctuations in flow rate, a lock
hopper which pressurizes the coal, a localized fluidizing fuel
injector or feeder which feeds and distributes the coal, and several
dense phase pneumatic transport lines which convey the coal.
In the local fluidization hopper fluidization takes place only in the
solids in the vicinity of the outlets to the conveying tube.
In
a conventional fluidizing hopper the fluidization air
would have to be recycled and repressurized.
In the local flu-
idizing hopper some power is saved as the fluidizing air also
becomes a portion of the pneumatic transport medium.
Petrocarb
has combined these components in what they call the Petrocarb
Mark IV Coal Injection System illustrated in Figure A5-9 and A5-l0.
The system is normally recoumended for blast furnace
operation.
In this case, it was modified to handle the higher
pressures.
The primary injector is the heart of the system.
It has
the function of maintaining a continuous feed of coal to the
furnace at a designated rate, and distributing the coal among
the working tuyeres in proportion to the blast air passing
through each tuyere.
Above the primary injector is the storage injector, which
automatically replenishes the coal injected from the primary in-
jector without interrupting or disturbing the injectionproces~.
Above the storage injector is a surge bin containing a sup-
ply of coal for ready transfer through the storage injector to
the primary injector.
Prepared coal is fed continuously to this
H-152
-------
RAW
COAL
STORAGE
I
)
/
/1
/
/
\
WEIGH
FEEDER
CYCLONE
,
I
! COAL
! DRYER
!
CRUSHER
AIR
CYCLONE
CYCLONE
\~
i
i SURGE.
I
I
,
BIN
...
.-_ft-
STORAGE
NJECTOR
TO TUYERES
FIGURE A5-9 COAL HANDLING AND INJECTION SYSTEM
H-153
-------
PRESSURIZING
AIR FLOW.
CONTROLLER
INJECTION AIR
'CONTROLLER
PROCESS AIR
t
COAL
OUST
COLLECTOR
DEPRESSURIZING
VALVE
PRESSURIZING AIR
INLET VALVE
COAL INJECTION
RATE CONTROLLER
WEIGH APPARATUS
MEASURES COAL
INJECTION RATE
IIh
.
.
. &..
ONE OUTLET FOR
EACH TUYERE
COAL INJECTION
RATE INDICATOR
COAL INJECTION
SHUT OFF VALVE
INJECTION AIR
FLOW INDICATOR
FIGURE AS-lO
J
ao.
FUR.NACE SAFEGUARDS
COAL INJECTION
STOPPED BY
A. !..OW BLAST PRESSURE
B. HIGH BLAST PRESSURE
C. LOW PROCESS A.IR PRESSURE
D. INSTRUMENT AIR FAILURE
E. ELECTRIC POWER FAILURE
: BUSTLE PIPE
PETROCARB PRESSURIZED COAL FEEDING SYSTEM
H-154
-------
bin, which is sized to provide a ready supply for the storage in-
jector.
The means by which the surge bin is automatically kept
supplied depends on local conditions.
Frequently the Petrocarb
pneumatic transport system is recommended.
In this case, the
McNally Handling Plant provides the continuous feed of coal to
the surge bin.
Regardless of the system used, means for main-
taining an adequate supply of coal in the bin must be employed.
.2.2
Instruments and controls
The instruments and
controls of the Petrocarb Mark IV System, alarms and indicator
lights are mounted on a semigraphic, mimic control panel showing
the complete installation from the storage bins to the furnace
tuyeres, it is incorporated in the control panel.
"Instrument alarm annuciators, pressure gauges
and valve position indicating lights, mounted on the face
of the panel enable the operator to determine at a glance the
cyclic position of the automated system.
The rate of flow is
determined by the different pressure between the furnace
and the primary injector, and once the plant has been
calibrated, the rate of coal injection can be varied by altering
the setting of the differential pressure controller which there-
after maintains a constant differential pressure between the hot
furnace and the injector.
Thus, if the pressure in the
furnace increases, the pressure in the primary injector is
automatically increased in the same proportion, and the reverse
compensation takes place if the pressure in the hot blast main
drops." (9)
(9)
E. M. Summers, "Engineering and Design Considerations of
Coal Injection", AlME Ironmaking Procedures, Vol. 23, pp. 69-96,
1964.
H-155
-------
"The automatic cycle is' controlled by sequence timers which
trip relays to energize the operative circuits, and a cycle is
started when the weight of the coal in the primary injector ves-
sel falls to 2000 lb., thus producing a low ~evel signal from
this vessel.
On receipt of this signal, the sequence automatically
continues in the following order:
a.
The ball valve between the primary and storage injector
vessels and the pressurizing valve in the storage injector vessel
open, while the pressure equalizing valve between the two vessels
closes, coal then flows from the storage into the primary injector
vessel.
b.
A low level signal from the storage injector closes the
ball valve and the pressurizing valve, and the vessel is vented
to atmosphere.
c.
The vent closes when the pressure in the storage vessel
reaches atmospheric.
d.
The inlet ball valve on the top of the storage injector
vessel opens, together with a vent valve fitted with a cyclone
dust extractor and rotary valve.
e.
Coal flows from the surge bin into the storage injector.
f.
A high level signal showing that 4000 lb. of coal have
been transferred into the storage injector closes the ball valve
and vent valve on top of the stora~e injector.
The vessel is,
then, pressurized to the same pressure as the primary injector.
g.
The pressure equalizing valve opens leaving the storage
injector ready for the next cycle.
H-156
-------
"At the completion of each full cycle the timers return to
their original position.
The entire cycle takes 20 minutes to
complete. and the storage vessel then stands full and pressurized
until the primary injector calls for coaL"
"Several interlocks and switches are included in the in-
strumentation of the plant to insure safe operation. and an
alarm system comes into operation in anyone of the following
circumstances:
1.
Low solids flow to any of the tuyeres
2.
Low solids flow to storage injector
3.
High and low level in the storage hopper
4.
Plant air failure
5.
High level in the surge bin
6.
High and low level in the storage injector
7.
Low level in the primary injector
8.
Failure of fluidizing air to primary injector.
conditions:
pr~ry injector is cut off in anyone of the following abnormal
In addition to sounding an alarm. the coal feed from the
lows:
1.
Excessive high or low pressure in the hot blast main
2.
Plant air failure
3.
Instrument air failure."
"Other special devices in the instrumentation are as fol-
a.
An interlock is provided which prevents the ball
valve between the primary and storage injectors opening until
both vessels are at the same pressure.
H-157
-------
b.
When the pressure in the furnace falls, the differential
pressure controller automatically drops the pressure in the pri-
mary injector vessel.
To avoid the consequential large scale
discharge of air from the primary injector vessel at times when
the furnace pressure has been deliberately reduced, a special
arrangement comes into operation.
A solenoid valve in the line
from the furnace closes when the pressure falls to below a pre-
scribed level and another solenoid valve in the instrument air
line opens and this now maintains a differential with the primary
injector through the differential pressure controller."
"When operating normally, the injection plant is fully auto-
matic from the storage bunkers onward.
However, from time to
time, it is necessary to break the automatic sequence and adopt
manual control.
The changeover from automatic to manual control
is done very simply by altering the switches on the panel to the
desired positions.
In doing this, the manual cycle must follow
.the same steps as the automatic. cycle.
The timers which control
the automatic cycle will return to their "home" position and re-
main there until the plant reverts to normal automatic working."
.2.3
Scope
For the specific application of the fluidized
bed steam generator consisting of four modules each containing four
coal fed beds with four independent coal injection points, Petro-
carb proposed a system with a feed rate turn down ratio of 30%.
This will be provided as 30% of the total rate to each bed.
Four
points of injection are to be provided for each bed.
Each of the
points will require a direct pipe run, supplied by Purchaser, from
a common primary injector.
The feed rate through these lines
H-158
-------
would be field calibrated to provide equal flow, with only a small
deviation allowed, to each of the four feed points.
Each of the sixteen (16) injection systems will include two
vessels.
The primary injector to be maintained at a preset and
controlled feed rate at all times.
The second vessel, a storage
injector, will periodically replenish the material supply in the
primary unit, operating automatically in lock-hopper manner.
The
feed rates for the four fluid beds are not so diverse as to dictate
disparate vessel sizing.
Therefore, for the sake of economy all
storage injectors are sized alike as are the primary injectors,
six and eight feet in diameter respectively.
In addition to the sixty four (64) injectors complete with
their proprietary internals the stated estimate includes the fol-
lowing equipment:
Complete lot of process and specialty valves.
Valves
involved in the automated cycling operations will be
either electric motor or air cylinder actuated ball
valves.
Sixty four proprietary injection solids/air mix as-
semblies, one for each of the feed points.
All required flex hoses and expansion joints.
Vessel relief valves.
Complete instrumentation and controls for functional
operation and vital indications.
A semi-graphic panel with enclosed internally piped
and wired cubicle for each of the four injection sys-
tems serving each of the four boilers.
H-l59
-------
The estimate also includes the following design and services:
Schematic piping and wiring diagrams.
Design criteria and specifications for design of
structures to support the vessels on their force'
cell mounts.
Consultation in design and Bpproval of fabrication and
installation of injection lines from primary injectors
to fluid bed feed points. .
Bills of Materials.
Equipment Manuals.
Operating Instructions.
Start-up assistance, one engineer for a period of thirty
(30) days.
Subsistence an4 local transportation to be
for the account of the Purchaser.
Compressed air requirements for each group of four injection
units serving a boiler is estimated to be 8400 scfm at 200 psig.
Oil free air having a dew point sufficiently low that
moisture will not condense in the injection systems after expansion
from the 200 psig regulated pressure. is essential.
Excluded from this estimate are the following:
Air compressors and related equipment.
Coal bins and bin gates.
Structural steel.
Piping, standard valves and fittings.
Electrical wiring and conduit.
H-160
-------
.2.4
Cost
The cost of the fuel injection system for
four field erected vessels including calibration of coal feed
lines for a 300 MW plant is $1,800,000.
The same plant with
eight outlets supplying coal to supplementary units such as
the regenerator or simply increasing the number of bed feed
points is $2,000,00.
Extrapolating the system to a 600 MW level the price for
a four outlet feed system is $2,800,000 and an eight outlet
feed system is $3,000,000.
The 600 MW feed system would use
the same number of vessels lock hoppers and bins.
The cross-
sectional area of the vessels would simply increase in pro-
portion to the feed ratio.
A5.3.3
Literature survey
The art of pressurizing coal
and feeding or pumping at elevated pressures is not clearly
defined.
This area of technology has received only sporadic
attention within the last 10 to 20 years as interest has been
directed at such coal burning processes as the coal fired gas
turbine, the pressurized steam generator and pressurized coal
gasification.
Selection of the appropriate coal feeding system
for the pressurized boiler thus required reviewing the litera-
ture and soliciting information from various investigators.
In the various processes investigated the solid fuel has
been pulverized, crushed or sized. Loose-packed bulk densities
range from 20 lb/ft3 for sized coke, 30 lb/ft3 for pulverized
coal, 40 lb/ft3 for sized coal, 55 lb/ft3 for crushed coal,
100 lb/ft3 for stone and up to 200 lb/ft3 for rich ores. (14)
(14)
M. N. Aref, "Pressurization of Granular Solid Fuels".
H-161
-------
Capacities run from 2 tons/hr .for small gas turhine plants to
100 tons/hr or higher for big gasification plants.
Delivery
pressures range from 5 to 1000 atm. and powdered fuel size, for
satisfactory pumping varies from 80 percent through 200 mesh for
pulverized coal down to 1/8 x 0 or 1/4 x 0 for crushed coal.
Solid fuel pumping has been broken down into two basic
groups; cyclic action and continuous action. . Some systems are
hard to define as they .may contain components that fall into
either group.
Each category includes the following fuel feeding
systems:
1.
Cyclic action group:
Simple lock hopper, lock hopper with moving wall, posi-
tive displacement ram pump, solid extension, slurry pump.
2.
Continuous action group:
Positive-displacement gear pump, multi-stage centrifugal
compression with air, peristaltic-displacement (rubber)
pump, fluid bed fuel injector, jet pump fuel injector.
.3.1
Cyclic action group
Simple lock hopper
The lock hopper system is
.1.1
probably the most common and well e~tablished of all the methods
of pressurizing granular solids.
The method employs as shown dia-
grammatically in Figure AS-II, two high pressure closed hoppers
connected in series to .an atmospheric hopper.
The sequence of
third cycle is as follows:
1)
Valve 1 is opened.
The solid is introduced by ,gravity
at atmospheric pressure into the lock hopper, Valve 2 being closed.
2)
Valve 1 is closed.
Auxiliary pressurizing air is applied
through Valve 3 to the lock hopper. until it reaches the same pres-
H-162
-------
\!7
'IIDIII "0"111
ATIIOS,,"IIIIC 11M
"0"111
t
COMPRESSOR
&GITATOII
FIGURE AS-II TYPICAL LOCK HOPPER ARRANGEMENT (14)
H-163
-------
sure as that of the feeder hopper.
3)
Valve 2 is opened.
Solid is then displaced by gravity
into the pressurized feeder hopper at system pressure.
Valve 4
serves to equalize pressure in both hoppers.
4)
Valves 2, 3 and 4 are closed.
Valve 5 is open to vent.
In each cycle a certain volume of pressurized air must be
vented to the atmosphere.
This volume of vented air equals the
difference between the volume of lock hopper and any dead space
inside of it as for example the operating valves and rods.
The
energy required to pressurize this particular volume of air added
to the working pressure of the system is wasted.
The pressurizing air displaces the whole bulk volume of coal,
thus an equal volume of air per cycle has to ~e vented.
This rep-
resents a power loss for each cycle according to the volume and
pressure of air involved.
The minimum power loss assuming poly-
tropic compression is given in hp:"'hr/ton of coal by:
W .
m1n
= CRT Ln r/n hs
isot
(1)
S = [(Pfb/Mar)-ll/l1-(Pfb/Pa~)]
Where:
-3
C = Constant equals 1.OlxlO
S = Coal/Air Ratio by Weight
Pfb = Bulk Density
P = Bulk Density
ac
M = Specific Weight per Cubic Foot of Air
a
T = Temperature Level
r = Compression Ratio
R = Gas Constant
W = Minimum Work
nisoth = Efficiency due to isothermal compression
H-164
-------
The weight ratio of coal to air, S, at varying compression
ratios is given by equation 1.
The variation of S with the com-
pression ratio r at different bulk densities of the coal-air mixture
as a parameter is shown in Figure A5-l2.
Assuming a constant iso-
thermal efficiency for multistage compression constant at .90,
the minimum power loss in venting the pressurized air from the
lock hopper per ton of coal is as shown in Figure A5-13 for dif-
ferent final bulk densities of coal-air mixture.
The lock hopper system is a means of pressurizing coal.
As
already indicated, pressurizing is done at considerable power loss
in venting and pressurizing the lock hoppers and feeder hoppers.
The complete system requires feeders at the inlet and exit which
control the flow rate of coal.
Stone feeders, table feeders and
screw feeders have been used with the lock hopper system to regu-
late the flow of coal from the pressurizing vessel. (15, 16, 17,
18, 19, 20).
They are expensive and subject to wear and are limited
15)
J. D. Spencer, T. J. Joyce, and J. H. Faber, "Pneumatic Trans-
portation of Solios", Proceedings: Institute of Gas Technology -
Bureau of Mines Symposium, Morgantown, West Virginia, October
1965, U. S. Bureau of Mines IC 8314.
W. J. Morley and B. Parmington, "Preliminary Investigations into
the Downdraft Combustion of Granulated Coal in Air-Cooled Equipment",
Mechanical Engineering Technical Memorandum 303, Department of Sup-
ply, Australian Defense Scientific Service, Melbourne, Australia,
August 1967.
W. J~ Morley, "Pressuriz~d Combustion Pot Tests of a High Volatile
Bituminous Coal", Mechanical Engineering Note 270, Department of
Supply, Australian Defense Scientific Service, Melbourne, Australia,
July 1965.
J. P. McGee, J. Smith, R. W. Cargill and D. C. Strimbeck, "Bureau
of Mines Coal-Fired Gas Turbine Research Project", Redesign and
Assembly of Turbine, United States Bureau of Mines Rl 5958, 1962.
J. Smith, R. W. Cargill, D. C..Strimbeck, W. M. Nabors, and J. P.
McGee, "Bureau of Mines Coal-Fired Gas Turbine Research Project",
United States B~reau of Mines lR 6920, 1967.
16)
17)
18)
19)
20)
W. R. Huft, J. H. Holden, L. F. Willmott, and G. R. Strimbeck,
"A Pilot-Scale Fluidized Coal Feeder Utilizing Zone Fluidization",
United States Bureau of Mines lR 6488, 1964.
H-165
-------
FIGURE A5-12
FIGURE A5-13
.
I
.
C
o
..
J
3
"
...
o
o
~
..
.
(REF. 14)
VARIATION OF COAL/AIR RATIO WITH COMPRESSION RATIOS AT VARIOUS BULK DENSITIES
II
J
i
a 14
!
ill
&:
.
I
J
. .
..
.
o
~
.
.
to
40
to
(REF. 14)
POWER REQUIREMENTS FOR DIFFERENT COMPRESSION RATIOS AND FINAL BULK DENSITIES
10
COMPIICSSlON .II"TIO - r
LOG. "O~~I" COII~"r'IION LOIS IN
W8.'INO ~"II'U"lzro "III
II.... AlSUIIID 0., - ..u~ TI- IT"OI
.TII. CO"~.IISIO"
II
.
I
o
10 . 10 .
. COII~III"IO" ."'10 ,
10
40
H-166
-------
with regard to distribution.
Only one feed point per lock hopper
is available.
Feed to the lock hoppers has been accomplished
pneumatically as illustrated in Figure AS-14 or by such mechanical
devices as the rotary valve or screw pump as illustrated in Figures
AS-IS.
The conventional lock hopper system is reliable and well
established with regard to experience.
However, it requires a
large capital outlay for feeders and controls, it consumes subs tan-
tial quantities of power per ton of feed, and is subject to con-
siderable wear in the feed system.
.1.2
Modified lock hopper system
Conservation of
energy lost during pressurizing and venting operations is one
obvious source of cost reduction in the lock hopper system.
This
might be simply accomplished by placing lock hoppers in series.
Figure AS-16 illustrates the ratio by which the operating pressure
is reduced in proportion to the pressurizing level for 2, 3,
and 4 equal hoppers pressurized in series.
It is noticed that
a considerable reduction in pressure to be vented can be obtained.
If the hoppers are of equal volume, the pressure of air to be
vented after pressurizing two, three, or four hoppers approaches
0.5,0.34, and 0.2S of that of one hopper, respectively as the bulk'
density of the mixture is reduced.
Figure AS-17 shows what power sav-
ings can be realized for a coal with a bulk density of 30 lb/ft3.
Other modifications to the lock hopper system that have
been proposed to reduce power consumption include lock hoppers
in parallel and cascading of pressurizing air through a system
of lock hoppers operating in parallel and serving a multiplicity
H-167
-------
c
--"""-"'''''----~. ,
~~
VENT
I
L - - -,
I
3
WEIGHT
INDICATOR
CONTROL
--~
r-------------+-
I
I
I
I
I
JNJE~TJON
VALVE
I
I
I
. I
- - - -~. MA~ER
CONTROL
I
I
----------_.J
2
INJECTION RATE
INDICATOR
6
FEED VALVE
(PUSHBUTTON CONTROLLED)
TO PROCESS
FIGURE AS-14 PNEUMATIC FEEDING OF COAL
H-168
-------
Silo
...
.
lock
hopper
,
,
I "-
: . 'a
:~~~
WU Sc;:p
/~
~
~'" ~
",fE)
Star-wheel
feeder
Rotary
valve
Co.l ..
Inert ps q
Coal.nd c;
inert 'liS
FIGURE A5-15
TYPICAL LOCK HOPPER FEED SYSTEM USED TO FEED COAL UNDER
PRESSURE TO GAS TURBINES
H-169
-------
FIGURE A5-16
'0
I ..
o
..
J Q8
8:
...
t
¥
~ o'
...
8:
:>
..
..
...
fOt
to
(,REF. 14 )
~
.
~
o
..
.. 0 S
o
o
~
C
8:
r Q<
&"1"-
0'
01
..,
10
so
REDUCTION IN OPERATING PRESSURE BY PLACING HOPPERS IN SERIES (14)
FIGURE A5-17
10
10
<0
" lULl! OfHSlTY 0' COAi:.- L.BS/H'
o
II.- POWER I.OSS BY V£NTII'IG AT 20 ATMOS. WHEN ON[
ItOPP£R .5 USED. ' .
B-P()W[R L.OSS WHEN TwO HOPPERS ARE U$[D.
C-P()W[R \.OSS WHEN THREE HOPPERS ARE USED
.
I
...
.
o
u
~12
z
o
..
....
II!
%
'"
::= 8
II>
II>
9
ar .
w
2
4
-
010
ao
~
40
~
BUL.I! DENSITY 0' COAL.-L.IS/cun
(REF. 14)
REDUCTION IN POWER USING HOPPERS IN SERIES (14)
H-170
-------
of feed points.
Savings ar~ acllicved which might not he as great
as lock hoppers in series and at the expense of more complicated
controls.
Bituminous Coal Research uses two lock hoppers in
parallel feeding, a pressurized piston common to both, and a feed vessel
for pressurizing to 1000 atm. (27)
Petrocarb (28) proposes cascading of
pressurizing air when using a multiplicity of lock hopper systems to
feed large numbers of feed points.
In any case the power savings must be realized at the ex-
pense of an additional capital outlay in lock hoppers and controls.
Neither time nor scope of effort permitted optimizing the lock
hopper system for the pressurized fluid bed boiler.
Attempts
were made to obtain a price for a simple single stage system.
Lurgi, one of the prime vendors of lock hopper systems, would
not quote a price or provide a conceptual design as they felt
,
it would give away portions of their proprietary position.
.1.3
Lock hopper with moving wall
A positive dis-
placement or moving wall lock hopper is another attractive method
for reducing power loss by venting.
In place of a pressurizing tank the principle of a moving
wall uses a continuous positive displacement pressurizer which
conveys into a stream of high pressure air or feeding vessel
whatever quantity of pulverized or crushed coal it may receive
from the feeder(14, 29).
Dr. Donath proposed a system illustrated
in Figure AS-l8.
27)
28)
Communication with Dr. Glenn, Bituminous Coal Research.
Communication with Mr. Rienjtes of Petrocarb, New York City.
29)
E. E. Donath, "Progress Achieved in Development of a
Coal Feeder", Proceedings of Gas Technology - Bureau
Symposium, Morgantown, W. Va., October 19-20, 1965.
Piston
of Mines
H-171
-------
Valve 1
Cylinder
A
I
Pressurized coal
to alSi'ier
Piston
FIGURE AS-18 SCHEMATIC DIAGRAM OF DR. DONATH'S PRINCIPLE OF THE CONTINUOUS
POSITIVE DISPLACEMENT PRESSURIZER EMPLOYED AT BCR (29)
H-172
-------
Coal from the bin flows through valve I. into the auxiliary
feed vessel B.
While in a fluidized state it is blown with inert
gas through valve 2 into cylinder A while the piston moves up-
wards.
The admission ports for the gas are not shown in Figure AS-IS
When the piston reaches the top position valve 2 closes and
cylinder A is pressurized with product gas at the feeding pressure.
Then valve 3 opens and the coal, suspended in high-pressure gas
is pushed by the descending piston into the gasifier.
Power requirements for the piston feeder can be calculated.
Dr. Donath compares them with other feeders in Table A5-5 .
TABLE AS-5
POWER REQUIREMENTS FOR FEEDING COAL TO
A 1000 PSI GASIFIER
Types of Feeder
Kwh per MM
Btu in Gas
Density of Coal
Change lb/ft3
Piston
Slurry Pump
0.2
0.2
1.4
35
35
42
Lock Hopper Gas Compression
The reduction in power requirements would not be expected
to be as great at lower pressures, say 10 atm.
Calculations,
however, have not been made to verify this.
The pump has not
been put to practice.
There is no information on such character-
istics as capacity, limitations, wear, or economics.
It is defin-
itely limited to single feed point applications.
Bituminous Coal Research in cooperation with Petrocarb has
put together a system using two lock hoppers in parallel feeding
to a rubber "boot" or rubberized piston which in turn, feeds to
H-l73
-------
I"
I
I
a single feeder vessel.
The system essentially puts to practice
the Donath system at the pilot plant level.
Data on economics
and maintenance are not yet known.
.1.4
Rotary pumps using the moving ball principle
Two similar types of solid-fuel pumps working on this method in-
eludes the rotary pumps designed by Yellott (30) in the U.S.A. and
by the Incandescent Heat Company in England (31).
These two pumps
illustrated in Figure A5-l9, are designed for applications where
the work pressure need not exceed 10 atm.
The speed of the rotary
disc carrying coal to the high pressure zone can vary up to 60 rpm
and coal flow rates can vary up to 2.5 tons/hr.
The practical problems center around:
1)
Disc wear due to abrasion caused by entrained, fine par-
ticles of coal during its traverse between sealed pads or covers
from atmospheric hoppers "to high pressure air duct.
2)
Perfect sepling between high-pressure zones, while main-
taining at the same time efficient operation of the sealing medium
upon surfaces in contact.
3)
Avoiding venting of pressurizing air" from the pockets
before reaching the atmospheric hopper each cycle.
This can be
overcome by momentarily closing the pockets after the coal discharge
by means of mechanical or hydraulic thrust if the preSsure to be
regained is not exceedingly high.
30)
J. 1. Yellott, "Gas Turbine Power Plant Solid-Fuel Feeding
Machine", United States Patent No. 2652687, September 1955.
31)
G. Waller, "Rotary and Ram Pumps for Solid Fuels", Journal
of the Oil Engine and Gas Turbine, May 1953, pp. 28-30.
H-174
-------
FIGURE A5-19
HIGHo":fJlSSURE
TILLOTT ROTARY PUMP
ROT ATING
DISK
,
HIGH PRESSURE AIR
IHCAHD£SCENT HEAT
ROTARY PUIIIP
ROTARY PUMPS PROPOSED BY YELLOTT AND INCANDESCENT HEAT COMPANY (14)
POCKETS
OPt:NE~
FIXED
CAMS
MULTI-RAM ROTARY PUMP
FIGURE A5-20
STATIONARY
CAMSHAFT
. .
POCKETS
CLOSED
" " ':.,,". ","
. ..
..
. ..
PRESSURIZING
All'
MULTI-RAM RO'IARY PUMP (14)
H-175
-------
As a modification of these pumps Dr. M. N. Aref proposed a
multi-ram rotary pump illustrated in Figure A~-22.
The pump
essentially consists of a rotary cylinder contal11ing two s~tH
of four spring loaded pistons.
The pistons are diametrically op-
posed and are actuated by a cam which remains fixed on a stationary
shaft.
On the hopper side the piston retracts forming a cavity
allowing coal to flow into the vacated space.
As the cylinder
rotates. the pocket is sealed.
At 1800 from the start or hopper
position, the cam forces the piston to compress at the time when
the seal is broken forcing the coal into a pressurized gas stream.
The pressurized coal is then transported away with the pressurized.
air.
The cylinder continues to rotate and the pocket is once
again sealed.
Just prior to returning to the initial position
on the hopper side after almost 3600 of rotation has been completed
the pocked is vented.
This depressurizes the pocket and purges it
at the same time.
The pocket is ready to repeat the cycle.
The moving wall principle requires less power.
However. it
is subject to wear.
Nothing is known about such characteristics
as maintenance, capacity or overall economics.
Care must be taken
during the short period of compression that briquetting of the coal
does not take place.
The pump may be more readily adaptable to
multi-feed point distribution by using several rotating cylinders
on a comm9n shaft;
This.would require further investigations.
.1.5
Koppers coal pump
Koppers developed a "gear"
type of coal pump-that.a1so operates on the moving wall principle.
It is illustrated in Figures A5-21 and A5-22.
In the Koppers system, coal arriving at the injection plant
H-176
-------
Coal feed
~
Primary
vent
Secondary
vent
FIGURE A5-21 KOPPERS GEAR TYPE PRESSURIZED COAL PUMP
Blast
furnace
FIGURE A5-22
KOPPERS PRESSURIZED COAL FEED SYSTEM
Splitters
- u.-ShU~?
Prepared.coal bin
Transfer lines
Compressor
H-l77
-------
from the mine or from storage is dumped into a truck hopper from
which it is carried by belt to an impact. crusher. . The crushed
coal is. transferred by the bucket elevator from the crusher
to 8 vibrating screen which scalps the over~1ze coal.
The over-
size material is returned to the hopper.. The coal p~ssing the
screen. is fed' by belts to a reversible shuttle~conveyor which
deposits the prepared coal evenly in the rectangular bin.
The
coal in the bin is maintained at atmospheric pressure.
Underneath the bin are ten BCR patented "Easy-Flo" bin
discharge sections, each supplying a feeder, in order to ensure
continuity of feed to feeders, particularly with wet coal.
The
bin is mounted on load cells so that the weight of coal in the
bin can be determined periodically to obtain a check on the
feed rate.
Compressed air is supplied. to all the feeders through a
common header from which parallel branch lines flow to the
individual units.
The coal-air mixture leaving the feeders
flows through transfer lines to the splitters located near the
bustle pipe.
After the splitters the branch lines lead to al"';
ternate tuyeres.
The main transfer lines vary in length from
about 250 to 300 feet, including about 40 to 45 feet of vertical
rise.
The coal injection system was designed to supply the furnace
with as much as 600 tons per day of coal.
The system handles the
minus 3/16-inch or minus lIB-inch coal with the fines included.
and requires no 'special preparation of the coal with respect to
H-178
-------
particle size distribution.
TIll' molstur~ cont~nt uf the "as-rcc~ ived"
coal usually averages between 3 and 4 percent and on occasions, cuals
with a moisture content up to 8 percent have been used.
No probleras
have been encountered in feeding coals of the higher moisture con-
tents from the atmospheric storage bin.
Instrumentation provides for complete automatic control with
remote adjustment from a panel board located in a centralized con-
trol room.
Air pressures and air flows are automatically regulated
to follow changes in furnace pressure.
Feeder speeds can be varied
either simultaneously or individually.
The control system provides
for automatic shut-down and start-up of the feeders during cast
periods or whenever checking of the furnace is required.
Controls
also provide for automatic shut-down of the injection system in
the event of electrical. power failure or a failure of auxiliary
equipment.
If, for any reason, such as slag build-up at a tuyere, an
individual line is plugged between the splitter and the tuyere,
the respective feeder is shut down automatically; no plugging
of the main transfer line occurs.
This is an inherent feature
of the system wherein one feeder supplies two tuyeres.
Another
advantage of this arrangement is that not more than two tuyeres
need be without coal at anyone time or for more than a few
minutes.
The piping arrangement at the lances is such that,
if the lance-piping plugs, unplugging may be accomplished in a
matter of minutes.
Koppers claims no major difficulties have been encountered
with the equipment or the operation of the ~oal injection system.
H-179
-------
Start-up operations were completely .free of. difficulties custom-
arily associated with initi31 start-ups.
Per f nrm,] nct.' con t [nUl.':-;
to be excellent.
Koppers claims the following advantages.
1.
"No special equipment is required, such as pressurized
bins, lock-hoppers, etc.
Materials are delivered from a storage
bin at atmospheric pressure to the blast furnace or other vessels
operating at high pressures by means of the high-pressure feeder.
2.
Virtually all types of solid carbon, such as bituminous
or anthracite coals, lignites or chars, can be used.
3.
No special preparation of the coals with respect to
size consist is required.
Simple crushing to minus 3/16-inch or
minus liB-inch is all that is necessary.
Coarser or finer sizes
may be handled if desired.
4.
No drying of the coals is required.
Coals with moisture
contents up to 9 percent have been used in the pilot plant.
5.
The system is flexible.
Large turn-down ratios can be
built in without sacrificing accuracy of feed rate.
6.
The system is completely automatic.
Intermittent shut-
down and start-up during cast periods or furnace checking are
controlled automatically.
7.
The system is adaptable to injecting other types of
solid materials, into vessels operating at atmospheric or high
pressures." (32)
32)
, "Operating Characteristics of Koppers High Pressure
Solids Injection System", Brochure, Koppers Company, Inc.,
Engineers and Cpnstruction Division, Pittsburgh 19, Pennsylvania.
H-180
-------
The Koppers system is not without liabilities.
Koppers is
reluctant to design for pressures in excess of 100 psi Rnd tll~y
are reluctant to handle stone.
The pump is subject to wear and
it does not easily handle the multiple feed point problem.
Kop-
pers would not quote on the system as specified.
.1.6
Screw feed using moving wall principle
The Ful-
ler-Kinyon Pump is not a rotary pump.
However, it does use the
moving wall principle in the form of a screw feeder which forces
the coal into a pressurized chamber.
The pump is illustrated in
Figure A5-23.
Robert F. Loomis (33) reports that the Fuller-Kinyon system
by virtue of its high material-to-air ratio makes safe handling
of pulverized coal a reality.
The total system air is only
0.0014 percent of the air necessary for combustion.
Basically the pump consists of a high-speed screw with a
gradully reducing pitch section at the delivery end.
The material
being conveyed is advanced by the screw from the hopper section
into a short barrel section where it is compressed to form a seal
against blow back.
The material is then discharged into a mixing
chamber where compressed air is introduced through a series of
nozzles or jets.
The air mixes with and fluidizes the material
and conveys it as a relatively dense mixture through the conveying
line.
Air requirements are relatively low as compared with those
of most other pressure systems.
Pick-up velocity is usually about
1,600 to 2000 ft/min with material-to-air ratios of 40 or more
to 1. on a weight basis.
Maximum air pressures are usually limited
33)
Robert F. Loomis, "Pipeline Transport of Dry Solids", Pro-
ceedings, Institute of Gas Technology - Bureau of Mines Sym-
posium, Morgantown, W. Va., October 19-20, 1965.
H-181
-------
~
FIGURE A5-23
FULLER-KINYON SCREW FEED PUMP (33)
H-182
-------
to 35 to 40 psig keeping within the limits of a single stage
rotary compressor.
The pump is built in a wide range of sizes
with capacities from 100 to 5000 Cfh.
Distribution and compression ratios are the two limiting
factors for this system.
.1.7
Positive displacement ram pump
This type of
pump has proved satisfactory in operation to pressurize solid
fuel at higher pressures than 10 atm.
Figure AS-24 depicts
a diagrammatic arrangement of a ram pump and its cycle.
It
operates by drawing air-laden solid-fuel dust into a cylinder
through a non-return valve by means of the suction strokes of a
reciprocating ram, which is connected to a conventional crank
chain assembly.
The ram is usually hollow and cooled during
operation.
Situated at a mid-point in the cylinder wall is a
carn operated, non-return valve which admits high pressure air to
the cylinder.
At the start of the compression strokes, the
tappet valve opens to admit air having a pressure at least
equal to that of the system being supplied with fuel.
Through-
out most of the compression stroke the contents of the cylinder
are discharged into the receiving system through a non-return
outlet valve.
Unfortunately the main drawback of a ram pump is that it
suffers from a limited low filling density of the solid fuel
in order to avoid briquetting.
Careful control of initial or fil-
ling density must be assured, particularly at higher pressures
to avoid damage to the pump.
This requires using a sensitive
quantity governer for the solid fuel charge.
The relationship
H-183
-------
FIGURE A5-24
I.Y.
~
~I
O.Y.
Ptl
... YI
YI"Y'
PI Y. Y
AU.ILI AllY &111
COIIPIIUIOII
CLUII&IICI
YOWII!
P
p. -K' ~., .
~ -- .
&T..05.
..~~&)"oG~:~,,1
OUICK PIIISSURIZ''''
TO 'ULL DILIYIII' '1I15SUIII
PI. 14(0)
PIIUSUIIIZ'NG &'"
. OtLlVIRY TIIIII &'''05.
YIIITING.
I
, I
1:1/\
&"110.. &TIIOS.
IIOTKIIIII&L . CII&IIGIIIG ,
COMPIIUSIO.. ..U.)O LISII'T
y
DIAGRAMMATIC ARRANGEMENT OF A RAM PUMP AND ITS CYCLE
H-184
(14)
-------
between Initial and fioal solid-air mixtures versus the compres-
slon ratio is illustrated In Figure A5-25.
it has been found that
brlquettlng of the solid fuel inside the cylinder may occur at
20 atm if the final mixture density exceed 30 Ib/ft3 which cor-
3
responds to about 2.5 lb/ft initial density as illustrated in
Figure A5-25.
Consequently, a very low solid-fuel output per unit
volume of pumps may be expected which is greatly reduced by the
rise in temperature.
This may be compromised by increasing the
pump speed or number of cylinders in the cycle.
The power requirements for the positive displacement ram are about
the same as a lock hopper with a moving wall and a final bulk density
of about 30 lb/ft3.
This is illustrated in Figure AS-26 and represents
the maximum practical limit for 20 atm. before briquetting.
In some
cases additional cylinder volume clearance is included to avoid dama-
ges due to briquetting.
Scavaging air is used at the end of compres-
sion to vent the cylinder to atmosphere.
In this case the power
requirements must increase over a simple lock hopper system.
.1.8
Solid Extrusion
H. Koppers (34) has shown that a
coal plug 20 inches long can be extruded by means of a 2 in.-diameter
plunger coaxially located in a 2.5 inch diameter tube at a rate
of 120 strokes per minute and are extension pressure of 700 atm.
and satisfactorily sealed against 30 atm. gas pressure.
The plug
~an be repulverized very easily in a simple air-jet micronizer.
This system is illustrated in Figure A5-27.
Substantial briquetting occurs. however, when the greater
part of air in the voids is removed by the extension pressure.
34)
H. Koppers, "Improvement in or Relating to the Inttoduction
and Removal of Granular Solid Materials into or from Closed
Chambers at Increased Pressures", GmbH Co., Germany, British
Patent No. 699747. Appl. Date, October 1950.
H-185
-------
1""'1
...
11-1
......
tI)
.c
poi
801 I
j I
! I
1 !
60, I
- ; BRlQUETTING I
i ZONE I
401
I
.
i
I
~
....
en
Z
~
Q
~
S
I:Q
...:I
~
....
~
i
20i
t
I
1 OF COAL TAKEN 80 1bs/ft~
a
---1---- --'---1
INITIAL DENSITY
15 1bs/ft3
. 10
5
o
i I
4----- ._._----,~-_.-
10 - 15
COMPRESSION RATIO y
2.5
. -., BRIQUETTING
I LIMIT
"'--1
I
I
I
t
j
20
5
. FIGURE. A5-25 - RELATIONSHIP BETWEEN INITIAL AND
FIBAL AIR MIXTURES VERSUS COM-
PRESSION RATIO AND BRIQUETTING LIMIT
H-186
-------
'1
10
.
..
4
o
..
..
o ,
'"' '
~ ~~
.. ,
.
,.
.:
i
!
"4
..
o
..
II:
...
.
o
..
'.
o
FIGURE AS-26
A - TOT AI. ~PW[" lOSS
. - ~O.[" lOSS TO OtS~lAt[
"U5UII'Z[O AlA '"0..
["~TY ~OC.[TS . ''''CTOO''
C' ~O.[A lOSS ," ''''CTOO''
;
l ::
i 3
I: ..
~ ..
i II
..
i :.
. ...-
u
9
10 20
CO"~IIUSIO'" IIATIO ,
JO
40
POWER REQUIREMENTS FOR SIMPLE
LOCK HOPPER AND LOCK HOPPER
WITH MOVING WALL
H-187
-------
COAL
CHUTE
..r1'"
P /r1! I I
, ; I
FIGURE.AS-27 H. KOPPERS COAL SOLID EXTRUSION
",",,- - - ~'-:
\~,'
/
STAR FEEDER
v
/1'1
/~/ II
, II:
! '
---- ....-..__..h-
/' ,.- ---- \,
/ '(5\ '. \,
\ Iii
, " 1- 1/1
\!9
,
I .
;- I
I
, I
; I
W
,
\
T-?-j
,// / /
/ / ~/ ./ //1
," /' / ,.' "1
' < ./ ,/ I
I
.i
I
"
H-188
CRANK CHAIN
PLUNGER
EXTRUSION CYLINDER
MICRONIZER
-------
This air escapes past the cylinder wall when the plug advances
therein under the action of the plunger.
A small portion of air
in the voids remains in the form of more or less small compressed
bubbles and this air, together with any pressurized air from the
high pressure chamber which may have penetrated into the plug,
tends to expand during the return stroke of the plunger.
This
tends to press coal particles against the cylinder wall thus
increasing the sealing pressure of the plug, particularly in
that constricted passage nearest the high pressure chamber.
Sufficient compression by the plunger is therefore required
to:
1)
Maintain high friction-bearing pressure between coal
plug and cylinder wall in order to hold it in place against
the pressurized air from below particularly on the return stroke
of the plunger.
2)
Achieve satisfactory sealing pressure of plug, depending
on type of coal and its fineness.
It is possible to reduce the friction pressure which con-
tributes to excessive wear of the cylinder, if the diameter of
the plug is decreased to a practical minimum while the plunger
stroke and speed are correspondingly increased.
Although this
procedure undoubtedly reduces the plunger loading and may in-
crease the sealing efficiency of the plug, yet it has to be
determined experimentally whether or not it significantly re-
duces wear.
Minimum power loss is substantially higher than other
systems proposed at the lower compression ratios.
Solid extrusion
H-189
-------
is more adaptible to the very high pressure levels.
It is not
certain'that it has been reduced to practice at this point.
"
.1.9
Slurry pump
Hydraulic pressurizing of coal-
water slurries by lock hoppers with moving walls or ram pumps,
reduces the power to almost that required for positive dis-
placement of solids alone but this gain is swamped by the thermal
effect of increased moisture content - after dewatering and by
the serious complication of pressure drying even if the residual
moisture can be used effectively in the system.
See FigureA5-28 .
Usually coal-water slurry contains from 37 to 45 percent
water by weight, depending on size of the coal particles and
type of coal.
The plunger may be considered saturated with water when the
bulk density of its mixture approaches 'the absolute density of
coal, which often occurs when the water content reaches approxi-
mately 40 percent by weight.
Oversaturation, however, takes place
when the water content exceeds that limit and consequently the
water, unless prevented, starts to drain out of the slurry
mixture.
Power requirements for pressurizing coal slurries with vari-
ous percent water are shown in Figure A5-29.
.3.2
Continuous action group
.2.1
Position displacement seal pump
In this type of
pump, positive displacement can be approximated and leakage reduced
by meshing several gears together, three to four gears being suf-
ficient.
This is decided according to whether or not a maximum
sealing distance is obtained due to a central zone of intermediate
H-190
-------
(35)
Cool and
in.rt oos
Wot.r
Vent
Premia tonk
Drain
Cool slur,y
Cool- wale,
slur,y
Piston-type pump
Condensate .
FIGURE A5-28
Air PIIrOt
Vent
Natural
OQ~
Ai,
Convection- type
slurry heater
Steam- cool
milture
Steam
sepo,ato,
FEED COAL
Woler
SCHEMATIC FLOW DIAGRAM OF A COAL SLURRY
FEED SYSTEM (35)
L. F. Willmott, K. D. Plants, W. R. Huff and J. H. Holden,
"Gasification of Bituminous Coal with Oxygen in a Pilot
Plant Equipped for Slurry Feeding", U. S. Bureau of Mines
RI 6117, 1962.
H-191
-------
t. Off COAL TAkl" 80 LIS"
.
.
~
..
as
.
o
..
....
.
.
.:
Jt
. a
9
.
...
.
o
..
10 10
COII'IIOIIOII IIATIO r
JO
80
FIGURE AS-29
POWER REQUIREMENTS FOR PRESSURIZING
COAL SLURRIES (14)
FIGURE AS-30
PERISTALTIC OR RUBBER PUMP (14)
H-192
-------
pressure.
Undoubtedly this is a practical variant of the YelLott
design to eliminate venting hut In this CllSI:', It is prllhahly tlte
wear of the rotary disc seals which limits the speed and capacity
rather than rate of filling and discharging.
(14)
.2.2
Multistage centrifugal compression with air
A
small rubber-lined multistage shrouded centrifugal compressor
offers another possible method for pressurizing finely pulverized
materials with an intake density below 2.3 lb/ft3 for 20 atm.
delivery.
This, however, is the limit over which briquetting
of the solid might occur and cause damage of the impeller vanes.
This pump has the advantage of keeping the solids fully entrained
and their cooling effect at pressurizing will contribute some-
thing to efficiency.
Nevertheless, excessive wear of the casing
is liable to occur, particularly at higher impeller speeds and
solids concentrations.
Obviously this limits the practicality
of the pump.
(14)
.2.3
Peristaltic or rubber pump
A peristaltic pump
based on the principle of squeezing rubber ducts by a set of
cams mounted on the same shaft provides a promising method for
pressurizing solid fuels in the low pressure range up to 6 or
7 atm.
In this case, wear, leakage, and air venting are elimin-
ated while the pump offers a steady continuous flow path for the
coal.
Even so, it has the disadvantage of a pressure limitation
with the unsupported side of the rubber duct.
This is illus-
trated in Figure AS-30 where it has been established that
collapsing the rubber at intermediate .points along its length
is more feasible than by a longitudinal roller system.
(14)
H-193
-------
.2.4
Jet pumping (35)
The jet pump fluidizing feeder
was developed to produce a uniform solids delivery rate when feed-
ing against a constant pressure.
It produces the desired uniform-
ity mainly because it has no moving parts to suffer wear from
abrasion.
A jet pump employing a high velocity,
inert motivating
gas to entrain the particles of solids and propel them from at-
mospheric pressure to a higher pressure should also give a steady
feed rate.
The jet pumping of solids functions on the theory that
when a pigh pressure fluid is discharged from a nozzle of a jet
the stream of high velocity fluid acts as a pump for moving a
low-pressure surrounding fluid at the periphery of the nozzle.
When the pumping process occurs there are two principle mechan-
isms taking place.
(1) Acceleration of the particles of the
surrounding fluid, which are relatively at rest, by the impact
with the high-velocity escaping nozzle fluid, (2) entrainment
of the surrounding fluid particles by. viscous friction around
the pumping of the nozzle of the jet.
Fluidized solids behave as a non-homogeneous fluid..
When
the non-homogeneous fluid surrounds the jet, the air molecules
associated with the solid particles can be effectively pumped.
However, the larger and heavier solid particles tend to lag
thus reducing the effective work produced by the jet stream
by consuming much of the energy.
It is the high transfer of
energy to these larger solid particles, serving to increase
their velocity and moving them against pressure which reduces
35)
T. E. Corrigan, M. J. Dean, and D. Denton,- "Feeding Pneumatic
Conveyors", British Chemical Engineering, March 1969, Vol. 14
No . 3 .
H-194
-------
the ability of the jet pump to move the non-homogeneous fluid ef-
fectively.
This method of pumping is not practical for conveyinR large
quantities of fluidized solids into a higher pressure zone.
The
pressure range against which solids can be pumped is too small and
this method would not be economical because of the large volume
of high-pressure motivating gas requirements.
It is believed that
the design of the pump could be improved so as to increase the
efficiency slightly but that this increase in efficiency would not
produce a sufficiently high solids-to-air ratio to be an economical
method of transporting solids.
2.5
Local fluidization
In the local fluidization hopper
fluidization takes place only in the vicinity of the outlet to the
solids conveying tube.
See Figure A5-3l.
The fluidizing gas for
the most part is also used to convey the material from the hopper.
When used in conjunction with a lock hopper system, the total con-
cept offers the capability of pressurizing over a wide pressure
range with a minimum of maintenance and power requirements.
In addition
it offers the flexibility of feeding to a large number of feed points
from a single feed vessel using the simplest of feed devices.
Ex-
cept for the lock hopper valving there are no moving parts.
At
high pressure levels dense phase transport can be used to further
minimize the total gas or af.r requirements.
The system makes use
of practical, available, equipment and has been put to practice
by the Petrocarb Corporation.
A5.3.4
Fire and explosion in the pneumatic transport of
A primary concern in the pneumatic transport of coal is
coal
the conditions which lead to fire and explosion.
While this
H-195
-------
---+ +-
.
---+ +-
Partly --+
fluidized coal
from storage
Fluidizing -.
gas
Flu i d i zed c a a I
to proc~ss
~
tank
+-Fluidiz ing
gas
Scale
+-
--+ Fluidized coal
. to process
FIGURE A5-3l SCHEMATIC ILLUSTRATION OF LOCAL FLUIDIZED
. FEEDING OPERATION (37)
(37) W. R. Huff, J. H. Holden, L. F. Willmott, G. P. Strimbeck,
'''APilot-Scale Fluidized-Coal Feeder Utilizing Zone Fluidi-
zation", U. S. Bureau of Mines, RI 6488, 1964.
H-196
-------
problem is less with the crushed coal which is to be used in the
fluidized bed systems than with the more conventional pulverized
coal, an evaluation of the problem was thought to be in order es-
pecially for the high pressure system.
Discussions were held with personnel at the Bureau of Mines
at Bruceton and Morgantown and at Bituminous Coal Research to get
the benefit of their experience in this area.
The consensus
among these groups was that crushed coal with a low fines content
could be transported with air at atmospheric pressure with no ex-
plosion hazard and that there would probably be no problem at
pressures up to 10 atmospheres.
At substantially higher pres-
sure an inert gas would be required.
The primary consideration in the prevention of explosions
and fires in mixtures of coal and air is the ignition mechanism.
As temperatures approach the autoignition level any coal which
deposits in the transport duct is a potential source of ignition.
The key to preventing fires is the prevention of saltation or
deposition of coal particles in the duct.
The effect of pressure on ignition of coal deposits depends
upon the rate of heating.
In situations with slow heating rates,
the ignition of coal is zero order with respect to the partial
pressure of oxygen.
The rate limiting factor is the thermal
decomposition of the coal surface.
With higher temperatures
and heating rates which result in. thermal cracking and the re-
lease of volatiles, parti~l pressure of oxygen is important.
However, even under these conditions, residence time is the
controlling factor.
If the coal particles are kept in motion
H-197
-------
the deposition of fines is prevented and fires can be avoided even
at elevated pressures. . Therefore, the most important effect ,of
pressure is in the area of two-phase flow.
Deposition can be prevented by the use of high transport
velocities 'and proper design of' bends.
For atmospheric pressures,
velocities of 60 ft/sec are recommended.
Higher velocities should
be used in high pressure systems to provide a margin of ,safety.
The general conditions which lead to fires and explosions
in coal-air mixtures are as follows:
Particle size - <100 mesh
Air temperature ->600°Fto 700°F (500°F is safe)
Concentration of fines - 50 mg/liter of the
particles which are less than 100 mesh
Type of coal - high volatile, e.g., Pittsburgh
seam coal and highly reactive, e.g. lignite,
Pipe diameter - large diameter ducts have a low
quenching effect (stay under 6 inches - the
smaller the better)
Pipe 'temperature - insulated pipe reduces the
heat losses from material deposited in the pipe
and promotes fires.
When deposits of coal 'dust are formed anywhere in the duct,
.
localized ignition occurs if the rate'of heat' generation exceeds
the rate of heat dissipation.
The system design should be made
to promote the dissipation of heat from any deposits which might
occur.
Do not insulate the pipes at p~ints where deposition is
likely to occur.
Private communication with A. A. Orning, Bureau of Mines,
Bruceton, Pennsylvania.
H-198
-------
A5.3.5
Conclusions
rhe problems confronting most solid
pressurizers are (a) power 108s due to venting of pressurizing
air, (b) wear of surfaces in contact with solid, (c) effective
and reliable sealing, (d) capital cost and capacity limitations
of device and (e) pressure limitations.
Practicality and state-
of-the-art development are also pertinent to short term evalua-
tion or immediate applicability of equipment.
Local fluidization
in combination with a simple lock hopper or staged lock hopper
appears to be the only device that is presently marketable which
minimizes all the problems confronting the solid pressurizer in
the pressure range of 10 atm.
It gives the best combination of
pressurizing feeding and distribution characteristics of all
the devices reviewed.
It is on this basis that the Petrocarb
system is recommended for the 10 atm. pressurized fluid bed
operation.
H-199
-------
A5.4
Sorbent Circulation System
A possible method of circulating the sorbent is shown
schematically in Figure A5-32.
This system relies on columns
of sorbent to seal pressure differences and pneumatic trans-
port to move the solids.
A pipe from each of the beds penetrates
the pressure vessel shell and travels downward either vertically
or with a relatively steep slope.
Each pipe has a slide valve
located at a specific point in the line.
Above the valve the
pipe is designed for dense phase flow and the pressure head of
this column of absorbent allows the pressure in the dilute phase
transport line to be greater than the pressure in the beds.
Piping below the slide valves is designed for dilute phase
transport.
The pipes can be combined into a larger pipe if eco-
nomics dictate this.
Below the lowest bed, transport air is
injected into the line, and the sorbent is transported pneumatic-
ally to the sorbent regenerator.
The same principle of a stand-
pipe and air injection system is used to transport sorbent from
the regenerator to the sorbent storage tank.
From this tank
gravity flow regulated by slide valves is used to feed the sorbent
back to the fluidized beds in the steam generator.
This circulation system uses a minimum of mechanical equip-
ment and requires no pressurizing equipment such as lock hoppers.
It does, however, place restrictions on the location of the
sorbent regenerator.
The elevations of the fluidized beds,
sorbent regenerator and sorbent storage tank are determined by
a pressure balance around the loop.
THe height of the dense phase
standpipes must be balanced with the pressure drop and gravity
H-200
-------
suo£....
\j l:>. I. " l ~ --
""-.
,
,
SO~~f.~ 'T
4t.~llZ...l\.\09.
.t
,)
i
Si~~O - i
P \P!.
PI4U#,~T'C.
\~~"~ tott ..
J>... \ It. \NJEqIO"",,
"
I
"
I
i
~....
~ou...~L~T
~i'''''A4~ T~M"-
\
\
\\
Si!...~ M
~E.~1.~A1°R..
I
I
!
\
\.
,
:so~~~\ "
\t-.l'-.~\ ...,"'t1.#'
--~_.
--'-----
~(\'\lM~\\(
~f SOR...~t.~i C\~C.UL~1\O~
s~~,t.t'I\
V~Lvt5
\
.'f
"I".
O,.OE,. NO.
D,.AWN BY:
4 .
jQ... I' ',1
CHECKED BY:
.
Thl, tn..ln, I, the Pro,.rt)' 0' the
FOSTII ,"IILII COI'OI. TIOM
1" IOU1M 0ItAM1 A..MUI
U""'T-. ... J..SIY
ANO ,. L.NT WITHOUT C:ON8tD...ATt- OT"'." THAN TH. .O""OW."'.
A."..""'T THAT IT 8HALL NOT .....-OD\.IC:.O, C:O~I.O, L.NT, 0" 0'8-'
~O..O 0,. Ol".C:TLY 0" INOI".C:TLY "_U..O "0" ANY ~U"~O.. OTH."
THAN THAT "0" W",CH IT I. 8...CI,.ICALLY ,.U"NI-.O. TH. A~PAIilATU.
81040- IN T... O"A..... I. C:OY.III.O .., "AT.NT..
c;. .. CO.. NO. ...8'8
H-201
APP~VED BY:
SCALE:
':: ,. - 0'"
---,-- ......-
0-5 ~-714- 5~
F 'u. AS -"32
-------
potential losses',
This restricts the 'possible equipment locations
and also limits the range of circulation rate that can be achieved.
The high temperature slide valves are used to control the rate of
flow, but the pressure drop across these valves is limited to about
3 psi.
This could restrict the range of flow rates that can be
achieved,
An alternate approach to the system described above would
be a lock hopper system similar to the coal feeding system described
in this report.
This type of a system would allow more flexibility
in the location of the regenerator,
Also the relative pressure
of the steam generator and sorbent regenerator could be varied
considerably,
Westinghouse has included this type of a system in
the overall plant design.
H-202
-------
A5.5
Gas Piping
The layout of the flue gas piping system up to the secondary
cyclone inlet can be seen in Figure A4-5.
The gas pipe connecting
the steam generator and the first cyclone stage is a 74 in. 0.0.
pipe with an inner liner of a 3 in. thickness of hard formed re-
fractory and a 4 in. thickness of insulation.
In order to keep the
cyclones as close to the steam generator as possible, both the cy-
clone pressure vessel and the steam generator are supported at
the same elevation.
This support arrangement allows the use of
a straight gas pipe between the two vessels.
The expansion joint
in this line is only effected by the radial growth of the two
vessels and the thermal expansion of the line itself.
The gas
outlet pipe from the carbon burn-up cell to the first stage
cyclone pressure vessel is the same type of a pipe as the main
gas outlet.
This pipe. however, is 30 in. 0.0.
Two possible designs were considered for the first stage
cyclone pressure vessel and the gas lines from it to the second
stage cyclones.
In one design the first stage cyclone pressure
vessel and the gas lines were lined with a stainless steel shroud.
This type of a gas pipe design can be seen in Figure A5-33.
The
inner shroud is used as a safety precaution to prevent any re-
fractory from breaking off and being carried to the gas turbine.
The other design that was considered uses a hard refractory as
the inner liner instead of stainless steel.
A considerable cost
savings could be realized by using this type of a gas pipe as can
be seen in Tables 6.1 and 6.2. but a further investigation of the
desirability of using this type of pipe is needed.
Besides the eco-
nomic considerations. customer acceptance from a safety point of
H-203
-------
'II
c..o co.. NO. ......
/ \~S\jl ~i :1\4(.
Q..t.Fg,~CiOR.'i'
/
7'.~h
.' ,
,. i
.. - --= .~
I
I
I
I
I
"
\~~c..~
\. T ~ l 2.. M A. '...
JO\t-.4T
\..\Nl~
\-101
?\PI~G
G ~:>
Thll Dr..I"1 II tho Property 0' tho
FOSTIR WHIIllR COR'OR. TIOM
110 1OU1II ...... AftMUI
LIVlll8lTOM. 88'- J.8SIT
AND ,. LaNT WITHOUT CON.IDa..ATION OTH." THAN THa .o....owa..'.
A...aIlMENT THAT IT "ALL NOT .a ..a_ODUCaO, CO~laO, LaNT, 0" 01.
~o.ao O~ OI"aCTL" 0" INOI..aCTL., N_U..O ~O" AN., ~U"~08a OTH."
THAN'THAT ~- _ICH IT I. .~aCI~ICAL~" ~"NI8HaO. TH. A~~A"ATU8
..0- IN THa _AWlN. 18 CO".".O." ~AT_T..
H-204
tX~A~~\ON
O"DEA NO.
D"AWN BY:
CHECKED BY:
A...-oVt:D BY:
SCALE:
0-5'\.11'32
s/lC!,
Jt
.--.L-
= ,. .. 0"
~D 704 . \ Z Z
F\G.AS-~S
-------
view must also be considered.
H-205
-------
A5.6
Second Stage Particulate Remova). '.
For the 300 MW plant each steam generator module requires
a secondary particulate removal system capable of handling 62,400
CFM of flue gas with a temperature of l600°F and a pressure of
145 psia.
The particulate rate is 5,397 lb/hr.
The particulate
removal system selected uses two Aerodyne Development Corporation
high pressure, Model 18,000, Type "S", collectors.
'These separators
were designed for 97% collection efficiency by weight with effectively
all particles larger than 5 microns removed from the stream.
A frac-
tional efficiency curve is shown in Figure A5-34.
The detailed
design of the separator can be seen in Figure A5-35.
The flue gas is cleaned by the centrifical effects of two
rotating ga~ streams.
The motion of the gas streams are shown
pictorially in Figure A5-36.
One gas stream enters at the bottom
of the inner cylinder in an axial direction.
This stream is given
a rotational motion by guide vanes at the bottom of the inner cy-
linder.
The second gas stream enters the iriner cylinder tangen-
tially near the top and spirals downward along the walls of the
cylinder.
There is a baffle plate near the bottom of the inner
cylinder that fills most of the space b~tween the inlet duct
and the cylinder wall.
There is, however, a 1-3/4 in. gap be-
tween the baffle plate and the cylinder wall.
The downward
flow of gas hits the baffle plate and is then reflected upward.
The particles, however, fall through the gap and are collected
in the chamber below.
The separator shown in Figure A5-35 uses dirty flue gas
for both of the gas streams.
Another method of operation would
H-206
-------
,....,
iN!
'-'
>0
t.J
Z
I.::a
1-1
t.J
1-1
fz.<
::r: fz.<
I I.::a
I\) Z
o 0
~ 1-1
Eo<
t.J
I.::a
~
~
o
t.J
100
9
,/'"
8
7
/
I
I
/
5 I
i
I
I
,
4 /
3
2
1
FRACTIONAL EFFICIENCY OF AERODYNE
TYPE "s" COLLECTOR
~._--
,,,/..,,,.
,
~._-----_...--...~~---
2
3
4
5
6
PARTICLE SIZE (MICRONS)
7
8
9
10
FIGURE A5-34
-------
s4"s6.,so...~@ 7so.F.
4-4. ,'/4 91 ~O'-t.S 0" 5~t4. &.C.
"Z' I c.\..\.. ,",
(," ,,,, c:. "-)
4. \:ca,,"'1. } '-'-
~~...'" t.~ = ,
-, \ '/1." ON '--.i
Sf'a..,..1. @ ;
aoo "1>"''''1. i
-1._,
'~';,UlAlI0 to.I_.- ",
'-. ~;;;.
"v
:,%).
"".
. ---'rr-
, I
. I I
0, I
; I
.' , I
~: I
!
! ,.;?\
_.~/
+
+
+
- --- "-.,...-.-. . +
x
~ '." ~/4." I. I).
'1'.011."
I
,.D. l.,..t.L
I"
II'. oz' ~1L5""t.'-1..
I .
AI..l. \"'"T~a..."""'I...$ T"
&t. S~. \~& PL"'"Tf.. .
3/e.. T~~, ,,;,col..ay
I"
. -/" "
~ . J la 1.1). :
I
I
I
44~4.. t.C 1 I () N
---J-
01
..1
.1
I
--t-
i
i
i
i
s !
tni
I
-'I
0'
N;
!
~
i
I
J
!
! 4e.";. 150 \..& @750.
I 4. 4. - 'i'a"f ,",01...f.5
i 0>-\ S"Z Ya" ~.c:.
i
I
I
i
i
I
I
:.,!
.' i
r-:
I(1j
I
I
!
I
I
-
I
i
.1
-!I !
I I
_Ll
J"- .-
~ ;
,,.
"I
\)
i...
4e."~-170U).@ 150.F
- ~ 4.4.. \1&"' ~OL.f..S 0'"
'J"'v~ -=-- ""''''"" 5'Z'Ia".tI.")
,. ~ - ---
r ~ ? -- . ~. ~ ~ ~.~
(/ If' - - ~,,~ I
r ~./ ~ ~ - - "::::::... ~~ ~ .
V /-J ~ ~
fj ~" ~ . ~ "
I; // ~ '\ ,
r II ft ~-=...., ,\ \, \
~.'L -.. \ \ .)(...'-- -- -
I II h I~= '7/--~~ \. ' ,,--,
. /1 1'1/1 ~ /1 , \" .\ u..' '\'
'/ I' I. . \. II ' .
-~. ff (1" \t~----T---:-1- - --ij -- OJ -',:
I" ~ I :- II '/ :: '
\ Illi_~\=..~- ,-~~ // I ~~-
I ~ II \ \' '':::c ::h ~;:(/ 1 't h
t II" ~ " //,,--
~ " . / ~ I.
I ~ II '\ ~" . ~ 1/ I.
~, ~ ~ fI
I ~ \. ~-=.:'"-==-« .'7 A
I II ~. 't I ~J/../
I II ~ ..~... . --.::-:::->' /-
~ ~-~~- ----~
I II ~ '"
I I. Ilo--~--. - ~ .0
I' I
~......_.
~.~~-~.
Pl~N
IH..x,1>If.t.1. Mt.:!>'"
R.L~a..."'t~...II."( "I..I. I!. 0
Il.~$ co.. 1"701\ 011.-
I:.u. WAoI.IC.t.L 22.
oil- t.QIIII.I..
Y4" L-lt04t.L
Sl\-'l.~o T\(Pt.. '04.
:r
- ,
~. ,
"
'5lCT'O~
)(..- X"
.\ X-
.J
--.,
FIG.AS-3'5
o -s~" \\~ l
~t.Nt~~l
"'P\t~
I. Vf.~::'l.l. 1.\1041"40 "" CI.. '.~
,,"Cc:."a.O"'NoCL ...,~'.. w-.w.
ST"'''O..'''''O ~: '0"':1
2.."""""'" \It.!>:!>~1. 'To CL 1"4
A.c:.C"v...tHU4CI 'NIT'" "~""L
COD" ~'-C.T ~ Ol\l.~.
Ct.:>,......., 14-,P:'\-G,50.'
. ~"'-'l.I!!>.'c.
~.'t04~,-v...N"'I.$ T" lit.
Fp~ 1'700. F.
ot.:.,.. "" t.o
4. TI4\S 0f..:'1"'~ '5 ""
"'''OIF'~''''\''"'''' '" 01..51"'''
~ ... D W No ;:> .. A. f. Q.o 0"( '" ..
cl1:a..""''''''''* S~-\e.ooO-41.0.,
;
Af-~O O~ ~E. SEPARATO~
\ ~ P R..l ~ !I U l..l V l5 ~ ll.
fi)
. TIlle -.. Ie .. "-" of ..
FOSTER WHULER CORPORATION
110 SOUTH ORANG. AVE.. LIVINGSTON. H..JI:Rstr
...0 .. LUI'T WI1'MOU1' ~DA'ftOII crn88""'" TN8
8OII.0W8r8 ......arr TMAT " ........ IitOT - ~
"'ODIIC8D.~L88T.- ~..D8CC1L" -
1NDC8t&e"n." -- UMD P08 ~ ~ ~ ftIAII
TMAT POIt WIIICM "' '8 ~y~. ".
.......ATV8 ....... I" ft8 ...... . CO'ID'CD 8Y
PAftJI'78, .
DRAWN 8V:
-'''0'
CHECKED 8V:
._ED ft,
R..D-71 '2-IS'.
. 1'0'" u~"c
-------
.,:" .'
. '
. .. I -.. ' . . ", "/
~~:l... I .~' '=,,:: .
?:". .,," '.' .;'..~ .
\;"; .1;0 I -,H:
'. ,: ' " , . ,'.- , , ,". .
GAS) ---T------+. "".' ':..) :,ic,:
:;"X': .. ... ' .../i:
. '::iJ:t':f;//ig-gy
\ ':,>~:.-: :"jf
INLET (DIRTY
0\
II)
N
~
N
-
II)
..;
.q
..,
!:
z
:)
ca:
CD
\IJ
"ORM 2811.82.C
OPERATION OF AERODYNE PARTICULATE SEPARATOR
This Drawing is the Praperty of the
FOSTER WHEELER CORPORATION
110 SOUTH OIIANGI AVENUE
LIVINGStON, NEW JIISn
AND 18 L.ENT WITHOUT CON.IOIERATION OTHIER THAN THE BORROWER'S
AGREEMENT THAT IT SHAL.L. NOT 81E REPRODUCED, COPIED, L.ENT, OR OIS,
POSIEO OF DIRECTL.Y OR INOIRECTL.Y NOIt USEO FOR ANY PURPO.E OTHIER
THAN THAT FOR WHICH IT 18 SPIEC'..ICAL.L.Y FURNISHED.. THE APPARATUS
8HOWN IN THE DRAWING 18 COVERED 8Y PATENT.,
H-209
,,,,..-- FALLING OUST is DE-
POSITED iN HOPPER
ORDER NO
DRAWN BY:
CHECKED BY:
APPROVED 8Y
SCALE:
, ".0"
FIGURE AS-36
-------
be to use clean gas for the second stream, but using dirty gas for
both streams allows a greater throughput of dirty flue gas.
The
distribution of the flue gas into the two streams is achieved by
the sizing of the inlet orifice for the inner flow stream and
the sizing of the nozzles for the tangential flow stream.
