EPA-650/2-73-048c
December 1973
Environmental Protection Technology Series
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EPA-650/2-73-048c
EVALUATION
OF THE FLUIDIZED-BED
COMBUSTION PROCESS
VOLUME III -
PRESSURIZED FLUIDIZED-BED
BOILER DEVELOPMENT PLANT DESIGN
by
D.L. Keairns, D.H. Archer, E.J. Vidt,
and E.F. Sverdrup
Westinghouse Research Laboratories
Pittsburgh, Pennsylvania 15235
Contract No. 68-02-0217
ROAP No. 21ADB-09
Program Element No. 1AB013
EPA Project Officer: P.P. Turner
Control Systems Laboratory
National Environmental Research Center
Research Triangle Park, North Carolina 27711
Prepared for
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D.C. 20460
December 1973
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This report has been reviewed by the Environmental Protection Agency and
approved for publication. Approval does not signify that the contents
necessarily reflect the views and policies of the Agency, nor does
mention of trade names or commercial products constitute endorsement
or recommendation for use.
11
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ACKNOWLEDGMENTS
The results, conclusions, and recommendations presented in
this volume represent the combined work and thought of many persons at
Westinghouse and the Office of Research and Development (ORD). Westinghouse
subcontracted Foster Wheeler Corporation to prepare the preliminary design
package.
In particular, we want here to express our high regard for and
acknowledge the contribution of Westinghouse personnel and the personnel
at ORD who conceived the overall fluidized bed combustion boiler effort
and who. have defined, monitored, and supported the efforts of Westinghouse
and others on the program. Mr. P. P. Turner, Chief of the Advanced Process
Section, has served as EPA project officer on our work. Numerous enlight-
ening and helpful discussions have been held with Mr. Turner; with section
members D. Bruce Henschel and Sam Rakes; and with R. P. Hangebrauck,
Chief of the Demonstration Projects Branch. Personnel from the Westinghouse
Research Laboratories have made significant contributions. Dr. W. C. Yang,
Mr. J. R. Hamm and Dr. R. W. Hornbeck participated in the development plant
design and evaluation. Mr. P. J. Hopkins, Turbine and Generator Division,
Westinghouse Canada Limited, performed an investigation into turbine
suitability for the development plant. Mr. G. S. Howard and Mr. W. F. Stahl
of the Westinghouse Gas Turbine Systems Divisions participated in the
evaluation of the gas-turbine test facility. Mr. L. W. Zahnstecher,
Foster Wheeler Corporation, served as project manager for preparation of
the preliminary design. Foster Wheeler personnel made significant
contributions through their expertise in boiler design.
We gratefully acknowledge the work of our secretary, Ms. Sylvia
Nalepa. We are also grateful to Ms. Nancy Berkowitz who coordinated
the final editing and production work and to Ms. Deborah Conrad for
typing the editorial material.
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PREFACE
The Office of Research and Development (ORD) of the United
States Environmental Protection Agency (EPA) has organized and is sponsoring
a fluidized bed fuel processing program. Its purpose is to develop and
demonstrate new methods for utilizing fossil fuels — particularly
coal and oil — in utility power plants. These methods should:
• Meet environmental goals for S00, NO , ash, smoke emissions,
£m X
and wastes
• Compete economically vith alternative means for meeting
these abatement goals.
Westinghouse Research, under contract to the Office of Research
and Development (ORD) of the Environmental Protection Agency (EPA), is
carrying out a study to evaluate and develop fluidized bed combustion
and oil gasification in air pollution abatement. The goals of this work
are:
• To identify which fluidized processes might be economically
employed in utility power plants or industrial boilers to
reduce SO., particulate, and NO emissions
& X
• To assist in planning and implementing a program to
develop the fluidized bed systems deemed effective in
air pollution control and economical in steam/power production.
Tasks in the evaluation of fluidized bed combustion set forth
by EPA which have been completed at Westinghouse under a previous
contract are:
• To search the technical and patent literature in fluidized
bed combustion, to canvass commercial organizations with
expertise pertaining to this field, and to survey the
market for industrial boilers and utility power systems
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• To design a fluidized bed industrial boiler and two
fluidized bed utility power systems — one 300 MW
capacity, the other 600 MW; and to provide performance
and cost projections for the equipment designed
• To provide technical consultation and assistance on the
ORD fluidized bed fuel processing program, including both
combustion and gasification
• To conceptualize a development plant which will prove the
configurational or operating features of the fluidized
bed boiler designs not confirmed by prior art or experience
• To assess the effectiveness and economics of an
atmospheric-pressure, fluidized bed oil gasification-
combustion system and to aid in planning for a demonstration
installation of such a system.
The results of these surveys, designs, evaluations, and
comparisons were published in a three-volume report, "Evaluation of
the Fluidized Bed Combustion Process," in November 1971 under contract
No. CPA 70-9.
These results provided the basis for the work performed from
July 1971 to May 1973 which is described in this four-volume report.
Tasks in the evaluation of the fluidized bed combustion process set
forth by EPA under contract 68-02-0217 have focused on the development
of pressurized fluidized bed combustion for power generation and
fluidized bed oil gasification for power generation. These tasks have
included:
• Extensive process evaluation studies of the pressurized
fluidized bed combustion system for power generation.
These investigations predict the sensitivity of operating
and design parameters selected for the base power plant
design on plant economics; provide additional experimental
vi
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data on sulfur removal and sorbent regeneration using
limestones and dolomites; project economics and performance
for various sulfur removal systems, both regenerative/sulfur
recovery and once-through sorbent; establish a plant operation
and control philosophy and evaluate alternative pressurized
fluid bed combustion concepts, both economic and performance.
Preparation of preliminary plans and a cost estimate for a
30 MW (equivalent) pressurized fluidized bed combustion
boiler development plant. The design provides sufficient
detail to locate a suitable plant site and to obtain a fixed
cost bid for the preparation of detailed plans. The plant
will provide the capability to study effectively the
remaining technical problems to achieve the greatest
potential for reducing emissions and to achieve economical
power generation.
Identification of a project 'team to demonstrate fluidized
bed oil gasification/desulfurization for power generation.
A cooperating utility — New England Electric System (NEES) —
has been identified to carry out a 50 MW demonstration
plant program. Further process evaluation has been
carried out and experimental data obtained on sulfur
removal and spent stone disposal.
Evaluation of pressurized oil gasification for combined
cycle power generation. Oil gasification process concepts
and options have been reviewed, material and energy balances
projected, performance projected, and capital and energy
costs estimated.
Provision of technical consultation and assistance on the
ORD fluidized bed fuel processing program, including both
combustion and gasification processes. Technical and
economic comparisons have been carried out on various
fluidized bed fuel processing systems and various conventional
means of steam/power generation.
vii
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This volume (Volume III) contains the preliminary design of a
30 MW (equivalent) pressurized fluid bed boiler development plant.
The design basis, design details, cost estimate, experimental program,
and recommendations and alternatives for commercializing the process
are presented. Volumes I and II contain the pressurized fluid bed
combustion process evaluation studie's. Volume IV presents the work on
fluidized bed oil gasification/desulfurization.
viii
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VOLUME III
PRESSURIZED FLUID BED BOILER DEVELOPMENT PLANT DESIGN
TABLE OF CONTENTS
Page
1. SUMMARY 1
2. INTRODUCTION 3
3. BACKGROUND INFORMATION 7
4. DEVELOPMENT PLANT DESIGN 17
4.1 Design Basis 19
4.2 Flow Diagram 22
4.3 Material and Energy Balance 22
4.4 Boiler Module Design 22
4.5 Auxiliary Equipment 38
4.5.1 Dolomite and Coal Preparation and Feed 33
4.5.2 Water and Steam Supply 39
4.5.3 Dolomite and Ash Disposal 40
4.5.4 Steam Disposal 40
4.5.5 Particulate Removal 4Q
4.5.6 Combustion Gas Disposal 40
4.6 Gas-Turbine Test Facility 41
4.6.1 Test Turbine 43
4.6.2 Stationary Test Passages 45
4.6.3 Test Rig - Required Engineering 43
4.7 Regeneration/Sulfur Recovery 50
4.8 Instrumentation and Control 50
52
4.9 Perspective View
4.10 Plant Model 5g
5. EXPERIMENTAL PROGRAM 59
6. COST ESTIMATE 63
7. IMPLEMENTATION 65
8. REFERENCES
APPENDIX: Pressurized Fluid Bed Boiler Development
Plant Designs and Estimates
IX
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LIST OF TABLES
Page
1. Pressurized Fluidized Bed Boiler Apparatus 15
2. Design Basis for Pressurized Fluidized Bed Boiler 21
Development Plant
3. Material Balance 35
4. Material Balance 36
5. Heat Balance 37
6. Survey of Gas Turbines for Development Plant 44
7. Comparison of Test Turbines for Fluidized Bed Combustion 45
Process Development Plant
8. Approximate Cost of Rotating Test Rig Based on Solar 49
Recuperative Centaur Engine
9. Cost of Two Test Passages 49
10. Operation of the Pressurized Fluidized Bed Combustion 62
Boiler Development Plant
11. Capital Cost 63
12. Demonstration of Boiler Concept 67
13. Demonstration of Plant Concept 68
xi
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LIST OF FIGURES
Page
1. Pressurized Fluidized Bed Boiler Power Plant 8
2. Pressurized Fluidized Bed Steam Generator for Combined 10
Cycle Plant
3. Process Flow Diagram: Pressurized Fluidized Bed Boiler 23
4. Engineering Flow Diagram: Proposed Coal Preparation and 25
Injection System
5. Engineering Flow Diagram: Pressurized Fluidized Bed Boiler 27
6. Engineering Flow Diagram: Spent Solids Letdown and Turbine 29
Test Rigs
7. Pressurized Fluidized Bed Boiler 31
8. Boiler Section and Details 33
9. Gas Turbine Erosion and Corrosion Test Facility 42
10. Pressurized Fluidized Boiler Plant 53
11. 30 MW Pressurized Fluid Bed Boiler Demonstration Facility 56
12. 30 MW Pressurized Fluid Bed Boiler Cutaway 57
13. Pressurized Fluid Bed Boiler Combined Gas- and Steam-Turbine 66
Power Plant
xiii
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TABLE OF CONTENTS
Volume I
FLUIDIZED BED BOILER COMBINED CYCLE
POWER PLANT DEVELOPMENT
Volume II
APPENDICES TO VOLUME I
Volume IV
FLUIDIZED BED OIL GASIFICATION/DESULFURIZATION
xv
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VOLUME I
PRESSURIZED FLUID BED COMBUSTION PROCESS DEVELOPMENT EVALUATION
Page
1. SUMMARY 1
1.1 Economic Comparison 8
1.2 Environmental Impact 11
1.3 Energy Resources 11
1.4 Technical Uncertainties 11
1.5 Development Status 13
1.6 Comparison with Alternative Technology 16
2. ECONOMIC SENSITIVITY 17
2.1 Basis for Sensitivity Analysis 18
2.2 Operating Conditions 28
2.2.1 Bed Temperature 28
2.2.2 Fluidizing Velocity 34
2.2.3 Excess Air 44
2.2.4 Operating Pressure 51
2.3 Boiler Design 53
2.3.1 Heat Transfer Surface Configuration 53
2.3.2 Heat Transfer Coefficient 68
2.3.3 Tube Materials 75
2.3.4 Module Capacity 75
2.4 Particulate Removal System Economics 78
2.4.1 Range of Dust Loading and Particle Size Distribution 78
2:4.2 Gas-Turbine Specifications 78
2.4.3 Effect of Dust Loading and Particle Size on Cost 82
2.4.4 Effect of Gas Flow Rate on Cost 85
2.5 Power Plant 93
2.5.1 Gas-Turbine Inlet Temperature 93
2.5.2 Steam Temperature 97
2.6 Assessment 97
2.7 Conclusions 101
xvii
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Page
3. LABORATORY SUPPORT STUDIES 103
3.1 Introduction 103
3.2 Apparatus 106
3.2.1 Modification of the TG Apparatus 108
3.2.2 Operation 110
3.2.3 System Performance 113
3.3 Process Variables 114
3.4 Previous Laboratory Studies ^
3.5 Summary of the Results 116
3.5.1 Pressure 116
3.5.2 Sulfur Dioxide Concentration 117
3.5.3 Temperature 117
3.5.4 Agreement with Previously Reported Data 117
3.5.5 Stone Type 117
3.5.6 Particle Size 119
3.5.7 Oxygen Concentration 119
3.5.8 Stone Pretreatment 119
3.6 Experimental Program 119
3.6.1 Sulfation of Dolomites 119
3.6.2 Atmospheric Pressure Tests 122
3.6.3 Dolomite 1337 at 10 Atmospheres 128
3.6.4 Sulfation of Tymochtee Dolomite at 10 Atmospheres 130
3.6.5 Effect of Low Sulfur Dioxide Levels 130
3.7 Theory 136
3.8 Kinetics of Dolomite Sulfation 137
3.9 Qualitative Comparison with Fluidized Bed Results 139
3.10 Quantitative Comparison with Fluidized Bed Results 142
3.11 Comparison of NCB Data and Westinghouse Data 144
3.12 Regeneration 147
3.13 Previous Regeneration Studies 148
3.14 Conclusions from the Regeneration Experiments 150
3.15 Two-step Regeneration Experiments 151
3.16 Exploratory Runs 157
xviii
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Page
3.17 Tests with Powdered Calcium Sulfide 157
3.18 Tests with Sulfided Dolomite 158
3.19 Current and Future Experiments 160
3.20 Conclusions 163
REGENERATION SYSTEMS ASSESSMENT 165
4.1 Introduction and Scope of Investigation 165
4.2 Regeneration Process Concepts 166
4.2.1 One-Step High-Pressure and Low-Pressure 166
Regeneration Concepts
4.2.2 Two-Step Regeneration Concept 169
4.2.3 Constant*Load Concept 171
4.2.4 Once-through Operation 171
4.2.5 Wellman-Lord Stack Gas Cleaning Process 171
4.2.6 Alternative Concepts 173
4.3 Process Options and Variables 173
4.4 Base Case Designs 175
4.5 Economic Results for Base Case Designs 178
4.5.1 Process Capital Investment 178
4.5.2 Plant Energy Costs 178
4.5.3 Constant Load Concept Economics 180
4.5.4 Effects of Boiler Conditions 180
4.5.5 Process Cost Comparison 185
4.6 Process Performance 188
4.6.1 Plant Heat Rate 188
4.6.2 Temperature Control 188
4.6.3 Process Turndown 190
4.6.4 Process Environmental Comparison 191
4.7 Assessment 193
4.7.1 Economic Factors 193
4.7.2 Environmental Factors 196
4.7.3 Base Design Feasibility 202
4.8 Combustion of Low-Sulfur Coals 208
4.9 Conclusions 210
xix
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Page
5. PLANT OPERATION AND CONTROL 213
5.1 Introduction 213
5.1.1 Plant Criteria 213
5.1.2 Control System Requirements 214
5.1.3 Pressurized Fluid Bed Boiler Power Plant Concept 214
5.2 Unit Start-up 221
5.2.1 Introduction 221
5.2.2 First Module Start-up 234
5.2.3 Second Module Start-up 236
5.2.4 Third Module Start-up 237
5.2.5 Regeneration System Start-up 237
5.2.6 Auxiliary Fuel Storage Requirements 239
5.3 On-Line Loading 239
5.3.1 Introduction 239
5.3.2 Sequential Loading 241
5.3.3 Predictive Loading 243
5.3.4 Rapid Loading 244
5.3.5 Loading Events Diagram 244
5.3.6 Dynamic Analysis 247
5.4 Unit Shutdown 249
5.4.1 Introduction 249
5.4.2 First Boiler Module Shutdown 249
5.4.3 Second Boiler Module Shutdown 254
5.4.4 Shutdown of Fourth Module 255
5.4.5 Emergency Shutdown 256
5.4.6 Dolomite Sorbent Regeneration System Shutdown 258
5.5 Trips 259
5.6 Runback, Run-ups, and Limits 263
5.7 Total Plant Control System 264
5.7.1 Introduction 264
5.7.2 Plant Master Control System 269
5.7.3 Steam Turbine 270
5.7.4 Boiler Feed Pumps 271
xx
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Page
5.7.5 Gas Turbine 272
5.7.6 Flash Tank 277
5.7.7 Boiler Module 278
5.7.8 Boiler By-pass 280
5.7.9 Regeneration System 281
5.7.10 Stone Feed System 282
5.7.11 H-S Generator Control 284
5.7.12 CaS04 Reducer Vessel 285
5.8 Conclusions and Comments 286
5.8.1 Conclusions 286
5.8.2 Comments 287
6. ALTERNATIVE PRESSURIZED FLUID BED BOILER CONCEPTS 289
6.1 Fluidized Bed Adiabatic Combustor Combined Cycle Power Plant 289
6.1.1 Adiabatic Combustor Concept 289
6.1.2 Cycle Performance 290
6.1.3 Plant Turndown 293
6.1.4 Environmental Considerations 295
6.1.5 Fuel Processing Equipment 295
6.1.6 Power Plant Cost 300
6.1.7 Conclusions 300
6.2 Recirculating Bed Boiler Design 310
6.2.1 Deep Recirculating Fluidized Bed Boiler Concept 314
6.2.2 Cold Model Studies 316
6.2.3 Bed Tube Heat Transfer Coefficient 321
6.2.4 Conceptual Recirculating Bed Boiler Design 323
6.2.5 Boiler Operation and Performance 325
6.2.6 Economics 330
6.2.7 Conclusions 333
335
7. REFERENCES
xx i
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VOLUME 11
APPENDICES TO VOLUME L (PKKSSURiZED FLUID BED
COMBUSTION PROCESS DEVELOPMENT AND EVALUATION)
ECONOMIC .SENSITIVITY
A. Boiler Tube Specifications
B. Effect of Operating Conditions and Boiler Design ,on
Boiler Cost
C. Parametric Study of Elutriation Rate from a Fluidized
Bed Combustion Boiler
SULFUR REMOVAL
D. Base Design — High-Pressure One-Step Process
E. Base Design — Low-Pressure One-Step Process
F. Base Design -- Two-Step Process
G. Temperature Control and Process Turndown
H. Effect of Boiler Conditions
I. 'Once-through Process
J. Constant Load Concept
K. Process Comparisons
L. General Study of One-Step Process
M. Low-Sulfur Coal
N. Limestone Wet-Scrubber Cost
PLANT OPERATION AND CONTROL
0. Part Load Operation
ALTERNATIVE PRESSURIZED FLUID BED BOILER CONCEPTS
P. Recirculating Bed Boiler Studies
xxii
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VOLUME IV
FLUIDIZED BED OIL GASIFICATION/DESULFURIZATION
Page
1. SUMMARY 1
1.1 Introduction i
1.2 Technology Assessment 2
1.3 Environmental Impact 5
1.4 Development 7
1.5 Conclusions 9
2. ATMOSPHERIC PRESSURE FLUID BED OIL GASIFICATION n
2.1 Process Evaluation H
2.1.1 Gasification/Desulfurlzation Concepts 11
2.1.2 Experimental Work 13
2.1.3 Design 14
2.1.4 Evaluation 17
2.2 Demonstration Plant Program 23
2.2.1 Scope 23
2.2.2 Location of Utility Partner 27
2.2.3 Conclusions 31
3. OIL GASIFICATION FOR COMBINED CYCLE POWER GENERATION 33
3.1 Introduction 33
3.2 Process Concepts and Options 34
3.2.1 Gasifier Air/Fuel Ratio 36
3.2.2 Limestone/Dolomite Regeneration Method 37
3.2.3 Once-through System 37
3.2.4 Other Options 39
3.3 Process Specifications and Design Basis 39
3.4 Material and Energy Balances 39
3.5 Capital Investment Evaluation 40
3.6 Performance 45
3.7 Comparison with Alternative Power Generation Systems 49
xxiii
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Page
3.8 Shell and Texaco Pressurized Oil Gasification Processes 52
3.9 Conclusions 55
4. SUPPORT STUDIES 57
4.1 Introduction 57
4.2 Sulfidation of Calcined Limestone and Dolomite 58
4.2.1 Conclusions from this Study 59
4.2.2 Experimental Methods 59
4.2.3 Equipment Problems 60
4.2.4 Atmospheric Sulfidation of Tymochtee Dolomite 61
4.2.5 Further Isothermal Experiment Results 61
4.2.6 Calcined Dolomite 1359 62
4.2.7 Sulfidation at Pressure on Dolomite 64
4.2.8 Stone Substrates 65
4.2.9 Sulfidation: Interpretation 68
4.2.10 Calcium Utilization 70
4.2.11 Fuel Gas 70
4.2.12 Mass Transfer Limits 71
4.2.13 Comparison of TG Data and Fluidized Bed Results 72
4.2.14 Outline of the Apparatus 73
4.3 Waste Disposal 74
4.3.1 Conclusions from This Work 76
4.3.2 Previous Investigations 77
4.3.3 Experiments 78
4.3.4 Initial Investigation 79
4.3.5 The Oxidation of Sulfided Dolomite 81
4.3.6 The Oxidation of Sulfides Prepared from a 87
Series of Limestones
4.3.7 The Kinetics of Oxidation 87
4.3.8 Summary 88
4.3.9 Some Implications of the TG Study on 90
Calcium Sulfide Oxidation
xx iv
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KKFKKKNCKS
APPENDICES
A. Performance of the Oil Gasification Process as a Function
of the Air/Fuel Ratio
B. Space Requirements and Gasifier Start-up
C. Evaluation of Oil Gasification Process Costs
D. Oil Gasifier Turndown-Variable
E. Presentation Document — Clean Boiler Fuel by
Fluidized Bed Gasification/Desulfurization
F. Utility Prospects for Demonstration Plant
G. Utilities Visited
H. Proposed Utility Agreement
I. Utility Manpower Requirement
J. Follow-up Meeting Agenda
K. Letter of Intent
L. Invitation to Bid
M. Partial Oxidation Processes
N. Material and Energy Balances
0. Equipment Design
P. Capital Investment
Q. Performance and Energy Cost
R. Shell and Texaco Process Data
XXV
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CONVERSION FACTORS — ENGLISH TO METRIC UNITS
Length
Area
Volume
Mass
Pressure
Temperature
Energy
Power
English System
in
ft
"3
ft"*
gal
oz
Ib
ton
lb/in2
in H20
°F
°R
Btu
Btu/min
Metric Equivalent
2.54 cm
0.305 m
6.45 cm2
0.0930 in
16.39 cm3
28.32 1
3.785 1
28.35 gm
453.6 gm
907.2 kg
51.70 mm Hg
1.865 mm Hg
1.8 (°C) + 32
1.8 °K
252 cal
252 cal/min
xxvi
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1. SUMMARY
A 30 MW (equivalent) pressurized fluid bed boiler development
plant has been conceived to demonstrate pressurized fluid bed boiler
operation. Such a plant is needed for further development of pressurized
fluid bed combustion combined cycle power plants which offer an
opportunity for minimizing sulfur dioxide, nitrogen oxide.and particulate
emissions; reducing thermal emissions; increasing overall power plant
efficiency;and producing electrical energy from fossil fuels with
reduced capital and energy costs. The plant will provide the capability
of studying fluid bed combustion and heat transfer, steam generation,
solids feed and handling, particulate removal, gas-turbine performance,
boiler control, and sulfur dioxide and nitrogen oxide emission control.
Preliminary designs, cost estimates, experimental program,
schedule,and program alternatives are presented. This document and
the support material will be used to locate a plant site, to obtain
fixed cost bids for the preparation of detailed plans,and to form a team
to implement the development plant program. Information received from
continuing laboratory and pilot plant programs will be used to improve
the development plant design and program.
Detailed design, construction,and operation of this plant is
recommended for the three-year period 1974-1976 in order that a
demonstration pressurized fluid bed combustion boiler power plant can
be built and operated before the end of the decade. The capital cost
for the nominal plant adjacent to a power plant is estimated to be
approximately $10 million. Operating costs are estimated to be
between $2.4 and 3 million per year,depending on the plant site.
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2. INTRODUCTION
A recent technical and economic analysis for the Office of
Research and Development, EPA, has shown that power plants using
pressurized fluidized bed boilers can be built which are:
• Economical in capital requirements. Estimated costs for
such plants are 20 to 30% less than are those for conventional
steam power plants.
• Efficient in operation. Pressurized fluidized bed boiler
plants using conventional steam technology are equal in
overall efficiency to the best of conventional plants —
about 38%; the use of increased steam temperatures and
pressures and of increased combustion gas temperatures
will increase overall plant efficiency to 46% or more.
• Effective in pollution abatement. Pressurized fluidized
bed boiler power plants meet emission requirements
established for S0_, NO , and particulates.
£ X
Pressurized fluidized bed combustor test units have and are
being operated to obtain data on sulfur removal; nitrogen oxide
minimization; particulate emissions; boiler tube materials; gas-turbine
component corrosion, erosion,and deposition and coal feeding. These
units include bench-scale tests and pilot plant units of ^ 1 MW
equivalent capacity. A larger fluidized bed combustion boiler facility
is now required to demonstrate:
• Operation of deep fluid beds with commercial heat transfer
surface
• Operation of multiple beds
• Particulate removal system capability and reliability
• Gas-turbine reliability
• SO, and NO pilot plant emission results.
*• X
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Several concepts have been considered for a demonstration
facility to extend the current program and commercialize the pressurized
fluid bed boiler concept. The following alternatives illustrate the
options available:
• Demonstrate the boiler concept with a single fluid bed
unit (20 to 30 MW). The plant could stand alone as a
development plant or might be integrated with an
existing steam-turbine system and/or a process steam
supply system.
• Demonstrate the plant concept with a multiple bed unit
and gas turbine (75 to 150 MW). The plant could be a
new integrated facility with steam-turbine power
generation and/or process steam production, or it could
be retrofitted on an existing steam-turbine plant.
The choice of a development/demonstration facility will depend on the
available funds, the project team,and the location of a site. A pre-
liminary design of one concept — a single bed development plant — has
been prepared to provide a basic plant concept and cost data for
assembling the project team.
A preliminary design has been prepared for a 30 MW
pressurized fluidized bed boiler development plant. The design package
was prepared by Foster Wheeler under contract to Westinghouse. The
boiler comprises a single fluidized bed of 5 ft x 7 ft rectangular
cross-section. Bed depths of 3 to 30 feet are possible to accommodate
tubes for steam generation. The boiler represents a single bed in a
module of a 300 MW power plant boiler. Alternative designs
investigated include construction adjacent to a power plant and con-
struction at an independent site; fluid bed combustor pressures of
170 psig and 320 psig; and coal feed rates from 22,000 Ib/hr and
33,000 Ib/hr.
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Four approaches to sulfur removal were considered for the
development plant:
• Once-through operation
• Integral boiler—regeneration—(sulfur recovery) system
• Two partially independent systems — boiler and
regenerator/(sulfur recovery)
• Regeneration system with flexibility to evaluate
alternative regeneration/sulfur recovery processes.
The plant is designed to study the once-through limestone or dolomite
sulfur removal system. This is recommended for the first generation
plant based on the sulfur removal system study (Volume I) which
weighed the energy requirements, economics, make-up stone requirements,
and environmental parameters. Provisions are made for a regeneration
system to be added at a later date.
This demonstration boiler plant would obtain data for the
design, construction, and operation of a demonstration power plant
based on pressurized fluidized bed combustion. The preliminary plans
provide a basis for detailed designs and for overall planning through
the preparation of site requirements, program schedules, and cost
estimates specific for any proposed site. The plans will be useful
also in gathering technical ideas for the development plant and in
focusing attention on the technical problems which it must solve.
The Appendix presents the plans and estimates for the plant*
The assembling of a United States government, industry, and utility team will
required to undertake the financing, construction, and operation of the
plant.
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3. BACKGROUND INFORMATION
A 635 MW pressurized fluidized bed combustion boiler power
plant has been designed. The power cycle schematic is shown in
Figure 1. Operating at elevated pressure, a fluidized bed combustor
requires a compressor to pressurize the air and to overcome the pressure
loss over the fluidized bed combustor. At an operating pressure of
10 to 15 atmospheres, excess air of 10 to 15%, and fluidizing velocity of 6 to
12 ft/sec, a depth of 8 to 15 feet is required to accommodate the heat
transfer surface in the bed; the pressure loss over the bed is thus
four to eight times as large as that over an atmospheric-pressure bed. The
pumping energy, however, is actually less because of the greater
density of the gas at high pressure. Energy can be recovered from the
high-temperature, high-pressure gases by passing them directly into a
gas-turbine expander, reducing their pressure to atmospheric as shown
in Figure 1. This expansion lowers the temperature of the gases by
600 to 800°F, thereby reducing the amount of surface required to
recover heat from the combustion gases leaving the fluidized bed. The
pressurized system can be operated at higher excess air rates. Such
operation increases the fraction of gas-turbine power, reduces
combustible losses from the boiler, and increases the waste heat
recovery after the gas turbine. It also results in improved plant
efficiencies.
Several boiler systems have been built, tested,or proposed
which incorporate fluidized bed combustion. These systems, as well as
alternative concepts, have been evaluated. The early concepts did not
incorporate heat transfer surface or sulfur removal in the bed,and were
generally designed to burn low-grade fuels. The heat released was
extracted from the combustion gases during their passage through a
conventional boiler. Recent concepts and studies incorporate heat
transfer surface in the bed to achieve a more compact and efficient
design and/or remove sulfur during the combustion process by using a
limestone bed.
-------
Air
I
Compressor
k
Coal
Pressurized
Feed
Limestone
^
Sulfated
Limestone
Dwg. 6182A71
Gas
Turbine
Electric
Generator
\/
Particulate
Removal
Reheated Steam
Heat Recovery
(Boiler Feed Water)
Steam Electric
Turbine Generator
Fluidized
Bed
Boiler
Stack
Boiler Feed-
Heat Recovery Water
(Flue Gas)
. Water
Discharge
Figure 1-Pressurized Fluidized Bed Boiler Power Plant
-------
The boiler design considered most promising consists of four
modules. The modularized design provides for a maximum of shop fabrica-
tion and standardization, and assists in meeting the turndown require-
ments for the plant. Each module includes four primary fluidized bed
combustors, each containing a separate boiler function — one bed for
the preevaporator, two beds for the superheater, and one bed for the
reheater. Evaporation takes place in the water walls. All of the
boiler heat transfer surface is immersed in the beds, except for the
water walls. There is no convection heat transfer surface since the
maximum allowable bed temperature is less than the state-of-the-art
gas-turbine temperature. The fluidized bed combustors are stacked
vertically because of the advantages in gas circuitry, steam circuitry,
and pressure vessel design of deep beds. Each module contains a
separate fluidized bed or carbon burn-up cell (CBC) to complete the
combustion of any carbon elutriated from the primary beds. A separate
bed may not be required since carbon losses may be low enough in the
proposed pressurized boiler design with deep beds. A CBC is not
envisaged if the system is operated with high excess air, which has
the attraction of increasing plant performance by increasing the fraction
of gas-turbine power. A simplified drawing of a module is shown in
Figure 2. The 318 MW plant module can be shop-fabricated and shipped
by rail. The 635 MW plant module is designed to be shipped in sections,
each shop-fabricated. The primary beds for a 318 MW plant are approximately
5 ft x 7 ft. The bed depths are approximately 12 ft — sufficient for
the required heat transfer surface. The carbon burn-up cell (CBC) is
approximately 2 ft x 7 ft. The CBC contains no submerged surface in the
bed. The submerged tube bundles are formed by vertical tube platens
or planes, each platen a continuous boiler tube in a serpentine arrange-
ment. A platen is schematically represented in Figure 2. The heat
transfer surface can be viewed as horizontal tubes. The preevaporator
and reheater contain 1-1/2-inch diameter tubes; the evaporator water walls
and reheater bed contain 2-inch diameter tubes. Details of the boiler
design and the plant layout are presented elsewhere.
-------
Reheated Steam
Reheatei Bed
T8
Superheated Steam
Superheater Bed
Superheater Bed
Pre-evapcrator Bed
feed Water
I O
<<"
CD m
t
t
110 Ft.
t
Provision
LforCarbon
A' Burn-up
Cell*
PLANT VESSEL
SIZE DIAMETER. D
320 mw 12 Ft.
635 mw 17 Ft.
BipHltit in iinitui uidiiiiis:
ncnt it, lid («I». IK >ilodlj
Grade Elevation
ELEVATION
PRESSURIZED FLUIDIZED BED STEAM GENERATOR
FOR COPIED CYCLE PLANT
FOUR (4j REQUIRED
Figure 2 Pressurized Fluidized Bed Steam Generator Module
10
RM-59131
-------
The effectiveness and economics of a pressurized fluidized
bed boiler power plant have been evaluated. Demonstrated SCL and
N0x reductions are adequate to meet emission standards. Energy costs
are projected to be ^ 10% less than conventional power plants using
current power generation technology. There is thus a large economic
margin for solving technological problems, and there is also the potential
for increasing performance and reducing costs by increasing both gas-
turbine and steam-turbine performance.