This
system does not allow for adjustments during operation, but the
absence of valves or dampers increases the reliability of the
system.
H-210
-------
APPENDIX I
SORBENT REGENERATION/SULFUR RECOVERY SYSTEMS DESIGN AND COST
ABSTRACT
Flow diagrams, material balances, equipment design, and cost
estimates for the regeneration and sulfur recovery plants are presented.
The regenerator process coupled to the pressurized boiler employs the
two-step conversion of CaS04to CaC03 while producing HZS for sulfur
recovery in a Claus plant. The regenerator process coupled to the
atmospheric boiler employs the one step conversion of CaS04 to CaO while
driving off S02 for subsequent sulfur recovery as sulfur or sulfuric
acid.
I-I
-------
1.
High-Pressure Regenerator: Reduction-
Steam C02 Oxidation Producing H2S
Flow diagram and material balance information for this process
is given in Figure I-I and Table I-I.
Figure 1-2 shows a plant layout for
this regeneration scheme.
This information was presented in Volume II.
Table 1-2 decribes the operation of the dolomite surge tank.
Cost estimates for the reducer vessel, the H2S generator
vessel, the gas producer vessel, and the particulate collector pressure
vessel are based on the preliminary sketches shown in Figures 1-3 to
1-6.
Included in this section is a description of the solids feed
system by Petrocarb; a description of the Claus plant by Ford, Bacon
and Davis; a description of the C02 scrubbing system by Benfield
Corporation; and a cost estimate for process vessels prepared by
Westinghouse Heat Transfer Division.
2.
Atmospheric Pressure Regenerator:
Direct Reduction Producing S02
Flow diagram and material balance information for this pro-
cess are given in Figure 1-7. Figure 1-8 shows a plant layout for this
regeneration scheme.
This information was presented in Volume II.
Wherever possible cost data from the pressurized regenerator
design was scaled to estimate the cost of this process.
Figure 1-9 is
a sketch of the regenerator vessel used to estimate its cost.
Process
vessel costs were scaled from the Westinghouse Heat Transfer Division
estimate for a high-pressure regenerator. These costs are given in
Table 1-3. Sulfuric acid plant cost information from Monsanto and
Parsons is included in this section as is a summary of sulfur recovery
cost information obtained from the Allied reports.
I-3
-------
Boilers
Hold
Vessels
()-.o
.H
I
..,-
S2
S3
D\tlg. 2950A 14
t To Final
I Particulate Removal
~ Turbine
G4 --.r4 Expander
i-- ~Waste
CaS04 Solids
Reduce r
Ve s se I
:
G2
Gas Gl S~eam
V) 0- Produce SI Air
CtJ Coa I
u
- - - GIL - - ~s~ - -1
H2S
Generator GlO
Ve s se I
Spent
Stone
I
~I Compressor
G9 Gg
-- -
C02
Scrubber
Fig. I -1-Pressurized regeneration System-Flow Diagram
I GlO: Tail Gas
to Stack
Sulfur
G7
---
Slip Stream
From Stack
-------
TABLE 1-1
HIGH PRESSURE REGENERATION BALANCE
T P lb mole Mole %
Stream (OF) (psia) 1b/hr hr H2 H20 CO C02 N2 02 H2S
G1 640 150 183,000 6,300 79.1 20.9
G2 640 150 9,000 500 100
G3 1500 135 221,000 8,400 8.0 8.4 16.3 7.4 59.4 0.5
G4 1500 120 182,000 6,800 1.0 19.8 0.3 5.5 73.4
G5 1500 116 182,000 6,800 1.0 19.8 0.3 5.5 73.4
G6 '\,18 182,000 6,800 1.0 19.8 0.3 5.5 73.4
G7 230 135 595,000 20,000 8.6 0.2 16.0 73.4 1.7
H
I G8 220 19.7 266,000 10,000 68.8 30.9 0.2
\on
G9 212 19.0 179,000 6,500 63.7 36.3
GI0 >212 180 179,000 6,500 63.7 36.3
G11 1100 165 117,000 4,900 73.9 16.1 10.0
Sl Amb 135 33,500
(coal)
S2 1500 135 400,000
(spent dolomite)
S3 1100 180 450,000
(regenerated
dolomite)
-------
Regenerated Dolomite
H
I
0'\
Transfer Li ne
from Coal Feed
System
Transfer Line to
H2S Generator
_/ Vessel
Plant
B
B - Boiler Module
H - Holding Vessel
5'11, 10' ht One Boiler
R - Regeneration System Module
Vessels: RV-Reducer
vessel, G-H2S Generator
Vessel, C-Particulate
Collector
GP - Gas Producer
S - Dolomite Surge Vessel
1 0 I '1, 60' h t
Holding
Vessel
for
Boiler
Module
Dwg. 2950A12
To
Recovery
Turbine
To
Claus
Plant
G
11.51'1
541 ht
H
7.51'1
20
Li nes
to
Boi ler
Modules
A Li nes
Shown
On.e
From
Each Holding
Vessel
Fig. 1-2 - Pressurized regenerator System: Plant Layout
701 Transport
Line ( 301
Extends into
H2S Generator)
GP
91'1
501 ht
Coal
Ai r Steam
-------
TABLE 1-2
DOLOMITE SURGE TANK UTILIZATION
Start up
. Surge tank gas turbine assumed operating to supply
transport air.
. Use coal feed system to fill the fluid beds.
- 2nd superheater and reheated beds are filled
to operating depth.
- pre-evaporator and 1st superheater bed are
filled to ~ 4 ft.
. Use coal feed system to fill surge tank with stone
required to fill the partially filled bedst for make-uPt
or for start-up of regeneration vessels. Stone could
be transported to the regenerator vessels directly from
the beds.
. After the partially filled beds are ignitedt stone is
added from the H2S generator vesselt which is supplied
by the surge tank.
Shut down
. The surge tank is designed to receive all of the stone
from two boiler modules (10 beds). This is provided
for maintenance. The stone is removed from each bed
via a pipe through the distribution plate to the surge
tank. The surge tank is below grade to provide gravity
feed of the solids from the beds.
Normal .operation
The surge tank could provide back-up dolomite in case
of problems with the dolomite feed system or poor
performance which could be overcome by using the
surge tank.
I-7
-------
Sol ids Feed
(See Be low)
Temp"" 17000F
Diameter"" 10" Each
Reducing Gas Inlet
Tem p. .... 18000F
Pressure"" 9 atm
Pipe Diameter 36"
Flue Gas
T = 15000F
Pipe Diameter"" 36"
30' Pressure
,.., 9 atm
Solids
Withdrawal
Tern p. ,.., 1500°F
Press. ,.., 9 atm
Pipe Diameter"" 24"
Fig. 1-3 -Reducer Vessel
1-8
Dwg. 2950A20
Cross-Section
Vessel Wall
9' Diameter
Insulation
,
5" Th ick
Active Bed
Diameter"" 7.8'
Castable
Refractory,
2" Th ick
Twall = 25Q-300°F
-------
Solids
T'" 1500°F
Diameter'" 24"
'" n. 5' Vessel Dia
3" Insulation
1. 5" Refractory
'" 7.5' Vessel Dia
3" In sulation
1. 5" Refractory
Refractory Distributor
Plate
In stalled Cost
'" $ 20 , 000
25'
r
4'
20 Pipe s fo r So lid s
Removal Each 6" Diameter
Fig. 1-4 -H2S Generator Vessel
I-9
Dwg. 2950A 19
Gas
T'" nOOoF
P ",.n atm
Diameter'" 27"
54'
Pressure", n atm
Vessel Wall Temp '"
250°F
Gas In let
Tern p '" 600°F
Diameter'" 27"
-------
Vessel Dia.
"" 9'
In sulation 6'1
~efractory 3'1
Coal Feed
"" 11 atm
4" Diameter
Pipe
Refractory Grid
Installed Cost '"
$ 20,000
-_.-
Air i
600°F
Sol ids
Dwg. 295M17
.
Gas
T '" 18000F
Diameter. 36"
Pressu re '" 9 atm
SO' Vessel Wall Temp. '" 2S0oF
---
Steam
'" SOooF
Fig. I -S-Gas Producer
I....IO
-------
Gas
T"" 15000F
Diameter 36"
Gas
T,.., 15000F
Diameter 36"
5'
Diameter
22'
Solids
T ,.., 15000F
Diameter"" 6"
Dwg. 2950A18
Pressure ~ 9 atm
T ,.., 250°F'
wall
Lined with In sulation
Fig.I-6-Pressure vessel for particulate collector
I-II
-------
Coal
Spent Stone
(4 Lines)
Air
Regenerated
Stone (24
Lines)
Steam
Regenerator
Vessel
Dwg. 2950A 15
To Sulfur
Plant
Ash
Waste
Spent Stone: 56.6 tph = 113,000 Ib/hr, 37.8 wt % CaS04' 15000F
Regenerated Stone 43. 5 tph =87,000 Ib/hr, 1. 33wt%CaS04' 2000°F
Waste Stone: ~ 9000 Ib/hr
Ai r: 2800 Ib mole/hr
Coal: 5. 6 tph
Ash: O. 48 tps
Sulfur Gas: 3500 Ib mole/hr
S02: 6.3% (mole %)
H20: 13.3%
C02: 18.9%
Adiabatic Heat: -9 MMBTU/hr
Distributor
Vessel
20000F
N2: 61.1%
CO: O. 3%
H2: 0.1%
Fig. 1-7 -Atmospheric pressure regeneration flow diagram
I-12
-------
Atmospheric-Pressure 300 MW Boiler System
Dwg. 2950A 13
1.
2.
3.
4.
5.
6.
7.
Boiler Module..........161 x 161 ea
Regenerator Vessel.....See Sketch
Distributor Vesse1.....121 a x 121 ht.
Hold Drums.............51 a x 51 ht.
Cyc lone. . . . . . . . . . . . . . .
Waste Stone Hopper.....81 a x 121 ht.
Air Blower.............
CD--
H
I
f-'
W
-------
Bottom: 9' L. d.
Top: 12' L. d.
26' r
15'
6" Refractory;
6" Refractory;
60" o. d.
14'
Dwg. 2950A16
6" In sulation
6" In sulation
Stone (4 Lines)
II'
Coal
Fig. I -9 -Regenerator Vessel
48" o. d.
i Air
I-14
-------
TABLE 1-3
PROCESS VESSEL COSTS - S02 RECOVERY PROCESS (200 MW)
F.O.B. Erected
Regenerator vessel $115,000 $485,000
Distributor vessel 68,000 290,000
Hold drums (4) 41,000 175,000
Waste ,stone hopper 21,000 89,000
Cyclone
Air b lowe r
I-15
-------
PETROCARB. INC. 250
BROADWAY, NEW YORK, N. Y. 10007
t AtJL' AOII'H.'19 CAOOCARU NlW YORK
Tll.fPMON!. 1212 267- e~10
April 30, 1971
Westinghouse Electric Corporation
Research and Development Center
Beulah Road
Pittsburgh, Pennsylvania 15235
Attention:
Dr. D. L. Keairns, Senior Engineer
Chemical Engineering Research
Gentlcmen:
We are pleased to supply "order of magnitude" cost estimates for two
additional solids feeding systems required for the 600 M.W. pressurized
fluid bed boiler system. These are referred to as A (Solids handling
for the dolomite regeneration system) and B (Coal feed to the gas producer).
Our concept for System A has been described to you verbally but will be
summarized briefly herein. We propose that solids will be removed from
each of the fluid beds in the boiler through down-regs that are kept full.
of solids. A level control impulse from each bed will initiate a regulated
flow of solids from the down-legs by means of a fluidizing jet of air.
Solids will thus flow into a Petrocarb High Temperature Injector from each
group of four fluid beds in a boiler module. There will thus be four Petrocarb
High Temperature Injectors - one associated with each of the four boiler
modules. The Injector will continuously feed solids to the upper regeneration
vessel. The rate of solids flow will be controlled by two rate control
functions, a) the pressure in the regenerator - which will vary as directed
by a gamma ray level control signal indicating the level in the Injector- and
b) the volume of transport air. You are to provide means for varying the
pressure in the regenerator to follow a 1inQar signal from our Injector.
The pressure should be capable of being varied from approximately 8 to 10
atmospheres based on 10 atmospheres in the boiler. We will provide necessary
transport air controls.
The Petrocarb High Temperature Injector will be a refractory lined pressure
vessel approximately six feet outside diameter and approximately ten feet
overall height. Approximately three foot clearance should be provided below
the vessel for additional fittings.
1-17
-------
ET No.2
FROM
PETROCAAB, INC.
To
Westinghouse Electric Corporation
Pittsburgh, Pennsylvania l52~5
April 30, 1971
The second phase of the System is based on our concept that you will provide
an outlet pipe with flange under the lower regenerator vessel for each of the
sixteen streams of regenerated dolomite. To these outlet flanges - tentatively
six inch pipe size - will be attached Petrocarb Feeder Assemblies which will
include a shut-off valve capable of handling 1l00°F solids. The equipment will
be alloy steel applicable for the service. It will be necessary for the
r~gencrator to modulate in pressure between the range of approximately 10 to 12
atmospheres to control the level of solids in the fluid bed and thus control
the rale q[ solids discharged. Secondary air controls will be provided by
PC'trocarb to further adjust the flow of solids to the fluid beds in the boiler.
Transport piping is included in the estimated costs on the assumption that there
will be 2500 linear feet of piping between the regenerator vessel and the fluid
beds in the boilers.
The lump sum estimated price for the dolomite recirculation system is
Five Hundred Thousand Dollars. ($500,000.00), exclusive of erection costs.
The air required to serve the dolomite handling system would be approximately
50,000 SCFM at 175 psig.
System B (Coal feed to the gas producer) will be capable of feeding prepared
coal at a controlled rate of 11 TPH to a single point in the gas producer.
The arrangement will encompass a typical Petrocarb system including a Surge
Bin, Storage Injector and Primary Injector generally as covered in our 1ette~.
of February 18, 1971 to Foster Wheeler. The cost of this system would be '
approximately One Hundred Twenty Five Thousand Dollars ($125,000.00) assuming
that it would be procured as part of the package of coal feeding systems
supplying the boilers.
This coal feeding system would require approximately 2,000 SCFM.of air compressed
to 175 lbs/in2. Incidentally I wish to call your attention-ro the fact that
the overall air requirements required for feeding coal to the boilers may be
reduced by about 25% in the final analysis if the instantaneous demands are
scheduled by a logic system to avoid pyramiding of peak loads. Some adjustment
of cycle time and equipment sizing might be affected, but this should not
influence equipment costs at this time.
,
Enclosed is a copy of a letter to Foster Wheeler which confirms the costs for
changes in the coal feeding system and the cost of a solids feed system to
the carbon burn-up cell
We are looking forward to working with you on further phases of the project.
Very truly yours,
PETROCARB, INC. ,
.-..~.--
.~--
--.
t ..- -.
., Ha~-old 1~ei~~.:;7'~
President"
I, .......~.
HR:jml
enc1s. (1)
-Letter dtd. 4/30/71 to Foster Wheeler
'-.. -..
I-18
-------
~._,.. .
PETROCARB. INC.
250 BROAOWAY, NEW YORK, N, y, 10007
,...... ,c,- --
CABL~ "DDR~5S "CABOCARB' NEW YORK
TELEP"DNE (212) 267-6510
April 30, 1971
Foster Wheeler CorporattoD
John Blizord Research Center
12 Peach Tree Hill Road
Liv1Jlgston, New Jer..y 07039
AttentiOD: Mr. Richard W. Bryers, Research Associete
Subject: eoal Injection Systems for Pre88ur1~ed.F1uidized Boilers
Petrocarb Project £-430
Gentlemen:'
"
,.
\
At the request of Dr. Dale L. Kaairne of Westtnghouse va are p1..984 to
supply th8 foll~1ns additional information on the .pprox~t. COSC' ot
coal feeding 8y8t8ll18 for the pra.surbed fluid b.d b011er.:
Four Outlet Coal Feeders
Eight Outlet Coal Feader.
300 M.W. System
$1,800,000.00
$2,000,000.00
600 M.W. System
$2,800,000.00
$3,000,000.00
Aleo Dr. K.ea1rus requastec1 that v. supply SOlll8 Informatiou 011 d .,atem to
feed 850. 801ids to .ixteen carbon burn-up cells al.oct.at.ct with the boU.r
modules. The 80U.dl vere stated a. b81q approxiMt.l, 100 1ba/cu ft. IN1k
density aDd that the max1mum rat. waa 10 tas/hr. Obv1ou81y tb18 uatt ...t
be deaigned for the abnormall, h1ah temperatura of 850°F but thi. caa be
accommodated. 'Other ~ thi., the .y.t..vould" 4U1t. 8~1.r to the otber
systems de.cr1b8d ta .arl18r corra.poadeDPI.
,
A cost of approstut.ly $250,000.00 ba. b.. alt_t.d for thl. .yiteU1 OD ,he
88me b.si. .. previously ~t.d. \ ,
th. peak load .11' clem8ad would .. approx18at.ly 2,000 SCFM compr..'" to 200 p'!a.
Pl.a.. l.t u. Ia::Dc8 11 you have .y qu88C1oa. COIaCftD.f.ug this ..tte~.
Vel'J truly Y01lr8,
IITROCAU, DIC.
HRljaal
cc: Dr. D. L. lCea1ms, Senior EngiD881'
W.8t1qbOUI. Electric Corporati88
b...rcb u.d Development C8Ittar
B8ulab 1Nd, Pittsburgh, Pa.
Harold Bailatj..
~e.id..t
I-19
-------
~.."OLD I. WARNICK
Vice P,esident
jfott. J~lIcon ~ 'VlWi0 leXa0
..:mCOrpor4t~O
ENGINEERS - CONSTRUCTORS
fl. O. 101 38209 . D"lIel, T el"l 75238
2908 Netionol Drive
Gerlend. Texes
214/278.8 I 2 I
April 30, 1971
Westinghouse
Research and
Beulah Road
Pittsburgh,
Electric Cdrporation
Development Center
I
Pennsylvania 15235
Attention:
Mr. L. M. Handman
Chemical Engineering Research
Gentlemen:
In accordance with your letter of 12 Pebruary 1971, we
have estimated the cost of a Claus type sulfur recovery unit.
This unit will feed about 2000 moles/hr of acid gas having about
14% H28 and 43% CO. The cost estimate for this plant has been
previously reporte~ to. you via telephone by our Chief Process
Engineer, Mr. David Parnell, and this letter serves to confirm
these numbers.
//' I
The feed gas as reported in yo~r letter has as much as 43%
water and is available at 10000P and 130 psig. The presence of
this,much water is detrimental to the Claus reaction, thus we
would recommend that the acid gas be cooled to about l200p prior
to feeding the Claus sulfur plant. The estimated installed cost
for the sulfur unit including the suggested feed gas cooler is
$1,360,000. This includes a two catalytic reactor Claus plant
with a tail gas incinerator-stack combination for oxidizing all
the sulfur bearing compounds to 802 before atmospheric discharge
via the stack.
If the feed gas cooler is not installed, the added water
. processed by the sulfur plant increases the equipment size.
It is estimated the plant would cost $1,410,000 installed without
the feed gas cooler. An additional disadvantage of this unit
would be the reduction in overall sulfur recovery caused by the
excess water present in the system. Installation of the plant
without the feed gas cooler is not recommended.
Por either of the above plants, a plot area of at least
4000 sq. ft. would be required. There are essentially no tall
vessels in the sulfur unit except the incinerator-stack. . A
summary.of the estimated utilities is shown on the attached
table.
1-20
-------
Westinghouse Electric Corporation
Attention: Mr. L. M. Handman
April 30, 1971
M. ~4Con & 'i'lIVi& texlle
300
-------
Westinghouse Electric Corporation
Attention: Mr. L. M. Handman
April 30, 1971
.fo~. :~4Con & ~11Vi0 lCZX40
--, Ofpo.Or.O
DALLA8. TF.)(A~
Page 3
size of the sulfur plant, the ratio of the sulfur capacity
raised to the 0.6 power can be used to arrive at an approximate
estimate for the installed cost of the revised plant.
All of our sulfur recovery plants have been designed under
license from Pan American Petroleum Corporation. Presently, we
have designed more sulfur recovery units than any other Pan
American licensee. Our\experience provides extensive know-how
for design and operation of sulfur recovery units. This
particular process was developed in 1956 and is a modern day
improvement to the classic Claus process. It involves patented
equipment and design features combining process functions into
one or two pieces of equipment such as oxidizing H2S, cooling
the gases, condensing sulfur and separating the liquid sulfur
from non-condensed gases. These design concepts have provided
a better operating plant, installed and maintained at lower
cost than was possible with the older style Claus units. The.
attached article reprint describing various sulfur plant design
concepts provides additional information on this process.
Ford, Bacon & Davis Texas has consistently made efforts to
improve our design by obtaining actual operating data from on-
stream units. This has resulted in a continued optimization and
improvement in the type plant we design and build. Attached is
a current list of sulfur plants we have designed and/or
constructed. /
'\
- We hope this information will be helpful to you. We
appreciate your continued interest in our services and if we
can be of further assistance, please contact us.
Very truly yours,
FO~D, BACON & DAVIS TEXAS
j~~~'1 fJf{~~w~~rf.
1'£;Old B. Warnick
DCP: jr
Attachments
1-22
-------
Power
TABLE I
UTILITY SUMr-1ARY
Air Blower
Sulfur Pump (1)
Boiler Feed Water Pump
Lighting and Controls
Total
Fuel Gas, SCFM
Acid Gas Burner (2)
Incinerator
Instrument Air, SCFM
Boiler Feed Water, GPM (3)
-..
Stearn, Ibs/hr
Production
Consumption
Cooling Water, GPM
(l)
(2)
(3 )
(4 )
Ibri). :eaco1l &. ~ '(eX40
. ~.
DALLA.. TEXA8
April 30, 1971
KW
250
20
15
15
300
300
200
8
50
24,000
1,200
3,200(4)
Not for Continuous Operation
For Startup Only.
Based on 5% b1owdown, rate measured @ 600F
Based on 200F rise
I-23
-------
Dl'enfiel~8
file 0 R P 0 RAT ION
.666 WASHINGTON RD., PITTSBURGH, PA. 15228
February 23, 1971
Westinghouse Electric Corporation
Research and Development Center
Beulah Road
Pittsburgh, Pa. 15235
Attention:
Subject:
Reference:
Gentlemen:
Mr. L. M. Handman
Benfield design for flue gas scrubbing
Your letter of February 9, 1971
We have studied the process conditions outlined in your
referenced letter and offer the following information on a Benfield
unit to satisfy those conditions:
RDK: em
1.
Feed gas (flue gas) flow rate to the absorber w0uld be
3,480,OJO ncfh or 9,694 lb. mols/hr and this would be at
approximately 135 psia and 1100 C.
2.
CO2 produced would be 1500+ lb. mo1s/hr at 19.7 psia and
o '
approximately 105 C. The CO2..out of regenerator would
be mixed with about 60,000 1bs/hr of water vapor and there
would be approximately 15 lb. mo1s of other gases - mostly
nitrogen. .
3.
A ~ 15% estimate of the total investment cost of the
Benfield plant would be $1,300,000.
4.
Approximately 535 hp would be required for solution
circulation.
5.
Regeneration energy requirement would be approximately
80.2 MM BTU/hr.
6.
Solution cooler duty would be approximately 53 MM BTU/hr.
Very tru~y yours,
THE BENFIELD CORPORATION
(~~-;L D0~
Robert D. Karns
Engineering Sales Manager
CABLE ADD~r:SS' F:[NFiflD PITTSBURGH. PHONE: .112-?.;1-.1rsr, TE!.F.k C8f:-732
I-24
-------
.
flfl'll
HEAT TRANSFER DIVJSTf
\WI
Westinghouse R&D Center, Pittsburgh
Energy Systems Research Bldg. 501
Dilln : May 5, 1 9 71
SlIlljr.r.t F. B . C . 0 . M. Pro j e c t
Regenerator Vessels
Study
r.1r. D. Keairns
ct:
r~essrs. S. Lemezis
R. Giardina
This is to confirm the prices given to you by phone on May 3,
1971 .
Based on the preliminary information given to R. Giardina, our
estimates of the 1971 price for the pressure vessels are as
follows:
One (1) Cyclone Pressure Vessel
One (1) Red u c er V e sse 1
One (1) Gas Producer Vessel
One (1) H2S Generator Vessel
$52,500
$110,000
$147,500
$210,000
These estimates include only the shells and insulation. Internal
structures, vessel supports, support skirts, and accessories are
not included.
No attempt has been made to ascertain a realistic shipping date.
If an indication is desired, please contact me.
The prices given above are for reference and study purposes only
and are not to be considered as an offer sell at these levels.
,'1
V~ :.
" ~ \1: /U:-y:z.c.
G. F. P. erson
\
GFP/nmm
I-25
-------
Monsanto t, .10 SOUTH RIVERSIDE PLAZA / CHICAGO. ILLINOIS 60606 / (312) 782-5041
Env~o.f';~
~
II C em
II Systems Inc.
June 24, 1971
Westinghouse Electric. Corporation
Research and Development Center
Beulah Road
Pittsburgh, Pennsylvania 1~235
I
Attention:
Mr. L. M. Handman
Chemical Engineering Research
Subject:
250 T/D Sulfuric Acid Plant
Gentlemen:
In answer to your letter of May 7, your study of a limestone-
base sulfur dioxide recovery process, we are submitting the
followi~g information. .
AS'you requested, we have included order of magnitude pricing
and operating data on an interpass absorption sulfuric acid
plant based on the information as.follows:
/
Flow Rate
Pressure
Temperature
Dust Loading
3500 pound moles per
Atmospheric
400 - 500op..
0.5 grlscf (maximum)
hour
Composition
Mole %
S02
H20
C02
N2
CO
H2
6.3%
13.3%
18.9%
61.1%
0.3%
0.1%
Continued. . .
I-26
-------
Westinghouse Electric Corporation
Pittsburgh, Pennsylvania 15235
Mr. L. M. Handman
June 24, 1971
Page Two
Our order of magnitude cost for an interpass absorption sulfuric
acid plant with a rated capacity of 250 tons per day (100% H2S04
basis) on a turnkey basis is estimated to be $3,100,000.
The above price does n~t include:
Product acid storage
Water cooling tower
Paving
Piling
Sales or use tax
The plot required would be approximately 125' by 200'.
Operating utilities are as follows:
Power 1100 HP
Other electrical 70 KVA
Natural Gas 0 - 500 scfm
~nstrument air - 30-40 scfm
Process water - 20 GPM
85°p. Cooling water - 3000 GPM
,..- \
/
The estimated yearly downtime is 15" days per year. Estimate
annual maintenance cost will average 4-1/2% of installed cost.
--.
The plant will handle a turndown of 50% of the feed gas rate
keeping the mole % constant.
. .
The process is relatively insensitive to fluctuations of SO
concentrations of plus or minus 1%. The conversion efficieficy
usually increases as S02 concentration decreases, assuming 02:S02
ratio ;increases.
Monsanto Enviro-Chem will guarantee 99.5% conversion of S02
at the converter to S03. The stack gas will contain 500 ppm
or less S02.
Feed gas characteristics shown above:
Temperature
Pressure
Dust Loading
400-5000P.
Atmospheric
0.5 grlscf maximum.
Continued. . .
I-27
-------
Westinghouse Electric Corporation
Pittsburgh, Pennsylvania 15235
Mr. L. M. Handman
June 24, 1971
Page Three
We have included a typi.ca1 "Description of Process" for an
interpass absorption sulfuric acid plant.
-. ---
If we can be of further assis~ance, do not hesitate to contact
us.
Ver~ truly yours,
MONSANTO ENVIRO-CHEM SYSTEMS, INC.
--:;/ CJ~
.-
H. C. Heinemann, Sales Director
Chemical Process Division
HCH:s1c
Attachment
.,,/ \
'\
1-28
-------
(./1-~~/ 71
..;
SECTION V
DESCRIPTION OF PLANT
E-2519
5-25-71
B.
DESCRIPTION OF PROCESS
A general description, of the process and plant is
as follows: \ '
. - --
The p!'ocess consists qf three (3) principal steps :',
1.
Purification, cooling and drying of the sulfur
dioxide gas from the copper converters.
2.
Conversion of sulfur dioxide gas to sulfur
trioxide gas.
3.
Absorption of the sulf~~ t~:oxide gas in.
sulf'uric acid.
The copper converter' ga,s C':::.t 3.in:3 dust, metallic
fume, acid mist, water vap~r, and other impurities
varying with the composi tlan of' ore, converter,
operation, gas coolirtg in ~he converter gas handling
and cleaning system, ,and '::!'f.lf:lency of dust removal.
/ -
The gas purification ste:3 ~o~sist of gas scrubbing,
gas cooling and acid mis ',;. !"~:lloval. The gas scrubbir,~
and gas cooling are acco~~lished in a combinat~nn
urli t .
'..
Host of the dust, metalli8:'ur.:e and sonie acid mist,
are removed from the g~3 ~~ scrubbin~ ~ith acidic
liquor ~.:1 the IOi'lel'" Op,::,'i-~-,:-p~ hUi1:idifying 5~C,;",')n.
The gas flows upward thr:'.;h a spray of weak :.~!j.
The gas is cooled by eva~oration of water frG~ t~e
weak acid. The weak a~id ~s recirculated withcu~
cooling.
The gas t:l(.;;;: ~;::,::":" : .:.:.':'US~ the gas cooling section,
which is locat::~::'::-.:? ')f tte humidifying sectlcl:.
Cooling is ac':::.,' "':::'.~ .:: ';l.:'c:.:.lating cooled weah: (:.(.~id
over the packec:. sec~lc:. fJ.'l:e 1,veal<: acid is cool.::': by
cooling t;)wer T."'~ter if! ~:-l':?ll a:'ld tube heat excha.:1gers.
A purge s:ream of weak acid is delivered to battery
limits.
I-29
-------
" ..
~..-
"
SECTION V
DESCRIPTION OF PLANT
E-2519
5-25-71
B.
DESCRIPTION OF PROCESS (Cont'd)
The.process gas then flows through an electrostatic
precipitator. ~n the precipitator, the acid mist
and those solids not previously .removed.in the
hum1di~ying and gas cqo1ing tower are removed.
; .
-
'.
The renova1 of the acid mist and solids is accomplished
by passing the process gas between pairs of electrodes.
An electrical charge-is imparted on the particle of
acid m~st or solid and the particle is deposited on
the electrically grounded collecting tube. The acid
mist serves to wash the solids collected to the bottom
chamber of the precipitator. .Liquid effluent from
the mist precipitator flows to the humidifying and
gas cooling system.
-
The process gas and dilution air then pass through
the packed drying tower countercurrent to a flow of
93% H2S04 to remove water vapor contained in the gas.
Sufficient acid 13 circulat~d\over the tower so that
the wate~ vapor r~~o7~d doe~ not significantly r~duce
the streng~h c~ :~e acid in a :ingle pass over the
tower. Entrai~ej ~cij 5~ :~2 ~~5 i5 removed by a
~ist eli~i~a~c~ ~.~~ :~~~:~:~d in the top section of
this. tower.
Gas from the d~j~ng t8~~~ i3 com~ressed in the main
cornpressors and £'O!>~,:;-:~ t::rough the remainder of the
plant.
The clean dry gas now passEs through the shell sides
of two cold heat exc~~nge~s arrang~d in series, 2nd
the hot heat exc~~r.;2~ where it is heated.
From the hot heat exchanger, the gas flows to ~he
first converter pass where the sulfur dioxide is
partially converted :0 sulfur trioxide in the presence
of Monsanto Enviro-Chem's vanadium pentoxide catalyst.
The conversion reaction consumes oxygen and produces
heat.
I-3D
-------
, ,
SE :;'TION V
DESCRIPTION OF PLANT
E..,.25 19
5-25-71
B.
DESCRIPTION OF PROCESS (Cont'd)
Gas leaving the first converter pass flows in parallel
to the tube sides of the hot heat exchanger and the hot
interpass heat exchang~r~ where it is cooled by the S02
gas passing through the shell sides, and then flows"to
the second converter p,ass.
In the second converter pass, additional conversion of
sulfur dioxide to sulfur trioxide takes' place accompanied
by the generation of" additional heat.
Hot gas leaving the second converter pass is then cooled
by passing through the cold interpass heat exchangers
arranged in series. The gas then goes to the interpass
absorption tower where the SO 'is absorbed. After the'
absorption has been comPleted~ the precess gas and acid
m~st pass through a high efficiency Brink Mist Eliminator.
The gas then passes back through the cold interpass heat
exchangers and'the hot interpass heat exchanger before
entering the third converter pass. On leaving the third
converter pass, the gas flo~s throug~ the tube side of
the cold heat exchangers wh~re it is cooled.
-"
The converter preheater is used to bring the cataljst
in t:-:e converter ::;~-:',>:::1 up to the t:::~~::;:;:':it...,r~ requi.>::d
for t~e catalytic c0~version of S02 to 503 if the' ,
conver:er temperat~::."~s have d':.'creased du::: to a pro~~r.ced
shutdo\'m. The preheater will also be t'.'sed to heat
part IJ f the lncomin~ S02 gas stream as the gas st :'s~; 7:(:
drops below 5.3% S02 or the gas volume ex~eeds 11'i,106
SCFM (dry basis).
After leaving the tube s ide of the colJ ::8:J.t exchai.gers,
the 303 gas passes to the final absorbinE tower. The
gas passes through the packed absorbing tower counter
current to a flow of 98-99% H2S04 which absorb~ that
S03 contained in the process gas. Sufficient ~cid is
circulated over the tower so that the S03 absorbed does
not significantly increase the strength of the acid in
a single pass over the tower.
I-31
, '
-------
..
SECTIQN V
DESCRIPTION OF PLANT
E-2519
5-25 -71
B.
DESCRIPTION OF PROCESS (Cont'd)
After the absorption has been completed, the
gas passes through a Brink Mist Eliminator.
mist Qarticles present in the gas are almost
pletel] removed by the,mist eliminator.
I
process
The acid
com- . '--~
The gas now passes to the atmosphere through the
exit stack.
The strong acid circulating systems used to dry the
S02 gas from the purification system and to absorb
the S03 gas from the converter system are separate
sys tem~, each with a pump tank, circulating pump, .
coolers and piping system. They are interconnected
to permit control of drying and absorbing acid con-
ce~tration'3.
The acid circulated over the drying tower is weakened
by the water vapor remo7ed from the 502 gas, while
the acid circulated over the/absorbing tower is
strengtheDed by :~:',"'; 0..b30rpt:Lrr: of the SO gas. To
cou,...ter""'~ '-hc.-, ."-...,-,..,~;..h ""'-:.".-'.'s absor~er aCl"d is
!& c,,-,L........ -;.::,.': .::...... :::..:.~~....... .......L~.....:.-.G , u. .
pumped to t~.2 Jry::~~; 3.~:,::~. ~j"J.r.:;; ~ank ::nQ. dr:iing acid
is allO'.>J'ed to L':; .1::::-:', :>: ".:, t':.e ~')sorbing :lcid pUr.1~
t.::' is added direc'cly to ti:e
absorbing 3.c1:1 pc-;,r:p tanks"
The dilution of the dry in,; o.c:id by the ",;e..ter 'Jape::'
from the proces~ S~3 cJ.nd the add~~ion of 98-99~
acid to the dryin~ 2cid pump tan~ raises the te~-
perature of the acid. To reduce the temperature,
the drying acid is passed through coolers where cooling
tower water removes the heat. A side stre~u of 93%
I-32
-------
4
, ""
SECTION 'V
DESCRIPTION OF PLANT
E':'2519
5-25-71
B.
DESCRIPTION OF PROCESS (Cont'd)
acid is taken from the drying tower pump tank,
equivalent to the quantity of acid produced and flo\>ls
through the 93% product cQoler' to storage. -
,',
;
In th~ interpass abso~bing tQ~er, the S03 does not
combine directly with water, but must be combined
indirectly by absorbing it in sulfuric acid where
the 501 reacts with water in the acid. The tem-
peratuf\e of the 98-99% H2S04 circulated over the
interpass absorbing tower incre~ses due to the heat
of formation and the sensible heat of the gas stream
entering the tower. Acid from t~e bottom of the
interpass absorbing tower is ~assed through coolers
and returned to the tOD of the tower. A side stream
of. 93-99% acid is taken froTl ,:he interpass absorbing
tower pump tank and flows ~o the drying tower pump -
tank. ' '
Sufficient water and 93% dr¥~Mg tower acid are
admitted to the interpass 2~sGrptic;. tower system
to make up for quantity ::~. ~~ ,:' ,'~ acid ;',1 thdrawn
from the system, and to (;;.:;;;,;.;:,..,l trle :;trength of
Cici~~ circulated over t~:..; ~,.',:::':':';):':'::.:, '~::;:ler bet...:c:::.
98-99%. '
-..
In the final absorbing tC'.;2r', SO~ in the gas strea..-n
reacts i'i.:!.th water in the )'-99% dirculating ::..;~j,.:i.
The temperature of the s:;o;.g;acid circulated (. .,r,?>:"
the final absorbing to:oJ2::' :.:1creases due to ~;'.( '1 ~at
of fort:1ation and the sens .:.':: le heat of the gas s ~ ream
entering the towe~. Acid :rom the bottom of t~e
final aos:J:-bi:1:': \>~;..'(::, i:::, -:::<'::Jsed through coolerE.'l:'ld
returned ;:0 L:-, 1:,,~,: [,';:e tower. A side stream ()f
98-99% acid 15 ~~,~ .rem the final absorbing ~o~er
pump ta:--,;:, eq\.::,'."::,>,:, :.':: :')ie quantity of acid prC,(,'.'.lced
and flo\>,::: thr:.:_:,;n -';~le >"~,: ;:L'cduct cooler to sto::'::.ge.
Sufficie~t 93% acid frc~ product 'stripper is"ad~itted
to the final absorbing to~er system to control the
strength of acid circulated over the tower betwee~
S~-9?~f .
1-33
-------
. ..
SE"::TION v
DESCRIPTION OF PLANT
E":'2519
5-25-71
B.
DESCRIPTION OF PROCESS (Cont'd)
The plant water balance is based on an incoming gas
strength of 5.3' S02entering the drying tower.
When .the incoming gas ;strength drops below 5.3%
S02 for an extended p~riod of time, it will be.- ".-
necessary to bring 98% acid back from storage to "
hold drying acid strength at 93%. When the in-
coming gas strength rises above 5.3% S02' surplus
98% acid will be re~urned to storage. .
""
/ \
/
"\
----..
I-34
-------
The Ralph M. Parsons Company
E1Jgi1J~"s. Constructors
617 WEST SEVENTH STREET, LOS ANGELES, CALIFORNIA
90017
July 20, 1971
Mr. L. M. Handman
Westinghouse Electric Corpcration'
Research & Development Centeri
Beulah Road .
Pittsburgh, Pennsylvania 15235
"
SUBJECT
Your Letters of June 4 and June 7, 1971
Concerning Conversion of S02 or H2S to
Sulfuric Acid or Elemental Sulfur'
Dear Mr. Handman:
.'
On June 28, 1970 we sent you a letter stating that a plant for the
manufacture of sulfuric acid being fed with Stream I of your letter
of June 4, 1971 would cost $5.5 to $6 million installed. Approximately
.."l1al.f of this capital cost is required in the gas cleaning section of
the plant. " '
"
The operating cost of such a plant for utilities and operating personnel
would be approximately $4.00 per ton of acid produced. '
/
"
With respect to the manufacture of elemental sulfur from stack gases,
I am enclosing a copy of a memo from our Mr. D. K. Beavon, Director
of Proc~ss Operations. His memo discusses in some detail possible
process configurations that might be used to supplement your process
schemes. The fifth paragraph of his memo may be of special interest
to xou.
It is not possible for us to give you a capital cost estimate or an
operating cost estimate without doing considerable process design work.
Further, before proceeding with process design and estimating, we should'
have agreement from you that our process scheme is compatible. Since
the development of such a process scheme involves a considerable number
of manhours, we feel we should be paid for this work. We estimate such
an effort would cost approximately $8,000.00 plus whatever travel ex~enses
mig~t be involved. We believe that such an effort might be of considerable
value to your project.
We will be pleased to discuss such an undertaking with you in more detail.
I am enclosing our latest brochures dealing with Sulfuric Acid, and Gas
Processing Plants and Sulfur Recovery Unhs. As you will see by the
I-35
J~\
-------
THE RALPH M. PARSONS COMPANY
Mr. L. M. Handman
-2-
July 20, 1971
enclosed brochures we have had substantial experience in the field of gas
treating and sulfur recovery.
Very truJy yours,
THE RALPH M. PARSONS COMPANY
\
--~~~.~
DF :jp .
Enclosures
As above
...
.'
"
//
'.
. -
I-36
. .-. ....-" .
-----
-------
THE RALPH M. PARSONS COMPANY
INTEROFPICE CORRESPONDENCE
Date July 2, 1971
To
Dudley Field (2)
From
D. K. Beavon
SUBJECf
Westinghouse Electric Corporation .
S02 Abatement Process for Boiler Plants
. I have reviewed the information sent you by Mr. Handman of Westinghouse R&D
and offer.the following comments.
, .. . \ .. . .. .
Wh,en thesulfJjr.:is produced in th!e form of S02'. there is another optian
available beside making sulfuric jacid, which 1S the Bureau of Hines'. sodium
Citrate Absorption process. We. have. followed the development of this
process with keen interest and it. appears to me that it is the best one
under development for scrubbing out S02 and producing elemental sulfur.
The gas would need to be pretreated by cooling and washing to remove solids
as. it would be ahead of a sulfuric acid plant. The SO" is then washed
out in a countercurrent tower using sodium citrate solGtion;the rinse
solution is reacted withHzS to form elemental sulfur, which is centri-
fuged, washed and melted. .
.-_. ,The H;S needed in the process is produced by hydrogenating part of the
sulfur product (we have worked out a good design for the HZS producti~n
plant in'connection with an inquiry by Sherritt Gordon).
.'
I am inclined to favor the alternate procedure of producing an HZS-rich
gas, with eventual conversion of HZS to sulfur by the Claus process. I
recognize that it costs more to produce::the HZS-rich gas and a complete
economic study might change my initial feeling that this is the way to go.
ff-the H2S -rich gas is produced, I would recommend a flow scheme different
than that described, which produces C02 for the H2S generator by treating
a flue gas with MEA or hot carbonate. I think it would be preferable to
~treat the gas from the H S generator at 10 atmospheres pressure with
Purisol to extract both ~2S and C02 together, then regenerate the Purisol
in two stages; the first stage would produce H?S-rich feed gas for the.
Claus unit, and the second stage would produce-CO" for recycling to the
HZS generator. This scheme would ,be more economical, I think, than the
one Westinghouse proposes and I believe that it has a very substantial
operating advantage in making the HZS concentration in the Claus feed
controllable at a level which would assure good operation of the Claus
unit, regardless of variations in the sulfur content of the fuel.
'-...
I note that the written description states that the HZS concentration of
the Claus feed gas is 23% (dry basis) while Table I Stream Gll seems to
indicate about 38% on a dry basis. We have found the Claus unit operation
begins to be tricky at a concentration around 30% and it would be very
desirable to have a flow scheme which can reliablY produce the H2S in a
a controlled concentration preferably substantially higher than 30%.
I suggest that ~~. Handman investigate rather carefully the formation of
. sulfur compounds not listed in his tabulations which are almost surely
present in substantial concentrations. In the production of the SOZ-rich
I-37
-------
THE itALPH M. PARSONS COMPANY -,
Dudley Field (2)-
-2-
July 2, 1971
gas, it. would appear to me that some-CaS and some.cSZ would be formed.
Simi1ari1y in the production of HZS, where the formation of cas is
acknowledged, some CSZ is probably present also.
It is apparent that a firm recom'mendation on a £IoN scheme ''lould have
to be based,_on a fairly extensive study which ''lould require considerable
process design work and cost estimating, which we have not done. My
opinion is that a promisi~g flow scheme would involve the production of
,HZS-rich giS, with subsequent Purisol treatment and a Claus plant. -
Beavon
DKB/ju .
CC:
L. W.
- \'Y.. M.-
F. 'C.
O.C.
Dailey
Parsons
Riesenfe1d
Roddey
. "'.
.'
/' .
---
1-38
-------
100 NTD:
200 NTD:
Basis:
SUMMARY SULFUR PLANT COST DATA
Fixed
Capital
MM$
Operating
Cost
$ /NTD
DMA Plant
Asarco
Total
3.2
1.2
4.4
27
17
44
DMA Plant
Asarco
Total
4.8
1.8
6.6
20
13
33
6% S02 in feed gas to DMA absorber.
Cost information scaled from Allied Chemicals reports with
lO%/year inflation.
I-39
-------
APPENDIX J
PRESSURIZED BOILER COMBINED CYCLE PLANT REPORT
Prepared by United Engineers and Constructors Inc.,
a Subsidiary of Raytheon Company
Authors
M. Casapis
E. Berman
w. Craig
J. Crowley
J-l
-------
.... m!!~o~~gineers
&;I a subsidiary of Raytheon Company
I N D E X
635 MW FLUIDIZED BED
BOILER COMBINED CYCLE PLANT
SECTION TITLE PAGE
--
1 DESCRIPTION OF OPERATIONS J-5
2 START-UP SYSTEM J-11
3 EQUIPMENT 11 S T J-15
4 ALTERNATE HEAT REJECTION SYSTEMS J-49
5 CONSTRUCTION SCHEDULE J-57
6 COST SUMMARY J-61
7 PLATES J-67
J-3
-------
1.
DESCRIPTION OF OPERATIONS
J-5
-------
...- m!!!~o~o.gineers
~ a subsidiary of Raytheon Company
PRESSURIZED FLUID BED BOILER
DESCRIPTION OF OPERATIONS
1.
GENERAL
The modules of the once-through pressurized fluid bed boiler consist of four
individual beds, filled to the required level with particulate matter through
which air flows.
The pressure drop
6 p across the packed bed of particulate
increases with increasing air flow.
Fluidization of the bed occurs when the
6 p (lb/in2) equals the per unit weight loading of the bed (particulate
weight/bed area).
When the critical air velocity is reached and the bed fluid-
ized, the particulate matter behaves like a fluid and not as a solid mass.
2.
CONTROL SYSTEMS
The control systems for operation of the pressurized fluid bed boiler are de-
signed to perform the following functions:
(1)
Maintain steam header pressure to the turbine at the desired
value by regulation of the turbine valve control.
(2)
Maintain the steam header temperature to the turbine at the de-
sired value by regulation of the fuel input to the boilers.
0)
The boiler feedwater flow is set by the load demand from the dis-
patcher.
A.
Combustion Control
The temperature in the steam header to the turbine is directed to a
Boiler Master Steam Temperature Controller and compared to an internal
set point (automatically set and adjusted to plant demand requirements).
As the header temperature decreases/increases, the output signals in-
creases/decreases and are directed as an internal set point to the
J-7'
-------
...- ffi!!~o!~.gineers
&;I a subsidiary of Raytheon Company
individual Boiler Bed Steam Temperature Controllers.
The temperature
at the superheater exit of the individu9l module is compared to the
internal set point. As the header temperature decreases/increases,
the output signal increases/decreases.
This signal is directed to the
individual Bed Fuel Stations which provide:
(1)
A means for allowing the operator to adjust the individual bed
output so that it represents a greater or lesser share of the
boiler load and the reheat bed output to maintain a constant
reheat temperature by permitting the operator to add or subtract
a manually adjusted bias to the automatic set point signal trans-
mitted by the Master Stearn Pressure Controller.
(2)
. .
Interruption of the automatic set point signal and substitution
of a manually adjusted set point signal.
The output signal of the Bed Fuel Station is directed to the Bed Fuel
Controller.
Signals from the Bed Fuel Controller are directed to the
Petro Carbo control system for feeding of coal to the bed and to the
Bed Coal Feeder Transport Air Valve Controller.
B.
Steam Flow. Control
The basic control parameter for Steam Flow Control from the boiler is
Feedwater Control to the boiler.
Stearn flow is measured by the Steam Recorder.
The recorder senses the
differential pressure generated by the orifice in the steam line, ex-
trac.ts . the. square root and transmits a signal inversely proportional
to the .measured flow.
.The output is directed to the Boiler Feedwater
Valve Position Controller and compared to an internal set point (set by
J-8
-------
.... H!!t@~o!ugineers
~ a subsidiary of Raytheon Company
the dispatcner to meet plant demand requirements).
When the steam
flow decreases/increases, the output signal from the Boiler Feedwater
Valve Position Controller is directed through the Boiler Feedwater
Valve Station to the Valve Power Positioner which assumes a position
relative to the control signal, opening/closing the Boiler Feedwater
Valve, increasing/decreasing feedwater flow to the boiler.
C.
Dolomite Regeneration and Make-Up 'Control
The basic control parameter for recycling regenerated dolomite back
to the beds and adding make-up dolomite to the coal feed is performed
by an S02 analyzer located in the flue gas piping leaving the boiler.
The flue gas is monitored for percent of S02.
When the S02 content
exceeds an internal set point value, an alarm is activated to notify
the operator that the rate of recycle of regenerated dolomite and/or
the rate of addition of make-up dolomite should be increased.
In a
like manner the S02 monitor could be equipped with a low level alarm
to prevent excessive use of dolomite.
J-9
-------
2.
START-UP SYSTEM
J-ll
-------
...- m!t@~o~~.gineers
~ 8 subsidiary of Raytheon Company
PRESSURIZED FLUID BED BOILER
START-UP SYSTEM
1.
GENERAL
The start-up and placing in operation of a steam turbine generator requires low
pressure and low temperature steam.
Since the once-through pressurized fluid
bed boiler cannot operate at low pressure, a special start-up system must be
provided.
The capacity of the start-up system should be capable of bringing
the steam turbine generator up to and handling 10% load.
Included in the start-
up system are all the necessary valves, controls and a flash tank which is
utilized for providing the low pressure required.
2.
FLASH TANK OPERATION
During initial firing of the boiler either from a cold start or a hot restart,
Valve A is modulated to maintain a feedwater rate of approximately 25%, Valve
C is modulated to maintain required pressure in the evaporator bed.
Since the
outlet from the boiler has a high percentage of water» the flash tank will be
flooded and the pressure low because Valve 2 is open.
During firing, the water
warms and steam flashes across valves C and D and accumulates in the flash tank.
The level of water goes down causing Valve 2 to close.
Closing Valve 2 increases
the flash tank pressure, following the saturated water temperature into the tank.
The flash tank provides the storage facility where the high water is separated
from the fluid entering the tank and settles to the bottom.
The steam raises
to the top of the tank.
The flash tank level control regulates the opening of valves 1 and 2 putting
steam and water to the deaerator.
If the deaerator cannot absorb all the water
and steam, the excess is passed through Valve 1.
When the flash tank pressure
J-13
-------
'-- m~~o~~.gineelS
~ 8 subsidiary of Raytheon Company
reaches approximately 400 psi, Valve G is opened and stearn admitted to the
second superheater bed.
Valve. I is opened?-nd tq.e: steam lines to the turbine
warmed.
At 600 psi and 100°F superheat the turbine stop valve is opened
and the turbine rolled and brought up to speed.
At 900 psi the turbine is
synchronized and load is picked up.
After the turbine is synchronized the
stearn temperature to the turbine is approximately 700°F.
Stearn flow to the
reheater bed: is established', Valve J is closed and Valve K is opened.
3.
INCREASING PRESSURE, TEMPERATURE AND LOADING
Now that a complete stearn cycle has been established the firing rate of the
boiler may be increased to provide the higher temperature and pressure required
to sustain operations.
The governor valve of the main turbine is set at a fixed
position 25%.
Valve F is opened and valves E and G are closed, passing all
the feedwater into the turbine as steam through the second superheater bed.
The
feedwater flow rate is maintained at about 25% and the firing rate increased to
approximately 100% increasing temperature and pressure..
When the pressure
reaches 2400 psi, Valve C which has been regulating the furnace will be wide
open.
The boiler is now up to full pressure and temperature.
J-14
-------
3.
EQUIPMENT LIST
J-15
-------
Account No.
G1 ~:!~~~~!~~~~
635 MW FLUIDIZED BED BOILER
COMBINED CYCLE PLANT
TURBINE GENERATOR & AUXILIARIES
a)
Turbine
538 MW turbine; tandem compound four flow
exhaust; 25 inch last stage blades, rating
at 1-1/2 inch Hg A; 3600 rpm.
Turbine
throttle conditions 2400 psig at 10000F
and reheat conditions 500 psia.
b)
Generator
597, 778 KVA; 3600 rpm, 3 phase, 22kv, hydro-
gen cooled at 75 psig.
c)
Exciter
Director connected rotating rectifier brush-
less exci ter.
d)
Lubricating
Oil Condi-
tioning
Equipment
One continuous by-pass lube oil conditioner.
2000 GPH capacity; with clean and dirty oil
storage tanks, circulation pump and transfer
and clean-up pump.
HEAT REJECTION SYSTEMS
a)
Circulating
Two vertical motor driven pumps each to
deliver 162,000 gpm @ 21 ft. TDH, 89%
efficiency, 250 rpm, 965 BHP, with 1250 hp,
600 rpm, 4160 volts, 3 phase, 60 cycle.
,
J-17
-------
Account No.
b)
Traveling
Screens
c)
Chlorination
System
d)
Variable Weir
.... m~~o~o.gineelS
t.;I a subsidiary of Raytheon Company
Two 12 ft. wide by 43 ft. high screens, tra-
ve1ing at 10 fpm.
Each screen has 49 baskets,
24 inches high and 8 ft. long, covered with
.080 dia.
Type 304 stainless steel wire cloth
with 3/8 gpm at a velocity of 1.0 fps to a
circulating water pump and is cleaned by a
spray system.
One 4 ft. wide screen with same
construction that passes 10,000 gpm to service
water pumps at a velocity of 1.00 fps.
Storage tanks, pumps, control devices and
diffusers provided to inject liquid sodium
hypochlorite into the river water as it leaves
the traveling screens to prevent the formation
of algae and slime in the circulating and ser-
vice water systems.
A variable weir maintains a constant discharge
channel water level to allow the recovery of a
substantial portion .of the circulating pumps
discharge head by virtue of the syphon effect.
This is accomplished by the automatic position-
ing of two nested submerged movable gates, in-
stalled in the discharge channel.
J-18
-------
Account No.
C# ~:~~o~~~!~~~~
a)
Condensers
CONDENSING SYSTEMS
b)
Condenser Air
Removal
Equipment
c)
Condensate
Pumps
Two main surface condensers single stage,
single pass with fabricated steel water boxes
and steel shell.
Each with condensing surface
of 132,000 square feet, 10,100 tubes, 1 inch,
22 BWG, 50 ft. long A-249 welded Type 304
stainless steel.
162,000 gpm cooling water
required at 57°F with 90% tube cleanliness
factor, l8.48°F temperature rise, tube velocity
8 ft./sec. and 3.1" Hg absolute exhaust pres-
sure.
Two Condenser Vacuum Pumps cast iron construc-
tion, fitted with a steel shaft and directly
connected through a Fasts gear type flexible
coupling to a 125 hp motor.
Rated holding
capacity at 1. 5" Hg A is 24 scfm and hogging
capacity at 15" Hg A is 800 scfm.
125 hp induc-
tion motor, 600 rpm, 480 volt, 60 cycles.
Two condensate pumps rated at 3,100 gpm, 350 ft.
TDH, 86% efficiency at 1185 rpm, driven by 400
hp, 1200 rpm, 4160 volts, 3 phase, 60 cycle.
FEEDWATER HEATING SYSTEM
a)
Two 1,400 sq. ft. horizontal feedwater heaters
Feedwater
Heaters
with 5°F terminal difference each transferring
3-19
-------
Account No.
a)
(Cont'd)
No.1 Low
Pressure
Heaters
No.2 Low
Pressure
Heat ers
No.3 Low
Pressure
Heaters
No.4 Low
Pressure
Heat ers
...- m!r@~o!~.gineers
~ a subsidiary of Raytheon Company
14.20 X 106 Btu/hr; 50 psig shell design, 750
psig tube design.
Each with 26" ID steel shell,
steel tube channel, plates and baffles; A-249 -
Tp 304 stainless steel tubes 3/4" OD, No. 22 BWG
with effective length of 30 ft.
Two 5,860 sq. ft. horizontal feedwater heaters
with 10°F approach and 5°F terminal difference
each transferring 55.4 x 106 Btu/hr; 50 psig
shell design, 750 psig tube design.
Each wi th
39 inch ID steel shell, steel tube channel,
plates and baffles; A-249 - Tp 304 stainless
steel tubes 3/4"OD, No. 22 BWG with effective
length of 30 ft.
Two 4,910 sq. ft. horizontal feedwater heaters
with 10°F approach and 5°F terminal difference
6
each transferring 49.1 x 10 Btu/hr; 50 psig
shell design, 750 psig tube design.
Each wi th
38 inch ID steel shell, steel tube channel,
plates and baffles; A-249 - Tp 304 stainless
steel tubes 3/4" OD, No. 18 BWG with effective
length of 30 ft.
Two 6,900 sq. ft. horizontal feedwater heaters
with 10°F approach and 5°F terminal difference
6
each transferring 64.1 x 10 Btu/hr; 100 psig
J-20'
-------
Account No.
a)
(Cont'd)
No.5 Low
Pressure
Deaerator-
Heater
No.6 High
Press ure
Heaters
No.7 High
Pressure
Heaters
.... m!!~o~~.gineers
~ B subsidiary of Raytheon Company
shell design, 700 psig .tube design.
Each with
32 inch ID steel shell, steel tube channels,
plates and baffles; A-249 - Tp 304 stainless
steel tubes, 3/4" OD No. 22 BWG with effective
length of 30 ft.
One full size, horizontal, 8 ft. dia. and 35 ft.
long deaerator; 12 ft. dia. and 60 ft. long
storage tank.
Feedwater leaving deaerator:
2,317,487 #/hr. @-358°F.
Condensate entering
deaerator 2,197,050 #/hr. @ 289°F.
Extraction
steam entering deaerator: 121,000 #/hr. @ 1365.0
Btu/# and 148 psia.
Design pressure 250 psig to
29 inches vacuum.
Two 8,200 sq. ft. horizontal feedwater heaters
with 10°F approach and OaF terminal difference,
each transferring 63.5 x 106 Btu/hr; 450 psig
shell design, 4000 psig tube design.
Each with
40 inch ID steel shell, steel tube channels,
plates and baffles; A-249 - Tp 304 stainless
steel 3/4" OD, No. 14 BWG tubes with effective
length of 30 ft.
Two 6,530 sq. ft. horizontal feedwater heaters
with 10°F approach and OaF terminal difference,
each transferring 79.6 x 106 Btu/hr; 800 psig
J-21
-------
Accotmt No.
~. m~!!~o.gineers
~ 8 subsidiary of Raytheon Company
a)
(Cont'd)
Each
shell design and 4000 psig tube design.
with:40 inch ID steel shell, steel tube channels,
plates and baffles; A-249 - Tp 304 stainless
steel 3/4" OD, No. 14 BWG tubes with effective
length of' 30 ft.
Stack Gas
. Coolers
Two (2) Stack Gas Coolers arranged in parallel
with the high pressure heaters No.6 and 7.
Each stack gas cooler consists of three modules.
The design of the modules is :as follows:
. .
Module #1 - Shell:
3/4" Carbon Steel Plate,
insulated with 2-1/2" thermosbestos
block, lagged with .060" thick car-
bon steel lagging; headers = six
(67, each" 10" long (4 internal,
2 external 8" sch. 120 Al06 Gr. C;
Modules 2 & 3
Shell: 3/4" C.S. plate insula-
ted with 2-1/2" thermos-
bestos block lagged with
.060" thick Carbon S tee!.
Headers:
Twelve (12) headers each
10" long (8 internal, 4 ex-
ternal) 8" sch. 120 Al06
Gr. C
J-22
-------
Account No.
a)
(Cont'd)
b)
Boiler Feed
Pumps &
Drive
Tu rb ines
c)
Pumps
d)
Condensate
Transfer
Pumps
G1 mltBd engineers
& constructors inc.
a subsidiary of Raytheon Company
Tubes:
2.0" OD, 30' long, 0.259
min. wall
A192
Fins:
1.0" high, .0478" thick,
0.156" reg. width.
Pump - two one-half size horizontal, high speed,
multistage, double case barrel type, centrifugal
pumps each delivering 1,750,000 #/hr. at 7350 ft.
TDH with a suction temperature of 358°F.
Drive Turbine - each pump directly driven by a
turbine rated at 7,730 hp and 5,350 rpm.
Tur-
bine operates at normal loads with cross-over
steam and steam direct from steam generators
during start-up and reduced load operation.
Two horizontal condensate booster pumps each
delivering 3200 gpm at 462' TDH with a suction
temperature of 10l.4°F.
Each driven by 600 hp,
4160 V, three phase, 60 cycle, 3550 rpm motor.
One condensate transfer pump delivers 1500 gpm
at 400' TDH and 70°F temperature.
Driven by a
250 hp, 3550 rpm, 480 V, three phase 60 cycle
motor.
J-23
-------
Account No.
. .
e)
S tack Gas
Cooler
Boiler
Feed
Pumps
C# ~!~!~~~~~~~~
Two Stack Gas Cooler boiler feed pumps. each
driven by a 3000 hp motor to deliver 650,000
#/hr of feedwater at 7350 ft. TDH with suction
temperature of 226°F.
'-
STEAM GENERATORS & AUXILIARIES
a)
Four, once through, single reheat type, pres-
Steam
Generators
surized fluidized bed ?oiler modules, to
supply steam to the turbine generator unit.
Each designed for continuous operation at
875,000 #/hr, 2400 psig and iOOO°F at super-
heater outlet and 800,000 #/hr, 580 psia at
the reheater outlet; maximum allowable working
pressure of 3000 psig.
The units are arranged
for firing bituminous coal having a higher
heating value of 13,000 Btu/#.
COAL HANDLING AND FEEDING SYSTEM
a)
The coal is transported from the mine in
System
Description
specially constructed cars assembled into a
unit train comprised of high capacity, semi-
automatic bottom-dump hopper cars providing
10,000 tons each shipment; two shipments per
week.
The rail car receiving hopper will have a mini-
mum of 400 tons capacity to provide storage
J-24
-------
Account No.
.... m!t!~o!~.gineers
t.;I 8 subsidiary of Raytheon Company
a)
(Cont'd)
volume for controlling unloading of moving cars.
The coal discharge from the receiving hopper
will be controlled by four reciprocating feeders,
F1-A, F1-B & Fl-C, Fl-D, each feeder nominally
rated at 500 tph but capable of delivering 700
tph if one feeder is out of service.
A 54" wide inclined belt conveyor No.1 will
transport the coal at a rate of 2000 tph to the
s Ho .
Conveyor No.1 will be equipped with a tramp
metal detector and belt scale for weighing and
recording coal quantities delivered to the plant
site.
A 12,000 ton silo will nominally contain an
entire unit train delivery without exposure to
wind blown dust and provide active storage for
plant feed without the use of mobile equipment.
Excess coal will overflow the silo to an initial
pile for placing in permanent storage.
During extended periods of no-train delivery,
coal will be recovered from permanent storage
through a reclaim hopper and Feeder No. F2 de-
livering to Conveyor No.1 for refilling the silo.
J-25
-------
Account No.
...- m!!!!!~ugineelS
~ 8 subsidiary of Raytheon Company
a)
(Cont'd)
Coal will be fed from the silo by seven Feeders
. . ,
No. F3A to F3G, each rated a maximum of 150 tph
and operating in timed sequence for uniform
drawndown of the silo, onto a 24" wide belt
Conveyor No.2.
Conveyor No. 2 will be fitted with a tramp iron
magnet before delivery to the coal dryer.
The
McNally F10wdryer is sized to evaporate 12 tons
per hour of water from a feed of 150 tph (dry
basis) of 1-1/2" X 0 coal and deliver a procuct
containing 3% total moisture.
The dryer will be
fueled by pulverized dried coal and will be fit-
ted with a cyclone dust collector to capture the
coarse dUsts and a high energy scrubber to re-
duce exhaust dust to acceptable limits.
Effluent
from the scrubber will be disposed to the pcwer
plant ash pond.
Coal hom the dryer will be crushed to 1/4" X 0
size in a reversible hammer mill and, along with
the coarse dust from the dryer cyclone, will be
delivered via 24" belt Conveyor No.3 to the
plant surge bin.
Conveyor No.3 will be fitted
with belt scale No.2 to weigh and record coal
quantities to the boilers.
J-26
-------
Account No.
G1 ~!~o~~~~~~~~
a)
(Cont'd) From the 150 ton capacity plant surge bin the
coal flow will be split into two streams each
served by a 0 to 75 tph vibrating Feeder F4-A
and F4-B to its associated coal feeder surge silo
group through scraper Conveyors No. 4A and 4B.
The silo fueling system will be provided with
automatic sequential controls with provisio~s
for operator to override to accommodate unusual
operating conditions.
The plant surge bin level
will control the feed to the dryer and in turn
the dryer surge bin will regulate the silo with-
drawal feeders.
b)
Equipment
a)
The coal handling system will consist of the
following equipment, material and services:
1. Receiving Hopper
2. Feeders No. FlA, FIB, FlC & FlD
3. Chutes
4. Conveyor No.1
5. Metal Detector
6. Belt Scale No.1
7. Reclaim Hopper
8. Shut Off Gate
9. Feeder No. F2
J-27
-------
Accotmt No.
b)
(Cont'd)
a)
b)
C# mitBd engineers
& constructors inc.
a subsidiary of Raytheon Company
10. Silo
11. Feeders No. F3A-F3G
12. Conveyor No.2
13. Tramp Iron Magnet
14. McNally F10wdryer
15. Mill
16. Conveyor No.3
17. Belt Scale No.2
18. Surge Bin
19. Feeders No. F4A & F4B
20. Conveyors No. 4A & 4B
21. Dust Collecting Equipment
22. Ventilating & Heating Equipment
23. Control Equipment
24. Motors & Controls
25. Structures
26. Fotmdations
27. Electric Wiring
28. Erection
The associated coal feeder surge silo group
will consist of the following:
1. Screens
2. Cyclones
J-28
-------
Account No.
...- W!!~o~~.gineers
&;, e subsidiary of Raytheon Company
b)
(Cont'd)
b)
3. Surge bins
4. Storage injectors
5. Primary injector
6. Booster air compressor
CLOSED WATER COOLING SYSTEM
The closed cooling water system provides water
to the sample coils, pump glands and motor
bearings, oil coolers, turbine generator oil
and hydrogen coolers, boiler feed pump turbine
oil coolers, air compressor coolers, instrument
and station air after-coolers, condenser vacuum
pumps, air conditioners, etc.
It includes three
pumps @ 4000 gpm capacity with a total head of
50 psi, each driven by a 200 hp, 1800 rpm, 480
volt, 3 phase, 60 cycle motor, two horizontal
single pass heat exchangers 8000 sq. ft. trans-
6
ferring 28 x 10 Btu/hr., 150 psig shell and
tube design pressure.
WATER TREATMENT SYSTEM
a)
Water is supplied to the raw water treating sys-
Raw Water
Treating
System
After
tern by the low pressure water pumps.
softening and coagulation (by reactivators) and
filtration (by gravity filters) the water is
pumped to the treated water storage tank.
J-29
-------
Account No.
...- m!!~o~~.gine ~ 'S
&;I a subsidiary of Raytheon Company
a)
(Cont'd)
The raw water treating system is sized to handle
a capacity of 500 gpm and includes the following
components:
1)
One reactivator flow split box.
2)
Two reactivators with integral cleanwells
(each 250 gpm capacity and 15,000 gallons
clearwell capacity).
3) One ferric sulphate feeder.
4) One ferric sulphate solution pump.
."
5) Two lime feeders.
6)
Two lime solution pumps.
7)
One chemical solution flow split box.