The primary potential advantages of a fluidized bed boiler
power plant are:
• Reduced volume and modular construction. Because com-
bustion rates are more intense in fluidized beds than in
the fire box of a pulverized fuel furnace, and because the
heat transfer surface can be placed in the bed,
fluidized bed boilers are more compact than conventional
coal-fired boilers. Pressurized boiler modules can be
fabricated in shops and installed at a power plant site.
Considerable economies are possible in the fabrication
and erection of pressurized fluidized bed combustion
boilers.
• Reduced heat transfer surface requirements. Because heat
transfer coefficients are an order of magnitude greater
in fluidized beds than in the fire box of a conventional
boiler, less heat transfer surface is required in the
boiler. In a pressurized boiler, less heat is extracted
from the combustion gases after they leave the fluidized
bed because they are cooled by expansion in the gas
turbine. Further large reductions in heat transfer
surface are thus possible. The heat transfer surface in
the pressurized boiler is * 80% less than the surface in
a conventional p.f. boiler.
11
-------
Reduced steam tube and turbine blade corrosion/erosion
and fouling. Because the fluidized bed boiler operates
at a maximum combustion temperature far below that in a
conventional boiler, volatilization of alkali metal
compounds and fusion of ash is reduced or eliminated.
Sulfur and vanadium compounds are removed from the
combustion gases by the sorbent. The corrosion/erosion
and fouling of steam tubes and turbine blades is thus
minimized. Under these conditions, higher steam
temperatures and pressures may become economically
feasible,and greater efficiency in power generation may
be achieved. Somewhat greater efficiencies can also be
i
achieved in pressurized fluidized bed combustion by
using gas turbines with high inlet temperatures.
Reduced fuel costs and increased flexibility. Because
fluidized beds can readily burn crushed coal (fine
grinding is not required), coal with a high ash content,
and a variety of miscellaneous combustibles (from sewage
/
sludge, municipal solid wastes, paper mill liquid wastes,
and oily wastes to residual oil and natural gas), boilers
using such beds can utilize cheap fuels and a wide
variety of fuels to generate power and steam.
Reduced emissions of SO, and NO . Because a limestone/
£• X
dolomite sorbent can be utilized in a fluidized bed
combustor, SO- reductions of 90 to 95% can be economically
achieved. The low combustion temperature at which the
bed operates minimizes the formation of NO by fixation
A
of atmospheric nitrogen. Production of NO by oxidation
A
of nitrogen in the fuel is minimized by operating the bed
at high pressure. Compliance with NO emission regulations
X
at atmospheric pressure will require design and/or
operating modifications to the boiler.
12
-------
Several characteristics of a pressurized fluidized bed boiler
must be demonstrated: operation of deep beds with internals, adequate
particulate removal for reliable gas-turbine operation, and sorbent
regeneration of high stone utilization to permit once-through operation.
Pressurized fluid bed boiler apparatus and support facilities
have been operated to supply information on:
• Combustion and combustion efficiency
- C carry-over
- Burning above bed — C solids and gases
• Pollution abatement
- S02
1 Removal
• Regeneration
Recovery
- NO reduction
- Particulate
Formation, ash, and sorbent attrition
• Removal
• Heat generation and transfer
- Combustion in deep beds
- Temperature distribution
Heat transfer coefficient distribution
• Reactant feed and distribution
- Fuel
- Sorbent
- Air
• Materials
- Steam tube
- Turbine blade
13
-------
This information has 'been and is being obtained on different
types of experimental apparatus and on different scales. A summary of
available and planned pressurized fluidized bed boiler apparatus is
summarized in Table 1.
14
-------
TABLE 1
PRESSURIZED FLUIDIZED BED BOILER APPARATUS
Type
Location
Capacity
Diameter
Lb coal/hr
Operating Limitations
Temperature
°F
Pressure
psi
Gas Velocity
fps
Purpose
Status
Special Purpose
TG
TG
Fluid bed
Fixed bed
Cold models
Pilot Plants
Semi- batch
Semi- batch
Continuous
Semi- hatch
Westinghouse
CCNY
Argonne
Esso
Westinghouse
Esso
Argonne
Argonne
Esso
Esso
Esso
BCURA
-
- -
2 inch
1 inch
1-1/2 "x9"
4 inch
4 inch?
6 inch 60
3 inch
3 inch
5 inch
12.5 inch 480
2'x4' -x-400
2200
>2000
>2000
ambient
ambient
ambient
1900
2100
2200
2000
1700
1500
450
150
150
ambient
150
40
135
135
150
150
150
90
-
5
1-40
up to 6
up to 10
5
5
10
2
kinetic studies
on sulfur removal/
regeneration
alternative concepts
fluidization and
solids handling
fluidization and
solids handling
sulfur removal/
combustion
regeneration
regeneration
combustion/sulfur
removal
regeneration
combustion/ sulfur
removal
combustion/sulfur
removal
Development Plant
?
5'x7* nominal
22,000
2000
225
15
data for demon-
stration plant
operating
operating
operated
operating
operating
operating
operating
operating
Kov. 1972?
Jan. 1974
Jan. 1974
operated
1969-1971
1973-
preliminary
design, Dec.
1972
-------
4. DEVELOPMENT PLANT DESIGN
The pressurized fluid bed combustion boiler program at BCURA
demonstrated the feasibility of pressurized fluid bed combustion in an
2
8 ft combustor. Specifically, it demonstrated:
• S0_ emissions of £ 0.7 lb/10 Btu
^ f
• NO emissions of 0.07-0.2 Ib NO-/10 Btu
X it
• Coal feeding at 3-1/2 and 5 atmospheres
• Continuous operation — runs up to 350 hours
• No erosion or corrosion of gas-turbine blade test
passages after 200-hour tests
• Particulate removal at ^ 1500°F and 5 atmospheres by cyclones
proved adequate for turbine blade tests
• Adequate boiler tube materials for commercial
applications
• Bed operation with horizontal tube bundle.
Commercial boiler design operating conditions require that
the bed be operated at higher gas velocity, higher bed pressure, higher
temperature, and with a deeper bed than the BCURA unit. A development
plant is required to investigate the design, construction, and per-
formance of the proposed boiler plant equipment system design at the
proposed operating conditions so that commercial feasibility might be
assessed. Several features require a large plant to evaluate the
design and performance:
• Operation of deep beds (10 to 20 ft) with horizontal tube
bundles and headers with aspect ratios < ^ 2.5
• Heat generation and temperature distributions
• Coal feeding requirements and sorbent distribution in a
large bed (^ 35 ft2)
• Particulate control equipment performance
• Heat transfer surface configuration and materials
requirements
British Coal Utilization Research Association.
17
-------
• Gas-turbine blade materials nnd component life
• Disengaging height design criteria
• Operational techniques — start-up, shutdown, load
follow, stability
• Long-term operability at design and operating conditions
• Fabrication, maintenance, and repair of boiler and
auxiliary components.
The plant is also required to confirm, on larger scale, results obtained
in laboratory and bench apparatus and in pilot plants:
• Emissions — SO., NO, CO, C, alkali metals
• Combustion efficiencies
• Sorbent utilization
• Sorbent attrition
• Air distribution
• Boiler tube materials
• Particle carry-over and the sources.
Further, only a full-scale unit will provide solutions to the following
problems:
• Erosion that may occur due to full-scale tube configurations
• Feed point location distribution requirements for coal and
dolomite into a full-size fluidized bed (number of feed points
and their location)
• Thermal inertia effects in turndown and start-up of a full-
scale module
• Physical arrangement for maintenance access (tube repair,
coil replacement, instrument replacement, etc.)
• Determination of shop-fabrication methods and costs, and
the associated shipping protection requirements
18
-------
• Mechanical design methods suitable for tube bundle support,
grid plate support, differential expansion of water-wall
penetrations, etc.
• Investigation of tube vibration over the long span tube
lengths only utilizable in a full-scale module
• Determination of field-erection methods and costs, not
obtainable from a small-scale unit
• Determination of various unusual operating effects on the
full-scale module mechanical design. Conditions created
by an emergency shutdown of the turboexpander or a low-flow
surge of the centrifugal air supply compressor would be used
to test the design adequacy of the full-scale module.
• Investigation of optimum space utilization and heat transfer
surface configuration within the fluidized bed can best be
proved out by testing alternative tube bundle designs in the
full-scale module.
Other objectives which are being considered for the facility include:
• Need to test sulfur recovery system
• Feasibility of studying advanced concepts — higher steam
temperature and pressure, higher gas-turbine temperatures,
circulating beds, deeper beds (30 ft), higher pressures
• Feasibility of expanding to multiple bed operation.
The development plant is planned so that sufficient information can be
obtained to design, build, and operate a demonstration plant of 150 to
300 MW. Appendix I provides the complete design, and estimates as
prepared for Westinghouse by Foster Wheeler, Inc.
4.1 DESIGN BASIS
The development plant design is based on the objectives outlined
for it and for the commercial plant design. For the plant to provide
sufficient information to design, build, and operate a demonstration power
plant, the unit must be large enough to:
19
-------
•• Test multiple point coal feeding,
•' Avoid untypical height/diameter ratios, with, bed' operation
•• Test proposed heat transfer surface configurations)
• Test effect of bed emissions1 on1 gas-turbine performance1.
These design characteristics, can be met by constructing a fluidized'
bed unit with a capacity equivalent to) one bed in. a 75-to- 100'-MW
1 e
module., The range of operating, conditions: and' design criteria
established for the plant are summarized' in Table 2\
The location of the plant is' an important consideration.,,
since large- quantities of coal and- water are required' and: large- quan-
tities of steam, are p-roduced. Several advantages, could be achieved' by
locating' the development plant on1 an' existing- power1 plant site1:;
• Availability of coal-handling, water preparationyandl
solids disposal facilities
•' Existing' plant would dispose of steam1
• Superheat and' reheat steam generation' cam be studied7 by
using bleed stream from existirtg plant.
•• Utility partnership1 would minimize1 site development and'
development time,, and provide plant utilities- and
maintenance facilities.
Thus, the preferred location option would be adjacent to a
large power plant where appropriate tie-ins> could be effected1 for the
supply of utilities, coal,, boiler feedwater,; andi saturated steam;; and-' the
return of superheated steam.. Such a location) would simplify and reduce
the cost of installation of the developmental test boiler.
If it is not possible to locate adjacent to' a- utility,, then
it will be necessary to install water purification1 equipment, as: weil
as boiler feedwater storage, condensers for steamyand1 adequate boiler
feedwater pumps. In addition1,, various' auxiliaries, such' as" instrument
air,, cooling towers, and a packaged' boiler would be required at an1
independent site.
201
-------
TABLE 2
DESIGN BASIS FOR PRESSURIZED FLUIDIZED BED BOILER
DEVELOPMENT PLANT
Coal
Sulfur Removal Sorbent
Pressure
Temperature
Gas Velocity
Bed Area
Bed Depth
Ca/S
Heat Transfer Coefficient
Particulate Carry-over
Particle Size
Coal
Dolomite
Site
Air supply
Excess air
Air preheat
Feedwater temperature
Heat transfer surface
Pittsburgh No. 8 (4.3% S)
dolomite (1337)
1-20 atm
1500-2000°F
6-15 fps
•». 35 ft2
4-30 ft
1-6 for once-through
2-10 for regeneration
50 Btu/hr-ft2-°F
10-30 grains/scf
-1/4" x 0
-1/4" x 0 or 1/4" x 28 mesh
existing power plant
separate air compressor, motor drive
> 100% capability
to 600-850°F
to 230-500°F
capability for testing water
walls, preheat, evaporation,
and superheat tube bundles
21
-------
4.2 FLOW DIAGRAM
Figure 3 is a simplified flow diagram of the pressurized
fluid bed combustion boiler development plant. The plant is adjacent
to a large power plant to which it has access to provide interfaces
with the coal, water, steam, waste stone, and utilities. Engineering
flow diagrams are shown in Figures 4, 5, and 6.
4.3 MATERIAL AND ENERGY BALANCE
The material balance and operating conditions for the develop-
ment plant at the projected 100% load nominal design condition are
presented in Tables 3 and 4. A heat balance for the nominal design is pre-
sented in Table 5.
4.4 BOILER MODULE DESIGN
The pressurized fluidized bed boiler for the development
plant comprises a single bed of the four required for an 80 MW module.
The steam generator is a water-walled box formed of vertical 1-1/2 in.
tubing within a 12-ft diameter pressure shell approximately 78 feet tall
designed for 320 psig pressure. The combustor has a rectangular cross-
section 5 ft x 7 ft. The design of the pressurized fluid bed boiler is
shown in Figures 7 and 8. The air distributor plate at the bottom of
the box can be raised by as much as 4 feet to vary the distance between
the base of the bed and the bottom of the horizontal steam tubes sub-
merged in the bed. These steam tubes form sets of parallel vertical
platens of serpentine bends filling the cross section of the bed.
Three sets of platens or heat exchange bundles are provided so that
three different bed heights (and three different amounts of heat
transfer surface in the bed) can- be provided.
Two tube bundle designs were developed. One, shown in
Figure 7, supports the tube bundle from headers located in the high-
temperature gas pass. Spare bundles are used to study different bed
heights. This design minimizes the number of connections which provides
22
-------
PAGE NOT
AVAILABLE
DIGITALLY
-------
TABLE 3
MATERIAL BALANCE - NOMINAL DESIGN*
u>
In
Stream
No . Daacr
Temp.
lotion T
1 Vet coal from BL ambient
2 Sized Coal 100
3 Dolomite ambient
4 Dolomite ambient
5 Coal to R-101 ambient
6 Spent Dolomite 1600
7 Fines Discarded 1600
8 Fines Discarded 1600
9 Fines Discarded 1600
Pressure Flow
ps la lb/
Rate Particle
hr Composition Size
15 120,000b moisture 10.0 wt.X 1-1/2" x 0
VCM 36.8 wt.X
fixed carbon 45.3 wt.X
ash 7.9
Total 100.0
15 111.240b C 71. 3 wt.X 1/4" x 0
H 5.4 wt.X
0 9.3 wt.X
N 1.3 wt.X
S 4.3 wt.X
ash 8.5 wt.X
Total 100.0
15 150,000b CaC03 49.59 wt.X 1/4" x 28 mesh
MgCO, 49.36 wt.X
Inert s 1.05 wt.X
Total 100.00
15 35,728 same as Stream 3 1/4" x 28 mesh
176.4 mln. 22,000 same as Stream 2 1/4" x 0
176.4 20,979 CaS04 18.0 wt.X 1/4" x 0
CaO 39.3 wt.X
MgO 39.6 wt.X
Inerts 1.8 wt.X
ash 1.3 wt.X
Total 100.0
165 2,900 ash 60.0 wt.X
carbon 30.0 wt.X
dolomite 10.0 wt.X
Total 100.0
165 1,432 same as Stream 7
165 same as Stream 7
^Nominal design la Case A-l; see Appendix II.
Flow rate based on 40 hr. operation per week.
-------
TABLE 4
MATERIAL BALANCE - NOMINAL DESIGNa
LO
CTi
Stream
No.
10
11
12
13
14
15
16
17
18
19
Temp
Description °F
Air to C-101 ambient
Air to C-103 100
Air to R-101 500
Air By-passed 500
Flue Gas from R-101 1600
Flue Caa from C-101 1600
Flue Gas to Turb. Cascade 1600
Flue Gas to Quench 1600
Quench Water 200
Flue Gas to SL-101 600
Pressure Flow Rate
ps la Ib/hr I MMSCFD
14.3 366,504 116.8
180 53.500 17.0
175 238,988 76.17
175 73,611 23.46
168 273,737 82.8
165 273,737 82.8
165 60.000 18.1
165 213,737 64.7
185 65,683 131 gpa
atm 339,420 116.1
Composition
o2
N|
H-0
£
02
N2
H^O
£
same as
same as
CO
CO2
H20
°2
N2
SO,
NO
same as
same as
same as
CO,
CO
H20
°2
»2
SO.
WT
20.6 M I
77.3 M Z
2.1 M Z
Total 100.0
21.0 M Z
79.0 M Z
nil
Total 100.0
Stream 10
Stream 10
18.3 M Z
0.2 M Z
8.5 M Z
1.7 M Z
71.2 H Z
148 ppm
198 ppm
Stream 14
Stream 14
Stream 14
11.5 H Z
0.12 M 1
42.9 M Z
1.1 M Z
44.4 M Z
92 ppm
124 ppm
Dust
Loading
ar/ACF
20.8
V3.01
M>.30
*0.30
tO. 30
design is Case A-l; see Appendix II.
-------
TABLE 5
HEAT BALANCE AROUND FLUIDIZED BED BOILER
Nominal Design
Datum: 77°F
Lb/Hr
Input
Dried coal 22,000
Sensible heat
LHV
Comb, air 238,988
Fresh dolomite 35,728
Fines returned 2,900
TOTAL 299,616
Output
Flue gas 273,737
Spent dolomite 20,979
Fines elutriated 4,900
Reaction heats
Reactions with dolomite
CaCOa + S02 + 1/2 02 = CaS04 + C02
CaCO, = CaO + C02
MgC03 = MgO + C02
No formation
1/2 N2 + 1/2 02 = NO
Incomplete coal combustion
CO, = C + 02
C02 = CO + 1/2 02
Heat loss
TOTAL 299,616
Temp.
°F MM Btu/Hr
77
0
275.0
500 24.98
77 0
1600 1.13
301.11
1650 119.4
1650 8.1
1650 1.9
-3.91
11.4
10.58
0.07
1.69
2.08
0.20
151.51
Heat Available for Steam Generation = 301.11 - 151.51
= 149.6 MM Btu/Hr
Nominal design is Case A-l; see Appendix II.
37
-------
for convenient tube bundle removal or installation and permits a con-
tinuous tube bundle to provide superior fluidized bed hydraulics. A
second design was conceived which contains three separate bundles which
can be stacked one above the other with three feet of crawl space
between the bundles for assembly and maintenance. Headers are located
in the preheat air zone where temperatures are low (^ 600°F). This
design requires extensive cutting and welding to change tube bundles
and has discontinuities in the tube bundle for deep bed operation. ,
Both designs are presented in the Appendix.
The tube bundles can be operated as either a superheater, an
evaporator, or a preheater; or, by reducing the mass flow, as a combined
evaporator and superheater.
The use of a refractory backed by structural steel for one or
more walls of the boiler has been considered as a means of simplifying
construction and of easing maintenance. The water-wall construction,
however, seems to have all the advantages:
• Lower cost
• Less bulk
• Cheaper fabrication, less maintenance
• Better means of support for submerged tubes
• More heat exchange surface.
The,possibility of locating headers for the tube platens within the
water walls has also been considered as a means of easing the removal
and/or replacement of tube bundles. More expensive materials and
costlier fabrication techniques would be required, but significant
savings in carrying out repairs would be realized.
4.5 AUXILIARY EQUIPMENT
4.5.1 Dolomite and Coal Preparation and Feed
Wet coal is received in open-rail cars and in the size range
of 1-1/2 in.x 0. The cars are unloaded over a hopper below the tracks.
38
-------
The hopper feeds a conveyor to a dryer where coal is dried (from as high
as 10%) down to ^ 3% moisture. The coal is crushed to 1/4 in. x 0 and then
conveyed to a covered silo for storage. Coal may then be blended with
dry, crushed dolomite in the order of 10% of the coal. The coal plus
dolomite is pressured up to boiler fluidized bed pressure, and then it
is injected into the boiler through a Petrocarb pneumatic injection
system.
The dolomite is received dry and double-screened 1/4 in. to 28
mesh in covered rail cars. The cars are unloaded in a closed building
into an underground hopper to prevent the picking up of moisture. The
dolomite is elevated by conveyor to a storage silo, from where it is
either pressurized in a lock hopper and then injected into the boiler
or added to the coal for injection into the boiler. The dolomite can
be injected above the grid.
Spent sorbent is discharged from the bottom of the bed, a
position just above the grid, or it may be withdrawn at 24 in., 48 in.,
and 72 in.from the bottom of the tube bundle, depending upon the position of
the grid with respect to the tube bundle.
4.5.2 Water and Steam Supply
The water and steam are assumed to be available at 2400 psig
at the capacity required by the development plant. The water at 500°F
and under pressure would be received from the utility power company's
economizer and sent to the water walls for preheating and evaporation.
Saturated water and saturated steam from the flash drum are returned
to the utility company. Either water or saturated steam is taken from
the utility company and sent to the fluidized bed tube bundle. The
saturated steam is superheated to 1000°F, or the water is evaporated
in the tube bundle and returned to the utility company.
39
-------
4.5.3 Dolomite and Ash Disposal
Solids disposal is accomplished by cooling the ash plus the
spent sorbent in a water-jacketed rotary cooler to 300°F from a temperature
of 1750°F, with equipment design adequate for 2000°F. The ash is then
conveyed to the utility's ash pile for disposal.
4.5.4 Steam Disposal
Normally, all steam is returned to the utility. In the case of
an independent site without a nearby utility, the steam from all sources
(flash drum, tube bundle, or water jackets) would have to be condensed,
and the condensate less the blowdown would be returned to the boiler
feedwater storage and pumped into both the developmental boiler and the
package boiler.
4.5.5 Particulate Removal
Hot flue gas at 1600 to 1750°F and at 155 psig leaves the boiler
together with most of the ash and some dolomite, as well as a small
amount of unburned carbon. The larger-sized solids are removed from
the hot gases in a single-stage cyclone. Solids may be returned to
the combustion zone if the carbon loss is high, but it is believed that
the combustion zone is large enough to ensure adequate residence time
for complete reaction of the coal. With complete combustion and negligible
solid carbon carry-over, the first-stage cyclone dust will be sent to the
cooler through lock hoppers. The flue gas will then be sent to a final
cleanup consisting of a centrifugal or tornado-type cyclone. Most of
the particles 5 vi and larger are removed. If this equipment should
prove unsatisfactory for either gas-turbine or pollution control, space
is allowed for inclusion of alternative particulate removal equipment such
as sand filters or ceramic filters.
4.5.6 Combustion Gas Disposal
Flue gases from the test cascade or from the turboexpander
will be quenched to drop the temperature. The pressure will be lowered
40
-------
to atmospheric, and then the gas will be sent to a stack through a
silencer. In a commercial unit, extra heat recovery equipment and
recuperators would be installed on the turbine exhaust gas to recover
the most heat possible from the flue gas in order to maximize the
thermal efficiency.
4.6 GAS-TURBINE TEST FACILITY
A test facility consisting of a rotating multistage turbine
and two stationary test passages is recommended for the development
plant. This test facility, used in conjunction with analytical studies,
will allow assessment of turbine blade erosion or deposition due to
particulate matter and hot corrosion and/or deposition initiated by
alkali metal compounds in the gas stream. The multistage test turbine
will provide information on the effects on erosion and deposition of
temperature variations through the turbine flow path, radial pressure
gradients, local flows due to stage to stage interactions, and particulate
carry-over to later stages. One stationary test passage, designed with
long particulate acceleration nozzles to obtain the high particle impact
velocities that will be typical of an electric utility gas turbine, will
be used to correlate test-turbine erosion to full-scale turbine erosion.
An additional full-scale first-stage turbine nozzle cascade will assess
damage to this highest temperature component. Figure 9 is a schematic
of the test facility indicating the two stationary test passages and
the rotating test turbine.
-------
Dwg. 621^18
Stationary Cascade of-^)
501 Stator Vanes
Hot Gas From Participate^
Removal Equipment
Solar
Recuperative
Centaur
Figure 9: Gas-Turbine Erosion and Corrosion Test Facility
-------
Conditions selected for the development plant turbine must
ensure operability of a large electric utility gas turbine. Operating
conditions must be duplicated in such a way that the potential for
condensation of volatile alkali metal compounds - sodium and potassium
chlorides and hydroxides and subsequent reaction to sulfate or molten
sulfate-chloride mixtures - can be studied. Provision must be made to
measure the rate of deposition of any deposits. This requires similar
gas and metal temperatures at points of corresponding pressure, and
similarity of flow conditions. Blading must be of hot corrosion resistant
materials so "hot corrosion" attack of the test turbine will be comparable
to attack of the large turbine. Erosion damage will be comparable if the
velocities of particulate impact with turbine components are comparable
in both magnitude and impact angle. A number of turbines capable of
handling the gas flow available from the development plant were identified
(Table 5). Detailed engineering comparisons were made between the turbines
shown in Table 6.
4.6.1 Test Turbine
The recuperative version of the Solar Centaur industrial gas
turbine appears attractive for the multistage rotating test vehicle.
This machine is of the right scale for pilot plant operation. Its gas
flow requirement (42 Ibs/sec) is less than the bed output (76 Ibs/sec)
but is sufficiently large to be useful as a demonstration of the
viability of the overall concept. The inlet temperature of 1600°F is
acceptable for use on the fluidized bed combustion system, and the
turbine can accept the required 10 atmosphere inlet pressure.
Corrosion resistance of the first two stages of the Solar
turbine is approximately comparable to that of a modern electric utility
gas turbine. The third-stage stator nozzles and blades should be replaced
with those made of more hot-corrosion resistant materials such as
alloys having at least the corrosion resistance of MAR 421.
43
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TABU 6
SURVEY OF CAS TURBINES FOR DEVELOPMENT PLANT**
Coapany
Cooper Bessemer
Oe Laval
Detroit Diesel
General Electric
General Electric
General Electric
Ingersoll Rand
1-H Heavy Ind.
Lycooing
Mitsui
Nordberg
Orenda
Rolls Royce
Ruston
Ruston
Ruston
SNECMA
SOLAR
Stal-Laval
Turboneca
Turboaeca
Turboaeca
Turbo Power
and marine
Canadian ®
Gas-Turbine
Model PR
Coberra 30 6
TP350 9
501 - K 9
7LM350 6
M1402 5.9
M1502 7.0
JT-35 8.5
T64-1H1-10 12.7
T35 8.0
SB150 6.5
G-55-2 7.4
OT-C-516 4.1
Proteus 7.3
TF1200 6.5
TB3000 5.85
TB1500 4.2
THS2000 14.5
T3001 8.0
HP components 4.0
fro. GT35
Marbore IX 3.85
Marbore VI 3.72
Larzac 9.0
PT12A 7
GG12A T
H101 6.6
Ha Va/PR
38 6.3
34 3.8
31 3.5
44 7.3
39 6.6
45 6.4
31 3.7
24.5 1.9
T T
28.7 4.4
60 8.1
23.8 5.8
43.40 6.0
23.8 3.7
43.0 7.2
23.4 5.5
54 3.7
32.2 4.0
65.0 16.0
17.6 4.6
21.2 5.7
57.0 6.4
T 1
T t
124 18.8
*Source: Sawyer's Gas Turbine Catalog for 1971
bDevelopment plant design conditions: plant capacity - 10 to 30 MW;
airflow, Wa - 20 to 65 Ib/sec; pressure ratio, PR - 10:1; Va/PR - 2.0 to 6.5.
44
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The regenerative configuration of the machine provides both
compressor outlet and hot gas feed in locations that are immediately
*
accessible. The recuperative Centaur is virtually identical in all
important characteristics to the present production model of the
Centaur (except for the compressor outlet and hot gas inlet) and should
be reliable.
Gas velocities relative to blading approach those of a large
electric utility gas turbine (similar to the Westinghouse 501) at the
rotor trailing edges and at the exit to the third-stage stator. At
other locations in the turbine, however, the gas velocities are considerably
lower, typically reaching only about 50% of the Westinghouse 501 gas
velocities at blade and vane leading edges.
If the particle velocities exactly follow the gas velocities,
the erosion rate of the Solar blading at the rotor trailing edges and
at the exit to the third-stage stator should be comparable to that in
the Westinghouse 501, while the erosion rates at the leading edges of
stator vanes and rotor blades may be as low as 6% of those at comparable
locations in the full-size machine. Because of the rapid acceleration
of the gas passing through the stator vanes and the deacceleration in
the rotor blading, particles as small as 2 y in diameter may have too
much inertia to follow the gas flow. An analysis of this effect in a
full-scale electric utility turbine showed that the variations in particle
velocities lagged the variations in gas velocity. This effect increased
with increasing particle size and resulted in particulate velocities
leaving the rotors that were significantly higher than the gas velocity.
A similar analysis of the test turbine flow path must be made to allow
the erosion data to be interpreted properly.
Note: In designing this facility, the turbine inlet design must be
carefully examined to control dust concentrations presented to the
first-stage vanes.
-------
4.6.2 Stationary Test Passages
The fact that impact velocities cannot be duplicated in the
rotating test facility is the reason that the stationary passage
erosion tests mentioned earlier are required. Particle acceleration
nozzles of sufficient length (# 4 ft with nozzles whose flow areas
decrease linearly with length) must be used to provide sufficient time
for particles to reach gas velocity before impacting the erosion targets.
Erosion targets must be carefully designed so that the impact angle as well
as the velocity is accurately known at the locations where erosion rates
are measured.
First-stage stationary vane erosion/deposition can be
measured in a stationary cascade provided that full-scale vanes are
used in the passage. Such a cascade would require about 16 Ibs of gas
for each nozzle passage used in the cascade. The effect of cooling air-
flows on deposition and erosion could be effectively studied in this
facility.
4.6.3 Test Rig — Required Engineering
The recuperated Solar Centaur turbine has a three-stage
turbine of which the first two stages are used to drive the axial com-
pressor. The compressor cannot be divorced from the turbine, and the
engine must be bought as a unit which would be mounted on a bed plate
including its own lubrication and necessary control system. The mani-
folding for the inlet and outlet to and from both the compressor and the
turbine would be part of the package, but Solar would not wish to under-
take the design of the hot gas ducting to the turbine. They would give
advice in the load transference system to the turbine manifolding. The
load absorption system for the power turbine, which could be either
generator or water brake, could also be supplied by Solar with the
mounting bed plate. It would, therefore, be necessary to engineer and
supply for this engine the following:
48
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• The hot gas ducting to the turbine
• The ducting from the axial compressor including the control
valve gear to allow it to be operated at correct conditions
• The cooling arrangements for the load absorption
• A control link-up between the hot gas flow control and
turbine speed to provide overspeed protection.
Table 8 estimates the cost of the rotating test rig. (The
costs of reblading third-stage rotors and stators have not been included.)
TABLE 8
APPROXIMATE COST OF ROTATING TEST RIG
BASED ON SOLAR RECUPERATIVE CENTAUR ENGINE
(Solar-Westinghouse Estimate)
Basic Cost of Solar Regenerative Gas Turbine $300,000
including Generator or Water Brake, Bed
Plates, Manifolding, Lubrication and Controls
Inlet and Exhaust Ducting for Axial Compressor 15,000
and Control Valves
Exhaust Ducting for Turbine Expansion Joint, 30,000
etc.
Turbine Inlet Ducting. Design and Manufacture 75,000
including Control Valves
Cooling System for Load Absorber 5Q,000
TOTAL $470,000
Table 9 estimates the cost of the two test passages.
TABLE 9
COST OF TWO TEST PASSAGES
Design $ 60,000
Manufacture of Two Test Passages 200.000
Including Control Valves
TOTAL $260,000
Estimated Total Test Facility Cost. $730,000
49
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4.7 REGENERATION/SULFUR RECOVERY
Unlike Che boiler where a design concept is established,
sufficient data are not available to permit the selection of a preferred
regeneration process (see Volume I). A process might be selected for
the development plant on the basis of available data, but the available
data are inadequate to design equipment. Several key parameters which
determine the equipment sizing cannot be specified. Areas of uncertainty
include:
• Sulfur in the spent stone and stone circulation rate from
the boiler
• Regenerator operating conditions which determine the
quantity of heat which must be supplied to or removed
from the process
• SO. or H.S concentration which is related to gas supply
requirements to the regenerator and the sulfur recovery
equipment.
An evaluation was made to determine if a regeneration system
could be designed with sufficient flexibility to study alternative
processes. Such flexibility cannot be provided economically at this
time. Since sufficient information is not available, the plant is
designed for once-through operation, and a regeneration system is not
included in the preliminary design. Provisions are made for a regeneration
system — space, stone feed to the boiler, and removal — which can be
installed at a later date.
4.8 INSTRUMENTATION AND CONTROL
Instrumentation and control for a commercial plant are discussed
in Volume I, Section 5. The development plant will provide the opportunity
to test and demonstrate the proposed operating procedure and controls.
Control of the boiler differs slightly from the standard
once-through boiler practice but is very similar to the process Industry's
practice. In a conventional boiler, variation in the steam side
operation affects the radiant combustion zone only very slightly. In
a fluidized bed unit, however, a slight variation in steam flow
-------
rate, temperature,or heat transfer immediately affects the fluidized
bed temperature.
For the development boiler, the steam pressure is controlled
at 2400 psig, which is in line with modern power plant practice for
subcritical installations. The superheat outlet temperature is
limited to 1000°F; this temperature readjusts the water-flow control
rate to the tubes in the fluidized bed. The fluidized bed is main-
tained at the proper pressure by back-pressure control on the effluent
gas or on a by-pass around the turboexpander. The temperature in the
fluidized bed is used to readjust the coal feed rate, automatically,
after which the air rate is manually adjusted to provide the excess
combustion air at the desired percentage of the flue gas.
The reason for manual readjustment of the air rate is that
a very slow response is desired so as not to destroy the fluidized bed
characteristics of the boiler. Too rapid a response in air rate may
either entrain the entire bed or cause the fluidized bed to collapse.
The emergency control systems will involve immediate stopping
of the flow of coal to the boiler. This will occur under such condi-
tions as:
• Power loss or failure
• Instrument air loss
• Low pressure in fluidized bed
• High pressure in fluidized bed
• Low-pressure combustion air
• Low-pressure injection air.
If the coal flow is halted by an emergency condition, the air-
flow will continue for five minutes and then slowly by-pass the boiler.
The air compressors will then be stopped automatically.
The demonstration of satisfactory operation of a fluidized
bed boiler depends upon both the efficient generation of steam as well
as upon the reduction of pollutants such as S0_, N02,and particulates.
51
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To reasonably demonstrate satisfactory pollution control, the effluent
flue gas will be monitored for particulates, S0_,and NO ,as well as
for the usual effluents of CO*, 0-, and CO.
Particulates can be monitored by means of a beta gage
attenuation of particles deposited on a moving tape (Freeman Laboratories)
or by means of particles deposited on the surface of piezoelectric
quartz crystals (Thermal Systems, Inc.). These methods allow a cal-
culated value of particulate concentration in weight of solids per unit
volume of gas flow; but it is also necessary to determine particle size
distribution for proper operation of cyclones and dust removal equipment,
and for extended operation of the turboexpander. The size distribution
can be determined intermittently by means of a multijet impactor
(Monsanto Enviro-Chem Systems, Inc.) or by a stack gas sampler
(Anderson 2000).
Flue gas components such as SO-, NO™, C02, SO, can be analyzed
by infrared and/or ultraviolet methods, oxygen by paramagnetic methods, and
NOX by Chemiluminescence.
4.9 PERSPECTIVE VIEW
A preliminary arrangement of the development plant equipment
is shown in the perspective drawing shown in Figure 10. The fluidized
bed boiler is contained within the vertical cylindrical vessel in the
foreground; behind it and to the right is the coal drying and sizing
equipment. Coal and dolomite storage silos and feed systems are shown
behind and to the left of the boiler. A compressor shelter in the
right foreground has been provided for the air supply system.
The entire installation is contained within a 185 ft x 200 ft
site. The top of the pressurized fluidized bed boiler is about 95 feet
above grade, and the highest point of the particulate removal system
is about 115 feet above grade.
52
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AVAILABLE
DIGITALLY
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The structure lias been designed to provide ease of access
to the boiler and its accessory equipment for maintenance and for
normal operating checks. Also, gravity flow of solids Into the solids
feeding vessels from elevated surge bins is utilized to provide for
maximum solids flow reliability.
4.10 PLANT MODEL
A 3/16-in.scale model of the pressurized boiler development
plant and a 3/8-in. scale cutaway of the boiler were constructed. Photos
of the model are shown in Figures 11 and 12. These models will be
used to illustrate the boiler concept and to provide a tool for explaining
the development plant concept, selecting a site, and assembling a
project team.
55
-------
Figure 11: 30 MW Pressurized Fluid Bed Boiler Demonstration Facility
-------
Figure 12: 30 MW Pressurized Fluid Bed Boiler Cutaway
57
RM-59197
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5. EXPERIMENTAL PROGRAM
The experimental program for the pressurized fluidized bed
boiler development plant has three objectives:
• To verify that the technical findings made with smaller
scale equipment (such as those relating to combustion,
pollution abatement, heat transfer, materials, etc.)
apply directly or can readily be extrapolated to large-
scale equipment
• To study technical problems that can only be studied on
larger scale equipment (such as those relating to coal
and lime feeding, nonuniform temperature distributions,
erosion-corrosion-deposition on moving blades of
turbines, etc.); and to demonstrate that no new technical
problems (such as vibration and fatigue of boiler tube
bundles, etc.) are encountered
• To explore advanced fluidized bed boiler concepts (such
as steam generation conditions of 4500 psi/1200°F/1200°F
with gas-turbine inlet temperatures of 1900 to 2200°F,
recirculating bed boilers, etc.).
The end goal is to provide the technical and economic information, and
to create the confidence necessary for proceeding with the installation
of a demonstration pressurized fluidized bed combustion power plant.
In order to meet these objectives and to reach the goal,
measurements are required over a variety of operation conditions — inlet
and outlet flows, compositions, and temperatures — sufficient to carry
out complete material and heat balances. Such balances permit the
computation of combustion efficiencies and heat transfer rates. Analyses
of the combustion gas stream emerging from the boiler are required for:
• Primary gaseous components — 0_, C0_, H-O, CO, H , N-,
and unburned hydrocarbons
59
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• Pollutant gases — S0_ and NO
£• X
• Particulates — ash, attrlted sorbent, unhurncd carbon
(both composition and particle size distribution)
• Trace contaminants.
Some gas composition profiles across the bed and through the bed and
disengaging zone are desirable. Occasional measurements of the compo-
sition and particle size of solids at various points in the bed are
helpful in analyzing boiler operation. Measurements of boiler tube
vibration and fatigue and of tube and turbine blade erosion and corrosion
are required to estimate long-term durability of boiler and turbine.
Operating conditions at which measurements should be obtained include
primarily the pressure, temperature, airflow, fuel/air ratio, sorbent/
sulfur ratio, and bed height over ranges anticipated in the operation
of a commercial plant.
To convince utilities that the concept of pressurized fluidized
bed boiler operation is practical as well as economical, the boiler must
produce steam reliably, must be capable of easy turndown to 50% of its
capacity, and must produce combustion gases sufficiently clean to meet
pollution control regulations and to provide reliable, long-term turbine
blade life.
In order to be convincing, the experimental program must produce
data on:
• Boiler dynamic operation characteristics
• Durability of materials and construction in the boiler and turbine
• The ability to provide any maintenance necessary to achieve
- Uniform and efficient heat transfer
- Particulate removal from combustion gases
- Solids feeding to and from a pressurized system.
To meet the requirements just outlined, the experimental program
must demonstrate continuous, controllable coal and dolomite feeding in a
sufficient number of feed lines to give uniform bed operation for at least
60 days without interruption.
60
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Concurrent with the boiler proof run, data on NO and SO.
A £f
emission, and on particulate content at the turboexpander inlet, will
be acquired.
Following a 60-day proof run, the boiler system will be
subject to a series of tests to experiment deliberately with the
start-up, shutdown, and emergency shutdown systems, controls, and
operating techniques »in order to determine the best methods for coping
with and controlling transient phenomena.
The foregoing experimental program will permit the design
and construction of a full-scale power-producing combined cycle
pressurized fluidized bed boiler.
The operation of the fluidized bed combustion boiler
development plant will be carried out in three phases outlined in
Table 10. In the first phase of the experimental program, operating
procedures will be proved put; engineering design and performance data
will then be gathered on a variety of coals and limestone or dolomite
sorbents. In the second phase, overall systems — boiler, gas-turbine,
and regenerator — control and operation will be investigated; and the
long-term (60-day) boiler run will be carried out. Finally, in the
third phase of the program, modifications will be made in the boiler
to enable the study of advanced boiler designs and operating conditions.
Tests will then be carried out to evaluate the effectiveness of such
modifications.
61
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TABLE 10
OPERATION OF THE PRESSURIZED FLUIDIZED BED
COMBUSTION BOILER DEVELOPMENT PLANT
Phase I Boiler Operating Characteristics
(boiler, test passage, no regeneration)
• Ambient T&P operation
- Check out solids feeding and withdrawal
Fluldization
Particle carry-over
Water circuitry/boiler tube configuration
- Use dolomite only
• Ambient T, high P
- Check out solids feeding and withdrawal
Fluidlzatlon
Particle carry-over
Water circuitry/boiler tube configuration
- Use dolomite only
• Start-up Procedure
- Check out using start-up burner and dolomite
w/o coal: ability to reach 700-800°F
water circuitry
air control
• Operate with low-sulfur, non-caking coal
• Operate with low-sulfur, caking coal
• Operate with high-sulfur, caking coal
Phase II Long-Term (60 day) System Operation
• Boiler control capabilities
turndown, operating ranges
• Boiler/gas-turbine expander operation
• Operate with boiler/gas-turbine expander/
regeneration
Phase III Concept Alternatives
• Advanced steam conditions
• Boiler tube configuration alternatives
• Higher gas-turbine temperature
• Possible expansion of plant to a four-bed
stacked module
• Recirculating bed concept
62
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6. COST ESTIMATE
Factored estimates were prepared for plant capacities from
22,000 Ib coal/hr to 33,000 Ib coal/hr and operating pressures from
170 psig to 320 psig. Plant costs were prepared for a 'stand alone1
plant —not adjacent to a power plant —and a development plant
adjacent to an existing power plant. A summary of the capital cost
estimates, factored from quoted equipment costs, is presented in Table 11.
Plant cost for the nominal 22,000 Ib coal/hr plant at 170 psig is
* $10 million erected excluding the gas-turbine test facility. The
cost of the boiler unit and extra bundles is •*» $940,000 — excluding
erection. The main air compressor for the 170 psig plant represents
the other major equipment cost: $940,000 excluding erection. The
proposed gas-turbine test facility will add ^ $600,000 to the plant
cost. The operating cost for the plant is estimated to range between
$2.4 and 3 million per year.
TABLE 11
CAPITAL COST
Coal Capacity
Ib/hr
22,000
33,000
33,000
Boiler Pressure
psig
170
320
320
Site
adjacent to
power plant
adjacent to
power plant
independent
site
Plant Cost
Delivered & Erected
(Factored Estimates)
$ 9,730,000
16,420,000
19,170,000
63
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7. IMPLEMENTATION
The schedule presented in Figure 13 indicates the basic steps
toward a commercial fluidized bed combustion boiler power system which
will:
• Reduce capital cost
• Increase operating efficiency
• Reduce pollutant emissions
for electrical energy generation from fossil fuels. Preliminary plans;
a detailed design, procurement, and construction schedule; and an
overall plant cost estimate have been completed. These plans, schedules,
and estimates will be used to locate a plant site, to develop financial
backing, and to form a team to construct, operate, evaluate, and lead
in the development plant effort. This team should include EPA (and
perhaps also other governmental agencies concerned with fuel utilization
and power generation), the electric utility industry, electrical generation
equipment manufacturer(s), and steam generation equipment supplier(s).
Detail design and construction of the development plant could begin in
1974. Information from various laboratory, bench, and pilot operations
throughout 1973 and 1974 will be factored in the plant design. Operation
of the development plant could begin in 1976. Sufficient information
will be available from the development plant to begin design of a
demonstration fluidized bed combustion boiler power plant in 1977.
This plant could be operational late in 1980.
The program represented by the development plant design and
the projected schedule may be altered to adapt to the project team and
site selected. Several demonstration program options are available.
Five alternatives have been developed for demonstrating the pressurized
boiler concept which account for variations in potential plant sites.
Table 12 presents projected boiler designs, plant output, and plant costs
for the five options. Demonstration of the total power plant concept
can also be achieved by a number of different system configurations. Six
alternatives have been developed and are presented in Table 13. Possible
65
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Figure 13
PRESSURIZED FLUID BED BOILER COMBINED GAS-AND STEAM-TURBINE POWER PLANT
ILLUSTRATIVE DEMONSTRATION PLANT PROGRAM
1973 . 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983
Fluid Bed Steam Generator
Demonstration
Preliminary Design
Assemble Project Team
Detailed Design/Construction
Operation
Power Plant Demonstration
Preliminary Design Analyses
ON Establish Program
(Par t ic ipants/Funding)
Detailed Design
Construction
Operational (Experimental)
-------
TABLE 12
DEMONSTRATION OF BOILER CONCEPT
1.
I Ves
(dia
Stand- Alone
sel No. of Coal
/ft) Beds i Input
1 Ib/hr
Independent Air Supply 12 1 22,000
2.
Independent Water Supply
Steam Directly to Condenser
Process Steam
Gas Generator Gas Turbine 12 1 22,000
3.
Steam to Process
Condensate Return
Gas Turbine Power
Gas Turbine with Generator 12 1 22,000
Independent Water Supply
Steam Directly to Condenser
12 2 44,000
4.
Gas-Turbine Pwr. & Process Steam 12 1 22,000
Gas-Turbine with Generator
Steam to Process
Condensate Return 12 2 ^^
5.
Steam Plant Integration 12 1 22,000
Gas-Turbine with Generator
Water from Steam Plant ,, , ,, nnn
Steam to Existing Turbine t*,uuu
Output
180 x 106 Btu/hr
(rejected to condenser)
185 x 103 lb/hra
(process steam)
3.0 MW (G.T. Power)
180 x 106 Btu/hr
(rejected to condenser)
6.0 MW (G.T. Power)
360 x 106 Btu/hr
(rejected to condenser)
3.0 MW (G.T. Power)
185 x 103 lb/hra
(process steam)
6.0 MW (G.T. Power)
370 x 103 lb/hra
(process steam)
3.0 MW (G.T. Power)
27 MW (S.T. Power)b
6.0 MW (G.T. Power)
54 MW (S.T. Power)b
i Cost
j Capital
l( ins tailed equip)
$12.5 x 106
$11.9 x 106
$12.8 x 106
$18.1 x 106
$12.2 x 106
$17.3 x 106
$10.0 x 106
$14.1 x 106
Operating
($/yO
2.5 x 106
1.7 x 106
1.8 x 106
2.7 x 106
1.7 x 106
2.7 x 106
1.7 x 106
2.6 x 106
.Based on process steam conditions of 300 psig and 500°F.
Based on 2400 psia, 1000°, 1000° steam conditions.
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oo
TABLE 13
DEMONSTRATION OF PLANT CONCEPT
1.
2.
3.
4.
5.
6.
Single Boiler Module
Single Boiler Module
Two Boiler Module
Two Boiler Modules
(back-fitted into
existing steam plant)
Single Boiler Module
Single Boiler Module Steam
Generator for Eugene, Ore.
Installation
Module
(dia-ft)
12
17
12
12
12
(1 bed)
12
G.T.
Model
English Elect.
EA1
W251
W251
W251
Canadian ©
W41 (Mod.)
English Elect.
EA1
Output
™ Cap
Cost
ital Operating
-v. 75 $43.8 x 106 $4.1 x 106/yr
'v.lSO $69.8 x 106 $6.6 x 106/yr
-x.150 $69.8 x 106 $6.6 x 106/yr
^25 $34.9 x 106 $3.4 x 106/yr
additional
30 $26.2 x 106 $2.2 x 106/yr
13 MW (G.T.) $19.3 x 106b
422,000 Ib/hr
of steam at
1450 psia-950°F
aTotal plant costs
Installed equipment cost only
-------
boiler designs, gas turbines, and plant costs are indicated in the table.
Selection of a particular system will depend on the project team,
available site, and economics. An understanding of these and other
options will be used to develop a firm demonstration program.
The benefits of a pressurized fluid bed boiler power plant
in the economical generation of electrical energy from fossil fuels with
minimal pollutant emissions amply justify vigorous pursuit of the
recommended program.
69
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8. REFERENCES
1. Westinghouse Research Laboratories. "Evaluation of the Fluidized
Bed Combustion Process." Final Report to the Office of Research
and Monitoring of the Environmental Protection Agency on
Contract CPA 70-9, November 1971. Available from NTIS as
PB-211 494, PB 212 916, PB 213 152.
2. National Coal Board (U.K.), "Reduction of Atmospheric Pollution."
Final Report to the Office of Research and Monitoring of the
Environmental Protection Agency, June 1971.
71
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APPENDIX
Pressurized Fluid Bed Boiler Development Plant
Designs and Estimates
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PA8E 1
INDEX:
Page No.
!• ABSTRACT I~1
II. DESCRIPTION OF PLANT
1) Description of Plow II-1
2) Schematic Flowsheet II-2a
3) Heat and Material Balance II-8
U) Engineering Flowsheet 11-12
in. BASIS OP DESIGN III-1
1) Range of Operating Conditions III-3
2) Site Location III-3
3) Auxiliary Systems III-li
U) Vfcter and Steam Supply and Disposal III-7
5) Spent Dolomite and Ash Disposal III-8
6) Test Cascade and Future Turbine Expander III-8
7) Combustion and Qas Disposal III-9
IV. DETAILED BOILER DESIGN IV-1
V. DESIGN PROBLEMS AND SOLUTIONS V-1
VI. EXPERIMENTAL PROCRAN
1) Startup and Shutdown Procedure VI-1
2) Boiler Performance Test VI-6
3) Test for Operability VI-7
U) Reliability Demonstration VI-10
5) Tests of Pollution Abatement VI-10
6) Test of Long Range Objectives VI-11
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FOSTER WHEELER CORPORATION REF. 11-5.2331
DATE April 1973
PAGE ii
INDEX (continued)
Page No.
VII. PLANT CONSTRUCTION
1) Safety and Engineering Control System VII-1
2) Utilities VII-U
3) Plot Plan and Elevations VII-6
li) Schedule of Design and Construction VII-6
£) Cost Estimate and Economics VII-6
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FOSTER WHEELER CORPORATION
LIST OF TABLES
REF. H-52331
DATE April 1973
PAGE
TABLE I
TABLE II
TABLE III
TABLE IV
TABLE V
TABLE VI
TABLE VII
TABLE VIII
TABLE IX
TABLE X
TABLE XI
TABLE XII
TABLE XIII-A
TABLE XIII-B
TABLE XIII-C
Primary Cyclone Efficiency
Material Balance
Heat Balance
Basis of Design
Coal Specification
Sorbent Specifications
Boiler Tube Material
Pressure Drop
Utilities
Capital Requirement
Working Capital
Manpower Requirement
Plant Cost Estimate
Cost Estimate - Major Equipment
Cost Estimate - Materials & Labor
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FOSTER WHEELER CORPORATION
REF. 11-52331
DATE April 1973
PAGE iiii
DIAGRAMS AND DRAWINGS
FIGURE NO. I
FIQURE NO. II
FIGURE NO. Ill
a,b,c
FIGURE NO. IV-A
FIGURE NO. IV-B
1,2,3,U
FIGURE NO. V
FIGURE NO. VI a
b
c
d
e
f & g
h
i
FIGURE NO. VII
FIGURE NO. VIII a
b
FIGURE NO. IX a
b
c
FIGURE NO. X
Perspective View of Plant
Schematic Flow Diagram
Engineering Flow Diagram
Original Boiler Design
Pressurized Fluidized Bed Boiler
Effect of Heat Flux on Burnout
Steam Separator D-110
Lock Hoppers D-112 & D-U3
Primary Cyclone Seal Drum D-llU
Primary Cyclone Lock Hopper D-ll£ & D-117
Quench Drum D-118 A & B
Cyclone Drum D-120
Main Air K.O. Drum D-121
Injection Air K.O. Drum D-123
Boiler Performance Heat Balance
Operating Schedule
Emergency Control System
Plot Plant
Plans & Sections
Plans & Sections
Construction Schedule
After
Page No.
See Figure 10, text,
11-11
IV-2
IV-8
IV-17
A-II-5
A-II-5
A-II-£
A-II-S
A-II-5
A-H-£
A-II-5
A-II-S
VI -6
VI-1U
VII-1
VII-7
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FOSTER WHEELER CORPORATION
I. Abstract
A coal fed developmental pressurized fluidized bed boiler tu generate
steam and control S02, NOX and particulates has been designed. Alternates
investigated include construction adjacent to a power plant vs. an inde-
pendent site, coal feed rate at 22,000 Ibs/hr (equivalent to 30 MW) vs.
coal fed at 33j000 Ibs/hr and combustion side pressure of 170 psig vs.
320 psig.
Flexibility has been designed into a single fluidized bed boiler to
generate steam in one of three different sized tube bundles, two different
fluidized bed grid plates, two different piping arrangements for water-wall
tubes, superficial fluidized bed velocities of 6 to 15 ft. per second and
bed heights of 10 to 30 feet. Steam is generated at 2l|00 psig and 1000°F.,
with the boiler capable of operating in preheat, evaporation or superheat
mode or all modes in series.
Capital investment for the case of coal feed rate of 22,000 Ibs/hr. at
170 psig boiler casing pressure is $9,730,000 with the total program cost
for 3 years of operation including capital investment is $17,02U,000. Other
alternates increase both capital and operating expense.
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II
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE H-1
II. Description of Plant
1. Description of Flow
The flow through the plant is shown in Figure IE, Process Flow Diagram
OP-721-U33 and on Engineering Flow Diagrams OP-721-U2.}, U21;, and 1*26.
The developmental boiler plant includes coal receiving, crushing, drying
and storage. Both coal and dolomite receiving and storage. Both coal and
dolomite are injected into the fluidized bed boiler using a "Petrocarb"-type
injection system. Combustion air from a centrifugal compressor passes down
the annulus of the boiler between the water wall and boiler shell, then
passes up through the grid to the fluidized bed. Steam is generated in the
water wall tubes and in the tube bundle of the boiler. Flue gas passes
through two stages of cyclones to remove particulate matter. Part of the
flue gas flow is diverted to a turbine cascade to test turbine blades and
the remainder is vented to the stack. A portion of the flue gas can also
be diverted to a future turbine expander. Both ash entrained in the flue
gas and removed by the cyclones and spent dolomite are depressured, cooled
and sent to disposal.
Wet coal from railroad hopper car will be discharged to the below-grade
Wet Coal Hopper, CR-101. The coal is then conveyed to the Coal Dryer, RK-101,
where the moisture content of the coal is reduced from 10.0 vt% to 3.3 wt$.
The dried coal is then discharged to a Vibrating Grizzly where all oversized
coal is fed to a Coal Crusher, SR-101. The coal crusher will normally yield
coal particle size of VxO. Preheated air from Air Heater, H-101, is used
for drying the coal. The elutriated coal dust from the coal dryer is first
recovered in the Primary Cyclone, G-103, and finally in a Bag Filter, F-102.
The recovered particulate matter is combined with the crushed coal. The
coal is then forwarded by a Redler-type Dry Coal Conveyor, CR-102, to the
Coal Elevator, CR-103. The coal handling and processing facility in this
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE II-2
II. Description of Plant (continued)
1. Description of Flow (continued)
section is designed for 60 short tons per hour, based on a l|0-hour week.
The Coal Silo, D-102, is designed to hold two-days inventory. The
silo utilizes a "live shelf" bin section for supplying of coal to the
Lock Hopper, D-105. The lock hopper will replenish the Petrocarb's
Injection Drum, D-106. Four (U) coal pneumatic conveying lines are pro-
vided from the injection drum. The feed rate of coal will be carefully
controlled to maintain proper boiler bed temperature.
To replenish the "live shelf", coal is withdrawn continuously from
the coal silo and conveyed to the "live shelf" via the coal elevator.
The fresh dolomite for the unit will be purchased as dried and screened
to V x 28 mesh. The dolomite will be conveyed from the covered railroad
car by Dolomite Conveyor, CR-10U, and Dolomite Elevator, CR-105, to the
Dolomite Silo, D-108. The dolomite silo is designed to hold two days of
inventory. This silo also employs a "live shelf" bin whereby the dolomite
is first fed to the Lock Hopper, D-109, under atmospheric pressure. Period-
ically, the lock hopper is pressurized and feeds the Dolomite Injector, D-lll,
to replenish its supply. The dolomite is fed continuously to the boiler
from the dolomite injector under a controlled rate.
Combustion air required for the fluid bed boiler is provided by the Main
Mr Compressors, C-101. Compressor, C-101, is designed for 185 psia discharge
pressure. In addition to the combustion air requirement, Compressors, C-101,
will also provide:
a. Injection and pressurizing air for the Petrocarb's Bulk Material
Handling System. This air is obtained from C-103 which takes suction
from C-101.
b. Instrument purge and blowback air which is also obtained from C-103,
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PAGE NOT
AVAILABLE
DIGITALLY
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FOSTER WHEELER CORPORATION
PAGE 11-3
II. Description of Plant (continual)
1. Description of Flow (continued)
b) (continued)
this portion of air is dried to -UO°F. dew point.
c) By-pass air to Cyclone, G-101, to maintain the cyclone
efficiency required.
d) Excess air from the unit which will be vented for the
Stack, ST-101.
Combustion air enters from the top of the boiler. This air will also
be used to protect part of the discharge line and unprotected portion of
the boiler from high temperature. The air then enters from the bottom of
the boiler through a grid plate. The grid is equipped with perforated
nipples which divert the air downward to cool the grid plate. Four (U) coal
injection nozzles enter from opposite sides of the wall tubes.
Three (3) ignition guns are provided above the grid for startup. In
n' addition, an Air Preheater, H-102, has been provided. The preheater will
<• raise the bed temperature to 1000 to 1200°F. to initiate the coal combustion.
p The preheater, as well as the igniters, will be taken out of service as the
bed temperature is established.
The heat generated in the boiler will be removed by the horizontal tubes
bundle as well as the wall tubes through either boiler feed water preheat,
steam superheating or evaporator. Steam generation in the horizontal tube
bundle is based on a once-through boiler principle. Steam generation in
the wall tubes can be on either a once-through or a forced circulation
principle. A Steam Drum, D-110, has been provided to separate the steam
from boiler feed water as required.
Three (3) horizontal tube bundles will be provided designed for 60Jg,
100$ and l£0# of the normal capacity which corresponds to cases A-2, A-l,
A-3. In addition, a single-loop test coil will also be provided for
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE II ~k
II. Description of Plant (continued)
1. Description of Flow (continued)
various testing purposes. The test loop will be designed to test metallurgy
under conditions of erosion, corrosion and severe temperatures. Heat transfer
can also be tested under conditions of nucleate and film boiling.
The fluidized medium in the boiler consists essentially of dolomite with
a small amount of coal. At proper operating temperature, about 9056 of the
S02 generated by the coal combustion will be picked up by the dolomite in
the form of calcium sulfate (CaSOl;). To maintain a high efficiency of SQ2
removal the dolomite requirement is greater than stoichiometric. The re-
quired fresh dolomite is fed from top of the bed at a carefully controlled
feed rate to meet the required calcium to sulfur mol ratio. Spent dolomite
from the unit is withdrawn from the bottom of the bed to the Spent Dolomite
Lock Hopper, D-112 or 113. The dolomite withdrawal is controlled by the
boiler fluidized bed level controller which regulates one of the two oper-
ating slide valves to the spent dolomite lock hopper. A bed level recorder
has been provided at the lower section of the boiler. This recorder is used
for continuous monitoring of the dolomite bed density and height.
The disengaging space above the boiler bed can be adjusted by extending
part of the outlet pipe into the dilute phase. The flue gas with its en-
trained dust will be directed to the First-State Cyclones, G-101 A, B, C
or D, where over 88$ of the dust is recovered. Due to the various oper-
ation modes of the boiler, two of the four cyclones are equipped with spool
pieces whereby one or two cyclones may be taken out of service to maintain
the recovery efficiency. At normal operating conditions the inlet velocities
to these cyclones are approximately Sh fps. It is possible to operate the
cyclones at 1$% of rated capacity without appreciable loss of efficiency.
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE II-5
TABLE I
PRIMAIff CYCLONE EFFICIENCY
Dust removing efficiency is1 a function of particle size and for
a given dust size range it is also a function of velocity. The
following variation in dust removal efficiencies was received from
Ducon for various capacities:
Inlet Dust Removal
Capacity Velocity Est. Eff.
% of Max. FPS %
100 53.5 89.60
3 75 UO.l 88.67
| 5 26.7 85.28
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FOSTER WHEELER CORPORATION REF. 11-^2331
DATE" April 1973
PAGE II-6
II. Description of Plant (continued)
1. Description of Flow (continued)
When the capacities are further reduced, provision has been made to intro-
duce by-pass air to the cyclones to maintain the proper velocity at turndown.
The dust recovered from the cyclones will be directed to the Primary
Cyclone Seal Drum, D-lllj.. When this drum reaches its high level it. will
discharge the dust to the Primary Cyclone Lock Hopper, D-11J>, through a
series of interlocked valves. When D-llU reaches its low level, its outlet
valve will be shut to maintain a minimum level. The solid accumulated in
D-115 will then be discharged to the Spent Dolomite Cooler, RC-101.
The effluent from Cyclones, G-101, will be forwarded to the Cyclone
Drum, D-120. The cyclone drum contains four (I;) Second-Stage Cyclones,
G-102A, B, C & D. Again, two of the four cyclones will be fitted with spool
pieces so that one or more cyclones can be'taken out of service to suit the
mode of operation. When D-120 is full, the dust will flow to the Secondary
Cyclone Lock Drum, D-117, through a series of interlocked valves. The solids
in D-ll? are then weighed and discarded to the spent dolomite cooler.
The flue gas from G-102 cyclones are then divided into two streams. Part
of the flue gas will go to the Turbine Cascade unit. The main purpose of this
unit is for erosion and high temperature tests of various types of turbine
blades. Due to the presence of CO and coal dust in the flue gas, the flue gas
temperatures may be as high as 2000°F. as a result of after-burning. The flue
gas is quenched by water to 600°F. or less,before discharging to the Quench
Drum, D-118B.
The remaining flue gas stream is also quenched to 600°F. The boiler
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FOSTER WHEELER CORPORATION REF. n-52331
OATE April 1973
PAGE H-7
II. Description of Plant (continued)
1. Description of Flow (continued)
back pressure controller is located on this stream downstream of D-118A.
The effluents from D-118A & B is forwarded to the Flue Gas Silencer, SL-101
and finally to the stack.
Spent dolomite discarded from D-112 or 113, and flyash from D-115 and
D-117 will be forwarded to the rotary Spent Dolomite Cooler, EC-101. The
waste matter will be cooled to approximately 300°F and discarded via the
Spent Dolomite Conveyor, CR-106.
-------
TABLE H
MATERIAL BALANCE
Case A-l
Stream
No. Description
1 Wet coal from EL
2 Sized Coal
3 Dolomite
k Dolomite
5 Coal to R-101
6 Spent Dolomite
7. Fines Discarded
Temp. Pressure
°F psia
Ambient 15
100 15
Ambient 15
Ambient 15
Ambient 176. U
min.
1600 176. k
1600 165
Flow Rate
Ib/hr Composition
120,00000 Moisture
VCM
Fixed Carbon
Ash
Total
1U,21|Q(*) C
H
0
N
S
Ash
Total
150,00000 CaCOo
MgC03
Inerts
Total
35j728 Same as Stream 3
22,000 Same as Stream 2
20,979 CaSOi.
CaO
MgO
Inerts
Ash
Total
2900 Ash
Carbon
Dolomite
Total
Particle
Size
10.0 wt.g l*g"xO
36.8 "
U5.3 "
7.9
100.0
71.3 wt.g V x 0
5.U "
9.3 "
1.3 "
h.3 "
8.5 "
100.0
U9-59 wt.# V x 28 mesh
U9.36 »
1.05 "
100.00
%" x 28 mesh
V x 0
18.0 wt.Jg ' V x 0
39.3 "
39.6 »
1.8 "
1.3 "
100.0
60.0 wt.^
30.0 "
10.0 "
100.0
-------
TABLE II
MATERIAL BALANCE (continued)
Case A-l
Stream
No.
8.
9.
Fines
Fines
Description
Discarded
Discarded
Temp.
oF
1600
1600
Pressure
psia
165
165
Flow Rate
Ib/hr
U432
Same
Same
Composition
as Stream 7
as Stream 7
Particle
Size
(*) Flow rate based on 1;0 hr. operation per week
-------
TABLE II
MATERIAL BALANCE (continued)
Case A-l
Stream Temp
Mo.
10
11
12
13
Hi
15
16
17
18
19
Description °F
Air to C-101 Ambient
Air to C-103 100
Air to R-101 500
Air By-passed 500
Flue Gas from R-101 1600
Flue Gas from G-101 1600
Flue Gas to Turb. Cascade 1600
Flue Gas to Quench 1600
Quench Water 200
Flue Gas to SL-101 600
Pressure
psia
1U.3
180
175
175
168
165
165
165
185
Atm
Flow
Ib/hr
366,501;
53,500
238,988
73,611
273,737
273,737
60,000
213,737
65,683
339, U20
Rate
MMSCFD
116.8
17.0
76.17
23.1*6
82.8
82.8
18.1
6U.7
131 gpm
116.1
°2
N2
H20
02
N2
H20
Same
Same
C02
CO
H20
°2
N2
SOo
NO
Same
Same
Same
C02
CO
H20
02
N2
S02
NO
Composition
20.6 M %
77.3 "
2.1 "
Total 100.0
21.0 M %
79.0 "
nil
Total 100.0
as Stream 10
as Stream 10
18.3 M %
0.2 "
8.5 "
1.7 "
71.2 "
1U8 ppn
198 pan
as Stream lU
as Stream lU
as Stream lU
11.5 M % •
0.12 "
U2.9 "
1.1 "
hk.h "
92 ppn
12l| ppr:
Dust
Loading
gr/ACF
20.8
-3.01
~ 0.30
~ 0.30
~ 0.30
M
g
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FOSTER WHEELER CORPORATION
REF. 11-52331
DATE April 1973
PAGE II- 11
TABLE III
HEAT BALANCE
around
Fluidized Bed Boiler
Case (A-l)
Datum: 77° F
INPUT
Stream
Dried Coal
Sen. Ht
Chemical (LHV)
Comb. Air
Fresh Dolomite
Fines Returned
Total Input
OUTPUT
Flue Gas
Spent Dolomite
Fines Elutriated
Reaction Heats
Lb/Hr
22,000
238,988
35,728
2,900
299,616
273,737
20,979
U,900
Temp.
op
77
500
77
1600
1650
1650
1650
MM Btu/Hr
0
275.0
2U.98
0
1.13
301.11
119.U
8.1
1.9
Reactions with Dolomite
CaCO-i + SOp + *
CaCO^ = CaO
MgCOJ = MgO
No Formation
*2 + ^2 '
%o2= CaSV
+ co2
NO
i- C02
-3.91
11. U
10.58
0.07
Incomplete Coal Combustion
C02 = C + 0«
co2 = co + %
Heat Loss
Total Output
>2
299,616
1.69
2.08
0.20
151.51
Heat Available for Steam Generation = 301.11 - l5l«5l
= Hi9.6 MM Btu/Hr
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PAGE NOT
AVAILABLE
DIGITALLY
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FOSTER WHEELER CORPORATION REF. H-52331
MTE April 1973
PAGE HI-1
III. Basis of Design
A pressurized fluidized bed boiler has been designed to demonstrate
the possibility of pressurized fluidized bed steam generation while de-
creasing pollution from the combustion of high sulfur coal. For this
study, an Ohio Pittsburgh No. 8 Seam coal will be burned at a normal
rate of 22,000 Ibs/hr with 10# excess air. The crushed coal is injected
into a fluidized bed consisting of particles of 28 mesh to %" dolomite.