8)
Two gravity filters of 250 gpm capacity
each, 10 feet dia. x 15 feet high.
9)
One local control panel with annunciator,
flow recorder, indicator, timers, control
switches, level indicator gauge, etc.
10)
Two treated water pumps each of 250 GPM
capacity and a total head of 40 psi driven
by a 7.5 hp motor, 1770 rpm, 3 phase,
60 cycle, 480 volts.
11)
120,000 gallon carbon steel treated water
storage tank, 27 feet dia. x 30 feet high.
.J-30
-------
Account No.
b)
Deminera1izer
System
6)
.... Mt~~o!~~.gineelS
~ a subsidiary 01 Raytheon Company
A header from the treated water storage tank
supplies the deminera1izer feed pumps and in
turn supply the deminera1izers and other ser-
vices requiring treated water.
The deminera1i-
zer system includes the following components:
1)
Two demineralizer feed pumps each with a
capacity of 250 gpm and a total head of
91 psi, driven by a 20 hp, 3550 rpm,
3 phase, 60 cycle, 480 volt motor.
2)
One cation exchanger having a capacity of
100 gpm - size:
54" dia. x 8'-0" high.
3)
One anion exchanger having a capacity of
160 gpm -
54" dia. x 8 '-0" high.
size:
4)
Two 60 gph acid pumps each driven by a
1/2 hp, 1750 rpm motor.
5)
Two 32 gph caustic pumps each driven by
1/2 hp, 1750 rpm motor.
Two caustic heat exchangers to heat 8.2 gpm
of 4% caustic solution from 40°F to 110°F
utilizing 400 lbs./hr of 20 psig steam.
7)
Two 50 gpm recycle pumps with a total head
of 50 psi driven by a 2 hp, 3600 rpm motor.
8)
Controls and instrumentation including a
local panel with a service selector, power
switch, "Regen. Test" pushbuttons, "Alarm
J-3l
-------
Account
Account No.
b)
(Cont'd)
c)
PC?lishing
System
- 8)
...- m!!~o~o.gine ~ "S
~ a subsidiary of Raytheon Company
- "
Silence" pushbuttons for annunciators, and
local "s tart-stop" motor pushbut ton s ta-
tions, etc.
9)
One stainless steel basic demineralized
water storage tank having a capacity of
250,000 gallons - size 34 ft. dia. x 39 ft.
height.
The polishing system consists of the following
equipment:
1)
One 250,000 gallon stainless steel polished
deionized water storage tank - size: 34' dia.
x 39' heigh t.
2)
One pre coat tank to prepare a precoat
slurry, with agitator.
3)
Dust collector to remove resin fines from
the air.
4)
Three precoat type filter deionizer tanks
containing nylon wool filter elements.
5)
Precoat pump for transferring precoat
material to the filter deionizer tanks.
6)
Blower for backwashing filter elements.
7)
Control panel for precoat system and filter
deionizer tanks.
Associated valves.
J-32
-------
Account No.
c)
(Cont'd)
.... M1oni!!~o~~.gineers
ta;I a subsidiary of Raytheon Company
9) Control, interlocks & alarms.
10) One motor driven air compressor.
FIRE PROTECTION SYSTEM
a)
Fire Service
Water Tank
b)
Diesel Engine
Driven
Fire Pump
The fire protection system is designed to con-
form to the guide lines set up by NEPIA.
The fire line headers are designed as a loop
system to permit water flow in either direc-
tion.
Sectiona1izing valves throughout the
system are located to permit isolating damaged
sections of header.
The fire protection system includes a network
of fire service water piping, a fire service
water storage tank, a diesel engine driven fire
pump, fire protection systems for fuel oil sys-
tern, generator hydrogen seal oil unit, turbine
oil reservoir and transformers, and hydrants
and hose reels located at various places through-
out the plant and yard.
One combination filtered and fire-service water
storage tank (above ground) having a capacity
of 200,000 gallons.
The fire pump has a capacity of 2000 gpm at a
total head of 150 psi driven by a 250 hp,
J-33
-------
Account No.
b)
(Cont'd).
c)
Motor Driven
Fire PlUIlpS
d)
Motor Driven
" Jockey"
PlUIlp
e)
FireProtec-
tion Sys terns
f)
Hydrants and
Hose Reels
...- ID~!!~o,gine ~ 'S
1.;1 8 subsidiary of Raytheon Company
1750 rpm diesel engine. ,'The engine is equipped
with a hot start engine preheater, fuel system,
muffler, 350 gallon fuel tank, batteries and
battery chargers, and combined manual-automatic
controller.
Two motor driven fire pumps each having 2000 gpm
capacity at 150 psi total head driven by a 250
hp, 1750 motor.
One jockey pump having a capacity of 100 gpm.
This pump starts when the system pressure drops
to 135 psig.
Water spray, automatically operated and remote-
manual with automatic detection.
Fire protec-
tion includes automatic water spray systems
with automatic fire detection, detection and
alarm panels and necessary piping, fittings,
flanges and valves.
The fire hydrants have a 5" main valve opening.
Th~ hose reel assemblies are continuous flow
un,its provided with two 50' lengths of 1-1/2"
hose. ,
OTHER MECHANICAL EQUIPMENT. '
a)
Gas Turb ine
Generators
Two Gas Turbine Generators each rated at
56,556 KW at 3600 rpm.
J-34
-------
Account No.
a)
(Cont 'd)
b)
Emergency Gas
Turbine
Generator
c)
Emergency
Diesel
Generators
d)
Service Water
Pumps
e)
Instrument Air
Compressor
...- m~~o~~gineers
1.;1 a subsidiary of Raytheon Company
The generators are supplied with pressurized
flue gas connections and a starting motor rated
at 800 hp.
One 22 MW emergency gas turbine generator.
Two emergency diesel generators capable of
providing the power for one set of safeguards
equipment.
Each generator is rated at 350 KW
at 1800 rpm.
The diesel generators are supplied
with a 2000 gallon underground day tank, fuel
pumps, lube oil system, engine cooling system
and starting system.
Two vertical service water pumps each to deliver
5000 gpm at 220 ft. TDH; 85% efficiency, driven
by a 350 hp, 60 cycle, 3 phase, 480 volt motor
at 1770 rpm.
Each with steel column and dis-
charge tee, chrome steel shaft, cast iron bowls,
bronze impellers and bearings.
One horizontal, motor driven single-stage,
double acting, non-lubricated compressor, in-
c1uding intake filter and silencer, after-cooler,
air dryers, dual control, receiver and 60 hp
motor with V-belt drive; rated 215 scfm at 100
psig discharge pressure.
J-35
-------
Account No.
f)
Station Air
Compressors
g)
Booster Air
Compressors
h)
Crane
.... ID!!~o~~.gineelS
~ a subsidiary of Raytheon Company
Two angle type, motor-driven, two-stage, double
acting, lubricated compressors including intake
filter, 100 hp motors, inter-cooler and after-
cooler, dual control and receiver; rated 320
scfm at 125 psig discharge pressure.
Two booster air compressors each rated 13,000
cfm at 50,psig total h~ad~ suction pressure:
150 psig; suction temperature:
636 ° F .
Turbine Building - one (1) 60 ton overhead tra-
ve1ing crane with 20 ton auxiliary hook.
Main
hook 80 ft ~ lift, auxiliary hook 80 ft. lift.
Main hoist speed 4 fpm, auxiliary hoist speed
15 fpm, bridge speed 75 fpm, trolley speed
50 fpm.
OTHER MECHANICAL EQUIPMENT
C02 Scrubber
One C02 scrubber rated 7,000,000 ncfh of flue
gas at 135 p~ia and 230°F.
The C02 scrubber
consists of two 12 ft. diameter and 100 ft.
. '" .
high columns and one hot carbonate regenerator
. ,
23 ft. diameter by 100 ft. high producing a gas
mixture of 1~080,000 ndfh C02 and 2,390,000 ncfh
steam at 19.7 psia and 220°F; one reboiler re-
quiring 160 MM Btu/hr; horsepower required for
the various equipment is 1100.
J-36
-------
ACCOlUlt No.
Claus Plant
Dolomite
Regenerator
System
~. m!!~o~o.gineelS
~ a subsidiary of Raytheon Company
One "package" Claus plant (manufactured by
Ford Bacon and Davis, Texas) to produce 200
tons per day sulfur.
Gas from the dolomite regenerator system (H2S.
generator vessel) at the rate of 117,000 H/hr
is expanded to 15 psig and cooled to condense
out water vapor.
The process involves comb us-
tion of the H2S to S02 and subsequent reaction
between the remaining H2S and the produced S02
to form sulfur and water.
One dolomite regenerator system consisting of
the following:
Reducer vessel:
9' O.D. x 30' high.
Gas Producer vessel:
9' O.D. x 50' high.
H2S Generator Vessel:
bottom portion = 7-1/2' O.D. x 25' high.
top portion
= 11-1/2' O.D. x 25' high.
Cyclone Pressure Vessel:
5' O.D. x 22' high.
Description:
The dolomite regenerator system receives
sulfated dolomite ([CaS04 + MgO] and [Cao + MgO])
from the pressurized fluid bed boiler modules and
converts - 90% of the sulfated stone to half ca1-
cined dolomite ([CaC03 + MgO]) for recycle back
J-37
-------
Account No.
" Dolomi t e
Regenerator
System
.... M!~~o~~"gineers
&;I a subsidiary of Raytheon Company
to the boiler modules.
A hydrogen sulfide rich
gas is produced and sent to a Claus Plant where
elemental sulfur is produced.
Spent dolomite is pneumatically conveyed to
the regenerator system from four separate FBB
discharge holding vessels (~ 50 tph each).
One holding vessel serves all 5 beds in a
boiler module.
Spent stone first enters a reducer vesS"el
in which the calcium sulfate, reacted with a
reducing gas, is converted to calcium sulfide.
The reducer vessel, 9' O.D. x 30' high, is a
fluid bed reactor operating at l500°F and
8 atms.
A portion of the calcium oxide carried
with the spent dolomite is carbonated to half-
calcined dolomite in the reducer vessel.
Ten
percent of the stone charged to the regenerator
system is carried overhead from the vessels or
removed from the reducer vessel and sent to
was te .
Top gas from the reducer vessel passes
through a turbine expander, which drives a com-
pressor to compress the gas to the HZS generator
vessel.
J-38
-------
Account No.
Dolomite
Regenerator
System
C# mltBd engineers
& constructors inc.
a subsidiary of Raytheon Company
Reducing gas for the reducer vessel is made
in the gas producer vessel, a 9' O.D. x 50' high
fluid bed gasifier operating at 1800°F and 9 atm.
Approximately 55% stoichiometric air containing
27 gr/scf of moisture is used to combust 17 tph
coal, producing 221,000 #/hr reducing gas con-
taining 8.0% H2 and 16.3% CO.
(% by volume.)
Reduced stone, 400,000 #/hr of [CaS + MgO],
[CaC03 + MgO] and [CaO + MgO], is gravity fed
from the reducer vessel to the H2S generator
vessel through a dip leg pressure seal.
The
H2S generator vessel is also a fluid bed reactor
with an expansion section on top enclosing a
solid separation cyclone.
The bottom portion of
this vessel is 7-1/2' O.D. x 25' high and the
top expansion section is 11-1/2' O.D. x 25' high.
The H2S generator operates at 1100°F, 12 atms
and produces a 10% H2S gas stream by volume which
is sent to the Claus Plant.
Twenty, 20, separate
solids removal ports are provided to pneumati-
cally transport regenerated dolomite back to
each FBB module.
Feed gas for the H2S generator,
180,000 #/hr, 64% H20, 36% C02 (% by volume) is
. made in the C02 scrubber system.
This gas reacts
with the reduced stone to produce the H2S rich
gas and the regenerated stone [CaC03 + MgO].
J-39
-------
...- m~~o~~,gineers
~ a subsidiary of Raytheon Company
EQUIPMENT LIST - ELECTRICAL
& INSTRUMENTATION
Account No.
MAIN POWER TRANSFORMERS
One - 600 mVA transformer; oil immersed, 55°C rise, 3 phase,
60 Hz,FOA, 22 kV-345 kV, de1ta-wye, 1050 kV - H.V. BIL, no-
load tap-changer, four - 2-1/2% H.V. taps, liquid level guage,
dial type 1iqutd thermometer, vacuum pressure guage, tank
pressure relief device, tank grounding provisions, valves,
three 312 kV lightning arresters, six-bushing~.T. 's, one
--.
winding temperature relay, three-L.V. bushing enclosures, one
sudden pressure relay.
One 115 mVA transformer, oil immersed 55°C rise, 3 phase,
60 Hz, FOA, 22 kV-138 kV, de1ta-wye, 550 kV - H.V. BIL, no-
load tap-changer, four - 2-1/2% H.V. taps, liquid level guage,
dial type liquid thermometer, vacuum pressure guage, tank
pressure relief device, tank grounding provisions, valves,
three 144 kV lightning arresters, six-bushing C.T. 's, one
winding temperature relay, three L.V. bushing enclosures one
sudden pressure relay.
MAIN GENERATOR BUS
An isolated phase bus is run betWeen the main generator line
terminals and the low voltage bushings of the main 600 mVA
step-up power transformer.
The isolated phase bus is meta1c1ad,
J-40
-------
...- m!t!~o~o.gineelS
~ a subsidiary 01 Raytheon Company
Account No.
MAIN GENERATOR BUS
(Cont'd)
forced cooled, continuous housing, 3 phase, 60 cycle, 23 kV,
150 kV basic impulse level, 17,000 ampere, 65°C temperature
rise with forced air cooling.
An isolated phase bus is run between the gas turbine driven
generators and the low voltage busings of the main 115 mVA
step-up power transformer.
The isolated phase bus is meta1-
clad, forced cooled, continuous housing, 3 phase, 60 cycle,
23 kV, 150 kV basic impulse level 3750 Amperes from each
generator to connecting tap, and 7500 Amperes from tap to
transformer, 65°C temperature rise with forced air cooling.
NEUTRAL TRANSFORMER
Each generator neutral is grounded through a single phase
transformer rated at 20,000 volts on the primary and 240
volts on the secondary.
The secondary of the transformer is
connected to a resistor bank.
STATION START-UP TRANSFORMERS
One 20 mVA transformer, oil immersed, 55°C rise, 3 phase,
60 Hz, FOA, 138 kV - 6.9 kV, de1ta-wye, 550 kV - H.V. BIL,
no-load tap-changer, four - 2-1/2% H.V. taps, liquid level
gauge, dial type liquid thermometer, vacuum pressure gauge,
tank pressure relief device, tank grounding provisions,
3-41
-------
...- m!!~o!o.gineers
&;I' a subsidiary of Raytheon Company
Account No.
STATION START-UP TRANSFORMERS
(Cont'd)
valves, three 144 kV lightning arresters, six-bushing C.T. 's,
one winding temperature relay, three-L.V. bushing enclosures,
one sudden pressure relay.
One 20 mVA transformer, oil immersed, 55~C rise, 3 phase,
60 Hz, FOA, 22 kV - 6.9 kV, delta-wye, 150 kV - H.V. BIL,
no-load tap-changer, four - 2-1/2% H.V. taps, liquid level
gauge, dial type liquid thermometer, vacuum pressure gauge,
tank pressure relief device, tank grounding provisions,
valves, winding temperature relay, H.V. bushing enclosures,
L.V. cable entrance, one sudden pressure relay.
AUXILIARY POWER TRANSFORMER
One 20 mVA transformer, 011 immersed 55°C rise, 3 phase,
60 Hz, FOA, 22 kV - 6.9 kV, de1ta-wye, 150 kV - H.V. BIL,
no load tap-changer, four 2-1/2% H.V. taps, liquid level
gauge, dial type liquid thermometer, vacuum pressure gauge,
tank pressure relief device, tank grounding provisions,
valves, winding temperature relay, H.V. bushing enclosures,
L.V. cable entrance, one sudden pressure relay.
4160 VOLT INDOOR METALCLAD SWITCHGEAR
The 4160 volt, 3 phase, 60 Hz indoor meta1c1ad switchgear is
arranged into two sections each consisting of:
Three - 2000 ampere, incoming line circuit breaker units
J-42
-------
C# mltBd !OI1n8ers
& constructors inc.
a subsidiary of RIIYtheon Company
Account No.
4160 VOLT INDOOR METALCLAD SWITCHGEAR
(Cont'd)
each with voltmeter, ammeter, ammeter switch, breaker control
switch with indicating lights, two draw out type potential
transformers, six current transformers and relaying.
Six 1200 ampere, motor feeder circuit breaker units each with
ammeter, ammeter switch, breaker control switch with indicat-
ing lights, six current transformers and relaying.
Two uni ts
include three motor differential relays.
Ten 1200 ampere, transformer feeder circuit breaker units
each with ammeter, ammeter switch, breaker control switch
with indicating lights, six current transformers and relaying.
STATION SERVICE TRANSFORMERS
Ten 1500/2000 kVA transformers, dry type, 3 phase, 60 Hz,
AA/FA, 6900 volt - 480 volt, delta-wye, 35 kV H.V. BIL, 10 kV
L.V. BIL, with two 2-1/2% taps AN and BN.
480 VOLT METALCLAD SWITCHGEAR
The 480 volt metalclad switchgear is rated 600 volt, with
2000 ampere busses arranged in sections.
Each section is
supplied thru a 2000 ampere, 75,000 ampere i.c. incoming
line circuit breaker from one of the 6900 volt - 480 volt
Station Service Transformers.
All feeder circuit breakers
have an interrupting capacity of 50,000 amperes.
J-43
-------
C# mitBd engine ~ "S
& constructors inc.
a subsidiary of Raytheon Company
Account No.
MOTOR CONTROL CENTERS
Eleven 480 volt motor control centers are located at various
points of electrical load concentration.
Each motor control
center compartment is provided with circuit breaker, motor
starter, overload relays, control power transformers and
auxiliary relays as required by the individual auxiliaries.
Reversing starters are equipped with electrical and mechani-
cal interlocks.
MAIN CONTROL ROOM EQUIPMENT
The main control room contains the following supervisory and
control panels for control and operation of the stearn gener-
ators, gas turbine generators and boilers.
The panels are
complete with required instrumentation and control devices:
Main Control Benchboard
Stearn Turbine & Generator Control Panels
Gas Turbine & Generator Control Panels
Start-up Turbine & Generator Control Panels
Boiler Control Panels
Coal Handling Control Panel
Supervisory Control Board
J-44
-------
BOILER INSTRUMENTATION & CONTROL
EQUIPMENT LIST
SERVICE
INSTRUMENT
Main Steam Output
Recorder
Reheat Steam Flow
(Input & Output to
Reheat Bed)
Recorder
Boiler Feedwater
Consumption
Recorder
Boiler Combustion
Ai r Flow
Recorder
Bed Comb us tion
Ai r Flow
Recorder
Bed Fuel
Recorder
Bed. Pres. & Temp.
Recorder
Flue Gas Output
Recorder
S02 Content
Analyzer
Bed. Temperature
Monitor
3-45
QUANTITY
l/Boiler
2/Boiler
l/Boiler
l/Boiler
l/Bed
l/Bed
l/Bed
l/Boiler
l/CBC
l/Boiler
l/Bed
C# mltBd engineers
& constructors inc.
a subsidiary of Raytheon Company
COMMODITY
Steam - Flow
Steam - Pressure
Steam - Temperature
Steam - Flow
Steam - Pressure
Steam - Temperature
Integrated - Steam Flow
Water - Flow
Water - Pressure
Water - Temperature
Air - Flow
Air - Pressure
Air - Temperature
Comb. Air Flow
Coal FDR Transport Air Flow
Reg. Dolomite Transport Air
Flow
Coal Flow
Rec. Dolomite Flow
Fuel Oil Flow
Bed -
Bed -
Bed -
Bed -
Diff. Press.
Heigh t
Temp. (Lower
Temp. (Upper
Zone)
Zone)
FI ue Gas - Flow
Flue Gas - Pressure
Flue Gas - Temperature
S02
Bed Temp. - 9 Thermocouples
Tube Temp. - 9 Rtd's
Shell Temp. - 6 Rtd's
-------
SERVICE
Main Stearn
Bed Stearn
Boiler Combustion
Air
Be d Comb us t ion
Air
Bed Fuel
Main Stearn
Account No.
INSTRUMENT QUANTITY
Controller l/Boiler
Controller l/Bed
Load Station l/Bed
Transmitter 1/Boi1er
. Controller 1/Boi1er
Control Valve l/Boiler
Transmitter l/Bed
Controller l/Bed
Damper Station l/Bed
Damper Positioner l/Bed
Transmitter l/Bed
Transmitter l/Bed
Controller l/Bed
Control Valve l/Bed
Recorder - l/Boiler
Transmitter
Valve Station l/Boiler
Control Valve l/Boiler
COMPUTER
C# UlitBd engineers
& constructoro inc.
8 subsidiary of Raytheon Company
COMMODITY
Stearn Pressure
Stearn Pressure'
Combustion Air Flow
Combustion Air Flow
Coal Flow
Dolomite Reg. Flow
Coal Feeder
Coal Transport Air
Stearn Flow
Feedwater Control
One Westinghouse PRODAC 250 process computer system.
STATION BATTERIES
Two station batteries rated 125 V d-c, 60 cell, lead acid type
480 ampere hour at 8 hour rate.
BATTERY CHARGER
Two static rectifier type battery chargers rated at 15 kW
each, 100 d-c amp output, 140 V d-c output.
J-46
-------
C# mired engineers
& constructors inc.
a subsidiary of Rsytheon Company
Account No.
POWER INVERTERS
Two 10 kW static type power inverters for instrument control
busses.
DISTRIBUTION PANELS
Two 125 V d-c power panels 200 ampere main bus with branch
circuit breakers rated at 10,000 amperes i.e.
Three 120/208 volt, 3 phase, 4 wire instrument panels each
with mechanically interlocked 100 ampere main breakers and
30 branch circuit breakers.
Ten 120/208 volt, 3 phase, 4 wire lighting panelboards.
Two
480 volt, 3 phase, 3 wire power distribution panelboards.
LOCAL CONTROL STATIONS
Approximately 50 miscellaneous local control stations consist-
ing of essentially NEMA 1 enclosures containing:
pushbuttons,
control switches, control relays, motor starters, terminal.
blocks, etc.
PLANT COMMUNICATIONS SYSTEM
One plant communication system complete with speakers, hand-
sets, amplifiers and communications console located in the
control room.
J-47
-------
C# mired engineers
& constructors inc.
a subsidiary of Raytheon Company
Account No.
LIGHTNING PROTECTION MAST
Lightning protection masts complete with air terminal and
baseplates.
CATHODIC PROTECTION SYSTEM
Cathodic protection is provided for underground piping and
other vulnerable plant equipment in the vicinity of the
river.
J-48
-------
4.
AL TERNATE HEAT REJECTION SYSTEMS
J-49
-------
CI mlt8d engineers
& constructorn inc.
a subsidiary of Raytheon Company
FLUIDIZED BED BOILER COMBINED CYCLE PLANT
ALTERNATE HEAT REJECTION SYSTEMS
1.
INTRODUCTION
This report presents the design and economic evaluations for the utilization of
natural draft and induced draft cooling towers in lieu of once-through river
water cooling for condenser circulating water for the 635 MW Fluidized Bed Boiler
Combined Cycle Plant.
It is recognized that optimum conditions have not been realized for each of the
alternate systems.
The use of cooling towers in lieu of a once-through system
would require a complete re-evaluation of the turbine steam, condensing and heat
rejection systems.
The cold water from the cooling tower will be at a higher
temperature than the river water used for once-through cooling.
This will result
in a higher condenser pressure, affecting the station heat balance.
The site land area is sufficient to incorporate either type of cooling tower
within the established boundaries.
The accompanying equipment list and cost estimate show only those accounts
affected by. the substitution of cooling towers for once-through river water.
All other accounts remain as shown in the basic reports.
No evaluations of maintenance or operating costs for induced draft towers are
included.
2.
COOLING TOWERS
The natural draft towers consist of a concrete hyperbolic shell supported by a
foundation ring on soil.
The internal fill consists of asbestos-cement board
sheets supported by a concrete structure on spread footings.
J-5l
-------
CI tnilEd engineers
. & constructors inc.
,8 subsidiary of Raytheon Company
lnduced draft towers consist of a structural framework and fill support system
fabricated from, treat~d lumber supported on the cooled water basin.
Fill mater-
ial is fire retardant polyvinylchloride.
Fan, gear and motor are supported on
a structural steel framework.
The cooled water basin-is constructed of reinforced concrete with an overflow
sump for removal of blowdown and for draining the tOwer basin for silt removal.
The basin floor is sloped to the de-silting sump mentioned above which is fitted
with a sludge valve to allow for removal of silt.
All towers are 'provided with drift eliminators to reduce entrainment losses to
not more than 0.2% of the circulating water flow.
Also provided are access
stairs and platforms, lightning protection system and a de-icing system.
Cooling tower design conditions assumed for this report were 15° approach, 70°
wet bulb and 50% relative humidity.
Quantity and resulting heat rise of 'cooling
water are approximately the same as the basic plant with once-through cooling.
A greater heat rise would reduce the quantity of water required and permit a more
efficient cooling tower design, but the .condenser operating pressure would be
increased. .
3.
CONDENSERS
When a cooling tower is used for heat rejection, the condenser will operate at a
higher pressure than with a once-through circulating water system using river
water.
The higher initial temperature of the cooling water to the condenser and
the increased temperature rise result in a higher condensing temperature which
corresponds to the operating pressure of the condenser.
J-Cj2
-------
...- m~~o!ugineers
~ B subsidiary of Raytheon Company
A condenser pressure of 2.5" Hg. has been assumed.
Condensers are two pass de-
sign with 46 ft. long tubes.
The material selection is identical to the basic
plants, and the number of tubes has been adjusted to maintain a water velocity
of 8 ft. per sec.
J-53
-------
Account No.
C# mitBd engineers
& constructors inc.
a subsidiary of Raytheon Company
ALTERNATE HEAT REJECTION SYSTEMS
EQUIPMENT LIST - MECHANICAL
POWER PLANT
HEAT REJECTION SYSTEMS
a.
Circulating
Water Pumps
b.
Make-up Pumps
Cooling Tower
J-54
Four horizontal centrifugal pumps,
motor driven, each to deliver 80,000
gpm at 80 feet TDH; 90% efficiency;
590 rpm; 1800 BHP.
Each with 2000
hp, 6900 volt horizontal induction
motor, 3 phase, 60 cycle, 600 rpm.
Two vertical sump-type pumps, each to
deliver 5000 gpm at 20 ft. TDH, 80%
efficiency, driven by 50 hp, 440 volt
motor at 1200 rpm.
Pumps located in
intake structure similar to service
water pumps.
a.
One hyperbolic natural draft cool-
ing tower designed for 70° wet
bulb, 15° approach, 18.7° range,
50% R. H. and 320,000 gpm total
water flow.
Overall dimensions
390 ft. diameter at base, 400 ft.
high.
or
-------
Account No.
Cooling Tower (con't)
Traveling Screens
Variable Weir
CONDENSING SYSTEMS
Condensers
J-55
C# ~~~~~~!~~~~
b.
Two induced draft cooling tower
units, each with 8 cells, designed
for 700 wet bulb, 150 approach,
18.70 range and 320,000 gpm total
water . flow .
Unit dimensions:
288
ft. long, 75 ft. wide and 65 ft.
high .
Total fan hp, 3200.
Two screens, one to pass 10,000 gpm
to Service Water Pumps and one to
pass 10,000 gpm to Circulating Water
Make-up Pumps.
Not required
Two single stage, two pass surface
condensers with fabricated steel water
boxes and steel shell.
Each wi th
condensing surface of 220,000 sq. ft.,
18,300 one inch, 22 BWG, 46 ft. long
#304 stainless steel tubes (9150 each
pass) .
Condensers to operate at
pressure of 2.5 with 320,000 gpm water
from cooling tower (tube velocity,
8 ft/sec).
-------
5.
CONSTRUCTION SCHEDULE
J-57
-------
II:
~
.
C# mltBd engineers & ccrstrucUJr9~ 635 MW Fluidized Bed Boiler
Proposed Proiect Schedule Combined Cycle Plant
J.O. 9729-01
Date: 6-1-71 1st Year 2nd Year 3rd Year 4th Year
J F M A M J J A S 0 N D J F M A M J J A S 0 N D J F M A M J J A S 0 N D J F M A M J J A S 0 N [
En2ineering c
Preliminary ..... c
Detail -- - - - - - -- -
~ u
Q)
Site Clearance Excavation I-< ~
Q)
..... t.:)
D ......
Yard Foundations Intake Structure - ....
I-< ~
oJ
Buildings & Structures CI) CI)
Foundations V "
Structural Steel
SUDerstructures - - -
Boilers & Flue Gas Processing
Roilers
SeDarators & Ducting
H?S roen CO? '. r.l"II" Plant
Turbo EXDander - Compressor
Coal & Dolomite Bins & Conveyors
c
Yard EQuipment & Auxiliaries .::;
Tanks PumDS Q) oJ
C I-<
Stack .D Po
Diesel & Gas Turbine Generators ='
E-< ......
0 .:::
Generators & Auxiliaries " !;:
Steam Turbine Generator - - -- ~ ~
Gas Turbine Generators - - - UJ u
Condenser " ~
Stack Gas Coolers
Heaters & Water Treatment ~_.
P;n;ne> -. "" - - -
Instrumentation - - .- - -
Electrical I- - - - -, .
Systems Check Out & Start-Up
Preliminarv Operation
3-59
-------
6.
COST SUMMARY
J-61
-------
635 Mw Fluidized Bed
Boiler Combined Cycle Plant
June 19, 1971
SUMMARY
Account No. Labor Material Subcontract Total
10. Land and Land Rights "Not Included"
11. /Structures and Improvements
Yard Work $ 900,000 $ 550,000 $ $ 1,450,000
Boiler Module Area 840,000 900,000 1,740,000
Turbine Room and Heaner Bay 2,465,000 1,885,000 4,350,000
Control Building 420,000 400,000 820,000
~ Serv~ces ~u~ldipg 1,675,000 1,235,000 2,910,000
I Administration Building 383,000 407,OQO 790,000
0\ Intake and Discharge Struct~res 850.000 470,000 1. 320 .000
w
Total Structures and
Improvements, - 7.533.000 5.847.000 13,380.000
12. Boiler Plant Equipment
Steam Generating Equipment 750,000 7,500,000 8,250,000
Draft System 3,030,000 8,180,000 11,210,000
Coal Fuel and Equipment 341,000 709,000 5,900,000 6,950,000
Ash and Dust Handling System 175,000 175,000 350,000
Dolomite Regeneration System 1,769,000 2,361,000 3,920,000 8,050,000
Other Mechanical Equipment 705,000 8,695,000 9,400,000
Instruments and Controls 695,000 1,275,000 1,970,000
Miscellaneous Suspense Items 50()~, 000 100.000 600.000
Total Boiler Plant Equipment, - 7,965,000 28,995.000 9,820,000 46.780.000
-------
635 Mw Fluidized Bed
Boiler Combined Cycle Plant
June 19, 1971
SUMMARY (Continued)
Account No. Labor Material Subcontract Total
14. Turbine Plant Equipment
Turbine-Generator Equipment $ 828,000 $11 ,042 ,000 $11,870,000
Circulating Water System 1,336,000 1,274,000 2,610,000
Condensing Systems 950,000 2,520,000 3,470,000
Feedwater System 1,285,000 5,070,000 6,355,000
Other Turbine Plant Equipment 1,409,000 1,531,000 2,940,000
Instruments and Controls 200.000 585.000 785.000
Total Turbine Plant Equipment, - 6,008,000 22,022,000 28.030.000
c...
I 15. Electric Plant Equipment
~
~ Switchgear 135,000 695,000 830,000
Station Service Equipment 410,000 2,800,000 3,210,000
Switchboards 121,000 459,000 580,000
Protective Equipment 150,000 90,000 240,000
Electrical Structures and Wiring
Containers 1,196,000 414,000 1,610,000
Power and Control Wiring 1. 931. 000 869.000 2,800,000
Total Electric Plant Equipment, - 3,943.000 5,327,000 9,270.000
16. Miscellaneous Plant Equipment
Transportation and Lifting Equipment 50,000 190,000 240,000
Air, Water and Steam Service Systems 757,000 703,000 1,460,000
Communications Equipment 85,000 55,000 140,000
Furnishing and Fixtures 55,000 365.000 420.000
Total Miscellaneous Plant
Equipment, - 947.000 1. 313.000 2,260 .,000
-------
Labor Material Subcontract Total
$ 51. 000 $ 779 ,000 $9,820,000 $ 830,000
26,447,000 64,283,000 9,820,000 100.550.000
635 Mw FluidizeQ Bed
Boiler Combined C~cle Plant
SUMMARY (Continued)
Account No.
53.
Station Equipment - Transmission
Main Power Transformers
Subtotal, -
91.
Undistributed Costs
Engineering Construction
and Field Supervision
Temporary Facilities
Construction Equipment
Construction Services
2,800,000
1,670,000
375,000
380,000
5,225,000
- Management
<=-i
I
0\
V1
Total Undistributed Costs, -
Subtotal, -
31. 672 ,000
Other Plant Costs (pnclqssified)
Operator Training' .
Spare Parts
Owner's General Office and
Administrative Cost
Total Other Plant Costs (Unclassified), -
Subtotal, -
31, 672 ,000
Normal Contingency
Subtotal, -
June 19, 1971
7,110,000
750,000
3,665,000
1. 250,000
12 , 77 5 , 000
9,910,00Q
2,420,000
4,040,000
1. 630,000
18,000,000
77,058,000
9,820,000
118,550.000
100,000
750,000
100,000
750,000
1. 000 , 000
1. 850 ,000
1. 000 ,000
1. 850,000
78,908,000
9,820,000
120,400,000
7,300,000
Escalation 7~% per year (1975 Operation)
Interest during Construction 7~% per year (3-1/2 year schedule)
127,700,000
23,900,000
19,900,O~0
Total Estimate, -
$171,500,odo
-------
635 Mw Fluidized Bed
Boiler Combined Cycle Plant
SUMMARY
Account No.
Labor
y
I
0\
0\
Alternate I Induced Draft Power
Net Additional Costs
Undistributed Costs
Other Plant Costs
Normal Contingency
Escalation 7-1/2% per year
(1975 Operation)
Interest during Construction
7-1/2% per year (3-1/2 year
schedule)
$825,000
Total Net Additional Cost
Alternate I, -
Alternate II Natural Draft Tower
Net Additional Costs
Undistributed Costs
Other Plant Costs
Normal Contingency
Escalation 7-1/2% per year
(1975 Operation)
Interest during Construction
7-1/2% per year (3-1/2 year
schedule)
300,000
Total Net Additional Costs
Alternate II, -
June 19, 1971
Material
Subcontract
Total
$1,155,000
$1,200,000
$3,180,000
No Change
No Change
180,000
620,000
520,000
$4,500.000
1,000.000
3.600.000
4,900.000
No Change
No Change
300.000
980.000
820.000
$7.000.000
-------
7 . PLATES
3-67
-------
PLATE NO.
I
II
III
IV
V
VI
VII
VIII
IX
X
XI
XII
XIII
XIV
xv
XVI
XVII
XVIII
.... m!!!~o~~gineers
&;I a subsidiary of Raytheon Company
635 MW FLUIDIZED BED BOILER COMBINED CYCLE PLANT
MECHANICAL
TITLE
Composite Flow Diagram
Performance Diagram
Site Plot Plan
Plan @ Grade Floor - Elevation - 18'-0"
Plan @ Operating Floor - Elevation - 58'-0"
Mezzanine Floor Plan
Elevation
Flue Gas from Boiler to Gas Turbine - Isometric
Plan - Gas Piping from Separators (2-2nd Stage Separators)
Elevation - Gas Piping from Separators (2-2nd Stage Separator)
ELECTRICAL
Single Line Diagram
Start-up Sequence Diagram - Sheet No. I
Start-up Sequence Diagram - Sheet No. 2
Start-up Sequence Diagram - Sheet No. 3
STRUCTURAL
Steam Generator & Storage Bins - Concrete Foundations
Steam Generator & Storage Bins - Structural Framing
Steam Turbine Foundations - Plans & Sections
Steam Turbine Foundations - Cross Sections
J-69
-------
CO,
SCRU8&ER
SVSTI!:M
r------r---------~
I I I
I I I
I I I
I I I
RMI..
COAL
,,10R~1
alLO
':;poa TON
CiI"I."'"TOR
~
I
.;
~
~
1
I
__~ll!l!T-L-__J
INI-rl.A.l CHARGE
OF OOLOMI1l!
r-- T1> SfAQ('
r~--1~
p'.",u,"" Q' ~'l
com«'" . .... ,....-. ~
~I ~
r-- _I,,~ fl'
50..105 fU 8
I ,
:~CJMCi .. .I i
I GA& w'
I PROQue ~I
F"ROM =
BOIL.ER -..::
rRo,,", BOlLE fl . 3-
FRO"" 8OU.4R.~
FRo"" eOIl..e:R.-I-
SURGE
VESSEL
..,
,
SURGE: aiM {
COA.L FUD
~YSTfM
~I~ ~~~:J:
8
.
°
.
o
~
f~
- ~
~o
":;
J
.J
. .
. -
,
BOOS1Ut AIR
""'PO<"'"
",-UI! (iA$
,R'"
STACK 6A5 COOUR&
635 MW FLUIDIZED BED
BOILER
-------
I ~~
I ~~
-0
u
I;.
I ;~
I I
I I 4aO.7F
I I .65. h
Ixi
I~
PI
I ~I
I "I
I~ .
Lt~---- -- --_~::'_~6::"___- --
-=------------,
I
I
I
I
I I
L = - ~..:!:~ _8~.~ _t!!~ - -~ ~...J
IIOILUI MOOULE
ci
%
..
d
"
0
0
'"
'"'
~
-------
@
z-..
+~
@
00
y.
@1.
@
(0 &011£3 .@ CLAUS PLAIoIT & .suLfUR UIoUIII&
@ lUll&INf &AY @ COt A&SOIl&EIlS
0 HEATE Il lAY @ REGEIoIERATORS &,suUS! VUUL
@ S10IlACiE BINS @ DEAEIlATOIZ
0 ADNllloIlSTIZATlOIol BLOG;. @ ASII . DOI..O"Un 811..0
@ !WtTlCULAT£ JilEMOV4L E'QtJIPT @ WATEIl STOIl'Aa TAIJ"S
CD GAS TUIl6INE GUIEIl'ATI:I1?S @ lIGIlT OIL TAN I(.
@ 5TACIC 6.0.5 COOLE;Ii!S @ LIGIITOIL U>lLOADING pUMP
@ STACie:: @ ClIlCUI..ATIIIIG WATER I>JTAlCE PlpE.'!>
@ 150 TON SURGE 51101 @ PA_ING NUiA
@ Ii!ECSIVIIoIC, IIOPP~ @ GASES (5TOIZAGIi):
@ RECLAIM IIOPPE~ @ FILT€I1ED6 FlU ~VICE WATEIP TAII/"
I
@ SILO (rz,ooo TONS) @ SEINICE WATER PUMP !lOUse.
@ 02YER @ CII!.GElSO,OOOlU"'S) @ ClHDIZINATIOtJ EQUIPMVIT
@ WATEIl TlZEATM[IIT @ VAIZIA&LI! WEIIlS
@ DIESEL GENEIlATOl' IilOOM @ 5""TCII VAIlD
@ COIolTIi!OL Ii!OOM @ CONVEYORS
@ M-'CWINE SHOP @) DOLOMI1£: SOLO ~12,OOO TO,",S)
@ TRA~FOIlMEIZS @ 1'1 I I..L
38
NOIl1~ 121VE£
PLOW.
SITE PLOT
PLMJ
0) JO
I I
100 100
I I I
.KML
)DO
I
635 Milt' FLUID/ZED BED
801l.ER COMBINED CYC"£"
,PLRNr
SITE PLOT PLAN
".....- II -
PLATE ill
-------
p.R.
OIL UNL.OADING
ST"'rION ~
~
m EMEIi!GENCY -GAS-
. Tt/IIB/IIE G£II.
J./GHT OLL
~ GAS TURBINE
. GtEN.
~
CONOENSII.TE
POL.ISHING
EQUIPMENT
ADMINISTRATION aLI)/O'
I
R.R.
CO""OENSE~S
o
<
o
(II
CLEAN" OIR'T'l'
OIL. STORAGe
ROO,""
COOLING WATeR.
EAT' EXCHANGER AtPlJ
MAIN t STARTUP
fffiM'M
c......e.
ReG. 'F.elfTlJl!"
~~"
19iJ5<:JA'JJE4.
G- Ct:)e S1'SMl"?
- ~- . h TR;l9rE~ WIlTE"R
. S'fr)M6* 'T19NK
@~~~ W"T'~.e
I 'Q.4~ AI.
- !
I . -- .
. -
I
E[11 PNC'/""lm~
(0 P T'I OIV 19'
i COIVOENSArE
, SrDR.4<1iF mAlK
. ~ WATEf\
X !.R E....rMt:NT
'.
\...
DiIESEL..
r..E.N. R M.
"
"X-'
/~.. I
.-~
/
/
PLAN
@
GRADE
EL.
18'-0
FL
o ~ 80 1'2.0
I - ... --------
sc. 1'\ L.£. -
,
~D
C:HL.O~INATION
EOUIPt-IIEN"T
5
'"
5Cf\EENS
$FIRE. W"TI.R TAN'"
+ ~ NORTH RI"E~-
; 1
; FLOW
,
Q
<
o
IE:
H1. $ c. o~
STOR~.
~.35 MW ;:;'VIIJIZED BED' 801i.6~
COM SINE/) CYCI.E 'plAlVr
~19/11@' G.eI'9IJ£ /io".e - EaY.4nON /B
-------
~ASH AND
~ lJO'OMnE 51'0
5U2GE
P.l?ECIPlrA7().€~ ..AL!!L
(OPTIONI"IL) ~~r~GK 6'A~
. g _COO~t:,E' OIlers
'. CL 1.15 , . PA,er/ct/~ATG
. z IV ' REMOVAL Et)(/IA
24/0 S7Jf6E 'O/~,e ,
SEP"q,eA7ZJ,Ii!~ I
!
ROO~
(/IVLO,llOIl"l6 8,q Y
.:j7'ACK
I
! '
I
~ TU/!UJIN£
i G£1V£/MTCe ,
: I
,.
/ sr S7'»ti1E
S£PAeA?D1e
"
; ',1 :' I
1.1 I. I
I J I I
I I I
II I I
I I I I !
I IT .frAtf~ 5E,PA,QA Tb.t!
2#OS~1
~ Se.PA.lATZMe I
'smclt' GA.$
c'O'O~ PV~".$
srORAtiE 'x' I /:
.!fINS i / I
' \ 1)(' ,
. H\.
X' . AfbcF X
'-,
P-elCIPITlfn1,e
( OPTION,qL)
,,/
OPERATING
FLOOR
58'-0
EL
o 40 eo .to
1_I11III_liliiii_liliiii
SCALE
~
S3S M W
T.G. UNI"
"6NMATf:)fl
61(CI nF,£!
~35 MJr. hV/D/ZG"O 8FI) BOI,~2
COM8/NFI) C-Y~tE A-'1N7
Ope-eAr/IV<$' ROO2 AAN Et.E~ stRi.
UNITE/) ENO/NEEI2S ~ awSl%'. lAIr. PN/tA~ ,qr.....
PLATE Y .
-------
ROOF
STORl'ksc 11111\15
Ii
6~ ,qND SfZ"IIM
CONa£N.J£.e
MAIN SrT,A1V1 ,sn,r>
'A, VI~ .lCO/Vl'RCi.
I/IN. Vir $
#EArr,es
S7l:JRI4t$E 4/N 5
MCC
I..~
MEZ ZAN/NE
FLOOR EL. 43:0"
o 40 80 /20
1_liliiii_liliiii.-
SCALS
0.35 M/IlI. /"Lt//OIZED .f)cl) 80n.t:-R
COM81NcO eyC, E PL /1/11 T
MEZZANINE FLOOR ~/91v'
IINITE,o E#G"INI£E,ES &C-ON,slE lAIC ;:;'J/tA,~ENAI;tI.
PLATE
"SZI
-------
El,/i)A £"IJ!o "I
.. ~.sTAc::K
~ C.I1.1lA.-v.. ~TE H£GE/ilEIi!,q7De
T ;<'IYiEN ;'R.Q7l),e ~""STeM ----.
. ~O~ A8SD£SE.e I.
/- 'CC/I'/TIITD,q- .5, &,&;.$. H SOlLER r
(oPTIONAl.) . ' ~
I ",COft t;.R T/CUL p71( - ..... r-.
i ~Y57E/VJ 'EMtlYI9L £f1UIJP. ~
CLAl/,sJOt.ANT . -,;;;~ I'~-~ ~n-'~ i .
CONOENSATE"\ .: '(, ~I'\' /1 - - =-- :EI!
SToR.41f£ TANI( _\.------ - 7 I ~: i /~ I: I 1.-LJr.
.oeM'INJ?;eAUZ£D_~ "~- --r-~ : I ~ 7,. J j.. I! ; JUII I .
w/!JTFe.srDlI1/kif1! ~ ;---..., I t5<.-t'-1: I: I,.' I Ms: ~. ~S
~~~-~~Y . "~~'I I I~'! " : : . t g-[ ~nmij Ii
ROAD J/~~ H !r,!. l/' 1 ill 1['. rt WlI., . IT]
S1J:Ic /(. I I I
T;QN/(S- ! .+. llWnaN/Je4 l,J:
I I ~f ~
DI$II:H fUAlNtR7
, Tl/.eB/NI 4E1V~
STDe..4~E 8/N~
"f E JIIE.eA7ae
.~~
CH""'~
. ,
~
~~1
i!!!:J!!£ -
A.1DP of 7f!/VS3 £U~ IS1!o'"
j.OhIB; (#II!? crtlllA m~~
I ~ 'MINISTlPRTlON B~Cti.
\\. J:--1'l2/JN$IW?M'{7g
r+, ~ ,Ii
I I I 1 £i!PJl.
.,
-
ZC/PG"'~ J'#IPII
~ t:11?~ WIIITl?I2 ~P$
rrt"!i~'::. /~Q.
g ~f'P#~
I ~:~=:to'
G 35 MJ.-Y.' Ft. UIOIZEJ) 8EL) i301L.E,E
COM41NE CYC~$ ~~~Nr
ELEV/lTiON
11#17£0 £/tItS//tIec~$J cDiVSr"'- lAIr. ,911~JII., ,P.I'~
PLATE :w
-------
'1
"
-~5k
" r-~
I ",/i
I .
..>~~
.... I .
~+
"
~:
EXF>ANS/DN ..feIAiTS AR. ...wOMlI'J /'iJ.e &;j.De
Moou'E N!'~ 'T't'l"lrAj. ..- H!' /?iI,j ;N~j..
w~5A1W: ~(UII)/ZE[) 6ED
BOIUA? COMBINE/) CYClE
'pI. .4/VT
rzuE G'tl/5 r.ct::>M &7/LE-e7ZJ
5"q.s rU'R8//VE. /SO~J'ZIC
t./F tlC. f?h'M"
PLATE 1ZIII
-------
GAS TUA!GIN4
C;cN.
~
/ C 4'=
5Y.s~M
",.
"{
I ' ,
. +, '"
r:\",
. "+/ '"
. eol ',,-
'A650..;8€K.
/
~TAC)( G~S
COOl. £~
---
PtJEL OIL-r+-,
;:V/V1P~ ~
Pl'Illi I c.l.lt. Ai'll
~"/ItI10VI4, /:f;tjIP
f Soll.E~
I /V10"UL£~
I
i
, I-IO'DIN6 V~ $51:7..5
~800 S7~.E "';11(2
cO"",If1~~ 55 ,,£
°
0: ' GA5
I ~. ~. ~~4F~Ee
..()=(), , . ;
I! j
I I ,:
. 1 I ! I t
. "0
&- 6-E/t/£A'A 7b~5
2EiJU~iN6.
Va 5S~1.
1°
t.
r
- ----- -
rp
b;o*:
'Q:O::
10(l.
:00
.... ;... .
"'j
T~~/N4"
"eo C) /';f
...
.. . ...
"0'r::J~ :
o .
.Oi8~
-+Q'O!
l__~
s roR 196 E IiJ/AI S
'Cc;oJ'rt:.'oi.
,e (; (,.".-1
PLATE IX
[CIU'lIr 8RFAJ/Y.: -;3~~~ ~;UI/)/ZED 8£LJ 8cJ~LGI2
AN4:J T~ANS. : _C0/V18/N£J) C-YC'-E p~' A/\/r
~,4.s ,P/~/N<:I /"1201''f SE~~/;?~/-C.2 S
1/ E ~ Co 1'111'14 ~A. .5/e8!71 .. ..
-------
I
;
,
! !
. i
PLATE X
~3~ UK/. ,rLt/IO/ZED 8';1) BOILc,C"
COM~/A/£.O cY~~ c Pi ANT
G".4S P/p/I./($ ,J:/2D~ SE.P~RfiFo,e6
£i.EYA71oN ~1/71
t/~4c ~11"
-------
13e.~\1
JJ,~I'
*IW ~ ~NS~. ~
IISM.A W r.oHl
FQ4 'ZlKV-I~K" t!.
345""
MA'N PtIIIEIZ ~IOAHS". I )C'"
600MVA'S4l,60HZ ~
0:0" 'Z'Z1CV-345KY t!.
GUlfl1:A,TOII'
S97,17~KV" ~9PF l
'Z'ZKV,~C),60H~ e }'
~ . "'EUT~AL CO~UIIOIIJG
~~:: ,.".-.~-'"~,
~ GA!> TU~5I>lE G,E"!;~,OIZS
. 5',&518KW E:A,-Z'Z\(V 3/t>60l'l
~T"I[T.Ue> '1I.I1t&llle!
aell&.ItATOIt.
t!.
STAIZT UP mAI/!oF.
"ZOIo!VA. S~ ~HI -/.
FeA UlC.v. 4.16 I{V .r
AUI<. POWEIZ ~1UIISF.t!.
'tOM"A-3Q,COOHl F'OAo
'Z'2:K\I-4.:I'..1I t
'f 'f t
¥~l~Jf~
. ~
.. 0
.. ~..
ti-~~ ~
In.' ~
~~ d ~~
3~ 8~ ~6'.
+) ')
f t!.~1'500ltooo..v"
e """ 4.1(,1CY 4&oV
'"t ~~ 'OH~
..~ f)
~~ t
tit' '
0:1,
i8
'0
>-2
~~
~~
is
~!
~
.~
:Z1E
i"
":z
:>-
,..t-
..
!~
~ ~
~j f:"--v--J
CLAu5 Pl.AH~ ~ ~ co'Z SC~Ut!.&EIl'
UHI~ sua L..........J UI/IT !!oUS
H!4A N!4& )
6 ,_/1:0001(..4
~ 4.I'KV 4aOV
lf A ~~, (,OH~
- t)
~
Y TU~I\I'IE 5'I;..'r. 460V !I~ 6OH~
1111111
;:u ,",0 ~u
Zu o. c) It'"'
..? Z% ~:);
2., ~U\ >-V)
~~ ~~ l:~
f!~ f!~ k1~
~~ ~~ ~~
""OO/2t)OOKVA
4.161CY 4SoV
!4, 6OH~
IS
Z
-'"
~~
on.
110
lOt'"
n
f1
~*)
f f
150'~EIl $WGIt 4e.O\l!!~ GOHZ
J. J. J. J. J. J. J.
t) t) t) t) t) t) t)
f f f f f f f
ks .
~
u
>
i1
01
~
..
x
- ~
.. 2
:z ..
.,0.. :I,
6 . III~\(VA ~~ ~~
T 4.1'''' ~V" ;:\~
X !I~,(,OH~~:% 2:::J
* - ~~ a~
t 3~ 9~
¥
Y
n. I
..J 8
,.." It
~t; 8J
~~ ~~
d ..~
v~ i!o
PLANT C:OhtIdOIl S--'G ~ Io/! I ~I!.ov a~ &OH~
~ ~ ~ ~ ~ ~ ~ ~ ~
!l!!ffff
.-; t-I 80
:..'" .. .,
c; Q. Z %
-zZ ,,0... ,,~
::;~ ~ii'x ~~
~.." "i
tj~ g~ 8(1
D to OG)
pbl DfIt Q
gS ~t fiE ~
u~ u~ c;. iL
) ) if) if) if) if) if) '\ )
! iff f f 111
~ &l
~ I!'
~'" ~:..
~!Z 111;
-0. ~Il
~:s: >~
::~ ~~
..
z
0.
:I
d
,..
~ -
~:1 ::I 02
"I IJ~ ..
~~ ~1 ~~
"'I':' ~~ ~o
~" :::i'" _III
~~ ~;. M'
v
U
I
'"
"
~
- Qt'J ~...,
o. tio, NU tIl
~~ ~~ :i~ ~~
i5 Q I.. ;S~ ~:z
..J11 ~a ~II >0..
-j! -II -Iii "':1
it.. ~., ~>- W;J
",II. on ii:n.
I?>e. KV
61 !!>~"'- c j!~ 46QII1Q.tQa
~- ..~ C>.ii1 T IN~n:UIoII!N~
".. ~ ~ =='1 TIU-N~I!;:
~2 IO;C t-
i~ ~~ ~~ )
~i1 . Ltov AC 1-
.. 0 "
~ 8 ~"
g . g ~1
iI ~1 it~
~i
U
5ATTE~Y
C:H"IZ:Qelt
'51(.W
..
Z
t/
..
..J
o
II
N
..
2
~
"
S
t!
:\~~
A~o
6.~-
rto/ZO&V ~,4W i
''''$~It. eu~ N! 'Z i
I I) I)
) 1 1
if) )
+ .
4-1. 4'&OV SW(;~ N~'Z 3~ 6OH~'
if '- ~ ~ ~ ~ * ~
. J ; ; J ; ; i ;
~:r+~~~ I; ~@~
t w: al ~! t~: ~
..) .~ 80 ~ ~D I!!~ /!!.. n
~ .."::.." (TIS '0(0.
~= ~~ ~F ~~ ~~ 1.2 S~
, ..0. >tal ..It 1"111 ".. z;" =>:1
8~ ~g <~ ~~ 8~g ~~ ~1< 6 1500/'1:000"""
IOU .,111 "" 1'"<::1 II> ".. 0) 4.1'I<.V 480"
t'T!!~,GOHf
if)
i
11/
.,,,
~ti~
0"0
D.~-
"
...
2
11/
.
..J
~
r
1'2&" oc ~TT!IlN~O CYCLI: PLANT
ELec.Tr:lCAI..
Slr.lGL.E LIN~ OIAG~M
g......-....-..
PLATE XI
-------
"'U
r
»
-t
fTl
~
TO IF> STEAM Tu~e.I\.Je
TUR:elll,ie'
STOP VAI.Ve
ItEHeAT ST!AM
FJC:OM HPTURe,IN&
F~OM MILER:. 'Z.
FR:OM BOII.ER: 3
F"R:OM 801l.ell: 4-
TO HP TUII:I5IIJE
@
@
<9
@
@ @
CID
TO CO~D~t-JSA.TF.:
COOI.Er: Ii- POLISH.
It-JG, eQUI~J
@)
r
1
I
-i
I
I
1
--...I
CD
@
cot-JDeNSATE
PUMP
i=~OM HEA.TERS
N~"Z,3 ~4
@
I>l.
VI-
~i
D. VI
22
..t
~1Il
IIJI-
J...J
-w
0::>
IOu.
@
TO 101'" HEATEItS
NS'647
@
@@
15011.E~ MODULES
A
( N!Z ~~3 N~~l
F~ON1 I.,P. H EATER ~
@
@
STACK GAS
COOI.ERS
'A e.OILe.~ 'E5 .
FeeD
PUMPS
eOILeR \.J'!I
COM8USil0t! AIR
FR:CM
HEAnft it 7
FUEl.. O~ioJ 1'2. O"'EN A~ CLOSED
o OPEN il-lJC:OTTLED 4 OPEN 1~ !5Y PASS - oPe\.J A4 CI.OSED
!: OPEl.! & OPEIo.I 14 ~v PASS-OPEN AS Cl.ose"
F CLoseD G OPEt-J I!:) ~y ""'55-opeN AG CI.OSED
G CLoseD 7 OPEN 1<0 15'(' PASS-OPE'" Ai CLOSED
H CI.OS!!:D 8 OPEN 17 OPEI-.I
I Cl.oseD '" opeN 18 OPE:1o.I
J CL.OSeD
I<. CLOSED
L. CLo~eD
I,jOTE:: IT HAS ~ee'" ASSUMED TI4Io.T ~~ A COLO
r. TH~ PI..At-IT WATER: svsTeM I-4A5
~EeN Pl.A.CE:O IN OPER:ATION AND
DeMINe~ALIZED WA"TER \oIAS 8E&I-.I
USEO TO 1=11.1. TI-IE! co"'ceNse~
1. "'HE SUR:Ge .,.AIo.II<. HA'S. E5EEN
FILLeD WITI-I DOI.OMI"Te
STA~T-UP ~UeNce THAT
ZI. TI-4 e PLANT <:OAL AND DOLOM Ire ~EEOIN~
SYSTEMS HAve ~eEN PI.Ac:eo It-J OPE~ATION
A"IO FUel. IS AvAIL.AeL.E AT TI-IE STO~ACOE
~INS AND IN.lec"O~S FO~ TItANSF\O~T
TO "THE BED.
VALVe POSITIONING. HOT ~OI~E~ R:ESTAItT
eOI~e;1t VALove:. FEEDWATe~ S,(SU:M--\lALVES . Alit. VALvE':>
Io.!~ POSITION N~ P051TIOlo.! t-J~ POSI'T 1010.1 N! PoSI'T10N
A OpeN-if.lR:OTTI.ED I CLoseD 10 OPEN Ai CL.OSeD
o oPeN 'Z. CI.O~ED 11 OPEN All CI.OS!!:D
C OPEN -rH~onL.r:D 3 OPEN 12. OPE.Io.I A3 ope~
D c:lPI!!N -Tf.lR:OTTL.ED 4 OPEIo.I 13 opelol TO ~OOLE:1t. A.4 CLOSED
~ OPEN ,5 opelo.l 14 OPEN 1=~01<1 COOL.EII: AS CLOSED
F CLOSE!:) ~ OPEN 15 OPEtJ TO COOI.EIt. A~ CLO!lEO
G CI.OSED .., ope~ liO OPeN FIr.OM COO~EIt Ai Cl.05EO
1-1 OPEN 8 opeN '"7 OPEN
I CLoSED ~ OPct.l I~ opaN
oJ" CLOSED
K CL.OSED
L. CL.OseD
IIJOTe ; IT HAS I3EeN Assu..."eo THAT FOil A HO' 1tESTA~T Se!QUEIoJCe TI-IAT
I. Tile BEes ARe I=II.I...I:D WITH OOI..OMITE 'Z.AT LEA'!.T OIoJ= I5Oll.elt IS IN OPE~ATIOIIJ
STAIl:T-U~ seQUEIIJCe DIA.
-------
'1)
r
~
fT1
~
i
n
Fe-ED WATEIt SY5T~M
CI~ULAT~ WATe:1t TO DEA~ItATOIt
ACp WATe~
TO DEAERATOIl.
R:AISe F'Ee:DWA"E~ ~eSsulle
lioJ EVAI>OR:ATOIt ~eD 'TO 600PSI
ItEGULATE It. CONT~OI. VALVE C
R:AISING 1>R:E"SSU~e 1101 EVAPO TO~
BED TO OPEIlAiINC:; PItESSUlt.e
SUFFICI EioJT EIJTHALPY
lioJ FLASH TANK
yes
O~EioJ YALVE (\() AioJ 0
CHeCK CI.O~O
I>OSITIOI-J OF
VALve @
FUEL/ AIR: SVS"T!M
OPeN BOILeR: COM~.AlIt YAL.VE. @
STAItT ~OSTell Alit COt-l\l>~!!SSOIt.
OI>EioJ DOLOMITE TltAioJSPOR.T AlII:.
VAWES FeeOll-JG OO~MITe ~~M
5UItG,E: TAWK TO INDIVIDUAL. ~eDS
CL.ose I:VAPO~ATO~ I~TSUP~ItHI!ATEe
BeDS DOI.OMITI! TItANS II:.T AIR: VALVE Wi-IeN
FL.UIDIZED ~eo HEIGHT lteACHeS 3 FT
CL.OSE 'Z liD SUPEItHEATEIt~~E~i:ATER.
e.EOS OOL.OMITE TR:ANSPOItT AIR VAI.Ve
WI-IE"IoJ QPf;II:ATIIoJ<4 I=LUIOIZeo BED
HEIGHT IS R:EAcHEO
opelJ evAPoRATOIt I ~:r SUPERHEA,elt
I!:,ecs L.IGHT OFf 011. VAL.Ves
EioJER:GIZE 3UR:lJe~ IGNITOilS FOR:
EVAPOltATOIt , I~ SUPEItHeATEIt 6eoS
FILL ~eos TO OP!;ItAT1NG HEIQHT
CHECK I!SE:D TEMPEP.:ATUItES t WHE'ioJ
IGioJl"TtO.., TEMP. IS ATTAINeD
O~ioJ J:UEL T~NSI>ORr Alit VALVe:5
tI '0 EVA?OltATOIt ~ IST5UPf~HE~
B S ~GuLATE Fuel. FEEDING AND
WHEIII COMBUSTION IS SUSTAINED
CLOSE EVA.I>O~ATOIt ~ I STSU PEItHeATE~
LIGHT-OFi= OIL V~LV!S~SHUTO~~ l6""IiOIZS
Pl.ACE EvAPOR:AiO~ ~ I!!.T5UPE~HEA'TC-P.
I3EDS FUEL/All!'.. COioJTR:OI. SYSTEMS
ON AUiOMATIC.
OPEN CMi301J BED COMBU~"Of.l Alit
II-ITAKe DAMPER
ENEp':(iI?E e,U~IoJEIt IGIoJITO~S FOR:
C.A1t.150N e,eD
Ci-IeCK CARf!>O~ l!>eD TeMP 4 WHEN
COMI5USTION IS SUS'TAIN!O SHUT O~F IGNITORS
OPEioJ 'Z 'il) SUPE~HEA"TEI!: BED LIGHT-
OF'~ OIL VAL.VE
EN~GiIZE ~U~ioJEe IGNITOR:5 FO~
'Z."!P SUPEIC:HEATER: e.eD AIoJD WHEN
II3NITION TEMP. 15 AiiAIN!:!)
peN ~uel. TR:ANSPORT AIR vALve
F02 'Z1!9 SUP~HeA'TE~ e:.eD
pl.Ace 'Z'iP SUPE~HE'ATEii:: e,ED
FUel./AI~ SYSTE:M ON AUTOMATIC
O~cN !eEH EATE~ L'lED LIGHT. OFF OIL. VALVE
eioJ~COlze I3UtNER: IGillITOR:S ~ ~EAT
e.EDfWIoIEN IGNIT10N 'TE101P.IS ATTAINED
OPEioJ IOUfL. T~SPO~ Allt VALve
@) FQ~ 1tE'1oI~A.ift ~ED
CHECI<. 151:0 TeMf'ER:A.TIJItE or; WHeN
COM&U5iION 1$ $USTAINeo
CLose LICOI-IT-OFI: Oil. VAt.ve AIo.IO
SIolUTO~j: e,UR.N!1t IGI.jITO~S
pL.ACe R:EHEATEIl I5ED FUEL/AIR.
SYSTEM ON AUTOMATIC
NOTES 4 ~Y""e.oLS
I. IGNliOR: FOR Alit 'aV'. PASS C.OM ~USTOIl
AUTOMATICALL.V 94UTS OF~ WHeN FloUE GrAS TEMPEIZ.
A"TUItE F~ !!SOlLER: IS WITH IN TUIt~INE OPeItATING; LIMI"TS
(
I
(
) O~tJQTeS ACTION
~ e.e jAI(!N
I
)
OeNO"T'~S QPeRATION
'TO ~e: PUFQ~M ~o
oeloJOTe.s CH!!CK TO 81 10140& aer::OItE
Io.I1iI
-------
-u
r
}>
-i
fTl
~
C U\ ()I
; ~ lJI
; >("\01
110 ~O~
="'U\C~~
.Z:x:1JOJ"TJ
'C\fII Zr
ZIl1U\I"1~
11 "'"""rtoo
.. 111 -
ZIQZC"N
Z III '0 (WI -< ITI
),..U)%n
. n ~~(J)
o O.1I~
Z »,
'" "'>0
~ ~Zr
. ~-f111
~ ~ ?J
FeEDWATE~ SYSTeM
CI~ULATE wATE~ THItOUGI-I ~OILE~
THR:OTTLE VALve TO PItOVIDI! LQW
FEEDWATclt F=LOW"TO ~OIL.e~
TI-lItOTTLE VALve @ TO KEEP FLASH
TANK. p~eS5Ulte AT 1000 PSI
COt..ITI~OL It ~EGULATE' POSITION OF
VAlVe. (b) TO MAINTAII-I FLASH TMJK
p~e55UR:e
II-JC~eA'3e FeEDWATei?: FLOW TO ~OILEIi:
DeC~MSE TH~OTTLe OF VALVe. @
OPENIr-.lG VAI.V~
tlltCULATe WA~MING STEAM T141l0UtqH
'Z,Io.IO 5UpeItHE'ATE~
CLOSE VALves @ r$ @
OPEN VAL.Ve. @
I\.ItI<:EASE: pR:eSSUR:~ IN ,ST It 'ZND
SupeltHeATeR BEDS
OPEt-J VAL.Ve@ U~TIL UNiH~OTn.eD
PCSI"TIQt-J I S ~EACHeD
IIJCREASE FEcDWATE~ FL.OW
CHeCK STl'AM FLOW "TEl\I1pe~ATU(l.E
f$ Pitt: SSUIt=
CIR:CUL.ATE STEAM "TO TUltl3lr-.1E
CloleCK H.P. TUItI5INE ~E~EAi SieAM HOW
OPEl.! VAL.Ve @ AND CIoIEc'K.
CLQSED POSlilON OF VALve@
HOT e!IOlLl!1t IlI!START SEQUENCE
DIAGRAM- SHE.ET ..as
FUEL. / AI It SYST!.M
LIQIoIT-OFF ~VAPO~ATOrz:. It 1ST
5uperz:.I-IEATER: l3eo~
OPEt-J COMI3USTION AI~ VAL.VE @
FLUIDIZING l3eOS
OPE-N EVAPOR:ATO~ t! I ST supe~-
HEATER ~eD5 L.1G,l4i OFF OIL VALVE
E't-IER:GIZe I5UR:NER:: lG.tmO~S I=OIZ
EVAPOR:ATO~ ~ 1ST SUPER::HEATe~ BEDS
A~D WI-IEN IGNITION TEMI=! IS ATTAHJED
OPEN FUEL T~ANSPO~T AIIl. VAL.VE!S
@ IJ@ TO EVAPO~ATO~ 4 I STsupe~-
I-IEATeR: ~eDS. RI;GULATE FUe'L. FEEDING
CHEC-IC. lSeD TeMPEItATU~e5 AND
W\oIEW COM!USTIOI.! 15 SUSTAINEO
C~OSE eVAPORATOR: 16T5UpeR:HC:ATe~
LIGI4T.OFF OIL.VALV!!, ~SHUT.OFF 1(iIJITO~S
I=II.L BEDS TO OPER::AT1NIit HE\<;;I-4T
PLACE EVAPO~ATOR ~ 1ST SUPE~'
He~T~R I3EDS FUEL/AI Ie:: COt-JT~OL.
SYSTEMS ON AUTOMATI~
L.IGHT OFF 2ND SUPE~I-IE'A.TE~ gED
ope!.l 'Z NO SupeR: 1-1 fA iE~ I3ED
LIGHT OFF OIL VALVF:.