The ash formed after combustion is less dense than the dolomite and is
elutriated out of the bed. Specifications for the coal and dolomite are
given in Tables V and VI.
Three boiler load conditions, heat and material balances have been
calculated for corresponding to 60#, 100# and l50# of normal coal rate as
indicated in Table IV Basis of Design. The tubes for steam generation
in the fluidized bed can be operated in the preheat, evaporation or super-
heat mode. The water wall tubes can be operated in the preheat and evap-
\ oration mode. It is also possible to operate the boiler to sequentially
preheat, evaporate and superheat by supplying boiler feed water preheated
to 5£0°F. to the water walls- and further penetrating water in the water
wall tube to 6?2°F. The preheated water is then evaporated and super-
/•
heated in the coils in the fluidized bed tubes. The superheat section
can also operate as a reheat section as the temperature profile is the
same but reheat pressure is lower than superheat pressure.
Equipment has been designed to supply sufficient fresh dolomite charge
for a maximum calcium to sulfur mole ratio of 6 to 1 or a regenerated
dolomite circulation rate to provide a maximum of 10 to 1 mole ratio of
calcium to sulfur, with makeup of fresh dolomite set at 1056 of the re-
generated dolomite rate.
-------
SEI-OEI 'ON U1JO.J
TABLE NO.IV
PRESSURIZED FLUIDIZED BED COMBUSTION BOILER
Basis of Design
A-l
100
ic.) Ib/hr 22,000
10
/hr 35,728
6/1
238,988
273,737
i psig 335 °0
ic 9.19
M/Btu/hr 1U9.6
A-2
60
13,200
20
21,U37
6/1
156,U28
177,283
218.9
6.00
85.7
..£2*
150
33,000
0
53,592
6/1
325,892
377,966
U83.9
13.28
222.0
o
CO
o
o
Case No.
Load Factor % of Normal
Coal Injection Rate (as
Excess Air %
Dolomite Injection Rate Ib/hr
Mol Ratio Ca/S
Combustion Air Rate Ibs/hr
Flue Gas Rate Ibs/hr
ACFS @ 16500F & 1?0 psig
Superficial Velocity ft/sec
Heat Absorption by Steam M/Btu/hr
m m
-::-It is not necessarily intended that case A-3 be operated with zero percent excess air;
rather, A-3 conditions indicate the maxijnum design air, coal and dolomite ratio. H-o
ro
VjJ
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FOSTER WHEELER CORPORATION REF. 11-^2331
DATE April 1973
PAGE III-3
III. Basis of Design (continued)
1. Range of Operating Conditions
The boiler has considerable flexibility built into the equipment speci-
fications. Coal and dolomite can be varied from 1056 to 13$ of normal flow
rates. Fluidized bed heights can be varied from 3 feet to 30 feet. Pressure
of the fluidized bed can be varied from atmospheric to 160 psig above the
fluidized bed. The boiler shell is designed for future operations of up to
320 psig. Two separate air distribution grids are provided for various
capacities from 60$ to 1J>0$ of normal design. Three separate steam gener-
ating coils are provided for 60$, 100$ and 150$ of normal steam generation.
Boiler feed water can enter at 212 to 6UO°F. with flow rates of up to
£00,000 Ibs/hr. The combustion air bypass control can accommodate 0 to 100$
of the total design capacity of the air compressor.
The fixed parameters are: the use of a single fluidized bed of approxi-
mately 35 square feet in cross-section, a steam pressure of 2UOO psig and
temperature of 1000°F. superheat (when operating in the superheat mode).
2. Site Location
The preferred location of the demonstration boiler is adjacent to a
large existing power plant where appropriate tie-ins could be effected for
supply of boiler feed water, coal, power and the disposal of ash and steam,
either saturated or superheated. Such a location would simplify and reduce
the cost of installation of the development boiler.
If it is not possible to locate close to the site of an existing utility,
then it will be necessary to provide various auxiliaries to the developmental
boiler such as condenser, water purification equipment, boiler feed water
storage, as well as feed water pumps, and cooling towers.
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE III-U
III. Basis of Design (continued)
3. Auxiliary Systems
a) Compression
A major auxiliary with respect to cost is the air compression
systems. Air is required for combustion, for pneumatic injection,
for pressuring lock hoppers and for instrument purges as well as
for instrument air. Best economy is obtained by compression of air
from atmospheric to 170 psig and £00°F. in a single two-casing
centrifugal compressor. Space is provided to install, at a future
date, Compressor C-102, motor-driven, to compress air from 170 psig
to 320 psig in one stage. A third machine is required to compress
transport air from 170 psig to 320 psig (i^O psig future) for pneumatic
transport. A standby instrument air compressor is supplied to supple-
ment instrument air from the power plant.
b) Coal & Dolomite Injection
Wet coal is received in open hopper cars in the size range of
l3g" x 0 per coal specifications indicated in Table V. We have assumed
1056 moisture to allow for rain wetting. The cars are unloaded into
a hopper under the railroad tracks. The coal is dried to 3% from 10$
surface moisture to insure uniform flow and then it is crushed to
V'xO and conveyed to a covered silo for .storage. Unloading coal is
scheduled for 8 hours per day, UO hours per week at a rate of 120,000
Ibs/hr. Coal is injected from the silo by means of a Petrocarb in-
jection system. The Petrocarb system consists of a storage vessel,
a pressurizing vessel and an injection vessel. The coal is injected
into the boiler by means of k injection nozzles. Injection of the
maximum rate of 33,000 Ibs/hr of ^"xO coal requires 3,000 SCM of
pneumatic air when the boiler operates at 160 psig.
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FOSTER WHEELER CORPORATION
REF. 11-52331
DATE April 1973
PAGE III-5
COAL SPECIFICATIONS
TABLE V
OHIO PITTSBURGH NO. 8 SEAM COAL
(Source of data: USBM, Pittsburgh Pa.)
SAMPLE; Run of Mine - As received
PROXIMATE ANALYSIS (wt. 50 :
Moisture
Volatine Matter
Fixed Carbon
Ash
3.3
39.5
U8.7
100 !o
ULTIMATE ANALYSIS
(includes moisture
C
H
0
N
S
Ash
(wt. g):
)
71.2
90
1.3
U.3
100.0
GROSS HEATING VALUE; 13,000 Btu/lb
NET HEATING VALUE; 12,500 Btu/lb
ASH ANALYSIS (wt. %): Si02
A1203
Fe20o
Ti02
COAL DENSITY;
Particle
Bulk
95 lbs/CF
55 "
CaO
MgO
Na20
K00
FUSIBILITY OF ASH; Initial Deformation Temperature
Softening Temperature
Fluid Temperature
GRINDABILITY (Hardgrove); 50 - 60
FREE SWELLING INDEX; 5 - 5-5
2080°F
2230°F
2U20°F
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE Apri
PAGE in-6
TABLE 71
SORBENT SPECIFICATIONS
Dolomite Properties
Type Dolomite - BCR 1337
Size - Purchased dry and double-screened in size of 1/U" to 28 mesh.
(61+00 to 580 microns)
Recycle size range due to attrition and elutriation is 600
to 63JJO microns with average size of approximately 2000 microns.
Density of 1/U" to 28 mesh
A - Particle - 175 Ibs/CF
B - Bulk - 95 Ibs/CF
C - Fluidizing 1^0 Ibs/CF @ 6 ft/sec
Chemical Composition Analyzed as Oxide
Wt. % Mol %
MgO U5.0 53.00
CaO 53.0 Ui.81;
Msc. 2.0 2.16
100.0 100.00
Hardness
Moh - 3.5
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FOSTER WHEELER CORPORATION REF- 11-52331
DATE April 1973
PAGE III-7
III. Basis of Design (continued)
3. Auxiliary Systems (continued)
b) Coal & Dolomite Injection (cordbinued)
Dolomite is received crushed and dried in the size range of 28
mesh by V in covered rail cars. The cars are unloaded in a shed by
means of a hopper under the tracks and then conveyed to a dolomite
silo. From the silo the dolomite is injected into the top of the
boiler fluid!zed bed by means of a Fetrocarb Pneumatic Injector.
Spent sorbent is discharged from the lower section of the bed,
i.e., just above the grid. The grid may be located in any three
positions, from 3 ft. to 7 ft. below the bottom of the tube bundle.
Spent sorbent may be discharged at elevations of 2 ft., U ft., or 6 ft.,
2k"j i|8" or 72" from the bottom of the tube bundle. A view of the coal
unloading systems and coal and dolomite silos is shown in Figure 1,
the plant perspective drawing, in Section I.
k- Water & Steam Supply & Disposal
Pressures and temperatures for boiler operation were chosen to repre-
sent the recent steam generator practice for sub-critical operations.
The actual pressures will depend upon the adjacent power company's boiler
design. Water and steam are assumed to be available at 2600 psig and at
the capacity required in the developmental plant as shown on Drawing
OP-721-U33C. Saturatated water at 6UO°F. and 2600 psig would be received
from the power plant economizer or heat exchangers. Sub-cooled water at
212°F. and 2600 psig would be received from the power plant deaerators.
Saturated steam and 1000°F. superheated steam are returned to the utility
company. The pressure drop in the system was purposely kept low (below
110 psi for normal flow) in order to fit into the utility company's
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FOSTER WHEELER CORPORATION REF. 11-^2331
DATE April 1973
PAGE III-8
III. Basis of Design (continued)
U. Water & Steam Supply & Disposal (continued)
boiler operating pressure drop. Normally all steam is sent to the
utility company's power plant for disposal. Superheated steam may-
be sent directly to the high pressure turbines. Saturated steam may
be sent to intermediate or low pressure turbines or the pressure may
be dropped so that the steam can be used for heat exchange.
J>. Dolomite and Ash Disposal
Spent dolomite and ash from the bottom of the boiler, as well as
ash and carryover removed by cyclones are water-cooled in a rotary
cooler to 300°F. from a maximum temperature of 1?50°F. in the fluid-
ized bed. Water sprays are provided if additional direct contact
cooling below 300QF. is required. The ash is then transported to the
power plant by conveyor. Alternately the ash can be slurried and
pumped to the power plant's disposal facility for settling. It is
necessary to cool the ash as it is conceivable under certain conditions
that quantities of unburned char nay be released at a high temperature
causing the char to burn in the air.
6. Turbine Expander and Test Cascade
A stationary cascade to test turbine blade materials may be provided
in the flue gas stream after the cyclones. It is expected that the
temperature and pressure of the flue gas will decrease only slightly
passing through the test cascade. Space will be provided for future
installation, of a small turbine expander to take part or all of the
flue gas and recover some of the energy residing in the high temperature
and pressure of the gas. Such a turbine expander should be designed
to operate with an inlet rated for l600°F. and l£5 psig, and with flow
characteristics similar to a commercial utility gas turbine. In order
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE
. Basis of Design (continued)
6. Turbine Expander and Test Cascade (continued)
to control the pressure at the boiler fluidized bed, a bypass line
would be used around an expander operating under pressure control.
To keep the pressure control valve from reaching too high a temp-
erature the bypass line with the control valve in it would be
quenched to a low temperature. To prevent the flue gas temperature
from rising too high about 1600°F., which would limit the life of
the expander turbine blades, the flue gas is tempered with cool air
(at J>00°F.) from the compressor C-101, which air normally bypasses
the boiler.
7. Combustion Gas Disposal
Combustion gas from the boiler may be generated at 1600 to 17J>0°F.
and at pressures up to 160 psig (320 psig future). Part or all of
the flue gas passes through the test cascade. The flue gas stream
is quenched to below 600°F. and the pressure is dropped by means of
back pressure control. The flue gas is then sent through a silencer
to the stack.
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IV
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE IV-1
IV. Detailed Boiler Design
1. Boiler Design
The pressurized fluidized bed boiler consists of a single fluidized bed
enclosed with a monofin membrane water wall containing a horizontal serpentine
heat exchange bundle. The bed and steam generating pressure parts are con-
tained in a 12-foot diameter vessel approximately 78 feet tall designed for
320 psig pressure. Where possible the test facility was designed to duplicate
a single module of the original 300 MW Foster Wheeler-Westinghouse conceptual
design consistent with the flexibility requirements of the test program.
Boiler Drawings are OP-720-9, OP-72U-82, 83 and 81*.
a) Boiler Specification
The boiler is designed to operate at: gas side pressure up to 20
atm.j bed temperature 1300-20000F; gas velocity 6 to 15 feet per secondj
bed depth 10 feet to 30 feetj bed plan area 35 square feet; three heat
exchange bundles capable of handling bed heat exchange duties of 8j>-7 x
106 Btu's/hr, 1U9.6 x 106 Btu's/hr and 222.6 x 106 Btu's/hr at l600°F.
. Each bundle would be capable of operating as an economizer
or preheater, an evaporator and a superheater. Furthermore
the bundles would be capable of operating at reduced mass
flows as a combined evaporator and superheater connected in
series with the water walls. In the latter case, water at
20°F. below saturation would be fed to the water walls and
leave the bundles as superheated steam at 1000°F.
. The water walls.would be capable of operating as a water-
cooled heat exchanger or an evaporator generating saturated
steam.
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•'I
0
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE IV-2
IV. Detailed Boiler Design (continued).
1. Boiler Design (continued)
a) Boiler Specification (continued)
. The steam generator would be designed such that the
three different heat transfer surfaces, submerged in
the bed could be interchanged with minimum cost and
effort.
. The boiler would be- designed such that each bundle-
could be installed or withdrawn as a single unit.
. The air distributor1 grid could' be relocated at three
different elevations.
. A variable freeboard height above, the bed would be;
provided with a maximum of 20 feet, for disengagement
of particles splashed up from, the bed.
. An overall heat transfer' coefficient of J>0 Btu/hr ft2 °F
would be used to determine surface requirements.
. The boiler would be installed in one of a variety of sites-..
Two> designs were1 proposed, to meet these requirements1. The first
design, shown in Figure' IV-A, contained three separate bundles stacked'
one above- the other with three, feet, of crawlspace between bundles, per-
mitting access for-maintenance., Headers were located in- the* preheated
air zone where temperatures were, low and. operating conditions less.
severe-. Either1 individual coils1 -or platens or the; entire1 bundle, can
be pulled to- fulfill changes, in test requirements- or make repairs.,
The second design shown in. Figures I.VB-1 through k supported from
headers' located in the* high temperature; gas- passes, reducing- the, number
of connections- that must, be broken or made, for removal or1 installation
of the bundle-.,
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PAGE NOT
AVAILABLE
DIGITALLY
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE IV-3
IV. Detailed Boiler Design (continued)
1. Boiler Design (continued)
The first design has the advantage of utilizing only that coil
surface area required for either oases A-l, A-2 or A-3 operation.
The second design always has two spare bundles since each of the
bundles is adequate for its own operating capacity. However, the
first design has the disadvantage of requiring many cutting and
welding operations on each tube to make any changes in tube bundles,
adding time and money to any change. The first design also has the
disadvantage of using crawlspaces between bundles which would not be
designed into the commercial units. These crawlspaces may upset the
fluidization hydraulics leading to difficulties in scaling-up from
the demonstration to the commercial unit. The second design was
chosen as superior in flexibility and in fluidized bed hydraulics.
b) Construction
The steam generator was designed to operate on feed water from
an existing 2i|00 psig once-through system with a final steam tempera-
ture of 1000°F. These conditions are considered to be representative
of existing power plants.
The heat transfer surface inserted in the bed consists of one of
three separate but continuous bundles of horizontal serpentine tubes.
The surface requirements of each bundle were selected to meet the bed
duties specified with due consideration given to the duty of the
enclosure wall. The smallest bundle consists of forty rows of single
loop-in-loop, l^g" O.D. tubes with alternate rows off-set vertically
(see Drawing OP-72U-8U, Fig. IVB-2) providing a triangular pitch with
tube spacing of 2.828 inches. Larger bundles make use of the same
tube arrangement and tube size. However, double loop-in-loop and
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FOSTER WHEELER CORPORATION REF. 11-£2331
DATE April 1973
PAGE IV-U
IV. Detailed Boiler Design (continued)
1. Boiler Design (continued)
b) Construction (continued)
triple loop-in-loop construction is used to accommodate higher steam
mass flows at the higher bed duties with nearly constant steam side
pressure drop. The schedule of tube material and wall thickness appears
in Table VII. The latter was selected on the basis of superheating in
the bundle and should be equally satisfactory for evaporating and pre-
heating functions providing demineralized water from an existing once-
through installation is used and no chlorides are present.
The bundles are constructed with one inlet header and two outlet
headers operating in parallel. That is to say alternate tubes feed to
alternate headers. This was done so as to support the bundle from the
headers located within the gas stream. Continuous bundles in beds 1J>
to 27 feet deep are too heavy to be supported off lugs attached to the
water wall. Individual loops are held together with a sinuous strap
made of an alloy steel running the full length of the bundle. The
sinuous straps are tied to the supporting headers. In addition to
supporting individual coils and preventing them from arbitrarily
expanding of their own weight, the sinuous straps make the bundle
rigid and reduce the stress on the tubes at the first tube bend created
by the bending moment of the cantilevered bundle.
Two headers are used in series at the outlet to facilitate support
during operation and simplify removal during modification. The first
is essentially a collecting header for the tubes in the bundle. The
second header is a steam-cooled beam supporting the bundle and pro-
viding access to either end for cutting during removal. The two
headers are connected with four transfer pipes forming a truss capable
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FOSTER WHEELER CORPORATION REF. 11-£2331
DATE April 1973
PAGE IV-5
IV. Detailed Boiler Design (continued)
1. Boiler Design (continued)
b) Construction (continued)
of discharging steam from the bundle. The supporting header requires
a cylindrical insert to form an internal annulus so as to maintain high
steam velocities, good heat transfer and low mean wall header temperature.
The two supporting headers penetrate the water walls at four locations.
The four steam outlet pipes are collected or manifolded into a single
discharge line outside the boiler. By connecting two outlet headers
with a series of transfer pipes judiciously located along the length
of the header, sufficient room is provided at either end of the support-
ing header to cut the header at the time of removal. Two cuts must be
made at either end, one on either side of the water wall. The spool
section thus formed is removed to provide sufficient room for pulling
the bundle. Re-welding of the header requires stress retrieving and
X-raying the welds.
The same outlet and inlet header connections will be used for all
three bundles. The difference in elevation of the outlet headers for
the smaller bundles is absorbed by longer transfer pipes between the
collecting and supporting header.
The fluid bed is enclosed with a monofin membrane wall capable
of withstanding 12 psi pressure differential- (maximum expected with
a 30' bed) between the preheated air and the products of combustion.
The water wall enclosure serves as a heat transfer surface, a partition
between the preheated air and flue gas, and means of structurally support-
ing the pressure parts. It also acts as insulation providing a means for
designing the shell for high pressure low temperature operation.
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAQE IV-6
IV. Detailed Boiler Design (continued)
1. Boiler Design (continued)
b) Construction (continued)
The water wall enclosure can be penetrated rather simply. This
permits locating larger, more expensive piping not serving as heat
transfer surface in cooler gas zones outside of the enclosure surface
where the environmental conditions are less severe. Locations of
water wall penetrations can be changed in the field by simply cutting
out the section of offset tubing and replacing it with a section of
straight tubing, or vice versa.
The water walls also provide a simple means of support with
appropriate consideration given to load and local stress concentrations.
The favorable characteristics of the membrane wall already cited
demonstrate some of the advantages of this type of construction. On
the other hand, refractory-lined plate steel greatly complicates tube
support. Maintenance will be high, particularly with severe thermal
cycling associated with a test vehicle. The wall areas in the immediate
vicinity of the tube bundles are inaccessible. Refractory could be
particularly troublesome if large pieces breaking loose from the wall
become entrained in the exit flue gases.
A rough cost estimate indicated one square foot of reinforced
monofin wall might run $12 per square foot. A refractory wall,
constructed of % inch plate with U inches of refractory and 2 inches
of insulation, would cost approximately $2U per square foot. About
20$ additional surface would have to be added to the bundle immersed
in the bed to compensate for the loss in heat transfer to the wall.
The load-supporting water wall is constructed of 1-7/8 O.D. inch
tubes on 2 inch centers. The remaining two walls are constructed of
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FOSTER WHEELER CORPORATION REF. 11-^2331
DATE April 1973
PAGE IV-7
IV. Detailed Boiler Design (continued)
1. Boiler Design (continued)
b) Construction (continued)
1-3/7 O.D. inch tubes on 2 inch centers. Tube thickness and material
selection appear in Table VII. The water walls are reinforced with
10 W tie bars on variable centers. As the pressure differential
across the wall increases the center lines between adjacent tie backs
decreases.
Each wall is terminated at both ends by a header. The headers
are partitioned such that the water wall circuit nay be operated as a
single-pass or four-pass heat exchanger in four walls connected in
series rather than parallel. Modifying the water walls from single-
pass to four-pass is achieved by cutting loose the second ring header
at the transfer pipes and sealing the latter. The single inlet pipe
to the primary header then is connected to the feed line. A similar
modification is required at the discharge end.
The bundles and enclosure walls are hung from the shell at the
uppermost extremity. Since the shell water walls and preheated air
are at about the same temperature, expansion problems are minimized.
All water/steam pressure parts were designed according to Section
I of the American Society of Mechanical Engineers Power Code.
The shell is a self-supporting vessel approximately 78 feet high,
designed according to Section VIII UG27 Un-fired Pressure Vessel
American Society of Mechanical Engineers Power Code for pressures of 320
psig at temperatures of J?00°F. The vessel is constructed of 1-3/8 in.
thick SA 516-70 steel and lined with a 2-inch layer of batten insulation
with an 0.0k"aluminum sheathing. The shell is 12 feet in diameter.
The size was selected as the maximum diameter permissible for shipment
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE IV-8
IV. Detailed Boiler Design (continued)
1. Boiler Design (continued)
b) Constraction (continued)
as a complete shop-fabricated and assembled unit and minimum diameter
for internal access to the water-steam pressure parts.
The upper section of the vessel is reduced to 8 feet 6 inches in-
ternal diameter by a conical transition piece to permit installation
of a removable head by means of a flange connection.
Preheated air is introduced and flue gas withdrawn through an air-
cooled pipe penetrating the upper-dished head closing off the top of
the vessel. The air-cooled piping penetrates the vessel approximately
five feet. A transition piece is attached to its furthermost extremity
completing a sealed connection to the uppermost point of the water walls.
A mechanical seal completes the connection. VJhen broken, it provides
access to the entire fluid bed and immersed heat exchanger bundle. This
permits removal of the bundle as a single unit.
The air distributor, shown in Fig. IVB-3» consists of three sections
of Wrought Incoloy 800 plate, supported by scalloped bars welded to the
water walls and completely circumscribing the bed. The air distributor
is held in position by wedges inserted between inverted water wall
hanger supports and the grid plate. The air distributor contains 598
bull plugs, each containing 16, 0.2 inch diameter holes for emitting
and distributing air to the fluid bed. The three sections of air dis-
tributor are bolted together at the web located in the plenum chamber.
This arrangement makes it possible to remove the air distributor and
relocate it at any one of three elevations.
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PAGE NOT
AVAILABLE
DIGITALLY
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE IV-9
IV. Detailed Boiler Design (continued)
1. Boiler Design (continued)
c) Maintenance
Access to the fluid bed is achieved through either the removable
head for major repairs or manways in the pressure vessel and water
walls for minor repairs. The manways are located above and below the
bed and in the transition piece at the flue gas exit.
The bundles may be removed and interchanged by unbolting the flanged
head and mechanical seal between the air-gas duct and water wall headers.
The section comes off as a single unit. The supporting outlet headers
must be cut at four locations on either side of the water wall enclosure.
The lower inlet header must also be cut on both sides of the water wall.
After the bundle is raised slightly the spool sections formed by the two
cuts can be removed. After this the bundle is free to be pulled as a
single unit.
Repair of individual tubes requires pulling the entire bundle. This
is one of the disadvantages of locating the headers inside of the water
wall enclosure. In the original design, individual coils or platens can
be pulled up into the freeboard area and repaired without having to remove
the pressure vessel head.
Installation of the bundle requires stress relieving and X-raying of
the header welds.
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FOSTER WHEELER CORPORATION REF. 11-^2331
DATE April 1973
PAGE IV-10
IV. Detailed Boiler Design (continued)
1. Boiler Design (continued)
d) Operation
All three bundles can be operated as either a superheater, evaporator
or preheater providing proper consideration has been given to the relation-
ship between bed duty, waterside mass flows, inlet enthalpy and pressure
drop. The cooling fluid must be de-mineralized water, free of chlorides
to prevent stress corrosion on the stainless steel segments of the bundle.
The heat flux to the tubes is low according to the design conditions
specified, 30,000-60,000 Btu/hr ft2. Therefore, overheating of the tube
surface in the evaporation mode of the transition from wet steam to dry
should not present a problem. Figure V illustrates a typical relation-
ship between tube metal temperature, heat flux, enthalpy and steam
quality.
By dropping the mass flow, the bundles can be operated as a combined
evaporator and superheater.
The water walls can be operated as a single water-cooled heat transfer
bundle in either the single-pass or multi-pass arrangement. The water
walls can also be operated as a verticle tube evaporator.
By selecting the appropriate mass flows and making necessary changes
in the circuitry piping the water walls can be connected in series with
the immersed bundle such that the boiler can be operated as a once-through
boiler with 20°F. of sub-cooling at the feed inlet and 1000°F. at the
superheater outlet.
All of these operating modes are subject to restrictions of the
system pressures, temperatures and operating conditions. These cannot
be taken into consideration until a site is selected and specific system
piping is established. The boiler was designed to operate on a slip-
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE IV-11
IV. Detailed Boiler Design (continued)
1. Boiler Design (continued)
d) Operation (continued)
stream from a once-through boiler at 21*00 psig. The feed water would
most likely come from the economizer outlet* The saturated steam may
be produced as superheated steam that has been de-superheated to
saturation. Unless a very special boiler is selected with adequate
temperature control, slipstreams of the size required cannot be taken
from the boiler at locations between the economizer and superheater
outlet.
Table VIII is a schedule of pressure drop for the various modes of
operation requested in the final design. These will have to be modified
to the system requirements by changing header sizes, tube sizes, number
of tubes or other physical modifications that may be found necesaary.
-------
TABLE VII
IV-12
BOILER TUBE MATERIAL
ITEM
DESCRIPTION
SIZE
MATERIAL
NUMBER
REQUIRED
21 & 22
23 & 24
25 & 26
27 & 28
29 & 30
31
32
33 A
33 B
33 C
33 D
33 E
34
35
36
37
38
39
Inlet Header
Water Wall Tubes
Water Wall Tubes
W/W Outlet Headers
Transfer Pipe
Superheater #1 Inlet Header
Superheater tfl Outlet
Header
Superheater #1 Tubes
Superheater #1 Tubes
Superheater //I Tubes
Superheater #1 Tubes
Superheater #1 Tubes
Superheater Support Header
Outlet Pipe
Superheater #2 Inlet Header
Superheater #2 Outlet Header
Superheater #3 Inlet Header
Superheater #3 Outlet Header
4" Pipe SCHXX
1 7/8 OD x-220 MW
1 7/8 OD x-220 MW
6"Pipe SCHXX
2 1/2MOD x-200 MW
8" Pipe SCH 160
6"Nom x 1.28 AW
1 1/2"OD x .225 MW
1 1/2"OD x .192 MW
1 1/2"OD x .375 MW
1 1/2"OD x .385 MW
1 1/2"OD x .232 MW
8 5/8"OD x 1 1/2 AW
3 l/2"Pipe .469 Wall
5"Pipe SCH 160
4" Pipe SCHXX
4" Pipe SCH 160
4" Pipe SCHXX
SA-106C
SA-210A
SA-210A
SA-106C
SA-210A
SA-106C
SA-335-TP304H
SA-210A
SA-213-T2
SA-213-T11
SA-213-T22
SA-213-T304H
SA-335-TP304H
SA-335-TP304H
SA-106-C
SA-335-TP304H
SA-106-C
SA-335-TP304H
1
43
32
1
6
1
2
120
120
120
120
120
2
8
1
2
1
2
(1) Numbers refer to items illustrated in Drawing L-725-32, Figure 1.
(2) Superheaters 2 & 3 require the same material as Superheater 1.
(3) Superheater 2 requires 2/3 the number of tubes in Superheater 1,
Superheater 3 requires 1/3 the number of tubes in Superheater 1.
(U) SA material specifications may be found in Section II, Materials Specifications
of the ASME Boiler and Pressure Vessel Code.
-------
TABL13 VITT
SUMMARY
OF
PRESSURE DROP CALCULATIONS
1V-13
CASE
Bed Duty BTU/HR x 106
Bundle Duty
Wall Duty
Superheater Outlet Temperature
Superheater Outlet Pressure
U • 50 BTU/HR F2 °F
A-l
A- 2
A-3
MATERIAL
SELECTION
Water Walls
SA 106C
Headers
Bundle
Sec. 1
Sec. 2
Sec. 3
Sec. 4
Sec. 5
(1 Pass)
SA-106C
SA-210 A
SA-213-T2
SA-213-T11
SA-213-T22
SA-213-TP304
149.6
98.3
51.3
1000°F
2400 PSIG
85.7
55.1
30.6
227.6
146.1
76.5
TUBE
P.P. I.D. Ac# t * LENGTH
1 7/8 1.435 1.670 0.0018 53
4.5 3.152 7.80 «.-»— ™
1 1/2
1 1/2
1 1/2
1 1/2
1 1/2
1.024
1.100
.750
1.700
1.024
.824 0.0018
.950 0.001
.442 0.001
.385 0.0005
.824 0.00006
Headers
SA-106C
6.625 5.5 23.6
129, 150, 127
17, 17, 17
27, 27, 27
32, 32, 32
16, 16, 16
35, 59, 35
CASES STUDIED
(1) Bundle 1, 2, 3 as a superheater. Sat. steam in. 1000'F Supht. out
at 2400 psig.
(2) Bundle 1, 2,3 as an evaporator. Sat. water in. Sat. steam out
at 2400 psig.
(3) Bundle 1, 2,3 as a preheater.Subcooled water in. 212°F inlet temp.,
2400 psig.
(4) Water walls as a preheater subcooled water 212°F inlet temp., 2400
psig press. - Single and four pass arrangement.
(5) Water walls as an evaporator 20°F subcooled water in at 2400 psig press.
and saturated vapor put - Single and lour pass arrangement
(6) Cpmplete once through system. 20° preheater to water walls. 1000°F
superheat from bundlef^Single and four pass arrangement of water walls.
^Nomenclature appears at the end of Table VIII.
-------
TABLE VIIT (continued)
SUMMARY
OF
PRESSURE DROP CALCULATIONS
(Continued)
iv-iU
CASE 1. 2. 3
PRESSURE DROP THROUGH BUNDLE
BUNDLE INSTALLED
Mode of Operation
AP, PSI
W x 103 Lb/Hr j
W/A x 103 Lb/Hr - Ft (inlet)
Mode of Operation
AP PSI
AP
AP
W x 103 Lb/Hr „
W/A x 103 Lb/Hr - Ft (Inlet)
Mode of Operation
AP PSI
AP*
AP*
W x 103 Lb/Hr j
W/A x 103 Lb/Hr - Ft (Inlet)
AT
CASE 4
BUNDLE INSTALLED
Single Pass
AP, PSI
AP*
AP*
W x 103 Lb/Hr
W x 103 Lb/Hr - Ft (Ave.W.W.)
AT..
Four Passes
AP PSI
AP
AP;!
W x 103 Lb/Hr -
W x 103 Lb/Hr - Ft (Ave. W.W.