EIJ EI!:
-------
-- ~. I .. I . <---..-. ..,
. ':::>...."""'I>.~~
,
- -
, t-- I --,-
-' i~-"H3-."
I I
I
I~- ...~ "i-$- .
4 ,;':;,:, t:.t.t-. . -H-. , --r W-
! -. ~~
-- . . 1 ~ -
Fi f\
.,-& t '~'~'... I
r~ ~_-1"'~ -11"-'<..---'
~40:0__- u.f.,-- - _3J-" ~
A @ @
--{
I
Q!
..1
-,
'0
FOUNDI\TION
PLAN
-.
n.
------- u-
rOUNOA., \ON Sc.~~t>\.),-~
'::: T\ti:- 00,..101 .." TO "..
:S..... Go.- Foa~~ ~I'\.~ Co'- 'F~. Ca..Co ,,. f"~~
~~~~~::O ~ '1.4" \'l.~ 104 ,t-O'. .",... j-~4 II~ 912 I 9411
--- ----.- - ._.. -- .. ---4;-' -n~'~;-
n ~ S-o-5-o - ,,,- 1.4 90 1-0 -'2.'0 ICS'O
-~ . -"
I V'.> ! I~ [ ,.0 ''''0 , '1.4' ~~- 12. '1-0 "'t-O tL5-0 I .14 40 !1 107.2, I un.
I rol. I - ~ c----- ~- ---r-r--
i
; fS I & ~ \\.0 -\\-0 . ~o' 11.2 ' '1 l~~
110 'l'~ -'l..'S ..~-o .94 4S I
I i" I 4 i 1'7" ....." .4"" ~J.4. '1H "Z.?> II 1'~ tI S'O .0;14 I 4S I 1~1.4: lIoa
I Fl 4 r ~.". ~." . ,'1.' .45 14 ,.~. ~-~ .'5-0 .'19 lS i ~ I IS<-
,
f I
- r " -.-...--- - .--- - --- --- i ..
-. i
! I
1 I_-
Go"" \"UR,'O\w.'i. V-Guw.t>"-,\ON. 1 lOOOn~
3000 Co"," \1#14.~!u,~S"a
p",. 16 g...,.
t..OOC) ?~, t:lt.u.o..u.....1.( _. 9::t.........,....
\.1. \"t'.o
.
<
o
'-I
"'I
!
I
I-
r.
l
0/1:
t:
-I
cDl
I
o
~
~
~
U1
\'( o;>,c:./Oo.\. ~OO\\~G,
l
3.'.0
I
~
~ 3 5 MW i=lUIDI7ED BED
50lLER COMBINED CYCLE PLANT
STEAM GEN. ~ STORAGE E>INS
CONCRETE. ~oUNDA.TI(jN"5
@l1Iitede09meer.stcoastwctcn lilt.
PLATE x:sz
-------
~
'"
~
~
.,
"
.".
"
~
-
~
.
~
I
1- ...
rt1
i + I
~.'-- j
: "-.. --" .
./.'
'S~C~ION. C'C
I
-~
r' -'[~.-.!.~' . i
-------
.'"
.- ---.-- -----~~. ---
Gr...".,. t--,..- .".,.""",..""", }....,-
7 1"-., i ~ i Sl f7 i
71 I I ~ elk"" "au. - I's"'''a..~. 1",,".lr."c....r IIIU
. ," ,- 1~'IO".'t-~~"t. AIK""" 1\".~~-.....I'oO
I c.uT.I.... ..,... .
31
.~~'rl~
~11I11"TrkI
..
91 ~
1:114... ""'1.L-.o~L. ,.,-..'..-
~~'i...~'..:.'.-~o;~~::,. ~.~G..~u
:... ,,"'. ."
~
..."."
. ..,""
, ":'-/:.
,. , , ' : . ,.'. .: ~,
'"" {.~.;'i;f
~ :~,;"t ..--!- :;~c -:':':
:~ ::; -,' '.,~ .. ': ~,
, '
Q
~
~!r: ,r.'--: ~':'
.
'.
T~....~
,.. ~ 6--
,':'. ::".~ ..~.~
, :' ; :.,'~:'
, ..., ".."
',' "
Q
"~
11.*-"111"
"'EZZAN"N~ F~t:)(:)lfl S~r"':>NA~ P~N
F/M ,"-. £-<,£11. 3#'D
"
.!
L£:of.~ -
"-t'S). .....c'....J"# ,. 'it~'I!"
II"~(;,,. ~ ~.,~..,. ,
/It..(1).1 ,...-.....
II"S'" I/-U'"
.
H
.
. -. ~ ..;.
"
'.," ,-,',
A, ...:
"" OJ
';.
FOUNP,Q T/ON
,,,,, O~ MA"/:' I~£~
PL oPN,
S!<:::J
,..,c..,
1
...~,
.,"..N~
"
. , . ,'~'
: ~ , ' .
. ~" ,'" ~ .:
i.
MR.'''''''''
......,...
£/..EVAr/oA/
I-I
dlyt
~.,,,''a-
0"
'tJ~.
, ,
: ,. .
.' ~!~ ":.;'-""'. " : . :~.:
-~
:.., .. ° '
t.'.
r .,...r
~ A ...
;',:.:: ~:: "'.~ :',,; . ~;'.
, "".":""_',;.,".-..,..,.
. :~-, ..
-,
'. " . "'~'~' -'.-.'" .."',,' ,,~,':,::..-:.;,
f"~1":,,:,
SECT/ON'
2.2
i
,
I
j
!
tO~5 MW FLUIDIZED BED
BOILER COMBINEDC'(ClE PLANT
STEAM 1'U~aINE FOUNDATION
PLANS ~ SECTIONS
(!}lJIlterJ englneers,-,...
PLATE X2I[
-------
---I
.~. I
~6'.O
r~'''''''''''';
. ~"t...,. ,.,".-<,.,-,...,.-
f,' -
"""'~ ".......or
b"
.. ~ '.
. I ~o
o
.~
.-r. .-." 6£. .~!.
.\. ,"
,',
~LcVAT/CJN
3-3
..'."
~:a- ~
, ,
, .'
','
.,
" '"
.seCT/ON
7-7
T' -
I I:!'
'..
I"
I' 1~
I
r-~- ,.,,-"'---~--
.!.~., f' ~
.~
- - .
~~s:*..~.
J.
~
,...,...,:.,
.
~
",
.
.~
:;eCTION 4.+
, '
SECT/OIV
8.S
~
SECTION
5-5
.-to
-.
.
"
.s~C7/0/V
9-9
1'-1
t
.
t
--,
SeCTION
':;-(0.
.....
I.~#"'~'t
, '
,,'
'-,
I'.-U-"'"
i
-,
--
"
:.' ','".",
',I ~'., .
e,!E 0',11 T/CJN
/0-/"
~35MW FLUIDIZED &D
BOilER COMBINED CfCLE PlANT
STEAM TU~f>INE FOUNI1ATlON
C20'SS SECTIONS
@lJttedengineens._-
PLAT E XSZIII
-------
APPENDIX K
ATMOSPHERIC-PRESSURE BOILER DESIGN REPORT
Prepared by:
Foster Wheeler Corporation
Authors:
R. W. Bryers
J. D. Shenker
K-l
-------
ABSTRACT
A proposal type design of 280 MW atmospheric-pressure
fluidized-bed boiler was prepared after reviewing several
alternate arrangements.
The preferred arrangement, a once-
through, sub-critical pressure steam generator, consists of
four modules each containing six vertically stacked beds
including a crabon burn-up cell.
The investigation included
a study of the boiler design and operation, the selection
of coal handling and feeding equipment, the selection of
particulate removal equipment, and cost estimation of the boiler
system with auxiliary equipment.
The cost estimates were
extrapolated to 300 MW and 600 MW level and compared with con-
ventional boilers of similar size.
It is concluded that an
--atmospheric pressure fluidized bed boiler would generate steam
" - ,and provide adequate control of particulates, at a capital cost
of boiler plant equipment 10% lower than a conventional coal-
-
fired plant.
, -
K-3
-------
SUMMARY
The preferred concept for the atmospheric fluidized bed
steam generator is a subcritical, once-through, four-module boiler
with six vertically-stacked beds including a carbon burn-up cell.
The once-through system permits more freedom to the designer in
locating and orientating heating surface, which is compatible
with the fluid bed concept.
2
of btu/hr-ft _oF at bed temperatures of 1600°F, there are
With overall heat transfer coefficients
no particular problems with high tube metal surface temperatures
because even though the average heat flux is greater in the fluid-
ized bed steam generator, the maximum heat flux is much lower than
the peak heat flux rate encountered in the furnaces of conventional
steam generators.
The preferred concept was selected over other arrangements,
including a compartmentalized, vertically-stacked bed arrangement
and a horizontal, tandem bed arrangement. for its simplicity in
construction and adaptability to the desired mode of operation.
The vertical arrangement greatly simplifies water circuitry
and eases construction by reducing the need for headers, downcomers.
-
and inter-connecting pipes to a minimum. . This arrangement also
simplifies the distribution of air to and gas from the steam
generator.
Plenum chambers used for providing and distributing air
to the bed also serve the purpose of isolating adjacent beds.
The vertically-stacked, modular const~~ction using six beds
including the carbon burn-up cell minimizes operating problems.
By assigning separate beds to carry out the functions of reheating,
K-5
-------
superheating and evaporating, individual beds may be started
up in sequence thus avoiding the risk of overheating uncooled
surface.
Turn down ratios of 4 to 1 are achieved with four-module
construction by simply shutting down individual modules as
required.
To maintain continuity in plant load as the modular load
. is reduced and individual modules are shut down each module must
have a turn down capability of 25% at 75% of plant load, 33% at
50% of plant load and 50% at 25% plant load.
Load reduction on
any give~ module is accomplished by dropping the firing rate at
constant excess air with a fixed bed height.
The bed temperature
drops to about l325-l375°F at 75% full load, l300-1350°F at
50% load, and l144-1223°F at 25% load.
The turn down .capability
of anyone individual module of'50% required for continuous load
reduction actually extends the load reduction capability of the
plant to 8 to 1.
Particulate removal from the flue gas is achieved by
means of a mechanical dust collector operating in series with an
electrostatic precipitator.
One mechanical dust collector serves
the main fluid bed cells and discharges its particulate effluent
to the carbon burn-up cell.
The second mechanical dust collector
-
serves the carbon burn-up cell and discharges its particulate effluent
to the ash removal system.
The total particulate removal system
reduces the dust loading of the flue gas to 0.01 grains per standard
cubic foot.
The system costs $5.00/KW.
There is no direct cost com-
paris on with a conventional plant equipped with a wet scrubber for
pollution control.
Tubular air preheaters were selected over regenerative air
heaters to minimize excessive gas losses associated with the higher
flue gas pressure in the fluid bed boiler.
This results in a net increase
K-6
-------
:I.n capital cost of the air preheater of $l/KW.
Coal injection is accomplished by dilute phase transport
of 1/4" X 0" coal from a fluid bed dryer-distributor.
Coal
~u1v~rizing equipment is not required by the fluid bed boiler system.
This results in a net savings of $2.08/KW in coal handling and
feeding equipment.
The surface requirements of this boiler have been reduced
by about 37% in comparison to a conventional boiler.
The total
volume has been cut in half.
This results in a reduction in
cost for the steam generator of about 20%.
The reduction in
cost of the entire boiler plant equipment including the steam
generator and accessories such as particulate removal, coal handling,
etc. is 9% or $6.94/KW.
Construction time has been reduced from 17 to 14 months
with each module requiring about 10 months.
This savings in
time appears as a reduction in cost of erection and interest paid
during construction.
The operating availability should increase considerably with
modular construction.
Outages need only affect the module in
question and result in partial load rather than full load reduction.
The availability of this boiler should also increase by
-
virtue of its inherent capability to handle low grade fuels.
At
l600°F bed temperatures the high temperature fouling and corrosion
attributed to the alkalis should be supressed.
Furnace slagging
should be nc problem, as this bed temperature is sufficiently below
the softening a~d initial deformation temperatures of the most basic
ash to avoid the presence of a liquid phase.
High ash coali ~hou1d
not present a problem as the concentration of the ash in the bed at
any given time is small.
K-7
-------
In conclusion, this conceptual design study has shown,
based on the design data used, that the atmospheric fluid bed
boiler is a workable concept offering an opportunity for a net
reduction in capital cost of 9% over a conventional pulverized
coal-fired steam generating plant equipped with pollution
abatement equipment.
The concept also shows a reduction in
construction time which should be reflected in a savings in
interest during construction and ultimately total plant investment.
The fluid bed boiler should be capable of handling fuels which
are troublesome for the present conventional pulverized coal
plant.
This should result in an improvement in boiler availability.
-
~a
-------
...~'
ABSTRACT
SUMMARY
TABLE OF CONTENTS
PAGE
K-3
K-5
TABLE OF CONTENTS
1.
2.
3.
4.
K-9
INTRODUCTION
K-19
SPECIFICATIONS
K-20
2.1
Fuel Specifications
K-20
2.2
SorbentSpecifications
K-20
2.3
Fluidized Bed Specifications
K-20
2.4
System Specifications
K-28
BOILER DESIGN CONCEPTS
K-30
3.1
General Considerations
K-30
3.2
Selection of Preferred Desig? Concept
K-30
3.3
Future Concepts
K-38
DETAILED BOILER
K-44
4.1
K-44
Circulation Steam
4.2
K-46
Air and Gas Circuitry
4.3
K-48
Energy and Mass Balance
4.4
K-52
Tube Details
4.5 Air Preheater Surface
K-53
4.6
K-54
Particulate Removal
4.7
K-57
Coal Handling
4.8
K-57
Coal Feeding
4.9
K-62
Sorbent Feeding
..
4.10 Carbon Burn-Up Cell
K-63
K-9
-------
5.
6.
7.
TABLE OF CONTENTS (cont'd)
OPERATION AND PERFORMANCE
5.1
Operating Procedures
5.1.1
PAGES
K-65
K-65
5.1.2
Ignition
General Operating Characteristics
K-65
5.1.3
Start-Up
5.1.4
Load Control
5.1.5
Shut-down
5.1.6
Emergency Shut-down
5.2
Performance Characteristics
BOILER COSTS
6.1
Capital
6.2
Maintenance
6.3
Operating
DEVELOPMENT REQUIREMENTS
Steam Generator
APPENDIX
7.1
7.2
Coal Handling
Al. CANDIDATE CONCEPTS
A1.2
Al.l Preferred Concept
Horizontal Concept
Future Concepts and Potential Modifications
K-10l
A1.3
A2. ENERGY AND MASS BALANCE
A3.l
A3. OVERALL BOILER DESIGN
Tube Design Information
K-10
K-69
K-72
K-74
K-75
K-77
K-78
K-80
K-80
K-86
K-88
K-89
K-89
K-90
K-9l
K-9l
K-94
K-96
K-107
K-107
-------
A3.1.1
A3 .1. 2
A3.1.3
A3.1.4
A3 .1. 5
TABLE OF CONTENTS (cont'd)
Bundle Arrangement
Tube Sizes
Tube Temperature and Material
Selection
Overall Heat Transfer Coefficient
Distribution of Surface Area
A3.2" Mechanical Design
A3.2.1
A3.2.2
A3.2.3
A3.2.4
A4.
Ductwork
Plenum Chamber and Distribution
Plate
Maintenance'
ACCESSORY EQUIPMENT
Expansion
A4. 1.1
A4.1 Coal Handling and Limestone Make~Up
A4 .1. 2
A4 .1. 3
A4 .1. 4
A4 .1. 5
A4.2
Assumptions
Scope
Equipment
Cost
Limestone Make-Up Storage and Feed
A4.2.1
Coal Feeding
Scope
A4.2.2
M.2.3
A4.2.4
Equipment
Cost
A4.3 Particulate Removal
Carbon Burn-Up Cell Feeder
A4.3.l Mechanical Dust Collector
K-ll
PAGE
~:-: = 'I
K-110
K-1l4
K-1l5
K-1l7
K-1l7
K-1l7
K-1l7
K-l23
K-l24
K-127
K-127
K-127
K-129
K-131
K-132
K-133
K-135
K-136
K-143
K-148
K-149
K-151
K-151
-------
A4.4
--
A4.3.2
TABLE OF CONTENTS (cont'd)
Electrostatic Precipitator
A4.4.l
Heat Recovery Equipment
Introduction
A4.4.2
A4.4.3
A4.4.4
A4.4.5
Description of Tubular Air Heater
PAGE
K-l59
K-164
K-l64
K-l65
Description of the Regenerative Air
Heater . K-l66
Selection of Equipment and Costs
Optimization Study
K-12
K-l69
K-l72
-------
.'~
FIGURE
2.1
2.2
2.3
2.4
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
4.1
4.2
4.3
4.4
4.5
4.6
LIST OF FIGURES
Distribution of Coal Size as Received and after
Crushing
Fluidizing Velocity and Terminal Velocity for One
Atm. System
Projected Particle Size Distribution for Material
Elutriated from the Fluidized Bed Combustor
Projected Particle Size Distribution for Material
Elutriated from the Carbon Burn-Up Cell
Temperature Entropy Diagram
Effect of Change in Heat Flux on Burn-Out and De-
parture from Nucleate Boiling Points
Effect of Change in Flow in Burn-Out and Departure
from Nucleate Boiling Poin~s
Effect of Change in Pressure on Burn-Out and De-
parture from Nucleate Boiling Points
Conceptual Arrangement of Atmosp~eric Utility
Boiler (One Module of Four)
Vertical Arrangement of Pressure Parts - Atmospheric
Fluidized Bed Steam Generator for 300 MW Plant
Plan View Atmospheric Fluidized Bed Steam Generator
for 300 MW Plant
Plan View Atmospheric Fluid Bed Boiler
Once-Through Fluidized Bed Steam Generator Circuitry
Air Flow Diagram
Overall Material Balance - Full Load
Overall Energy Balance - Full Load
Air Heater Atmospheric Fluidized Bed Steam Generator
for 300 MW Plant
Tubular Air Heater
K-13
PAGE
K-23
K-25
K-26
K-27
K-3l
K-32
K-33
K-34
K-36
K-40
K-40
K-40
Facing p. K-44
K-47
K-50
K-5l
Facing p. K-54
K-55
-------
FIGURE
4.7
4.8
4.9
4.10
4.11
4.12
4.13
5.1
5.2
5.3
5.4
6.1
6.2
---
6.3
LIST OF FIGURES
Dust Collector, Atmospheric Fluidized Bed Steam
Generator for 300 MW Plant
Coal Handling Plant
Atmospheric Fluidized Bed Coal Drying and In-
jection System (300 MW)~
Direct Firing System
Central Pulverized-Coal Circulating System
Bin System
Direct-Fired Circulating S~stem
Pressure Drop over the Distributor and Bed of a
Fluidized Combustion Boiler
Warm-Up Ignitor
Boiler Start-Up System
Operating Characteristics during Load Reduction
Cost Distribution for Four Field Erected Steam
Generator
Distribution of Cost of Steam Generator and
Accessories
Maintenance and Operating Costs for Boilers of
Various Capacities
APPENDICES
Al-2
Al-l Atmospheric Fluidized Bed Steam Generator
Horizontal Atmospheric Fluid Bed Steam Generator
Al-3
Al-4
Al-5
Typical Atmospheric Fluid Bed Cell with Preheat
Tubes Submerged in Second Fluid Bed.
Vertical Arrangement of Pressure Parts for A~mospheric
Fluidized Deep Bed Steam Generator with Circular
Shell
Plan View, Modified Atmospheric Fluid Bed Boiler
K-14
PAGE
Facing p. K-56
K- 5 8
Facing p. K-58
K-60
K-60
K-6l
K-61
K-67
K-70
K-73
K-76
K-82
K-84
K-87
K-92
Facing p. K-94
K-97
K-lOO
K-lOO
-------
FIGURE
AJ-l
A3-2
AJ-3
A3-4
A3-5
A4-l
A4-2
A4-3
A4-4
A4-5
A4-6
A4-7
A4-8
,.-
A4-9
LIST OF FIGURES
Water Wall Tube Penetration
Fin Tube Wall Construction
Typical Construction of Wall Insulating the Boiler
Plenum Chamber Detail
Distributor Plate Detail
300 MW Atmospheric Fluid Bed Boiler Site Plot
Plan
300 MW Atmospheric Fluid Bed Steam Generator
Conveyor System
300 MW Atmospheric Fluidized Bed Steam Generator
Conveyor System
Elevation of Limestone Feed Plant for the 300 ~M
Boilers
Bunker to Fluidized Bed Boiler Arrangement Stock
Volumetric Feeder
Ducon Cyclone - Atmospheric Boiler Fuel Injection
System
Fluidized Bed Coal Distribution and Feeder 300 M:~
Atmospheric Fluidized Bed Steam Generator
Pneumatic Conveyability of Angular Coal Particles
. in Dilute Phase at 1 Atm and Temperatures of 100-
500°F
Pneumatic Conveyability of Angular Coal Particles
in Dilute Phase at I Atm and Temperatures of 100-
500°F (2 Inch Diameter Tube)
A4-10 Pneumatic Convey ability of Angular Coal Particles
in Dilute Phase at 1 Atm and Temperatures of 100-
500°F (2-1/2 Inch Diameter Tube)
A4-li PneumaticConveyability of Angular Coal Particles
in Dilute Phase at 1 Atm and Temperatures of 100-
500°F (3 Inch Diameter. Tl1he)
A4-12 Size Distribution of Ash to Ducon Cyclones - Atm
Boiler Fuel Injection System
K-15
PAGE
K-l09
K-lll
K-1l9
K-120
K-l21
Facing p. K-128
Facing p. 1(-128
Facing p. K-128
K-134
Facing p. K-136
K-137
Facing p. K-138
K-139
K-140
K-141
K-142
K-147
-------
.-'
LIST OF FIGURES
FIGURE
A4-l3 Arrangement of Multicyclones
A4-l4 Mass Balance Particulate Removal System 300 MW At-
mospheric Fluid Bed Boiler
A4-l5 Distribution of Particulate Matter in Flue Gas
A4-l6 Size Distribution of Particulate Matter from the Me-
chanical Dust Collector
A4-l7 Micron Efficiency Curves Tubular Dust Collector
Design Load
A4-l8 Modified UOP Series 100 Tubular Dust Collector
Dimension Sketch Side Inlet - Top Outlet
A4-l9 Sized Distribution of Part1culate Material to
Electrostatic Precipitator
A4-20 Design Features of Electrostatic Precipitator
A4-2l Side and Elevation View of Research Cottrell El-
ectrostatic precipitator
A4-22 Ljunstrom Regenerative Air Preheater with Vertical
Flow
A4-23 Temperature Distribution.Heat Recovery Equipment
I .
A4-24 Optimization. of, Economizer and Air Heater Surface
in the Heat Recovery Section of the Boiler
A4-25 Effect of Cost of Conductance of the Air Preheater
on Minimum Total Cost and Optimum Temperature Level
A4-26 Effect of Cost of Conductance of the Economizer on
Minimum Total Cost and Optimum Temperature Level
A4-27 Effect of Flue Gas Exit Temperature from the Air
Preheater on the Minimum Total Cost and Optimum
Temperature Level
A4-28 Effect of Cost of Conductance of Surface Transfer-
red to. the Fluid Bed on the Minimum Cost of Surface
and Operating conditions
A4-29 Effect of Feedwater Inlet Temperature on Minimum
Cost of Surface and Optimum Temperature Level
K-16
PAGE
K-152
K-153
K-154
K-156
K-157
K-158
K-161
K-162
K-163
K-167
K-173
K-179
K-183
K-184
K-185
K-186
K-187
-------
--~
TABLE
2.1
2.2
2.3
5.1
5.2
5.3
6.1
6.2
6.3
A2-1
A2-2
A2-3
A2-4
A2-5
A3-1
A3-2
A3-3
A4-1
A4-2
A4-3
A4-4
LIST OF TABLES
Specifications of Ohio Pittsburgh No.8 Seam Coal
Sorbent Specifications
Steam Cycle Conditions 300 MW Atm. Fluidized Bed
Boiler
300 MW Atmospheric Utility Boiler Plant Performance
Summary of Gas Side Pressure Drop
Summary of Steam Side Pressure Drop
Summary of Cost; Principle Equipment, 300 MW
Atmospheric Fluid Bed Boiler
Summary of Cost; Principle Equipment, 600 MW
Atmospheric Fluid Bed Boiler
Comparison of Cost of A Fluid Bed Boiler with
Conventional Boilers
APPENDICES
Fluidized Bed Parameters - Design Load
Fluidized Bed Parameters - 70% Load
Fluidized Bed Parameters - 67% Load
Fluidized Bed Parameters - 50% Load
Summary of Energy and Mass Balance - Part Load
Operation (One Module)
Summary of Tube Size and Material Selection
Distribution of Heat Transfer Surface
Nomenclature
PAGE
K-2l
K-22
K-29
K-78
K-79
K-79
K-81
K-83
K-85
K-102
K-l03
K-104
K-l05
K-l06
Facing p. K-1l4
K-1l8
K-125
Comparison of Capital Cost of Coal Handling Equipment K-132
Cost Breakdown of Coal Feeding System
Air Preheate~ Performance
Nomenclature
K-17
K-148
K-l71
K-188
-------
1.0
INTRODUCTION
As subcontractor to Westinghouse on Public Health Service
Contract CPA 70-9 to evaluate the fluidized bed combustion
process, it was Foster Wheeler's responsibility to prepare
proposal type designs of utility boilers at the 300 and 600
MW level according to specifications provided by Westinghouse.
At the onset of the program it was decided that design of a
pressurized boiler as part of a combined cycle and of an atmos-
pheric boiler as part of a conventional cycle, both at the
300 MW level, would probably be the most worthwhile approach.
As work developed and a better assessment of the boiler market
was obtained, it was decided to extrapolate the designs and
cost data to 600 MW to provide more meaningful results.
This second volume of the report, which appears in two volumes,
discusses the atmospheric boiler designed and cost estimated at the
280 MW level nominally referred to as the 300 MW boiler.
The data
is extrapolated to 300 and 600 MW's to make more meaningful com-
parisons with conventional equipment.
The report includes a pre-
sentation of specifications provided by Westinghouse resulting from
a state-of-the-art review and discussions of boiler design, performance,
operation, cost and trade offs in design where they apply.
Auxiliary
~quipment such as coal handling, coal feeding, heat recovery and
particulate removal were selected and cost estimated through the
courtest and cooperation of numerous equipment manufacturers.
This
informatic~ is given in appendices.
Concepts investigated and discarded are briefly reviewed and
reco~~endations for future consideration are made.
K-19
-------
2.
SPECIFICATIONS
2.1
Fuel Specifications
The fuel selected for the atmospheric fluidized bed steam
generator was Ohio Pittsburgh No.8 Seam coal with the detailed
specifications listed in Table 2.1.
The coal is sized to 1 1/2" x
0".
This is a standard commercial size and no penalty is paid for
the specification.
Typical size disbributions are' illustrated
in Figure 2.1.
The coal will be received by unit train.
2.2
Sorbent Specifications
The sorbent selected for the atmospheric fluidized bed
boiler was BCR 1359 Limestone with chemical composition and flow
rates as prescribed in Table 2.2.
The dolomite will be received
pre-crushed to -1/4 inch size in covered
, ,
rail cars.
Truck
unloading will be offered as an alternate.
The recycled
sorbent
ranges in size from 1000 to 5000 microns with a mean size of
2500 microns.
...
The.feed requirements are based on the assumption that 90%
of the S02 is removed with six times the stoichiometric feed
rate of regenerated stone plus make-up.
The recycle and feed make-
up rates were based on the assumption th~t 3% of the limestone
would be elutriated with the fly ash and 10% would be rejected in
"the regeneration.
The stope after regeneration enters the boiler
at 1900°F and has a heat of reaction of 3xl06 btu/ton of CaS04
produced.
2.3
Fluidized Bed Specifications
A fluid bed superficial space velocity of 10-15 ft/sec at l600°F
was specified.
The allowable velocity was based on the average
particle size of the bed.
It was selected sufficiently below.
K-20
-------
~. ~.
TABLE 2.1
SPECIFICATIONS OF
OHIO PITTSBL~GH NO.8 SEAM COAL
(Source of data:
SAMPLE: Run of Mine -
PROXIMATE ANALYSIS (wt %):
ULTIMATE ANALYSIS (wt %)
(includes moisture)
GROSS HEATING VALUE:
NET HEATING VALUE:
ASH ANALYSIS (wt %):
Sia2
A1203
Fe203
TiO .
2
P205
CaO
MgO
Na20
K20
S03
FUSIBILITY OF ASH:
USBM, Pittsburgh, Pa.)
Moisture
Volatile Matter
Fixed Carbon
Ash
3.3*
39.5
48.7
8.5
100.0
C
H
o
N
S
Ash
71.2
5.4
9.3
1.3
4.3
8.5
(~60% organic, 40% pyritic)
13,000 Btu/1b
12,500 Btu/1b
45.3
21.2
27.3
1.0
0.11
1.9
0.6
0.2
1.8
0.7
-
100.1
Reducing Atmosphere
Initial Deformation Temperature -- 2080°F
Softening Temperature -- 2230°F
Fluid Temperature -- 2420°F
PARTICLE DENSITY:
Coal -- ~1.4 gm/cc
Ash -- ~2.8 gm/cc
GRINDABILITY (Hardgrove):
FREE SWELLING INDEX:
5-5.5
50-60
COST:
$5.50-5.75/ton for ~% S coal, 13,000 Btu/1b
($6.00lton cost projected by end of 1970)
*Possib1e Pick-up in Storage and Handling 6.7%
Giving Maximum Total Moisture as Received of 10%
K-21
-------
TABLE 2.2
SORBENT SPECIFICATIONS
,BCR 1359 DOLOMITE
COMPONENT
% WEIGHT AS RECEIVED
S102
Al203
Fe203
MgO
Cao
T102
SrO
0.78
0.15
0.25
45.0
53.0
0.02
0.03
<0.02
Na20
K20
Mn°2
<0.1
<0.03
Sorbent to Boiler
from Regenerator (600 MW)
Feed Make-Up Sorbent
K-22
83.0 tons/hr
7.1 tons/hr
-------
(FEED TO BOILER)
KOPPERS REVERSIBLE
25 HAHHERMILL /
.' ~: CRUSHER /~.
55 - /
L / .
93 -/-
96 I=--
t--
1
1 -
5 --
15 ---
~
I
f\.)
W
E-<
G
H
~
~
:>-<
I:Q
N
a 85
~
N
H
V)
P<::
t>~
:>
o
98 r--
.LLl.UJ_~LJiliLj
1000 10_000 100_000
PARTICLE SIZE. MICRONS
16 1/8" DIA.
I I
iT',-'!'Tr
/
/
~~y
~'\: /'
~~ /'
~\:j /
f?'\:
(,O~ ~
vO
V
",-Q;- / '
/'
/
99
100
100 60
I I
28
I
. I
I
1/4" DIA
r--'l-fTil--
RAW COAL
PITTSBURGH
SEAM NO.8
.
4
1/2" DIA.
I I
2" DIA.
- - I
--
PARTICLE SIZE, ROUND HOLE SCREENS
1" DIA.
PARTICLE SIZE. U.S. MESH
'2j
H
c;)
~
N
~
t:I
H
V)
o-i
:>d
H
Cd
c:::
o-i
H
o
Z
o
'2j
o
o
:I>
t"'
(J)
H
N
t>1
:I>
(J)
~
o
t>1
H
~
t:I
~
t:I
:I>
'2j
o-i
t>1
:>d
.0
:>d
c:::
(J)
::r:
H
z
c;)
-------
the terminal velocity to prevent loss of the bed and sufficiently
above the minimum fluidizing velocity to ,insure fluidization of
the bed.
The ranges of fluidizing and terminal velocities with
particle size is illustrated in Figure 212;
The material elutri-
ated from the bed consists of 33.75% ash, 59.45% Coal and 6.8%
limestone with a size distribution as illustrated in Figure 2.3.
The coal combustion efficiency in the primary beds is assumed
to be 87%.
10% excess air is specified. The particle size
of the feed required is 1/4" x 0" with a distribution as illus-
trated in Figure 2.1.
The carbon burn up cell operates at=1900°Fwith sufficient
excess air to maintain the temperature level.
No heat transfer
surface is installed in the bed.
The superficial fluidizing
'velocity is 9.2 ft/sec.
The fuel to the bed contains 59.45%
carbon.
The remaining portion is ash and limestone.
:Material
elutriated from the bed has a size distribution as shown in
Figure 2.4.
It consists of 79.5% ash, 18.7% coal and 1.8%
limestone.
Air preheat temperature would be in the vicinity of about
700°F.
Heat losses from the boiler would include 0.18% radiation
loss, unaccounted for and manufacturer's margin L 50%., unburned
combustible 2.39%, dry flue gas loss 6.50%, and total moisture
loss of 5.15%.
The boiler efficiency would be 84.78%.
The stack gas temperature was set at 340°F.
Two stages of particulate removal equipment are required,
each with an efficiency of 96%.
The grain loading of the stack
gas emissions should not exceed 0.01 grains per standard cubic
foot.
K-24
-------
?;;
I
I\)
VI
..
p:::
~
E-<
~
~
H
Q
~
H
U
H
:E-<
~
p...
10,000
U')
~ 1,000
p:::
U
H
~
100 -
10
0.001
I I I
I -T,u-..--r--r---r
I , I
BASIS
/
V
,/I
,./
Temperature
Pressure
1700°F
Solid Density, ps
Gas Density, p
. g
Gas Viscosity, \.I
1 atm
125 1b/ft3
0.0189 1b/ft3
0.045 cp
"
\.~'3
"\ 0"
~e"
\.~'b
0.\.'"
~\.~\!
#
y..\.~~
-..,.-<"4.
OV
~
~
;>-
~<:'
~~
'"
"
0.01
0.10
ACTUAL GAS VELOCITY, FT/SEC
1.0
10.0
100
FIGURE 2.2
FLUIDIZING VELOCITY AND TERMINAL VELOCITY FOR 1 ATM SYSTmt
-------
~
I
f\)
0\
. 1
1
5
15
25-
H 35-
:x: -
t-' 45
H
w -
:3: 55 ----
>- 65-
I:Q
~
~ 75 ---
w
N
H
U)
p::
w 85 ._-
::>
o
93 --
96 --
98 -
~IIII
I 'f-II'I
1
l'l'I'\
><
~i~~<.
Coal:
-1/4" x 0
Gas Velocity:
10-15 fps
'/./-.«
Represents Data Spread
- 99
, I, LJ
1000
PARTICLE SIZE,
LJJ_-~--Ll
100
MICRONS
---------
325 200 100 61
I
------ ----- _.1__- -.- - ---.---.._.____1_- --
PARTICLE SIZE, U.S. MESH
FIGURE 2.3
,8
PROJECTED PARTICLE SIZE DISTRIBUTION FOR HATERIAL ELUTRIATED FROM THE
FLUIDIZE!) BED COHBlISTOR.
1L
-------
"
'p;;
I
I\)
-..:j
l[rrq-----I
:1--
<:
oJ
15
25 --
3~--
E-<
~
t..:I
H
W
~
><
I'Q
45-
5)
65
~
~ 75
w .
N
H
U)
~ 05-
:>
o
93
96 -
'98 -
99
1
f'l'flI
.--
LlJ-
1
1JOO
P.\ .....~.~. ..,. r'"
1.\:-\.,) . .'~
5lL.f:. m.CRi.',:i:~
325 200
_.._..._~___l____.. I
1 °1° ;;~
,8
p/Jr:':r:c.-:: SIZE, U.S. !1.~SH
FlCURE 2.4
PROJECTED PARTICLE SIZE DISTRIfjUTlON FOR HATERIAL ELUTRIATED FRUl'1 THE
CARBON IHnW--(jl' CEI.L
J
!
16
I
-------
No specifications were set for bed depth.
It was felt that
pressure drop requirements would limit it to about 2 1/2 feet.
An overall coefficient of heat transfer of 50 was.selec~ed based
on the experience of the British and U. S. work~
A heat transfer
coefficient of 40 was assumed in the 3 foot space above the bed due
to combustion of volatile matter and partial elutriation of
larger particles.
The heat absorbed in this zone is credited
to the bed.
Tube spacing and size was left open to the designer.
. Fluidized-bed combustion data indicate that corrosion, erosion
and slagging problems either do not exist or can be overcome.
2.4
System Specifications
The capacity of the proposal type design was specified as
280 MW with the intent of extrapolating costs to the 300 and 600
~.-
MW level.
Steam cycle conditions selected were the same as
Georgia Power and Light's Hammond No.4 conditions.
They are
tabulated in Table 2.3.
The preliminary design was to include
coal handling plant, fuel injection system, steam generator, fans,
-
heat recovery system and particulate removal system.
The plant turn down ratio was specified as 4 to 1 with a
" -
response rate 'to load changes of at least 5% of load per minute.
K-28
-------
TABLE 2.3
STEAM CYCLE CONDITIONS
300 MW ATM. FLUIDIZED BED BOILER
Primary Steam Flow
Steam Pressure, Superheater Out
Reheater In
Reheater Out
Steam Temperature, Superheqter Out
Reheater In
Reheater Out
Steam Flow (Reheater)
Bo.ller Feed Water Temperature
K-29
L 9xl06 Ib/hr
2400 psig
601 psig
581 psig
1000°F
650°F
1000°F
L 6x106 lb/hr
480°F
-------
3.
BOILER DESIGN CONCEPT
3.1
General Considerations
A 2400 psig once-through unit with cycle conditions similar
to Hammond No.4 was considered as the basis for design.
The
once-through unit was selected for its inherent flexibility with
regard to steam heating circuitry, thereby offering a greater
freedom in surface arrangement and location.
The once-through boiler
offers an improvement in cycle efficiency and eliminates the
need for a cos~ly steam drum.
rhe improvement in cycle efficiency
over the natural circulation boiler is due to higher operating
tempera~ures clearly illustrated by the diagram of Figure 3.1.
. The subcritical cycle offers severalad.vantag~£ over the
supercritical cycle.
These include lower tube metal temperatures
associated with lower steam temperatures (See Figure 3.1), some
improvements. in mean temperature difference between the gas and
the steam and less severe operating conditions during turn down.
In addit~on, lower alloy shiels .can be used.
Although the once-
through su~critical uni~sa~e freque~tly plagued with departure
from nucleate boiling causing burnout of heating tubes, the pro-
blem should be minimized in the fluid bed boiler where steam
2
mass flows approach 1,500,000 lb/hr-ft and heat flux approach
2
50,000 Btu/hr-ft at full load operation.
This is illustrated
in Figures 3.2, 3.3, and 3.4.
Physically, the boiler ccnsists of four modules, each contain-
ing five fluid beds and a carbon' burn-up cell.
This arrangement
should simplify start-up, shut-down and partial load operation.
It also facilitates turning down 4 to 1 by cutting one boiler
K-:30
-------
TEMPERATURE-ENTHALPY DIAGRAM
FOR STEAM AND WATER
500
. . .. ~ i 1111
, I J:~:I/?
. / /11/ I
I 1/1/;1
/1 /'/1/;
'/ 11//
-~ L I----L- - ___m__m_- ------ - / /, / //?
i . / 1 I
PR - , I 1 I /
EVAPO~TOR ~ EVAPORATOR'~ ./ ~,/ " ,/1
I ' I .'" :\.~ " / I I
: . i .! ...--. '/.--.. ; . .........-1C)C) ~~/".: //~I
SUPERCRITICAL i.__- ~---J :,H- -.....; - '" :f ".~ 1 /,1 / ~
i ~. ; -- '. ./ ", ~(Q ~C) " r" I ."
I - , .-'Jr' ,,~/' I
' :JI' . .-- --- !",-----I-~~I" / /
-t.- - "'-',/-'-- ,,'-'" ~!7 /~/I- I
!. _.:~- .;: ! ,. - -I-r ....~. ;,../ r" y~ 1/1'
SUBCR~TICAL . - ~~ -r--- -~ - - -+- - - - - - L--,\"" -1/./ /, r
600 '--"-" _1......-.--.-- _.L_.._- -~~-t! ---~-~/~1---____1__~'C"1 ~~~/ )' i ..-.
I . :/- -=t-=-t/' ; 1 : / I; I !'
./ : / ~ ; 1. \ ~ ,/ ;
NATU~ -.--;--- /- -'~--=- - ~ - - - _:- -- ~ - - -- -~,r t-,f::Jf::J/ i j-REHEATER
CIRCUrTION ;, /' i '[ I ; i I ': /' i I
- i. - . ;~.~..- - - ~._.- -"'--"'-',"~' t i ""1" - ... 1 .. ~//; I -. .'
. ~/-_:_---+--~--- --T----+----r---1 : I
/ . ~ i " - I : ! .J !
I , . i. I
:; I ;:, i
/' ~ i ; : ; ~- I" '- I
! .
i
I
,.
I
. I
1100
SUPERHEATER ..
1000
I
I
~
::>
E-<
~ 800 '.-.
~
~
~
E-<
i
-._- .-.- ....- i.. ---.-
I
I
I
I
I .
I
I
!:< 900
. ..... --.p -
!
i
i
- j-
700
?:;
I
W
f-..J
:
i I
!
400
300
. 1---- .-
, I
--
I
-!-.;--------- .
I
!
400
500
600
700
800
900
1000 .
1100
1200
1300
1400
1500
1600
ENTHALPY - Btu/1b
,
FIGURE 3;1
-------
- 1500
....
- PRESSURE . 2980 PSIA
~~ FLOW RATE . 5?O,OOO L8 / H R - FT2
QQ ~
.... ~ LL.
::s ~
~ I 1300
!D :::c
11 .
.... UJ.
::s "1 a:
OQ 11
'<: ::J
t-t I-' . t-
::s....
n::S ~
OOQ a::
11 ..
"0 W 1100
0 a.
11 n
cu 0 :E HEAT FLUX
" a
!D a' W I03BTU/HR-FT2
p.~ t-
.. IJJ
" I
I-' .... -.J 258
\00 ~ 900
a-~
~ a- 221
. M W
I P
W OQ ~ 184
f\) .... 147
p w
(1) 110
(1) C
11 - 92
.... en 700-
p
OQ Z
0 ~5 50 75 100 '-
n . .
0 PER CENT STEAM
s
a'
~ 500
IJJ
"
.... 500 600 700
0 800 900 1000 '1100
~
ENTHALPY { BTU / LB J
553 628 682 695
FLUID TEMPERATURE- F
FIGURE 3.2
EFFECT OF CI~GE IN HEAT FLUX ON BURN-OUT AND DEPARTURE FROM NUCLEATE BOILING POINTS (REF: 1)
-------
1500
- HEAT FLUX . 221,000 BTU/HR- FTz
.....
........
I&.. FLOW RATE II 520,000 LB IHR- FTz
to:!C)
::I..... ~ 1300
OQ It)
1-'-::1 ---.
::I ::I
It) a: PRESSURE
It) ::>:'
t; . :>
I-'- (PS I A )
::I "'1 t-
OQ t1 ~
'<
HI-" a:
::I f-'. ~1I00 2700
n::l
OOQ
"C ~
0 ~ 2840
t;
IU (") W
n 0 t-
It) a
Pocr' ..J
~ ~
?i [/) <
I I-"n 900.
w '" f-'. .... 2980
w 0\0 W
0\::1 ) SATURATED
to:! ~
;'
::s LIQUID
OQ W
f-'.
::I a
It) -
ro (I) 700 -
t;
I-'- Z
::I
OQ-
(")
0
a 500
cr'
~
[/) 500
n 600 700 800
I-'- 900 1000
0 1100
::I ENTHALPY ( BTU I LB )
FIGURE 3.3 EFFECT OF CHANGE IN PRESSURE ON BURN-OUT AND DEPARTURE FROM NUCLEATE BOILING POINTS (REF: 1)
-------
,-
...
....
'"
I
W
+=-
'~l "'~
:I ~
OQ (D
.... ::I
::I ::I
(D
(D ~
11 .
~,.
P "1
00 11
'<
H~
::I ....
() P
000
11 ..
"!j
o :
11 (")
IIJ 0
" a
(D tT
j:l.C
... CJI
"
t-' ....
\CO
C1\P
. C1\
. tTJ
::I
00
....
::I
(D
(D
11
....
::I
00
(")
~
0"
C
CJI
"
....
o
P
'~00
LL.
.11300
0:
:)
....
e
0:
~Hoo
~.
I£J
t-
..J
e
t; 900
'2
I£J
c
-
~.. 700
.-
500
500
~ .-.-+-.-.... . .
PRESS'UR'E II ~9a() PStA
HEAT FLUX.. 221,000 B,TU/HR- FT2
FLOW RATE
( LB/HR-FT2)
I
25 50 15
. PER CENT STEAM
.600
700 800 900
. ENTHALPY (BTU/ LB )
.1000
1100
I
. I
I .
553 628 . . 682
. fLUID TEMPERATURE - F
695
FIGURE 3.4 EFFECT OF CHANGE IN FLOW ON BURN-OUT AND DEPARTURE FROM NUCLEATE BOILING POINTS (REF: 1)
-------
module out of service.
Two of the beds are assigned to evaporat-
ing functions, two to superheating and one to reheating.
The en-
closure walls are comprised of evaporating tubes.
Preheating
of feedwater normally assigned to the economizer is accomplished
in the convection pass.
The schematic in Figure 3.5 illustrates
the concept as it might look in a vertical arrangement.
Ac tually
several geometric orientations were considered.
The fluid beds for a four module construction are nearly
square, with dimensions of 2 1/2' x 13' x 12'.
The depth is pre-
sently limited by pressure drop.
Future concepts incorporating
"high-pressure" fans may justify the use of deep beds.
This ap-
proach represents a significant deviation from normal practice
and is beyond the scope of the present study.
Rectangular or
square beds are used to facilitate installation of conventional
banks of heat exchange surface, making use of presently available
fabricating techniques.
The approximately square shape is a
compromise between steam side pressure drop and mass flow re-
quirements, and shipping tolerances.
Three basic bed arrangements were considered:
1)
Vertically stacked beds in a square array.
2)
Vertically stacked beds in separate modules in an
in-line arrangement.
3)
Horizontal tandem arrangement with four modules in
parallel.
In the firr~ arrangement the five beds in each module are
stacked one above the other~
Air is introduced to the beds by,
way of a common duct on one side of the module.
Gas is withdrawn
on the opposite side in a similar manner.
By arranging the four
K-35
-------
NOTE:
T---
rv 100'
AIR IN
FBC - FLUID BED CELLS
CBC - CARBON BURN-UP CELLS
BEDS CONTAIN SUPE~EATING, REHEATING AND,
EVAPORATING SURFACE
CONVECTION SURFACE,- FEEDWATER HEATING
SURFACE
6' I
PRIMARY
, CYCLONE
12' x 13'
I 6'
--
FLUE GAS
---
1-' '- .- . ' --:::', -:- '. . J
~Y'FBc~~S:~V
~ -----~::::-
~I
, . " \. .. \ '\ '- '.' ,"-. '. 'J
.".
~
t
t
'--'-
_. ----
0__.__. --
--.----
RECYCLE TO
CBC
~
".-- - ---- .n.
..
,~
, \' FBC ,\\',\\
'\ \ '- \ ..', \ \. . '.. '.
t
~~
......-
CONVECTION BA~~S
\~~~,\ ~
,\\,\ \' FBC. \\:. ,\ ..', I
, . ,-- ..----:
. --
--"" .--J-
-------- . ,.,-..-
p ". ~..,..- -. --.--"---
,..,
-.- ...._-_..._-.-.._----_._~--
--"----------'-
-----..------- .
- .-.....----- -...,.
,>,-.-~\"'~ "-'cnc' \.'\. . '.
\. . : '.
-FIGURE 3.5 CONCEPTUAL ~{GEMENT OF A~10SPHERIC
UTILITY BOILER (1 MobuLE OF 4)
K-36
--"-
r--
I
i
I
I
I
I
I
I
1
-------
modules in a square pattern with each module sharing two adjacent
sides with two other modules it was hoped some savings in duct
work and boiler structure might be achieved.
This arrangement,
however, was dismissed for several reasons.
1)
Sharing common walls or partitions offered little savings
in construction costs and no solution was forthcoming on how to
isolate a shut down module.
2)
Shared partition walls can present thermal expansion problems
and circulation problems.
3)
It is almost impossible to arrange auxiliary equipment
symmetrically about the boiler without introducing complicated
duct work and piping.
The horizontal arrangement is illustrated in Figure Al-2
of the appendix.
The horizontal arrangement hopefully would
reduce structural steel requirements and facilitate shop fabri-
cation.
After a brief but careful evaluation of this arrangement
it was dismissed for the following reasons.
1)
The number of headers and dOWncomers required is almost
quadrupled.
This introduces a very complex, costly piping system.
2)
Downcomers and headers could be reduced by introducing
horizontal tubing in the water walls.
This may not create
any unusual problems for a single phase fluid.
However,
in the evaporating zones the possibility of the separa-
tion of phases which may result in tube failure is greatly en-
hanced unless some basic modification is made to the system such
as turbulators, forced recirculation, etc.
Expansion and circuitry
problems may also exist due to the differences in heat flux in
and above the bed.
K-37
-------
3)
The horizontal unit virtually dictates the use of a re-
generative air heater with its high leakage loss at the higher
pressures associated with the fluid 'bed.
In the vertical arrange-
ment a vertical tubular air heater is compatable with'the
stacked fluid beds and there is no air leakage.
4)
The head-room below the mechanical dust collectors is
small, making it impossible to install a suitable particulate hand-
ling system for the carbon burn-up cell fuel feed injector without
losing some of the advantage of reduced height.
5)
The clearances on the beds violate shipping tolerances,
necessitating field erection.
6)
Isolating' plenUm chambers below bed grids for the in-
stallation of dampers is complicated.
'Large areas may have to
be sealed off to accommodate air control dampers.
The vertically stacked bed in an in-line arrangement as
shown in Figures 3.5 and Al-I appears' to have overcome mos t of
the liabilities cited for the other two systems arid, 'therefore,
was selected as the concept to develop.
The accessories accompanying the fluid bed steam generator
include a conventional coal handling system, a modified fuel
injection system, heat recovery equipment, fans and particulate
removal equipment.
In the basic concept the coal handling system includes
receiving, crushing, conveying and storage of coal.
The fuel injection system includes pressurizing coal to
furnace pressure, drying, distributing and transporting to the
fluid beds.
K-38
-------
The heat recovery equipment is required for the exchange
of heat from the flue gas to the incoming air to reduce thermal
losses to the stack, to provide heat for drying the coal and to
insure the beds are not quenched by cold air resulting in the
loss of ignition.
The particulate recovery equipment is divided into two stages.
The first stage recovers elutriated material rich in carbon from
the fluid beds in order that it may be returned to the carbon
burn-up cell.
It also collects ash elutriated from the carbon
burn-up cell which is removed from the system.
The two processes
are structurally integrated but ,functionally segregated, thereby
prev.enting contamination of either stream.
A mechanical dust
collector is proposed for the first stage of particulate recovery.
The second stage of recovery is strictly flue gas clean-up.
An
electrostatic precipitator is proposed for this job.
3.2
Preferred Steam Generator Concept
The vertically stacked bed arrangement selected as the
preferred concept is illustrated in Figures 3.6, 3.7 and 3.8.
The steam generator consists of four separate modules, each
part of four completely separate but parallel processes from the
coal handling plant to the electrostatic precipitators.
The steam generator contains five fluidized beds and a
carbon burn-up cell stacked one above the other.
The lowest
bed is the carbon burn-up cell which receives elutriated material from
the other fluidized beds collected by the mechanical dust collector.
Directly above the carbon burn-up cell are two evaporating beds,
two superheater beds, and finally the reheater bed.
The fluid
K-39
-------
T-~'
'I
1 ,
/
/
r'--
/
/
...<>-/
~
~
o
CgC 611'
.::~-=----- .
(",
/
/
/
;::
Jt
-- - -- .. - - - --
-,
"
;;
,
I
I
I
I
~ ~ ! @
"';;: I
~ ~ ~~._-
~~
:I~~
....~
...
~
,
c;:
I~ I
I~ :
I~-+- ..
,-= I
I~ r[
~f-\ , ~
~\."'-" . ~
" I
'",
i
I .{;j)
I ~~
. ,,"
. ,,~
~~
I, ~~
~~
5- .
,,:, . 'ce:. I L-"!>~-:
7,4;. ~"'~.,
....
c~
~!J
'R
. ~~
"'
'"
~
u.
J .
4'.O'.........e~2l-..4':.Q:~/~:~:~" ."'of)- II:~ 9 4~O"
----~--~'--L-_-
s'
4'-O~ ;7~~' 4'.0" b5P~-f"
~~i~ -. 4~~~
w'" ..
135"$'! ~
"...,.
4:0"
1,'-0"
.'0'
1.3$'$ ~~'.
-4'-:,--:-
~
135I'U.~
4 -4"
z'.~-
~~'-- ..
t! .
".,"
-- "----
-~------
. .-._--- ---
'}
\P'
I
~~:~~~
IT'..!'"
3.10
<
Q
t:::
~
liJ
-J
I.t-J
..
'"
~
\JE.~;. AU.C.;. OFPU55.?A2.15
AiM05PHE \tIC flUID II EO
~~ D SiEAM GUIE~AiOQ..
F 0 i...
300 M IJ.J
P lAl-.I i
FOUQ..(4-) ~E.QU\Rt.D
-------_._----
f\(,\JR.L
3.6
-------
"'.
iUNlr
:JI'MM'
-------
j
-
,
i
I
i
- !
- ,
0:
.., i
"1
I
I
I
I
I
+---
i
i
,
!
.t-
i
I~
!III
;..
iG
: ! ='
~I~
~I;
Ni...
@J!~
.1
--ID
.. , .
",I\)
1=
Nit
t'- -
'J
I
il
J.
Q
....
1..\""t.'~!O""~.l
IN\.'-, 't:
-----
-- -r-
:,j
-' I
NI
+- i
." I
,
I
. i
'01
-' !
"j
I
I
-
o
..
N
--*-----
REVISION
~
Cf>C-GAS
G ~ S
4
H -'
I
I
~
I
I
I
I
I
I
I
?
I
I
I
I
I
I
~
I
I
I
t
I
I
6
r , I I
, , '
", I I
'-
, , .
I
r
78 SUI @ ," t 1I3'.d'
- -- <., ~/,,". 0.0, ~i"a... w'II\\,\. i~t.t. S) --
~1 1I"S (!I 4": 12'.4-' -,4"
- ('Ii" _rTO~ T;.I~.L~""-Im.)!
, i \ I
I I I
+- t t
I I t
I I I
I I I
I , I
I I I
I : I
~ ~ 9
I I I
I I I
I I I
I I ,
I I I
I I I
~ ~ ~
I I
I I
I I
I I
I I
I I
b. 6
I
I
I
I
I
I
6
------------- -
I 1
t~
A\9..
-
\ -~ t. " 0 Eo It.. $
,
. .
- .---.-
-# -......- -.
-
6- rt\.. ~ ---Lh- rt"\
---'f ---y---''V'-- 'y --y-
5ECT\ON
-4
I .
-1
r
LIM.l~TI)Ioa OU'TI.E.T
-I-~") ,. PLP ~
co,,-\.. ''''4\..t.iS
h-
e;)
to"
-
2
\3
-
-i
i
.l:I
ORDER NO.O.5 -1\ ~ 't
w
DRAWN BY:
CHECKED BY:
APPROVEp BY:
3.1..1
A\M05PKt.~\C.
flU\O
~EO
~Olle. tl-.
TM.. .D...'- 's T... ...o..aT., O. TIt.
FOSTER WHEELER CORPORATION
110 SO. ORANGE AVE., UVINGSTON, N~.
AND I.\.CNT WITHOUT CON.IDIEItATION 0TMIE1t THAN THIE.
.OItItOWIEIt'. AGItIEIEMIENT THAT IT .HAL.\. NOT .IE lllE.
~IIODUCIED, CO~IIED. LIE NT. Olt DI.~O.IED 0,. DIItIECTL.T Olt
INDIItIECn. T NOIt U.IED I'01t ANT ~UIt~O.E OTHIER TNAN
TNAT 1'01t WHIC.. IT I. .~IECII'ICA\.LT !'UItNI.HlED. TNIE.
A~~AItATU. ...OWN IN THIE DItAWING I. COVEItED 8.,
~ATlENT.. .
JR-
S'- 71 SCALE:
is ~,.
= 1 '-0"
RO 713- 100
Fig. 3.8
-------
beds are enclosed by welded fin tube walls which carry evaporating
water.
Each fluid bed cell contains a convection bank which
cools the hot flue gases before they leave the steam generator
and screens out some of the large particulate material elutriated
from the bed.
Air from the air preheater passes through two ducts, one
on each side of the boiler as shown in the half plan view in
Figure 3.7, to a common air duct which runs the full height of
the boiler.
Portions of the air feed into each plenum chamber
located below the fluid beds.
The quantity is regulated by
dampers located in the air duct.
The air then passes through
the distribution plate supporting each bed and into the bed
itself.
A separate air stream fed directly from the forced
draft fan feeds cool air to the CBC to regulate the temperature
of the bed by control of the excess air introduced.
Separate gas streams leave the fluidized beds and the
-.carbon burn-up cell, thereby separating the carbon rich ash from
the spent ash. The CBC duct is located inside the flue gas
duct on the back side of the boiler and extends over its full
length.
The gas is withdrawn at the top,of the duct where it
is fed to the dust collector.
Coal is pneumatically transported through sixteen separate
feed lines to each bed as a dilute phase of dried coal at 250°F.
Distribution and drying is accomplished in a fluid bed injector
constituting part of the coal feeding system.
The coal feed lines
enter the gas duct from either side of the boiler, pass through
K-41
-------
the flue gas exit opening in the water wall of the preceding cell
and then up into the plenum chamber and throughth~ grld plate.
Penetrations through the duct work are made on opposite sides
of the boiler to which' the coal 'will be fed.
This should provide
, .
sufficient length of feed line to take up any differenti~li~
expansion of duct work and steam pressure parts.
The coal is
injected into the bed in the horizontal direction in an area free
of tube bundles.
., " '
One coal injector is provided for each ten
~quare. feet of fluid bed surface.
For steam generators 300 MW and larger the boilers will be
field erected.
Beds'are 12' x 13' in size to permit shipment of
bundles.
, . . I
The overall size of the boiler modules is too large
for shipment in assembled sections.'
Furthermore, the cost of
reinforcing the boiler, which is designed to hang from structural
steel, for shipping purposes would nullify some of the advantage or
shop assembly over field erection.
Each module requires about 10 months to construct.
Off-
setting construction of each module by one month to minimize
total labor force required and to allow free flow of labor and materi-
als from one module to the next would result in a total field
erection elapsed time of 14 months.
This represents about 18%
savings in erection time over a conventional boiler of similar
capacity.
3.3
Future Concepts
In the course of developing the concept selected new ideas
for improvement were generated requiring less conservative design
practice but hopefully resulting in an improved cost picture.
K-42
-------
The study indicated that pressure drop across the bed and number of
coal feed points required are two key problem areas with the atmos-
pheric fluidized bed boiler.
By increasing bed depth and pressure
drop the number of coal feed pipes and feed injection points could
be gre~tly reduced.
This could result in a smaller bed cross-sectional
area which might ultimately result in a shop-assembled, sectionalized
unit.
If the number of boiler penetrations required for the coal
and limestone feed are reduced, the designer might consider replacing
the structural s~eel with a self-supporting cylindrical vessel com-
pletely enclosing the pressure parts.
This approach would not only simplify shipping; it would also
reduce field erection time, eliminate the need for flues and
duct work, and minimize structural steel required.
Since the
air and gas temperatures are nearly the same during normal
operation and start-up, expansion problems, sealing problems
and shell distortion should be minimal.
With a small pressure
differential
between the air and gas side (40-86 in. w.g.) sealing
the two streams should not present a problem.
The "pressure"
vessel or boiler shell can also be insulated on the inside
rather than outside to minimize heat losses and maintain a cool
vessel.
Other consideration should be given to installation of
the tubular air heater in the convection pass above the water
or steam cooled heat recovery surface, thus providing a much more
compact boiler and minimizing duct work.
K-43
-------
4.
DETAILED BOILER DESIGN
4.1 Circulation of Steam
The heating of the water as it passes through the boiler is clear-
1y illustrated in the temperature-enthalpy diagram in Figure 3.1.
Water
entering the boiler at 480°F is heated to the evaporation temperature
of about 690°F in the pre-evaporator.
Then the water and steam remain
at approximately this temperature until all the water is evaporated.
The steam is then .superheated to a temperature of 1000°F at a pressure
of about 2,400 psig.
Some of the energy in the steam is released in
the high pressure turbine after which it is returned to the boiler
for re-heating to 1000°Fat 581 psig.
These same -steps are followed
in the once-through boiler in a simple,. continuous path which is
only interrupted at appropriate points with mixing vessels or headers
to insure good distribution and uniform heating of the steam.
This system is applied to -the fluid bed boiler by breaking
up the heating functions into individual beds and tube bundles
or enclosure .walls. . To minimize .the surface requirements the
largest mean temperature difference is maintained t;'henfeasible.
To do this the preheating or .feedwater heating is accomplished
in the convective passes.
The first stage of evaporation takes
place in the tube bundles.
It is completed in the enclosure walls.
Superheating and reheating takes place in tube bundles located
in the beds.
The circuitry may be simply followed on the isometric flow
diagram illustrated in Figure 4.1.
Water at 4~:J°F enters the
feedwater inlet header at point (1).
It proceeds through a series
of banks of preheater tubes (2) located in each convection pass of each fluid
K-44
-------
@
1
'11
L~
lr
1
~ ' ~ >/ ~; "
' ",-""'~/ ~" """"."
'" il'-.: '" < ~~~ $'- r
,.,"',0'" !t'-';~~ ~<~~) r;
.~ ~~~~~: ~ ~;~~ 1 ~
-------
bed including the CBC.
The bundles are all connected in series.
The water leaves the outlet header (2) at the top of the boiler and
proceeds thro~gh some feeder tubes (3) to a downcomer (4) which
carries it to the first stage of evaporation (5).
Evaporation
takes place in two separate bundles (6) located in two adjacent
beds.
The bundles are connected in series without the benefit
of an intermediate mixing header.
The partially evaporated
steam leaves the bundles through feeder tubes (7) to the downcomer
(8) which feeds the front wall header (10) by a second series of
feeder tubes (9).
The mixture passes up the ,entire evaporating wall (10).
At
the top of the boiler the mixture is collected in header (10),
and fed by means of a series of feeder tubes (11) to a downcomer (12)
which carries the mixture to the side wall header (14).
All four
walls are connected in series as described for the front wall.
At
header (22) the evaporated water is collected and passed through
a series of feeders (23) to a downcomer (24) which carries the
steam to the first bank of superheater tubes (26) located in
a fluid bed.
Superheating is completed in a second bank (27) connected
in series with the first and located in a separate bed.
The con-
necting tubes are interrupted by a mixing header.
The steam leaves
the second bundle and the steam generator through a single-ended header (27).
Reheat steam enters the boiler at the header feeding bundle
(28) and leaves the boiler from the header collecting steam ~t the
opposite end of the bundle.
Both headers are single ended.
The
bundle occupies one fluid bed.
K-45
-------
4.2
Air and Gas Circuitry
Pressurized firing was selected over a balanced draft system
for the fluidized bed boiler.
In conventional practice selecting
one over the other is very much dependent on the personal prefer- .
ence of the customer.
Pressurized firing offers the advantage
that a single set of fans handle only clean, low-temperature air
and thus have reduced maintenance.
Controls are also simplified.
It is readily adaptable to the new furnace wall construction which
is gas tight.
With pressurized firing plant maintenance frequently
goes up.
It also requires a pressure-tight boiler and air or steam
lancing or furnace probing becomes more difficult.
In the case of
the fluid bed a gas tight enclosure must be used to contain the bed
and accomodate the relatively high gas side pressure differentials
that are proposed.
There is no need for lancing or probing in the
fluid bed boiler.
Therefore, pressurization seems a natural choice.
The air and gas flow circuitry for the fluid bed boiler
is illustrated in Figure 4.2.
Air enters the system at three
points, the forced draft fan, the coal-air transport lines and
the sealing air to the coal feeders.
The latter two sources are
minor and may be dismissed from further discussion.
The primary
source of air in conventional practice is referred to as the
secondary air stream, as it supports combustion.
To avoid con-
fusion the nomenclature will not be changed.
The secondoLY air enters the system at the forced draft
fan.
It is heated in the. air preheater to 735°F and passed on to the
air ducts of the boiler where it is split into five streams
feeding each one of the fluid beds.
A separate cool air stream .is
K-46
-------
I
.
I
.
~ :~
"I"" I'
~ I I
. . I .
i FEEDERS i I FUEL
: ; INJECTOR
L .J.. b-.,.
.. COAL- --T"'~ .:. '/~
TRANSPORT AIR i!
--r~'-'4
FEEDERS
I
. !
COAL
TRANSPORT AIR I
---@--c::::J-._._~
~
F.D. FAN
LEGEND .
COAL FLOW
-....-
AIR FWW
.
FIGURE 4.2
AIR FLOW DIAGRAM
(ONE MODULE OF FOUR)
o
-,
I
,
CYCLONE
PRIMARY
AIR FANS
CYCLONE
PRIMARY
AIR FANS
I . .
I I
I
, I
I
I I
a, I
r----- ------y+ ----.L -_-J
, ,
,
, -,
, I
I I I
I I AIR I
I IPREH~TER :
L_____- -1-- - !.{jA~~-~--
TO PRECIPITATOR
DUST
COLLECTOR
.
AIR AND GOAL -'-
GAS
---
K-47
-------
taken off after the forced draft fan and before the air preheater and
is feed to the CBC.
This is done to maintain the bed temperature
at 1900°F, since the CBC does not have submerged cooling surface.
A second stream of air, referred to as the primary air, is
drawn off after the air preheater.
Again, this is a practice carried
over from conventional boiler design.
This hot air is pumped to
a higher pressure by primary air fans and fed to the fuel injector.
At the fuel injector it passes up through a grid plate and through'
a bed of fluidized coal where it acts as a drying a~d fluidizing
agent for the coal.
The air, cooled to 250°F, leaves the fuel injector
laden with coal fines which are subsequently removed by a Stairmand
type single cyclone.
The clean air is returned to the secondary
air stream.
The combustion gas leaving the beds is withdrawn from the
boiler through a common gas duct and passed through, a mechanical
dust collector where it joins a gas stream from the CBC which
has undergone a similar process.
The united streams pas's through
the air preheater and electrostatic precipitator before leaving
by way of the stack.
4.3
Energy and Mass Balance
The energy and mass balances were calculated for full load and 75,50
and 25% of full load.
The calculations were made on the basis
of data specified in Section 2 by Westinghouse.
Partial load
data was calculated for reduced bed temperaturRs on the basis
of steam duty and selected air-to-coal ratios. The bed temperautre
is allowed to drop to avoid overheating of the tubes but not
to a level which would risk unstable combustion or impair sulfur dioxide sorpti~n.
K-48
-------
The overall energy and mass balance appears in Figure 4.3 and
4.4, respectively.
Partial load operation is tabulated in the
appendix along with energy balances for individual beds and
carbon burn-up cells.
The energy balance for individual beds was mad~ by consid-
ering the bed a control volume and balancing the energy input and
energy losses.
The difference between the two or the unbalance
is the heat transferred to the steam in the bed.
The input.
energy includes the sensible heat of the air, coal and limestone
at 80°, and the heats of reaction of coal and limestone.
The out-
put or losses, includes the overall steam generator loss, and the
heat 105s to the convection bank.
At partial load the energy in-
put and energy losses (excluding some of the fixed losses affecting
boiler efficiency) all change due to the decrease in air and coal
input at constant excess air.
At full and partial load the unburned carbon loss with elu-
triated material accounts for a 13 percent loss in heating input
tc the fluid beds.
The carbon burn-up cell is designed to be maintained at 1900°F
entirely by the combustion of carbon e1utriated from the fluid
beds and collected by the dust collector.
This amounts to 11.6%
of the carbon feed to the steam generator.
Bed temperature is
controlled by introducing cool excess air from the forced draft fan.
A portion of the heat is removed by the enclosure walls.
The
flue gas leaving the bed is cooled by a feed preheating convection
bank.
At reduced loads the CBC temperature is held constant to avoid
a loss in combustion efficiency.
This is accomplished by reducing
the excess air requirements.
K-49
-------
-
;:>;
I
Vl
a
COAL
100 Tons/Hr 1
SORBENT-4?5 T/hr.'
AI.R (80°F)
.>
50.6 T/hr
- 43.5 T/hr
7.1 T/hr
MAKE-UP SORBENT'
FLUE GAS
--
PARTICULATE: 21.0 T/hr>
ASH: 33.75%
COAL: 59.45%
U.S. :
6.80%
FLUID BED
COMBUSTION
SORBENT
5.1 T/hr
AIR 800F
1600°F
VEL.~11 ft/see
X's AIR 10%
EFF. 87%
I
AIR
(780°F)
\
, ) I USED
SORBENT
50.8T/hr
CaS04:37.8%
CaS04 11.4%
PRIMARY
CYCLONE
T)=96%
PARTICULATE: .84 T/hr
20.1 TONS/HR
COAL CONC. 59.4%
C.B.C.
1900°F
VEL. 10 ft/see
X's AIR 70.5
EFF. 85%
FLUE GAS
--
PARTICULATE 10.85 T hr
ASH: 70.79%
COAL 14.01%
U. S .: 15.2%
AIR
(80°F)
USED SORBENT (U.S.)
5.65 T/hr
CaS04 :37 .8%
56.5 T/hr
-------
~
(FOUR MODULES)
OVERALL MATERIAL BALANCE - FULL LOAD
FIGURE 4.3
J
1. 27 T/HR
to ELECTRO-
sunc
PRECIPITATOR
.43 T/HR
f\=96% SECONDARY
CYCLONE
10.42 T/HR
~ TO SORBENT
REGENERATOR
,
REGENERATED
SORBENT
-------
--c
SUPBT. STEAM
2400 PSIG - 1000°F
,
"~AT2R IN
430°F
---~
REHEAT
STEAM
"6"fl) 0 F
601 PSIG
--
COAL AND
SORB"ENT
- --
I
I
I
ELUTRIATED
"SOLIDS
(59.4% CARBON)
,
;;<;
I
Vl
I-'
I
i
1- ----
SORBENT
REHEAT STEAM
581 PSIG - 1000°F
FLUID BED CELL
---
Heat of Comb~stion
22.46 x 10
Sensible Heat of Air
4.05 x 108
Heat of Reac.tion
0.44 x 108
Sensible Heat - CaO
O.(J6 x 10
Heat Losses
2.99 x 108
Heat to Steam
16.45 x 108
Boiler Performance
FLUE GAS 1600°F
85%
USED SORBENT
--_.-
1600°F
--.-'-.-... ~.'.. ------
CARBON BURN-UP CELL
Heat of Combustion
2.79 x 108
Seasib1e Heat of Air
."
Heat of Reaction
0.05 x 108
Sensible He~t - CaO
0.01 x 10
Heat Losses8
0.73 x 10
Heat to Steam
0.58x108
. .
---.--...----.-
. USED SORBENT
1400°F
-'---
---...)0--
FLUE GAS
1900°F
FIGURE 4.4
STACK
TO GAS
340°F
-<
CONVECTION PASS
HEAT TRANSFERREO
840°F
8
4.56xlO
HEAT TRANSFERRED
8
1. 18x10
840°F
AIR IN 780 of
(10% Xl s)
AIR IN 80°F (70.5% XIs)
AIR 80°F
AIR HEATER
- 8
4.05 x 10
HEAT TRANSFERRED
t"
OVERALL ENERGY BALANCE (FULL LOAD)
(FOUR MODULES)
!
-------
4.4
Tube Details
Enclosure walls are fin tube construction, a1so frequently
referred to as membrane walls.
The walls are made of panels
of tubes connected by metal fins welded to the tubes.
The
panel walls are common construction used in pressurized furnaces
of large capacity steam generators.
The panel walls are fabri-
cated by automatic procedures presently available.
The tube walls serve several functions.
They act as heat
absorption surface for evaporating water as well as a partition
to separate gas and air streams.
Where air must be admitted to
"the fluid bed the fins are simply dlscontinued and the tubes
are bent out of line to provide a suitable opening.
The walls are relatively inexpensive and require little
maintenance.
They also serve as a conventional support system
for the horizontal tube banks, base plates, roof plates and
many of the air control dampers.
. The ..walls are supported off
of structural steel by hinged rods connected to the upper wall
headers.
The tube. banks consist of standard serpentine tube elements"
-
constructed of 1 1/2" and 2" O.D. tubes as commonly used in the
convection passe~ of l~rge boilers,' The number of tubes in the
bundle is dictated by the steam side pressure drop.
The ar-
rangement of loop-in-loop or single loop tubes is a compromise
worked out by the designer between numbers of tubes required,
surface required and geometry. or the volume the bundle is to.
occupy,
The tubes have a minimum bending radius of 1 1/2 times the
tube diameter which more or less limits the longitudinal pitch
K-52
-------
.-
of the tube bundle.
In conventional boilers the lateral pitch is
fixed by erosion, heat transfer and gas-side pressure drop con-
siderations.
In the case of tubes in the fluid bed the lateral
pitch is dictated by the tube penetration spacing of the "Monowall"
enclosure.
The tube bundles are fabricated on automatic tube bending
machines at an average rate of 1.4 bends per minute.
After the
individual tubes are bent they are assembled into elements and
:inally into tube banks ready for shipment.
Individual coils or loops forming elements of the bundle
are connected by welded fins near the bends of the tube.
At
this point the tubes in the lOwer half of the bundle are slightly
offset to minimize the fin required.
The tube bundles are sup-
ported off the finned water wall enclosure tubes.
4.5
Air Preheater Surface
Air preheater surface serves several purposes, 1) it
minimizes hot gas losses and thereby improves plant performance,
2) it provides hot air to the furnace to avoid excessive quench-
ing of the bed temperature and, 3) it provides hot air for drying
the coal.
Several types of heat exchangers are available for this
service.
These include the regenerative air preheater and the
tubular air preheater.
The regenerative air preheater simply
consists of a large rotor containing buckets of corrugated
surface.
As thes~ buckets are rotated they are alternately
heated and cooled by exposure to the hot gas and cool air stream
K-53
-------
respectively.
Air leakage is inherent to this system at the
seals between the hot gas and cool air stream.
In low pressure
systems this does not amount to much.
In the atmospheric'
fluidized bed boiler substantial pressure differential must'
exist between the inlet air and outlet gas stream by virtue
of the large'pressure drop across the'bed.
To minimize the
system pressuredrop'without effectively reducing bed depth,
the pressure drop through the air heater and other auxiliaries
must be as' ,low as possible.
This requires large auxiliary
equipment which increases the size of the seals and compounds
the air leakage problem.
The' tubular air heater, as the name implies, is simply
a tubular heat exchanger with the gas inside the tubes and the
air making about 3 passes over the outside ~f the tub~s., It
is illustrated in Figures 4.5 and 4.6. 'In this type of heater,
there is no' air leakage. ,The cost of' conductance, Le., the
cost of surface divided by the heat transfer coefficient is
slightly higher for the tubular heat exchanger and, therefore,
it is not as frequently used as the regenerative air heater.
Both units were designed and priced and the tubular air
heater described in detail in the appendix was selected as
the preferred heat exchanger.
4.6
Particulate Removal
A two-stage particulate removal system is proposed, using
a mechanical dust 'collector in the first stage to retrieve the
carbo~ from the fluid bed and ash from the CBC and an electrostatic
K-54
-------
'~".I
<.
~
~
I ..
J
---:.-~-
-=z~
_"::-~
25'~O.
"
Z !.c.
!" "
~ ~
~ ~
-t ~
.$!.CP
- ~:::~'4
I
I
I
~
25J-O~.
~~
."-
~
--:....-:."':1
~5=
- ~~~=
4.12
~
~~ ~
~II)
" ~
25~O'.
~
<:)
i=:
<{
:>
~
-J
~
~
..
~
lUll tH..I\1t~
AHI05PHB..\C FLUIDIZEO
oED 5HAM GtlJeU10~
fo~
300 M W
PLAN i
fOu!?..(4.) R.EQUI"e:.D
fl(,UQ..t. 4.5
-------
."
I
I
I "
I
I
Sit!" f0""-"
be.~.....s
.
ORDER NO.
C-Sl:\-\\q1.
TU'OULAt
A\~
HeAlER..
DRAWN BY:
,J---
5{7/."
CHECKED BY:
R.'~.
~
Thi. Drawing i. the Properly 01 the
FOSTER WHEELER CORPORA TIO"
"0 SOUTH OIlAtoIC! .to V£toIUI!
LIVINCSTON. toIl!W JERSn
AND '1 LeNT WITHOUT CONStO~".TtON OTHE~ T~.... THill .O"fIIO.~"..
AQIltCaWENT THAT IT 'HALL. NOT 8£ '-£PlltOOUCED. COPIED, L.ENT, 0" 0'14
-oleo Oil' O"~.CTLY Ollt INO,IIt£CTLY NO..UII£O IJ'Ollt "'N'" PU"'POIE OTHE;1It
TMAN THAT "'0111 W"ICH IT 'I SP£C' II'IC A L..L..Y fJ'Uflll:NISH«'O. THC .~~""'.TU'
"H01ll... IN TH. O".W\NG ,. Cov£"I£O 8V
APPROVED BY:
SCALE:
=- I' -0"
~D7\4.\\2
c. .. co.. ...0. ...-...
K-55
FIGURE
4.{,
PO".. ....8..C:
-------
precipitator in the second stage to clean the flue gas to .01
grains per standard cubic foot.
The gas laden with elutriated material rich in carbon en-
ters the multiclone cyclone dust collector illustrated in Figure
4.7.
Ninety-six percent of the material is removed, collected and passed
on to a Petrocarb fluid bed 'injector which sends it to the CBC as
a fuel.
The collected material contains about 59.45 coal.
A portion of the dust collector has been partitioned off to
receive flue gas from the CBC laden with ash and spent sorbent.
Ninety
six percent of this material is collected and withdrawn from the system
as waste material.
Multiclone cyclones in theory are more effective collectors
of small particles than larger cyclones using the same gas
.. .
velocities.
In practice, this imporved efficiency is re-
duced because of the increased short ci.rcuiting that takes
place in small cyclones operating in parallel.
Theo~
important asset of the multiple cyclone arrangement is the
efficient use of space at high capacity in contrast to the
large volumes and high head-room required by the single.
Stairmand type of dust collector.
An electrostatic precipitator is used to clean the effluent
---
gas from the mechanical dust collector.
This is not an uncommon
practice.
Electrostatic precipitators are often combined
with mechanical dust collectors in cases where gases have except-
ionally high dust concentrations.
. .
One electrostatic precipitator .is used for all four boiler
modules as the most economical approach to the problem.
K-56
-------
II
I I
: I
~
T()!JiJlAR
~C'(j)f
"-
'-j"1-------------
I I
II
I I
I
-&s.-
Pus T (1()I'P~R
I purF()R}t1
C.8ciruEL
INJE(: rote
,..
- -I -
I
eL [VATION
UI \Y »
." ,..,. -4
0 0 CJ ;:: 0
c 0 (;> C
." fO \J\ V' <./I
~ ~ ""
" ~ ,.., :r .4
,..,
c :E I~ ~ TO n
f' :s: 0
fJ ~ fO ,...
,... fTI " r ~
.... .." ,... t:
p. p r z: r rn
c ;p ,." c "
-..I Z; 10 a -4
fC' :P ;::; (;>
", -4 .....
0 0 .... I"
10 0
-------
4.7
Coal Handling
The (:oal handling plant was designed to process 1 1/2" x 0
coal.
The handling process illustrated in Figure 4.8 includes
receiving, storage, crushing and conveying of coal to the feed
injection system.
Coal arrives at the plant twice a week by unit train and
is discharged into the receiving hopper.
Unloading requires about
5 hours.
The coal is conveyed to a 12,000 ton silo which acts
as a buffer between the batch-type receiving operation and the
continuous feeding operation.
It also handles live storage to
compensate for short term interruptions in delivery.
Live storage is supplemented with a 50,000 ton open pit dead
storage system including reclamation equipment to provide for
longer term interruptions in coal delivery of up to four weeks-duration
The coal from the silo is fed to a reversible hammermi11
crusb.e:rwhere it is ground to 1/4" x 0 with a size distri-
bution as shown in Figure 2.1, Section 2.1.
The ~rushed coal is then fed to a 150 ton surge hopper
feeding a second series of surge hoppers serving individual
feed injectors to the boiler.
4.8
~ f'-'~ding
A d1rect fired coal feed system illustrated in Figure 4.9
was sel~ctcd to dry, distribute and transport crushed coal to
the boi1~' r.
G~nerally, one of four systems is used to distri-
buting p"lv,orlzed coal to steam generators.
These include:
1)
Bin system
2J
Direct firing system
K-57
-------
DC
~
4 FEEDERS
500/700 tph
EACH
"'1
,H.
C')
~
~
.
po; 00
I
Vl n
Cb 0
>
t"'.
~
t"'
H
Z
C')
"'C
~
t-i
El.170'
I! I r11
I
RECLAIM
HOPPER El.270'
400 TON H0Y:PER -~EEDER F2 -----
00 tph - ~-o
1\ /\ 80' -~-----
-!:J,H ----::::::.->-.-;:::---l-tETAL DETECTOR
1 ~ :TI-:::::;::::;--- 200 tph 12 x 0 12.000
I I ~BELT 54" BELT CONV. NO.1 TON
56 p-- . ,~CALE SILO
. . 'NO.1' DC 70' DIA.
-~~ ~ 1\7\7
~_.
CONVEYOR NO.2
150 tph
CRUSHER'
24 x '6 SCRAPER CONVS.
----
COAL FEEDER SURGE SILOS BY OTHERS
BY-PASS TO DEAD
STORAGE
DEAD STORAGE
50.000 TONS
~>._JiJ DUST COLLECTOR
--'
150 TON,
. SURGE BIN
2 FEEDERS F4
0/7 5 tph EACH
'.
. /
~
GROUND E1.100'
77;is/~~4 .
/
_/><~
--__._._1.____--0.
/~/.!::~.,
-------
: 4018
NOTES
~t
W.
.' I . I
I .
I . I
! H
~ :
:--: i
r
--_.1kJ~-
8CAL8 TMI8 ....-- ~ ~
I. 00 ..,.,. OM.T.
~ Da&_"
.. A88aY1A'n0M8 "::.. OII~ .,.=
:===...U8088DIM
CbA..\-
"""
&'.0"
-r ,
r-~ci
.' I
I
..~I
. __2~:. '--r l
I :
"AI i I
"'-LII..~
c 0 Po \..
&U""Y...t.L.~
1.0'.0"
"'.0"
t# t:~~~-~~._._-
. ""1~Oe...c.
-~\..,&'-o.
. ---.-
~ :
01 I
'0: I
-, I
I
- ~."~': :;'14-1" !
.
O\lCDW i
~tCc"'" I ;
~:~J: Jr I
-. .4
. i
, I
.~i
'l
.1
0,
'~I
..,
.t\.!~' })'~. .
O~c.o~
c.'( C.\.DWt.
i ;LI
f i l _1
f--
i -
, ..
. !
?Q..'~""''( ,..\~ TO
J..t."UR..'" O\"\::\"'Ob~A
V\'\UO 11:).
"A.J
(L.12""
PLAN
AI
E.lll/. 40',0'
~ !
- .._~! I
l_i1n!
I -
I I
i .
I i
...-
- DOft
....-
..VI.'O..
- .~- A.'
5E.C.iION
F \ G. 10.4.'3
.~\lIOI'tlO
O~P....la..\'
~iM ~~I~~
- COA.l. 0
~t.O &'(~'H.II\
I"'Jt'i~ON.
A.K t) FUI1..
~OOMW PI.A~i
TIdII~""~~
IF08TDI ~ &.--na~:'
lJ]ii ... -::::: -::. ~==.r,;.!
-- y:-ur:...:..~. ~
-,. -=- - ... -....
- ~
t:~J:
'20'... 4~.
P't.l."".Q.,. AIL
U..I\o.t.T
G~O'" t.I..O'-O"
-,
. ~, b'O
~E.c:.TION
o-!>'-\l'H
DtlAW1III "'1
CMaCIC8:D 8Y:
........... ft,
-------
3)
Central pulverized-coal circulating system
4)
Direct firing circulating system
They are illustrated in Figures 4.10, 4.11 4.12 and 4.13.
The direct firing system is simple and efficient in opera-
tion and well adapted to automatic control.
Practically all
pulverized coal installations within the last 25 years have used
the direct firing system
(2) .'
The system normally consists of receiving bunkers, feeders,
pulverizers, transporting conduit burners and primary or trans-
port air fans.
The functions of the equipment is to pulverize
dry and feed coal to the boiler., Adaptions of the system to
a fluid bed boiler require several modifications.
The modified
system must dry, pressurize, distribute and feed coal to a
multitude of injection points far exceeding the number of
burners used in a conventional boiler of comparable size.
The
key factors here are multipoint distribution and pressurizing
to 45" H20.
The modified system includes a receiving bunker, a surge
bin, volumetric feeder, fluid bed dryer and distributor dust
collector, primary air fan and coal-air transport lines.
The
coal flows from the surge bunker through a downspout which acts
as a pressure seal to a volumetric feeder.
The feeder regulates
(2)
Allen J. Johnson and,George H. Auth, "Fuels and Combustion
Handbook", McGraw-Hill Book Company, Inc., New York, 1951.
K-59
-------
Raw ,,," bi"
F"rnac,
.-,wall
Bi"
1fI"- -
FIGURE 4. 10
DIRECT FIRING SYSTEM
(The Babeoek & Wiieox Co.)
REF.
(2)
.-
.' R",,", 'l/ltl
- - e.rhousler
"DlSldb"flng mol"
,
;1
;'1 I
. ,
t~
~I E~=~~
<»;t---f$'
, ul
- I I~ ,.1
, t 'f
. :1.
i i1 ~!i ~
I <-==~=:..~ ill I' ~'- .
~~~l
FIGURE 4.11
CENTRAL PULVERIZED-COAL CIRCULATING SYSTEM.
(&tbeoek. & Wileox. BulL No. 3-392) REF. (2)'
K-60
-------
ep.~ting ",Iitll vtlnl- ~ D D- -[f-- --Vtlnts
/I,li,1 valv,- - -
Primar, cyclon'!. -
.pa~tor" --
$#tI1 valve 0 . - -
- - - Seal valve
/law luel bin
Pulverired luel
18eder
,
,
" Pulvtlrlred lutll
jt' to burners
,
,
I
FIGURE 4.12
BIN SYSTEM (The Babeoek & W~eox Co.)
REF. (2)
/1- coalleed8r. . ,
.-Coalllopp8r
1!8turn lin6-,. ,
,
,
,
,Air temp8ruture dampe'
,/ .
. - Hal air supply lrom reto,t main Il""
-Coal distributing lin8 lotal length 008 fl.
Centrol - -
val", - - - -
- -Oistributing blo...e,
/Retort furfltlces
I
Cut-off valve
,
,
,
,
Forced draft
combination
t:COl and oil
b41r~'
Natural draft pulveriud cool bUM8r - - . - - -
Coal and air control valv8 ,.
FIGURE 4.13 DIRECT-FIRED CIRCULATING SYSTEM. FIRING..
CHEMICAL RETORT FURNACES AND STEAM BOILERS AS INSTALLED
IN 1944 AT STAUFFER CHEMICAL CO., BENTONVILLE, VA.
CAPACITY 23,000,000 Btu PER HOUR. LENGTH OF LINE 608 FT.
(The Babeoek & W~eox Bull. No. 3-392) REF. (2)
K-61
-------
the coal feed to the system by means of a wire and variable speed
belt.
The coal flow's, by gravity from the feeder to a fluid bed
dryer and distributor.
Aft~r car~ful consideration of numerous
possible means of flow splitting and, distribution within the
boiler shell and out the fluid bed with its" inherent homogeneous
distribution characteristic appear to be the most reliable means
of distribution to a large number of feed points.
Its desirability
was further enhanced by its ability to dry coal in the same
operation eliminating the need of a separate coal dryer and
enclosed feed conveyors.
The fluid bed dryer is illustrated
in Figure A4-7 of the appendix.
Its accessory equipment in-
eludes a primary air fan providing hot pressurizer air for flu-
idizing and drying and dust collectors for removal of elutriated
material from the cooled air.
One inch feed lines transport the coal froin the bed to 2"
feed lines.
The coal is pneumatically conveyed to the boiler
in a dilute phase.
4.9 ,Sorbent Feeding
Sorbent, feeding falls into two categories; feed make-up
and recycle of regenerated sorbent.
Provisions were made in
each of the beds for one injection point to handle the regenera-
te4 material and one withdrawl point for removing spent lime-
stone.
The regeneration cycle and equipment was designed by
Westinghouse and are discussed in their portion of the final report.
The feed make-up system was included as part of the boiler
. . ..
accessories and is described in Figure A4~4 of the appendix.
It simply consists of a receiving hopper capable of
K-62 ,
-------
handling limestone delivered in covered rail cars or trucks, a
storage silo for dead and live storage and pertinent conveying
belts.
The limestone is discharged on to the coal conveyor just
before the surge hopper to the boiler feed system.
Although the
limestone feed is -1/4 as received at the plant the hopper bin
angles and conveyor belt were designed to handle the fine material
(
(1000-5000 ~ in diameter) at little if any extra cost. Conveyor
elevations had to be minimized and hopper slopes had to be increased
to 63°.
4.10 Carbon Burn-Up Cell
The carbon burn-up cell is a sixth fluid bed located at
the bottom of the boiler.
Its function is to burn-up the materi-
al elutriated from the fluid beds and collected by the mechanical
dust collector.
This material contains about 60% carbon with
a reactivity somewhat lower than the raw coal feed.
The bed is
operated at 1900° without submerged tube surface to insure com-
plete combustion.
High excess air (about 50%) at ambient temperature
is. used to control bed temperature.
Material elutriated from the main fluid beds and captured
by the mechanical dust collectors is fed to the CBC by a Petro-
carb fuel injection system.
This is illustrated in Figure 4.7.
The system includes a collector vessel receiving the partially
spent ash from the dust collector hoppers.
The ash flows
freely from the dust collector minimizing its residence time
and exposure to ~Qt gases and thereby avoiding the risk of fire.
If necessary the atmosphere in the collector can be maintained
inert.
From the collector vessel the material flows to the
fuel injector at periodic intervals.
By means of localized
K-63
-------
fluidization the pa~~iculate matt~r is fed from the fuel in-'
.. jector vessel through 1 1/2" lines. to 16 individual feed in-
jection points.i~ the CBC.
.1
.'
. ,
K-64
-------
~-
5.0
OPERATION AND PERFORMANCE
5.1
Operating Procedures
5.1.1
General Operating Characteristics
Operation of the
steam generator might best be discussed by considering it as a simple
heat exchanger containing an exothennic reaction.
Its behavior then
is dependent upon the operating characteristics of the two flow
streams, the hot gasses and steam, and their interactions.
The steam side of the heat exchanger is a once-through flow
circuit in which water is heated, evaporated and superheated.
There
is little difference between it and a conventional once-through
boiler and, therefore, its mode of operation is basically the same.
The gas side flow path is d~cidedly different from a conven-
tional steam generator.
Therefore, an understanding of the behavior
of the fluid bed and its limitations and restraints are essential
to an understanding of the operating characteristics of the boiler.
Combustion takes place in the bed at a nearly uniform temp-
erature,
as a result of the excellent mixing of particulate
material.
These are somewhat idealized conditions.
However, they
are reasonable assumptions for developing a preliminary design.
Gas side heat transfer coefficient is nearly constant regardless
of bed temperature or gas mass flow.
.The overall heat transfer
coefficient is reduced slightly at reduced loads due to a decrease in
the steam side heat transfer.
Credit may also be taken for a high
heat transfer coefficient in the volume immediately above the bed
about 3' high due to partial elutriation of large particles which
.fa11 back into the bed and the combustion of some volatiles .from
the coal.
For any given bed there are essentially two limits which
define its size
1) heat transfer and
2) pressure drop.
K-65
-------
, ,"
Once fluidized, the pressure drop through the, bed remains es-
sentially constant until the terminal velocity for the bed particles
is exceeded and the bed is'partially elutriated.
This is
illustrated in Figure 5.1.
The gas velocities then are limited to
a range bounded by the fluidizing velocity and terminal velocity
as shown in Figure 2.2~
Pressure drop througl) the bed and distributor plate is high.
Therefore, the bed depth is limited to about 30 inches at atmospheric
pressure.
Deeper beds require optimization of the trade~off of
capital investment in the shell structure and feed points versus
, the increase in capital cost and operating cost of larger fans.
The maximum bed temperature'is 1700 - l80bo F based on
characteristics of the ash and sulfur recovery considerations.
l600°F was selected as the design temperature fo'r the atmospheric
boiler.
l300°F is set as a lower limit for'continuous operation
based on sulfur' recovery liinitations and stable combust:1on.
The fluid bed'appears to be restricted to a large flat "pan-
cake" type furnace constructions or combustion zone unless stacked
as selected in the conceptual design.
At temperatures'of l600°F it
--'
is essential that most of the steam vapot superheating surface be
installed in the bed.
To avoid overheating during start-up, the
stacked beds were assigned individual heating'functions permitting
independent light off in a sequence that would be compatible with steam
generation.
This arrangement has the added feature of separate control
of firing rates for each heating function,
heating,evaporating, and feed heating.
i.e. ,
reheating, super-
Since the rates of transfer of heat in the bed and in the
K-66
-------
-
.-
--
----- - -
TOTAL tiP
~
.........
- --
-
p..
-------
volume immediately above the bed are high and nearly the same, load can-
not be effectively controlled by raising and lowering bed height.
Needless to say, the mechanical problems of doing this may also be
quite cumbersome.
Modular construction appears to be the logical
means of meeting a 4-to-l turn down.
This arrangement also re-
duces construction time and should minimize total outage.
Modular construction also minimizes an otherwise disturbing
meta~ temperature problem.
The transfer of heat in the bed is
governed by the simple relationship described by Equation (1).
q = US
fiT
mean
(1)
Where:
fiT
mean
=
Tl-TZ
(TB-Tl)
Ln(T -T )
BZ
q = Duty Btu/hr
S == Surface FtZ
~. U = Overall Heat Transfer
T == Bed Temperature of .
~ == Temperature Steam In of
12 == Temperature Steam Out of
The equation indicates that a drop in load reflected in
Equation (1) as a decrease in heat flux q/S must be accompanied
by a reduction in mean temperature difference.
U is virtually
independent of load.
With a constant bed temperature and reduced S
the tube metal surface temperature must increae~.
This may have serious
consequences.
Higher alloy steels are required.
In addition the
tube life may be shorter and the risk of burnout exists.
By going to modular construction any individual module need
" ,~
K-68
-------
only be turned down 50%
This load reduction in the module may be
achieved by reduction in bed temperatures of about 200°F.
Stable
combustion is maintained and sulfur recovery is assured.
furn
down to levels of 4-to-l are achieved by cutting out individual
modules.
5.1.2
Ignition
Ignition of the fluidized bed is broken
down into three basic steps 1) warm-up of the bed and pressure
parts, 2) heating of the bed to ignition temperatures and 3)
coal injection at ignition.
Ignition of coal in the bed should
take place once the bed temperature exceeds 850°F.
Warming up of the beds and pressure parts is accomplished
by six 6.0 x 106 Btu/hr ignitors located in the air ducts upst~eam
of the steam generator but down stream of the air heater as shown
in Figure 5.2.
This insures rapid heating of pressure parts in
the immediate vicinity of the fluid bed in the most efficient
manner.
Heat not absorbed by the bed waterwalls or heating
bundles is partially recovered in the heat recovery equipment and
recirculator.
Warming up the heat recovery equipment is of
secondary interest and will probably not be completed until after
the coal is injected into the bed and ignited.
.'
Air flow may be increased as the pressure parts and bed
temperature rise.
°
Once the pressure parts approach 650 F, the
air flow can be increased to fluidize the bed.
Once the bed is fluidized the second set of ignitors 10-
cated immediately above the bed surface at an acute angle with
the waterwalls can be turned on.
There function is to heat the
K-69
-------
f-
'"
...I
2
\~,'51~Ll ~11~""
~P~.Lt.~
L t F T
t'~L'(
~r
-S I 0, l
AIIl. "0
~1"~ ,
~MI!>f.il.~
01
~l
~\R.. \~\..~T
O\,)c.'t
\
\
"-
-
\
\
-----~---....
'--~";'-::;" -" ........--~-
~ GU\Cf..,
""~E..~
"2
''Zo
~~
'.
<%,
.,
... .., ~
" Ii: l'I
J 4.-Z
- ~-
o.itL.y)
~,
~l
,,!
:----.
\.5p~a."
,P\.U4'"
13314--
,
. ,MA'TC~ l\t.1f.-
, , L s if., F \ 4. ~. ~
. #'
(t, 11 ~ -0.
"
f
I
I
I
-~-----~-~~-~
. -------------.
I
I
I
I,
-------------..
-- ---='==---- - - :....;;=-->r-
I
I
I
- - -~----- -----'
- --- ==-:-":_--"-----==1
.
I
I
I '
I
j
"
I'
t-
U
::a
,I~
I I
Vt
.,
11110
4.:)
\1'-
//,. ;'---::-""':,
" ...~....
, ",,-,
. -'-"~¥_", ...."",
~~~ "',.
::0.-- /' ' ".. '\ '",
, ...............-....... , ..........
-..::-..... ,
. """.:'~
o
o
~
". ....-:. ,.......~.:"
fl, ":::~""-"" / ,"'"
,=r .~co~iS-C//
t--- .,
ORDER NO.
O.S~.1I1'Z.
J~ 7 '7~/"
"
W t\ ~ M. Up' \ G ~ \ "\() ~
~1MP~P~t2...\' FL\J\,OllED ~tD
b~ , L ~ ~
DRAWN BY:
CHECKED BY:
I
e
,: Thh Orowlng i. th. Prop.,ty olth.
FOSTER WHEELER COR?ORATIOM
110 SOUTH ORAHGE AVEMUE
LIVINGSTON. NEW JERSEY
AND .8 LENT 'If! THOUT CONStOER A rlON OTH ER ~H AN THE 80""OW~"..
AO"..".NT THAT IT IHALL NOT 8E REPROOUCED.COPIEO. LENT, 0" 018-
"01.00... O."ECTLV 0'" IND'"IECTLY NOAUJiEO ,rOR ANY PUR POlE OTHER
THAN THAT ,"OR WHICH IT II SPEC'II"CALLY FuANISHED. THE APP.."..TUI
.HOWN IN THE O"AWING " COVEIIIIED BY PATENTS. .
C. 8. CO.. .0. "..'8
APPROVED BY:
SCALE:
= " .. 0"
K-70
Q..D.114- 159
F \ G.
5.2
-------
bed to ignition temperature.
If it is found that total fluidiza-
tion of the bed dilutes the heating process and prolongs the final
warm-up stage to ignition. Local airports using compressed air
from the coal feed system can be used to locally fluidize the
bed along one wall.
The secondary ignitors are shorter versions of the warm-up
6
They are rated at 2 x 10 Btu/hr since over bed ig-
ignitors.
nitors are reported to be only 70% efficient in transmitting
heat to the bed.
When the total or local bed temperature» as the case may be»
reaches 850°F the coal can be injected into the bed.
It may be
that a separate coal injection port will be required at the top
of the bed in the vicinity of ignition for light off purposes only.
The carbon burn-up cell will receive less reactive coal so
its ignition point will be higher.
The bed should be heated
to 735°F before it receives any fuel.
This cell should be equipped
with a gas burner capable of on or off operation based on bed tempera-
ture.
This will insure combustion of the elutriated material
and account for variation in rates of carryover.
A review of the literature indicated of the four possible
." -
arrangements of ignitors» i.e.» 1) external burners 2) internal
submerged tunnel burners 3) tunnel burner above the bed» and
4) open flame above the bed.
The tunnel burner above the bed
was selected as the best alternative.
K-71
-------
5.1.3
Start-Up
Start-up from a cold condition is achieved
by placing one module in operation at a time.
Starting up the
second, third and fourth modules differs slightly from the first
in that feed water circulating through the tubes will be 500°
rather than 80°.
The start-up system for the boiler is the same
as that for a conventional once-through unit and appears in Figure 5.3
Valves B, W. P and D are initially open.
Water flow is then
"
started through the pre-evaporator bed wall tubes and first super-
heater bed.
, ,
After the first superheater bed the water flows'to
the flash tank and then to the condenser.
Next the pre-evaporator
and first superheater beds are ignited.
As heat is added to the system valve D is closed and the heat
recovery valve E is opened.
This mode of operation allows a
more rapid heating of the water than would be possible with cir-
culation through the condenser.
As heat is added to the circuit
a pressure of 2900 psig is maintained in the pre-evaporator and
evaporator circuits by throttling the W valve.
The pressure in the
first superheater and flash tank is kept at 600 psig by controlling
the A, D and E valves.
A steam-water level forms in the flash tank
and the N and I valves are opened to allow this steam to warm the
second superheater tubes and subsequent steam lines.
Next the
second superheater bed is ignited.
When the steam enthalpy is sufficient the turbine can be
warmed and rolled.
The flash tank pressure is then raised to
1000 psig and the steam flow is increased until the load is
about 10% of full plant load or 40% module load.
At this point
the turbine throttle pressure is raised to the operating value
K-72
-------
"
?<:
I
-:j
LA>
i
XI3
r\ -l U2
y~
~ r><1
TURBINE
14 ST~~_~ALVE
r---r U3 n 'U4
0: T~
Q ___I_...u~
r:-
t
Xu
r- - -"
() 1m
~'\
2nd SH
2nd SH
Nl
Or!
H
C)
c::
~
~ 7 1
'~
~E:;J
W1V1 WZUYZ
I~ B
-r:-r
~,H2
I
,
) f---'
2nd SH
2nd SH
-
N2 IX
V3 N3 V4
P2 I
P3
1st SH 1 s t SH I
--
.L, W4~
W3~- Y3 Y4
-,HI
I
I
) (-I
\J1
UJ
EVAP
EVAP
fB3
., H3
I
) l--!
~H4
I
I
)(u.'
..... TO TURBINE
A
r--{)
I
~
P4
LC I
I
,
1
,
,
D ,
B>---~
~ . :
,
D------'
E
C
t,
TO
CONDENSATE
PUMP
b:I
o
H
t""
t>:I
::Id
CI)
~
::Id
o-i
I
c::
'"d
CI)
>-<:
CI)
o-i
~
-------
by closing the P and N valves and opening the V and Y valves.
Subsequent increases in load are controlled by the turbine gov-
ernor and accomplished by increased steam flow.
Start-up of addition~i modules is very similar.
There
are ~ few differences, however.
First the feed water temperature
as already mentioned will be greater than SOO°F, rather than 80°F
as it is durin~ the first module cold start.
Initial feed heating
should be considerably quicker.
With the second, third and fourth
modules the flash tank is used in the same manner as before but
the I valve cannot be opened until the steam temperature and
pressure match the existing steam turbine conditions.
Until
these conditions are reached the U valve will be open and the-
steam will be sent to the condenser or a high pressure feed
water heater.
S.1.4
Load Control
There are numerous turn down techniques
which can be employed to achieve the percentage turn down desirable,
however,the turn down technique preferred must be the one based
on the consideration of ease of contiol, stability and reliability
of operation; degree of turn down desir~ble and rate'of response
. necessary.
Turn down for the atmosphere'utility boiier should
be 4-to-l at a load swing rate of response of 5% per minute.
In Section.5.l.l it was explained that turn down would be
achieved by using modular construction with constant bed heights.
Reduction in load from full plant capacity would Qe achieved
by reducing load on all four modules simultaneously until 75%
plant load is achieved.
At this point one module would be re-
moved from service and the load on the remaining three modules
K-74
-------
would be returned to maximum capacity.
Further reduction would
be achieved in a similar fashion until two remaining modules are
at 50% capacity.
The optiont thent is left to remove one of the
boilers and return the last module to full capacity or to continue
to operate both modules at 50% load.
The selection of the appro-
priate alternative would depend on length of time at reduced load
and operating characteristics of the sulfur removal system or
boiler in general.
Reduction in load is illustrated in Figure 5.4.
Turning down of individual modules to 75%t 67%t or 50% of full
load may be achieved in one of two ways.
(1)
Turn down by decreasing fuel and air input and main-
taining excess air and bed depth'constant.
(2)
Turn down by decreasing fuel input and maintaining
air input and bed depth constant.
For the same bed temperature mode 1 offers the greatest
reduction in load.
With a reduction in air flow along with coal
flow the gas mass flow through the convection section is reduced
significantly resulting in a substantially lower convective head
transfer coefficient.
Since the gas temperature follows the
bed temperaturet the convection section duty is proportionate
to heat transfer coefficient.
In addition to the greater flexibility
in operation less fuel and lower limestone recirculation rates
are required and much less heat loss through the flue gas is realized.
5.1.5
Shut-down
Normal shut-down is accomplished in ap-
proximately the reverse manner to start-up.
The first module
load is reduced until it is 50% of full module steam flow.
At
K-75
-------
. .,
.
. BOILERS IN OPERATION ( )
100
/
/
N // /
~ 60 . /'" / . /
',2 #/ #
o ~ ~
:i: I ~c<,,/ ~r
:;i! ~/ Cj
S 40 r-,/...$ ~ / ~$7
> A..J ~ / ,,~
H '. 6'¥/ ~~/ '\-/
~ "''/ IV / / '
~ /. .#; / / :.
~ ~I ./ /
~20 /I~/
if,
20
Q
<
3 80 -
,.J
,.J
::>
~
~
o
~ (1,2,3)
~.
SYSTEM LOAD
o
J
40
I
. 60
I
. 80
100
TOTAL BOILER LOAD, % OF FULL LOAD
. FIGURE 5.4 BOILER LOAD REDUCTION
.
K-76
-------
this point the I valve would be closed and the U valve wo~l~
be open to permit flow to the condenser.
Fuel flow would be
stopped but fluidizing air would be maintained in the beds in
order to purge and cool the beds.
When the bed is sufficiently
cooled the air flow can be stopped.
If it is desirable to keep
the module in a standby condition, feedwater flow would be
continued through the pre-evaporator bed, evaporator walls and
first superheater bank.
This flow would be achieved by closing
the V valve and opening the P valve.
Feedwater would then flow
through these tube circuits and maintain the bed at approximately
500°F.
If it is not required that the module be kept in a stand-
by condition feedwater flow will be stopped by closing the B
valve.
The last module is removed from service by throttling the
pressure reducing valve Wand controlling the P valve in order
to reduce the turbine throttle pressure linearly with load down
to 1000 psi.
At this point the steam turbine would be removed
from service and the I valve would be closed.
From this point
on the shut-down operation would be the same as with the pre-
viously removed modules.
5.1.6
Emergency Shut-Down
Emergency shut-down due to steam
side problems is accomplished in the same manner as in conventional
units.
Loss of turbine, trip of fans or loss of pump should auto-
matically cut off the fuel supply.
Loss of fans, fuel supply or
pump automatically trip the turbine and the feed pump if the case
applies.
Although the unit contains large quantities of ash in the
bed which has a reasonably high thermal inertia or stored heat
K-77
-------
capacity the bed temperatures are low by conventional_stan~ards.
With only a 5%. fuel charge in the bed at any give~ time .the bed
temperature should not experience much of a rise before it starts
to decay.
Tube metal and stored water should. 9issipate the heat
when the bed temperatures are the.highest. - This may result in
popping of safety valves for a short period of time.
This, how-
ever, is not certain.
Once the fans are cut off and the stored
air is dissipated, the. bed will slump and heat ~ransfer from the
limestone to Efie"tube surfac:e should be greatly diminished.
5.2
Performance Characteristics
The unit performance is summarized in Table 5.1.
TABLE 5.1
300 MW ATMOSPHERIC UTILITY BOILER
PLANT PERFORMANCE
Losses
Percent
Dry Gas Loss (Stack Temp. 340°F)
6.50
Loss due to Hydrogen & Moisture in Coal
5.05
Loss due to Moisture in Air
.10
Ra9iation Loss
.18
.-'
Incomplete Combustion
2.39
Boiler Performance
1.50
15:22
84.78
Manufactures Margin & Unaccounted for
Radiation, moisture, and manufacturers losses are the same
as for a conventional boiler.
Dry gas is slightly lower than
. " .
most units due to the low stack gas temperature.
Incomplete
combustion must be higher due ~o the elutriation of fines from
the FBC and CBC.
K-78
-------
Pressure drop at full load is summarized in Table 5.2.
Pressure drop at lower loads should be only slightly less as
the bed differential essentially remains constant.
TABLE 5.2
Summary of Gas Side Pressure Drop
Duc ts
1.43
Distributor Plate
10.8
Bed
27.5
Convection Bank
0.1
Dust Collector
3.0
Air Heater Air Side
3.0
Gas Side
1.5
Electrostatic Precipitator
3.0
TOTAL
50.33
TABLE 5.3
Summary of Steam Side Pressure Drop
Reheater
PSI
125
96
41
55
55
51
142
.TOTAL 565
17.30
-
Feed Heating, Convection Bank
Evaporator Bundle 1)
Evaporator Bundle 2
Water Walls Pass 1
Water Walls Pass 2
Water Walls Pass 3
Water Walls Pass 4
Superheater Bank 1
~uperheater Bank 2)
K-79
-------
.-",-
6.0
BOILER COSTS
6.1
Capital Cost
The capital cost of the 300 MW atmospheric boiler and assess-
ory equipment is summarized in Table 6.1.
All cost data was de-
veloped to proposal accuracy by commercial estimators..
Quotations
for standard equipment and assessories were obtained form quali-
fied
Where possible the costs have been broken down
vendors.
to show the cost of erection.
Erection cost for the assessories
include field assembly of the equipment.
Erection cost for
structural steel was all assigned to the steam generator.
.Steam generator cost includes headers, tubes, insulation,
ignitors, plCitforms, structural steel, flues and ducts, seals,
coal feed piping, tie backs and buckstays, springs, thermocouples,
etc.
Cost distribution of majoI' components of the steam generator
cost have been broken down and appear in Figure ,6..1.
This -data
is also e~t~apolatedto 600 MWwith reasonable accuracy to 11-
lustrate the effect of capacity on component cost.
The total capit~l .cost has also been broken down by indi-
vidual components and extrapolated Co 600 MW.
This is illus tra-
ted in Figure 6.2 and Table 6.2.
.' To complete the comparison and provide a measure forevalua-
tion the cost of the fluid bed has been compared with several .
cost estimates for 600 MW boilers in Table 6.3.
The figures quoted in these tables reflect the estimated cost
of the design developed in the report and show areas where efforts
IDa}' best be directed to further reduce cost.
The data indicates
substantial reduction has been achieved in steam generator fab-
K-80
-------
TABLE 6. 1
SUMMARY OF COST
PRINCIPLE EQUIPMENT
300 MW ATMOSPHERIC FLUID BED BOILER
1) Steam Generator $5,500,000
Erection 3,320,000 $ 8,820,000
2) Dust Collector 116,000
Erection 13,400 8,949,400
3) Precipitator 614,000
Erection & Foundation (3) , 645,600 10,209,000
4) Air Heater 1,110,000
Erection 272,000 11,591,000
5) Fans 200,000
Erection & Foundations (3) 220,000 12,031,000
6) Fuel Injection (FBC) 1,780,000
Fuel Injection (CBC) 500,000
Erection (3) 1,020,000 15,331,000
7) Coal Handling (2) 1,750,000 17,081,010 .
8) Limestone 325,000
TOTAL $17,406,000
(1) Cost extrapolated from 280 MW Boiler
(2) Complete cost including erection and foundations
(3) Cost provided by United Engineers
K-81
-------
. I
12,000,000 .-
FIGURE 6.1
COST DISTRIBUTION
FOR FOUR FIELD ERECTED
STEM1 GENERATORS
/
10,000,000 -'
8,000,000 r- .
I
~
~
o
Q
ERECTION.
.
~
en
o
to)
6,000,000.
"
4,000,000 . STRUCTURAL STEEL 'L
~ FLUES. DUCTS AND .r- ~
'INSULATION ~..
1_.
.' 'I
~.
2,000,000 PRESSURE PARTS 1 * Including Engineering, Drafting,
lho Contract Reserve, etc.
r zbo . ~u--~ I
~ . 5(\1) 600
PLANT SIZE (MW)
Lo
K-82
_.
I
-I
I.
-.
i
i
I
!
-I
I
-,
I
!
-,
.__J
-------
TABLE 6.2
SUMMARY OF COST
PRINCIPLE EQUIPMENT
600 MW ATMOSPHERIC FLUID BED BOILER(l)
1) .steam Generator $10,100,000
Erection 4,200,000 $111,300,000
2) Dust Connector 232,000
Erection 26,800 14,558,800
3) Precipitator 1,228,000 (3)
Erection and Foundation 1,291,200 17,078,000
4) Air Heater 2,220,000
Erection ~44,000 19,842,000
5) Fans 400,000 (3)
Erection and Foundation 440,000 20,682,000
6) Fuel Injection (FBC) 3,560,000
Fuel Injection (CBC) 550,000
Erection 2,040,000(3) 26,832,000
7) Coal Handling (2) 2,000,000 28,832,000
8) Limestone Feeding 325,000
TOTAL
$ 29,157,000
(1) Cost extrapolated from 300 MW level
(2) Complete cost including erection and foundations
(3) Cost provided by United Engineers
K-83
-------
2 DUST COLLECTOR-
22
20
\0
0 ;.
.-4
>< 18
en
j 16
,..J
8
z
H 14
E-<
en
0
t..)
12
10
ERECTION
/8
6
4
2 -
o
34
2
FIGURE 6. 2
DISTRIBUTION OF COST OF
STEAM GENERATOR AND ACCESSORIES
, I
LIMESTONE FEED
..
COAL HANDLING
FUEL INJECTION
FANS
AIR HEATER
STEAM GENERATOR
200
300
400
500
. L
600
PLANT SIZE (MW)
..
K-84
-------
TABLE 6.3
COMPARISON OF COST OF A FLUID BED BOILER
WITH CONVENTIONAL BOILERS
BOILER PLANT EQUIPMENT
600 MW
CONVENTIONAL
BOILER
DOLLARS
$/KW
74.49
29.8(5)
TOTAL
44,707
1)
2)
Steam Generator and Support
Draft System
17,800
(a)
(b)
(c)
(d)
0.96(5)
(1).
2.47(5)
0.45(3.5)
3.10
12.91(5)
2.54(5)
18.9 (5)
582
Fans
Particulate Removal
------
Draft Flues and Ducts
1,490
270
1,860
7,850
1,520
11,300
Stack and Foundation
3)
4)
5)
6)
7)
8)
9)
10)
Air Heater
Coal Fuel Equipment
Ash and Dust Handling Systems
Stack Gas Cleaning
Regeneration System
Sulfur Recovery System
Instruments and Controls
-------
-------
1'500(4)
,
535
2.50(5)
0.89'5)
Miscellaneous Equipment
(1)
(2)
600 MW
FLUID BED
BOILER
DOLLARS
$/KW
40,735
14,300
840
2,830
940
270
2,640
6,550
1,520
2,360
6,200
1,750
535
67.83
23.8
1.42
4.71
1.37(2)
0.115 (5)
0.45
10.90
2.54(5)
-------
3.97(5)
10.3(5)
2.92(5)
0.89(5)
No particulate control assumed beyond wet scrubber.
Ducts incorporated with steam generator; cost between air preheaters,
precipitator, and stack obtained from United Engineers cost estimate for
, ducting at the same conditions for the pressurized plant.
(3)
May be greater since no NO control assumed. Stack height assumed for all
plants of 280 ft. based onxemissions projected from presurized fluid bed
boiler combined cycle plant. '
Instrumentation for stack gas cleaning, regeneration, and sulfur recovery
systems is included with ,the respective systems.
(4)
(5)
Data provided by United Engineers.
K-85
-------
ricating cost.
However, there appears to be room for improvement
by reducing structural steel, cost of flues and ducts, and erection
time.
A reduction in the cost of the former must also result in
a reduction in erection cost.
As indicated in other sections
this might best be achieved by going to a self-supporting boiler
enclosed in a '~ap around shell.
6.2
Maintenance, Supplies and Operating Cost
Maintenance, supplies and operating cost are most frequently
lumped together.
In keeping with convention, they are lumped
together here.
Maintenance, costs, etc., are virtually impossible to esti-
mate for untried equipment.
With proven systems the costs vary
from year to year, station to station and fuel to fuel.
It seems
reasonable then to project-available maintenance and operating
cost and indicate what affect the fluidized boiler might have
on it.
Figure 6.3 illustrates maintenance and operating cost as a function
of plant capacity for oil fired, gas fired and coal fired boilers (5, 6).
Maintenance, operating and supply costs for the fluid bed
boiler should be less than those indicated as the system no longer
requires the services of mills and soot blowers.
Tube fouling
has been minimized which should reduce outage and downtime for
cleaning operation.
The combustion temperatures are much lower
than conventional units and as long as erosion is not found to be
(5)
G. Guarria and T. V. Rallo, "Technology for Domestic Boiler
and Power Plant Designs", Foster Wheeler Corporation, June 12,
1969.
(6)
F. L. Roisson, A. J. Giramonti, G. P. Lewis, G. Gruber,
"Technological and Economic Feasibility of Advanced Power
Cycles and Methods of Producing Non-Polluting Fuels for Utility
Power Stations", UARL Report J-970855-l3, December 1970.
K-86
-------
~
I 400
~
H
::><: u
<
I ~
CP
-.;j U
H 300
j
~
600 -
500 -
200-
100
/0
)
r-
[1 OIL - REF. (5)
.:.\ COAL - REF. (5)
o GAS - REF. (5)
. COAL - REF. (6)
. OIL - REF. (6)
,-'---1---'."---,--'--
°
o
'-----L
200 400
~
:z:
H
H
~
~~
~::x::
o.
~~
....:I
~....:I
UH
:Z:~
<
ZI
~
HH
ZU)
HO
~u
t-
r---"-
.. I
<"':10::;::
>O~>
;o:;.:lt'1H
H :;.:IZ
0~>1-3
Cr'Ht'1
U»HZ
ZZ>
nl-3G)z
> u)' n
I-d nrr:l
>00
~'Tj~~
H tJ
H
rr:I
U)
PLANT CAPACITY - MW
200 400 600
1. 0 -'-'T-'-'-"-'T'-~'-" ,.---..., 'T--'--~T--'-" -'" r "..--
.8
°
. ,
.4- . -6-~\- 0
"
..cu-
.2
}
6100-_'---86~----" '--WOO-
I
1200
I
1bOU
--r4bu
MAINTENANCE AND OPERATING COST $1000
"':I
H
G)
,:a
t'1
. 0'
w
I
-'
I
..~-,,_J
-------
a problem.
The operating conditicns to which tube surface is '
exposed is much.less severe.
Coal feeding and drying may present some maintenence problems
in the development stages.
It would not be expected, however,
that these costs would be projected on to established power plants.
6.3
Operating Costs
Operating costs in this case include fuel cost, limestone
feed cost and power requirements as distinguished from supplies,
salaries, wages, etc.
Westinghouse indicated the coal should cost $6/ton.
No penalty
is paid for crushing to 1 1/2 x 0 at the mines.
Mills exhaustors, soot blowers and motor drives in the air
preheater have been eliminated in the fluid bed steam generating
plant. ,Fan power has increased and may increase further if it
is deemed worthwhile to go to a deep bed.
Power requirements
for transmitting the air pneumatically have increased somewhat.
K-88
-------
7.0
DEVELOPMENT REQUIRE~ffiNTS
One of the purposes of going through the exercise of de-
veloping a conceptual design for the fluid boiler is to pinpoint
areas requiring development work for further exploration.
The
steam generator and coal handling plant development requirements
are discussed separately.
7.1
Steam Generator
Development requirements on the steam generator center
around the bed.
For the most part the information could be
obtained or the data confirmed on a single fuel scale fluid bed
cell.
The co~ents that follow do not concern themselves with
air pollution or limestone as they are treated elsewhere by
Westinghouse.
Some of the basic areas of operation should be verified.
These include the overall heat transfer coefficient and its rela-
tionship to other bed parameters, i.e., gas velocity, tube spacing,
etc.
The absence of erosion, agglomeration of ash in the bed, or
fouling of surface where the bed should be confirmed.
Distribution
of coal and air in the bed should be looked into with every effort
being made to reduce coal distribution feed points.
Improvements
in the latter area could open new areas for cost reduction in solids
handling as well as boiler construction.
Carryover must be con-
firmed and evaluated with regard to feed distributio~ gas velocity,
bed depth and coal feed size.
Modes of ignition a~d ignition tem-
perature for lar:e beds must be proven.
Temperatures distribution
in the bed and potential inbalances must be evaluated to economic-
ally and safely select tube materials.
Turn down of the bed at
constant bed depths and response time with a change in load should
K-89
-------
be investigated.
Control of air to four beds operating in parallel
should be investigated for instabilities during operation.
7.2
Coal Handling
The coal handling system proposed consists of a fluid bed
dryer-distributor and attendent equipment.
Controls should be
developed for the system and a detailed design should be made.
The dryer-distributor should be tested on a pilot plant scale
to confirmi~s ability. to dry, distribute and regulate the flow
of crushed coal.
The ability to pneumatically convey 1/4 x 0 coal
reliably. and maintenance free should be demon8trRtp.~ ~~d
design parameters should be confirmed.
-
K-90
-------
.' -
APPENDIX Al
M.
CANDIDATE CONCEPTS
Three basic concepts were considered in making the final
selection.
1)
Vertically stacked beds in a square array.
2)
Vertically stacked beds in four separate modules in
an in-line arrangement.
3)
Horizontal tandem arrangement with four modules in
parallel.
By initially assuming modular construction with a single
bed for each heating function many other concepts were auto-
matically considered and eliminated.
This, of course, would
include single bed arrangements, single module construction,
etc.
The virtues of the five bed, four module construction dur-
ingstart-up, operation, etc., are adequately discussed elsewhere
and need not be reviewed here.
M.1
Preferred Concept
The vertically stacked arrangement was selected as the
preferred arrangement.
It is illustrated in Figure Al-l primarily
as a reference for comparison with the horizontal arrangement
and discussion of future concepts.
The preferred concept was selected as it conveniently adapted
the once-through fluid circuitry to the multi-bed modular con-
struction concept of fluid bed combustion with a minimal need for'
interconnecting pipes, headers and downcomers.
This arrangement
also simplifies the flow pattern and distribution of air to and
gas from the steam generator.
Plenum chambers used for pro-
v1ding and distributing air to the bed also serve the purpose of
isolating adjacent beds.
The arrangement adapts quite readily to
K-91
-------
.:1
~
..
._~
! .
\(
Ii
~
~
"
~ I
.~YE~~~~~ i
. I, ...
,~Kn--- ~
'. I '~;/~
r, '. '"
I:';;
,~/-' ,:
, ...~I -' "
" I' ...
H
'i'
,
~
I
-jg-, ~
I ...~
, ~~
,.
~~..
~I~
~;;;~
14:0.
..'
~
~
I.
['\
I"'"
l .
::J
rs"IJ~
u:."-
":0.
-,
- <-
-e=--
~
~
I
~"I'
i ~i
~ ~!
,~ ~ i
.... "t!
-£ ~~ =--
---.----..-
"
~
~
~
't
~.
~
.~.
._-
....-----
~
~
~ _,n- -- -----..
------... - - --- - ---
: ~
~n'
IJ~' "~o'
_~4'
4:".
.'.f)"
'.iT ,,,,'
'~4'
,'.'
I!. ..
~I
0'
/ol!(j"
70~ .
ID~ . 'I
.~~
n._- ---
--.'''---
- -- -----'-
g- ;&=-::.~ u
I
~
---...
----- _n-
--. --- ----
G
.1'.
4"4
I "
I'~! i
--+.
Ji~i
..,.1J ".'
Ir:."
.' .
::t
C)
;::::
~
III
-.J
'
-------
auxiliary equipment with the minimum amount of interconnecting ducts
or pipes.
Orientation of the beds and the number required have little
if any affect on the coal handling plant.
The number of feed
points required is primarily a function of the ability to diffuse
the coal in the bed and thus is dependent on the cross-sectional
area of the bed.
Once the bed depth is set nothin~ can be done
to simplify the coal handling process unless there is something
unique about the system that complicates or simplifies the coal
transport lines.
Convection surface consisting of preheater tubes or economizer
tubes was. placed above the bed for several reasons.
First of all,
this arrangement makes effective use of the boiler cross-sectional
area.
Secondly, by inserting the convection surface above the bed
the gases are cooled down in a zone designed to handle hot gases,
thereby eliminating special high temperature convection pass en-
.. closures.
This arrangement also avoids thermal losses due to mix-
ing of hot gases at different temperatures as the gases from the
different beds rejoin as one stream.
Individual heat exchangers
are the most effective way to exchange heat from the flue gas to
the stream.
Finally the convective pass acts as a particle screen
returning large particles elutriated from the bed to the bed.
A cylindrical shell was considered as an enclosure for the
pressure parts.
It was felt that it would reduce cost by simpli-
fying the enclosure.
Being that the boiler would be self supporting
the cylindrical shell would also eliminate the need for expensive
structural steel.
Erection time should also be reduced.
The draw-
K-93
-------
backs to this arrangement were the large shell that would be re-
quired to house shallow beds at atmospheric pressure and the large
number of penetrations required by the coal handling systems, the
limestone recirculation system and the steam and water system.
Al.2 . Horizontal Concept
The multi-bed four module concept was laid out horizontally
by placing the beds side by side in a ~andem arrangment as shown
in Figure Al-2.
The beds had the same physical dimensions as the
vertically stacked concept.
This arrangement should minimize the
need of structural steel.
It was also thought it would offer
greater potential for shop fabrication.
Whatever advantages may have been gained in time, material
and labor appears to have been lost in complicating the fluid cir-
cui try with additional headers, feeders and downcomers.
The contin-
uous pattern of the water wall tubes in the vertical arrangement
is now broken with headers and downcomers required to transfer the
fluid from chamber to chamber.
A portion of the savings in structural steel, of course,
must be consumed in the form of supports in the horizontal plane.
Instead of the boiler acting as a column supported from the top, it
must be treated as a beam supported along its length.
Expansion
must be absorbed in the horizontal direction and the water walls
must be designed to be self-supporting.
Water wall dividers separating beds into various heating
functions present expansion problems and are subject to warpage
due to a difference in heat absorption rates on opposite sides of
the wall during normal operation as well as start-up.
Duct work has not been simplified.
Separate enclosures
K-94
-------
l:.
,.~---
,....~-- -
~--
/
/
i '
I
\ I
\ i
\ .:
IX
/ \
\
\
\
\!
I
/ \
..'-e.O
, /
\,j
\ '
. I
~LJ :~
/ \
/
....
l4t,.ait.1.
\
\.
"
'\
\,
/
'\, /
--*~
/'\
. "
/ '
-I
"",
.. ,./
. /
-~/~.
/'\
. ,
.4'."-
/
"\ ""~T-
--"'~*'"
, ~
\
\
,
I
I
,
-I.-.-.-.---e-
..---
'"
''\,
I
I
':} ti
I
i
I
\
-~.o~_t~
,",ogu\..,- 11
-----:--r
. i
. i
I',;. i~
-J 01.
"i...
. OJ'
I i~
! I
i
I
~
/
/
/
- ------
--------
e:...
/
:-
,.,.,-~
1400 II \..t ,I:
- -
:illlill
I IiI'L ~"10)
---r---- ---_.--
. I
:'~
, .'i-
I :~i
L
'~ "'.",~~..
-.1
5t.C'TION 'A.,A,'
.n
-_t.IO~~~ m. Ii
J
....oou....::ar
,.- --.---t-
, I
j.- #c."
j~ Lj
. .! I
L "
--: I-'--~
I Iii
I I I I
+ --t+--+
! i I !
~! i~ ~I 13
!\/
1./'\
c
.'..' I
I
I
-'-1- .
"001\..1 1X
CO..!. "'.15
to") 'A)J
iii'S ...
~"-~
III
, '
; °
! '
.''"''- -,.,/
~'"
':;E.C i. 1:>.1:>'
:'lC1. C. c'
::t
- f D'
'¥' ; / ~
~: j 0; ,
D i ~I
:' !
l' c ;, I, ;i
u ", I
.V\ \/ ...,
i
,
, .
/ .' I' i. I
\f ~ i i \ /; jl \ i
~ -;,':; i!
o ;; \ i 3: ' ~
ft
l\ c ~/ \!~/\I
v
I ! . \.
-,' /\~!
-\
" :1 '. . I;i
0 =, V
. ~,.\ ~I
< ~.; ,
v ~.
'~
~
!
!
.
J
!
.
.
.
~.5
IIOTU
.~caa:'--' -.-
..... ma... .
t.
.;\
~amt._~_.
AIZI8Z - -- ---
~"18__. ..
" ...
. ~
J
!
o! 2
o
. -
..
v
oJ
on
:/
~:
"\
G /
G,
r.
'\
"..",a#lo.T
e",..o\.&
111111
DWG. NO.
'SCHE.Ml
~ .-:.
HOII..I~O...1 ~l.
10.1 "'O'PIlt.I..\I;
fl.IIIQ toLD
51llo.'" CO t.Wt.lLAtOIl.
Q.D.710-5,c, .
.=:::.: -
- JL
-.....It.......,.... .
\iJ::::~~i '
-------
are required to house the headers.
The gas pass and air pass are
. complicated by the fact that dimensions of the fluid bed and the
auxiliary equipment are not compatible.
Regenerative air preheaters must be used with their inherent
high air leakage at the higher system pressure drop.
Head room below the dust collectors whether a single cyclone
or multiple cyclone arrangement is limited.
This complicates
collection of the elutriated material from the FBC which must
be returned to the CBC.
Each fluid bed requires its own lower and upper enclosure.
There is no sharing of plenum chambers as in the vertical arrange-
ment.
Large areas may have to be sealed off to accommodate air
control dampers.
The increased complexity of the fluid circuit is probably
the major objection to the horizontal arrangement.
Alternate
arrangements may be considered which reduce the number of headers
required.
This is not accomplished, however, without a price.
For example, the tube bundles may be connected such that the
elements run in a horizontal direction and the fluid flows along
the length of the bed rather than from the bottom up.
The verti-
-
cal water walls may also be arranged in a horizontal direction.
In this arrangement there is greater chance of liquid vapor phase
separation during evaporation which increases the risk of tube
burn-out.
Expansion problems are created between the tubes ex-
posed to the bed and tubes exposed to the hot gases above the
. .
bed.
Withdrawal of tubes through the water walls may become
complicated.
K-95
-------
For the many reasons cited the horizontal concept .'was ';
not selected.
Al,3
Future Concepts and Potential Modifications
Developing the preferred concept revealed other areas for
potential improvement of the design.
Neither the 'scope of work nor time
permits investigation and evaluation of all avenues of approach.
Furthermore, some of the ideas fallout of the range of conventional
practice, making technical and economic evaluation nearly impossible.
The potentials of several of the unexplored areas appear worth
noting for further consideration.
The areas worth mentioning include:
1)
Installation of a second bed in series with the first
which is not supporting a combustion reaction but serves the
purpose of improving heat transfer coefficients in the preheater
or convection zone.
2)
The use of a cylindrical shell with a "deep" bed.
In the first concept it is proposed that a second bed
be installed in series with the first such that it would contain
the preheater or convection tubes.
The fluid bed might be modi-
fied as shown in Figure Al-3.
Fan power would have to be increased
substantially to overcome bed expansion and pressure drop through
the distribution plate.
If the bed depth were approximately the
same depth as the primary bed the pressure drop of the system
would be a little short of being doubled.
Beds of this depth
should contain the entire preheater bundle once the heat transfer
coefficient was taken into consideration.
K-96
-------
I
"
'=>°T' T,U~.~~./\ I
~
,_u~1
i \.\Q\"E
OE-iAIL OF
A \ R... "'()~ E. S
i",FI..aoF- I
~1iQ"" i\J~E.si
C> N ~.,.
~~"" Eo /IIo'{£.1t.
,c\t1""" i
!
il ~
, ~'
-{-l~~.~ -
~t..'" ~ III. ~ " ....
\N~L'
t
'-
,1'" \>It.~'~tc..'n.~ Tu~tS
I
I
i
I
-0-
,.
~"II..E~~l>,iV.v.. "'1It)~S
I ~~'~To",,~
o\li~\..i.
II
-"-.
- - .-'.'-.- -
j.[
~
\! I
~
,Y?\CA\. AT~, ;:1..\J\t:) ~~t> c.~l..\..
W\i H ?R..f-~E ~i i\') tiES ~\)f)~~2.." It)
\N ~E.CQND FLUID ~~ 0
This Drowing i. ,he ProSIer', 01 ,he
FOSTER WHEELER CORPORATION
110 SOUTH ORANGE A VENUE
lIVINGSTON. NEtf JI!RSEY
ANO " LENT .ITHOUT CONI10E"ATION OTHER THAN THE eO..AoWCIIII",
ACI--Ca....8:NT THAT IT SHAL.L. ,""OT 8£ AE:PROCUCED.COPIEO. '-ENT, 0" 01'-
~o.co o~ DI"I[CTL.,Y 0" INDIRECTLY NO"USEO FON ANY PUAPO'I[ OTHE"
THAN THAT ~o.. "HIC'" IT II SPECI~ICALLY F~"NI'HI:D. THE APP."ATU'
IHOWN IN THE O".WING I' COv£"CO.... PATE""''''.
c. .0 CO.. MO. ...".
K-97
ORDER NO.
DRAWN B'-:
CHECKED BY:
APPROVED BY':
SCALE:
.
Q~S'\"",,\
.J~
= ,. - 0"
Q.D714-\\8
FIG. Al-3
-------
--~
A distribution plant could be formed by the lower row of
the tube bundle by using modified fin tubes.
Assuming the surface was reduced by a factor of two,
roughly speaking, one might expect a 20% reduction in the cost
of pressure parts which corresponds to a total reduction in the
cost of the steam generator of 6.5% or about $3.00/KW.
No credit
is taken for a reduction in boiler height and no additional
charge is made for handling the aggregate in the bed.
If the
fan powers were doubled there would be about $1.6/KW increase
in' cost that must be charged to the system.
Operating costs have
not been taken into consideration.
This concept may be subject to wear problems on the dis-
tribution plate as it must be designed'to handle dust laden
material.
The concept, however, appears worthy of more detailed analysis.
The second concep~ proposes increas1ng the bed depth by a
factor of two and enclosing the .boiler in a self-supporting cy-
lindrical shell as illustrated in Figures Al-4 and Al-5.
It is
not absolutely necessary to increase the fan power.
However, by
doing so one reduces the cross-sectional area of the bed and
thus reduces thenumber of coal feed points.
This simplifies the
shell design and makes it more attractive by reducing the number
of penetration and reducing, the diameter.
The height must be
increased but by only 30 feet.
Introducing a self-supporting shell eliminates a large quantity
of structural steel, reduces erection time and simplifies boiler
. .
enclosure.
Some structural steel must be attached to the shell
K-98
-------
for access.
Additional grating could be simply installed
inside the vessel either for maintenance either in a temporary
or permanent basis.
Since the gas and air temperatures are nearly the same,
there should be no warpage of the shell due to a difference
in expansion.
Sealing of the air and gas passages at the low
pressure differentials could be handled by a simple plate steel
weld or curtain on either side of the boiler.