AT
w
A-l
94.9
255
545
41.9
2.6
44.5
260
556
11.4
4.3
15.7
250
534
390
A-j-2
Superheat
130.1
143
614
Evaporator
51.7
1.9
53.6
147
625
Preheater
14.7
2.9
17.6
150
650
390
A-3
98.4
380
540
43.6
4.0
47.6
390
561
11.4
6.6
18.0
384
560
390
WATER WALL AS A PREHEATER
1
1.22
14.1
15.3
250
148
206
58.5
14.1
72.6
250
) 525
206
2
0.43
14.1
14.5
150
89
206
21.1
14.1
35.2
150
316
206
3
2.81
14.1
16,9
384
228
206
134.2
14.1'
148.3
384
810
206
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TABLE VHI (continued)
SUMMARY
OF
PRESSURE DROP CALCULATIONS
(Continued)
CASE 5
BUNDLE INSTALLED
Single Pass
APf PSI
APf o
W x 103 Lb/Hr
W x 103 Lb/Hr
Four Passes
APf PSI
W x 103 Lb/Hr
W x 103 Lb/Hr
CASE 6
BUNDLE INSTALLED
Single Pass
AP£ PSI
W x 103 Lb/Hr
W x 103 Lb/Hr
W x 103 Lb/Hr
Four Passes
AP, PSI
APh
W x 103 Lb/Hr
W x 103 Lb/Hr
W x 103 Lb/Hr
Inlet)
WATER WALLS AS AN EVAPORA'
ft (Ave. W.W.)
rt x 10
(Ave. W.W.)
2
Ft_ (Ave.W.W.)
Ft .(Bundle-
Inlet)
2
Ft^ (Ave.W.W.)
Ft (Bundle-
A-l
2.7
8.4
11.1
133
103
66.1
10.0
76.1
133
290
ONCE
1
81.9
8.4
90.3
203
122
435
230.1
10.0
240.1
205
490
435
A-2
2.0
8.4
10.4
81
60
24.5
10.0
34.5
81
170
A- 3
5.42
8.4
13.82
205
157
150.0
10.0
160.0
205
440
THROUGH SYSTEM
2
97.2
8.4
105.6
115
70
490
141.6
10.0
151.6
115
280
490
3
83.0
8.4
91.4
300
182
413
404.6
10.0
414.6
300
730
423
-------
IV-16
NOMENCLATURE
AP Pressure Drop LB/SQ IN.
W Mass Flow LB/HR
W/A Mass Flow Per Unit Area LB/HR FT2
U Overall Heat Transfer Coefficient BTU/HR FT2°F
AT Temperature Difference °F
O.D. Outside Diameter IN.
I.D. Inside Diameter IN.
A CrossSectional Area SO.IN.
c
c Roughness
Subscripts
f Friction
h Static Head
t Total
W Water
-------
1500
ffS
oo n
n •
3 H-
n 3
O 00
M •
•a
o =
0) O
rr B
» CT
O. C
- (0
09
M-
3
n>
09
a
a-
w
PRESSURE -2980PSIA '
FLOW RATE • 520,000 LB/HR- FT2
HEAT FLUX
I038TU/HR-FT2]
PER CENT STEAM
500
500
600
700 800 900
ENTHALPY (BTU/LB )
1000
1100
553 628 682 695
FLUID TEMPERATURE- F
FIGURE V EFFECT OF CHANGE IN HEAT FLUX ON BURN-OUT AND DEPARTURE FROM NUCLEATE BOILING POINTS
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V
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FOSTER WHEELER CORPORATION REF. 11-$2331
DATE April 1973
PAGE V-l
V. Design Problems and Solutions
1. Particle Removal from Flue Gas
Gas from the combustion zone, at 1600 to 17J>0°F. and at pressures
of from l£0 to 320 psig, carries a certain amount of solid particles
elutriated from the fluidized bed. These particles, consisting of fly
ash, dolomite and some uriburned carbon which must be removed from the
gas if the high pressure energy of the flue gas is to be recovered in
a turbine expander. It is vital for the process to recover as much
of the pressure energy of the flue gas as possible since the compression
of the combustion air consumes a large fraction of the total energy
input into the boiler plant. The removal of particulates a high temp-
eratures and pressures is not an easily solved problem. At the high
temperatures electrostatic precipitators lose efficiency. Cyclones
may remove much of the particulates above" a certain size range, but
removal efficiency tends to decrease below about 10 to 20 microns.
Removal of smaller particles is slightly improved by the use of many
very small cyclones, such as "Multiclones" or by the use of reverse
flow cyclones such as the "Aerodyne" type. For operation of the
pressurized fluidized bed boiler a first-stage cyclone removes bulk
carryover of particles greater than 20 microns. These may be removed
from the system or returned to the fluidized bed. The flue gases next
go to an Aerodyne cyclone which removes most of the particles above
6 microns. However, if this removal is still not adequate to meet
the required dust loading
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FOSTER WHEELER CORPORATION REF 11-$2331
DATE April 1973
PAGE V-2
V. Design Problems and Solutions (continued)
2. Fluidization Hydraulics
The fluidized particle- consists of dolomite in the size range of
Vx28 mesh (595 to 6350 microns). The large, average particle size
may be reduced slightly by attrition} however, it will still be necessary
to operate at a high gas velocity. It is felt that the smaller particles,
especially unburned coal, may be elutriated out of the bed very rapidly.
High gas velocity and large particles tend to produce surgining,
slugging and bumping fluidized beds.
It is felt'that during the preliminary operation it will be necessary
to experiment with the effect of particle size on smoothness of fluid-
ization. Directionally, it may be necessary to reduce the top size of
dolomite from V to k or^S mesh. The smaller, average particle size may
reduce capacity by limiting gas velocity but the smaller size should
improve heat transfer and smoothness of fluidization.
3. Steam and Boiler Feed. Water
It has been assumed that the pressurized fluidized bed boiler will
be located adjacent to> an existing power plant. The experimental, boiler
will take saturated steam from the existing power plant and return super-
heated steam, or the experimental boiler will take preheated water and
return saturated steam.
Since the adjacent power plant has not been specified, it has been
necessary to' design the experimental boiler on the basis of a series of
assumptions as to steam pressure, superheat temperature and also the
pressure drop through the experimental boiler. If the system pressure
drop is too high it will be impossible to get steam back into the power1
plant's system in which case it may be necessary to break the pressure to>
some lower stage on the power plant1s turbine interstage pressure.
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FOSTER WHEELER CORPORATION REF. 11-^2331
DATE April 1973
PAGE 7-3
V. Design Problems and Solutions (continued)
3. Steam and Boiler Feed Water (continued)
It also may be very difficult to convince a power plant to tap into
the power plant's main boilers to remove saturated steam and return
saturated steam to the power plant's superheaters. This could upset
the firing balance of the power plant.
It may be better to operate the test facility without tapping into
the power plant's boiler. Boiler feed water can be taken from the
power plant's boiler feed water preheaters and exchangers and this
water sent to the fluidized bed boiler water tubes for preheat and
evaporation. From the water wall tubes steam and water flows to the
tube bundle in the fluidized bed to complete evaporation and then to
superheat to 1000°F. The high pressure superheated steam would then
be sent directly to the power plant turbine without disrupting the
power plant boiler. The fluidized bed tubes would have to be designed
specifically for this case as it is necessary to maintain high mass
velocities to prevent burn-out of evaporation tubes. Each section of
tubes would contain sufficient instrumentation to evaluate design
parameters of heat transfer, hydraulic and pressure drop so that future
fluidized bed boilers may be designed with confidence..
it. Bundle and Tube Removal from the KLuidized Bed
In conventional boilers, each pass (platen) penetrates the water
wall at the inlet and outlet so that the tubes are headered outside the
water wall in the relatively cold sections of the boiler. In the pressur-
ized fluidized bed boiler it has been decided to header internally even
though the headers are now a more expensive, thicker-walled alloy. This
means that fewer penetrations of the water wall are required (two headers
instead of 80 passes). It is estimated that removal of the entire tube
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE V-U
V. Design Problems and Solutions (continued)
U. Bundle and Tube Removal from the Fluidized Bed (continued)
bundle with internal headers will require two weeks and $10,000 vs. 3
weeks and $20,000 for external headers.
J>. Start-up Heaters
To support combustion it is necessary to heat the combustion zone
to at least 700 to 800°F..
An air preheater has been provided to preheat air to 1200°F. When
the fluidized bed is held at a low level, the preheated air can heat
the bed plus the tubes in a reasonable time interval to 1000°F. To
avoid overstressing the grid an insulated plate is placed above the
boiler nozzle connected to the preheater to prevent radiation damage.
If additional heat input is required when the bed level is high or when
the steam flows in the tubes at a high capacity additional heat may be
supplied by firing three ignitor-combustor guns directly into the
fluidized bed above the grid.
6. Shell Insulation
To contain combustion at high temperature and pressure it is desirable
to reduce the temperature of the enclosure shell to a point where the
allowable stresses are reasonable, i.e., less than 600°F. This may be
accomplished by using internal refractory insulation, or alternately,
the shell may be cooled by surrounding the combustion zone by water-
wall tubes. The tubes are used to preheat or evaporate water, which
means that the water-wall temperature is less than 6?0°F. The annular
space between the water-wall and the pressure shell is cooled by com-
bustion air.
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE V-5
V. Design Problems and Solutions (continued)
6. Shell Jjiaulation (continued)
It has been decided to use water walls similar to conventional
boilers for the following reasons:
a) The water walls in general can be designed for higher heat
recovery and thermal efficiency than refractory insulation.
b) Water walls take up less space than insulation.
c) Insulation would have to be covered with a hard facing
refractory to resist erosion.
d) Water walls can be built to take slight pressure differential.
e) Water walls reduce the structural steel requirement by acting
as supports for coils in the bed and for the grid.
7. Steam Tube Orientation
Steam tubes may be positioned horizontally, vertically or at an
angle. It may be expected that the position of the tubes can effect
heat transfer rates, smoothness of fluidization and erosion. Heat
transfer rates, as pointed out by Genetti, et al. (l), suffer when
tubes are positioned at an angle. The same authors indicate that
vertical bare tubes have slightly better heat transfer rates than
horizontal tubes in the particular size range of 100 to 200 microns.
However, for larger-size particles (UOO microns), there is no difference
in heat transfer between horizontal and vertical tubes at any velocity.
The heat transfer rate was calculated by the method Vreedenburg(2) for
the normal capacity Case A-l. This method indicates a slightly better
Genetti, W.E.j Schmall, R.A. & Grimmett, E.S.
AIChE Symposium Series, Fluidization No. 116, Vol. 67, p. 90, 1971
(2) Vreedenburg, H.A., Chem. Eng. Sci., Vol. 9, p. 52, August 19!?8.
Chem. Eng. Sci., Vol. 11, p. 27U (I960)
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FOSTER WHEELER CORPORATION REF. llr$2331
DATE April 1973
PAGE V-6
V. Design Problems and Solutions (continued)
7. Steam Tube Orientation (continued)
heat transfer for vertical tubes than for horizontal. However, if the
method of Wender and Cooper(l) for vertical tubes transfer rate is com-
pared with horizontal tubes by the method of Vreederiburg, the horizontal
tubes show a better heat transfer rate.
From the literature it is difficult to determine if horizontal tubes
are superior to vertical. However, for deep fluidized beds of 10 to
30 feet, as designed into the developmental boiler, the horizontal tubes
may exhibit superior heat transfer characteristics since horizontal tubes
tend to act as baffles breaking the bubble growth which is detrimental
to good heat transfer rates.
Tube position can also effect erosion. Zenz(2) indicated that erosion
is a function of velocity to some power exponent ranging from 3 to 6, as
well as the distance from nozzle to target. This author also points out
that in pneumatic transport, there is often severe erosion on the outer
radius of elbows due to the impact of the curved wall of the bend. Similarly,
the impact of the fluidized particle will be greater against horizontal tubes
than vertical tubes. For the horizontal configuration, it is necessary to
weld a small impingement plate on the bottom rows of tubes. Similarly, for
vertical tubes, the bottom 180° bends must be protected by welding a wear
plate to the bottom U bends.
Both horizontal and vertical tubes must be well-supported or vibration
will cause serious mechanical difficulty. We propose that the fluidized
bed unit be constructed in such a manner that either horizontal or vertical
bundles can be used with headering occurring internally to the water walls,
(l)Wender, L. & Cooper, G.T., AIChE J., Vol. h, p. l£, March 1958
(2)Zenz, F.A. & Othmer, D.F., "Fluidization and Fluid-Particle Systems",
Reinhold Publish. Corp., New York (I960) p. 338
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FOSTER WHEELER CORPORATION REF. 11-$2331
DATE April 1973
PAQE V-7
V. Design Problems and Solutions (continued)
7. Steam Tube Orientation (continued)
so that replacement need only involve cutting and rewelding the header
instead of each pass of the tube bundle. For the test facility hori-
zontal tubes were chosen.
8. Position of Cyclones
Cyclones in fluid, bed operation can be positioned above the fluid-
ized bed in the same vessel as the fluidized bed or they may be
positioned externally to the fluid bed vessel. It has been decided
to position the cyclones externally. This will allow an increase in
flexibility by using multiple cyclones in parallel so that the removal
of one, two or three units will maintain a high efficiency at all
capacities. External installation will allow experiments on cyclones
and measurements of cyclone efficiency.
9. Coal Injection
3 Coal feeding and control of rate and uniformity of feed rate is
y
;
i a difficult problem. It has been decided to use a Petrocarb-type
" of feeding system. The total coal feed is weighed into lock hoppers
and then fed into a special injector vessel containing multiple nozzles
to uniformly inject the coal by means of hydraulic transport.
10. Shell Size
It was decided to restrict the shell diameter of the development
boiler to that used in a commercial design, i.e., the maximum capable
of shipment by rail so that the vessel can be shop-fabricated. In
this case the diameter of 12'0" was chosen and this allowed reasonable
internal area for headers and flexibility for various pipes penetrating
the shell. No advantage could be seen in increasing the diameter beyond
12'0" for the development plant boiler.
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VI
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FOSTER WHEELER CORPORA! I ON REF. n-52331
DATE April 1*73
PAGE VI-1
VI. Experimental Program
The experimental program and test procedures are the minimum re-
quired to meet the objectives of the demonstration boiler as outlined
in the Introduction in Section I. The sequence of operation of the
pressurized fluidized bed boiler including tests and experiments has
been divided into the following phases:
1. Startup
2. Boiler Performance Test
3. Tests for Operability
IK Reliability Demonstration
5. Tests of Pollution Abatement
6. Tests of Long Range Objectives
Some of the tests can be performed concurrently. For instance, the
heat transfer should be analyzed for every operation or test on the boiler.
In all phases it is planned to operate the boiler with a coal feed of
Ohio Pittsburgh Number 8 Seam Coal. The sorbent will be BCR 1337 Dolomite.
Testing other types of coal or sorbent will extend the test period.
1. Startup and Shutdown Procedure
Prior to the initial startup, careful and thorough preparation is
a prerequisite for satisfactory performance eliminating much trouble
and delay during the initial startup. A final inspection should be
given to all vessels before bolting of the manways. Refractory-lined
vessels of 12 feet in diameter or less and piping of monolithic con-
struction are cured and dried by others. Depending on the actual site
for this plant, the cyclone drum, D-120 may be too large to be shipped
in one piece. In this case, D-120 will be field-fabricated and the
refractory linings installed on site. The main air compressor, C-101,
and air preheater, H-102, could be used for drying of the refractory
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE VI-2
VI. Experimental Program
1. Startup and Shutdown Procedure (cont'd)
lining of this vessel. After curing and drying of refractory-lined
vessel cracks may develop. Small cracks of refractory-lined vessels
are normal. However,, when the crack is larger than 1/8" in width and
IV in depth, the crack shall be repaired prior to startup.
Particular attention must be given to the inspection of the Fluid-
Bed Boiler. The wall tubes and horizontal tube bundle should be checked
for signs of leakage. Care should be given to thorough cleaning of the
instrument purge line. After the instrument lines have been cleaned,
be sure that the proper restriction orifice plate has been put back
on the purge line. Piping supplying purge or aeration medium other
than instruments should be prepared in a like manner whenever particu-
late matter may be present.
During initial startup all instruments must be completely checked
out. This is particularly important for the ELuidized Bed Boiler unit.
The control valves should also be checked out for operability, i.e.,
stem travel, action on air failure, etc. All transmission systems for
each instrument shall also be inspected.
Preliminary Preparation
Utilities required for the startup shall be verified that all are
in service or in readiness. A thorough check for readiness of the
following utilities or service is required:
a) Instrument air supplied to all instruments as required.
b) Electric power available for all drivers.
c) High pressure boiler feed water and saturated steam are avail-
able for the fluid bed boiler.
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAQE VI-3
VI. Experimental Program (continued)
1. Startup and Shutdown Procedure (continued)
Preliminary Preparation (continued)
d) Medium pressure steam is available for Air JPreheater, H-102.
e) Cooling water must be available. Cooling water flow may be
established through the equipment required for startup.
f) Fuel oil should be made ready for the Air Preheater, H-102.
g) All fire fighting and other equipment.
h) Verify that all blinds are removed or is the normally open
position for operation.
Establish Air Flow
Before running-in the compressors, all auxiliary systems shall
be carefully inspected. Oil reservoirs, lubricators and oil lines
shall have clean oil circulated for verification of cleanness. This
oil should then be discarded and the proper lubricating oil supplied.
During run-in of the compreesor, all controls of the lubricating
system must be made to function correctly and satisfactorily. All
alarms and safety devices must be verified as to proper settings
and correct function.
At the completion of compressor run-in, the Main Air Compressor,
C-101, shall be put into service. Due to the high discharge temper-
ature of this compressors, a temporary air cooler may be required during
the initial startup to minimize thermal shock to refractories. The air
velocity in the fluidized bed boiler shall be maintained at 3 to k fps
and the air temperature set at approximately 2j?0°F to 300°F.
All refractory-lined vessels should be heated at this time. This
is accomplished by opening the balance line on vessels D-112, 113, llU*
115 and 11? to admit the heated air or flue gas and crack open the vent
valve on each of these vessels.
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAQE VI-U
VI. Experimental Program (continued)
1. Startup and Shutdown Procedure (continued)
Establish Air Flew (continued)
At the same time, the Injection Air Compressor, C-103, shall be put
into service to establish the required pressurizing and injection air
for the Petrocarb system. The instrument purge air from the Package
Purge Air Dryer, A-102, shall also be put into service.
Loading of Coal and Dolomite
Next, the coal and Dolomite Silos, D-102 & 3, shall be filled. The
Lock Hoppers, D-10J> and 109, and the Injection Hoppers, D-106 and 111,
shall be made ready for startup. At this time, the Petrocarb's system
shall be subject to thorough inspection and tests. Particular attention
shall be given to the performances of the Coal Crusher, SR-101, Coal
Dryer, RK-101, and the various conveying systems. At the completion of
the initial tests of the Petrocarb system, the dolomite shall be in-
jected into the boiler to a bed height of approximately four (U) feet.
Initial Startup
The air temperature to the boiler shall be increased gradually until
it reaches the discharge temperature of the air compressor. At this
time, saturated boiler feed water at 2UOO psig shall be circulated through
the wall tubes to the Steam Separator, D-110, and back to the power plant.
Saturated steam at 2^00 psig shall be admitted to the horizontal tube
bundle at a reduced rate of approximately 70,000 Ib/hr. Next, the Air
Preheater, H-102, is put into service. The fluidized bed temperature
shall be brought up very gradually by the air preheater at a rate not
exceeding 100°F per hour, until a bed temperature of 1000°F to 1200°F
is established. Next, one of the four coal injection lines should be
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE VI-£
VI. Experimental Program (continued)
1. Startup and Shutdown Procedure (continued)
Initial Startup (continued)
placed into service at a minimum coal injector rate. As the coal com-
bustion takes place, the air preheater firing rate shall be reduced.
When it is determined that the coal combustion will maintain the
fluidized bed temperature, the air preheater shall be taken out of
service completely. During the initial startup, the bed temperature
shall be maintained at around lUOO°F to 1^00°F. The fluidized bed
level and boiler feed water and saturated steam feed rates shall be
adjusted to maintain the bed temperature as the coal rate is increased.
The operation will be continued until the required coal injection
rate is established.
Spent dolomite from the boiler will be discarded to the Spent Sorbent
Lock Hoppers, D-112 and/or 113, and then to the Dolomite Cooler, RC-101,
for disposal.
Normal Shutdown
The following shutdown procedure covers a normal, scheduled and
complete shutdown such as would be required for turnaround and in-
spection.
Over a period of several hours, the coal rate to the boiler shall be
reduced. During this time, the air rate shall also be cut back to main-
tain a low oxygen content in the flue gas. When the boiler bed temper-
ature reaches 1000°F. The coal injection lines shall be cut off one at
a time until the coal feed is completely cut off. The dolomite feed to
the unit shall also be stopped. The compressed air, however, should be
maintained to facilitate the withdrawal of the dolomite. When the bed
temperature reached 6£0°F, the water quench to the Quench Pot, D-119,
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FOSTER WHEELER CORPORATION REF. 11-^2331
DATE April 1973
PAGE VI-6
VI. Experimental Program (continued)
1. Startup and Shutdown Procedure (continued)
Normal Shutdown (continued)
shall be taken out of service. The residual dolomite and fly-ash in
the system shall be emptied to the Dolomite Cooler, EC-101. At the
end of the operation, the boiler pressure shall be reduced gradually to
atmospheric pressure to complete the shutdown.
Schedule
The schedule for startup after acceptance of the boiler plant from
the contractor allows four (1;) months for initial startup. This time
period allows for repairs and minor modifications as well as training
of operators.
2. Boiler Performance Tests
The performance test for the Fluidized Bed Boiler unit shall be
adopted from the American Society of Testing Materials Power Test
Code^1). The Code is intended primarily for conventional steam
generation units. Minor modifications, therefore, must be made for
the performance tests of the Fluidized Bed Boiler. Figure VII offers
a format for evaluating the Fluidized Bed Boiler unit performance.
The major modifications included in this form deals with the reaction
and sensible heats of S02 sorption, and formation of CaO and MgO, etc.
Other modifications are minor and are self-explanatory.
For a large commercial unit, the efficiency of the power generation
will be high due to the inclusion of waste heat boiler, turbine expander,
as well as turbine steam generation. However, for the demonstration unit
(1) American Society of Mechanical Engineers PTC U.1-196U Power Test
Codes Steam Generation Units, herein, is believed to be in general
agreement and intention of the ASME Code.
-------
PAGE NOT
AVAILABLE
DIGITALLY
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FOSTER WHEELER CORPORATION REF. 11-$2331
DATE April 1973
PAGE VI-7
VI. Experimental Program (continued)
2. Boiler Performance Tests
these facilities have been deleted for reason of economy. To have a
meaningful determination of the Fluidized Bed Boiler efficiency, the
above facilities should be accounted for. A time period of one month
is allowed for the performance tests.
3. Tests for Operability
A series of tests are required to determine operability and response
of the unit. Operating factors such as capacity turndown, stability
at low capacity, response and tracking, testing for entrainment, heat
transfer, fluidization, removal efficiency of particles from flue gas,
efficiency of combustion and corrosion-erosion tests are required.
After the boiler performance test at normal (A-l Case) conditions,
it is necessary to test turndown from normal capacity with combustion in
the boiler and all auxiliaries operating. Turndown of coal feed (with its
proportionate air quantity) will drop the temperature of the fluidized
bed since the heat transfer area is fixed and the transfer rate in a
fluidized bed is approximately constant with velocity. A drop in temper-
ature of the bed below llj.OO°F may tend to reduce the sulfur removal capacity
of the dolomite. To maintain a temperature above lUOO°F with adequate
sulfur removal capacity in the bed, it may be necessary to drop the level
in the bed as the coal feed is decreased. At some low capacity the fluid-
ization and heat transfer will suffer due to low velocity and low level
of the bed. In addition to capacity turndown, it is desirable to test
fluidized bed pressure turndown. The pressure can be reduced from 160
psig to a few psig above atmospheric pressure. The compressor will still
operate at its design point, however, most of the gas will be bypassed
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE VI-8
VI. Experimental Program (continued)
3. Tests for Operability (continued)
around the boiler and the coal feed will be reduced from normal rate
to the lowest controllable rate, i.e., approximately 10/6 of normal.
A one-month period of operation is required to evaluate turndown.
Turndown tests should not be performed when the boiler is operating
under evaporation mode due to the danger of loss of nucleate boiling
promoting tube burn-out due to low flow and low velocity through
fixed-sized tubes.
Both heat transfer and hydraulics, which includes the determination
of flow vs. pressure drop for both the steam side as well as the fluid-
ized bed side, and fluidization characteristics such as slugging of the
bed, clinkering, etc., will be evaluated during every experimental run
and therefore separate runs are not required.
Operation to test entrainment can be effected by lowering an internal
air-cooled chimney from the outlet of the bed into the free space above
the bed. The internal chimney is welded or cut to fix the disengagement
height. This will allow an evaluation of the effect of freeboard for
various velocities on entrainment. A total elapsed time of four (U)
months may be necessary for this operation due to the down-time required
to modify the internal chimney.
Particulate removal efficiency can be evaluated at different velocities
of flue gases. Tests can be performed by sampling between the boiler
and the Ducon cyclone, between the Dueon and the Aerodyne cyclone and
also after the Aerodyne cyclone and after the quench. Velocity can be
varied by varying flue gas quantity, by changing the number of cyclones
in the flue gas stream and also by bypassing clean air into the cyclones.
Two (2) months are required for testing cyclone efficiencies.
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FOSTER WHEELER CORPORATION REF. 11-£2331
DATE April 1973
PAGE VI-9
VI. Experimental Program (continued)
3. Tests for Operability (continued)
The efficiency of combustion will be evaluated for each test pro-
cedure. Steam production, coal feed rate, amount of carbon in the
entrained particulate, unburned GO and hydrogen in the gas will be
analyzed for each test to calculate the combustion efficiency.
Corrosion-erosion testing will proceed during all tests by in-
spection of all existing equipment between tests, as well as by
inserting a special test loops in the fluidized bed. Each loop will
usually be constructed of a single material such as TP3014H (18-8) to
evaluate erosion-corrosion, as well as welding metallurgy. Loops can
be tested during other boiler test operations.
In addition to the test loop, the entire boiler unit will confirm
materials selection and bundle design by periodic inspection of those
portions exposed to the fluidized bed by measuring metal thickness. An
important part of the materials testing will be derived from the operation
of the turbine cascade tester. Separate test periods for erosion are not
required as erosion will be determined after every shutdown.
Heat Transfer and Fluidization
Various temperature points have been provided for both the horizontal
tube bundle and the wall tubes. The heat transfer rates of the dense
bed section, the dilute phase as well as the section immediately above
the dense bed can be computed.
Operating a fluidized bed unit with relatively large particle size may
sometimes result in slugging problems. The closely-packed horizontal
tube bundles will reduce coalescence and slugging tendency. Radioactive
probe has been provided. The probe could be located at various elevations
of the unit to monitor the slugging height.
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE VI-10
VI. Experimental Program (continued)
3. Tests for Operability (-continued)
The movement of individual particles past the tubes will be of
importance. Short-lived radioactive .particles .may be used .to study
the movement of the particles, the turn-over rate, .residence -tune,
etc., through the horizontal tube bundle, in a manner similar to their
use in commercial 'catalytic fluid .bed systems.
Three (3) sample 'Connections have been -provided on the dense bed
and one on the spent dolomite line. With these .samples it will be
possible to study the degree of particle size separation, at various
heights of the bed.
1;. Reliability Demonstration
In the process industry a new plant is .usually accepted as operable
if the installation-can be'demonstrated 'to -operate, at .-full .capacity
for some minimum .period, such as 'ten days. 'However-, in order to demon-
strate reliability, a developmental .boiler -must 'operate -at -full capacity
for an extended period of 'time. It has been assumed 'that a one-year
period of time will be .required .for operation .under normal capacity
(A-l design case) to adequately demonstrate reliability.
5. Tests for Pollution Abatement
Those factors in the operation of 'the pressurized 'fluidized .bed
boiler effecting S02, NOX and iparticulate matter are:
. Calcium/sulfur -ratio
. Bed temperature
. Bed -height
. Excess 02 in flue gas
. Operating pressure
i
.. Feed and removal locations
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE VI-11
VI. Experimental Program (continued)
5. Tests for Pollution Abatement (continued)
In order to test the effect of the above variables on emissions of
S02 , NOX and particulates, a set of experiments have been developed.
Case A-l will offer an ideal case for pollution control tests. In
this case the excess C>2 in tlie ^ue S38 can ^e increased to 5 mol£. The
normal bed depth of approximately nineteen (19) feet will offer adequate
latitude to study the effects of bed depth. The suggested parameters
to be used in this study will be as follows:
Bed Temp. °F 13*0 ll£0 1550 1650 1750
Ca/S Mol Ratio 2 3 k $ 6
Bed Depth, Ft. 9 H-5 Hi- 16.5 19
Ex 02 in Flue Gas,Mol % 0 1.25 2.5 3.75 5
Operating Press. Atm. Abs. 5 6.25 7.5 8.75 10
The above parameters may be evaluated by means of 33 experiments.
It is not our intent to commit the operation of the developmental boiler
to the full 33 experiment block, since preliminary operation of the boiler
will show that some of the proposed factorial tests may not provide use-
ful data.
6. Test of Long Range Objectives
The long range objectives studies include testing those factors which
may improve steam generating efficiency, reduce S02, NOX and particulate
pollution and will demonstrate the operability of a complete steam
generation facility.
a) Study of different coals and sorbents to improve pollution
removal efficiency.
b) Study of granular bed filter or alternate systems to increase
particle removal efficiency.
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FOSTER WHEELER CORPORATION "EF. 11-52331
DATE April 1973
PAGE 71-12
VI. Experimental Program (continued)
6. Test of Long Range Objectives (continued)
c) Study of turbo-expander operating characteristics to re-
cover as much compression power as possible, including ex-
pander control and its interaction with the air compressor.
The turbo-expander will demonstrate operability and control.
Metallurgy will be determined by operation of the turbine cascade
tester.
d) Alternate tube bundle designs can be studied to improve space
utilization, heat transfer, reduce tube cost and perhaps reduce
erosion.
e) High steam temperature and pressure, while increasing capital
investment, should increase power generating efficiency. The
feasibility of designing the fluidized bed developmental boiler
for steam at 6500 psig and 1300°F was investigated. An advantage
of operating at extreme conditions in a fluidized bed is that the
tube metal temperature can be kept relatively low allowing a reason-
able design stress on the tubes. If the fluidized bed temperature is
assumed to operate at a maximum of 1750°F when the steam temperature
is 1300°F., the skin temperature will be less than 1360°F.
An Inconel material Number 625 (ASTM RliWi) annealed has a rupture
stress of 18,000 psi for $0,000 hours of service according to Inco
Bulletin T-l|20. If an allowable stress of 15,000 psi is assumed
and with a tube thickness tolerance of + 15/6, the O.D. of a 1" I.D.
tube would be less than 1-3/U". This thickness-diameter ratio is
near the limit for hot bending of Inconel 625. At any thickness,
powerful equipment is required for heat forming which can only be
done in the 1950 to 2l50°F. range.
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE VI-13
VI. Experimental Program (continued)
6. Test of Long Range Objectives (continued)
e) (continued)
The developmental boiler has a small test loop which can be
designed for high temperature and pressure steam generation.
In addition to the test loop, some auxiliary equipment such as
a high-head plunger pump, a hairpin exchanger to preheat water
and a quench to reduce steam temperature, plus a pressure re-
ducing station and proper instrumentation to monitor and control
flow, pressure and temperature, must be provided. After success-
ful operation of the test loop, a small bundle could be provided
in the developmental boiler for actual steam generation including
preheat, evaporation and superheat in the fluidized bed boiler.
f) Study fluidized bed combustion at higher pressures. The plant
is mechanically designed to operate at 320 psig in the fluidized
bed. However, to increase pressure from 160 psig to 320 psig it
is necessary to insert an additional centrifugal compressor on
the combustion air (Compressor C-102).
g) Demonstrate operability of the complete power plant installation.
This will require additional fluidized beds for preheat evaporation,
superheat as well as for reheat. The water side will be piped in
series through the fluidized beds. The coal, dolomite, air and
flue gas will be piped in parallel. The beds do not have to be
stacked but all three can be built at grade level. Additional
equipment besides the turbo-expanders will be steam turbo-generator,
condenser, boiler feed water treatment, deaerator, boiler feed water
pumps, electrical switch gear and transformer, heat exchangers.
-------
WESTINGHDUSE RES. LAB
PRESSURIZED FLUIDIZED BED COMBUSTION BOILER
PITTSBURGH, PA.
FIGURE VIII a
OPERATING SCHEDULE
TASK
1
2
3
U
6
NAME
START-UP
OPERABILITY CHECKOUT
BOILER PERFORMANCE TEST
RELIABILITY DEMONSTRATION
TT?^T^ TTHP POT T TTTTOW POWPTJOT
LONfr RAMfiF TF^T^
1ST. Yr.
••
•
—
2ND. Yr.
_
3RD. Yr.
llTH. Yr.
^TH. Yr.
(D (B •
^t:
-------
VII
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FOSTER WHEELER CORPORATION REF. 11-$2331
DATE April 1973
PAGE VII-1
VII. Plant Construction
1. Safety and Emergency Control System
The boiler emergency shutdown trip system is shown on figure VIII-b.