Expansion pro-
b1ems might be resolved by removing steam lines either from
the top or bottom of the shell through a sliding sleeve.
The
coal and limestone transport lines might be removed at the ap-
propriate elevations by taking up the expansion through moment
arms as shown in Figure Al-5.
By offsetting the penetrations
in the coal position the relative movement between fixed positions
in the shell and pressure parts may go from +3 inches to minus 3
inches or a total of 6 inches.
The shell as proposed would be 1/2 inches thick in the lower
. half and 3/8 inches thick in the upper half with 4" x 4" x 3/8" stiffeners
located on the inside on 10 ft. centers.
The shell costs about $75,000
. per module.
Unfortunately this represents little savings over ducts
and structural steel material cost for the shell diameter proposed.
However, a savings of $100,000 per module may be achieved in field
erection cost.
This represents a savings of $1.33/KW.
No credit was
: taken for maximum shop fabrication of pressure parts at the smaller
diame.ter.
No credit was taken for reduction in coal feed points at
the smaller diameter.
No liability was assigned for the increase
in operating and capital cost of the fan.
At 300 MW the capital cost
should increase by $.42/KW.
This approach appears to merit 'further study and consideration.
K-99
-------
I I
I '
~!
f~~
f!~~=
[ .. r ;
I ~
I -
-'-'-r
'I
- ~I
-- 'I
I:!
,i -
- ---- -- --lL
~ -_~~:~~H'~& II
----r-
,I
I t'i~,~u,.~.~~~~,,~I,
~ . ,
L --=_u--~- ~_1
I~
+--- - -.--.... ----
i I ~ " ~y"r..
2 ~:-I...=..{~~~~'~.t~:~,~_: :-
'6' r
I' ~ .
I
-ri
, ,
~
o.
-1---
I~
I~
!
I~
[-
1-:-.
0,-
Itt"t~'llt.
0"'1 '-!."T
--- -----
'P\,.A.11=0..
I
-,
------
~--_.__..-
.-------
{j-
1"00 U~1"'.'T\lIU
1-
~-- ':.i=J:~?~"'~~~'-~"~t!-- .=-:
~ ~ 2...t..~~...,t.c.
O~ I~'-f..\
~
0.
P'-A't'O"'~
P~ArFo"""
-----
..
0:
.,
O.
'I."T'DIII.M.
, I=:J
,\ sunt ~,It T\I~E
-~ 1=
1\',u't~W'mu
.. -;;:--
t' "jf:'~2;'~?~,)
-- ...--.-.---"-
...
~
.-.-.-.---
~
~
PI.A'TfDLM
I~ -
-f:~:' : !../~~=~':;}'';':-
o.
.- ---_. - - . < ......".. .--..- "'
I~
t--
:
I"
i h
~~L_~"~~.~.
ip: f,,: \ .
~,:; L.lMo'-,,"""
t. .- '''~.'__--
: I~-
-4-.L,_.... -.-..--- --
4"...4".. }'6" Lf..''''''.
"...c.\o'" ~P""b
APPIitD'IC \0'-0" ""P"R.'t
,-
N
! C:
-'---- ..-...--..
a'"
...,
~~
!!l,..
~~
..'
",,'I~
~...o.
.."
o
c
\.II
o
o
~
~ I~
r
):>
Z
---I
II!: 0 » <
::; ..... --I IT'
::: .... ~ 1'"
-0 0 :-i
r\0''''J>
;0 ..... -0 f'"
,.. Q ~ :;
~ (}I 1" ~
»-1-0
f" ~ '" -n
" ... -0
(JI ,.. ~ ~
::J: z: - ""
m f" a "'"
:: fO i:4 :"
~ "' .
'C> 0 ~
fO' V'
r
~
!::-
7<:J
Q
~
fO
,...,
(;)
c:
\J1
'"
,..
I'"
o
I
-- _!.. -.
" -ffi
IZOO[VItoPOv.AtOC.1\ID
. LIM.t $'t",.,
- ~- -4-'" :.~': '--
, ,..
_I 1":
! --
8- CO"....
IN.\-\,. 1 "\~t.~
('T 'T ~.)
ll""UT""~
. 0 ~ , ..., r
.. -}:---
..+--t':
\,.\tv, ,-,:,
-'--t:.--
--~.
~.trf\~'Tg""ll
.~_c:> 0 '. "',l ,
~~:-
-...- ..- -PCl.~~",..,.t...
\N\.I.T ""Dil.
E..U.VAI\Ot\!
~
...
...
-------
&
~
0",
" -
dJl~
I~
t-
..
"
-'
(\a
'"
-'
REVISION
i-
'4w
~~
I ;
I I
I
I
~
\~\.o "I~
~/4"O,1). TII... )
Z:' I 4" \
8 S~"(E.~@ .,. 4." ( ~1 sp~(!>. It T\!~~".
"7 . 1(,.-:$ ~"~f.1o\~P\1-- .
- ... ""TOI1" 'n\~t~ ..,
. p "~PO..... , ,
I 1 'I.. ~ ~ . .
\ '.- I..\"""~\o~"
o'"'1\..1.'T
,
~
~
: I
I I
11
- .-
c..t;>.c,-
""~~
I
~A~
I
!
i
+
\\~
'\\
6QQ-: ! '~ +.--
+' + I :
I I I
'~ I I I
I .~, I I I
' ------., '.? , I
: - - - '~:~ : . --------:r
I .- -.--.---:;:- i' ~
G; A.~
\
~
.
-
~-
~\R.-
. ---i---
i
!
~ t:> t:.,~ S -
--~~ ,
~.~ '+--$~-
A\f&..
~"
,,-0
~~""
"~ ...
'" ~.....
"
\
5 E.c \' \ 0 ~
2" ?'\~E...
b- \~L...~ 1''5
c:.C)~1..
No o-S~. UC\'Z.
ORDER.
~
DRAWN BY:
CHECKED BY:
APPROVED BY:
A1.12
Ai
M05Pt1ER.\C
ED ~O\L to ~
~ N'" '0 n. N
KG IS THE ".0 ORA TIO
TH'. D.".'EELER CORPSTON N.J.
ER WH UVING. II:
FOST ANGE AYE.. ~.. ~.. ~.
110 SO, OR T CON5IDERA~~O:HA~L NO~::y OR
WITHOU THAT 0.. DIRE N
... ,. '":~. '..".'~T.. .,.....~.. ~.. ~~.
::~:~~:.; ".."~'~.~~..~::,:~C:.:'.:': .~:~'::::;. OT
INDIItIECTL WHICH IT 15 ~HII: DRAWING
THAT ..OR OWN IH 0"
"''''''''RATUS SH " = 1 '-
,.ATENTS. SCALE: 3 6
t2.D 713- 15-'
fLU\D
"OR III .......C
~"'~-' -
.- .
-------
APPENDIX A2
A2.
ENERGY AND MASS BALANCE
The partial load energy and mass balance are summarized
and illustrated in Tables A2-1 through A2-5.
K-IOl
-------
TABLE A2-1
FLUIDIZED BED PARAMETERS
,.-
DESIGN LOAD
(ONE MODULE)
FUEL FLOW AI R FLOW FLUE GAS SUPERFICIAL BED TEM;-~~~
LB/HR LB/HR LB/HR VEL. FT/SEC. TURE 0 F
I ----- -.-.-
REHEATER 11,600(2) . ~ 6 10.9 1600(3)
~ 0 .12~X10 ~.137X10
I 11,700(2) I 1600(3)
[SUPERHEATER I 10.126 0.138 11.0
J 1
I ,-
I 11,700 (2) i I
'I 0.138 ' 1600(3)
SUPERHEATER II ! 0.126 11.0
-''''--' --i.-..-- ...-.--. -_4__-
7 000(2) I I 1600 (3)
EVAPORATOR I , ! 0.076 1°.083 7.85
I
'~.07:-~~ --_....._.~.. ..
EVAPORATOR II 7 000(2) 7.85 1600(3)
, I
I I
10,300(1) i 1900 (3)
CBC j O. 103 (4) 0.108 10.7
(1)
59.45% Coal
33.75% Ash
6.80% Sorbent
(2)
(3)
Fuel as Fired
Specified by Westinghouse
(4)
70.5% X's Air Based on Coal Flow to CBC
K-I02
-------
j
; REHEATER
i
I
j SUPERHEATER I
I
i
: SUPERHEATER II
, EVAPORATOR
r-
! EVAPORATOR II
.
I
I CBC
(1)
59.45% Coal
33.75% Ash
6.80% Sorbent
(2)
(3)
Fuel as Fired
TABLE A2-2
FLUIDIZED BED PARAMETERS
75% BOILER LOAD
(ONE HODULE)
! FUEL FLOW AIR FLOW,
LB/HR LB/HR
i
! 8 630(2) 0.0935x106
I '
I 8,790(2) 1°.095
I 8 790(2)
, ,
,0.095
I
10.057
1
I
10.057
I
I
j 5,250 (2)
I
I
I 5,250
7,670(1) 10.076(4)
Specified by Westinghouse
FLUE GAS
LB/HR
!0.102X106
I
r-
0.104
!
)0.104 j
'1 --t
I
0.062
iO.062
!
10.081
(4)
47% xIs Air Based on Coal Flow to CBC
~
K-103
I SUPERFICIAL !BED TE~;~l
IVEL. FT/SEC iTURE of I
8.10 -G~;--'-
7.91
1390
8.29
1433
i
.- "'--'" --..j
I
4.74
1350
---'''"'r
4.74
1350
----.--..
6.10 1900(3)
-----L- i
,I
----_..J
-------
TABLE A2-3
FLUIDIZED BED PARAMETERS
67% BOILER LOAD
(ONE MODULE)
."
I
FUEL FLOW I AIR FLOW IFLUE GAS
LB/HR ' LB/HR ,LB/HR
REHEATER 7760(2) " 6 10.092x106
, 0.084xlO
7 ~40(2) \0.085 I
SUPERHEATER I '0.093
,
I S~ERHEATER II I 7 840(2) !0.085 ' i
,0.093
! '
! I I i
(2) j
~ EVAPORATOR I 4,690 ]0.051 10.055
! !
. .
(2) j
i EVAPORATOR II 4,690 0.051 ~O. 055
I \
, ;
I 1
I ' (1)
; CBC I .6,700 ,0.069 . ;0.07.3
I j j
I __1
" -
(1) 57.45% Coal
33.75% Ash
6.80% Sorbent
(2) Fuel as Fired
(3) Specified by Westinghouse
(4) 43.5% XIs Air Based on Coal Flow to CBC
K-I04
I SUPERFICIAL -("
I BED TEHPERA-
I VEL.. FT/SEC TURE of
--.......- '''''....'''-a....
7 .00 1350
6.94 1310
V"I',- '..... .........
.7.10 1360
I
4.05 1299 I
4.05 '."'1
L~~!o(-j). j
l
I
I 7.27
I
I
-------
TABLE A2-4
FLUIDIZED BED PARAMETERS
50% BOILER LOAD
FUEL FLOW
LB/HR
I REHEATER
5 800{2)
SUPERHEATER I
5 050(2)
'--
(ONE MODULE)
.-
AIR FLOW IFLUE GAS bUPERFICIAL
LB/HR 6 (B/HR iEt. FT/SEC
0.063xlO [,0: 068xlO 11 4.80
0.064 . 0.069 4.79
-~-'--'-"._'"
_?!.~~~.~._. E.~_~6~,~- ~. 069
SUPERHEATER II
EVAPORATOR I
3 500{2)
,
EVAPORATOR II
3,500(2)
CBC
5,150{!)
(l) 59.45% Coal
33.75% Ash'
6.80% Sorbent
(2)
(3)
Fuel as Fired
Specified by Westinghouse
0.038
0.041
-'._._-
0.038
0.041
0.052(4)
0.054
(4) 21.4% X's Air Based on Coal Flow to CBC
K-I05
4.70
2.79
-- -_.-
2.79
5.40
I
.BED TEMPERA-
I TURE OF
. 1223
"t"'-...~.._-_..
1170
-------
1218..... .~--I
I
1144
1144
1900 (3)
-------
TABLE A2-5
SUMMARY OF ENERGY AND MASS BALANCE
PARTIAL BOILER LO,\O OPERATION
(ONE MODULE)
LOAD 100% 75% 67% 50%
Coal Flow (Total) 1b/hr 3 37.2 32.8 24.5
49.5 x 10 6
Air Flow (Total) 1b/hr .602 x 106 .474 .425 .319
Gas Flow (Total) 1b/hr .658 x 10 .515 .461 .342
Reheater
Bed Temp. 1600 1425 1350 1223
Conv. Exit Temp. 840 780 764 739
Heat-Bundle btu/hr 80 x 106 60.5 54.8 42.2
Walls btu/hr 9 6.9 6.1 4.8
Conv. btu/hr 26.8 18.3 14.7 9.1
Superheater I
Bed Temp. . 1600 1396 1310 1170
Conv. Exit Temp. 840 764 745 "715
Heat-Bundle 85.5 65 58.8 44.7
Walls 9 6.9 6.1 4.8
Conv. 27.4 18.0 14.4 8.7
Superheater II
Bed Temp. 1600 1433 1360 1218
Conv. Exit Temp. 840 . 764 745 708
Heat-Bundle 85.5 65 58.8 44.7
Walls 9 6.9 6.1 4.8
Conv. 27.4 18.5 15.5 9.7
Evaporator I
Bed Temp. 1600 1350 1277 1144
Conv. Exit Temp. 840 750 726 687
Heat-Bundle 48 37.6 33.2 25.7
Walls 9 6.9 6.4 4.8
Conv. 16.3 10.7 8.6 5.4
Evaporator II
Bed Temp.. 1600 1350 1229 1144
Conv. Exit Temp. 840 740 717 668
Heat-Bundle 48 37.6 33.2 25.7
Walls 9 6.9 6.1 4.8
.-- Conv. 16.3 12.2 11.1 8~4
Carbon Burn-Up Cell
Bed Temp. 1900 1900 1900 1900
Conv. Exit Temp. 840 815 803 777
Heat-Walls 14.7 14.7 14.7 14.7
Conv. 29.6 21.2 18.2 11. 7
Air Heater
Mean Temp. Gas In 840 769 iS1 719
Temp. Gas Out 340 803 291 275
Air Temp. Out 780 720 700 685
FBC
X's Air 10% 10% 10% 10%
CBC
X I s Air 70.5% 47% 43.5% 21.4%
Cyclone, Eft. 11 96% 95% 95% 94%
K-I06
-------
APPENDIX A3
A3.
OVERALL BOILER DESIGN
A3.1
Tube Design Information
A3 . 1. I
Bundle Arrangement
Horizontal tube bundles are used
in all beds for evaporating superheating and reheating the water
and steam.
This arrangement makes use of conventional bundle fab-
rication ,techniques and maximizes the quantity of surface submerged
in the bed.
Long lengths of tubes to and from headers outside of the
bed are virtually eliminated and return bends on each loop may be
kept submerged.
By using shallow to moderately deep beds the num-
ber of bends required are minimized.
By maintaining 12 to 13 feet
lengths for each loop separation of phases in the evaporating section
should be reduced and the risk or tube burn-out eliminated.
With
the horizontal arrangement all tube bundles are drainable.
This
should simplify start up and minimize maintenance.
All bundles were constructed in a rectangular pattern and the
tubes are on a square or rectangular pitch.
All the tubes submerged
in the bed have a 4" horizontal pitch and a 4" vertical pitch.
The
horizontal pitch was dictated by the spacings on the wall tubes form-
ing the bed enclosure.
This arrangement also simplified maintenance
problems and should minimize the possibility of erosion.
The ver-
tical pitch was dictated by the minimum bending radius of the tubes.
Bends with radii smaller than one diameter thin out the wall on the
large diameter side of the bend subjecting the tube to rupture.
The
fluidizing characteristics of the 4" x 4" pitch was the subject of
much controversy.
Consideration should be given to the compromise
that might be required between fabricating techniques, economics
and fluidizing characteristics of the bed before modifying the
K-I07
-------
present bundle design.
The influence of bed design op fluidizing
characteristics should be investigated experimentally to be cer-
tain any changes are truly justified.
Water walls forming the enclosure of the beds are of the
wetted fin construction.
They are constructed of 1 3/4" tubes
on 2" centers requiring a minimum fin of 1/4".
The spacing se-
1ected is the minimum that could be used with this type of. con-
struction.
Smaller tubes would result in excessive pressure drop
on the steam side.
Preheater bundles are arranged horizontally in the convection
pass above the bed.
Once aga~na rectangular pitch is used, this
time to minimize gas side pressure loss.
The first two loops have
a vertical pitch of 4" and a horizontal pitch of 8".
The wide
open spacing provides for some subcoo1ing of e1utriated particles
at low gas velocities before entering the more tightly spaced gas
. pas~.
The loop and loop construction of the lower bundle becomes
.-a single loop construction in the upper bundle by simply dis-
placing the inner loop.
This is illustrated in Figure 4.1.
The
remaining portion of the bundle is constructed on a 4" x 4" square
pitch.
Preheater tube bundles are connected one FBC to another with
no intermediate header.
All other bundles are connected to. headers
located adjacent to the tube walls in the cooler air ducts.
The
inlet and exit tuJ.,es from each bundle pass through. the water walls
by bending alternate water wall tubes off center in the immediate
area of the. penetration.
The enclosure is sealed as illustrated
in Figure A3-1.
K-I08
-------
\
., I
\, /i / i I
--":rl I
G~f$::':!
~:j'I"
~~'t", .
5t~' ~ ~\N
\\', I
J~ n \
.5CAlLDPEDeA~~i\ '
, J
IN'TEqRt:L
WEi DE C FiNS ~/ - i
-
"1)ETA\ l Or
\"=) e:-~I E T R A\,\ 0
c. .. co.. "'0. .....'a
\ \..) ~ 't:.
1'- \
\.\'f?\CALJ
i'\
Thi, 0'0"';"9 is the P'o~erty 01 !I,.
FOSTER WHEELER CORflOr:tA TlOM
110 SOUTH OU/HiE "...~'W£
LIVINGSTON, HEW JERSEY
ANO '8 L..ENT WITHOUT CONI:OI:R"'TIO~ OTI-4£1It i......... T~iE 80IltRO"'E"..
AQ".CMENT THAT IT ,...A.!..\.. ~O? BE ~l[cu~OouCEO. COPIE:), \..ENT, 0" 01S-
-0'1:0 O~ O"'I:CTLV 0111 INO,G£CT\..Y NOR uSEO FC~ ANY puRPose OTMER
T""A,.. T.....T "'0" ....ICIo4!'!' IS ..O€'=I"!CA\..LY "U.'f"~EO. T"'fE AP.&IIIATI,J3
""0-.... IN TH. O"""'ING '8 Cov£".O 8" PATI[NTS.
K-109
.-
ORDER NO.
DRAWN BY:
CHECKED BY:
APPROVED BY:
SCAL.E:
Fi ~i.JRc
,
iO.c.i~\'~\~l.
JR
i ~Ic
1 /-' ";:
= " - 0"
A3-1
~o,u. ..!I....C
-------
. Bundlel?,~ay. be spop fabricateq. and shipped in a unit and in-
stalled in the field.
Headers with tube stubs welded in the shop
are attached to the bundles in the field.
This type of construction
limits the number of tubes contained in any loop to about three
which is no problem in the bundle arrangement selected for the at-
mospheric unit.
Very deep beds with a nearly square pattern would
normally require a greater number of tubes to provide sufficient
free area in the steam side to avoid high pressure drop.
This
would require more bed depth over and above that normally required
by the tube bundle to offset the tubes in groups of two or three
so that the bundle can penetrate the water wall enclosure and header
stubs can be welded in the fiel~.
Although this is no problem here
it is mentioned as a precaution when extrapolating the present de-
sign to larger capacities and possibly greater bed depths.
The width of the beds are set at about 13 feet.
This is
a reasonable limit to set for unsupported tube lengths.
Extra-
polation to larger capacity boilers should be done by simply ex-
panding the bed width.
Tubes are supported as shown in Figure A3-2.
Tubes that form
.'~
the inner loop of a loop in loop construction are supported by
off setting the outer loop tube just prior to the bend so as to
reduce the distance between center lines of adjacent tubes.
The
two loops are then connected by short welded fin connectors about
2 or 3 inches in.length.
AJ.1.2
Tube Size
Two inch a.D. tubes are used in the pre-
heater sections and reheater bundle.
Superheater and evaporator
tubes are T 1/2" a.D. tubes.
Enclosure wall t;ubes are I 3/4" a.D.
K-110
-------
rJJ
FORM ZI!5.I!Z.C
--.--...,,-
iUf>L
1
1
"
.,
,I
,,//
/.'
;'
-
I
L_l
Tu~t. t.Lt.MLN1
':> u. ~ p 0 ~ i A. S 5 l tv\ e, L ~
This Drawing is the Property 01 !he
FOSTER WHEelER CORPORA nON
110 SOUTH ORANGE AVENUE
LIVINGSTON. NEW JERSEY
AND IS LENT WITHOUT CONSIDERATlCN OTHER THAN THE BORROWER'S
AGREEMENT THAT IT SHALL NOT BE REPRODUCED. COPIED. LENT. OR DiS-
POSED OF DI~ECTLY OR INDIRECTLY NOR USED FOR ANY PURPOSE OTHER
THAN THAT FOR WHI\:H IT 15 SPECIFICALLY C'1!olU,c'..u~D. THE APPARATUS
SHOWN IN THE ORAWING IS COVERED BY PA
K-lll
..--.-.-
I
iE. \.. L N\ E.. ~ ,.
WA~\.. iue:.t.,
ORDER NO.
0-5 9' II ~ ~
DRAWN BY:
H...
3/:;,/7,
CHECKED BY:
APPROVED BY:
SCALE:
= 1'.0"
o -5 ~ .7) ~. 3:3
-------
Selection of tube size is a compromise between many factors.
The final selection is not arrived at explicitly but must be achiev-
ed by trial and error techniques using a good deal of judgment and
experience along the way.
The final solution, therefore, may not
be the optimum.
However, alternate solutions at this point should
not significantly influence ,the overall cost of the boiler.
Surf~ce requirements, geometric limitations of the bundle
and steam side pressure drop or mass flow per unit area are prime
variables in selecting tube size.
Bundle geometry fixes the tube
orientation and influences the gas side flow parameters and number
of tubes per loop.
Surface requirements fix tube length and total
number of loops required.
,
Steam mass flow rates and pressure drop
dictate the cross-sectional area and number of tubes required.
Once the bed geometry is fixed the problem becomes one of
selecting the number of tubes required to provide sufficient heat-
tng surface.
Connecti~g the tubes in adjacent rows in single loop
or loop-in-loop fashion depends on the number of tubes required and
thus the mass flow velocity and pressure drop requirements.
A
small pressure drop is essential to establish good distribution.
-
However, the pressure drop must not be so large that the pumping.
requirements become excessive.
There are obvious discontinuities
in selecting the number of tubes and number of rows to match steam
flow conditions.. The mere step from single loop to loop-in-loop
decreases the tube length by a factor of two and doubles the steam
mass flow area.
This problem may be partially resolved by selecting
different tube sizes and altering th~ tube pitch slightly.
Thus
tube size selection offers an. additional degree of freedom in bundle
design.
K-112
-------
Tube size is also dependent on pressure requirements, material
selection and tube wall temperature.
Large diameter, low alloy
steel tubes used in high pressure service must be thick.
There
outside surface temperatures, therefore, must be high.
Smaller
diameter tubes made of high alloy steel might be considerably
thinner with some reduction in tube metal surface temperature.
This is clearly shown by the ASME Code formulation for selecting
tube metal thickness.
PD
T = 2S+P + O.005D
T = Thickness
P = Pressure
D = Diameter
S = Allowable
Stress
Selection of tube size based on simple mechanical design
is a compromise made between size and material selection to give
the most economical solution.
At high pressures small diameter tubes with thin walls and
low metal surface temperatures would appear to offer the best ap-
proach to bundle design.
Limitations, however, are imposed by
process design.
As the tube diameter decreases the number of
tubes required to handle the steam flow increases inversely with
the change in diameter of the tube to second power.
Diameter in
this case must refer to the free flow area.
When the diameter is
expressed in terms of the outside tube diameter tube thickness
must be taken into consideration.
The increase in number of tubes
Eequired becomes even more pronounce as the outside tube diameter
K-113
-------
decreases.
Tak~ng into consideration the increase in number of
tubes required the length of the tube decreases in direct pro-
portion to the decrease in outside diameter.
This means that the
depth of the bundle must increase considerably unless the gas side
dynamics are adjusted to accommodate the new tube size.
With the reduction
in length and little change in fluid dynamics on the steam side
the pressure drop is greatly reduced. . Ultimately compromises may
have to be made between numbers of tubes and steam side pressure
drop which upsets the fluid dynamics and heat transfer on the steam
side.
Installation of the bundle'becomes complicated by the change
in number of tubes and spacing.
Tubes must be bent out of line
to penetrate the water wall enclosure.
If more than three rows of
tubes are required to connect the headers and the bundles they
will have to be separated into groups or legs to make welding
to the header stubs feasible.
This at~omatical1y increases the
bed size.
An increase in the number of tubes must also increase
.' -
. ,
. .
the man hours to fabricate the bundle or assemble it in the field
which might mitigate any savings in materiai cost.
. .
All these factors were taken into consideration in arriving
at the tube sizes specified for the fluid bed boiler.
AJ.1.3
, .
Tube Temperature and Material Selection
The metal
temperatures and material selection for the tubes and headers a1-
. .
ong with sizes and thickness are summarized in Figure A3-1.
The
data is coded so that the information may be related to the cir-
cuitry illustrated in Figure 4.1.
In arriving at tube metal
K-1l4
-------
AJ.9
ONCE-THRU FLUID BED STEAM GENERATOR CIRCUIT DESIGN SUMMARY (cont'd)
TUBES RISERS AND DOWNCOMERS
NOMINAL NOMINAL
DESIGN DESIGN NO.OF OUTSIDE NOMINAL CONNECTIONS OUTSIDE NOMINAL OUTSIDE THICKNESS OUTSIDE THICKNESS
KEY LOCATION PRESSURE TEMP. TUBES DIA. THICKNESS MATERIAL OR DIA. THICKNESS MATERIAL DIA. (IN.) MATERIAL DIA. (IN.) MATERIAL
(PSI) (F) (IN.) (IN.) DOWNeOMERS (IN.) (IN.) (IN.) IN. HEADERS (IN.) OUT. HEADERS
17 FEEDERS TO
PASS 5 3010 700 6 3 .30Omw SA-2l0
18 PASS 5 SA-213
SIDEWALL 3010 975 71 1-3/4 ,284mw T-22 8-5/8 1.13aw SA-106C 8-5/8 1. 13aw SA-l06C
19 RISERS FROM
. PASS 5 3010 700 6 3 .30Omw SA-2l0
20 DOWNCOMER TO
PASS 6 3010 700 1 8-5/8 SCH XX SA-106C
REAR WALL
21 FEEDERS TO
PASS 6 3010 700 6 3 .30Omw SA-210
22 PASS 6 SA-213
REAR WALL 3010 975 76 1-3/4 . 284mw T-22 /8-5/8 1. 13aw SA-106C 8-5/8 1. 13aw SA-106C
23 RISERS FROM
PASS 6 2760 700 8 3 . 280mw SA-2l0
24 DOWNCOMER TO
PASS 7
SUPERHEATER 2760 700 1 8-5/8 SCH 140 SA-106C
25 FEEDERS TO -
SUPERHEATER 2760 700 8 3 . 280mw SA-2l0
26 PASS 7a
SUPERHEATER SA-213 SCH 160 SA-106e
RUNS 1, 2, 3. 2760 875 76 1-1/2 . 150mw T-2 8-5/8
26 PASS 7b
SUPERHEATER SA-213
RUNS 4, 5, 6 2760 930 76 1-1/2 . 220mw T-2 8-5/8 SCH 160 SA-106e
27 SUPERHEATER
RUNS 7, 8, 9, SA-213 *
10 2760 1075 76 1-1/2 . 280mw T-22
27 SUPERHEATER
RUNS 11, 12 2760 1175 76 1-1/2 . 238mw TP-304H 10-3/4. 1.50aw SA-335
P-22
28 REHEATER SA-213
INLET LOOP 700 - 76 2 . 165mw T-22 12-3/4 SCH ST-405 SA-106C
48 REHEATER
OUTLET LOOP 700 - 76 2 . 165mw TP-304H 14 SCH XS SA-335
p_??
Fig. AJ-l
-------
A 3.10
ONCE-THRU FLUID BED STEAM GENERATOR CIRCUIT DESIGN SUMMARY
TUBES RISERS AND DOWNCOMERS
NO. OF NOMINAL NOMINAL
DESIGN DESIGN ~O.OF OUTSIDE NOMINAL CONNECTIONS OUTSIDE NOMINAL OUTSIDE THICKNESS MATERIAL OUTSIDE THICKNESS MATERIAL
KEY LOCATION PRESSURE TEMP. UBES DIA. Y'HICKNESS MATERIAL OR DIA. THICKNESS MATERIAL DIA. (IN.) DIA. (IN.)
(pc:T) fin (TN , fIN.' DOWNCOMERS (IN.) (IN. ) (IN.) N. HEADERS (iN.) )UT. HEADERS
1 FEED P r"PE
PASS I INLET 3260 495 1 8-5/8 1.04 aw SA-106C
2 PASS I
PREHEATER 3260 710 38 2 . 220mw SA-210A 8-5/8 1.04aw SA-106C 8-5/8 1.10aw SA-I06C
3 RISERS FROM .
PASS I 3260 700 6 3 .30Omw SA- 2l 0
4 DOWNCOMER TO
PASS 2 (EVAP) 3110 700 1 6-5/8 SCH 160 SA-106C
5 FEEDERS TO
PASS 2 3110 700 6 3 .30Omw SA-2l0
6 PASS 2a (EVAP) 3110 INLET 850 38 1-1/2 . 165mw T-l tS-:>/tS 1.UUaw :::I1\-l.UOl.
PASS 2b (EVAP) 3110 OUTLET 890 38 1-1/2 . 180mw T-2 8-5/8 1.00aw DES. T=700
n~~-1~~9()()
7 RISERS FROM
PASS 2 3010 700 6 3 .30Omw SA-2l0
8 DOWNCOMER TO
FRONT WALL
PACC 't 3010 700 1 6-5/8 SCH 160 SA-106C
9 FEEDERS TO
PASS 3 3010 700 6 3 .30Omw SA-2l0
10 PASS 3 SA-213
FRONT WALL 3010 975 76 1-3/4 . 284mw T-22 8-5/8 1.13aw SA-106C 8-5/8 l.13aw SA-106C 8-5/8 1 .13aw SA-I06C
11 RISERS FROM
PASS 3 3010 700 6 3 .30Omw SA-2l0
12 DOWN COMER TO
PASS 4
C:TOR WALL 3010 700 1 8-5/8 SCH XX SA-106C
13 FEEDERS TO
S IDE WALL 3010 700 6 3 .30Omw SA-2l0
14 PASS 4 SA-213
(SIDE WALL) 3010 975 71 1-3/4 . 284mw T-22 8-5/8 l.13aw SA-106C 8-5/8 1.13aw SA-106C
15 RISERS FROM
SIDE WALL 30~0 700 6 3 .30Omw SA-210
16 DO\v'NCOMER TO
PASS 5
(SIDE WALL) 3010 700 1 8"-5/8 SCH XX SA-106C
-------
temperature it was assumed that no unbalance in operating conditions
existed on the gas side and 20% unbalance may exist on the steam
side.
It was also assumed that no corrosion or erosion problems
existed in the bed on the gas side.
In several cases, material
selection was based on economic factors alone.
It was felt that
it would be cheaper to use a high alloy steel throughout the bundle
rather than use two grades of steel.
AJ.l.4
In each fluid i-
2
dized bed a bed-to-tube heat transfer coefficient of 50 Btu/hr-ft _oF
Overall Heat Transfer Coefficient
was used for the bed proper.
A zone extending two feet above the
bed was considered to be a transition zone between fluidized bed
heat transfer and gas convection.
The mechanism of heat transfer
in this zone would mainly be particles that rise above the rela-
tively dense phase of the bed transfer heat and then fall back
into the bed.
A bed-to-tube heat transfer coefficient of 40 Btu/hr-
ft2_0F was assumed and the zone was considered to be at the same
temperature as the bed.
The overall heat transfer coefficients
varied throughout the cycle depending on the liquid side heating
function.
Overall heat transfer coefficients for the evaporator,
2
superheater and reheater ran about 47, 45 and 43 Btu/hr-ft _oF,
respectively.
In the evaporator the water side coefficient varies accord-
ing to the mode of heat transfer taking place, nucleate boiling,
departure from nucleate boiling or film boilin~,
Numerous cor-
relations exist.
Each manufacturer has his own preference and
generally uses data developed in his own laboratory which he
keeps confidential.
There correlations are cited as typicai ex-
K-115
-------
amp1es.
These are not necessarily used by Foster Wheeler o~.any
. . . .
other boiler manufacturer.
Nucleate (8)
h ",S(0.00122)
0.79 0.45 0.49 0.256TO.246 0.75'
k1 cl Plge p
0.5 0.29HO.24 0.24
o III fg Pv
*
k
)( )0.8( )0.4 t
+F(0.023 Re 1 Pr I' D
e
DNa (Departure from Nucleate Boiling) (8)
DNB
q" -0.1 0.51
. erit = 0.00633H d (~) (I-X)
106 fy. 106 e
(low' flow)
(high flow)
II'
qerit
7=
A+l/4Cd(GxlO-6) (HI-H. )
l.n
(1 +CL)
Film Boiling (8)
:cDe .. 0.005 ~e:mPw,v)
W,v W,v
~yr
w,V
In the cases where superheated steam is being heated rather than
-,-
. boiling water the following correlation may be used.
U tD
a t
.~..
{GD 0.8 l }0.4 T 0.8
t l CpJ,J { b l
0.023 -;-J k "If
f
(8)
L. S. Tong, "Boiling Heat Transfer and Two-Phase Flow", John
Wiley and Sons, Inc., New'York, 1965.
* Nomenclature appears at the end of this section.
K-u6
-------
A3 .1. 5
Distribution of Surface
The distribution of sur-
face to the waterwalls. superheater. reheater. etc.. is summarized
in Table A3-2.
A3.2
Mechanical Design
A3.2.l
Duct Work
The duct work connects the steam gen-
era tor with the dust collector. air preheater. electrostatic pre-
cipitator, fans and air to the coal injection system and provides
a means of transporting air and gas to and from the steam gene-
rator.
The air and gas streams are illustrated in Figure 4.2.
The duct work also runs the full length of the front and back of
the steam generator providing ~ windbox for the distribution of
I
hot air and a means of collecting hot gases.
A seperate duct
as contained in the flue at the gas exit from the steam generator
to- segregate and carry off hot gases from the CBC to the dust col-
lector.
This makes it possible to segregate ash from the FBC and
carbon rich ash from the CBC.
The duct work is rectangular in shape and constructed of
gauge steel lagged with 3" of batt insulation suitable for
outdoor exposure.
The duct work contains expansion points and
dampers for control of gas flow where it is felt necessary.
Sides of the steam generator not protected by a windbox
or flue are enclosed with insulation and corrogated sheathing
as illustrated in Figure A3-3.
A3.2.2
Plenum Chamber and Distribution Plate
The plenum
chamber isolates one fluid bed from the other. provides a means
of distributing air and fuel in the bed and supports the bed
aggregate.
The plenum chamber is illustrated in Figure A3-4
K-1l7
-------
COMPARISON OF HEAT TRANSFER SURFACE AREA
TABLE A3-2
ATM. 300 MW
RESIGN
.1.9xlO Ib Steam/hr
FUNCTION 2400 psig/lOOO°F/lOOO°F
4
F"aporator 2. 64xlO -FBC-
~uperheater I .800 -FBC-
II .950 -FBC-
1 heater .825 -FBC-
r onomizer 5.72 -CONV. PASS-
TOTAL . 4
10.93 x 10
TUBULAR
. .r Preheater 104x104
.'
ATM. 600 MW .
~CALE-UP
3.8xlO Ib steam/hr
2400 psig/lOOO°F/lOOO°F
4
5.2Sx10
1. 75
1. 75
1. 650
11. 44
21.86 x 104
208xl04
K-1l8
CONVENTIONAL BOILER
(F.W. ~OND NO.4)
3.6xlO Ib steam/hr
2486 pSig/1000°F/IOOO°F
4
2.97x10
4
8.16xlO
11.3Oxl04
4
15.36xlO
4
37.79x10
REGENERATI~
53.OxlO
-------
,\ ,
I! Ii
i r '~ i':
jl~ II: I!: il
I I , i ~, ~
I' I, I, :, '!
" I' I' ": I; ,
11'1 ,;i 11 i! i I I:'! I d i :, I! I! ;
~ "I, I I I I! ~ Ii I,
'I ij i ~ It :1 I! i; ; I I : I : , ; II' !
; I ~ I' ~ I I! :. II! " !' r I
I" 'I t( i 1: ill! : 'I ' . 'II, : t I [! i ~ I
. " ~ I rl! i
, t !r : ; I I' I':;'! l q' 1, ~ I ~ ;
Ii: :! I 'II j i I .!' ,,: I
I' ;t: "'I I ~ '1'1' ' : !: r f i
~ ~ fl':
I
I
, [
.
ORDER NO.
D.S"q.llq~
j~ 1/8 71
FlN.1u~t
WALL
CONSIQ..UC.1l0N
DRAWN BY:
CHECKIED BY:
Thl, Drawing I. the Property af ,he
FOSTER WHEELER CORPORATION
110 SOUTH ORAHG!! AVE~U!!
LIVIHGSTON, HEW JEIIS!Y
AND '8 L8:NT WITHOUT CONSIDC"..TION OTHE" THA... THII: 80,."owl["..
.."&ItMItNT THAT IT SHAL.L. NOT 8E "E:F~OOUC~O. COPIEO. LENT, 0111 Ol.~
~O.IEO Oil' CI".CTLY 0" INDIIII£CTL.Y NOIIIUSE:D '-0" ANY PUlltP081t OTHI[IIt
THAN THAT "0" WHICH IT II SP£CIII'IC"'I..I..Y "UIIINj~HEO. TH~ AP".".TU8
""'0"''''' IN TWit OlltA"ING'8 COV£IIICO 8V PATI£Nrs.
A~ROVIED BY:
SCALE:
=,' .0"
QJ).lI4.1;~
K-119
FI~. A"!>-3
c. .. co.. NO. ......
-------
-,-
~
I
13'-0.
-I
.;-t
J~.. .. - - '---.. --=-- n."-' -. -rr- - -- - "
I " . I ,
~w ~:1-' --r- -~. - +=-'r~1:
IW'O ," --7- - ---4--- --,r-- :--',:
:. -~..- +-. .~_.. ---;-_. :~ --~ -~I
- --it-- ~"-r" -- --"-T--"-'-~
~!, --"'J._~.--.-t.-4- ---1t-----~
J .. ----1L .. . -T.- - . -+-.. ---J-. -'I
;:- h -' " . -------10. ----+- "
I ., '
~ - - r--- - Ii. - - ---t-- . -J.:-. .. -- - ----r- - -t!
1,.. I "I, II OJ
I ~. -.- - -.. -r- ......-. -'L-- ---f
,"'I , 'I., II . 'I
:: r----r-.. --r- - T - .-;t-.. -. -,r- . --r - -'I
I ~-. -'t-- '-r-" -~- . -.+-- -4-r-. -. -_. ..,
I~.. .!J.- - -1--.. ~_.. ,-- ..U-. - ----1-.. .,:
, ; I: -~- -~._--A --~--II. " ={
,I-+--r-- ~-- - -....,--. --+t-- - ~- - -- - r- !
(t--+- . .-.,,-. --f--. -,~.. .. ~-- ..:n.::.: - --.. I '
",, ' I' L' 1
'JI' - --. .- - -Jo-.- -- -- - ~ - I
1 " " " I
~r- - - - j- -il- -'----.---- -1,
, ,~- -4-. -r----'1r- -+---,-- - - '11
E- ~- ..~--tr.. ---J--~- --I,
'i e .. 9. ..~ :'1
e'a.~r .. -ll- - +--_...11..-- -~..-.--.._- -It i
u ~, 'I" u.....
I ~ ~ - ~.. -- - -..-- . - - -~_. -- - IJ ~
--L- .. ~ - II " '~ Ij.~
o
.' I
I
"'I
I
i
i.
C. 8. CO.. NO. ......
.~
Pltt"-l
I.
. .
5EC1. ~.~
Plt..~UM
~
;5 'E- 'f-
.......
,
o t. '1 z:.. \ ~ . f:;>.. "
f
.1
\
\
.~
"
~
. .
'"
~
"--.---. -
rn --
. ;
DE1All
. A"
ORDER NO.
~
~
I
oc{
l-
V
uJ
If)
DRAWN 8Y:
D .'5'1.(1"
j ~ 5/1 q
C 1'\ A. f'.A E> ll2.
DE. \~\L
CHECKED 8Y:
e
Thh O.owl"1I I. the Property 01 the
FOSTER WHEELER CORPORATION
110 SOUTH OItANGE AVENUE
LIVINGSTON. NEW J!IfSEY
AND I. L.ENT WITHOUT COHSIOlEtlltATIO... OTHI[" THAN THI[ 80 ""Ow......
A."..WENT THAT IT IHALL.. NOT BE ""~"OOUCIED. COPIED. L.EHT. 0" 0'8-
11'0..00... QU'IECTL.Y 0" INO'IItI:CTLY NO"UIEO frO" ANY ~Utllt~OSIE OTMC"
THAN THAT ~o... .H'CH IT IIIP€CIII"'CALLY ,.UllltNIIHI[O. THE .,....tlltATU8
SHO.N IN THE O".W'NG'I COv~"CO 8Y "ATI[NTI.
K-120
APP"OVED BY:
SCA L£:
Q. 0-714- \ '2 0 A
':,' -0"
FIG. £\3-4
-------
~
.r~1
----.---"
-..---
---- - I
---I
-l- t-f...LO
N01..1..Lt..8;)
---.----
--.+-
- ,.--.
--- - -----+-i
PL~N
.
.--:J
/ 'Z" 0-0.
\" ~o~!.~ -/ I
___1'/48
, --T
I
S Eo C. 1'. lib" ~.
~
,- 0'''',
5~C\
.c " c: "
D\51R-\5U10~~
P \ P t
--
.
4.
.
-------
and A3-5.
It consists of two steel plates separated by wedge shaped
stiffeners welded to the lower plate.
The two stiffeners closest
to the water walls also act as enclosure walls separating the air
stream to one fluid bed from the gas stream from the adjacent fluid
bed.
The lower plate to which the stiffeners are 'attached is
supported by lips resting on scallop bars welded to the water
wall enclosure.
The upper plate or distributor rests on top
of the stiffeners and scallop bars.
Coal feed lines penetrate the rear water wall enclosure
of the gas off take points where the tubes have already been sep-
arated to provide for gas departing from the fluid bed.
They
make a right angle turn and penetrate the lower plate forming
one side of the plenum chamber.
They are seal welded at the
point of penetration.
They proceed up through the distribution
plate to a coal nozzle which distributes the coal in the bed
in the horizontal plan in opposite directions. .
The coal is distributed in the bed in a miXing zone just
below the tubes.
Sixteen feed points are used to insure diffusion
.-
of the feed in the bed.
This provides about one feed point for
each ten square feet of bed surface as recommended by the British.
Air enters the plenum chamber through dampers on one side of
the boiler.
The stiffeners act as guide vanes to insure good dis-
tribution of air in the plenum chamber.
The a;r then passes up
through the one inch holes in the grid plate aligned in rows
on 7" centers.
The holes are drilled on I 1/2" centerlines.
Once
through the holes the air is enclosed in a slotted channel con-
structed from tubular material or angle iron.
This makes it possible
K-122
-------
to reduce the air over the distribution plate as it enters the bed,
sweeping the plate clean of particluate matter and cooling it at
the same time.
The tubular distributor should also prevent the
back flow of particulate matter during shut-down.
The angle of
repose between the slot and the hole in the distributor plate is
too small to allow the flow of small particles back into the
plenum chamber.
The pressure drop through the distributor is estimated at
.4 times the pressure drop through the bed.
Surfaces not swept clear with air are curved to prevent co l-
lection and agglomeration of ash particles.
A3.2.3
Maintenance
Throughout the design of the steam
generator compromises have been made between economy of design
and ease of maintenance.
Manholes have been provided for access
to windbox,duct work, flues and crawl space above each bed.
Sufficient room has been provided in each bed for removal of in-
dividual tube element from the convection pass or bed.
Access
to the plenum chamber may be had through the dampers.
Repair of tube leaks in the bundle would simply require
cutting the element at either end of the bundle and dropping it
into the crawl space for maintenance.
Complete replacement of
an element would require cutting in sections for removal and
welding in sections for installation.
Providing erosion does
not become a problem in the bed, the maintenance on the tube
surface should be minimal.
Fouling of tubes supposedly is
eliminated in fluid bed operation.
Replacement of entire tube banks or headers would require a
K-123
-------
major disassembly of the module.
The need for this type of main-
tenance is unlikely.
All anticipated normal maintenance appears
to be feasible.
Elimination of soot blowers, mills and exhausters from the
list of boiler assessories should also reduce the maintenance re-
quired by the boiler.
Constructing the boiler in four module
units should limit the complete down time for maintenance by iso-
lating the module requiring repair.
By operating three modules
at 8 to 9% overload the entire system could be kept at full load
during repair periods.
AJ.2.4
Expansion
The pressure parts are supported from
the top allowing the unit to expand downwards.
This is accomplished
by hangers that connect the upper wall headers and the structural
steel.
All penetrations made through the side of the boiler move
freely with the wall.
Duct work, tube wall and air and gas, to
and from the boiler, are at about the same temperature, thereby,
minimizing expansion problems between various component parts.
Coal feed lines enter the boiler through the duct work in
the wall opposite from the side of the bed it is feeding.
This
.--
should provide a sufficient length of unsupported tubing to absorb
any differences in expansion between the fixed support points.
K-124
-------
h.U
K
g
Cp
t
~
is
T
H
Hfg
G
g"
v
x
D
L
Pr
Re
S
F
,--
TABLE A3- 3
NOMENCLATURE
Heat Transfer Coefficient
Thermal Conductivity
Acceleration of Gravity
Specific Heat at Constant Pressure
Density
Viscosity
Surface Tension
Temperature
Enthalpy
Latent Heat of Vaporization,
Mass Velocity
Heat Flux
Velocity
Quality
Hydraulic Diameter
Length
Prandtl Number
Reynolds Number
Reynolds Numbe~ Factor
Subscripts
c Core Condition
f Film Condition
e Exit Condition
w Wam Condition
d Saturated Liquid
v Saturated Vapor
K-125
2
Btu/hr-ft _oF
Btu/hr-ft-OF
f.t/hr2
Btu/lb-oF
lb/ft3
Ib/ft-hr
Ib/ft
OF
Btu/lb
Btu/lb
2
Ib/hr-ft
2
Btu/hr-ft
ft/hr
ft
ft
C~/k
DpG/~
(t!To/t!T) 0. 59
(Re/ReL)o.8
-------
APPENDIX A4
A4.
ACCESSORY EQUIPMENT
A4.l
Coal Handling System and Limestone Make-Up
Coal handling for the atmospheric boiler includes receiv-
ing the coal, storage, transportation to the surge bins of the
injector, sizing and crushing.
McNally Pittsburg developed the
coal handling plant and a price including erection.
A4 . 1. 1
Assumptions
The coal handling plant was de-
signed on the basis of the following assumptions:
The coal to be used is Ohio Pittsburgh Seam No.8 described
in detail in Table 2.1 of the text.
The size of the coal is 1 1/2" x 0" as delivered.
It was
initially assumed that the coal would be sized to 5" x 0".
Ac-
cording to the Bureau of Mines at Bruceton, there is no penalty
paid for the 1 1/2" x 0" coal as it is a standard size commonly
requested.
Under these circumstances it was felt justified
to revise the specifications.
In addition to meeting the
technical requirements, there appears to be a savings in cost
of power required for crushing the smaller coal size.
Size distribution of coal crushed to 1 1/2" x 0" at the
mine appears in Figure 2.1 of the body of the report.
Moisture as mined, is 3.3% total and 2.1% inherent.
The
difference is surface moisture.
Moisture as-delivered is 10% total.
This is about 6.7%
in excess of the as-mined coal and represents a typical moisture
pick-up during handling and storage in an eastern steam genera-
ting plant location.
K-127
-------
Moisture required at the boiler feed system is a maximum
of 3.0% total moisture.. Higher moisture contents result in
agglomeration in the surge bins and feed lines.
Size required at the boiler feed system is 1/4" x O"~
The Hardgrove grindability index is 60.
The burning rates which affect hopper sizes, conveyor
speeds, etc., were set at 113 tons per hour; 2,712 tons per day
and 18,984 tons per week.
Allowance was made for handling of
limestone feed or limestone make-up, as it was not certain at
what pdint it would be added to the coal stream.
Storage of the coal is divided into two categories, active
storage to handle short term contingencies, such as weekend out-
ages for maintenance and repair, and dead storage to handle long
term outages due to short strikes, delays in shipment, etc.
Active storage was set at three days or 8,136 tons.
The stor-
age capacity of the silo was rounded off to 12,000 tons.
Dead storage was set at two weeks or 37,968 tons.
It
was rounded off to 50,000 tons of open coal pits.
The values were selected as typical based on the recom-
mendation of McNally.
Dead storage requirements are vulnerable to considerable
change according to individual customer's requirements.
Changes
should only affect operating cost and land requirements.
The
cost of coal handling should be marginal.
It was assumed that the coal would be delivered by 10,000
ton unit trains at a rate of 2 per week.
The unloading rate is
K-128
-------
50\. OIL C00
1
~
z-
.
CD .E.On.E~~ @ Cl~U!. ~i
@ TUmIRE. B"J.Y @ COi ",e!lORe£~
CD }fi!:~1"ER B~Y @ II.E"'E"'E""-:'OR~
G) 5W~"'c.1:. ~IN~ @ D£A.ER.}rt,TO~
@ At)MINISiR.A110W Bloc.. @ A)~ ~1\.O
@ P....v"ilC\:J.,t..Tt. REMOVAl.. EQu'PT. @ WATER ~TQIUI.CaE.. ThWIl.~
CD 1)E.\...1::"e,Q
@ t)EL~;IL!)
~ ST~CK
@ ~U'll~f:. an",
@ RE'E\VIN'- HOPP~Ct.
@ nC1..p.\N\ HOPPe,Q..
@ 511.0 (12.000 TO"5)
@ DELETED
@ D~D 5TOR>-C.E. (SC\OOO TON»
@ WAiER. 1'Re.iWlE wT"
@ CIE.5~l ~EN.ez.."\ott R.OO~
@ CONnel. ,,-00,",
@ w..C.HINE. ~HOI>
@ TAAN~FO'lME.~'
@ LI"'NT 011. l"'N~
@ UGoW"T O\l. Ut-\lO,flo.OIN' PUMP
@ Cf1lCU\.1o.'T1N~ WIro.TI.R IN"""X£, P"IPe.~
@ P,.R\(\WG ,llrt,,1l1!.A
@ COME~ (51C1l.AC.E.)
@ EILTEREt> e FIR£~£RVI""-""'TER
@ 5EI1.VICE W~TER 1'\1"" >iOU$E.
~ C\1t{:uu;.Tmt8 WA.1'U? \NTJtJ(E S~
@ C1ol.1..QR\WJlll.iION EQuIPTk\~WT
@ \D.a.\~ WE\RS.
@ S'Hnc.~ 'i/4..9..0
@ a»/V£YOR..
@ AIR NE~TE.R5
@ PREC.IOITl>iOR~
@ S,.ON£ S'Oi<:.~G€
DWG. NO.RD 710-105
A4.3
-ons
1. ....IUUT8S_--
_--r.
1. ~1ICIII....na___.
~ 8JftI...... ~-...
""""".-_C8-.-
LnTD -'III :.
300 M.W. l>iMOSPHE-RIC
>LVII) BED BOILER
51TE. PLOT PLAN
RD 710 -105
.=:::.: - Mn
_.-0-"'-h'2
.'P.M.5.1-
,.....,.-........-
\fH) ...... w.....- ~~
il ;.~::f!.:-:-:::'~~
Fig. .A4-1
-------
I-~' 1
~ . .
. I~ -..' . ----
. "; I f 1 --- - ". .:,;-:
:;. I
~ ~ ~ .
, '
.~L~
bOI' OIL C'1!
..
"
" ~.,
~~
,0"
~
~"
~iii
'ow
M
-~
"~
. 0"
e
~
"
<
e
..
o
~
~
I!
Q
-I
-8" ~.
'e;
-,
LrS:~--
~
o
I
'J
,
y
J
'"
""
----,- --- ---~------------------
KE Y PLI\N
N
I
OIIl£C.TION QP co.... P'£Eb
OF ~Cur.M
. MI)'II'£IL
~Q:"__.
80' -
jA: !ill@)
QF 400- '10N
ttc.£JV IN" HC/~
DWG. NO. RD 710-109
A4.4
-OIU
1. 10 IIn taLI 118 --.
-"'1'.
I. ~--_n8--".
~ -....... Sf_--
~... - CII ........
REFERE.NCE. t>~
I-~\~",~"'(.~~~U~\."U~~~~C\~O 8£0
~..,)'t.."" ~"1. 10' t ~01tO-IlO
una ... :.
;00 M.W A1M05PHERIC
fLUIDIZED BED STEAM
G.ENERA TOR CONVE YOR
SY5 TE M
~,",T. 'OF
- .....
RD 710-10'3
=:=.: -.
- _.- o.n-I"a
P.... W}I
ftIII""""""""'4-
-, P'MTD WtCD.a ~1'IOM
~ ~ -_::. -:.=..::;==.:~-
, ---..----
"- _.~=::..:r?~:1:::'~
-------
Oil-OIL CJ
"
"
/'
"
"
/
/
/
/
/
/
/
"
/
"-
"-
. "-
L"o." """
t1,Ooo 'tow ~1..0 ........
. "
.'t~~J.3:
'-01150 t..JIh-.-
-D;D\ .
~-=.LD_:.IZ;1>OO
I":tmr~
"
I,
II
'-0.
,
SEC.TJON.:::'A:K ~
. ~I..J:'
><~
~/ I
"/~.
--C.JU!UHO 1Z.VE.\. EL.d-o.
---r --
- --r-
I
r- -..., I
I I I
I"''''.~I :
I I 1
I , I I
L -;;-" '1>' J I
'e.... I
OF Rr::C\.~
""-'"
:GR01JND-~ EJ..:.d::A-
E.. !IO'--o"::.
F
, b.'"
.~.- r;.- sc..........
I "",U\cf
ItL ,...:.0-
.-~~I!.a,w
:- [,TYr.)
.= 1iL\...5"2.".o
-.:--.:J,.. "'0"
~~-1'-~
'0'
:'0.
---.- -- ...... ~..... t ,---
.n:,""WUS
:::sr.",
A4.5
80TII
L _-1IC8U1I8-.
---Y.
--
I.~_._-_.
-----.-- -......
~..__-.-
.P.E.FEP.EN<".E OWC;~"
I~ 100...... "'T~c. R.UlOIUD 88D
r~G\':.\~~ (.ONVS,VO:O'7I0-t0t
.
- -
..WI"..'
.JOOMW. ATMO~ERIC
flUIDIZED bED STEAM
!;ENERAlUR CONVEYOR
..5)'5 TEM
~""T-lQY~
- ,....
-...
,IUtno-- no " "-'
I.
I
-_8-
- -- 0"'''''1
. -:.=:.=:-
Ii ..---.-....
-.------
--------
--_._----
----------
---...---
=-----.--
-------
2,000 tons per hour and the train would require 5 hours to de-
liver its load.
The dead storage would require 49 weeks to complete to a
capacity of 50,000 tons.
A4 . 1. 2
Scope
The system begins with the unloading of
bottom dump rail cars in unit train delivery and continues through ac-
tive and dead storage, crushing and delivery to the coal feeder
surge silos provided by other vendors ahead of the boiler firing system.
The rail car receiving hopper will have a minimum of
400 tons capacity to provide storage volume for controlling un-
loading of moving cars.
Details of the receiving hopper and
other components are illustrated in Figures A4-2 and A4-3.
Their
relationship to other components in the coal handling system is
illustrated in Figure 4.8.
Their relationship to the entire
power plant facilities is shown in Figure A4-1.
The coal discharge from the receiving hopper will be con-
trolled by four reciprocating feeders, Fl-A, FI-B, Fl-C and Fl-D,
each feeder nominally rated at 500 tph but capable of delivering
100 tph if one feeder is out of service.
-
A 54" wide inclined belt conveyor No. I will transport
the coal at the rate of 2000 tph to the silo.
Conveyor No. I
will be equipped with a tramp metal detector and a belt scale
for weighing and' recording coal quantities delivered to the
plant site.
A 12,000 ton silo will nominally contain an entire unit
train delivery without exposure to wind blown dust and provide
K-129
-------
active storage for plant feed without the use of mobile equipment.
Excess coal will overflow the silo to an initial pile for placing
in permanent storage.
See Figure 4.8.
During extended periods of no-train delivery, coal will be
recovered from permanent storage through a reclaim hopper and
Feeder No. F2 delivering to Conveyor No.1 for refilling the
. silo.
Coal will be fed from the silo by seven feeders No. F3A to
F3G, each rated a maximum of 150 tph and operating in timed se-
quence for uniform drawdown of the silo, onto a 24" wide belt
conveyor No.2.
Conveyor No. .2 will be fitted with a tramp iron
magnet before delivery to the surge bin.
Details of the magnets
and dust recovery equipment have not been illustrated.
Coal from the silo will be crushed to 1/4" x 0" size in
a reversible hammermill and, along with the coarse dust from
the dryer. cyclone~ delivered via 24" belt conveyor No.3 to the
plant surge bin.
Conveyor No.3 will be fitted with belt scale
No.2 to weigh and record coal quantities to the boilers.
From the 150 ton capacity plant surge bin the coal flow
will be split into two streams each served by a 0 to 75 tph
vibrating FeederF4A and F4B to its associated coal feeder
surge silo group through scraper conveyors No. 4A and 4B.
The silo filling system will be provided with automatic
sequential controls with provisions for operator to override to
accommodate unusual operating .conditions.
The plant surge bin
level will control the feed to the dryer and in turn the dryer
surge bin will regulate the silo withdrawal feeders.
K-130
-------
A4 .1. 3
Equipment
The coal handling system will consist
of the following equipment, materials and services:
1.
Receiving Hopper
2.
Feeders No. FlA, FIB, FlC and FlD
3.
Chutes
4.
Conveyor No.1
5.
Metal Detector
6.
Belt Scale No.1
7.
Reclaim Hopper
8.
Shut-Off Gate
9.
Feeder No. F2
10.
Silo
11.
Feeders No. F3A and F3G
12.
Conveyor No.2
13.
Tramp Iron Magnet
14.
Mill
15.
Surge Bin
16.
Feeders No. F4A and F4B
17.
Conveyors No. 4A and 4B
18.
Dust Collecting Equipment
19.
Ventilating and Heating
20.
Control Equipment
21.
Motors and Controls
22.
Structures
23. Foundations
24. Electric Wiring
25. Erection
K-131
-------
A4 .1. 4
Cost
McNally Pittsburg indicate~ the cost for
the .system described should be about $1,750,00q.
The complete
system contributes about $5.8/KW to the overall cost at the 300
MW ],evel.
McNally Pittsburg indicates that for an increase ~~cap~city to
handle a burn rate of 226 tons per hour, the conveyor sizes should
stay substantially the same; however, their horsepower would also
increase.
The probable additional cost for increasing the system
might amount-to $250,000 or about $2,000,000.
This represents
about $3.3/KW at the 600 MW level.
The costs are comparable as shown in Table A4-1
TABLE A4-1 COMPARISON OF CAPITAL
COST OF COAL HANDLING EUQIPMENT
Plant Size (MW) 100 200 230 246 327 300 600 600
Fluid Fluid
Bed Bed
Coal Handling 1010* 1720 1860 1925 2240 1750 3122 2000
and Storage
$/KW 10.10 8.6 8.1 7.9 6.85 5.80 5.20 3.30
"fuel Burning 760 1295 1400 1450 1685 1,147 t 2,294
$/KW 7.60 7.4 6.1 5.9 5.15 3.8 3.8
* Values in $1000
t Not reported
Fuel burni~g equipment generally includes bunkers, feeders,
exhauster mills, burner, conduits and controls.
They have been
included here to be certain appropriate comparisons are made.
The
drying operations would normally take place in the mill under coal
K-132
-------
burning equipment, this operation has been included as part of
the fuel burning operation since drying and distribution are
handled together.
A4.l.5
Limestone Make-Up Storage and Feed
The lime-
stone feed make-up system which consists of a receiving hopper.
enclosed storage silo and discharge gallary is illustrated in
Figure A4-4.
Orientation with respect to the coal handling
system is shown in Figure A4-1.
The limestone plant is the same as that reported for the
pressurized boiler and need not be repeated here.
.~
K-133
-------
~-~-----.,
, I
I ~.'l.CfJ...i..1 rLl""l~'TOML \lll\alC,[-UP
I I
I I I2...tc.[\V\N.G GA,\.ll.t..,'t'
, I
, I
~ ~:.=.~ ;:~ ~
~., ~ ""-""l. 0".0-0'
-~:~ . ~:.'f .......
~I \4'.. \4' ;.
'1--- ;
~'." 70 ,.,,"", C..a..?8rrC''t''{.; ,../t.\Iro\t.,."frt.l.t.. UC.tl\,I""C;
!;'i... ..b'.o" ,. . 1"\t:J~~tQ..,.
(:... - - '! ~ .., L\~t.&i""'L FLLOI.Il.
~ .' .. / ''l,,./~.. c,,~
.,;, . ~ ~
..'!L.' : "
~.:'1~'.0"~
I'
- -----'------
.------ --...-
~E...C'T\O>.l "A-A'
400"0" MIN.
I
I
I
30(.- !JiLT
\'
I
!
'"
't
~
E~. 'i:o'
.-----~
~~.&~'.o~
L 'lilt 5T~'H- 5TO,,""," to
:s \ 1..0
l-~.. .."
:,* i.':~ .~ .~:: :":'~ :~':~~::~-':.'
.";':~ .:b'f'
.---t--
~o '~o" M.\,..:
5~CT\OI--l
5uQ..c...
"I(
e.,,,\. lD
"DcCQ,.,\.. C:O...V!,-(j{lw", ,P
~,HIIiLCAt. t:".... t IflLOt....
~-"P"'L.
I:...t..,. PI..A~
';:) I ':Jc, 104"'''''<' '- C I>4U-': 1-...
---
--~-~-~-..
.~. e,'
',,.
r .5'."
L
L:e.
, COA.L CO"1/t.'14i..
G,&It.\.Lt It..'(
co..\,. c.o....",.. '(gl..
...........
FI
A';)- IS
c:o-S~-I\~ 1.
A4.11
NOTES
I. DO MOT 8CAI..K TM88 CNtA.....
0IIiIDI880I8 0IiIL. Y.
--
a.. -'-YIATtOIII8 \I8D 0811 ntI8 DIU.- A-
.. A~ W"¥ ~ ft''''NDAMI
-....-v&4T1018 POll U8 OM 08&.""'-
.......
DA"
DUC""-
..VI.IO".
tLEVAilOIo.l
Of
L\"'£.~TO)..l{ fE{O
P\.AI..I T FO~ 'TIH
~OO Io'\W t!>OII.£1l..5
fJJ
TIII8,,--, III" ~....
f'08TKR WHEKLD CO-O""'T1ON
'10 80. OII"''''C ...va.. ~ lit. J.
D-.Wf18 8V,
1-6'"
.,'...
CHCCKCD .V,
A..-ov&D 8V:
r2..D 71 \'123~
-------
A4.2
Coal Feeding
The fuel injection system for the atmospheric boiler is
similar to the pressurized boiler system in many ways.
Although
the furnace pressure is much reduced, the problem of pumping to
an elevated pressure still exists.
Instead of dealing with 10
atm. we must now deal with about 45 in. w.g.
The large pressure
drop across the bed pressurizes the feed system at the tuyeres
or burners.
Fortunately, lock hoppers are not required.
Feeders
in "conventional" coal plants are capable of sealing against pres-
sures of about 60 in. w.g.
The coal feeding in the atmospheric boiler is complicated
by distribution requirements of coal in the bed.
According to
experimental efforts by the British (13). one coal injector is
needed for each 10 square feet of bed surface.
This means about
16 injectors are required for each bed.
In developing a concept to handle the problems of pressure
and distribution, consideration was given to flow dividers, mani-
(13) . D. H. Archer, et al, "Evaluation
Process", Sixth Monthly Progress
No. CPA 70-9, 1970.
of Fluidized Bed Combustion
Report to NAPCA Contract
K-135
-------
folds and other means of splitting the coal flow internally and
externally to the boiler.
There did not appear to be any method
of splitting the flow. once the coal was introduced to the trans-
port lines. that did not contain areas of high risk and uncertainty.
Distribution to a multi-point injection system from a fluid bed
seemed to be the only reasonably accurate approach.
This concept
is proposed.
M.2.1
Scope
. . .
The injection system chosen consists of
, . .
a coal surge bunker volumetric feeder. sealing air fan. fluidized
bed coal dryer and feed injection lines.
The complete system
is illustrated in Figure 4.9 of ~he text.
The surge bunker is
compartmentized and sized in the same manner as proposed by
Petrocarb.
This will discharge into a conventional Stock Volu-
metric feeder illustrated in Figure A4-5.
The feeder will. more
or less. act as a lock hopper and serve two functions. regulation
of the flow of coal and provide an air seal for the bunker. It
is fed sealing air at 300 scfm and 45 in. w.g. by a sealing air fan.
Coal flows from the feeder by gravity into the fluid bed
feed injector vessel.
In this vessel hot air from the. secondary
"
air ducts pressurized by high temperature primary air fans flu-
idize the coal and dries it.
The cooled air with elutriated
material passes out of the fluid bed dryer to the Ducon cyclones.
illustrated in Figure A4-6. where it is cleaned prior to being
;eturned to the secondary air duct.
Residue from the cyclones
is returned to the bed.
K-136
-------
2 ~ ,. ().t~:_...
DowAf.jPoi.Jr TOP ":UII/6.'!
----
- VII:W l-l
----. __-0.-
'-1'!iI
;
~
-J"
'~IIII
n i .
~ ' ~
~~~
~t
I i
II
c
i
z
"
~
i ;
c
........
()
~
OJ
.
a
~
"
.... :;:.
QI r~
- iI:i
t II ~ !i
flf I;:
Itlll
. If -n~
/'
\ h - "
\ "t= ..
" ~~' /
\~_. ~/
i.__. --- ----- .1
I
I
I
J
~
i
- FE/U.< fl-e
- £"ili.", r
1
\
~'"
~ 'if
~~
,
'r--'
)
_.. -(
L_-
.. fit.J~-'J.:.£ .c: £iE. r'. ,P
"-i-~:I~f~_~~~13 Ik.et
I Z
I
I ~
I \J\
I I
J
" '
~
,
"
\.
.
J
.
!'
I:}
.
,~
"
~
~
'oj ~
~ ~
, "
.'" "
,
.
,~
, ,
"
~
I
I
I
\'
I
I
I
I
-~_._.1_-
I
l~
t
~I
..
~.
1
2
OOWN:5PoIJT Z"~"O,D
M,;r/r fI,.- lYl/! 110 Sr :;rl,
~"
~
~
(.5'€' (0 P.ee~~.~If!&D (!f)NL
VAL.e- -,~/Pe Z~-I!I!-C8'~.
WiTH I,!, '0"" !b",ar:#6A"
/ -()IIIIWOVAKO' 1/:(, '!'ro,.
HN'I1L~~IN'J¥JN. /JLl Bo/)Y
~Arl!~ /.v ,4CrJlI£ ~O.-lt
R.ow To 8. r/"oo TY'E
-nit) .5r.ST't., -
I
, "" /,
(, , C {t},IoJ. fC .. 6"rt: C~ 1/'1l',ML
!
.!: 8-'
18"
---=
- - ---'"
r IJN'SH
- - '''' lIoN¥~
c;:. :: =- =--
!!I'" -
:fbI/Nt..
\
()
~
1
~
I
I
I
U
-. l_~~~~~~d~~ ----
iJRE_-'::E~ COi.JI>t.~AS cl.y,.'P~
~ -tIP :5r. sn. #,PPU "6
S. £.6> J/ OWI']E.T~1C FeG/J4',e
rE£OU I)v,u;r HOPt4rtl!!-
tn4r'l.' "/&'- ~ .3PI sr.!,'
(EJfl'liWOA.! ;:;"",.. ('"",sr.)
S-€-Co 191< CMf.. VilLi/e.
;')¥'o! 1t1.~.t:. (IJ-,SP
VvtrH 1t!J - 01';- /bear.J7lFoll
rlliliN ovlI-W.#" Pr OF
1I"",p ('/oIIiIN. 1?t.1. iJapy
P/,mES IN Acn"~ C!DIfI'
rlo"" ro BG J~ ¥ 7)1.4F
~(J# 5r.srz.
'E~P(o.:'lo,J If
-------
~
it'" :-....~
~~"';,"'1.
~:~M
"
.. -
_.
If
r~
.....
.. '. .
'~J;(~'
~'-'- ~::i '"',.00-
-,;''-,;[1,. ..
~";'~"'.~I:: ~7J-...
,.,~.,:~ ". .II~:- "~"
. ~ .. . .0. 'J :...;,:"';
"'..... "":,,: .-.~.' ~
.~ ::~"7"";'" "
'~~. '. '/
\"- ::i
'\;.". ¥. Type SDM Cyclone.
FIGURE A4-6 DUCON CYCLONE - ATM. BOILER FUEL INJECTION SYSTEM
K-137
-------
The fluidized material is removed from the vessel illustra-
ted in Figure A4-7 through 40 - 1" distribution lines penetrating
the bottom of the vessel and passing up through the grid plate.
Each one of these lines connects to a 2" coal feed injection
pipe which carries coal to various feed points in the stream
generator fluid beds.
The coal in the 1" withdrawal lines is
fluidized and thus acts as a pressure seal between the fuel in-
jector and the steam generator.
Coal is fed through the 2" line as a dilute phase at an
air-to-coal ratio of about 0.35 by weight.
Dilute phase was
chosen to minimize the pressure requirements to pump the mixture
to elevations of about 100 feet.
The pipes were sized to avoid
saltation of the coal and minimize pressure drop.
Calculations
were made of the saltation velocity for various pipe sizes and
temperature. levels according to Zenz (9) as recommended by
W. C. Yang (11).
These are illustrated in Figures A4-8, A4-9,
A4-l0 and A4-ll.
The correlations proposed by Huff and Holden
were used to calculate the pressure drop (10).
(9)
Frederick A. Zenz, "Fluidization and Fluid-Particle Systems",
Reinhold Chemical Engineering Series, Chapman and Hall Ltd.,
London, 1960.
(10)
William R. Huff and John M. Holden, "Pressure Drop in the
Pneumatic Transport of Coal", Proceedings, Institute of Gas
Technology, Bureau of Mines Symposium, Mc:gantown, West
Virginia, October 19-20, 1965, lC 8314.
(11)" Communication, W. C. Yang, Westinghouse
K-138
-------
-- J
1 .,,-' 2. ~' T c> c:::. '( C :... 0 ..... £.. 5
~ +--- j~
--~"-
--- - -- - ~
-- 8\{>~-- - ---- - J
i
i
1
/----
/
t- u
I
~-
. ,
I \~~
I"'" ---, /D£..fLe.c:\O~
PLA.1E.
/r
# ~
o \I<..o~
\1I-\C.\l.LE.
'I />.1..\1 ~
0;
-' I
(Q;
I
!
---4
I
i 2.0\. 4 Go'
, All
II)
N
or
N
II)
~
"
Z
Z
~ REVISION
III
I
"
\
",
''',
.....
"Au
L
-J/
ov;/
"(,/Q
I\. /~
j~V
'\r,o
\
\
...J
3" e.\I~I:)I..t.
~ .~/---OI;;,F\.EC.I4>~
c,..p~~~~- ~O- -_-.:~-~ - PL~l'~
// 0 0 0 0 0 0 0 0, /
~-.-' --,-1/ ~ ~ ~-+-e q},-~ e 4:,'~i),' s" {D 0" 0' ~ 1 Ii
" U;fD 0 ';:t- fr (1) U 0 0 0 0.0
--{-----,- -j -+- .. '~ -.- -. ~ I I
~ '0; 0 e 0 y~ 00'11-
-;l'B.do--~()~~e-+ ... .. "~ltJ "A-
~ o~e 4i B' : ,EDG,.
- I J 0 9: o~ f)-.~_et-~. ---. -- - . j0 ~,~-------1
:... 0 ~ 0 ~0 ..;.. -+ I
=+~
-------
120
100 - .
80
U
ILl
U'J
-
?) t
I
f--' 60
w >< -
\() E-<
H
U
a
~
ILl
>
Z
a
H
f-<
~
~
U'J
40
0.1
I
FIGURE A4-8 PNEUMATIC CONVEYABILITY OF ANGULAR
COAL PARTICLES IN DILUTE PHASE AT 1 ATM AND TEMPERATURES OF lOO-500°F
AIR-COAL RATIO - LB AIR/LB COAL
0.3 0.4 O.~ Q.6
:I-r- -/ - ,___h - -- ---1-- - - -----.-- - - r _.. 0- - - - r- _h-
0.8
T
0.9
1" DIA.-
..--
0---
.0' .----.....-" ...
DIA.
-~
. - .--------/--"'/
~
.-----
.....-,-- ...--
--
500°F
---=-~~~~~-=-
"
--------.--------- I
=-
3" DIA.
I
~ 2 1/2" DIA.
- 2" DIA.
1" DIA.
I
I
I
I
t
I
90
100 - 500°F --
o
L-____L____-1._.. - ------.1- ----- --- .J- ----- L
10 20 30 40 50 60
SOLID FLOW RATE - LB/MIN
J
80
L_-
70
-------
u
~
U)
-
E-<
fz.<
><
E-<
H
g
....:I
~
:>
z
o
H
E-<
~
~
U)
?;
I
I--'
.j::"""
o
120
0.1
I
FIGURE A4-9 PNEUMATIC CONVEYABILITY OF ANGULAR
COAL PARTICLES IN DILUTE PHASE AT 1 ATM AND TEMPERATURES OF 100-500oF
AIR-COAL RATIO - LB AIR/LB COAL
0.3 0.4 0.5 0.6 0.7 0.8 0.9
l ".. ... . TU---- ""1-'-5::'%'~~/;;/;~
/' ~Oo~/"/ //.
/ // 200°F ~.//
./ .,/ /~ ..,/
//~~/ /~oo~
// /,' /"
~ ..//., .~~
..'~' ~/
TEMP. 100-500°F /" ;//~ ~.
""/'..../ ........""
/' ../ //....../ .
~/-'~~/1~~ . -
/:/~///~~/~
, ~-
~
0.2
-,
~OO -
2-IN. DIAMETER TUBE
80 -
60
.-----
40
'.
20
o
J
10
90
'- -"'-'---' L'_h____-- -'....-..-______L
l__~__.___...L._.. .... -." . J..... .
20 30 40 50
SOLID FLOW RATE - LB/MIN
60
70
80
-------
u
w
U)
.......
E-<
~
?:; >-
I E-<
I--' H
+:-U
I--' 0
~
W
>
Z
O.
H
E-<
~
~
U)
FIGURE A4-10 PNEUMATIC CONVEYABILITY OF ANGULAR
COAL PARTICLES IN DILUTE PHASE AT 1 ATM AND TEMPERATURES OF 100-s00°F
AIR-COAL RATIO - LB AIR/LB COAL
120
0.1
--1
100 -
80 -
...--/
sOr'
~.
,-/ 400°F:
.-/ ./.
./
./
,,/
/- .,.-' - ./
,,/ ..,-,' ..' -------
.,.--- /' 2 00 ° F--------
/" . .' --,-,,/
./-/ ,..---' ..--
....-/,-/~:.,~-- /' '-~'~/,/"-' ."' "-.-. --- ..~~~.~~---
/ -"' ~ ~-~
/./"/~":'-:/' // -.' ;' ---'----..... .-/.' . ---- ------'
/' -- -,/ ....' ...,.~_. .----------
---------- ...------/ . "" -' - --.- . ." . ----- - ..-- .
...----" / _.",--/ _...--- ---------
...----...--/ ------.------- ---'
,// - ~ ..~ .----
/-
---- _/
.---.,.-
-'
_.~..,-i- -
0.2
r
0.3
0.4 0.5 0.6 0.7 0.8
,------- - r'-------f-----T--'-- "..
0.9
2-1/2 IN. DIAMETER TUBE
100-s00°F
60 :.-
!
I
I
I /--
40~~///
r--~.~~ - I
I ---------
20:
o
10
L
20
.--
300.0F .'
"
.
-1
L-,-__.-l
30 40
SOL ID FLOW RATE
I
60
L-
80
L
SO
- LB/MIN
J
70
90
-------
>-
f-<
H
~ U
I 0
I-' ...:I
+:-~
"\) >
Z.
o
H
f-<
~
~
en
u
~
en
-
~
120
0.1
FIGURE A4-l1 PNEUMATIC CONVEYABILITY OF ANGULAR
COAL PARTICLES IN DILUTE PHASE AT 1 ATM AND TEMPERATURES
AIR-COAL RATIO - LB AIR/LB COAL
0.3 0.4 0.5
I
0.9
OF 100-500°F
0.2
0.6
I
0.7
I
0.8
. .
100 -
3-IN. DIAMETER TUBE
TEMP. .
40
80 -
TEMP. 100 - 500°F
200
60 -
-.
20
o
L
10
I
40
90
_.J
50
I .
30
I
60
l-
20
70
80
SOLID FLOW RATE - LB/MIN
-------
A4.2.2
Equipment
The equipment in the coal feeding pro-
cess includes:
1)
Surge Bin
2)
First Downspout
3)
Volumetric Feeder
4)
Second Downspout
5)
Fuel Injector
6) Ducon 'Cyclones
7) Feed Injection Lines
8) Sealing Air Fan
9) Primary Air Fan
Volumetric feeder and connections include downspouts from
the surge bin hopper and to the fluid injector, volumetric feeder,
feeder hopper, mechanical and electrical positioners and electric
tachometer generator.
Downspouts from the surge bin are 24-3/4" O.D., 9'6" long,
and are constructed of Type 410 stainless steel.
Inlet and outlet
are fitted with 3/4" thick mild steel flanges.
Stainless steel is
usually selected for these fittings to resist corrosion due to the
presence of sulfur in the coal and to prevent coal from adhering
to the inside of the pipe.
Stock Equipment Company Type 24-RR-CB-SP coal gate valves
are installed at inlet and outlet openings and are 24" in diameter.
The inlet is fitted with a 3/4" thick mild steel flange and the
outlet is a collar sized for a Dresser Coupling connection.
The
body is of pressurized construction.
Body plates in active coal
flow are 1/4" thick Type stainless steel.
The valve is equipped
with a pocket sheave hand chain and chain guard.
K-143
-------
Style 38 Dresser Cquplings connect the 24-3/4",a.D. valve
outlet with the feeder inlet.
The coupling middle rin~ is ~/8"
thick, Type 410 stainless steel.
The Stock Equipment Company volumetric feeder has a capa-
city at maximum motor speed of 22,700 1bs/hr.
Two feeders were
selected for each fluid bed injector with sufficient over capa-
city to provide continuous flow at partial load with one feeder
out of operation.
Distance between the centerline of the feeder inlet to
centerline of the feeder hopper discharge is 3'-0".
The inlet
is 24 3/4" a.D. formed for used with a Dresser Co~pli~g.
portions of the feeder in contact with coal flow are either
All
rubber or Type 410 stainless steel.
The feeder body is explosion
. proof construction, rated at 50 psi.
Accessories furnished with each feeder are as follows:
Paddle alarm at the inlet over belt.
Paddle alarm at the discharge.
Stock Equipment Company solid,state speed controller in
separate enclosure.
Variable speed belt drive motor with reducer.
Tachometer indicator reading in pounds of coal per hour.
Purge air inlet connection.
The feeder outlet hopper is 4'-6" high, constructed of
3/8" thick Type 304 stainless steel and reinforced for 50 psi ex-
p1osion proof rating.
The inlet is sized to fit the feeder and
the outlet ,was originally sized to 18" diameter as appearing in
Figu!e A4-5,
This has since been changed to 12".
K-144
-------
_.-
The feeder discharge valves are Type 18-RR-VB-SP 18" (12")
diameter fitted with 3/4" thick mild steel flanges.
Body is ex-
plosion proof construction with a 50 psi rating.
Body plates
in active coal flow are 3/8" thick Type 304 stainless steel.
The
valve is equipped with a pocket sheav~ hand chain and chain guard.
The downspouts are 18" O.D. (12") by 10'-0" long,
constructed of 3/8" thick Type 304 stainless steel.
The inlet
is fitted with a 3/4" thick mild steel flange and the outlet is
plain.
Mechanical and electrical position indicators..are optional.
The position indicator can be used on either or both valves.
The
indicator consists of a large pointer and the words "open - closed"
which gives visual indication of the valve gate position.
It also
includes two micro-switches mounted in the housing to control indi-
cating lights at remote locations.
As an added option Stock Equipment Company includes a Gen-
era1 Electric D.D. Auxiliary Tachometer Generator to be mounted
on the feeder drive motor for feedback to the combustion controls
system or integrated into the coal feed flow controls.
Sealing air is provided at the vo~umetric feeder by a
Westinghouse size 2724-7 1/2 Turbo Blower sealing air fan with a
capacity of 300 dm and static pressure discharges of 43" H20 at
80°F.
The blower comes equipped with a TFC 7 1/2 HP - 3 phase
60 cycle motor.
~n alternate fan can be provided to give a
slightly higher pressure level of 51. 8" H20 at about twice the
price.
In the alternate case a 20 HP motor would be required.
K-145
-------
The fluid bed dryer and distributor is illustrated in
Figure A4-7.
It simply consists of a cylindrical vessel enclosed
at either end with ASME dished heads.
The vessel is constructed
of 3/8" rolled and formed 304 stainless steel.
The lower head is
flanged to accommodate a grid plate and provide access to the
internals of the vessel.
Coal is fed to the vessel at bed level
through two downspouts which are sealed with Ducon trickle valves.
Recyc~e coal from the cylones also arrives at the bed level through
a single 8" connection or dip1eg.
Carbon steel 1" coal withdrawal
lines penetrate the lower dished head where they are seal welded to
the grid plate at a simple air seal.
A rectangular air inlet is
located in the skirt of the dished head which allows hot air from
the primary air fan to enter the vessel and then pass up through
3" bubble caps in the grid plate.
The cooled air leaves the
vessel at the top through a 24" O.D. line where it is transported
to the Ducon cyclone. .
The bed was designed at 2-1/2 ft. depth to dry the coal at
about 250° exit temperature.
Air inlet temperature is 735°F.
The superficial bed velocity is 4 ft/sec.
It was selected to
handle 1/4" x 0" coal.
The air leaving the bed has an estimated
saturated loading of coal dust of 173 grains per standard cubic
ft. with a size distribution as illustrated in Figure A4-l2.
Sizing was accomplished according to procedures recommended by
Zenz and Othmer
(9) .
Deflector plates ~ave been installed to
insure mixing and avoid by passing of air ar0und the tube bundle.
(9)
Fredrick A. Zenz and Donald F. Othmer, "Fluidization and
Fluid-Patricle Systems", Reinhold Chemical Engineering Series,
Reinhold Publishing Corporation, New York, 1960.
K-146
-------
;:>;:
I
~
+:-
-.;j
\r~rT 'T'T"--I--i---r- r "-i -:-fi i---~
I
I
.
,
- .1[lT]
:~
151-
- 1-
- 25L-
351::_-
I
. 1--
- 45 ---
55 --
I j i i i I
E-4
6
H
~
FIGURE A4-12
><
~
~
N
H
C/)
~
~-
>
a
I
Bl-
93 L_-
- I
I
1.-
96 i----
I-
I
98 :---
I
j-
-. 99 i--Ul_~L_LLLL.IJ --..- .J._..I__LJ
10 100
PARTICLE
100 (IQ
~
325
200
SIZE DISTRIBUTION OF COAL
-TO DUCON CYCLONES - ATM. BOILER-)"
FUEL INJECTION SYSTEM. ~;
~
PARTIC~E SIZE, U. s. t.1ESH
I..J.L, I ----.I
1000-
SIZE, HICRONS
28 - 16
.
i u_uJ.d .--
- 10000
10
1
6
i
I
I
-I
,
-------
Air and elutriated material leave the vessel at 250°F at a
rate of 26,000 lb/hr and enter a Ducon Model 660 VM 700-150
Stairmand type cyclone constructed of 1/4" mild steel.
The an-
ticipated pressure drop is 5.3", H20.
It has an efficiency of
90%.
The cyclone is illustrated in Figures 4.9 and A4-6.
Feed lines withdrawing coal are 1" I.D. and transport lines
are 2" I.D.
They are constructed of mild steel schedule 80 pipe.
The lines should be installed such that minimum tube bend radii
are at least 12 diameters to minimize erosion.
The transport
medium is dilute phase at 0.35 pounds of air per pound of coal
and gas velocities of 30 ft/sec.
Two fuel injector vessel~ are used to serve the five beds.
Each injector contains about 40 feed points.
This is a conceptual
feed injector and experimentation would have to be carried out to
. be certain of the optimum number of feed points~
One Westinghouse primary air fan serves each fuel injector.
The capacities are too low for the pressure drops required to
provide individual primary air fan for each injector vessel.
The
fan has a capacity of 34,000 lb/hr at a pressure of 45" H20.
A4.2.3
Cost
The total cost of the system is broken
down as illustrated in Table A4-2.
TABLE A4-2
COST BREAKDOWN OF COAL FEEDING SYSTEM
1)
2)
3)
4)
5)
6)
Bunkers
Volumetric feeders
Cyclones
Fuel Injectors
Transport lines
Controls'
$691'1,000
. 269,214.
84,000
-220,786
16,000
500.000
TOTAL
$1,780tOOO
K-1U.A
-------
.' -
The estimates do not include a price for controls.
Develop-
ment of a control system is beyond the scope of effort of the
contract.
The system would probably be similar but less expen-
sive than the Petrocarb system since weighing is included in the
price of the volumetric feeders and no lock hopper controls are
required.
For estimating purposes a figure of $500,000 would prob-
ably be conservative.
A4.2.4
Carbon burn-up cell feeder
The carbon burn-up cell
feeder has been included here as an adjunct to the section on coal
feeding.
It was not mentioned in the scope of work in this section
and certainly it does not warrant a section by itself.
The carbon elutriated from the fluidized beds contain
about 13% of the original carbon fired.
Details of the exact
material balance are reported in the body of the report.
The
elutriated material must be recovered at the dust collector
and fed to the carbon burn-up cell as a fuel.
Collection takes
place at 840°F.
To avoid fires the residence time in the dust
collector must be minimized.
A modified Petrocarb system was selected to handle the
fuel to the carbon burn-up cell (CBC) at 840°F.
The elutriated
material passes on through the dust collector hopper to a col-
lecting vessel.
A level is maintained in this vessel to regulate
'control of the fuel from the Petrocarb fuel injector.
The com-
plete system is illustrated in Figure 4.7 of the body of the
report.
The collected material periodically flows from the
collector vessel into the localized. fluid bed fuel injector
from which it is pumped through 16 separate lines to the CBC.
K-149
-------
Once again 16 feed points were felt necessary for adequate dis-.
tribution of fuel to the larger flat beds encountered at atmos-
pheric pressure.
Petrocarb indicated service air for transporting
the fuel would be approximately 2000 scfm compressed to 200 psig.
One system as described above' would be required for each
module.
Consideration was given to one injection module for
all four boiler modules.
The problems of collecting. the residue,
integrating operation between modules and injecting to 64 feed
points were too great to consider the concept further.
Petrocarb estimates the cost of the system to be $500,000.
-
K-150
-------
A4.3
Patriculate Removal
A two stage particulate removal system is used to clean the
flue gases of carbon sorbent and ash elutriated from the fluidized beds
and carbon burn-up cell (CBC) to 0.01 grains per standard cubic foot.
The first stage is a multi-cyclone mechanical dust collector il-
lustrated in Figure A4-l3.
The second stage consists of a Research
Cottrell electrostatic precipitator illustrated in Figure A4-20.
The first stage of separation is divided into two streams,
one stream from the fluidized bed cells and the second stream
from the CBC.
In this way elutriated material from the fluid beds
can be segregated from the ash released in theCBC, so that it
can be used as a fuel in the la~ter.
The flow diagram in Figure A4-l4 illustrates the distribution
of flue gas and particulate matter in the various tanges of sep-
aration.
Size distribution of particulate material elutriated from
the beds is illustrated in Figure A4-l5, along with the size dis-
tribution of residue in the flue gas.
The sizing of elutriated
material was specified by Westinghouse based on data provided by
NAPCA contractors.
A4.3.l
Mechanical Dust Collector
A hot multiclone cyclone
-
dust collector was selected for the first stage of particulate
removal.
The dust collector was designed for high temperature
operation, 840°F, to avoid exposing the heat recovery surface
to heavily dust laden flue gases.
Multiclone cyclones in theory
are more affective collectors of small particles than larger
cyclones using the same gas velocities.
In practice, this im_O
proved efficiency is reduced because of the increased short cir-
K-151
-------
"~' ..~, ".." , ..'
'.':' ,~~~ " . ,.'i~"('~~~~~~~",."
j . ~:~ ~:.' :A1J:..L_, -~" , ',~t ~:;~.1~..al~~':;:;"~: ~:'
~ ~'. . '~\~fl~~~Jj~ItJ~~~P!.: I:-.:-'~lti~--
'. ," ~q-.,. - .-.t.- '1- "l."it !\i-,..-"-, \1- [4-118- ,,,- .,
;-..~-.1t-.~-rq-!q-r1t-,,- !.!-I~-ni-t1I..-.~- ,- '
. ,..-t-~q-~"-l\i-t\l--rll-'4 .~ 1- '" . 1.l1 '41, !.
--''-L t1ii.Ao ..(a -."'.-.ni - /,11- ""-.1j- ,,--~-- rU- .J,t -, ~ - ';': ,- "'i'?'~:..~
1 ~ '".....~...... ..... '-... - 11''".. .
- ,." '-:: .- - - ~ . J I. (,' .' 'J"
: . ""...~".:'4.'-~1U...~1i--"14 '"',"'--1'" .~ ~It 't.t at ,«' '... '."~
.:~l'~ . ,,", ,", " ..... ,'"
, \~' .... " "'..:
...t<..~~ .::~ -- ~" ' '
r '. -:~ ~I ~t '.
"'~' ,~
(....,
. 1,4
Af
,~
FIGURE A4-13 PARALLEL ARRANGEMENT OF MULTI CYCLONES
K-152
-------
;:>;
I
I-'
V1
W
FROM FBC
------.:>-
10.8 GRAINS/SCF
% Ash 33.75
% Coal 59.45
% U.L. 6.80
(UNREACTED LIMESTONE)
E :z 96%
TO CBC
FROM CBC
0.44 GRAINS/SCF
25.6 GRAINS/SCF
% Ash
% Coal
, % U.L.
70.8
14.0
15.2
\
"FIGURE A4-14 MASS BALANCE PARTICULATE REMOVAL
SYSTEM 300 MW ATMOSPHERIC FLUID
BED BOILER
FLUE GAS
1.03 GRAINS/
SCF
E = 96%
TO ASH REMOVAL
0.58 GRAINS/SCF
ELECTROSTATIC
PRECIPITATOR
l
TO ASH REMOVAL
PRIMARY CYCLONE
CBC DUST REMOVAL
TO STACK
>---
0.01 GRAINS/SCF
-,
-------
"
?::
I
I-'
Vl
~
1
//
... /X./'. .
93 --- ~~ MATERIAL ELUTRIATED FROM CBC
96--- / / . - . ..
98 -- /' .
1
5-
..
~
t"j
~
H'
N
t"j
D:t
0-<
15
25-
35-
4~'-
55-
65.-'
75 ._-
~
H
£
H
85--
MATERIAL ELUTRIATED
FROM FBC
99
"
1
10' 100
. PARTICLE SIZE, MICRONS
325 200
L I
1000
100 60
I I
28
I
---,-- -- --
PARTICLE SIZE, U.S. MESH
FIGURE A4-15
DISTRIBUTION OF PARTICULATE MATTER IN FLUE GAS
~
16
I
-------
cuiting that takes place in small cyclones operating in parallel.
One worker, in comparing high efficiency cyclones with multiple
small cyclone designs has shown that the multiple cyclone arrange-
ment is only marginally better than the large cyclone (10) (11).
The one important asset of the multiple cyclone arrangement is
the efficient use of space at high capacity in contrast to the
large volumes and high head room required by the single Stairmand
type of dust collector.
The Air Correction Division of Union Oil Products designed
and priced the mechanical dust collector to operate at 840°F with
96% efficiency on flue gas containing 10.8 grains per standard
cubic foot with a particle size distribution as shown in Figure
A4-15.
The size distribution of dust leaving the mechanical
collector for the precipitator is illustrated in Figure A4-16.
A single dust collector is used for each module capable of
handling 610,000 1b/hr of flue gas with a turn down of 70%
efficiency.
The pressure loss through the dust collector is
3" H20.
The guaranteed effic~ency for various Bahco dust part i-
cle size is illustrated in Figure A4-l7.
Dimensions of the unit
are shown in Figure A4-18.
.-
The collector is equipped with while iron tubes having an
average Brine11 hardness of 450 and special heat resistant tube
gaskets.
Each tube is 10 1/2" nominal diameter with 0.25" nominal
wall.
The tubes are equipped with directional guides at the in-
let openings.
The outlet tubes are 6 5/8" O.D. 1112 guage wall
standard tubing.
The lower tube sheet is constructed from 1/'11"
(10)
(11)
C. J. Stairmand, R. M. Kelsey, Chem and Ind. 1324, (1955)
W. Strauss, "Industrial Gas Cleaning", Pergamon Press, 1966.
K-155
-------
~
I
f-'
Vl
0\
1
- I I I
1-
5-
15 -
25 -
35 --
, 45 -
W
N
H
CI)
~
w
:>
a
Eo-<
z
W
u
~
W
Po.
-
55 --
65
75 ._-
85
93
96 --
98 --
; i
'-'--'-'1
DISTRIBUTION OF DUST
SIZE IN FLUE GAS FROM TIlE FBC
MECHANICAL DUST COLLECTOR
99
PARTICLE SIZE,
FIGURE A4-16
SIZE DISTRIBUTION OF PARTICULATE ~~TTER FROM
TIlE MECHANICAL DUST COLLECTOR
-------
, 1
100'
I
I
901-
I
H
Z 80-
C>J
u
p::
C>J
Po.
I 70
t;
z
C>J
'" H
U 60
I H
I-' ~
V1 i-L<
-.;J C>J
0 50
C>J
C>J
H
~ 40
«
::>
0
30
20
I~l
11-'1 I-----r-
. ~~'~"--
_./~>~--
,/ /-,'---~/
//
~/..
..
1.0" W.G.
1.5" W.G.
CONDITIONS OF CURVE
Dust Specific Gravity - 2.5
Dust Concentration - 2 to 5 gr/cu. ft
Gas Temperature 70-800°F
o ~-Li-LJ I. .
0 5 10 15 20 25 30 35 40
BARCO-DUST PARTICLE SIZE-MICRONS
FIGURE AlI-17 MICRON EFFICIENCY CURVES TUBUlAR DUST COLLECTOR DES IGN 106A
'.
-------
r
~I'
A
1:\: .
.. I
\' i . i
I( , t
'Ii' ,
;: I '
Ii
It
'I
'I
- -,
. -~.- ---''''''.'''--'' --."-
..'
~
I
I-'
Vl
ex>
t
I
I
~):..~
I,
I
c::J
WI TH CHANNEL
ASH HOPPER
18" DIA.
QUICK OPEN-
ING ACCESS
DOORS
NOTE:
STD. HOPPER FLANGES
MATCH 8" 150 LB.
ASA DRILLING
BY
OTHERS
CBC HOPPERS
11-
II
JI::'l
WITH WF BEAM
END ELEVATION
DETAIL A
6"
3 1/2"1 r--..-----.:. B
-, 1r
(J .
-r- . "t11")1
I :: .!nll"
C 1,111111 '"
! :1': :f' :!'; ...... " .... , ' J
111111 ,,--L-
- - - ~,) ',,1.1, - - - - - - -' l' fl"
" I ", ,I I I
3'-6" d :".1 ::,; I I
DMIN. ! \. r 't' I
!
SUPPORT
LEVEL
,
SIDE ELEVATION
DESIGNATION
DESIGN
106AWHS 1117-357
METHODS OF SUPPORT .
. 22~O DIME::::NS. (F:~3 ;;1~~~f~!~~¥ 5~1=~i~~~;:IiLo~-:f{t:1:r. ~
FIGURE A4-18 MODIFIED U.O.P. SERIES 100 TUBULAR DUST COLLECTOR
DIMENSION SKETCH
SIDE INLET - TOP OUTLET
-------
steel plate.
The upper tube sheet is 3/16" steel plate.
The
envelopes are made of 12 guage steel plate.
Casing and hoppers
are constructed from 3/16" steel. plate suitably reinforced to
withstand design conditions.
Hoppers are designed for a minimum
of 55° hopper valley angle.
Normally the dust collector comes
with 4 hoppers, two rows of two each.
To accommodate the
split gas stream and to segregate the material elutriated from
the fluid beds from that elutriated from the CBC, six hoppers will
be required as shown in Figure 3.7.
Each unit weighs 50,300 lb, costs $27,000, and requires 315
man hours to erect.
At $lO/hr mean cost rate for field erection
the total cost of erection amounts to $3150.
Other material,
equipment' and structural steel are included in the boiler cost.
A4.3.2
Electrostatic Precipitator
An electrostatic pre-
cipitator is used to clean the effluent gas from the mechanical
dust collector.
This is not an uncommon practice.
Elector-
static precipitators are often combined with mechanical
dust collectors in cases where gases have exceptionally
high dust concentrations or need conditioning or both (11).
The gas to the electrostatic precipitators is a blend of
-
streams from the barbon burn up cell and the fluid bed com-
bus tion cells.
It has an estimated grain loading of about 0.58
(see A4-32)grains per standard cubic foot.
Size distribution of
particulate material appears in Figure A4-l9.
The gas flow is
2,440,000 lb/hr ~see A2.6) at 275°F.
A residual gas loading of
0.01 grains per standard cubic foot is required.
K-159
-------
The particulate matter consists of 79.5% ash, 18.7% coal,
and 1.8% limestone.
For this particular application Research Cottrell selected
one precipitator consisting of four units serving all four boiler
modules.
Each unit contains 45 ducts, 9" duct spacing with 30' high col-
lecting plates and 36' of treatment length (12' + 12' + 12').
Each precipitator is energized by size 70 KV , 1500 on a silicon
. '. p
transformer rectifiers complete with automatic voltage controls.
Details are illustrated in Figures A4-20 and A4-2l.
The selling price of the precipitator is $571,000.
Erection
re~uires 16,869 boiler maker man-hours and 6,720 electrician man-
hours.
Assuming a,mean cost of $IO/hr for both, the cost of erection
is $235,000.
Detailed cost of erection cannot be made without an
W~gesand subsistence varies considerably
from union hall to union hall and the subsistence is not only
exact site location.
dependent upon the union and geographic location but the local
distance,from the hiring hall.
--'
K-160
-------
.
i
1
1
5
15
. 25
35 -
45
~
fj 55 -
U)
~65
. >.
o.
:::<: E-<75
I z
~ ~
0'. U
~ ~
~85-
93 -
96
98 -
.99
,
DUST LOADING TO ELECTROSTATIC PRECIPITATOR
..
d
1000
. 325
! .
, .
100
PARTICLE SIZE, MICRONS
100 60 28 16 10 6
..! --. ~ -- --.--....-1..- -.- -_L_~.--L _1
PARTICLE SIZE, U.S. MESH
200
- ,
FIGURE M-19
SUED DlSTRl~UTION OF PARTICULATE NATERIAL TO ELECTROSTATIC
PRECIPITATOR
'.
-------
FIGURE A4-20 DESIGN FEATURES OF ELECTROSTATIC PRECIPITATOR
K-162
-------
~~" {O~" hd.
D,,-+...
~\(dc.
;::.:
I
I-'
0'.
W
Gq,!.
f \ow
'1
~
Vi
.
~
i
I
I r-""""}~-"~--'-'--~~~-j! :.;
i' . ----~---f~ ~~
i r--~
I
I
I
1
I
I
1
..I
I
I
I
-
-
---- --- - d
..
u
~
o
, 0
"
£1
'"
-;.,
-- -;t---
'"
=~ti_--
.-' 0
.
.~
. ..
o :.
.' Q..
,t\ 0
-:t
i"
.. "
I
I
.J_9
I
I
--
t
! \ \
\
\ / ./ / /
,~.. \
!+.3 Ie;. \
\, \
F\v c. l~~)<
Ope"".., )\
\ '( p.'
/ \
I
/ \ \ , - \ /
\ \,
\
I
I
I
4:
.
c-I
.'
o
"
"'."T.
~tP~.
P\,,\c.
~1'P&,:
'i2...E. ~ E.~~C ~- CO" R..~LL I~ ,.
~D\)~O tILIO~. ~").
QP2E:.L PL~'~ PP1R
4.U,4-5 D ~")(.30~O~?>~"d'(\"1.~d\ PlS)
~~~: .)~ ~~:~ 51H~~~,- .I2..Q ]~-
F' ~'U R ~ I,ll :";
.
~~~: O\M~~'610"'~. CO,"" ~+,"\)c.~ \0,,",
~c.o\o.\\s. Aye:. ..~\.',c~"" ,,"0 c:~~""~.
-------
A4.4
Heat Recovery Equipment
A4.4.l
Introduction
Heat recovery equip~ent in thfs'ap-
"plication will refer to the air preheater which exchanges heat
from the effluent flue gas stream to the incoming
combustion air.. The heat exchanged is energy that is re-
circulated on the gas 'side of the boiler.
The energy has no
direct effect on plant performance. . The quantity circulated,
however, establishes the. mean temperatur~ level at which heat is
exchanged between the hot gases and steam.
In the case of a
fluid bed combustion process where the bed temperature is fixed,
the quantity of heat recirculated determines what what percent of
the overall energy exchange between gas and steam takes place
in the fluid bed. The heat recovery' equipment increases the
mean temperature.differen~e between gas and steam and 'thereby
reduces the total surface required to transfer energy to the
steam.
It does so, of course,. at. the expense.9f additional heat re-
covery surface.
This suggests. that there is a trade-off of steam gen-
erating surface and heat recovery surface which requires opti-
mization.. The end result of the s~udy is the selection of an
..-
operating temperature level for the heat recovery equipment.
The air preheater indirectly affects the plant performance.
The outlet. gas temperature is limited by the dewpoint of sulfuric
acid.
If this limit is exceeded cold end corrosion can be expected.
In a fluid "bed boiler process where 90% of the sulfur is captured
during combustion the permissible flue gas exit temperature can be
quite low., Westinghouse recommended 275°F.
Under these circumstances
the plant performance should be .improved by reducing the heat loss
K-164
-------
in the flue gas.
This also reduces the mean temperature difference
of the air preheater for a given inlet temperature and hence. in-
creases the surface requirements.
Trade-offs of surface and plant
performance can be made.
However, variations in either are
probab~y small and of minor importance.
Lar.ge quantities of heat recovery surface can result in in-
creased draft loss and hence increased fan power in a system which
already has a large system resistance.
Trade-offs in this
case are equipment, size, quantity of surface, capital invested
in fans, and power requirements.
Another facet in air heater performance is the service it
provides in heating air for drying coal.
Moisture requirements
if sufficiently large can dictate the air heaters duty.
Generally speaking it would be undesirable to drop the
temperatures of the air to the bed below 500°F for fear of quench-
ing ignition in the bed.
In addition the temperature of the transport
air for coal should not go below 250° for fear of allowing condensation
of moisture to take place.
This could cause pluggage of the coal trans-
port line and/or corrosion.
The influence of these' temperature levels
on equipment selection must be determined during the optimization study.
Two types of heat exchangers are commonly considered for
air preheating, 1) the Ljungstrom air preheater or regenerative
air preheater and 2) the tubular heat exchanger.
Other ver-
sions of these two types are available but not widely used.
A4.4.2
Description of the Tubular Air Heater
The tubular
air heater as the name implies, is simply a tubular heat ex-
changer which is normally arranged for vertical gas flow through
K-165
-------
the tubes.
The unit being proposed is iHus tra tedin Figure 4.6 '.
Air flows horizontally across the tubes which ?re generally in stagger-
ed relationship.. Air passes b~ckand forth over the heating surface
three times to approach counterflow.
Tube sheets are provided at top and
bottom through which the tubes pass and to which tubes are at-
tached.
Structural support is provided by members which are
attached to the top of the upper tube sheet or located below the
lower tube sheet.
The air heater is divided into three passes.
The lower pass
is constructed separately to allow for replacement of tubes in
the event of cold end corrosion.
The tubular heat ~changer has the unique advantage, of no
air leakage and thus a minimum contribution to fan power require-
ments.
A4.4.3
Description. of the Regenerative Air Heater
The
~jungstrom air preheater operates on the regenerative principle
in which rotating baskets are alternately heated and cooled by
the flue gas and air. streams, respectively.. The air preheater
assembly consists of a housing, divided into two end. or outside
~~ ~
compartments and one ,middle compartment in which the heating
surface contained in a slowly moving rotor is installed.
The
outside compartments are divided by partitions which confine
the hot gas to one side of the apparatus, while the air to be
heated is 9n the other side.
For each revol~tion of the rotor
there is a complete cycle of heat exchange in which heat from the
hot gas is continually absorbed by the regenerative method by
the heating surface, and then given up as the rotor moves
into the path of the air to be heated.
K-166
-------
:.<::'.
1
~ ~:
\ ~1
'-.....
FIGURE A4-23
LJUNGSTROM REGENERATIVE AIR PREHEATER WITH VERTICAL FLOW
K-167
-------
A typical unit of the vertical flow design is illustrated
in Figure A4-22.
The air for the combustion enters at the lower
left side, passes upward through the heating surface and discharg-
ing at the upper left side into the hot air ducts.
The hot flue
gases enter at the upper right side, flows continuously downward
through the heating surface into the lower right chamber, counter
flow to the air, and is then eXha~~;ed to t~~~tack.
flow of gas and downward flow of air are permissible if required.
Upward
Horizontal flow design may also be furnished with the flow pass-
ages either side by side, or with one stream passage vertically
over the other depending on the layout requirements.
Both vertical flow and horizontal flow designed units are
used with gas temperatures up to but not exceeding 1000°F.' For
gas temperatures in excess of 1000°F special designs are available.
The rotor which carries the heating surface contains sector-
shaped cells into which the heating surface is fitted.
The heat-
ing surface is divided into a number of groups or baskets which
.'can be easily inserted in the rotor.
The surface is made of com-
binations of. fiat or formed thin sheets.
The formed sheets may
be corrugated, notched or undulated with the ribs forming long i-
tudinal passages of the most desirable contours for the predetermined
spacing.
The design and arrangement of the surface provides only
point contact between adjacent plates.
The gas and air flow are
turbulent, but at the same time the flow path ~hrough the rotor
is ~oot~ .and offers low resistance.
The combined pressure. drop
through the air side and gas side generally runs about 10" H20.
As an approximate rule it may be stated that one inch of standard
K-168
-------
regenerative air heater surface will recover about as much heat
as a two-foot length of tubular air heater surface offering equiva-
lent resistance to gas and air flow.
The rotor motor is driven through reduction gears to a
pinion shaft and then, finally, through a pinion gear to a pin
rack mounted on the periphery.
The rotor turns from approximately
one to three rpm and the actual power required to drive it varies
from 1/2 to 5 hp depending on the preheater size.
Air leakage into the gas stream is divided into three
categories:
1)
Leakage into the gas chamber resulting from entrainment
in the rotor passages.
2)
Leakage at the periphery of the rotor through the clear-
ance space between the rotor and the housing and then into the
gas passage.
3)
The third source of leakage is across the radial seals
into the gas passage.
Although the air leakage in a conventional
preheater may be a small percentage of the air provided by the
forced draft fan, a significant loss might be expected in the fluid
bed application where the air-to-gas pressure differential
is large.
This is compounded by the fact that larger diameter
rotors must be used to minimize the resistance in the air and gas
passages.
In this case, more surface area is required and the
sealing area is ~-eater.
A4.4.4
Selection of Equipment and Costs
Selections were
made for the regenerative air preheater and the tubular air heat-
er in order to evaluate the applicability of both concepts to the
K-169
-------
fluidized bed boiler.
Two selections were made for the regenerative
air heater to determine the influence of draft loss on air leakage.
In all cases the units were designed on the basis of total gas flow
of 610,000 lb/hr at an inlet temperature of 840° and outlet temper-
ature of 275°F.
One heater was selected for each boiler module.
The gas temperature was selected to meet coal drying requirements
and to permit placing the greater portion of feed preheating
surface in the convection gas pass zone.
A crude optimization
of convective heat transfer surface requirements indicated the
duty would be nearly evenly split between the air preheater and
economizer.
Subsequently an optimization study was run to eval-
uate the selection.
"The inlet air temperature was set at 80°F with an approximate
outlet temperature of 735°F.
Total pressure drop desired was
estimated at about 4" H20.
The performance and specifications for all three air heaters
are summarized in Table A4-3.
The tubular air heater was selected
over the regenerative air heater on the basis of air leakage con-
siderations.
Air leakage amounting to almost 20% could be completely
.... ,
eliminated at an incremental cost of capital investment of only 15%.
Both the tubular and regenerative air heater require field
erection.
The regenerative air heater is generally shipped in"
sections and assembled in the field.
The units under consideration
would require 4300 man-hours, excluding duct work, which amounts to
about $43,000.
The tubular heat exchanger'must be completely field
erected.
Consideration was given to maximum shop fabrication.
It
was the opinion of the manufacturer that no real saving in shop
assembly would be achieved since so much additional stiffening would
K-170
-------
Gas Flow (per unit)
. Air Flow
Gas Temp. In of
Gas Temp. Out of
Air Temp. In of
Air Temp. Cut ,oF
liP In H20
, Air Side
Gas Side
Suriace
Weight
Air Leakage
Cost (4 Units)
~..:r-'" .
TABLE A4-3
AIR PREHEATER PERFORHi\NCE
610,000
560,000
840
274
80
750
4.5
3.0
1.5
260,000
986,000
$1,040,000
Constituents
C02
H20
. N2
8°2
°2
Gas Ash Loading
TUBULAR
1b/hr
lb/hr
of
of
of
of
In !l20
, In H20
In H20
Ft2
Lb
Lb/hr
Gas Composition
% Mole
14.76
8.71
74.46
330 ppm
1. 79
REGENERATIVE
LOW PRESS. HIGH PRES.
DROP DROP
, .
610,000 610,000
560,000 560,000
840 840
274 . 273
80 80
739 741
4~05 8.7
1.6 3.5
2.45 5.2
152,600 122,300
469,000 349,000
118,000 105,000
$899,000
$697,000
% Wt.
. .
22.0
5.25
71
330 ppm
1.75
1.03 grains/scfm
K-l71
-------
be needed or individual assemblies just for shipping purposes.
It was estimated that 8,360 field hours would be required for
field erection or about $83,600 per heater.
A4.4.5
Optimization Study
An optimization study of the
distribution of heat recovery surface in the convection heat trans-
fer zone was made to determine. what trade-offs could be made be-
tween steam. heating surface and air preheating surface.
In this
particular case.heat recovery surface refers to all surface
suJ>jected to convective heat transfer for all surfaces not sub-
merged in the. fluid bed.
It excludes the convective heat trans-
fer surface. above the beds which is normally considered an in-
,
tegral part o.f the bed enclosure. . The trade-offs are evaluated'
in terms of the parameters that might affect the optimum,dis-
tribution of, the surface.
These include the cost of surface,
the heat transfer coefficient, the water temperature to the
boiler, the stack gas exit temperature and the fluid bed temperature.
Two banks of surfaces must be installed in the flue gas
between the fixed temperatures of l600°F and 275°F for the ex-
change of heat to the inlet feedwater and the air to the combustion.
-
zone.
These banks may be represented as blocks of heat exchanged
as illustrated in Figure A4-23. 'As an initial condition it may
be assumed that the air inlet temperature is fifted at 80°F and
the water inlet temperature is fixed at 400°F.
Outlet temperatures
of the air and water are dependent upon the duty to each heat ex-
change bank.
The duty in turn is fixed by the prime variable
in the study, the gas exit temperature from the high temperature
bank which is also the gas inlet temperature to the low tempera-
ture bank.
Variations in air and water outlet temperature determine
K-172
-------
GAS I~
,
Tl
STEAM OUT
T4
tzJ
~I
~I
E-<.
.' -I
L
STEAM HEATING BANK
(ECONOMIZER)
AIR-HEATING BANK
(AIR PREHEATER)
GAS OUT
..-
TS
IJ~. IN
T6
TS
T2
----
--
---
T3
T7
WATER AIR
IN OUT
..,
T~
'~
T7
"'--,
'~
'-~
. T6
~
'':T3
ENTHALPY
'---'--'~-'_.-
FIGURE A4-23 TEMPERATURE DISTRIBUTION HEAT RECOVERY EQUIPMENT
~
K-l73
-------
the quantity of additional surface which must be installed or
removed from the bed to handle the increase or decrease in
heat released with the change in combustion air inlet tempera-
ture.
It should be pointed out that the bed temperature is
fixed and the duty required to genera~e steam, ,is constant.
The bed ,temperature acts more or less, like a fulcrum about
which the,bed and convection surfaces are balanced.
At high flue
gas exit temperatures to the air heater, feedwater'heating
surface or economizer surface must be placed in the bed.
At
low gas exit to the air preheater the surface must be placed in
the convection heat transfer zone or heat recovery area.
Optimizing requires selecting the'flue gas temperature to
the air preheater which gives the minimum total cost of economizer
surface in the heat recovery area, air preheater surface and feed-
water heating surface assigned to the fluid bed for a given set
of costs of surface and heat transfer coefficient assigned to
the respective surfaces.
Westinghouse (12) investigated cost of
air preheating surfaces and economizer surfaces and found that
economizer surface ran about $3/ft2 with heat transfer coefficients
rang~ng from 10 to 20 Btu/hr-ft2_oF.
For this analysis it might
be assumed that surface would cost the same but have heat transfer
coefficients of about 5 Btu-hr-ft2_~F.
Regenerative air preheater
2
surface should run about $l.2/ft for exchangers with total
installed surface exceeding 20,000 square feet with
, .
(12) D. H. Archer, et. al, "Evaluation of the Fluidized Bed Com-
bustion Process", Tenth Monthly Progress Report to NAPCA
Contract No. CPA70-9, 1970.
1<'_174
-------
heat transfer coefficients in the vicinity of 5 Btu/hr-ft2_oF. The
cost of tubular heat exchanger surface runs slightly higher than regen-
Riley estimated a figure of $1.5/ft2
erative air heater surface.
as a very general figure without reference to size.
Overall heat
2
transfer coefficients can be expected to range between 3-5 Btu/hr-ft _oF. (13)
Data obtained from vendors quotation indicate it is fair to
assume economizer costs of about $3/ft2, tubular air heater cost
of $ 1/ft2 and regenerative air heater cost of $1.47/ft2. For the
purpose of the analysis the exact costs are unimportant, as a design
point will be selected based on some reasonably assumed values.
The unit cost of conductance which is the unit cost of the sur-
face divided by the heat transfer coefficient will be assumed a
parameter and its effect on the optimum flue gas exit temperature
will be evaluated.
As indicated earlier the total cost of heat recovery surface
may be WTitten as follows:
CT = Ce + Ca + Cfb
(1)
Where:
CT = Total cost, dollars
C = Cost of economizer surface, dollars
e
C = Cost of air preheater surface, dollars
a
Cfb = Cost of feedwater heating surface assigned
to the fluid bed, dollars
(1.3 )
D. H.Archer, et. a1., "Evaluation of the Fluidized Bed
Combustion Process", Sixth Monthly Progress Report to
NAPCA, Contract No. CPA70-9, 1970.
K-175
-------
Th~ cost of th'e indi~idual components must be expressed
in terms of the cost of conducta?ce and heat exchanger perform-
ance.
Each heat exchanger bank's performance must be expressed
" '
in terms of the limiting temperature of the fl~id stream.
limits are either constant,or they can be expre~sed in terms of
These
th~ flu~ gas exit temperature, the primary variable with which
we are co~cerned and the one variable that divides the duty
to the two heater banks.
Recognizing these facts, equation
1 can be written in terms of the flue gas exit ,temperature
. '
with a few simple substitutions.
Thus:
CT = C' 5 +C' 5 + Cfb 5fb (2)
e e a a
Where':
C' C' , C~b = Unit cost dollars/sq. ft.
e ' a
and
S e' 5 a' 5fb = surface required, sq. ft.
Surface is a function of heater performance ,based on simple
heat transfer equations.
-
ECONOMIZER PERFORMANCE
(Tl~T3) -(TZ-T4)
Q= U 5
e e
[T -T -J
Lrt,~ .
. T -T
2 4
== W C (T -T )
g pg 1 Z
(3)*
* Nomenclature appears at the end of this section.
K-176
-------
W C (T1-T2) = W C (T3-T4)
g pg s ps
(4)
Simplifying Eq. 3 and Sub. Eq. 4:
S e U e fw ~ - W C 1 1
L g pg 5 ps -
~T1-T3)1
Ln (T -T )
2 4
(5)
Air Preheater
Q = U S
a a
[(T2-T7) - (T5-T6)]
[(T2-T7)]
Ln (T -T )
5 6
= W C (T -T )
g P 2 5
(6)
W C (T2-T5) = W C (T7-T6)
g pg a pa
(7)
Similarly
SAUA[W~Cpg - Ws~ps].
f
-------
Equations (5) and (8) indicate that the surface of each heat
exchanger can be expressed in terms of the flue gas exit temperature
T2.
Without going through the physical exercise, equaling ~quations (5), (8)
and (10) can b~ substituted back into the original cost equation.
The total cost, C , then, can be differentiated with respect to the flue
T .
gas exit temperatures T2.
Thus:
dC =
t
C a (S) +
a a
U a dT2 .
a (T2)
C a(S)
~ ,_e dT
. U~ a (T 2) 2
+
Cfb a(Sfb)
-- dT
U fb a (T ) 2
2
(11)
In equation 11 the heat transfer coefficients have been fact-
ored out as they are constant.
Setting
dCT and solving the equation for T2 an expres-
- = 0
dT2
sion is developed for the optimum flue gas exit temperature from
the steam. heating bank.
This must then be substituted back into
equation (2) to obtain the expression for the minimum total cost
of surface.
From equation (11) it is noted that the equation can
be expanded to include numerous other components of cost that may
have been considered similar and thus neglected by simply expres-
sing them in terms of T2 and adding on.
The final expression for the minimum total cost and optimum
operating temperatures are verycompiicated and require. consider-
able algebra to manipulate and simplify.
It is much simpler to
plot the cost curves, for the economizer, air preheater and
fluid bed surface, and graphically add them together.' The result
is an optimum curve: for a single.set of, parameters, 1. e., constant
. TI' T4' T5,T6' UA' UE' UFB' CA' CE' CFB' CpG' CpA' CpS' WG and WA.
This is illustrated in Figure A4-24.
K-178
-------
26
24
22
..:T 20
0
~
><
tf) . 18.
j i COST OF ECONOMIZER
8 16L SURFACE ~_...._- -"~'-"'
..
.
E-4
tf)
0 14-
u
1) C
e
.f U = .15
e
- C
a
.11 = .15
j- a
C
I -1E. = .06
.f Ufb
J-
,
t
1600
32
30-
28
FIGURE A4-24 OPTIMIZATION OF ECONOMIZER
AND AIR HEATER SURFACE IN THE
HEAT RECOVERY SECTION OF THE BOILER
..
.-...- TOTAL COST CURVE
,,/
./
~ .
MINIMUM COST. OPTIHUM
TEMPERATURE LEVEL ..
-\
i
-
~
-t
;
. \
-COST OF AIR "
PREHEATER SURFACE ~
~
I
1400
I
1200 1000 800
GAS INLET TEMPERATD"RE""JQ.,..,b.-IR HEATER - of
IV."". "'.
I
600
--_..'
400
K-179
-------
Heat transfer coefficients and cost per unit surface are
parameters that can be combined to form unit cost of conductance
which simplifies and enhances the analysis.
Each one of these
parameters may now be carefully examined to determine what af-
fect they have on the optimum temperature level and minimum cost
of total surface.
Figures A4-25, A4-26, A4-27, A4-28 and A4-29 show the
affect of the cost of conductance of the air heater economizer
and fluid bed surfaces, and the feedwater inlet and the gas exit
from the air heater on the minimum operating temperature and
minimum cost of conductance.
Numerous conclusions can be drawn from these curves.
First
of all the optimum operating temperature nearly splits the duty
between heat exchanger banks.
This is not unexpected if it is
realized that the cost of conductance of the two banks are nearly
the same.
Differences in duty are primarily dependent on the
differences in mean-temperature.
As the cost of conductance of
the air heater increases the optimum operating temperature (T2) drops
and the tendency is to eliminate the less desirable heat transfer
surface.
The same is true of the economizer except that the op-
.-
erating temperature (T2) must rise.
loosely refers to all convection surfaces including some evaporating
Economizer in this study
or superheating surface for' those cases in which the heat avail-
able exceeds the duty required by the economizer or feedwater
heating section.
. . For the design conditions it is noted that the optimum
operating temperature is slightly above the temperature original-
ly selected.
The effect of the deviation in cost does not war-
rant a change.
Furthermore, other technical considerations such
K-180.
-------
as change in material requirements, etc., may limit the selection
to an off-optimum choice.
Improvements in cost of conductance would lower the flue
gas exit temperature from the economizer and encourage more use
of economizer surface.
This affect might be achieved by instal-
ling a non-heating fluid bed in the convection pass in which the
heat recovery surface would be installed.
Such a step would have
to be further optimized by including a charge for fan power re-
quirements and capital investment.
As indicated earlier this would
require adding two additional cost factors to equation 1 or 11,
cost of energy, and cost of cap~tal investment.
The cost of conductance of the surface that must be placed
in the fluid bed at the high flue gas temperatures to the air
preheater has only a small effect on the optimum operating cost
of surface.
An increase in cost of conductance lowers the flue
gas temperature to the air preheater and encourages returning
steam heating surface to the convection passes.
Feedwater temperature to the boiler contributes little to
the total minimum cost of surface, however, it has a marked affect
.'~
on the flue gas exit temperature from the "economizer" bank.
As
the water temperature drops the total cost of surface rises and
the optimum operating temperature drops substantially.
A drop
in fluid bed-temperature or decrease in the top temperature
limit of the flue gas to the economizer section has a similar
effect.
In an earlier communication with W. C. Yan~ (14) a flue
gas inlet temperature of 1250 and a feedwater inlet temperature of 350
was selected which resulted in an optimum operating temperature
of about 740°F.
All the other variables were approximately as
. K-181
-------
selected in this study.
An increase in flue gas exit temperatures from the air preheater
reduces the total cost of surface. substantially and raises the optimum
gas inlet temperature level slightly for the design parameters.
The parametric. study provides a quick accurate way of se1ect-
ing and evaluating the operating conditions for the total heat
recovery equipment.
It also gives insight as to the effects of
future improvements or changes in selection of equipment.
Each
parameter in this study was evaluated separately.
Once the op-
timum equation is derived and simplified, the influence of
parameters on each other at the optimum point can be studied
giving families of curves representing different optimum con-
ditions for various parametric valves.
Studies similar to this have also been made by R. Ecabert
and L. Si1berring (15, 16).
(15)
R. Ecabert and L. Silberring, "Optimizing the Stack Gas
Temperature and Air Heating on Steam Generators" Sulzer
Technical Review 2, 1969. '
(16)
R. Ecabert and 1. Silberring, "Optimizing the Stack Gas
Temperature and Air Heating Surface on Steam Generators"
Combustion Engineering, 1970. . ,
K-182
-------
FIGURE A4-25
EFFECT OF COST OF CONDUCTANCE
OF THE AIR PREHEATER ON MINH!UM TOTAL
COST AND OPTIMUM TEHPERATURE LEVEL
\
\
\
\
36
34
32 \
30
28 -
'.
=-
-< 26
>< .,
j 24
g
. 22
'!:
;:;
20
18
16
14
12
\
\
\
\
\
C
2 x ~
U
a
C
a
_.5 Xu
a
/c
" Locus of Optimum Conditions
for Various Costs of
Conductance
1600
1400 1200 1000 800
GAS INLET TEMPERATURE TO AIR HEATER - of
600
400
K-183
-------
FIGURE A4-26 EFFECT OF COST OF CONDUCTANCE
OF THE ECONOMIZER ON MINIMUM TOTAL
COST AND OPTIMUM TEMPERATURE LEVEL
3 \ '
C
e
2. 5 xu-
34 - \ e
\
'" ''
''
32 C '
1. 5xU e ...- ':,-
e
30
28 /' -1
..:r 26
0
.-I
~
tn
~ 24
j
~
0
~ C
A 22- '~=1.5-
Eo-<
tn U
0 e
U :l
J Locus of Optimum I
Conditions for Various ~
Cost of Conductance of
the Economizer ,, - I
I
14 '" I
....
I I
I
1600 1400 1200 1000 800 600. 4.00
GAS INLET TEMPERATURE TO AIR HEATER - of
K-184
-------
I
18 l
16 ~
14
I I
i600 1400
34
32,
30 ~
28
..;to 26
~
>< 241
! 22 f
o
u 20-
Locus of Optimum Conditions for I
Various Flue Gas Exit Temperatures l
from the Air Heater
.
FIGURE A4-27
EFFECT OF FLUE GAS
EXIT TEMPERATURE FROM THE AIR PREHEATER ON
THE MINI~lliM TOTAL COST AND OPTIMUM TEMPERATURE LEVEL
.--
/
t
i
1
1200
600
400
1000
800
GAS INLET T&'1PERATURE TO AIR HEATER - of
K-185
-------
FIGURE A4-28 EFFECT OF COST OF CONDUCTANCE OF SURFACE TRANSFERRED TO
THE FLUID BED ON THE MINIMUM COST OF SURFACE AND OPTIMUM OPERATING CONDITIONS
.
'~'i \ I
, '
\
36 \
\
\
\
"
\
34 \ -I
321 \ -1
\ .
30 I I
l
r
,
i
~ t
0 28 j- -I
.-I
! I
><
, i
en I I
j 261-- I
I
~
0 I
~ 24 J.- I
.. I
E-t 22L ---<
en i
0 I
U I
I
-4
20 - Cfb ]
0.5 Xv
18r Locus of Optimum - fb
Operational Conditions I
I
16 '- I
I "
~----_J '-_I I I I I I
1600 1400 1200 1000 800 600 400
GAS INLET TEMPERATURE TO AIR HEATER - of
.
K-186
-------
I
361-
34 L
!
I
32!-
I
I
I
.
30 ~
!
-:t "
I
o 281
.-4
><
tI)
j 26 t
~
0
Q
~ 24
Eo-<
tI) ~
o
u
22
,
20 L
I
,- I
18 ~
1600
FIGURE A4-29 EFFECT OF FEEDWATER INLET TEMPERATURE
ON MINIMUM COST OF SURFACE AND OPTIMUM TEMPERATURE LEVEL
il
- 440°F
/
Locus of Optimum Operational Conditions
-1
-i
~
I
1__.,_____l--L-LJ_J_---t
~_....-..
1400
1200
1000
800
600
GAS INLET TEMPERATURE TO AIR HEATER - of
K-187
..._0' ..-
400
-------
CT
C
e
C
a
Cfb
C'
e
C'
a
Cfb
S
e
S
a
Sfb
Q
,
U
e
U
a
Ufb
W
g
W
s
W
a
C
pg
C
ps
C
pa
TI
T2
T3
T4
TS
T6
T7
NOMENCLATURE
Total Cos.t
Cost. of' Economizer Surface "
Cost of Air preheater Surface
. Cost of Fluid Bed Surface
Unit Cost of Economizer Surface
Unit Cost of Air Preheater Surface
Unit Cost of 'Fluid Bed Surface
Economizer Surface
Air Preheater Surface
Fluid Bed Surface
Heat Transferred
Overall Heat Transfer Coef., Economizer
Overall Heat TransferCoef., Air Preheater
Overall Heat Transfer Coef., Fluid Bed
Gas Mass Flow
Steam Mass Flow
Air Mass Flow
Specific Heat Gas
Specific Heat Steam
Specific Heat Air
Temperature, Gas In - Economizer
Temperature" Gas Out - Economizer
Temperature, Water In ~ Economizer
Temperature, Water Out - Economizer
Temperature, Gas Out - Air Preheater
Temperature, Air In - Air Preheater
Temperature, Air Out - Air Preheater
K-188
$
$
$
$
$/Ft2
$/Ft2
$/Ft2
Ft2
Ft2
Ft2
Btu/hr
Btu/hr-ft2_0F
Btu/hr-ft2_0F
Btu/hr-ft2_0F
Ib/hr
lb/hr
lb/hr
Btu/lb-oF
Btu/lb-oF
Btu/lb-oF
OF
of
OF
of
OF
of
OF
-------
APPENDIX L
BOILER BURNER FOR LOW BTU GAS
ABSTRACT
Burner design and engineering vendors were contacted to pre-
pare a preliminary design and cost estimate and to assess the develop-
ment requirements for a boiler burner for desulfurized, low Btu gas from
the atmospheric pressure fluidized bed oil gasification system.
A
burner for this gas is technically feasible, and burners could be
designed for a demonstration plant. Rough cost projections were made.
Correspondence with Process Combustion Corporation and Bloom Engineering
Company on a boiler burner design for this application is presented.
L-1
-------
~~
PROCESS
COMBUSTION
CORPORATION
South Hills Village, Suite 300-A . Pittsburgh, Pennsylvania 15241 . (412) 561.6200
Ct~ou~"'~'\
12 July 1971
WESTINGHOUSE ELECTRIC CORPORATION
Chemical Engineering Research
and Development Center
(Building 501-1W63)
Beulah Road, Churchill Borough
Pittsburgh, Pennsylvania 15235
Attn: Mr. Dale L. Keairns
Gentlemen:
Ref: ACH-0571-20
PCC/Bloom Boiler Burner
for Desulfurized Gas
Following your recent visit to the Bloom Engineering Company,
Laboratory, and our mutual discussions with Jim Johns, we are
pleased to confirm the points covered.
1. Our experience on boiler burner designs ranges up to 100
MM BTU/hour when using lean coke oven gas. There is no
reason why the larger heat releases should not be real ized,
providing that the combustion space avai lable is adequate.
2. Since we have had the necessary experience in lean gas, we
do not envisage having any development work involving your
ga s i fie d f u e 1 .
3. The gases, at 1600°F, will have no effect on existing gas
tube materials employed, and we do not feel that the small
quantities of H2S contained in the gases will have substan-
tial corrosion effects.
4. If the burners are vertically upshot fired, and utilizing an
open nozzle gas gun, the carry-over of 1 imestone particles
from the fluid bed should not have any build-up effects with-
,in the tube. However, this is something which only will be
brought out by experience, and if we find a problem in the
actual operating plants, we are confident that there exists
satisfactory solutions within our present technology.
5. Taking as an example the 100 MM BTU/hour unit, we estimate the
price of the burner and port block to be approximately $12,000.
6. Operational maintenance on the burners will be very low, since
they contain no moving parts, comprising only cleansing of the
ports due to 1 imestone blockage, if this occurs.
- continued -
L-3
-------
WESTINGHOUSE ELECTRIC CORPORATION
- 2 -
12 July 1971
7. Turndown in excess of 5:1 with good stability should be
achievable on this gas.
We hope that you have been able to visit an existing boiler burner
site in the locality, and that this together with your visits to
our plant has given you a good insight of our appl ication engine-
ering. .
If you require further information for the secorid phase of your
development work, we would be most happy to assist.
Sincerely,
~;~e,,-t
c
.c~.\""'.~~'--:"'
Vincent C. Grimshaw
Sales Engineer
cc: Mr. Richard Newby - Westinghouse Electric Corporation
Mr. James E. Johns - Bloom Engineering Co.
L";4
-------
~~
PROCESS
COMBUSTION
CORPORATION
South Hills Village, Suite 300-A . Pittsburgh, Pennsylvania 15241 . (412) 561-6200
CI~OU~p.~'"
19 July 1971
Mr. Dale L. Keairns
Westinghouse Electric Corporation
Chemical Engineering Research
and Deve lopment Center
(Building 501-1W63)
Beulah Road, Churchill Borough
Pittsburgh, Pennsylvania 15235
Dear Dale:
Ref: ACH-051-20
PCC/Bloom Boiler Burner
for Desulfurized Gas
I am pleased to enclose the information requested during our telephone conversation
last Friday, 16 July 1971, and confirm the points of our discussion.
Regarding the budget price of $12,000 given in my letter of 12 July 1971, this would
be applicable to an established design for a commercial plant where the necessary
engineering parameters were established, and possibly several burners involved. For
special applications, where engineering and drawing time could only be charged against
that specific job, it would be necessary to increase the base price accordingly. This
situation could well occur on pi lot plant designs, for instance.
The enclosed Bloom drawing C-2209-17 shows the overall layout of a 108 MM BTU/hour
combination fired Boiler Burner. This will give you a sense of proportion of the unit,
but it is not necessarily analagous to your own situation, and could well vary considerably
from the designs which we would propose for your purpose.
Typically, we would expect to use approximately 6 inches w.c. on both the gas and air
sides of the burner for a standard unit, but increasing the pressure drop as higher energy
flames and smaller combustion volumes came into the picture.
-continued-
L-5
-------
Mr. Dale L. Keairns
-2-
19 July 1971
I shall be making a request to the Bloom Engineers for a brief evaluation of the feasibility
and overall concept of a similarly fired 250 MM BTU/hour unit. This will be.processed
during the next few weeks, and I shall write to you again when the material is available.
In the meantime, if you require further assistance from us, please feel free to call.
Sincer.ely,
\ji~e.
c:..... ~.... ~lo.,-:
Vincent C. Grimshaw
Sales Engineer
-I ..,
dp
Enclosure-Drawing C-2209-17
L-6
-------
t-<
I
-.;j
-
-.--
.- l
.. - - - - - !
------- .---: .--~;:~'.. ';---~. . i
. : I :: .~ -','.';i I
'-".L._~\_~, ",..- ">:::-, ' '!
. :/;', ':':...1 ," :'.: ':: : N'
o . :' , 'S==~--)" d !
...l--. .-::'-r ~--'I 6l i;)"~, ! -~L :
........, .';-'., r 0 '0 : \.... ',' -:, I
..' : ~"",\'~:I~- . -'~:~:'\_,,;-::-
- . c:::-\'. ":_---. \~ 0>. ,
: --=..r... " --, ~ ~/ ~:::::.\ :
L-.:. . J ~ - ; 1;, .' " I ""
,',.', ~ ,'if ".\ .',' I '
( I " " ~.,-- :''>---'+.~-'
'-~"""':.'< '.1, ~ ~',
:::.'- :)'.(~1:}.i~-: ;~. .:
~ I , .. -..