In general, the procedure to be followed in an emergency is to follow
the pattern of a normal shutdown as closely as possible except where
particular emergency conditions require more drastic action.
a) Low Flow of Boiler Feed Water to Tube Bundle
When the boiler feed water to the tube bundle drops to its low
flow set point, an alarm will sound. This will allow the operator an
opportunity to correct the situation. However, should the boiler feed
water flow rate continue to fall to its low-low flow set point, the
low-low flow switch (FSLL) on the boiler feed water circuit trips
the injection and pressuring air to the Injection Drum, D-106, to cut
off the coal feed to the boiler. The switch will also actuate one point
of a multi-point, multi-variable alarm annunciator to indicate such an
emergency has taken place. The low-low flow switch shall be set to avoid
high tube skin temperature of the tube bundle. During evaporation oper-
ation the flow switch shall be set within its minimum nucleate boiling
range. When it is determined that adequate boiler feed water cannot
be obtained, the unit will shut down under normal shutdown procedure.
b) Low Flow Saturated Steam to Tube Bundle
The same type of protection has been provided for the saturated
steam circuit to the tube bundle as that provided for boiler feed water.
The coal feed to the boiler will be cut off when the saturated steam
reaches its low-low flow set point. This is necessary to avoid excess
tube skin temperature of the bundle.
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
VII PLANT CONSTRUCTION (continued) PAGE VII-2
1. Safety and Emergency Control System (continued)
c. Low Flow of Boiler Feed Water to Wall Tubes
The wall tubes of the boiler are also protected against abnormal low boiler
feed water flow rate. The low-low flow switch will trip the coal feed to the boiler.
The low-low now switch (FSLL) should be set within its minimum nucleate boiler range.
d. Tube Bundle Rupture
In the event of a tube leak or rupture of the tube bundle, the high pressure
boiler feed water or steam to the unit must be cut off to protect the boiler. The
flow rate of the boiler feed water or saturated steam to the unit is continuously
monitored against the corresponding preheated boiler feed water, saturated steam
or the superheated steam product. When the flow differential relay senses an ab-
normal difference in flow rates of the two streams, the high flow differential
switches, (FDSH) will cut off the boiler feed water or saturated steam as well as
the coal feed to the boiler.
e. Water Wall Tube Rupture
s The pressure drop data across the water wall tube will be monitored contin-
ually. In the event of a wall tube leak or rupture, the pressure drop across the
wall tubes will drop and the low pressure differential switch (HDSL) will trip the
boiler feed water to the wall and coal injection to the boiler.
f. Dilute Phase High-High Temperature
The boiler bed temperature is controlled by coal injection rate to the unit.
The dilute phase of the unit may at times experience higher temperature than the
bed due to possible after-burning. A high temperature alarm and emergency water
spray system have been provided on the dilute phase to control its temperature.
However, should the dilute phase temperature continue to climb, a high-high
temperature switch, (TSHH) will trip off the coal injection to the boiler.
°
-------
PAGE NOT
AVAILABLE
DIGITALLY
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAQE VII-3
VII. PLANT CONSTRUCTION (continued)
1. Safety and Emergency Control System (continued)
g. Low Pressure Flue Gas
A loss of flue gas pressure due either to back pressure
control valve or rupture disc failure, should cut off the main air
and coal injection to the boiler. This is necessary to avoid an
excessive superficial velocity through the unit to control the
dolomite elutriation loss.
h. Loss of Main Air
On loss of main air from the Main Air Compressor, C-101,
the low flow switch from the main air will cut off the coal and
dolomite to the boiler, followed by normal shutdown procedure.
i. Power Failure
During a power failure, emergency power shall be made available
for the electronic instruments, solenoid actuators and the slide valves.
9 Motor driven compressors, pumps, spent dolomite cooler, RC-101, and
0
the coal/dolomite preparation and injection system will be inoperable.
The safety circuit is so arranged that on trip of the circuit, coal
and dolomite injection to the boiler will be cut off. An interlock
system will be provided on the spent dolomite cooler, RC-101, to shut
off all spent solids to the cooler during power failure.
j. Cooling Water Failure
Upon failure of the cooling water, the main air compressor,
C-101, and the injection air compressor, C-103, will be shut down due
to excessive discharge temperatures. The loss of main air will in turn
cut off the coal injection to the boiler. When the spent dolomite
cooler, RC-101, senses a low flow of cooling water, the low flow switch
will cut off all spent solids to the cooler and shut off the fresh
dolomite to the boiler.
-------
FOSTER WHEELER CORPORATION REF. 11-^2331
DATE April 1973
PAGE ttl-fc
VII PLANT CONSTRUCTION (Continued)
1. Safety and Emergency Control System (continued)
k. Loss of Instrument Air
All control valves during instrument air failure will fail in
a safe manner. The coal and dolomite injections to the boiler will
be cut off. Control valves for the boiler feed water or saturated
steam to the tube bundle or water walls will be in locked position
and continuously admitting boiler feed water or saturated steam through
the tubes. The main air compressor,(C-101),will be taken out of ser-
vice.
1. Manual Shutdown
The unit can also be brought down manually through hand switches.
One hand switch will be located on the instrument board, and another
one mounted locally. In the event of a fire, failure at the main power
plant or any other reason, the manual shutdown switch will trip the
safety circuit to cut off coal/dolomite to the boiler, block off spent
solids to the spent dolomite cooler, (HI-101), and shut down the main
air to the unit.
2. Utilities
Table XEsummaries the utility requirements for four cases.
Coal Design Inclusion of
Capacity Pressure Expander and
Case TPD PSIG C-102 Location
I 26k 160 No ) Adjacent
II 396 320 No ) to a Power
III 396 320 Yes ) Plant
IV 396 320 NO Stand Alone
-------
TABLE NO. IX
CASE NO.
Coal Feed Rate TPD
Fluid Bed Pressure PSIG
Inclusion of Expander and
C-102 Compressor
Dolomite TPD
I Power in KW
a) 13.2 K7, 30,60
b) U.16 KV, 3Cf,60
c) UUO V, 30,60
d) 110 V, 30,60
TOTAL POWER, KW
II Cooling Water GPM
III Treated Water
IV Fuel Oil MM Btu/Hr
V Cooling Tower Make up Water GPM
UTILITY
I
26U
160
No
U32
15,70U
7U6
92
Uo
16,582
2,885
57
3.17
_
SUMMARY
II
396
320
No
6U8
21,221
7U6
110
Uo
22,117
U,OUU
85
U.76
—
III
396
320
Yes
6U6
21,221
3,838
110
25,209
U,63l
85
U.76
—
IV
396.
320
No
6U8
21,221
3,827
380
60
25,U88
*
**
U.76
800
3
m
30
m
m
S
§
so
*
»» >» m
0 -1 Tl
mm'
* Stand-alone unit contains own cooling towers requiring only makeup water
at 5# of circulation rate.
•s* Sttand-alone unit has demineralizer to produce both quench and boiler feed water.
I H'Ul
VAM l\3
\O
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE VII-6
VII. PLANT CONSTRUCTION AND OPERATION (continued)
3. Plot Plant and Elevations
Plot plan and elevations are shown on drawings OP-721-588,
589, & 590. The plot plan was based upon the assumption and
that the pressurized, fluidized bed boiler would be located
adjacent to an existing power plant. Dolomite would be trans-
ported to the plant site by"rail. The dolomite would be dry and
double-screened. Covered rail hopper cars would be required and
unloading would occur under a covered shed to prevent wetting by
the rain. Coal may be introduced by conveyor from the utility
plant's stock pile or it may arrive by open hopper- rail cars.
Steam and boiler feedwater are piped from the development
boiler to the Utility Plant. Spent dolomite and ash are sent
to the utilities ash disposal system by conveyor.
U. Schedule of Design and Construction
The schedule of design and construction is hown in Figure X.
Completion of design and construction will require 20 months.
5. Cost Estimate and Economics
A series of cost estimates are presented for various capacities
and design pressures. Case I has a plant capacity of 22,000
Ibs/hr coal feed (A-l Material Balance) and a design pressure
of 170 psig in the boiler. Case II refers to 50# higher
capacity of 33,000 Ibs/hr coal feed (A-3 Material Balance)
and an operating pressure of 320 psig but minus the high
pressure compressor C-2 and minus the turbo-expander C-U.
Case III at 33,000 Ibs/hr of coal feed and 320 psig includes
the high pressure compressor and expander. Case IV refers to
a stand-alone boiler not adjacent to a power plant.
-------
PAGE NOT
AVAILABLE
DIGITALLY
-------
WESTINGHDUSE RES. LAB
PRESSURIZED FLUIDIZED BED COMBUSTION BOILER
PITTSBURGH, FA.
REF: 11-52331
DATE: April 1973
PAGE: VII-7
FIGURE X
DESIGN AND CONSTRUCTION SCHEDULE
MONTHS
TEARS
PRELIMINARY DESIGN
DETAIL ENG. DESIGN
MAJOR EQUIPMENT
REQUISITION
PURCHASE
DELIVER
DRAFTING
CONSi.AUul.LON
1
0
?
N
3
D
1972
U ! 5 6 7 8 9 10 11 12,13
j IF M i A |M j j A|SJO
1973
i
•
;
i ; i ,
*
(£)••••<£)
(?) —
!
;
!
'Ill
iu 15
N!D
•"©
•
,
16 17 18 19120 21 22I23 2k J25. 26^27 ' 28
J i F M :A ;
M ' J J | A
197U
:
,
,
! ±
W
l
1
1
!
: ! i
i
•
; ;
! 1
J I
• I '
! !
1 ' •
; )
; j
i i
i
i ;
1 '
i 1
i 1
i |
sj
0 'N
D I
i
i
!
1
'
-t;
j
i
n™
i
i
'
•
j
i
•
i
i
-------
.FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE VII-8
VII. PLANT CONSTRUCTION AND OPERATION (continued)
5« Cost Estimate and Economics (continued)
Coal Capacity Boiler Pressure Comp. Plant Cost
Case Ibs/hr psig C-23C-U Delivered •& Erected
I 22,000 170 omit $ 9,730,000
II 33,000 320 omit 13,61;0,000
III 33,000 320 include l6,U20,000
IV 33,000 320 omit 16,390,000
An alternate case was considered when the developmental plant is
located at an independent site some distance from any power
plant. This alternate adds $2,750,000 to either Case II or
Case HI to cover additional equipment such as water treatment,
condensers, boiler feed pumpts, etc. required at our independent
site.
The total program cost considering a three-year operation with
Case I (A-l Material Balance) installation amounts to $17,02U,000.
The total program with a Case II (A-3 Material Balance) install-
ation for a five-year period, including long-term experimental
projects amounts to $29,515,000. Details are presented in
Table X. It has been assumed that no credit can be taken for
intermittent steam generation.
Tables XI and XII present the working capital required and the
operation manpower requirements. Tables XIII-A, XIII-B and
XIII-C present a breakdown of the cost estimates for Case II.
Details of the estimates may be found in Appendix I.
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FOSTER WHEELER CORPORATION REF. 11-$2331
DATE April 1973
PAGE VII- 9
TABLE X
CAPITAL REQUIREMENTS FOR
DEVELOPMENTAL BOILER
Case I Case II
A. Capital (3 years) (5 years)
1. Fixed Capital Investment $ 9,730,000 $13,6UO,000
2. Working Capital $95.000 816.000
$10, .325, 000 $1U, U#, 000
B. Operations
1. Labor @ $12,000/yr (3) $1,9UO,000 $ 3,21*0,000
2. Utilities (1) (2) 2,UU8,000 5,1*90,000
3. Coal & Dolomite (1) (2) 2,030,000 5,100,000
U. Maintenance (@ 3#/yr) _ 876.000 2.0U5.000
Operating Cost $.7.29U.OOO &L$.895.000
Total C ash Requirement 1 7, 6l9, 000 30, 331, 000
Less return of working capital 595.000 816.000
TOTAL COST OF PROJECT $17,021,000 $29,515,000
NOTES:
(1) Assumes on-stream factor of $Q% at normal rate.
(2) Unit cost of utilities, coal & dolomite on next page.
(3) Yearly rate includes fringe benefits and administration.
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April'1973
PAGE VII-10
TABLE No. XI
WORKING CAPITAL
1. One Month Inventory CASE T CASE-I][
a) Coal @ $6/T (l) $U8,000 $ 72,000
b) Dolomite @ $5/T (1) 65,000 98,000
2. One Month Wages plus Administration
5U men @ $12,000/yr (2) 51|,000 5U,000
3. Utilities (A-l Case), One Month
a) Power © $0.01/kw 119,000 159,000
b) Water @ 100/1000 gallons 12,000 17,000
c) Treated Water @ $1/1000 gallons 3,000 UjOOO
d) Fuel Oil @ $6/bbl 2,000 3 ,'000
k* One Year of Maintenance Equipment @ 3% TFI 292,000 t;09,000
Total Working Capital $ £9^000 $ '816,000
NOTES:
(1) Highly dependent on source of material .and location of
plant site.
(2,) Yearly rate includes fringe benefits 'and .'general administration.
-------
SE1-OEI "ON
TABLE NO. XH
MANPOWER REQUIREMENTS
Total *
Men/Shift Men Total ^
~~~~~~ m
m
3O
I. Supervision 0
•so
Plant Manager 1 ^>
Shift Foremen 1 U g
Maintenance Foreman 1 ^
Chemist & Engineers 3 §
Secretary - Clerk 1
Sub-total 10 10
II. Operators
Goal Handling &. Preparation (l shift/D @ 5 days/wk) - U
Dolomite & Coal Injection 1 h
Compressors 1 k
Boiler 1 h
Lock Hoppers & Ash Disposal 1 k
Utilities 1 U
Control House 2 8
Sub-total 32 32
III. Maintenance 2 2 S
~~~--~~— """^ o -i ^i
m m •
Instruments 1 U
Electrical 1 U
Welder - Boilermaker 1 U _
H-
Sub-total 12 12
TOTAL MANPOWER = $h
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAQE VII-12
TABLE XIII-A
COST ESTIMATE
CASE II CASE III
Materials $6,607,000 $7,763,000
Labor 5,131,000 6,370,000
Const. Insurance 72,000 87,000
Engineering & Fee 1,830,000 2,200,000
$13,61*0,000 $16,U20,000
-------
FOSTER WHEELER CORPORATION
REF. 11-52331
DATE April 1973
PAGE VIE-13
TABLE HIIB
COST ESTIMATE
MAJi
PMENT
ITEM
R-101
D-no
D-112
D-113
D-llli
D-n5
D-n6
D-117
DESCRIPTION
Boiler + Extra Bundles
Steam KO Drum
Spent Dolomite Lock Hopper
it ii it M
Primary Cyclone Seal Drum
11 " Lock Hopper
Secondary Cyclone Seal Drum
" " Lock Hopper
D-118 A&B Quench Drum
D-120
D-121
D-122
D-123
E-101
E-103
RC-101
ST-101
C-101
C-103
A-101
F-101
H-102
G-101
G-102
Cyclone Drum
Main Mr KO Drum
ii it it ii
Injection Air KO Drum
Main Air Com. Exch.
Main Air Comp. Exch.
Dolomite Cooler
Stack
Main Air Compressor
Injection Air Compressor
Instrument Air Compressor
Intake Air Filter
Peabody Heater
First Stage Cyclones (U) + Valves
Second Stage Cyclones (U) + Valves
MATERIAL
COST $
938,700
17,600
20,900
20,900
20,600
20,900
20,600
20,900
18,600
32,300
12,000
9,300
3,900
2$,000
5,000
60,000
26,000
9UO,000
155,000
8,100
8,600
28,700
102,500
180,500
CR-106 Spent Dolomite Conveyor
A-102 Purge Air Dryer
SL-101 Flue Gas Silencer
Major Equipment Cost
Labor to Erect Equipment
20,200
10,000
25,000
$2,751,800
$ 550,000
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE VH-Ui
TABLE XIIIC
COST ESTIMATE
CASE: II _ TOTAL MATERIALS & LABOR
MATERIAL LABOR
COST COST
Foundations, Paving & Cone. Structures $ ?li,000 $ U;2,000
Structural Steel & Pipe Supports 127,000 89,000
Building 28,000 l£,000
Piping l|12,000 U00,000
Instruments 137,000 59,000
Electrical 1,225,000 1,270,000
Insulation 85,000 127,000
Testing 2.200 U2.000
Total Other Equipment $2,110,200 $2,171,000
Process Equipment 2.75l»800 550,000
$lt, 862,000 $2,721,000
Coal & Dolomite Injection (D&E) 1.7li5.000 -0-
$6,607,000 $2,721,000
Field Supervision & Indirect Labor - 2.UlO,000
Total Material and Labor $6,607,000 $5,131,000
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Al
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FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE AI-1
APPENDIX I
BASIS OF ESTIMATES
Plant costs presented in Section VII for various cases are based
upon equipment quotations, equipment estimates plus standard account
factors for piping, Instruments and other materials and labor. Factors
are obtained by experience on chemical, petroleum and steam generating
plants of comparable size and complexity. A set of estimating backup
sheets detailing plant costs is included. Equipment items marked "Q"
•are obtained from vendors quotations, those items marked "E" are
estimated equipment. Accounts marked "F11 are factored based on
experience with comparable plants.
In transforming the estimate from Case II, representing a design
at 320 psig boiler casing and 33,000 Ibs/hr coal rate to 170 psig and
22,000 Ibs/hr coal rate (Case I), the plant cost decreased from $13,61$,000
to $9,730,000. Approxljnately $352,000 of this difference was due to the
decrease in pressure and a $3,558,000 decrease was due to the drop in
capacity. The influence of capacity on cost was factored for ,all
equipment except the boiler remained the same size only the two smaller
steam coils being retained. The influence of pressure on cost was
calculated on an item by item basis using such methods as cost per unit
weight for pressure vessels to arrive at a plant cost for 170 psig
design. These plant costs are indicated in Foster Wheeler Corporation's
letter of February 15,1973 to Westinghouse and the costs are detailed on
work sheets under Case I.
-------
FOSTER WHEELER CORPORATION
Kngineers • Manufacturers • Constructor!
110 SOUTH ORANGE AVENUK. LIVINGSTON. N. .1. 07039
BRANCHES IN PRINCIPAL CITIES OF
THE UNITED STATES AND AFFILIATES
IN CANADA. LONDON. PARIS. MILAN.
MADRID. TOKYO AND MELBOURNE
CABLE ADDRESS
REWOP LIVINGSTON HEW JERSEY
TELEPHONE 533-1100
(AREA CODE 2011
February 15, 1973
Mr. E. J. Vidt, Senior Research Scientist
Westinghouse Electric Corporation
Research & Development Center
Beulah Road
Pittsburgh, Pa. 15230
Subject: Pressurized Fluidized Bed
Combustion Boiler
FW 11-52331
Letter No. hi
Dear Mr. Vidt:
Enclosed please find four (U) copies of the revised estimate based
upon 2/3 capacity and a reduction of pressure from 350 psig to 170
psig. Equipment sizes, with the exception of the boiler, have been
changed to reflect the lower capacity.
The reduction in pressure decreases costs $352,000 from the base
case, or 9J6 of the difference between $13,6liO,000 and $9,730,000.
The change in capacity represents 9l£ of the above difference or
$3,558,000.
Very truly yours,
L. W. K&hnstecher
Process Technology Manager
Enclosures
-------
FOSTER WHEELER CORPORATION, 110 SOUTH ORANGE AVE., LIVINGSTON, N,
ESTIMATE SUMMARY
35
J.
«5
1
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0
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE A-II
APPENDIX II
EQUIPMENT SPECIFICATIONS
The following Appendix includes equipment specifications covering:
1. Vessels
2. Coal and Dolomite Receiving and Preparation Systems.
3• Compressors
U. Exchangers
1W'
5. Instrumentation and Analyzers
6. Piping
7. Vendors Proposals
-------
FOSTER WHEELER CORPORATION
REF. 11-52331
DATE April 1973
PAGE A-II-1
A-II. EQUIPMENT SPECIFICATIONS
Equipment List
The following items are included within the scope of the proposed
plant.
Item No. Service
REACTOR R-101 Fluidized Bed Boiler
DRUMS D-101 Wet Coal Hopper
D-102 Coal Silo
D-105 Lock Hopper
D-106 Injector Hopper
D-10? Dolomite Receiving Hopper
D-108 Dolomite Silo
D-109 Lock Hopper
D-110 Steam Separator
D-111 Dolomite Injector
D-112 Spent Sorbent Lock Hopper
D-113 Spent Sorbent Lock Hopper
D-11U Primary Cyclone Seal Drum
D-115 Primary Cyclone Lock Hopper
D-11? Secondary Cyclone Lock Hopper
D-118A Quench Drum
D-llbB Quench Drum
D-120 Cyclone Drum
D-121 Main Air K.O. Drum
D-123 Injection K.O. Drum
-------
FOSTER1 WHEELER: CORPORATION
A-II.EQUIPMENT SPECIFICATIONS, (continued);
Itemi No•«. Servica
T'ANK TK'-IOT Fuel. Oil Storage Tank
EXCHANGERS E-10T Compressor Air Cooler
Ei-103 Compressor Air Cooler
H-101' Air Heater
H-102 Air' Preheater
RC-tOT Spent Dolomite Cooler
RK-TOT Coal Dryer
C-101 Main Air Compressor
C-103 Injection Air Compressor
P-101A&B Fuel Oil Pumps
B-101 Air Blower
B-102 Vent Gas Blo-wer
Intake Air Filter
Bag Filter
First Stage Cyclones
Second Stage Cyclones
Primary Cyclone
Wet Coal Conveyor
Dry Coal Conveyor
Coal Elevator
Dolomite Conveyor
Dolomite Elevator
CR-106 Spent Dolomite Conveyor
REE., I1j-5233)1
DATE. April. 1973)
PAGE A-II-2
HEATERS.
ROTARY COOLER-
KILN
COMPRESSORS'
PUMPS
BLOWERS
FILTERS F-101
F-102
CYCLONES G-101
G-102
G-103
MATERIAL CONVENING CR-101
CR-102
CR-103
CR-10U
EQUIPMENT
-------
FOSTER WHEELER CORPORATION
A-II.EQUIPMENT SPECIFICATIONS (continued)
Item No.
MISCELLANEOUS
REF. 11-52331
DATE April 19?3
PAGE A-II-3
FUTURE
a
2
Service
A-101 Instrument Air Compressor & Dryer
A-102 Purge Air Dryer
SL-101 Flue Gas Silencer
SR-101 Coal Crusher
ST-101 Stack
Control House
Compressor House
Rail Unloading Shed
Coal Injection Shed
A-201 Water Treater
C-102 Main Air Compressor
C-10I; Turbine Blander
D-122 Main Air K.O. Drum
E-102 Compressor Air Cooler
E-201 Steam Condensers
FT-201 Cooling Towers
P-201 Booster Pumps
P-202 BFW Pumps
P-203 Cooling Dfeter Pumps
P-20U Injection Water Pumps
TK-201 BFW Storage Tank
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE A--II-U
A-II. EQUIPMENT SPECIFICATIONS (continued)
Vessels
Pressure vessels and atmospheric drums are included in this section
on the basis of the specifications noted on the following drawings and
as given below:
Item No. Service Drawing No»
D-110 Steam Separator OP-72U-852A
D-112 Spent Sorbent Lock Hopper OP-72U-8U9A
D-113 Spent Sorbent Lock Hopper OP-72U-8U9A
D-11U Primary Cyclone Seal Drum OP-72U-85QA
D-115 Primary Cyclone Lock Hopper OP-72l|-8!?1 A
D-117 Secondary Cyclone Lock Hopper OP-72U-851A
D-118A&B Quench Drum OP-72U-853A
D-120 Cyclone Drum OP-72U-898&899
D-121 Main Air K.O. Drum OP-72U-85U
D-123 Injection K.O. Drum OP-72U-860A
All pressure vessels shall be designed, constructed, inspected
and tested in accordance with the ASME Boiler and Pressure Vessel
Code, Section VIII, Division 1, latest revision and all applicable
addenda. Drums which will operate at atmospheric pressure shall
generally adhere to the requirements of the code, but actual con-
struction shall be in accordance'with what is referred to as "Good
Commercial Practice."
-------
FOSTER WHEELER CORPORATION REF. 11-52231
DATE -Aoril 1973
PAGE A-H-5
A-II. EQUIPMENT SPECIFICATIONS (continued)
The dual layer linings required for some of the vessels shall
consist of a lightweight insulating castable adjacent to the vessel
wall to give the desired reduction in temperature and a covering
layer of dense refractory castable to protect the insulating layer•
Both linings shall be gunned in place, if possible, and shall be sup-
ported by anchors welded to the vessel shell. Casting or trowelling
of the lining, will be allowed if access prevents the gunning operation
from being employed. The lining shall be installed in the vessel
fabricator's shop. The curing and drying of the lining installation
shall also be performed in the shop prior to shipment of the vessels
to the job.
The lining thickness requirements are specified on the vessel
drawings. The materials shall be as follows, or the equivalent thereof:
Insulating Castable - AP green Light Weight Castable VSL-J>0
as manufactured by AP Green Refractories
«•
Refractory Castable - Lo - Abrade as manufactured by AP Green
Refractories Co.
-------
FOSTER WHEELER CORPORATION
ITEM NO.
QUANTITY;
PURPOSE;
DESCRIPTION:
SPECIFICATIONS!
REF. 11-52331
DATE April 1973
PWE A-II-6
OM-101 Coal Preparation Unit
One (1)
To dry and crush coal to proper size range.
Vet coal will be received from an existing' hopper at
a size of l*g" x 0". The coal is elevated, dried and
crushed.
Supplier's equipment starts at the elevator after the
existing feed hopper. Supplier's equipment at the
injection system.
1. Capacity - 120,000 Ibs/hr of wet coal.
2. Maximum moisture- assume 10$ by wt.
3. Coal type - Ohio Pittsburgh No. 8 (see table of properties).
li. Operation - one shift of 8 hrs. per day for five days
per week at design capacity. For operation at maximum
capacity of $Q% over design (180,000 Ibs/hr) assume
operation for two shifts per day for five days per week.
5. Duty; a) To dry coal from 10$ by wt. to 3% by wt.
b) To crush coal from l^g" x 0" with minimum
fines below £00 microns.
6. Turndown required - none. (Operates UO hours per week)
7. Materials - suitable for size and type of coal indicated.
8. Location - equipment will be located outdoors in Midwestern
USA.
-------
PAGE NOT
AVAILABLE
DIGITALLY
-------
FOSTER WHEELER CORPORATION
REF. l
DATE April 1973
PAGE A-II-7
ITEM NO.;
QUANTITY;
PURPOSE:
OM-102 Coal injection unit
One (1)
Coal is continuously fed into reactor at a uniform
controlled rate through multiple feeders.
DESCRIPTION;
SPECIFICATION:
Dry and crushed coal is pneumatically conveyed from
existing storage silos, at a uniform feed rate to a
to a Petrocarb, Inc. or equal multiple injection
method. The supplier's equipment starts at the storage
silos and ends at the reactor.
1. Capacity - continuous
Coal - 33,000 Ibs/hr max.
2. Coal - V x 0" with 3.35? by wt. moisture
3. Operation - continuous, 3 shifts per day, 7 days
per week.
h' Pressure at reactor (receiver for injection)
a) Normal - 170 psig
b) Design - 320 psig
5. Feed Points
a) Four (h) active lines
6. Approximate dimensions for feeder lines about 50 ft.
lateral and hO ft. vertical.
7. Turndown required - to 2,200 Ibs/hr (10# of A-l Case)
8. Materials - suitable for continuous operation with size
and characteristics of coal indicated.
9. Location - equipment will be located outdoors in Mid-
western USA.
-------
FOSTER WHEELER CORPORATION REF. 11-52331-
DATE April 1973
PAGE A-II-8
A-II. EQUIPMENT SPECIFICATIONS
2. Coal Preparation Alternate
An alternate quotation Has received for a coal crusher and
dryer from Williams Patent Crusher and Pulverizer Company, Inc.
as a possible replacement for part of the Petrocarb Coal
preparation equipment. This proposal is included as well as a
comparison of the estimated coal size distribution from
Williams and from Petrocarb. It can be seen that the Williams
crusher claims a reduction of coal to 0 x 1/U" size with less
fines than the Petrocarb system. However, due to the higher
cost of the Williams crusher, it was decided to use the
Petrocarb system.
-------
WILLIAM*
IATE>
WENT CRUSHER**/PULVERIZER Cajnc.
CABLE AOORESS("OU5H£R:ST.LOUIS"
A-II-9
CRUSHERS
GRINDERS
SHREDDERS
AIR SEPARATORS
TELEPHONE: AREA'CODETl 4 e'n.3348
270l-'272r3-'NORTH BROADWAY
SI. LOUIS, MO., U.S.A. 63102
September 20, 1972
Foster Wheeler Corp.
110 South Orange St.
Livingston, N.J. 07039
Attention: Mr. L. W. Zahnstecher
Subject: Your Ref: FW11-52331
Westinghouse Research Laboratory
Gentlemen:
This is in reply to your September 1st request for a price
estimate and information on our coal preparation system.
Williams can provide a complete engineered package system entirely
automated, with our patented inert gas system to prevent
explosions and fires, and because the entire system is under
negative pressure it is clean and dustless.
We understand the system capacity and function is to handle
60 tons per hour of 10% moisture coal, to be crushed from 1%"
x o to kn x Q with the moisture reduced to less than 3%.
Based on the coal feed to the system containing 1% or less
minus 40 mesh (U.S. Std.) equivalent to 420 microns, the
approximate size distribution of the minus V product is as
follows:
USHERS.GBinOEqaSHREODERS.PUlVERIZERS.ROLLERmiLLS.fllBSEPBBPTOBS.VIBRBTinGSCREEnS.COMPLETE PinnT8.»CCESSORIES
-------
A-II-10
2 To Poster Wheeler Corp,
Date September 20, 1972
Sieve Size (U.S. Std.)
1/4"
6 pesh
10 mesh
40 mesh
100 mesh
200 mesh
Cumulative Percent Passing
From Crusher System From External Screen
86.7
54.1
38.4
13.5
4.0
1.4
100
62.4
44.4
15.6
4.6
1.6
From our discussions with Mr. Ed. J. Vidt of Westinghouse we
learned they intend to screen the one-pass crushed product and
recycle the oversize. This insures an absolute control^on 100%
passing V top size and avoids over-crushing to result in an
absolute minimum of fines as indicated above.
Please refer to page 4 of the enclosed Bulletin No. 856. This
illustrates the system we propose to furnish except that item
(B) Roller Mill will be replaced by an Impact Mill similar to
that shown by figure 1840- page 9 of the enclosed Bulletin No.
723. And item (D) Spinner Separator will be replaced by a Venturi
Separator.
Basically the system will consist of the following major
components:
(1) Vibratory Feeder with Automatic Feed Control Panel
(2) #5100 Impact Mill with V-Belt Drive and 200 HP Motor
(3) Venturi Separator
(4) Cyclone Collector, heavy duty vacuum type. Rotary Discharge
Valve, chain drive and 5 HP gear motor.
(5) Main Fan, heavy duty high static type, with drive and 600 HP
Motor. Rated at 74,000 SCFM.
(6) Air Duct for closed circuit Air System, including Inert Gas
Duct Circuit.
-------
A-II-11
To pogter wheexe,. Corp. Date September 20, 1972
(7) Air Heater, 25 million BTU capacity per hour, having
Automatic Ignition, latest Minneapolis-Honeywell Control Panel as
manufactured for Williams Crusher Company utilizing R4138A Flame
Safety Programmer and R7161C VersatroniK indicating high
temperature limit; Automatic Mill Temperature Control with
Partlow Recording Instrument suitable for modulating flame;
Controls mounted in a NEMA 12 Panel/ wired and piped, shipped
as a package including hot air duct to Mill.
(8) Fabric Dust Collector with 11 ounce woven dacron bags
complete with reverse jet blowers, factory assembled blow
ring carriage, housing braced for 16" water gauge internal
static pressure, pre-wired electrical controls for pressure con-
trolled cycling of blow ring carriage; factory assembled
complete with V type hopper; screw conveyor, airlock, and
drive motor.
(9) Auxiliary Exhaust Fan, heavy duty type with V Belt
drive and 250 HP Motor.
Total system price- approximately for estimating $320,000.00
F.O.B. factory.
Shipment approximately 25 weeks.
It is difficult for us to estimate the amount of sulfur
released to the atmosphere, but the dust emmission will be
practically negligible.
We are represented in your area by Brumitt Associates with
Mr. Ron Schmidt at P. O. Box 265, Madison, N.J. 07940 -
(201) - 377-2195.
Please let us know how we can be helpful as you proceed.
Yours very truly,
WILLIAMS PATENT CRUSHER & PULVERIZER CO.
rJ. P. Hensel
Regional Sales Manager
JPH/JS
-------
E-465
A-II-12
ESTIMATED PARTICLE SIZE DISTRIBUTION
OF
PREPARED COAL
100
1000
Microns
Q.I
Petrocarb, Inc.
10/2/72 HR
-------
FOSTER WHEELER CORPORATION
REF.