, '::......
0. - - - -. - - - - - - - i : - - - - -
~-
"..-
s...-
-
-- --.-
--'--. .
. ---
-
---
-
.......-
-....
. '
. - -----B'L-
I-
I
I
I '1 l'l~ '. : L'
..-o....)U :hl~~ -- ,,-- '~.
f~~"~i}t=- , . ,
~ . L!,!-<
'~::~~::':~;:Tt~1r;~lt~;0;~~g~I~;{~~~i~~g~;;,"'.n
- BLOg~PANY. INC.
ENGIN=~URGH. "A.
------
__M
. ==== ~:_:-- ~
,...::.== s ,,,
........
.......--~
-------
~~
'(;. . .
-------
APPENDIX M
GAS TURBINE CORROSION, EROSION, AND FOULING
M-l
-------
A.
B.
C.
TABLE OF CONTENTS
INTRODUCTION
REVIEW OF GAS TURBINE OPERATING EXPERIENCE
1.
2.
Pressurized Fluidized Bed Boiler Operation
Oil Refinery Experience with Gas Turbines
3.
4.
5.
Aircraft Gas Turbine Experience
Blast Furnace Gas Experience
Coal-Burning Gas Turbine Experience
EROSION IN GAS TURBINES
APPENDIX - CALCULATED FREEZING POINT CURVES
M-3
-------
A.
INTRODUCTION
At one time the gas turbine was thought to be capable of
handling the combustion product of any fuel from natural gas to solid
waste. This has not proven to be the case. Many ashy type materials
in the fuel and even in the combustion air have been found to be
corrosive at high temperatures, and those not corrosive may be erosive
or may build heavy deposits in the hot regions which tend to choke the
turbine and change the blade profile.
Solids in the combustion air are
sometimes collected in the compressor and are released in chunks, passing
through the combustor and eventually reaching. the turbine.
Normally combustion takes place at a temperature in excess of
3000°F in a gas turbine combustor.
At this temperature chemical
reactions are accelerated and the ashy material may become liquid.
Although secondary air is admitted to lower the temperature of the
combustion products, the ash particles may be molten or at least tacky
when they reach the turbine. If so, the ash particles will deposit on
the turbine surfaces, which may cause corrosion of the blade material
and/or heavy bonded deposits. Even if completely dry, it may be
erosive, having solidified into dense glassy beads.
In the pressurized fluid bed system, combustion takes place
at a much lower temperature; and it seems likely that dry ashy material
carried from the bed (and through the separation) will arrive at the
turbine in a dry form unlikely to corrode directly or form bonded
deposits.
Furthermore, photomicrographs of such ash, made by BCURA
using their pressurized fluid bed boiler, showed that the ash was in
the form of delicate disks, which should break up upon entering the
turbine with no erosion.
Their tests also confirmed that the ash (at
least from British coals) was not corrosive or deposit-forming.
M-5
-------
Production of dry ash has become more difficult over the
years of gas turbine development because turbine inlet temperatures
continue to rise. At one time gas turbines operated at l200°F. Now
they have passed the 2000°F temperature. At the same time it has been
necessary to develop new alloys with improved strength characteristics
at high temperature; and this has been done at the expense of corrosion
resistance. Present-day alloys have a reduced chromium content and
are considerably less corrosion-resistant than those in use ten years
ago.
Erosion has not been a problem in Westinghouse turbines
with gaseous and liquid fuels even though the additives used with
liquid fuels are sometimes abrasive and damage fuel nozzles.
Erosion
has been a problem, however, in experimental, direct-fired, simple
cycle gas turbines burning pulverized coal.
Severe erosion resulted
at the LDC Dunkirk test stand several years ago even though separators
were used.
Subsequently the LDC turbine was set up at the Bureau of
Mines, Morgantown Laboratory.
Redesign and improved separators
increased the projected life of the turbine. Projected permissible
dust loading was less than 1 gr/100 SCF. This operation will be
described in more detail in the review section.
Similarly deposits have not been a problem in Westinghouse
turbines mainly because a good grade of fuel is usually specified.
However, when residual oil was burned in a test stand under gas turbine
conditions, heavy deposits frequently formed.
This has been confirmed
by other gas turbine manufacturers based on field experience.
Brown
coal has been burned in an open cycle gas turbine
at the Aeronautical
Research Laboratories in Australia.
It was reported that even with
the characteristically low ash content (2%) of their coal and with gas
cleaning, heavy deposits formed in a few hours, requiring special
blade cleaning procedures.
This work will be described in more detail
in the review section.
~6
-------
B.
REVIEW OF GAS TURBINE OPERATING EXPERIENCE
O . 1,2
Pressurized Fluidized Bed Boiler perat10n
The British National Coal Board has operated a pressurized,
pilot-scale fluidized bed combustor at BCURA to obtain process data
and to assess the suitability of the combustion gases for gas turbines.
A diagram of the combustor and test passage is shown in Figure M-l.
The combustor is a refractory vessel of approximately 48" x 24" rect-
angular cross-section and 10' high.
cylindrical steel pressure shell.
The combustor is housed in a
The base of the combustor is closed off by a horizontal
bubble cap air distributor plate.
The fluidizing air, which includes
the corrosion tube cooling air, is preheated to 390 - 540°F in tubes
immersed in the bed.
During normal operation the fluidized bed contains approxi-
mately 1800 lb of coal ash at a fluidizing velocity of 1.8 to 2.0 ft/s;
the expanded depth is about 44 inches. Cooling surfaces, consisting
of 65 hairpin loops, are immersed in the bed.
A bank of four rows of horizontal, uncooled, heat-resisting,
steel tubes, 1" O.D., spaced on a nominal 3" triangular pitch, is
installed at the top of the bed as a baffle system to minimize splashing.
The combustion products leave the shaft via a 10" diameter
recirculation cyclone suspended from the top closure plate.
The fines
are returned via a dip leg which terminates approximately 3" above the
air distributor plate.
Combustion products from the recirculation cyclone exit pass
through 10" diameter primary and secondary cyclones arranged in series.
Fines from both cyclones are transported out of the pressure vessel.
M-7
-------
~
...... ..... USCAOC 0# ",....
""I .011 ,~ 180lIOII,
c_.... 8&JIOMf-
'18
, i ~-.77' _.._--
Ii!;
"
I : i ~-
I '
, '
I .!
j-fi
. >.
.-
.:t.,:
11-
2
I , :
j , i
~
,
19
3
-9
7
Cool
4
-
-20
,::1
"
-~
\ T. iT
\~ '~.'
I&C'hCII Oil .... ..,...,.. ~ .
1'\8.1" "-wOaoU Ie
FIG. M-l
The
48 in x 24in
M-8
pressurised
combustor
-------
Key' to Figure M-l
1
Water inlets and outlets
2
First-stage cyclone
3
Recirculation cyclone
4
Balancing air supply
5
Gas burners for initial heating of bed
6
Ash offtake from bed
7
Pressure casing
8
Water-cooled liner
9
Combustor casing
10
Second-stage cyclone
11
Ai r in take
12
Cascade
13
'Alkali' and NO sampling probes
x
14
Flow correction baffle
15
Cooled tube for studying erosion, corrosion and deposition
16
Water sprays
17
Air-cooled tube with corrosion specimens for studying
condensation of alkalis
18
Dust sample collection and gas analysis
19
To pressure let-down and stack
20
Dip-leg of recirculation cyclone
Note:
Air distributor plate is of bubble cap design with
465 caps on a 1 1/2" square pitch
M-9
-------
Gases from the secondary cyclone pass through an egg crate
type flow straightener before entering the cascade section.
The cascade
has been made from an inlet nozzle segment of a Rolls Royce Proteus
gas turbine engine and consists of five aerofoil blades.
The cascade
assembly, the measuring duct which follows and the subsequent quench
section, are mounted in a separate 2 ft diameter by 9 ft long horizontal
pressure vessel.
Data from the pressurized unit have been obtained at the
operating conditions summarized in Table M-l.
Typical results from
the unit using a U.S. coal and dolomite are summarized in Table M-2.
Slight deposits were formed on the turbine blade cascade.
The deposits
can be easily removed.
No signs of erosion have been observed.
Dust
loading of the gases has generally been less than 0.15 gr/SCF with
80 - 90 wt % less than 20 micrometers and 30 - 40% less than 5 micrometers.
Most of the particles greater than 'VlO~m are in the form of "platelets".
Thus, it has been very difficult to obtain a realistic size distribution
of the ash.
Oil Refinery Experience
Gas turbines have been used on expanders on catalytic cracking
units, and problems due to erosion and after-burning have occurred.
. d 'b d . 3
The two phenomena, erosion and after-burning, are escrl e ln a paper
by Ingersoll Rand.
Erosion, caused by minute. particles of catalyst
dust entrained in the flue gas, is considered to be more serious.
Relative velocity to the rotor blades was 1400 - 1500 ft/sec.
The particle size range was not stated, but it was observed
that some particles simply polish whereas larger ones erode.
It was
also noted that material sometimes collected on one row and let go,
eroding the next row.
Two fixes were proposed:
a) Use three stages
of separation.
Without separation, serious erosion occurred in 800
years.
Three separators gave satisfactory operation for four or five
b) Flame-spraying erosion-resistant ceramic coatings on the
hours.
blades is a promising possibility.
M-lO
-------
TABLE M-l
PRESSURIZED FLUID BED PILOT SCALE
Operating Conditions
Pressure
up to 6 atm
l500°F
1435 of
Bed Temperature
Turbine Blade Cascade Temperature
Bed Depth
Fluidizing Velocity
3.75 ft.
1. 8 - 2 fps
Heat Transfer Surface
Tube Diameter
1 in.
3 in.
Pitch
Bank Height
2.5 ft.
Sulfur Removal
>95%
NOX Emission
CalS Ratio
<150 ppm
2
M-ll
-------
TABLE M-2
PRESSURIZED FLUID BED PILOT SCALE RESULTS
Test Series
2
Feed Ca/S Ratio
Humphrey No.7
Dolomite 1337
2.04 - 2. 09
55
(2.8%S)
Coal
Sulfur Absorber
Duration of Test Period,
Hr. (Total)
Bed Temperature, of
1456 - 1465
5
94.4 - 96.8
72 - 107
73 - 126
0.3 - 0.5
0.1 - 0.2
50
Pressure, atm
S Retention, %
S02 Emission, ppm
NOX Emission, ppm
Na20 Emission, ppm
K20 Emission, ppm
C1 Emission, ppm
Exhaust Dust
Dust Loading, gr/SCF
0.07 - 0.16
Composition of alkalis, clorine, carbon, and sulfur
Carbon
2.3 - 4.0
0.1 - 0.2
3.3 - 4.4
0.1 - 0.3
9.0 - 10.5
5.2 - 6.5
0.7 - 0.8
1.6 - 1.8
6 - 8
Hydrogen
Sulfur
Chlo rine
CaO
MgO
Na20
K20
Median Diameter ~m
M-12
-------
Aircraft Experience
The problem of dirt removal for small gas turbine engines
was considered by the Donaldson Company.4 These engines are of a size
used in helicopters, wheeled and tracked vehicles, and air cushion
vehicles.
The paper contains a very complete set of 78 references.
In general it is oriented toward the use'of Donaldson Air Cleaners
(which is to be expected since the two authors are both associated with
Donaldson) .
The following items are noted:
1)
Experience is shown, both field and laboratory.
It is
concluded that air cleaners of some sort are necessary and that they
can do a satisfactory job of protecting the turbine.
\
2)
Typical dust concentrations around various types of
vehicles are shown.
For example helicopters may ingest a concentration
of 6 to 30 mg/cu ft. of particles 30 - 170 microns.
Hovercraft raise
concentrations of 140 - 200 mg of 100-micron particles. At the other
end of the scale are highway trucks, with 0.004 to 0.1 mg/cu ft. of
o - 20
micron size.
3)
Erosion depends on dust particle size, impact velocity,
concentration, particle hardness, angle of impingement, and properties
of material being eroded.
4)
Laboratory tests are made with five dust specifications:
AC Fine
AC Coarse
BS 1701
Mil-E-5007 c -
Ottawa Sand
39%
30%
33%
36%
70%
0-5 Micron
40-80 Micron
80-152 Micron
200-400 Micron
297-595 Micron
5)
Based on literature and experience, erosion has never
. '
occurred on a gas turbine fitted with a filter 99% efficient on AC
coarse dust.
6)
Three basic air cleaner types are offered:
a.
b.
Inertial separators
Barrier filters
Two-stage, i.e., inertial separators
by high-efficiency barriers.
followed
c.
M-13
-------
7)
90% efficiency filters extend engine life by 10 to 20
times compared to no problem with 99 + % barrier filters.
8)
Particles smaller than 1 to 2 microns pass through a
system without impacting, or deposit only by diffusion.
9)
Particles greater than 10 microns probably impact on
blade surfaces.
10) A well-designed cyclone should be capable of separating
nearly all the particles above 10 to 12 microns.
Blast Furnace Gas Experience
Experience on four gas turbines of 7500 KW rating, which
had accumulated a total of 10 years operating time, was reported at the
Gas Turbine Conference in Zurich.S The turbines were run for the first
six months on a blast furnace gas with a normal dust level of 4 to 10
mgr/Nm3. Later on, an additional electrostatic filter dropped the
3 .
dust level to 1.2 mgr/Nm. Finally, because of lowered gas rating
values, it was necessary to enrich the fuel with gas-oil or naphtha.
The first effect was a build up of deposit at such a rate
that the power dropped 16% in 4000 hours and 27% in 7000 hours. However,
with cleaning, sand blasting and metallic brushing during periodic
overhauls, power was always restored.
Some corrosion was also evident, although it was not as bad as
that observed in other turbines in Germany burning unenriched blast
furnace gas.
The first-stage stator and rotor blades of Nimonic 80A
(similar to Inconel X) had an expected life of 100,000
hours based
on stress considerations.
However, it was shown that because of
corrosion, the first stage would probably have to be replaced after
30,000 to 40,000 hours, having operated at 700 - 720°C. Cleaning
would be required every 7000 to 8000 hours to restore power. If
alkaline sulfates are present more severe attack would be expected.
M-14
-------
Westinghouse built and operated a blast furnace gas burning
gas turbine at the U.S. Steel plant in Gary several years ago.
This
was the forerunner of the Westinghouse 301 machine but used a large
external combustor, i.e., six feet in diameter. The blast furnace gas
compressor was the axial flow compressor from the W-2l machine. The
gas contained at most 15 grains/lOOO ft3 mostly below l~. With an elec-
trostatic precipitator dust loading dropped to 6 grains per 1000 cu ft.
The ,air rate was 38 lb/sec with 154 lb/sec extracted. This left 164
lb/sec for combustion. The fuel (saturated and 86 BTU/ft3) was equiva-
lent to 40 lb/sec. The machine ran regeneratively from 850°F to l350°F.
The machine ran at l350°F turbine inlet temperature with recuperation to 850°F.
40 3
The dust loading in th~ flue gas was: 6(204) = 1.18 gr/lOOO ft .
This contrasts to 140 gr/lOOO ft3 in the BCURA unit. 16000 hours of
operation were obtained on blast furnace gas without problem.
A light
dusty film of red deposit -- probably an iron compound -- was found on
the turbine blades.
It was not detrimental to the performance of the
unit.
There was a problem with the gas compressor.
The dust bonded
Failure finally
badly, perhaps because it was saturated with water.
occurred, thought to be due to stress corrosion cracking.
Coal-Burning Gas Turbine Experience
Starting in 1951, the Locomotive Development Committee
pioneered in the development of an open-cycle, coal-burning, gas turbine
which it ran for some 4000 hours in Dunkirk, New York. Various types
of separators were tried, but erosion was very severe and the blades
were replaced three times during the program, which finally ended in
1959.
The turbine was reassembled in Morgantown, West Virginia,
in 1959, and the work6 was continued. Some redesign was necessary.
The blade profiles were changed and the number of stages reduced from
six to five.
Armored strips of titanium carbide were inserted near the
blade platform.
bearing gases.
Attempts were made to spread out the flow of particle-
Nearly 2000 hours of operation were carried out.
It
M-15
-------
was estimated that the stator had a useful life of 5000 to 7500 hours,
and the rotor blades, 20,000 to 30,000 hours. Dust loading entering
the turbine was 12 grains/IOO SCF with sizes and concentrations:
above 20 micron - 2.4%
above 10 micron - 9.7%
above 5 micron - 26.5%
~o~ 2 micron - 100.0%
It was concluded that efforts should be made to reduce the size and
concentration of the ash particles.
Following work on the LDC turbine, a test facility was built
for further investigations of the effect of dust loading on turbine
blade erosion. 7 This facility consisted of a turbosupercharger coupled
with a natura1-gas-fired combustor.
Fly ash obtained from a pulverized
coal utility boiler was injected into the combustion gases to give a
particulate loading of 1 gr/100 SCF.
Erosion experienced in this
turbine was much greater than had been projected for this loading from
the LDC turbine tests.
However, the design velocities in this turbine
are unrealistically high for utility gas turbines and the size of the
fly ash used was 94% by weight greater than 5 ~.
Because of these
two factors, the results of the later tests at the Bureau of Mines
are inconclusive.
In Australia, the Commonwealth Department of National Develop-
ment and the Joint Coal Board have for some years sponsored a program
for burning pulverized coal in an open cycle Ruston and Hornsby TA gas
b' 8
tur ~ne. The turbine has been operated in two forms, without cleaning
and with cleaning using a mu1ticyc1one ash separator.
The combustor
was interchangeable with the standard oil-burning unit, but was modified
to provide a larger residence time for burning coal particles.
The fuel burned was a brown coal pulverized to 80% through a
300 mesh sieve. .The ash content was low by U.S. standards -- 1.5 to
2.5%.
Residence time in the combustion zone was 100 milliseconds.
Turbine inlet temperature was 650°C.
The ash composition was:
M-16
-------
Si02 0.07 - 0.82%
A1203 0.94 - 0.12
Fe203 1. 75 - 0.23
CaO 0.37 - 0.08
MgO 0.51 - 0.14
NaZO 0.19 - 0.05
K20 0.02 - 0.01
Ti02 0.07 - 0.01
S 0.41 - 0.22
Cl 0.16 - 0.04
Total Ash 2.5 - 1.5
It was estimated that the ash contained 50% unburned coal with a dust
loading of 9.4 x 10-4 Ib/lb of gas leaving the combustor and 3.4 x 10-4
Ib/lbof gas leaving the separator. Average particle size leaving the
combustor was 37 microns and that from the separator, 5 microns.
particles in excess of 23 microns were removed.
All
Although it was implied that erosion could be a problem,
this study was devoted mainly to deposit buildup. Two types of deposit
were evident, a dense, sintered material near the leading edge of the
blade, and a light, powdery material on the convex face.
The powdery
material was easily removed.
Underneath the dense deposit the blade
surface was shiny, with no indication of chemical attack.
Analyses of
the deposits showed oxides of silicon, magnesium, and iron.
It was
concluded that initially calcium sulfate was the bonding agent and
that over a period of time the level of sodium sulfate, also a bonding
agent, built up.
Final bonding took place in as little as 30 minutes,
and sodium sulfate had migrated to the metal surface in two hours.
It was concluded that severe ash deposition would occur from
burning brown coal either with or without a separator.
The rate of
build up depended upon the concentration of sodium, and incandescent
coal particles were found to accelerate bonding by producing locally
high temperatures in the vicinity of the blade.
Gas velocity and
temperature also had a measurable effect.
Deposits built up to an
. M-17
-------
objectionable degree in about 20 hours. No way to inhibit the formation
of the bonding sulfate could be suggested. Consequently a method of
cleaning was developed, adding water (under reduced load) to dissolve
soluble materials and milled apricot shells to abrade away the more
heavily bonded deposits.
9
In later paper, the Australian coal-burning unit indicated
that erosion had in fact occurred in the Ruston and Hornsby turbine
using brown coal but that a high-pressure turbine blade life of several
thousand hours could be achieved by using the ash separator.
The
erosion of the low-pressure turbine blades was much less, and a blade
life of many thousands of hours was predicted.
M-18
-------
c.
EROSION IN GAS TURBINES
Erosion of gas turbine blades is a function of:
1.
2.
3.
4.
5.
Dust particle size
Dust particle physical properties
Dust particle shape
Dust particle concentration-weight per unit volume
Impact velocity
Impact angles
6.
7.
Turbine material physical properties.
FinnielO has shown by analysis and experiment that the erosion
from a ductile metal by a given particle is proportional to V2 f(a)/p,
where V is velocity, a is angle, and p is plastic flow stress.
The
flow stress is proportional to hardness.
The maximum erosion occurs
at angles between 10 and 20 degrees for angular particles and at about
30 degrees for spherical particles.
For brittle materials such as glass, porcelain, and hardened
steel the weight loss was found to be proportional to the velocity to
a power varying from 3 to 6.10 The maximum rate of erosion of brittle
materials occurs at near 90°.
11
Martlew has investigated the impingement of ash particles
on turbine blading by calculation and test for turbine inlet conditions
of 120 ft/sec and 75°F.
Figures M-2 and M-3 show the calculated
trajectories of 4 and 16 ~ particles.
Figures M-4 and M-5 show the
resultant velocities and angles of impact with the concave blade surface
for the two particle sizes.
These show that the smaller particles have
higher impact velocities but less critical impact angles then the
larger particles. The angle of impact is nearly constant over the
blade chord distance, but the velocity increases with distance from
M-19
-------
~:
.:
0-97S -
0-8 -
i
0-6-'
~~
y-in.
i
I
0-0-:
oz"':
0:
Fig. M-2 - Trajectories of 4 ~ partic1es(11)
o
.
oz
,. :."'~~(
'-, _.~ -
"---
~
~
~,\\
\
o
o-z
Fig. M-3 - Trajectories of 16 ~ partic1es(11)
M-20
-------
00
~i ... '"
{\ ~
..-.I \~"o .;.-:--.. -...
. \ ~ i i O' ,-. ~'_o<.~~ -
: \ 0 j 1 : -~~c..:-"~----
I !,oJ ; I ----- !
! ~ j . ------;-- f
130 "'--~-,..-~~___.I !
--
------~~.._-_.
:~ .
i
I
I
-- L--,.-.--. , -
O'Z 0-.
0..
Cb
;.0
;.z
,
I
\-4
i SIS
4.
DISTANCE FRO", NOSE OF B~ADE - 0<5,
Fig.
M-4 - Angle of
impact (11)
)'0
I
I
\
,
~'~ ,,- ---1- -,- - ~ - - - .,,:..9;;f::~!:.;F~"-
! ~.~ 'iY'~ ~
. . =- ..".",.. ~
.'0( ."..""
ut.- .""..,.
~:~ ~
~!~ "
I ~i= ",.,,'/
/'
/'
~~
'~.:..::... 'IE~~:.~Y' .
:1
-v';:
o
o-z
04
:)1 S":"A:-OCE
o.
F;"v'~
08 ',0
~OSE OF BL"'CE - :SS.
: .z
..4
,.,
Fig.
M-5 - Velocity of
impact (II)
M-21
-------
the nose of blade.
This indicates that the erosive effect of particles
in this size range is greatest at the blade trailing edge.
For the purpose of determining the minimum particle size
which will impinge on the concave surface of a turbine blade, Martlew
has introduced the impact number, I.ll,12 Under conditions where
Stokes law applies, I is defined by the following groups of dimension-
less numbers.
o y 2 Lo V
I = K (--E.) (-) (~)
0g L ~g
where
° = particle density
p
° = gas density
g
Y = particle radius
L = characteristic length (blade chord)
V characteristic velocity (relative)
~ = gas viscosity
g
It is assumed that a particle which has an impact number less
*
than the critical value for a circular cylinder of radius equal to
the nose radius of the blade, cannot impinge on the nose or any other
part of the blade.
The blading configuration which was used in
Martlew's analysis had a minimum particle diameter for impingement of
0.7 microns.
11
Catch efficiency is defined by Martlew as the ratio of
actual impact rate to the maximum possible rate contained in the band
of gas which the blade intercepts in the approach velocity pattern. .
Figure M-6 shows the variation of catch efficiency with particle size
for the turbine blade used in Martlew's study.
For flow around a bend where the radius is large compared to
the passage width, the radial velocity, assuming Stokes law applies, is
*
This value is that at which impaction on the cylinder is incipient.
M-22
-------
100
~
~
u
c
Q)
.u 60
.-
-
-
LLJ
..c.
'-'
\ -
n:J
U 40
Curve 646940-A
80
20
o
o
8 12 16
Particle Diameter, microns
20
4
24
. Fig. M-6 - Catch efficiency of ash particles on turbine blades (11)
M-23
-------
approximately proportional to v2/R. Hence, the angle of impact would
be proportional to ViR. For impact angles up to about 20°, the
erosive effect is roughly proportional to the angle. Therefore, for
a given ductile
. 2 V V3
to V x R = R:.
metal and particle size, the erosive effect is proportion
The number of particles entering the passage between two
turbjne blades is proportional to the product of the volumetric particle
concentration and the gas inlet velocity, i.e., CV.
Combining this
with the previous expression indicates that the rate of erosion of a
turbine blade for a given particle size consist is
V3 -- Cv4
R x CV R
W. d 12 .
~s om c~tes experimental data which indicate that the erosion rate
is proportional to the fifth power of the velocity.
Using Martlew's trajectory and catch efficiency data, and
the particle erosion data obtained by Finnie, Dygert and Bjorklund13
estimated the life of turbine blading for two condition sets. It was
assumed that the useful life of turbine blading ends when 10% of the
total blade weight is removed. For one case where a high-efficiency
separator was used, the computed blade life was 14,000 hrs. In a
4000-hr test no blade wear was discernable, whereas a 3% blade weight
loss was predicted for this period.
Without the high-efficiency separator, the computed blade
life was 1400 hrs. A 650-hr test at these conditions indicated at
least an order of magnitude correlation, with the computed value being
conservative.
Fisher and Davis14 conducted laboratory experiments on
erosion using, fly ash samples from, ten different bituminous coals.
The
fly ash particles were introduced into a heated air stream in the
quantities required to simulate the exhaust from pulverized (coal
M-24
-------
combustion) and tests were conducted with and without Aerotec dust
separators.
The test specimens were discs, rectangular pieces of
metal, small turbine blades, and standard stress-rupture test specimens
which were kept at l350°F and J5,000 psi stress.
Tests were made
mainly in the velocity range between 500 and 850 ft/sec.
It was found that erosion when using the dust separator was
only ten percent of that with the raw ash for the same weight con-
centration of fly ash per unit volume of gas. The Aerotec separator
removed about 90 percent of the raw ash. Therefore, erosion with the
separator was only about 1% of that with raw ash.
A persistent deposit
of ash particles was found on the targets when operating with the ash
separator.
In general, it was found that deposit formation was
associated with the impingement of ash particles smaller than about 10
microns, while large particles tended to remove deposits and produce
erosion of the metals.
The amount of deposit increased with increasing
temperature.
The ash particles tended to sinter into a strongly adhering
layer even at temperatures as low as 800°F.
Dust Erosion in Small Gas Turbines
In 1960 the Southwest Research Institute made a study of the
problem of atmospheric dust erosion of small gas turbines under the
. . 16 17
sponsorship of the Corps of Eng1neers. ' . Tests were made to determine
the effect of particle size and dust concentration. The results of
these investigations are shown in Figure M-7.
The gas turbine life varies
inversely as the product of the maximum particle size and. the total
dust concentration.
It was concluded that all particles greater than
2 ~ would have to be removed.
The engine life levels shown are probably
not applicable to large axial flow rates, but the basic relations
probably apply.
The Army Material Command sponsored an investigation at South-
west Research Institute on the basic mechanisms of dust erosions.17
The following conclusions were made:
M-25
-------
100
8
6
4
V)
c:: 2
o
~
u
.E 10
QJ" 8
.!:::! 6
V')
~ 4
u
.-
-
~
(0
a.. 2
1.0
8
6
4
2
2
Cu rye 646941-A
L = -L = 138
C~ C~
where
L = Engi ne Life, Hour
C = Dust Concentration, G/Ft3
K = Constant, 138 (This Engine)
~ =Maximum Particle Diameter,
microns
10
4 6 100
Engi ne Life, hour
2
Fig. M-] - Particle size vs usable safe engi ne life
(max. impeller wt. loss of 21 gr.) (16)
M-26
-------
1.
Erosion by airborne dust is primarily a process of
plastic displacement of material by the impacting dust particle, and
the effects of dust particle velocity and angle of impact upon erosion
rates may be described adequately by equations defining the trajectory
of the particle through the material.
2.
The relationship between dust concentration and erosion
loss is not a linear one, the average erosion loss per impact being
greater at low dust concentrations than at the higher concentrati9ns.
3.
Erosion rates are a strong function of dust-particle
size,
the correlation being best described by consideration of the
average erosion loss per particle impact.
4.
The effect of material properties on dust-~rosion loss
must include consideration of local temperatures resulting from particle
impacts, as well as the relationship of depth of cut to the mean distance
between crystal imperfections.
In conclusion, the principal parameters in the erosion of
turbine blades by a solid particle are:
the kinetic energy of the
particle, the angle of impact, and the physical properties of both
materials.
M-27
-------
11.
REFERENCES
1.
Hoy, H. R., Paper presented at Second International Conference on
Fluidized Combustion, Hueston Woods, Ohio, October 1970.
2.
National Coal Board, reports prepared for APCO, August and November
1970, February 1971.
3.
Stettenberg, L. M., "Minimizing Erosion and Afterburn in the Power
Recovery Gas Turbine," Oil and Gas Journal, October 19, 1970.
4. . Mund, M. G. and H. Guhne, "Gas Turbines--Dust-Air Cleaner:
. and Trends," A. S. M. E. Paper 70-GT-104.
Experience
5.
Jaumotte, A. L. and J. Hustin, "Experience Gained from a Ten-Year
Operation of a Gas Turbine Working With Blast Furnace Gas," A.S.M.E.
Paper 66-GT-97.
6.
"u.S. Bureau of Mines Coal-Fired Gas Turbine Research Project,"
U.S. Bureau of Mines Report RI6920-l967.
7.
"Turbine Blade Wear by Coal Ash in Working Fluid at 1200 of ," U. S.
Bureau of Mines Report RI7255-1969.
8.
Morley, W. J. and J. C. Wisdom, "Brown Coal Ash Deposition in the
Open-Cycle Gas Turbine," Journal of the Institute of Fuel, May 1964,
pp. 187-200.
9.
Atkin, M. L., "Australian Coal-Burning Unit," Gas Turbine In ter-
national, September-October 1969, pp. 32-36.
10.
Finnie,::tain, "Erosion by Solid Particles in a Fluid Stream,"
Symposium on Erosion and Cavitation, ASTM Spec. Tech. Pub. No. 307,
1962, p. 70.
Martlew, L., "The Distribution of Impacted
Particles of Various
Sizes on the Blades of a Turbine Cascade", Proc. Con£. BCURA, 1960,
E. G. Richardson, Editor, Pergamon Press, London, 1960, p. 104.
M-28
-------
12.
Wisdom, J. C., "The Prospects of the Coal Burning Gas Turbine for
Electric Power Generation," World Power Conf., Sept. 13-17, 1964,
Switzerland, Paper No.8.
13.
Dygert, J. C. and G. S. Bjorklund, "Integration of the Power
Recovery Gas Turbine with Fluid Bed Processes", ASME, Paper No.
59-A-231.
14.
Fisher, M. A. and E. F. Davis, "Studies of Fly Ash Erosion", ASME
Paper No. 48-A-53, December, 1948.
15.
Report on Trip to U.S. Bureau of Mines, Morgantown, W. Va.,
January 5, 1965, Hamm, Wolfe, and Young.
16.
"Dust Erosion Parameters for a Gas Turbine", Petro/Chem Engineering,
December 1962, p. 198.
17.
Horton, J. H., "Environmental Factors in Engine Design for Military
Applications", ASME Paper 65-CTP-1, December 28, 1964.
M-29
-------
APPENDIX
CALCULATED FREEZING POINT CURVES
Westinghouse has built a micro-fusion apparatus which proved
to be useful as a rapid and convenient means for evaluating fuel
additives and can be used to evaluate the carryover from a flui~ized
bed system. However, early attempts to find a satisfactory additive
for a fuel with a high sodium concentration showed that what was
really required was a fairly complete set of phase diagrams of binary
mixtures for the different ash constituents and various proposed addi-
tives. As may be seen from the melting point diagram for Na2S04 -
MgS04 mixtures in Figure ~-7 in the text, when these two sulphates
mixed with a magnesium-sodium ratio of 0.5 the temperature of the
were
complete melting point was lower than that of either of the pure
compounds.
*
In a few instances such diagrams were found in the literature,
but for many of the more promising additives no diagrams were available.
However, using thermochemical data it is possible to calculate ideal
melting point curves for binary mixtures which have been of some use
in selecting ranges of fuel-additive compositions which should result
in solid ash products at turbine operating temperatures.
Theoretical melting point curves for binary systems can be
computed from the thermodynamic properties of the components.
Such a
as known amounts of solute are added to the solvent.
computation is based on the lowering of the freezing point of a solution
**
Rossini
considers
the case of equilibrium between a pure solid substance and an ideal
liquid solution containing the pure solid in dissolved form with the
following simplifying assumptions:
*Ginsberg, A. S., Proceedings Polytechnic Institute of St. Petersburg,
Vol. 6, p. 493 (1906).
**Rossini, F. D., "Chemical Thermodynamics," John Wiley and Sons, Inc. 1950.
M-31
-------
(a)
(b)
The mixtures are true binaries
They behave as ideal solutions over the entire range of
(c)
composition
The solutes are completely soluble in the molten state
and completely insoluble in the solid state
(d)
They form no intermediate compounds.
The mole fraction of one component, NA' will vary with the'solution
mel.ting point temperature, T, and may be found from either of the two
expressions:
In N =-
A
l\Hk [ 1. - 1. J
R T T*
A
In N = - l\~ r 1. - 1.l
,A R L T T!J
+
(c!) - = Indicates the solid 'state.
[ ] = Indicates dissolved substance.
The first of these expressions assumes that the heat of fusion
is constant for all concentrations of "A" and is equal to the value at
the melting point of the pure component as shown in Figure M-8, Assumption I.
M-32
-------
H [HAJT ~ [H:] = (H:)
.1 I
~a)T ~ ~=>
T T* T
A
A ssumpHon I
~HMA = Constant
. *
= ~HMA
or
[HAJ T - (HA)T = (H:) - 0:)
DWO. '..A.ZZ
C [C.]T !::::-===1 [C:] : (C:)
I I
(CA)T ~
T 1:* T
A
Assumption ]I
[CA] -
Fig. M- 8
M-33
-------
The second includes a correction which takes into account the difference
in specific heats between the solid and liquid phases of the pure solvent
as shown in Assumption II.
Further refinement is possible in the form of a third assump-
tion that the specific heat of "A" in the dissolved state is constant
over the range of composition (dashed line, Assumption II) while the
specific heat in the undissolved solid state may be e~pressed in terms
of the temperature.
This results in a more complicated form of expression
than II but produces insignificant changes in the calculated values of NA'
The first of the above expressions is intended to be used only
where the solution approaches pure "A" in composition.
A further exten-
sion of the range of composition is possible using the second expression,
but even in this case its application to actual fuel ashes would yield
approximate values at best, since such ash mixtures may not form ideal
solutions.
In one case where experimental data were available, for the
Na2S04 - MgS04 system, good agreement was found between such data and
calculated values obtained by means of the second equation, as shown
in Figure M-7. It was assumed that no intermediate compounds
form. If such compounds do exist, the experimental curve departs from
calculated values as shown in the 0.45 to 0.7 range of NA' Assuming
that these expressions are valid, it is apparent that on a mole basis,
the lowering of the fusion point of substance "A" depends on the
characteristics of "A" and the quantity of added substance "B".
When
the fusion point lowerings of two subatances are calculated, and the
curves plotted from opposite sides of the diagram, they will intersect
at a point shown in the curve. This will represent the lowest tempera-
ture at which any liquid can appear and is defined as the eutectic
temperature.
In the above formulas, all values are available except
the specific heat of the melted material, (C!), which has seldom been
determined for the high melting point compounds such as MgO. Also,
the specific heat of pure solid ~!> may be in error, since the range
of temperatures covered by the equation do not extend to the fusion
points of the compounds.
M-34
-------
An estimate of (C!) may be obtained as follows: Using the
first equation, the melting point diagram may be plotted for the compound
'* /:.
in question. From published phase diagrams,' several binaries may
generally be found which contain the compound in question as one of the
componenfs.
Eutectic temperatures and the corresponding concentrations
from such diagrams may be plotted on the calculated diagram. In general,
these points will lie below the calculated curves, -indicating the
neoessity for the specific heat correction.
Eutectics should be chosen
for relatively high concentrations to lessen the possibility of encounter-
ing an intermediate compound, and no eutectic containing such a compound
should be used.
Several points are desirable in order to minimize the
errors prevalent in any physical test.
A segment of the curve most
nearly satisfying these points is then drawn from the fusion point of
pure compound and a convenient value of molar concentrati~n and correspond-
ing temperature selected from this segment.
These values may then be
inserted in the second equation and a value for (C!) computed. With
this value for (C!), the second equation may now be evaluated through-
out the required temperature range.
The calculation of specific heats by such a method implies
that the mixtures of inorganic salts for which freezing point data were
available are ideal solutions, and it should be noted that such calculated
values are only first approximations.
However, the incorporation of the
experimental points may partially compensate for any departure from ideal
solutions and variation in solubilities. Here again the correction must
be considered only approximate since these characteristics probably vary
throughout the range of composition. This procedure, incidentally, might
be proposed as a method of obtaining approximate specific heats at the
fusion points of high melting point compounds where physical measure-
ments would be extremely difficult. Only observed melting points of
mixtures of the compounds are necessary.
'* International Critical Tables.
/:. Hall, F. P., Insley, H., "Phase Diagrams for Ceramists," American-
Ceramic Society, Inc., 1947.
M-35
-------
An uncorrected calculation for 'magnesium oxide obtained using
the first equation is shown in Figure M-9, and three experimental
points are also shown. From the broken curve fitting these points, a
value of NA = 0.5 at 2l90°C was taken, and using the second equation,
(C!) = 18.86 cal./moleoC was obtained. A continuation of the sample
calculation using the second equation with the value of (C!) obtained
above is also plotted on the curve. The calculated curve for magnesium
sulphate is also shown. Here, no correction was made for the change
in specific heat, since the several test points fell exactly on the
curve.
Figure M-lO shows composites of all the oxides and sulphates
examined, together with sodium sulphate. The intersection of each of
these curves plotted from the right-hand side of the diagram with the
sulphate plotted from the left represents the theoretical eutectic
point.
From such curves, it appears that variations in the amount of
an additive should have little effect on the sintering or deposit-
forming characteristics of an ash, since this probably depends on the
eutectic temperature which, in turn, is dependent on the composition.
At most, an additive can only raise the sinter point to a temperature
which approaches the fusion temperature of the corrosive compound.
This is evident from the intersections for aluminum and magnesium
oxides.
However, the quantity of eutectic material may be so small
that no liquid is evident when the ash reaches the eutectic temperature.
Of course, if compounds containing elements from the ash and additives
are formed, these calculated curves give no indication as to the actual
curves.
Ash fusion tests have shown magnesium additives to be quite
ineffective in raising the sintering temperature whereas aluminum
produces noticeable increases, indicating the possible formation of
solid solution.
In practice, both aluminum and silicon additives have
shown less tendency to produce deposits than magnesium.
Briefly, it
may be concluded, on the basis of the theoretical data, that magnesium
and calcium would be excellent additives if they were present as oxides.
M-36
-------
2800
2400
~ooo
u
o
c
.-
. cu 1600
~
~
+-
C
~
cu
a.
E 1200
~
400
o
Magnesium
Oxide
With Specific
Heat Correction
Magnesium Sulphate
o
.2 .4 .6 .8
Mole Fraction Concentration
1.0
Fig. M-9-Calculated freezing points of magnesium compounds
M-37
-------
2800
2400
. 2000
u
o
c:
.-
Q>
~1600
+-
o
~
Q>
a. .
E
{!!. , 2 00
800
400
i
o
. 1'0
Na2S04 1.0
Magnesium
Oxide
Magnesium
Su Iphate
.2 .4 .6 .8
.8 .6 .4 .2
Mole Fraction Concentration.
1.0 NA
o
Fig. M-IO-Calculated freezing point diagrams with sodium sulphate
M-38
-------
However, as sulphates, they are undesirable.
Although silicon oxide
has a lower melting point than either magnesium or calcium oxide, it
would appear to have an advantage in not forming a sulphate. Aluminum
is, perhaps, the best compromise.
While its oxide has a somewhat lower
melting point than that of either magnesium or calcium, it can be shown
that its sulphate, although stable at some conditions, reverts to the
oxide at a relatively low temperature. A calculated curve for the
magnesium-calcium sulfate system is shown in Figure M-ll. This indicates
a eutectic temperature slightly less than 800°C. But it must be
emphasized that this curve is not confirmed.
It has not been" located
in the literature, and no fusion test has yet been run in our laboratory.
M-39
-------
Curve 646942-A
2000
1600
u
o
c::
'-1200
Q)
~
=:J
-
n:J
~
Q)
Q.
E 800
Q)
~
Ca SO 4
400
Ca SO 4
o
o
1.0
1.0
o
.2
.8
.4 .6 .8
.6 .4 .2
Mole Fraction Concentration
Mg SO 4
Fig. M-1I- Calculated freezing point diagram for magnesium and calcium sulfates
M-40
-------
APPENDIX N
STACK GAS COOLER DESIGN
ABSTRACT
Design specifications for the stack gas coolers that recover
heat from the exhaust gas from the gas turbine are summarized in
Figure N-1.
Boiler feedwater is heated to 578°F in the heat recovery
system.
Two quotations which were received for the stack gas coolers
are presented.
The Westinghouse Heat Transfer Division submitted a
design and cost.
The design is modular, and the cost for both a 318
MW and 635 MW plant is $4.1/kw, which includes transition ducting with
the gas turbines.
Struthers Nuclear also submitted a quotation.
Their
estimate is $3.7/kw for the 635 MW plant and does not include ducts
and connection with the gas turbines.
N-1
-------
. "
. .
Dwg. 6169A81
Fig. N-I-Design specifications for stack gas coolers
Boiler Feed Water
8
578°F
U ppe r
Stack
Gas'
Cooler
2
4810F ~ 5
481°F
Lower
Stack
Gas
Cooler
3
225°F 2
@
cfJlue Gas
31°F
cv
25°F
N2
C02
H20
02
CO
S02
NOx
Flue Gas Composition:
Mole%
74.4
14.5
8.5
2.4
0.2
'" 100 ppm
< 400 ppm
100.0%
Q)
75°F
Solids:
< 0.15 gr/SCF
Ash 79.7 wt %
Carbon 6.6
CaO/CaSO 4 13. 7
100.0
Gas Flow:
Water Flow:
4
5
319MW
Case I
707 Ib/sec
635MW
Case II
1414 Ib/sec
Gas Side Pressure Drop:
PI - P 2
P 2 - P3
Water Side Pressure:
628,500 Ib/sec 1,257,000 Ib/hr
1, 727, ODO Ib/h r 3,454,000 Ib/h r
(State 3 '" Atmospheric)
0.29 psi 0.29 psi
0.28 psi
- '" 2800 psi
0.28 psi
N-3
-------
The gases then enter an ;inlet plenum which turns the
gas from the horizontal to the vertical direction.
Turning vanes, formed from incoloy (approx. 11% Cr)
,are used to evenly distribute the GT exhaust.
Q9Foliowing the inlet plenum the' g~ses enter the heat
exchanger sections. '
On the following page is a sketch depicting its design.
eo Th~ exhaust gases then pass through the transition ductwork
which is not insulated. The unit is completely supported
with structural steel able to withstand nominal wind
ioadings.
Total estimating price for 1971 delivery........ $1,300,000. ,
f . o. D . ' Les te r .
Ic' /, .
/ (;~'n
S. C./Jamison
SCJ/rimm
"
N.,..4
-------
WDTINCJHOU.. ~O"M I444D
WESTINGHOUSE ELECTRIC CORf'aRATION
~I<'l~w
r~/~./"1fI~I---I. I ~-
! I -----"~,',~-~~ '--'--! ~
~ i ~'I.~-~~.,,:,_..,-,_~~'_d~' =~~\-'i~-
I J : JJ"
:..,~ ~ I .......
\ . J .....
, . :1 ! . I
-""..-, I ..".:..,,-l---------l.- ' I'
. ' . J ~~:'-~'.:" ~~~ - ~".~ . - . ._-..~-..._~_._-.. ~
I "',""'---'--"-'''''''''''''----'' -
, I I .
'<._.l(j-,~...,::,:... /~,I_._,... -.1
- 1 _'f ~.
, . . " .' I,; /" /'" ",
1/:"t,1 /:"'j h{'.',: ( ,": li,~ ;"'" I f~~',r-.:"'.J ( J' :""'.d" ;~I(,i..i""(~')
, ," . I I ,"" -I- . / ..'
4J ri , (" i! ":>/ 11 ~'i (.. dH..' j' L.c ,,?~.....~<,"''''''
..j
,,~ ..'" ~ "
- _I (~. L{...,'']-;! ,,,
,'. :' l', ,..\....; I...)
(:.,4"'; 1 ~;. i I 0/
f ~-:t.
{<,Li .';:""
f
(~
( tti ( rr( ,)
.7
.... n~ ...~ L,~: (-
\
1
I
/\
I
I :~,
..,' .-.- on-.'
I
n~_'~}
I
t
I
I
! Ii '
"
~ f.f':
....~..~ ,':(:-.
I
"i
j
,....,.......1
~;,;:::.~
J...' / /, :?
{..[ /.:.."...\~ J
..
/1.::,.../, 'l.
-. .- .., -----1
I
" Ci'
.. "J
c-. ",.;
,. -* '. ,.-
..~ - . .. ...-..,.; . ;.- \,;.. .
ai'~,",,~. :
. i~.:\'" ,.: I
.~.
: 16 f
, '
~.:._~ -,')- T"
., -- f
, '
bd\ ,..... !
i
,--",,,,,,,"'.'
t" ..
I
, '.1
-. .-".:.~ ;/~)
)
': '.
'f
I
i/r./ j ,,) - /
i '-. ""0' ---- .-.. ... ..:~~:'.: ,~~~_.~~,'.~~,~ :.:/
../
It/
": ,- ".,,~.;' '""Ii.>,:
:-;'~;'i
I
r
l. f
---.-.--...-- ~----~ ..-... ~ ..
"'~...., "-'-. ~-... . '''''. '.-."-'
~ 1./ .
I
- I' ,
. 'j ....' I"
V'
I .
!,2::.!.( -. S'7"~(.,t ('T,,; ;'~L
:; 7(; ('i..
11-5
;~.,,;
;.-; .""/ ()~. t..J.'..'''',
.,Ij.".. ..'.'-
It' ,
;' ~ "
1..,/',
:,/--:.,./
. ....------..-...
-------
-. .-. . -.. .""
WESTINGHOUSE ~ORM t~D
WESTINGHOUSE ELECT.RIC CORPORATION
.,pe,> tfT; I)~ -fq
, ..........~~---
.' It/of) ,/~(.(~ .s ~ "
, . . ,-------
. . . . ~lt.cjL.~ 3~, I' e ,
i '''1,' I. . .1~' I .
".L'~ V);.<.i.-c. . i..Lt41'U"'~{/,:I..J l:lA,<~~-t': I:.~:' - ( ,.J .l.(.',!~ i hi-;
. .' / . ..," .J..// /. /
.' ,~.:(,'I.' Cl"v-(,,~
( l/ "':t.!.:"'iti ; ~ €.!.:. U.:'li,...i) .
-l:!
r' ../' ,.. J "
I I' il..(.,'l.~-~';;'S II'~(..-'~. (.;4 (2!!::.. . " . ./' "
.' ?...~ _.~. ~;. ',,, ;~..,. "..., , .,' /1. " ,. -"~,,,\.: .-11 .,',...,. f_". :'~.... }
L/.} .1L'.'j, ., f1.Q-'),G-',,';'''~'( ~II ""'(.""'l""" ('" ,,,'.',,..',, .,.,.",..1(.'..,.../
vi " - ~,--.., - J" ...:. _.' l..... ,,..',, .,.' ",' ~ ()'.. ,., '" "',
<.J . /'/ ,. , .. I' " I ,!
~.':./ . ::>,0 0 I), - '3/ J ')'il,... I. ,'. I / ~) -" I Q - H I ~ (j.' _:".,,~"'i'i'.:~
J. , J -.;;) """"",'l.....J' <.- " .J I
;,. /I" J / . i ,,. . j ...(. /'
,.' /. () N .' ':... . ()I/7f c.t....!./ (J/,(, '~:':"';f'"'~'(..."i.
'....~ . ,_",'~.r.f:!.\ ..I.' "'.. / ' ..
a""
;.
..
1/ /, .f. . '." "" 7 r, j I' ~'
L_.,::~..~":;~~:~:::.~:-,"~~~,, - ~~ (..; . ~=, ~1,/~'~..,r:
Sru!J>',~ -/y." /
"... / ' ....." '.. ,'/." I,' ....r,'...? (:..::. I '.' /,', ".: '.'J. .
/ : ,. ....~. ~"f (~). < .,.:. or~.. ~.
~l"
.'
.'
".
:. ....:: ';,,J
L .'.
, .f i.~. t': ." f ':.:
, .(
..,t "/L.?' ~< (~/'~: ,
{t".; < {o ~;~::
. ....;.;'; ~;.'" i....!
'//~, {" .;>
'--'.,,,,,......-. I,
:..i. :~~.
, '
I ,
.,/1/ .' .'''''~.,.f''~' { . : ',' ~
t,...'" ~
I d", ko-...t I,
, .-' I' --'.., ('
I':' .;. ,-;-:,',"'," ( P t,-- I ;".1., ",",' .:/
II. ,. ..''''' H" . iii
/~J( (1ft: ~ . '.' .
~> y' {.:..;: ',,:) I
./
s~' I' ':{.~,h i.).'"",
;11
. ( .
. .'? .f .{..;..~' . .
5'3 i'. C l..C.,l')' V !-,.').'-' -<::l.y '. .;' . ; I
j'! ..,' .. h:: c' ',. :.. ,~. ,,': ( ( =' ) r-,. ". . /'" "i,,'" t.,.,.; '.' ,. // /! i.. )
.:s do" <..vt,...~,.. :' ',' "',~.t.:.. . (;/'1,.-"; .(..::.,t,r..) ..~.. /" 11;..". !"''''''''/
~ I
t.-, /.;/. " . '.'-. \ -'. "'"\ ,'.. I'..... {'} -. ~-' ~:~~ . J /' ( 'j; c. e)
/...U."'.;'; ".) -"'.;. ,. ".. /. ""'. 1.." ',,' c... . .. tr'': I ')-1.t,,1'1 ~~." ,,,\,.. ~.,,, -. 1-.. I ~
{ , ~
I .
- I !. ,. ~~
<; .. . "
..
.
,. / "
/. iJ ,,;.., ::-; I
, ...' ~ (:' ): r.
.......' -: (:
tOo..;} ,."
L, l ,:~. r;,: -;~a<
" /3.,-'.;,
.~. of ,
,:i"f) (.,1- I ",,;' I,'
,1
/
~.'
f~1 ~7'~,,",.~yU-7"".~ ~7 ..
" . .~~~ ~~ ~fl'I)c-'&-etL"l"Cr ~ ,
N-6.
-------
"'~-"""'''''''~..,....",:"......
WDTINGNOUSE 1'0"" ~D
WESTINGHOUSE ELECTRIC CORPORATION
.I .-
/ 11 (J./'~'{ t.
a"\.
. .'/, ..,.'.1...
, t.. ~ l- '. I"
.. ,. I I
... i-;\ r(
::' ...1'\ ~.,.' 1>\ \,J.
:----."-'''.
v
ri-:~:-..'. '.
\ .:: i'
.. I :." .."
.
i .
j .
U
~ :
I j
, , '
I .j (".' ' ,
/IV.l I _.... !
~. ; \.., .~. ':". . I ~.~~=:-~:~~ ..; .
I /"., ,.., ~
. \ ,
i ;
..",...;J 4,'..
I .
/,~" ..\ .
1/ \
, I
'1~)
/.
C'; :
...
,-
j
r
.I
'- .
/'"
~' \.,~ . ....o' :
/L.. :( .
. l
1.1 '. i .
~ .-..~, (\:.-c ~k",'l...
'/
/
,
I
I
/
I
N-7
-.."","" -,,-.......-.............,.--.--,.. ..........-.----. -..----.--.... -'''-..'''-'.'-'......- -.-,-....,., ..-......... ,..,. .-.'--....'.- ---. -." .~....,_.--,
-------
MEMORANDUM'
WESTINGHOUSE FORM 2478 K
DEPT.
~p- "1/
10
? -Its 6'-t('.
;2 rr IJ
~ 1(,,--
LOC ION
DATE
SUBJECT
Sr-/1 c. K
6t9S""
('
-------
~
I
\Q
'."--""-'
.~(r.~n, ."U....IIt'1
.'iI'" Ilf'lY'l'
~
."..,J"
1',000
,....rt
..O."tll
.cr...'11: U.f.fIf
.".t"
.,..."
.j
11'" -+
...,"
L-
~
H
.,
-----.._-
~' ::
'"
"...
.t.
,.
I
i
...
-. 1
"..." ..,.:I.."
,-.,.#,' us
~-
~
-~
.,',.'
I
L
'.'" '.
. ..I' "'~ . -.
W.st.,M:JSt [ltctriC Ctr'OfIt!81
"'''U:1), ..... ~:. !oJ"''; r
n."t - - '::.'J!.t.:""!.
--@
....,'troO. ", toorn1
.; :.: ~~~~~.~~;~~~.~-~-~.~~~,~~ ~~ ,?D'~~
-------
Westinghouse Electric Corporation
Research and Development Center
Beulah Road.
Pittsburgh, Pennsylvania
RE:
Our Proposal 3492~W3
N-ll
15235
-------
-----'"
( St(uthersj )
-"'---.-R''-'-~
Struthers Nuclear ,& 'Process Company
division 01 STRUTHERS WELLS CORPORA nON
p, 0, 80X 8' WARREN, PENNSYLVA'~IA 16365' 814.'726 '000
February 11, ,1971
Westinghouse Electric Corporation
Research and Development Center
Beulah Road ,'," ",' ',',
Pittsburgh, Pennsylv'an1.a ' 15235
SUBJECT:
Dr. Dale L. Keairn's
Senior Engineer ,
Chemical Engi'nee-ring Res'earch
Stack Gas Coolers for
Pressurized Fluid Bed Power System
Our Proposal 3492~W3 "
. '. ..
ATTENTION:
I '
I
Gentlemen:
We are pleased to submit our engineering estimate for the equip-
ment as required on the above subject.
The waterside of this equipment would be built in accordance with
Section VIII of the ASME Pressure Vessel Code and would be so stamped.
The gas side would be code constructed but would not be stamped.
For this service we propose to furnish serpentine coil finned tube
bundles. We believe the coils should be arranged ,for down flow of
the flue gas, and soot blowers would probably want to be installed.
The dust loading of ,the gas as given (0.15 grains/SCF) would indicate
that some 715 #/hourof dust would be passing through the units. '
We cannot predict what amount of this dust would be retained by
the finned tubes, 'if any, and would suggest a small scale exper~-
mental model be used to determine the affinity of the dust for the
tubes. We, therefore"have not included any soot blowers or related
dust handling or collecting equipment in our proposal.
Desiqn 319 MW Case I
Upper Sta:k Gas Cooler
Wa designate this coil as our 1.5" VC 140-10-25. This, ,serpentine
,coil would be made up using l~" I.P.S. Sch. 80 SA..,1068 pipes, spaced
on 4~" triangular pitch, using long radius return bends. The coil,
N-12
-------
Struthers
Westinghouse Electric Corporation
February 11, 1971
Page 2
face would be 140 tubes wide and each would be finned for a distance
of 10 feet. The coil would be 25 rows deep. Each tube would con~
tain 5 - ~" high x .06" thick fins per inch. The inlet and outlet
header size would be 17-3/8" O.D. x 12-7/8" I.D. x 53 ft. long.
Each header would contain 3 - 1500# R.F. feedwater nozzles. One
end of each header would be capped and the other would contain a
special high. pressure end closure. Each of the 140 - l~" I.P.S.
pipes w~uld be connected to the headers thus providing 140 parallel
passes on the waterside. The coil would be co~pletely drainable with
this arrangement. One tube support plate would be provided at each
end of the finned section. '.
The coil w~uld be enclosed within a #10 Ga steel casing, suitably
stiffened to with~tand a design pressure of 12" W.C. . The casing
and coil would be provided with structural steel supports designed
to carry its own weight. The casing would be internally insulated
with one inch of block insulation. The insulation would be protected
from gas erosion by a #18 Ga carbon steel liner.
The ~nit would be painted with one coat of our standard shop primer.
Desiqn 319 MW Case I
Lower Stack Gas Cooler
Our designation for this coil would be a 1.5 VC
.differs from the upper stack gas cooler only in
of the pipes and the number of rows deep. This
14'-0" finned length with 59 rows deep.. .
The inlet and outlet headers size would be ,12-5/8" O.D. x 9-1/4" I.D. x'
53 ft. long. Each header would contain 3 - 6" 1500# R.F. inlet and
outlet nozzles.
140-14-59. It
the finned length
coil would use
One half of the 140 tubes would be connected to the headers, thus
providing 70 parallel passes on the tubeside. The coil would be
completely drainable. . .
All other remarks as given under th~ Upper Stack Gas Cooler would
apply to this unit also. .
The coil design as quoted exceeds your allowable gas pressure drop
. by 2 . 0" w. C .
N-13
-------
Struthers
Westinghouse Electric Corporation
, ;
February 11, 1971
Page'3
De~ign 635 MW Case II
Upper 'Stack Gas' GooIer
We designate t'his co'il as our 'l~ VC140-14-36. This serpentine
coil would be made up using l~" "I.P.S. 'Sch. 80, SA-I06-B pipes
spaced on 6" triangul~t pitch using e~tralong tadius return bends.
The coil f'a'ce would be 140' tubes "wide arid, each would be finned for
a distance of'14 feet. The coil would be 36 rows deep. Each tube
would cQntain 5 -~" hi~h x i06" 'thick finspef'inch. The inlet
and outlet header 'size would be 25-1/4" O.D. x 19-1/8" I.D. x
70' -0" long.' 'Each header would contain '3 - 12" x 1500# R.F.
inlet and outlet nozzles. . ,
Two rows of tubes would be c'onnected to each header which in effect
produces 280 parallel passes. The coil would be:completely drainab1e.
Three tube su'pport plates would be ptovided :for the coil; one at each
,end and one in the, center of ,the, finned' section.' "'" '
Casing, insulation and ;'struc'tural 'would' be -provided' as described
undeF Case I.
The coil design as quoted exceeds your allowable gas pressure drop
by 1.5" W.C.
Design 635 MW Case II
Lower Stack Gas Cool~r"
"
Our desIgnation for ,this coil' would be at.:, VQ 140'-'20';'92., It
differs from the, upper stack~as ~ooler ~nlY irith~ finned length '
and number of rows deep. Tbis coil would use 20'-0" finned length
,wi th 92 'TOWS' de,ep. : ". ' " ' " ",'
The inlet and outlet header size would be 17-1/8" OoD.x 12-7/8"
I.D. x 70'-0" long. Each header would contain 3 - 8" 1~00# R.F.
inlet and outlet noizle~." ~ ", 'j , .
Two rows of tubes would be connected to each header which in effect
produces 280 parallel passes on the waterside. Th~ coil would be
completely drainable." Three' tube support plates would be provided
, for the coil; one at each end and one in the 'cente~ ~f the finned
section.
Casing, insulation and structural would be provided as describe'd
under Case I.
N~14
-------
, '\
,\
Struthers,
Westinghouse Electric Corporation
February 11, 1971
Page 4
The coil design as quoted exceeds your allowable gas pressure drop
by 2.0" W.C.
B;Jdqet Price
, 319 MW Case I
For one upper and one lower stack gas cooler as described, F.G.B.
Warren, Pennsylvania, $880,000.
Estimated shipping weight of both coils 1,250,000 pounds.
,Budget Pri~
635 MW Case II
For one upper and one lower stack gas cooler as described, F.G.B.
W3rren, Pennsylvania, $2,370,000.
Estimated shipping weight of both coils 3,250,000 pounds.
Struthers would require that progress payments be made on any order
of this magnitude.
We would estimate delivery of this equipment cQuld be made in 40 to
50 weeks after receipt of the approved setting plan drawing to be
submitted 4 weeks after receipt of the fQrmal order.
We thank you for this opportunity to quote on your requirements and
trust that we may serve you further in this connection.
'N-15
-------
IIILET (-,1>.'0 FU ',\,.J
'* 10 G.A
.~u~--L
Ft ",1/STIFFIIEr-D
/
. A'
'c 0'
I:
A I
II
d'
~ I
--- - - I
(" - u~----"-~-- C~- ~O~::~-- n
FINNED
';S/
I='IF'ES I.S" I.P.S. SCI1 80
"8"
.
i ... -- u
;
I
;
/
Z
I
I--'
0\
.,,/-'
I' '\-
. ~_i J~_i
- !... I'
i!
"
J ' "B" .c. iIO'"
CASE I A
UPFEf( :--:' 12' 10' 17~I\O.D.
LO'.I/Ef( .: -::, I '2.3' 14' I '2. ~ II O. D.
'- -
CAe,E J[
;0' IB' 141 c:..L1I
UP~~r.. 'l~"2 i).D.
-: ;.1' 4c' ZO' ' II
LOll,' E::. 17:: C.L.
..~~: --- =--=-=-:~ ~~. --+. =: :
u-r'--'---- _.
IT
- n "_. -- -
,j
,I
----- . I
.
STRUTHERS NUCLEf.R & PROCESS CO.
WARHEN, PENNSYLVANIA
DIVISION Or- STRUTHE~S \'.'ELLS CORP.
DRAWN: ~
SCALE:
, .;; " ':--, P R t: o~.~ '-
i~~.~L-~D".-.:\rER E(,.
DRf..','/ING 1\ CO~TP,~CT /:0.
REV,
CHECKED:
I \ ~i' ~:"
. ,<
I' .
~..I i\
APPROVED:
. .
-- -,..".---
"'---"''''- _._~....- ~ ----~..._--.~~.. "~-.-
,:;. ~ ~:" ~. ..
------
-------
STRUTm:ns WELLS CORPORATION
PAGE
Terms of Sole
1. CONTRf..CT ScHer's proj)("'';:11 prt"vi011,) td :11'rl~ptanr.e is suhjrct to dHmge or withdrawa1 withulil n",-in:. PUrd13~H~r's 0rr!t;r.
ac('~pt::I, w\~h ur \\"1th,'ut ~pt':':ltic nVh:ii~ir:tt.i'):1S the (kscrit\t.irms, spt:citl(;H:.ms. terms 3nd e,.)nt!itinns ~'\'t'n 111 Sellrf':;.pr"p',snl.
wh.::n ~;'Ir"':n! a:':: aCl't';'lf'd '-'11 !Ia' ~t,!::d:1r1...! f~:n:1 n: S.-l!'.:r", ,t",of'pt:i::::' 14:. a:l :l11~l!'.ri;~t'd u:1i'!i,YCt,' 'If fh~ Sdl.'f :1t 'l:1t' I,j' its
p1ar.ls c<.nstitl,lcs thr cn~in' c;;ntr;ll"I" \vhlch then tnD:' be mruJifil",! ')Ii:j' by writtcn :1l:lt.'l':llr~I1t. approved by such an outh(Jrizc({
emp1oy~e and no other prnmise~. nb:fccments or uJ:!.krstandings shall he bmd1I1~ un th~ St'!il'r.
2. TAXES If any sates or use taxes or (,ther tn,e" whether n,)w in effect or he"',,fter enacted applicable t,) the equipment o.r
any Pt.-,rfl,..r:l1ancc 1:1 regard thereto afe iUlP',:;(.:\!. such ta:\~-'s ShCia he t"f.r the Purchrt..,(-'r-'s Account.
3. PAY1JENT (a) Payments are to be m~de in current funds of the United Stales to Stller at Seller's plant,
(b) Payml'uts for each invoke co,'ering p~rti,,1 shipments shall bl'c",""c dne in acc'>rd"nce with the quoted terms or' payment.
(c) If Sc:lcr slHlll be delayed in starting, n'l~nur~cture, shipment or other phasc.uf the contract by action or inaction of Pur:
chaser. pay,""cnt shall be due as if Se!:er had shipped the equipment as calleJ for in the contract, 'and when so delayed Seller may
store the equipment for Purchaser's account and risk. '
4. .GENERAL PROVISIONS (a) Right of possession to goods to secure the payment of the purchase price shall remain in Seller
until all payments therefor hereunder shall have been fully made. Upon request Purchaser agrees to do all acts necessary to perfect
and maintain such right to the Seller.' '
, (b) Seller shall be excused for reasonable delay in performance or for non. performance due to any cause beyond its control.
including but not limited to shortages of materials or manpower.
(c) If Purchaser desires to inspect goods for workmanship and material, inspection and acceptance must be made before
shipment, unless otherwise agreed in writing.
(d) Shipments and deliveries under this 'agreement shal! at all times be subject to approval of Seller's Credit Depnrtment.
(e) Receipt of goods by Purchaser without objection shall cunstitute a wai,'er of any and all claims for delay.
(f) Unless otherwise agreed in writing Purchaser and Carrier are responsible for goods lost or damaged in transit.
5. QUALITY, PERFORMANCE AND LIMITATION OF LIABILITY (II) Seller warrllnts the equipment IIgainst defects in
material and workmllnship, under normal use and service, for a period of one year after date of shipment of the equipment:
Sener's obligation under this Warranty being limited, however. to furnishing or repAiring, without charge, F.O.B., its Plllnts, a
similar part to replace IIny part of its own equipment which not more thlln one yellr after date of shi!'ment of the equipment is
proven to have been defective at the time it was shipped. provided PurchllSer has given Sener immediate written notice upon
discovering such defect. Seller shall have the option of requiring the return of the defective material. to establish the claim. Seller
Ihall not be held responsible for work done, apparatus furnished or repairs made by others unless done w:th Seller's written approval.
(b). Seller assumes no responsibility for the effects of corrosion or erosion.
(c) Seller shall not be liable for any special, indirect or consequential damages resulting in any manner from the furnishing
of the equipment. In special cases Seller's liability may be further defined previous to the acceptance of the order by mutual
agreement in writing between the parties hereto.
6. CANCELLATION Cancellation of orders accepted by the Seller clln be made only with the Seller's consent. Should cancella.
tion be accepted by the Seller, the Purchaser shall pay the full purchase price for items completed. On items not completed, a
charge will be made for incurred material and labor costs together with material handling, manufacturing, sales. engineering and
administrative overhead plus a reasonable percentage of profit. Purchaser shall also pay in full the cost of all special dies, tools,
patterns and fixtures, to all of which at all times possession IInd title remain in Seller unless otherwise 'expressly provided. Seller
may, at its option, accept cancellation on a no. charge basis, retaining in its possession any production material acquired for
processing the cancelled order.
7. GOVERNING LAW The entering into, construction, interpretation, performance and discharge of this contract will be
governed by the Laws of Pennsylvania.
PRICE:
As
noted on page 4. .
TERMS: 30 Days Net
DELIVERY: F.O.B. WARREN, PA.
Very truly yours,
STRUTHERS WELLS CORPORATION
-: R~ Engineer
Speclal Products Department
RRJ:par
(Original
+
2)
cc:
H.
E.
A.
w.
Backstrom
Eschborn
FORM 80.2
N-17
------- |