DATE April 1973
PAGE A-II-13
ITEM:
QUANTITY:
PURPOSE:
DESCRIPTION:
SPECIFICATION:
OM-103 dolomite loading and injection system
One (1)
To unload fresh dolomite from railroad hopper cars and
feeding the dolomite to pressurized reactor through lock
hoppers.
Dry and screened dolomite shall be fed from railroad
spur track to silo (s) for inventory storage. The
dolomite shall then "be fed from a live shelf bin to
lock hopper. When the lock hopper is full, the unit
shall be pressurized and feeding to a injection drum.
Dolomite shall then be fed from the injector to the
reactor under pressure and at a continuous rate.
1. Capacity
a. Silo(s) - l800 short tons (approximately two-days
inventory).
b. Dolomite injector - Dolomite injector shall be
sized for feeding the reactor at a maximum rate
of 28 ST/Hr at a uniform and continuous rate.
2. Dolomite Feed
a. Dried and double-screened lA" x 28 mesh
b. Bulk density 9$ lb/cf.
c. Skeletal density - 175 lb/CF
3. Operation
a. Silo (s) - silo shall be designed for intermittent
operation.
b. Feeding the reactor from the lock hoppers must be
continuous and uniform in the feeding rate.
c. Pollution abatement - dust generated during loading
of the silo and lock hoppers shall be recovered.
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April" 1973
NO: OM-103 Dolomite Loading (continued)
SPECIFICATION; U. Pressure
a. Silo(s)
a. Silo(s)
i) Normal operation - atmospheric on top head.
ii) Design-atmospheric on top head
b. Lock Hopper
i) Normal operation - 170 psig
ii) Design - 320 psig
c. Injector
i) Normal operation - 170 psig
ii) Design - 320 psig
5. Approximate Dimension
a. Railroad hooper cars will be located approximately
300 feet from the silo(s).
b. The dolomite injector will be located IjQ feet,
laterally, from the silo(s).
c. The dolomite injector will be .feeding the reactor
at an elevation of 80 feet above the grade.
6. Turndown Required
Required turndown is to 3,573 Ibs/hr (IQg of A-l Case)
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE A-II-15
ITEM NO.: G-101 A, B, C & D First Stage Cyclones
SERVICE! Fluidized Bed Boiler
NO. OF STAGE; One (l)
NO. OF CYCLONES Four (k)
PER STAGE;
TYPE OF CYCLONE; Ducan Type 700 VM, size 200 or equal
OPERATING CONDITION;
Cases A.1 A.2 A.3
No. of Cyclone in Service 3 2 h
Fluid Flue Gas —
Operating Temperature, °F 1,600 1,600 1,600
Operating Pressure, PSIA 169.7 169.7 169.7
Atmospheric Pressure, psia 11*.7 ll«7 ll*.7
Capacity, ACM 19,750 12,81*7 27.155
Gas Characteristics (Ex. Dust)
Density, Lb/CF 0.231 0.230 0.232
Average Mol Wt. 30.16 30.0U 30.30
Viscosity, centipoise 0.01*3
Dust Loading Grains/CF 28.9 26.7 31.58
Inlet Velocity, fps 51^.9 53.5 56.6
Pressure Drop inches W.G.
Inlet to Outlet 15.7 15.0 16.8
Inlet to Dipleg 22.6 21.6 2l*.0
Dipleg Diameter 8"
Cyclone solid emission grains/ACF 3.005 2.789 3.21*6
Dust Characteristics
Composition
Ash (Fly ash) 60 Wt. %
Dolomite 10 Wt. %
Carbon 30 Wt. %
Particle Size Distribution. grains/CF
(at inlet to cyclone)
Less than 1 micron 0.05
1 to 3 microns 0.1*79
3 to 5 microns 0.77li
5 to 10 microns 2.161
10 to 20 microns 2.21*2
20 to 50 microns 3.8?2
50 to 100 microns 5.095
Larger than 100 micron 5«706
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE A-II-16
ITEM NO.; G-101 A, B, C & D First Stage Cyclones (Cont'd)
Apparent Particle Density gin/ml
Flyash 0.5
Dolomite .- r.2.8
Carbon 1.2
Design Condition
For internal Ingtallation
Temperature, F. 2,000--
Pressure, psi '2—
For External Installation
Temperature, °F 2,000-
Pressure, psig -320—
Notes:
1. For external installation the exposed surface of the cyclones, shall
be kept at 300°F (max.).
2. Dimension insdie of the lined icyclone shall be the same as for the un-
lined cyclone.
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April "1973
PAGE A-II-17
ITEM ND.; G-102 A, B, C &. D Second Stage Cyclones
SERVICE; Fluidized-Bed Boiler
NO. OF STAGE; One
NO. OF CYCLONES Four
PER STAGE;
TYPE OF CYCLONES; Aerodyne Series S Type III Model 1»500 or equal
OPERATING CONDITION;
Cases A.1 A. 2 A.3
No. of Cyclone in Service 3 2 1|
Fluid ------------- Flue Gas — - --------
Operating Temperature, °F 1600 1600 l6oo
Operating Pressure, psia. 168.U 168.6 168.1
Atmospheric Pressure, psia 1U.7 1U.7 l[i 7
Capacity, ACFM 198^9 12,908 27839
Gas Characteristics (Ex. Dust)
Density, Lb/CF 0.2295 0.2289 '0.2301
Average Mol Wt. 30.16 30.0& 30.30
Viscosity, centipoise O.Oltf 0.0lj3 0.0li3
Dust Loading, Grains/CF 2.896 -2-.7761 3.220
Pressure Drop, Inc. W.G.
Primary Gas 5.5 5.«J 5.5
Secondary Gas 21.0 21.0 21 0
Dip Leg +2.0 +2.o +2.'0
Cyclone Solid Emission, grains/ACF 0.295 0.27lj 0.321
Ace. Cyclone efficiency, % 90.1 90. i 90
Dust Characteristics
^^^^^"•^^^^^•^"^^•"•^
Compositipn wt.
Ash (Flyash) __________________ 50
Dolomite __________________ lo
Carbon ,
-------
FOSTER WHEELER CORPORATION
Case
Particle Size Distribution
Particle Size
1.27
5.55
12. kO
2U.89
U6.62
77.81
81.67
85«5li
89.1*1
93*.27
97.09
100.88
10U.59
108.23
111.77
Less Than
Microns
n
n
n
"
it
n
n
n
n
n
n
n
n
n
Apparent Particule Density em/ml
Flyash
Dolomite
Carbon
Design Condition
For Internal Installation
Temperature, °F
Pressure, psi
REF. 11-523U
DATE April iy?3
PAGE A-II-13
A.I A.2
Ace, Weight Percent
Inlet Outlet
9.62 18.7
57.55 97.2
85.03 100.0
92.58
95.61
96.76
97.29
97.73
98.09
98.37
98.62
98.85
99.06
99. 2h
99. kO
Inlet Outlet
9.57 U8.5
57.29 97.2
8U.91 100.0
92.1i9
95.56
96.69
97.23
97.68
98.05
98.3U
98.59
98.83
99.03
99.22
99.38
p g
1 .<>
Inlet
9.73
58.22
85.32
92.80
95.8U
96.93
97. UU
97.85
98.19
98.U5
98.70
98.93
99.12
99.29
99.U5
Outlet
U8.75
97.3
100.0
——2
-------
FOSTER WHEELER CORPORATION
REF. 11-52331
DATE April 1973
PAGE A-II-19
ITEM;
QUANTITY;
TYPE; '
TYPE DRIVE;
PROCESS PERFORMANCE;
NOTES;
C-101 Main Air Compressor
One
Multistage Centrifugal
Motor
Fluid Air
Intake Temp., T1 77
Atmospheric Pressure, PSIA lU.7
Intake Pressure, PSIA 1U>3
Discharge Pressure, PSIA 185
Desired Discharge Temp., F 500
Capacity MMSCFD (Dry) (No Neg Tol) .llU.l
Moisture Content at Intake, Vol. % 2.1
(1) Intake temperature will vary from-10°F to 95°F. At temperature below
design the intake capacity will remain constant.
(2) When Intercoolers are required, allow 5 PSI pressure drop. Air outlet
temperature from the coolers 110°F (Min.).
(3) Vendor to provide complete self-contained oil lubricating system.
(h) Air filter and intake silencer will be provided by others.
(5) Buffer seal gas will be made available, if required.
-------
FOSTER WHEELER CORPORATION REF. 11-52331
6ATE April 1973
PAGE A-II-20
ITEM: C-103 Injection Air Compressor
QUANTITY: One
TYPE; Single Stage Centrifugal
SERVICE; a. Injection and Pressuring air to Petrocarb Unit
b. Aeration air to hoppers
c. Purge air for instruments
DRIVE! Motor
PROCESS PERFORMANCE; Fluid Air
Intake Temp., °F 100
Atmospheric Pressure, PSIA lU.7
Intake 'Pressure, PSIA 180
Discharge Pressure, PSIA 315
Capacity MMSCFD 17.0
Moisture Content at Intake, Vol.£ Saturated
NOTES:
(1) Compressor casing shall be designed for U65 psia discharge
pressure.
(2) Compressor will take suction from Main Air Compressor, C-101.
(3) Vendor to provide complete self-contained oil lubricating
system.
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE A-II-21
ITEM; F-101 Intake Air Filter
QUANTITY; One
SERVICE; Main Air Compressor
PROCESS PERFORMANCE;
Fluid Air
Intake Temp. °F -10 to 95
Atmospheric Pressure, psig lU.7
Capacity MMSCFD HU.U
Allowable Pressure Drop
across intake line, psi 0.3 max.
Allowable Noise Level dBA 90 max. (1)
Intake Line Size Inches 1(8 max.
NOTES;
(1) The noise level of the suction line shall be kept at 90 dBA at
less at 10 feet from air intake. If necessary, an intake silencer
shall be provided.
(2) Total pressure drop of the intake filter and silencer should not
exceed 0.3 psi.
(3) The intake air filter shall have weather louvres.
-------
FOSTER WHEELER CORPORATION
A-II-22
PUMP PROCESS DATA
CUSTOMER Westinghouse Research Laboratory
Pittsburgh. Pa.
P-101 A&B
LOCATION
ITEM NO.
SERVICE
SPARE ALSO COMMON TO ITEM
JOB NO
SHEET —L
11-52331
OF
1
Fuel Oil Pump
REV.
DATE
BY
PUMP TYPE: [] CENTRIF. 0 RECIP. POWER Q RECIP. STEAM Q ROTARY
one
NUMBER OF PUMPS REQUIRED: Two
TYPE OF DRIVER: Motor
OPERATING
OPERATING
one
SPARE
SPARE
METERING
one
one
DUTY: D CONTIN. D INTERMITT .« APPROX.,
2080
HRS/YR.
PROCESS REQUIREMENTS PER PUMP
OPERATING CASE
Desii
MINIMUM
FLOW CASE
JSE
LIQUID
No.
Fuel Oil
PUMPING TEMP.: NORMAL
OF
130
EXPECTED MAX.
130
SR.GR. 9 P.T.:
RATED (MIN.)
0.03
EXPECTED .MIN.
VAPOR PRESS. 9 P.T.
PSIA
0.1
VISCOSITY 9 P.T.
CAPACITY « P.T.:
CKS
REQUIRED U.S. GPM
NORM. U.S. GPM
DISCH. PRESS.;
REQUIRED PS10
SUCT. PRESS.:
REQUIRED PSIG
DIFFERENTIAL PRESS.
(MAX. POSSIBLE) PSIG
P5I
ISO
DIFF. HEAD (CENTRIF.PUMPS ONLY) FT
HPSH AVAILABLE
FT
CORROSION/EROS ION FROM
Nil
SPECIAL DETAILS
FLOW CONTROLLED BY
LC
TC
D OTHER
METHOD OF STARTING SPARE PUMP;
LJ MANUAL D AUTOMATIC
DRIVER STEAM: INLET
EXHAUST
NOTES:
MATERIALS RECOMMENDED
CASING
INTERNALS
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE A-II-23
ITEM: RC-101 Spent Dolomite Cooler
QUANTITY; One (1)
PURPOSE; To cool spend dolomite and fly ash from various look hoppers.
DESCRIPTION; Spend dolomite at elevated temperature and pressure will be
fed first to the lock hoopers. Periodically the lock hopper
will be depressured discharging the dolomite into the
spent dolomite cooler. Fartciulate (fly ash) recovered
from various cyclones will also be discharged to the
appropriate lock hoppers for loading to the same cooler.
SPECIFICATION;
Spent
Dolomite Fly Ash Design
Operating Temp., °F (Inlet) 1,750 1,600
Operating Pressure Atm. Atm.
Design Temperature, °F 2,000 2,000 2,000
Design Pressure Atm. Atm. Atm.
Capacity, TPH (Normal) 15.75 2.3U
Capacity, TPH (Design) 21.3 3.2 2l|.5
Desired Cooler Outlet Temp., °F 300 (Max.) 300 (Max.) 300 (Max.)
Particle Size
^' x 0
Less than 20 microns 28 Wt. %
20-50 microns 19 Wt. %
^0-100 microns 25 Wt. %
Greater than 100 microns 28 Wt. %
Particle Bulk Density, Lb/CF 95 31
NOTES;
1. In order to protect the down stream equipment, the outlet temperature of
the spend dolomite cooler must not exceed 300°F at the rated capacity of
2lu5 TPH.
2. The cooler shall be designed to handle very fine particles from spent
dolomite and/or fly ash.
3. Cooling water to the unit will be available at 85°F and 50 psig. Cooling
water return shall be restricted to 12QQF.
-------
FORM NO. 135-128 A
MATERIAL REQUISITION
FOSTER WHEELER CORPORATION
110 SOUTH ORANGE AVENUE, LIVINGSTON, N. J.
A-II-21
SHELL & TUBE
EXCHANGERS
PAGE 1 OF 1
CONTRACT NO. 11-52331 | REQ'N. NO. | DATE
CUSTOMERS NAME
Westinghouse Research Lab.
| LOCATION Pittsburgh, Pa.
9/13/72
SUPERSEDED BY
CHANGE NO.
DATE
SERVICE OF UNIT
C- I C-2 C
Compressor Air Cooler
SIZE UU» x 18'0" TYPE A-J-S
SQ.FT. SURF. /UN IT 'fffff 9700 SHELLS/UNIT
PERFORMANCE
FLUID CIRCULATED
TOTAL FLUID ENTERING
VAPOR
LIQUID
STEAM
HON-CONDENSABLES
FLUID (VAPORIZED)(CONDENSED)
STEAM CONDENSED
GRAVITY
VISCOSITY
MOLECULAR WEIGHT Vapor Mix
SPECIFIC HEAT
THERMAL CONDUCTIVITY
LATENT HEAT
TEMPERATURE IN
•TEMPERATURE OUT
OPERATING PRESSURE. INLET
NO. PASSES PER
SHELL
VELOCITY
PRESSURE DROP -
ALLOW. ICALC'D.
FOULING RESISTANCE, MIN.
HEAT EXCHANGED
TRANSFER RATE -
SHELL
-3 C-4 C-5
C-6
ITEM NO. E-101
nSfiyj1 CONNECTED IN
one SQ.FT. SURF. /SHELL 'ffrff
OF ONE UNIT
SIDE
Air
3&6.50U
361 .666
LB/HR
LB/HR
LB/HR
LB/HR
U83H
LB/HR
LB/HR
LB/HR
28.6
BTU/LB-°F
BTU/HR-FT-OF
BTU/LB
385
110
°F
OF
35 (P£H)(PSIQ)
Divided Flow
FT/SEC
li.O PSI I
0.002
- BTU/HR. 2L. LOO. 000
SERVICE 28.08
PSI
TUBE SIDE
Cooling Water
977 .200
LB/HR
LB/HR
(195U GPM) 977.
200 LB/HR
LB/HR
LB/HR
LB/HR
LB/HR
BTU/LB-°F
BTU/HR-FT-OF
BTU/LB
85
110
50
Two
5.9
10.0 PSI I
°F
OF
fcBSWHPSIG)
FT/SEC
PSI
0.002
MTD CORRECTED-OF 89.6
CLEAN
CONSTRUCTION OF ONE SHELL
DESIGN PRESSURE
TEST PRESSURE
DESIGN TEMPERATURE
TUBES C-STL
SHELL C-STL
75
Per Code
L35
PSIG
PSIG
OF
75
Per Code
160
PSIG
PSIG
OF
(3) NO. 1110 O.D. 3/U" BWG1U flm?? LENGTH18'0» PITCH 1"
Lh" I.D.
CHANNELXfflUfiSJKKX c-STL
TUBESHEET - STATIONARY C-STL
BAFFLES - CROSS
BAFFLES - LONG
TUBE SUPPORTS
C-STL TYPE DHL SEGM
TYPE
SHELL COVER C-STL (Mt&fi)(REMOV)
CHANNEL COVER C-STL
TUBESHEET - FLOATING C-STL
FLOATING HEAD COVER C-STL
IMPINGMENT PROTECT I ON Place Shell
Inlet on
vapor belt - leave K.O. on bottom for
TUBE TO TUBESHEET JOINT Expanded
exiting vapor
GASKETS
CONNECTIONS - SHELL SIDE IN 30"
CONNECTIONS - TUBE SIDE IN 10"
CORROSION ALLOWANCE - SHELL SIDE 1/8 IN
CODE REQUIREMENTS ASME VHI-Div. 1
OUT (2) 22" RATING 150
OUT 10" RATING 150
#RF
#RF
TUBE SIDE 1/8 IN.
TEMA CLASS B
REMARKS: 1 NOZZLE & SUPPORT LOCATION TO' BE AS NOTED ON F.W. STD. 2IBII.I
2 FOR GENERAL NOTES REFER TO REQ'N.
WHICH IS AN INTEGRAL PART OF THIS REQ'N
(3) Wolverine finned tube (19 F/I) #60-195065 or equal
-------
FORM NO. 135- 128 A
MATERIAL REQUISITION
FOSTER WHEELER CORPORATION
110 SOUTH ORANGE AVENUE, LIVINGSTON, N. J.
A-II-25
SHELL & TUBE
EXCHANGERS
PAGE 1 OF 1
CONTRACT NO. 11-52JJ1
CUSTOMERS NAME Westinghouse Research Lab.
I REQ'N. MO. | DATE
|LOCATIONPittsburg, Pa.
9/2/72
SUPERSEDED BY
CHANGE NO. C- 1 C-2
DATE
SERVICE OF UNIT Comp. Air Cooler
SIZE 21" x 20 "0" TYPE AES
C-3 C-4 C-5
C-6
ITEM NO. E-103
7&&V CONNECTED IN
SQ.fT.SURF./UNIT^ffftf' 96li SHELLS/UNIT one SQ.FT. SURF. /SHELL (Jffi
f 96U
PERFORMANCE OF ONE UNIT
FLUID CIRCULATED
TOTAL FLUID ENTERING
VAPOR
LIQUID
STEAM
NON-CONDENSABLES
FLUID (VAPORIZED)(CONDENSED)
STEAM CONDENSED
GRAVITY
VISCOSITY
MOLECULAR WEIGHT
SPECIFIC HEAT
THERMAL CONDUCTIVITY
LATENT HEAT
TEMPERATURE IN
•TEMPERATURE OUT
OPERATING PRESSURE. INLET
NO. PASSES PER SHELL
VELOCITY
PRESSURE DROP - ALLOW. JCALC'D.
FOULING RESISTANCE, MIN.
SHELL SIDE
Air
h0612
LB/HR
LB/HR
536
U03
LB/HR
LB/HR
LB/HR
LB/HR
LB/HR
BTU/LB-°F
BTU/HR-FT-OF
BTU/LB
500 °F
100
OF
170 (mSHPSIO)
One
li PS
0.002
HEAT EXCHANGED - BTU/HR. h. 120. 000
TRANSFER RATE - SERVICE hi. 8
FT/SEC
1 PSI
TUBE SIDE
C.W.
27U.667
5U9 GPM
LB/HR
LB/HR
LB/riR
LB/HR
LB/NR
LB/HR
LB/HR
BTU/LB-°F
BTU/HR-FT-OF
85
100
50
Two
BTU/LB
OF
OF
COUCH PSIG'
FT/SEC
6 PSI I
0.002
MTD CORRECTED-jPJ °F 97.5
CLEAN
PSI
CONSTRUCTION OF ONE SHELL
DESIGN PRESSURE
TEST PRESSURE
DESIGN TEMPERATURE
200
PSIG
PSIG
600
OF
TUBES CS NO. 252 O.D. 3/li BWG 1h W
SHELL CS 21"I.D.
CHANNEL XKJOHBSEK CS
TUBESHEET - STATIONARY CS
BAFFLES - CROSS CS TYPE SEGM'T
BAFFLES - LONG TYPE
75
150
PSIG
PSIG
OF
ft LENGTH ?0'0" PITCH 1" So.
SHELL COVER CS *£
SDERlfREMOV)
CHANNEL COi/ER CS
TUBESHEET - FLOATINGCS
FLOATING HEAD COVER CS
IMPINGMENT PROTECTION Yes
TUBE SUPPORTS
TUBE TO TUBESHEET JOINT Rolled
GASKETS
CONNECTIONS - SHELL SIDE IN 10"
CONNECTIONS - TUBE SIDE IN 6"
CORROSION ALLOWANCE - SHELL SIDE 1/8 IN
CODE REQUIREMENTS ASMF. VTTT Div. 1
OUT 1QH RATING 300
OUT 6" RATING 1 50
TUBE SIDE 1/8 IN
TEMA CLASS R
# RF
# RF
REMARKS: I) NOZZLE 4 SUPPORT LOCATION TO BE AS NOTED ON F.W. STD. 2IBII.I
2) FOR GENERAL NOTES REFER TO REQ'N.
WHICH IS AH INTEGRAL PART OF THIS REO'N
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE A-II-26
ITEM NO.; A-101 Instrument Air Compressor & Dryer
QUANTITY: One (1)
SPECIFICATION; Complete instrument air package system including air com-
pressor, filter, water trap, dual automatic pressure switch
dryer and all necessary attenting equipment.
Air capacity/ SCFM 70Q
Ambient Temperature: 95 F
Moisture content of Intake Air saturated
Dew point of instrument Air -UO°F
Atmospheric Pressure lit.7 psia
Compressor Drive motor
The instrument air shall be free of foreign matter and
dried to -ljO°F dew point at all time. The instrument
air shall be made available at the battery limit at 100
psig and 100°F.
-------
FOSTER WHEELER CORPORATION
REF. 11-52331
DATE April 1973
PAGE A-II-27
ITEM;
QUANTITY;
SPECIFICATION;
A-102 Package Purge Air Dryer
one
Complete instrument purge air dryer including feed gas
cooler, oil filter, dual automatic pressure switch
dryer and all necessary attenting equipment.
Air Capacity, SCSM
Inlet Temperature, °F
Inlet Pressure, psia
Moisture Content
Dew Point of air Required, °F
1,000
200
U65
Sat.
-liO
NOTES;
1 . An air cooler shall be provided upstream of the dryer,
complete with separator and water trap.
2. The purge air shall be free of foreign matter and dried
dew point at all times.
3» Cooling water will be available at 85 F and 50 psig.
Cooling water outlet temperature should not exceed 120°F.
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE A-II-28
A-II. EQUIPMENT SPECIFICAnONS (continued)
5. Instrumentation & Analyzers
The purpose of instrumentation is to control the process, to
indicate the performance of the unit and to effect safe action in the
case of emergency conditions.
Instrumentation shall be as shown on Engineering Flow Diagrams
OP-721-l£3, )&k and 1^6. Instruments and controls are identified by
a system of letters (and numbers) generally in accordance with the In-
strument Society of American Standard Sjj.l Additional symbols, if used,
will be explained by suitable notes on the flow diagrams. Pneumatic
transmission shall be utilizedj however, provision shall be made for
computer data logging.
The instrument panel shall be full graphic, with miniature in-
struments and a maximum instrument density of 2.5 maximum per lineal
foot.
Analyzers shall be provided for measuring the composition of flue
gases from the Reactors and the flue gas leaving the Quench Scrubber.
Also, the ash from the boiler and the cyclones shall be analyzed to
determine the extent of conversion of the coal. The components to be
analyzed are listed on the flow diagrams at the required points.
The selection, sizing and design of relief valves or other reliev-
ing systems shall be generally in accordance with API Standards, ASME
vessel codes, or applicable piping codes.
Instruments and their connections shall be located for maximum
convenience in operating and servicing the instruments, and shall be
oriented so as to avoid obstruction of aisles and platforms. Control
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE A-II-29
A-II. EQUIPMENT SPECIFICATIONS (continued)
5. Instrumentation & Analyzers (continued)
valves shall be accessible from grade or platforms. Local pressure
gauges, dial thermometers and test veils shall be located so as to
be at a visible level, and test points shall be readily accessible.
All instruments requiring adjustment must also be accessible for
servicing from grade, walkways, ladders or platforms. Accessibility
from grade may be from a portable ladder and, for transmitters, from
a portable platform.
6. Piping
Piping, the general arrangement of same with respect to equip-
ment and instrumentation, shall be as shown on Engineering Flow Diagrams
OP-721-li33, OP-721-lj2U and OP-721-U26. As a minimum requirement, the
design of piping shall be in accordance with the latest revision of the
Code for Pressure Piping, ANSI B31.3.
Materials of construction for pipe lines and equipment are noted
on the Engineering Flow Diagrams listed above. To explain the symboli-
zation utilized for each pipe line, the following example is employed:
3" - 300# CS-1
(600°F - HCJ
Above the line, in order:
a) Line size (3")
b) Nominal ANSI rating for flanges (300#)
c) Material specification (CS)
d) Corrosion allowance (l)
Below the line, in order:
e) Operating temperature, usually maximum (600°F)
f) Insulation requirement (HC)
-------
FOSTER WHEELER CORPORATION REF. 11-$2331
DATE April 1973
PAGE A-II-30
A-II. EQUIPMENT SPECIFICATIONS (continued)
6. Piping (continued)
For identification of all symbols on the flow diagrams, the
following represent a further breakdown of the symbols:
ANSI Ratings
l£0# - Equivalent to l£0# HF
300# - Equivalent to 300# RF
2$00# - Equivalent to 2$00# RTJ
2!>00#+ - Above the requirements of 2$00# RTJ. A review of
the nominal 2J?00# rating would be necessary to
determine what changes, if any, should be made to
existing standard dimensions to make the 2£OQ# RTJ
rating suitable for the pressure and temperature
conditions.
SPCL. - Special considerations required for piping (see
below for further data).
Materials
CS - Carbon Steel
1% Cr - 1^6 Chrome, ^ ifcly
Corrosion Allowances
1 - Nominal, equal to .0£" for carbon steel, .03" for alloy
2 - 1A6"
3 - 1/8"
li - VU"
Insulation Requirements
NI - Not to be insulated
HC - To be insulated for heat conservation
PP - To be insulated only where required for personnel (burn)
protection
-------
FOSTER WHEELER CORPORATION REF. 11-52331
DATE April 1973
PAGE A-II-31
A-"II. EQUIPMENT SPECIFICATIONS (continued)
6. Piping (continued)
The line sizes and operating temperatures as given for each line
are self-explanatory.
With reference to the above rating classification designated as
"SPCL", this particular classification has been used for pipe lines
operating at high internal temperatures. Such lines will require a
dual layer lining and should consist of a layer of lightweight insulat-
ing castable adjacent to the pipe wall, to give a desired reduction in
metal temperature, and a covering layer of dense refractory castable
to protect the insulating layer. Both layers must be gunned in place
and supported by anchors welded to the pipe wall. Casting or trowelling
of the lining is allowed if access prevents gunning.
Recommended materials and thicknesses are as follows:
a) Insulating Castable
VSL-£0 as manufactured by A. P. Green Refractories
Co. Thickness of layer - $%".
b) Refractory Castable
Lo-Abrade as manufactured by A. P. Green Refractories
Co. Thickness of layer - J&§".
c) Anchors
£/l6" diameter Nelson studs, Type 321 stainless steel,
welded to pipe wall, with £/l6" diameter refractory clips
(see anchor detail on vessel drawings where shell requires
similar dual layer lining) and heavy hex nuts, Type 310
stainless steel, attached to stud.
-------
FOSTER WHEELER CORPORATION REF. n-#331
DATE April 1973
PAGE A-H-32
A-II. EQUIPMENT SPECIFICATIONS (continued)
7. Vendors' Proposals
Included in this section are several of the vendors' quotations
that were received in connection with requests for price and engineer-
ing data for the various equipment items. Wherever the information was
useful for further descriptive purposes, it has been made a part of
the process and mechanical specifications for the individual items of
equipment.
-------
A-II-3J
PETROCARB, INC. zso BROADWAY. NEW YORK. N Y 10007
CABLE ADDRESS "CABOCARB* NEW YORK
207-esto
November 8, 1972
Foster Wheeler Corporation
110 South Orange Avenue
Livingston, New Jersey 07039
Attention: Mr. L. W. Zahnstecher, Process Technology Manager
Subject: Coal Preparation and Injection System and
Dolomite Injection System (Ref. No. 11-23351)
Petrocarb Projects E-465 and E-467
Gentlemen:
This will confirm our telephone conversation concerning our revision of
costs in connection with the subject projects. We have reviewed our estimate
of the coil preparation and injection system as well as the dolomite injection
Bystem.
The pre-blending of coal and dolomite have been eliminated. The coal will
be fed batch-wise from the upper "live shelf" directly into the "storage
injector". A special valve will be used to control the batch of coal and
will receive its impulse to open by the cycle logic and will close based on
an impulse from a special probe in the storage injector.
The revised estimated installed cost of the coal injection system is $425,000.00.
The primary advantage of this change is that the live shelf can contain a much
greater weight of coal or, if desired, the coal storage silo could be reduced
in total volume and height. This is of course dictated by your desired storage
volume.
The dolomite bin, steel supports, foundations, and bucket elevator will not
be needed since this equipment is being replaced by the dolomite system referred
to in our letter of September 6, 1972. This change results in a credit of
$70,000.00 which changes the coal preparation system estimated cost to
$730,000.00 with a total for coal preparation and injection of $1,155,000.00.
Our earlier estimate of $590,000.00. for the dolomite system is still applicable.
Please let us know if we can be of further service.-
Very truly yours,
HRrjml
cc: Mr. R. W. Bryers
Harold Reint
President
-------
A-II-3U
"
DUCON
DUCON CO!M!PANY, INC.
.EAST SECOND STREET •• (M.IN.EOUA. 'NEW VY*ORK 1I15O1
TEL1 516 741-61OO • CABUEt (DUCON iMINEOLANY • TWX <51O .222-0861
.September 19, 1972
•Foster Mheel-er Corp..
110 South Orange Ave.
Livingston,, ;New -Jersey
.Attention: .'Mr.. Chen
.Subj.ect-: Customer .Reference 'Number F.WC 11-52.33,1
Ducon Proposal P72-437
!Dear Mr. Chen1:
In response to your letter >of' September >6., 197,2., I ihave
enclosed our .budgetary estimate £or four !(4!) Ducon YM '700
Size 200 (Cyclones -along with icop&es of our Engineering
Design iData .Sheets (Tables 1-6') outlining ;expected Cyclone
operating results for your conditions,.
Design Data For External Installati
-------
THE DUCON COMPANY. INC. A-II-3J?
-2-
Ducon Proposal P72-437
The estimated price for four (4) Ducon VM 700 Size 200
Cyclones is
Eighty to Ninty Thousand Dollars ($80,000 - $90,000)
Our Granular Bed estimate will be forthcoming.
Sincerely,
THE DUCON COMPANY, INC.
D. Buzzelli
DB:aw
-------
A-II-36
THE DUCON COMPANY, INC.
I'JCDN i«7 i.Ai.r t,f_c-.oNi> :vir
-------
PROGRAM: BOCYIO
DATE: 10/20/72
THE DUCQN m. INC.
147 F. SECOND STREET
KJLNLOLA, N.Y. J I50t
A-II-37
CUSTOMER: FOUIL
CUBIUMLk KEFF.KCNCE NUMBER: I-MC ll-L.1'331
DUCON REFERENCE NUMDER! H72-43/
TABLE I
DUCON CYCI.DNE OPERATING ANLi Dl 'H-IN DATA SHEET
CYCLONE SELECTIONS NO. OF STAGES
TOTAL GAfi FLOW
TOTAL GAS FLOW AT' OPERATING CONDITION
OPERATING GAJ5 UIINSJTY 6> COND.
OFF-RATING VIUCU5JIIY (4 COND.
OPERATING tirtii TLMPF-RrtTURE
OPERATING liAU I'KIZSRDKE
PART I CUE DENSITY
OPF.kAT I NO UUL1LH INLET LOADTMO
OPERA T] NO QOL1L5J INLET LOAIUNl)
CYCLONE GTA13ES
CYCLONE SIZE
CYCLONE IYPE
CYCI ONE MO-NIL
NO. 01" CYCLONES
OPERATING DAS FLOW PER CYCLONE
CYCLONE INLET VI LOCITY
KALI AT I ON VELOCITY
FRACTIONAL EFFICIENCY CURVE NS.
OUTLFI TO INLCT RATIO
iOJillUE UROP
mp-i.ru SUCTION
DIP-LCD DIAMETER
J10L1D3 RATE.
SULIDO LOliS RATE
SOLIDS I. Ml Gf. JON
CYCLONE
CYCLONE
CYCLONE
CYCLONL"
CYCLONT.
CYCLONE
TOP-LEG
CYCLONE
CYCLONE
ACC. CYCLONE. Ll> J CIENCY
OUTLET PARTICLE DISTRIBUTION 01 STAGT. 1
37-/99D
LPS/HR
ACFM
LUS/CF
cr
DEG.F.
I'UTA
I.DS/CF
LPS/HR
(3RA1NG/ACF
0.2320
0.0430
1600
1A9.70
- 4?. 0
31'.60
FTRJiT
200
VM
700
A709 ACFM
56.A FT/fiCC
2:i.O Fl/GFiC
46.4
I . 50
16.0 IN.WO.
24.0 IN.WG.
0 IN.
1.31 LK8/SEC-SG.FT.
7GG.57 LDG/HR
3.246 GR/ACF
09.73 7.
PAP f
1 1
1C! E SIZE
;. ; THAN
1 .27
'...ns
II1. 40
">4 . JJ9
46.A'.»
V7 . Ji I
{(1.67
!i:).54
tlV.41
VJ.1'7
v/,09
100.00
104.-J9
lOJt. 23
ill.//
INLET
ACC. Ul)T.
PERCliNT
1.0
A.O
11.0
16.0
21.0
IV). 0
31.0
36.0
41.0
4A.O
Sl.O
56.0
61.0
66.0
7i.O
OUTLF.T
ACC. UGT
PIL'RCENT
9. 7 A
50.2?
on. 3?
92.00
95.04
96.93
97.44
97.05
90.19
90.45
90.70
90.93
99.12
99.29
99. 41,
-------
PROGRAM: BOCYIO
DATES 10/20/72
THE DUCON HO. ]NC.
147 E. SECOr'Ji j:TR' ET
WNEQLA» N.Y. U'-Ol
CUSTOMER! FOSTLK UHCl ' > r'
CUblOMLR REFLRErtCE NllnuEk: F'WU il-b >31
DUCON REFERLHl.l£ NUrtfcLK! P72-43/
TABLE
DUCON CYCLONE OPERATING ANji itKJGH DATA SHEET
CYCLONE SELECiIQN: NO. OF STAGE!.
TOTAL GAR FLOW
TOTAL CAS FLOW AC OPERATING CONlIT10N
OPERATING GAG DENSITY @ COND.
OPERATING VISCOSITY @ COND.
OPERATING OAS flTMPEKATURE
OPLRATJNO GAG PRESSURE
PARTICLE DENSITY
OPERATING SOL1DB INI.LT LOADING
OPERATING SOL JDS JNLLT LOADING
CYCLONE STAGES
CYCLONE SIZE
CYCLONE TYPE
CYCLONE MUHKL
NO. OF CYCLONCy
OF-ERAI ING GAS FLOW PER CYCLONE
CYCLONE INLtl VELOCITY
CYL:I ONE SALTATION VELOCITY
CYCLDNE FRA'CUOHAL Q FICIENCY CURVF. N J.
CYCLUNi: mJTLFf TO INI F.I RATIO
CYCLONE PRESSURE DRUH
CYCLONE LUI'-LLG SUCTION
CYCLONE PIP-LEG DIAMLTE.R
D3P-LCG SOLIDS KATE
CYCLONE SOLIDS LOSS RATE
CYCLONE SOLIDS EMISSION
ACC. CYCLONE EI-FICCCNCY
OUTLET PART1ULK DISTRIBUTION OF STAGF 1
A-II-38
PAI-T1CI.F SI7E
LllSfi 1HAN
1.J7
5.S5
12.40
24.89
46.6 '
77.01
HI.67
85.54
89.41
93.27
97.09
100.83
104.59
108.23
111.77
LBS/HR
ACFM
LBS/CF
CP
HEB.F.
PS1A
LDS/CF
LDS/HR
GRAINS/ACF
17H059
3 2047
0.2310
0.0430
1600
169.70
42.0
2740
2A.70
FTkBl
200
VM
700
64,>4 ACFM
53.5 FT/SEC
22.0 FT/SEC
4/.4
i.r»o
lb.0 IN.'UG.
21.7 IN.WG.
0 IN.
1.00 LD5/SCC-SQ.FT.
307.11 LDS/HR
2.709 Gk/ACF
Q9.b?i X
TNLET
ACC. UGT.
PERCtNT
1.0
A.O
11.0
16.0
21.0
26.0
31.0
36.0
41.0
46.0
Cl.O
56.0
61.0
66.0
OUTLET
ACC. WOT.
PERCENT
9.5/
57.2V
04.91
92.49
95.56
96.69
97.23
97.60
90.00
98.34
90.59
98.83
99.03
99.22
-------
PROGRAM: BOCYIO
DATE: 10/20/72
THE DUCON CO. 'MC.
14,' F. SECOND Sfl ' F.I
h]NE.OLA» N.Y. J Kj
CUS'lOMEk: FOSTER WIOLLrt
CUSTOMEK REFLRENCE rtllhUERs I Wlv I I-Ij
DUCON REFERENCE NUMHERs P72-43'
TAHLE
DUCON CYCLONE OPERATING AND DL'filNN DATA SHEET
CYCLONE SELECTION: NO. OF STAGES
TOTAL GAS FLOW
TOTAL GAS FLOW AT OPERATING CONDITION
OPERATING GAS DENSITY Q COND.
OPERATING VISCOSITY. @ COND.
OPERATING GAS TEMPERATURE
OPERATING GAS HtEGSURE
PARTICLE DFNStTY
OPERATING SDLms INLET LOADING
OPERATING UOI.TUS INII.T LOADING
CYCLONE STAGES
CYCLONi: 55IZF.
CYCLONE TYPE
CYCLONE MOIiEL
NO. OF CYCLONES
OPERATtNG DAI, FLOW PER CYCLONE
CYCLONE INLET VELOCITY
CYCLONE SALTftTION VELOCITY
CYCLONE PRAC'i TONAL FFF-ICIENCY CURVE NO.
CYCLONE DUTI I T TO INI.H RATIO
CYCLONF. h'RLSSURE DROI'
CYCLONE HIP-LCG SUCFLDN
CYCLONE HIP-LEG DlAMRfER
DIP-LEG SOLTDS RATE
CYCLONE HOLIUS LOGG RATE
CYCLONE SOLIDS EMISSION
ACC. CYCLONE EFFICIENCY
OUTLET PARTICLE DISTRIBUTION OF BTnOE 1
i-n-39
PAKCYCLE SIZE
I F :>«J THAN
1.27
5.55
J2.40
24.09
46.62
77.81
81.67
05.54
09.41
93.27
97.09
100.Ill)
104.59
JOU.L'3
I 1.1 .V/
273735
19750
0.2310
0.04'JO
1600
169./()
42.0
409'J
20.90
LBS/HR
ACFM
LBS/CF
CP
FiEG.F.
PS FA
LPS/CF
LB'J/HR
GUAING/ACF
FIRST
200
VM
700
3
61183 ACFM
54.9 FT/SEC
22.0 FT/SEC
47. J
1..50
15.7 IN.UO.
2i>.6 IN.UG.
0 IN.
1.16 LBH/SEC-SG.FT.
500.69 LP5/HR
3.005 GR/ACF
89.60 X
INLF.F
ACC. WG1.
PERCENT
1.0
6.0
11.0
16.0
21.0
26.0
31.0
36.0
41.0
46.0
51.0
'JA.O
61.0
66.0
71.0
OUTLLTT
ACC. UGT.
PERCENT
9.62
57.55
US. 03
92.50
95.64
96.76
97.29
97.73
90.09
90.37
90.62
90.85
99.06
99.24
99.40
-------
J.-T/ f.. &C.UUNU bIKLLI
MINEOLAr N.Y. 11501
ClJSJTUhLR: I'GSTER WHEELER
CUG'lOMER KlIFIiRENCE NUMBER: FUC 11-52331
MJCON RLFCRLNCF NUMBER: P72-437
TABLE 3A
DUCON CYCLONE OPERATING AND DESIGN DATA SHEET
CYCI ONE SELECTION: NO. OF STAGES
TOTAL GAS FLOW
TOTAL DAS.! fi.OW AT OPERATING CONDITION
OPERATING lirtS DENSITY G COND.
OPERATING VISCOSITY @ COND.
OPERATING IjAS TEMPERATURE
OPERATING GAS PRESSURE
PARTICLE DENSITY
OPERATING SOLIDS INLET LOADING
DPFKATING UOL1DS INLET LOADING
CYLLONK
A-II-ltO
CYlJLilNE lYi'E
CYC.LflNE MO»JC.L
NO. OF CYCLONES
UI'EIVJING RAS FLOW PFR CYCLONE
CYCIUNF INLET VELOCITY
CYCLUNE SALTATION VELOCITY
CYCLONE KPACTIONAL LFFICIENCY I
CYI:LUNC m. LEI TO INLET RATIO
CYCLONE n«: SSURE UKOP
(JYCLONC DII'-LEC SUCTION
UYCI.ONC DTI'-LCG DIAMETER
Ull'-l i G SUI IDS KATE
CYU.dNL SHI [DS I.OKJ5 KATE
CYCI ONt 'Jdl IDS EMISSION
ACU. CYCLUME EFFICIENCY
OUril-T PftUl [CLE DISTRIBUTION OF STAC5E 1
s
IDITION
URVE NO.
STAGE 1
PARTICLE SIZE
LESS THAN
1.27
5.55
12.40
24.09
46.6?
77.01
81.A7
85.54
89.41
93.27
97.09
100.88
104.59
LOS. 23
111.77
115.19
11B.48
121.62
1 .
•205123 LBS/HR
14800 ACFM
0.2310 LB8/CF
0.0430 CP
1600 FiEG.F.
169.70 PSIA
42.0 LBS/CF
3666 LbS/HR
20.90 GKAINS/ACF
FIRST
200
VM
700
3
4933 ACFM' '
41.1 FT/SEC
18.0 FT/SEC
52. 8
1.50
8.U IN.WG.
13.8 IN.WG.
R IN.
O.B6 LPS/SEC-SO.FT
41^.36 LBS/HR
3.274 GR/ACF
88.67 '/.
™' ET OUTLET
ACC,. UGT. ACC. WU1.
PERCENT PERCENT
1.0 8. 03
6.0 52.96
11.0 . 02. 54
16.0 90.fi:>
21.0 94.01:
26.0 9r..3V
31.0 96.0"
36.0 96.70
41.0 97. W
46.0 97.AIJ
51.0 9JI.OA
56.0 98. 3/
61.0 98.63
66.0 98.86
71.0 99.00
76.0 99.27
81.0 99. 4S
86.0 100.00
-------
l ll-k.l«UI\
KF.FHRLNCE NUHBER: FUIC 11-52331
DUCOH RLFEKtNUL- NUMULK: I-V2-437
TAULE 3B
JiUCllN CYCI ONE OPLKAT CNG AND DESIGN DATA SHEET
CYCI UNF: nn ECTIDN: NU. m STAGES
I I OW AT (II1! RAITNO CONDITION
(Jrt.S IIF'NSI If 6 C'UND.
VTGL'UfilTY G> HOND.
CASJ lEMhTKATURC
A-II-U1
TOTAL OiV.5
on .RA 11 NO
OITUATINO
OPL'KA I
OPF'KAHNG CAS PRESSURE
I DfN;iJTY
I NO SiOl.tJiS INLET
SUlIPS INLET LOADING
1
13A868 LUii/HR
90Vii ACFM
0.2310 LPU/CF
.0.0430 HP
1AOO Ll.fi. I- .
1A9.70 PS] A
4i». o i w/cr
CYCLONt.
CYCLUNb iJIZt.
(.YCLflNf lYPT
CYQflNI
CYCI.UNF
I:YI:I.DNI
NO. Of CYCLOMfS
DITRAllNli fiAf> TLUU PER CYCLONE
CYCLONI' liNlFT WEI.OHITY
rtl.lAntlN VkLOCITY
HACFIONAL FFriClENCY CURVE NO.
OUTI n TO INLET RATIO
URUP
I'.YCLONC
CYCLONE
nil-'-l LU
CYCI.UNF
TYCI ONC
IiLI'-l.liG D I rtHFTCK
JJOLJIiii UA1F
fjui rns i.una RATE
soi. i no r MISSION
ric;c. CYCI ONI" rr-nciCNCY
iMJllbT PAKIltlLE DISTRIBUTION OF STAGE 1
of-
28.90 RRAINS/ACF
FIRST
200
VM
700
3
3292 ACFM
27.4 FT/SEC
13.0 FT/SEC
7b.4
1.50
3.9 IN.UG.
7.3 IN.WG.
0 TN.
0.5',i I.PS/SEC-SO.FT.
360.08 LUK/IIK
4.2b4 GR/AOF
85.28 X
PARTICLE SIZE
LEGS THAN
1.27
5. 55
12.40
:>4.89
4A.62
77.81
81.67
80.54
R9.41
93.27
97.09
100.811
104.59
100.23
1 1 J . 77
IJO.J9
1 i(!.4i!
Ji»I.A2
U'4.60
127.39
INLET
ACC. WCT.
PERCF.NT
L.O
6.0
11. 0
16.0
21.0
26.0
31.0
36.0
41.0
46.0
51.0
56.0
6J.O
66.0
/l.O
7A.O
Hl.O
U6.0
91.0
96.0
ouTir r
ACC., m:
PIII
-------
A-II-U2
THE DUCON COMPANY, INC.
DUCQN 1<*7 EAST SECOND STREET • MINEOLA, NEW YORK MSO1
TEL- S16 741-61OO • CABLE. DUCON MINEOLANV • TWX S1O 222-9861
November 10, 1972
Foster Wheeler Corp.
Process Design 'Department
Process Plants Division
110 South Orange Ave.
Livingston, New Jersey 07039
Attention: Mr. C.W. Chen
Subject: Ducon Proposal P72-437
Gentlemen:
In response to your request, I have roughly estimated
the cost for eight (8) 8" Trickle Valves made out of
Hastalloy 188 to be about twenty five thousand dollars
($25,000). This .should not be taken as a final price.
A finalized estimate would require my investigating the
cost in much greater detail.
We hope the above is sufficient .for your present needs
and should you have any questions, please do not hesitate
to contact us.
Very truly yours,
THE DUCON COMPANY, INC,
>D. Buzzelli
DB:aw
AIR 'I- O I I..I I I I O N
-------
A-II-U3
AERODYNE DEVELOPMENT CORPORATION
24340 MILES ROAD, CLEVELAND, OHIO 44128 • Telephone: 218/292-2828
November 7, 1972
Mr. C. W. Chen
Process Plants Division
Foster Wheeler Corporation
110 South Orange Ave.
Livingston, New Jersey 07039
Dear Mr. Chen:
Four (4) Model 4500 Type "S" Collectors fabricated of Hastellory
188 would cost $42,000 each for a total of $168,000, fabricated
10 gauge.
Our quotation is good for 90 days, prices are P.O.B. Cleveland,
Ohio. Our terms are net 30 days.
Thanking you, we are
Very truly yours,
AERODYNE DEVELOPMENT CORP,
MG:rec Mack Gordon
DUST COLLECTORS • LIQUID-SOLID SEPARATORS • MATERIAL HANDLING VALVES • OIL SKIMMERS
-------
A-II-U*
THE DUCON COMPANY, INC.
DUCDN 147 EAST SECONO STREET • MINEOL.A, NEW YORK 1I5O1
TEL. 516 741-blOO • CABLE DUCON MINEOUANY • TWX 51O 222-9861
September 27, 1972
Foster Wheeler Corporation
110 South Orange Avenue
Livingston, New Jersey 07039
Attention: Mr. C. Chen
Process Design Department
Process Plants Division
Subject: Ducon Proposal P72-437
Granular Bed Filter
Gentlemen:
In accordance with your inquiry dated September 16, 1972,
we are pleased to offer our -proposal on a Ducon Granular
Bed Filter for use as a secondary particulate removal
pressurized system*
General Arrangement
For this service our selection consists of two (2)
Size 51/204 GB filter units operating in parallel.
Note, that the two filters should be arranged for con-
nection to a common gas inlet line. Each filter unit
during normal operating would handle 1/2 of the total
gas flow. The clean gas from each should discharge to
a common gas line. This arrangement can be modified to
suit the plant's requirements.
VJithin this arrangement one of the two filters could be
isolated by means of valving on the gas inlet and gas out-
let, without interrupting the operation of the other
filter.
AIR POLLUTION CONTROL EQUIPMENT • PNEUMATIC CONVEYING SYSTEMS
-------
nurnu THE DUCON COMPANY. INC.
1UCUN
-2-
Ducon Proposal P72-437
Details of Construction
The filter consists of a Carbon steel pressure vessel
casing, furnished with a suitable thickness of internal
insulating castable refractory lining. The refractory
lining will be supported by Stainless Steel tines, welded
to the vessel shell. The vessel is fitted with an in-
ternal Type 310 Stainless Steel plenum which supports
the filter elements and acts as a clean gas collection
chamber.
•Each vessel will be shipped in two major pieces, an upper
section containing the shop installed plenum and a lower
cone section, thus a circumferential field weld on the
shell would be required. The filter elements, filter
blow back manifolds, internal inlet ducts, walkways, etc.,
v/ould be shipped loose for field installation. The erec-
tion sequence would be as follows:
1. Erect vessel support structure.
2. Move lower cone section with loose internals to in-
side support structure.
3. Install vessel upper section.on support structure.
4. Install erection clips at field seam.
5. Move bottom cone section into place and secure with
erection clips.
6. Weld circumferential seam.
7. Install target plate and platforms.
8. Gun castable refractory on vessel shell.
9. Install filter elements.
10. Install external blow back piping.
11. Make external piping connections.
•NOTE: The number of pieces and sections of each module,
and the amount of field welding required may vary depend-
ing on shipping limitations from point of manufacture to
plant site.
-------
A-II-L6
DION ™E DUCON COMPANY. INC.
-3-
Ducon Proposal P 72-4 3 7
Performance
Based on your process conditions and the dust character-
istics which you indicate, we would anticipate that the
Ducon Type GB Filter would operate at an efficiency of
approximately 9Q%. Not having experience with this pro-
cess, we would strongly recommend that a pilot operabion
be initiated prior to a commercial unit.
Prices
We would estimate that the approximate selling price for
these units would be as follows:
•
Vessels $162,000 Each
•Filter elements (310 Stainless Steel) $ 41,400/Module
•Blow back piping, valving and instruments $ 8,470/Module
With regard to the design of the vessels required to
encase the Ducon Granular Bed Filter and the structural
steel support required for these modules, preliminary
calculations indicate that at 175 PSIG design pressure
and 650° shell design temperature, material thicknesses
in excess of 1% inches would be required. Furthermore,
due to the extremely high inbernal temperature and pres-
sure, the blow back system would have to be specially
designed also. The analysis required in order to proper-
ly design these vessels is involved and time consuming.
The Ducon Company has the capability of performing this
design work for a fee of seven thousand dollars ($7,000.00),
which includes five thousand five hundred dollars (£5,500.00)
for the vessel and structural design and one thousand five
hundred dollars ($1,500.00) for the special design of the
backwashing system.
This amount will be credited toward a Purchase Order for
the Ducon Granular Bed Filter for this service, if the
project were to proceed.
•NOTE: Two vessels are required.
-------
A-ll-Uf
THE OUCON COMPANY. INC.
JCQN
-4-
Ducon Proposal P72-437
Delivery of equipment could be made approximately four
to six months after receipt of approval drawings, and
we would estimate that the field erection time would be
one to one and a half months* We are enclosing three
copies of our Process Data Sheet and three copies of our
sketch SP 72-43 7-1 for your inspection.
We hope that the above and enclosed is satisfactory for
your present needs, and if we may be of further service
please do not hesitate to contact us*
Very truly yours,
THE DUCON COMPANY, INC,
< * t f «
A* Tesoriero
AT taw
cc: B. Kalen
-------
A-U-U8
Operating Data Sheet for Granular Bed Filter
Customer: Poster Wheeler Corporation
Customer Reference: FWC11-52331
Ducon Reference: P72-437
Number of Units
Size of Unit
Total Gas Plow
Total Gas Flow at Condition
Gas Molecular Weight
Gas Temperature
Gas Pressure
Gas Density at Condition
Gas Viscosity at Condition
Apparent Particle Density
Inlet Dust Load
Inlet Dust Load
Filter Efficiency
Outlet Dust Load
Outlet Dust Load
Outlet Dust Load
Total Bed Area
Flow to Bed Ratio
Superficial Bed Velocity
Pressure Drop
Design Backwash Cycle
Backwash Flow Required
Backwash Pressure Required
No. of Filter Elements
N'o. of Compt. per Element
Grade of Sand
CASES
SCPK
ACFM
op
PSIA
tt/CFT
Cp
#/CFT
#/HR
GR/ACFT
%
#/HR
GR/ACFT
GR/SCFT
FT2
FPS
IN W.G.
Win.
SCFM
PSIG
A.I
,2
60,500
19,665
30016
3.600
155
Oo232
,043
42
390 o 12
2.352.
8
.0475
.0155
408
48.2
.805
20-23
5
450
A.2
2
2-51/204
39,500
12,791
30.04
1600
155
0.231
.043
42
237.05
2.162
98 +
4.8
.0438
.0142
408
31.4
.523
10-15
5
450
360
5 I/Module
16
1/4
A. 3
2
89,000
27,038
30.3
1600
155
0.233
.043
42
500.37
2.159
10
.0432
.0132
408
66.3
1.11
28-33
5
450
-------
Operating Data Sheet for Granular Bed Filter
Customer: Poster Wheeler Corporation
Customer Reference: FWC11-52331
Ducon Reference: P72-437
A-II-U9
Number of Units
Size of Unit
Total Gas Flow
Total Gas Flow at Condition
Gas Molecular Weight
Gas Temperature
Gas Pressure
Gas Density at Condition
Gas Viscosity at Condition
Apparent Particle Density
Inlet Dust Load
Inlet Dust Load
Filter Efficiency
Outlet Dust Load
Outlet Dust Load
Outlet Dust Load.
Total Bed Area
Flow to Bed Ratio
Superficial Bed Velocity
Pressure Drop
Design Backwash Cycle
Backwash Flow Required
Backwash Pressure Required
No. of Filter Elements
No. of Compt. per Element
Grade of Sand
CASES
SCFK
ACFM
«p
PSIA
tt/CFT
Cp
#/CFT
#/HR
GR/ACFT
%
tt/HR
GR/ACFT
GR/SCFT
FT2
FPS
IN W.G.
Min.
SCFM
PSIG
A.I
2
609 500
19,665
30.16
1600
155
0.232
.043
42
398.12
2.362.
8
,0475
.0155
408
48,2.
o805
20-23
5
450
A.2
2 .
2-51/204
39 fl 500
12,791
30.04
1600
155
0.231
.043
42
237.05
• •2.162
98+
4.8
.0438
.0142
408
31.4
.523
10-15
5
450
360
51/Modu.le
16
1/4
A. 3
2
89,000
27,038
30.3
1600
155
0.233
.043
42
500.37
2.159
10
.0432
.0132
408
66.3
1.11
28-33 .
5
450
-------
A-II-50
Operating Data Sheet for Granular Bed Filter
Customer: Poster Wheeler Corporation
Customer Reference: FWC11-52331
Ducon Reference: P72-437
Number of Units
Size of Unit
Total Gas Flow
Total Gas Flow at Condition
Gas Molecular Weight
Gas Temperature
Gas Pressure
Gas Density at Condition
Gas Viscosity at Condition
Apparent Particle Density
Inlet Dust Load
Inlet Dust Load
Filter Efficiency
Outlet Dust Load
Outlet Dust Load
Outlet Dust Load.
Total 3ed Area
Flow to Bed Ratio
Superficial Bed Velocity
Pressure Drop
Design Backwash Cycle
Backwash Flow Required
Backwash Pressure Required
No. of Filter Elements
No. of Compt. per Element
Grade of Sand
CASES
SCFK
ACFM
op
PSIA
tt/CFT
Cp
#/CFT
#/HR
GR/ACFT
of
/J
tt/HR
GR/ACPT
GR/SCFT
FT2
FPS
IN W.G.
Win.
SCFM
PSIG
A.I
2
600500
195,665
30.16
1600
155
Oo232
«043
42
390012
2.362.
•
8
0OA75
.0155
408
48 „ 2
o805
20-2?,
5
450
A.2
2
2-51/204
39,500
12,791
30.04
1600
155
0.231
.043
42
237.05
2.162
98+
4.8
.0438
.0142
408
3104
.523
10-15
5
450
360
51/Nodule
16
1/4
A. 3
2
89,000
27,038
30.3
1600
155
0.233
.043
42
500,37
2.159
10
.0432
.0132
408
66n3
1.11
28-33 ..
5
450
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A-II-52
SP72-437-',
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A-n-53
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A-II-&
PMC CORPORATION
LINK-BELT MATERIAL HANDLING SYSTEMS DIVISION
3400 WALNUT STREET. COLMAR. PENNSYLVANIA 18918 • TELEPHONE (818) 888-0881
September 14, 1972
Foster Wheeler Corporation
110 South Orange Avenue
Livingston, N. J. 07039
Attention: Mr. C. W. Chen
Subject: Spent Dolomite Cooler
Westinghouse Research Laboratory
Your Inquiry N.O. FW 11-52331
Item RC-101
Dear Mr. Chen:
Thank you for your inquiry of August 23 which was received here on August 30.
We trust the delay in getting an answer to you has not inconvenienced you too
greatly.
Based upon the information supplied to us, we are pleased to offer a tentative
recommendation of a roto fin cooler to handle spent dolomite and fly ash from
1600° to 1750° initial temperature, and cool down to about 300° F. For design
purposes we are assuming a feed temperature of 2000° F. however and cooling
down to 300° F. at the rate of 24. 5 TPH.
Our tentative selection would be our No. 600 RF16 Roto-Fin Cooler. This
unit would be as described in our Book 3406, a copy of which is attached
for your reference. Page 25 of this book has some preliminary dimensional
information which would be of help in determining space requirements.
We would include with the equipment a mild steel rotor of our tube design and
which would be modified to handle the temperatures above. It would be complete
with a drive and reducer, a hood, and tank, and temperature recorders for the
inlet and outlet material temperatures.
ENGINEERED PROGRESS IN THE CREATIVE DESIGN. MANUFACTURE AND CONSTRUCTION OF MATERIAL HANDLING AND PROCESSING SVSTEMS
-------
A-H-55
FMC CORPORATION
LINK-BELT MATERIAL HANDLING SYSTEMS DIVISION
Page 2 September 14, 1972
Foster Wheeler Corporation
The approximate price for the above equipment would be $60, 000. 00 f. o.b.
Colmar, Pa.
Delivery at the present time for this equipment is running about 25 weeks.
With the preponderance of small particles in the material, the biggest
advantage here would be the lack of a requirement for any air moving
through the unit. All of the cooling would be done indirectly with the use
of water at 85°. However, to maintain a 120° exit water temperature,
our calculations indicate that the pumping requirements would be some-
thing in the range of 1500 GPM. You may want to review the exit water
requirement in view of the large amount of water needed.
After you have had a chance to look over our quotation, we would be pleased
to discuss it with you at greater length. However, if you have any questions
that need immediate answers, please don't hesitate to call us.
Very truly yours,
FMC CORPORATION
Link-Belt Material Handling Systems Division
V. A. Cheney f~~
Manager \
Dryers and CooleXg
VAC/sb
End.
-------
RC-101 Dolomite Cooler
t
WARM
WATER
SECTION A A
Roto- Fin
number
300
400
-**- 600
800
1000
A
B
3-0
4-0
6-0
8-0
10-0
0-4
0-4
0-6
0-8
0-10
C
D
E
FCET AND INCHES
0-9
1-0
1-10
2-4
3-4
0-9
1-0
1-10
2-4
3-4
1-0
1-2
1-4
2-0
7-8
f 1 G
2-3
2-9
3-9
5-0
6-3
4-6
5-4
7-8
10-1
13-2
Have dimemioni certified for inilallation purpoiei.
FMC/UNK-BELT • 25
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Peabody Engineering Corp
835 Mope Slrool | Slamfotd. Conncchcul 069071 Telephone 203 327-7000
A-II-57
°eabody Engineering
Peabody Proposal No. 72-306
November 27, 1972
Foster Wheeler Corporation
110 South Orange Avenue
Livingston/ New Jersey 07039
Attention: Mr. Chen
Reference:
Gentlemen:
Pressurized Air Heater
PEC Proposal No. 72-306
This letter is to confirm the information related verbally
to your Mr. Chen at our meeting on November 16.
In review, the system is to be designed for the following
conditions:
Heat release
Inlet temperature
Outlet temperature
Furnace pressure (operating)
Furnace pressure (design)
Fuel
Atomization
Atomization pressure
Location
Arrangement
35.0 MM BTU/hr.
500° F.
1500° F.
150 PSIG
320 PSIG
No. 2 oil
Steam
100 PSIG above furnace
pressure
Outdoors
Vertical
The overall dimensions and weight of the equipment is as
illustrated on the attached sketch. For vertical up-fired
arrangement as illustrated on the attached sketch, add
approximately 6'-6" to the length of the unit to obtain the
elevation of the outlet flange above the supporting steel
base plate.
We can furnish this unit complete with shell, super-duty
firebrick and insulating material (shipped loose), burner,
ignitor, FIA approved flame failure panel, oil valving and
temperature controls, including electrically operated
control valve, temperature controller and high temperature
instrument. Our budget price for this equipment is THIRTY-
ONE THOUSAND ONE HUNDRED FORTY DOLLARS ($31,140.00).
continued...
-------
A-II-58
Peabody Proposal 72-306
Page Two
The equipment would be supplied with all components, except
flame failure panel, shipped loose for wiring and piping by
your personnel in the field. If you choose to have Peabody
complete all such piping and wiring in our shops prior to
shipment we would charge an additional TWO THOUSAND SIX HUNDRED
DOLLARS ($2,600.00) for that service.
Further if you choose to deduct the temperature controls from
our supply our price will be reduced by TWO THOUSAND FIVE
HUNDRED DOLLARS ($2,500.00).
Our preliminary price for a Duplex pump set to supply the
oil at 300 PSIG is THREE THOUSAND FIVE HUNDRED DOLLARS
($3,500.00).
All prices are net, F.O.B. shipping points.
If further requirements evolve on this project on either this
portion or the two (2) burners previously quoted, please
contact the writer directly.
Yours very truly,
PEABODY ENGINEERING
Felix D'Avanzo
FD'A/mp
Letter in Duplicate
-------
OIL ftTOt.H7.ER
OR GAS GUM
I
-------
BIBLIOGRAPHIC DATA
SHEET
1. Report No.
EPA-650/2-73-048a thru -d
3. Recipient's Accession No.
4. Title and Subtitlc
Pressurized Fluidized-Bed Combustion Process
Development and Evaluation, Volumes I, H , m, and IV
(Vol H, Appendices; Vol HI, Boiler Development Plant Design;
*
5- Report Date
December 1973
6.
TV
7. Auihor(sr)
D. L. Keairns
D. H. Archer et al.
&• Performing Organization Rept.
No.
9. Performing Organisation Name and Address
Westinghouse Research Laboratories
Pittsburgh, Pennsylvania 15235
10. Project/Task/Work Unit No.
ROAP 21ADB-09
11. Contract/Grant No.
68-02-0217
12. Sponsoring Organization Name and Address
EPA, Office of Research and Development
NERC-RTP, Control Systems Laboratory
Research Triangle Park, North Carolina 27711
13. Type of Report & Period
Covered
Final July 1971 to
May 1Q73
14.
IS. Supplementary Notes
u. Abstracts
rep0rt presents: results of a process evaluation of the pressurized
fluidized-bed combustion (FBC) system for power generation; preliminary plans and
a cost estimate for a 30-MW pressurized FBC boiler development plant; identification
of a project team and program to demonstrate FB oil gasification/desulfurization for
power generation on a 50-MW plant; and evaluation of pressurized oil gasification for
combined- cycle power generation. It identifies no problems which preclude the
development of pressurized FBC combined- cycle power plants and FB oil gasification
power plants which can generate electrical energy within environmental goals at lower
energy costs than competitive systems. Work reported here, a continuation of earlier
FBC process evaluation efforts , is aimed at the development and demonstration of
these FB fuel processing systems.
17. Key Words and Document Analysis. 17o. Descriptor;,
Air Pollution
Combustion
Gasification
Fluidized Bed Processing
Desulfurization
Oils
Fossil Fuels
Wastes
Electric Power Generation
17b. Identifiers,'Opcn-Lndcd Terms
Air Pollution Control
Stationary Sources
Fluidized-Bed Combustion
17c. COSATI r-ield/Gioup
21B
18. Availability Statement
Unlimited
19. Security Class (This
Report)
UNCLASSIFIED
20. Security Class (This
Page
UNCLASSIFIED
21. No. of Pages
252
22. Price
FORM NTIS-35 (REV. 3-721
AII-60
USCOMM-DC I495Z-P72
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