BASIC OF BOILER
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Transcript of BASIC OF BOILER
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COURSE BB--11
CONTENTS Basics of BoilerBasics of Boiler
MITSUBISHI HEAVY INDUSTRIES, LTD.MITSUBISHI HEAVY INDUSTRIES, LTD.
TRAINER: Yuki Yoshikawa
PAITON PAITON EXPANSION PROJECTEXPANSION PROJECT
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 22
MHI BUSINESSCONFIDENTIAL
Upon completion of the lesson, the trainee will be able to describe the features and design considerations for Paiton boiler.
Instructor Guide Material Objectives
General Objective:
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 33
MHI BUSINESSCONFIDENTIAL
Outline
nn SummarySummary
nn Design of Design of PaitonPaiton BoilerBoiler Combustion SystemsCombustion Systems Vertical Water WallVertical Water Wall Pressure PartsPressure Parts Boiler Expansion SystemsBoiler Expansion Systems Air and Gas SystemsAir and Gas Systems
nn Basics of BoilerBasics of Boilernn Feature of Feature of PaitonPaiton BoilerBoiler
Major SpecificationMajor Specification Coal PropertyCoal Property Design for SubDesign for Sub--bituminous Coalbituminous Coal
nn OperationOperation
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 44
MHI BUSINESSCONFIDENTIAL
Outline
nn SummarySummary
nn Design of Design of PaitonPaiton BoilerBoiler Combustion SystemsCombustion Systems Vertical Water WallVertical Water Wall Pressure PartsPressure Parts Boiler Expansion SystemsBoiler Expansion Systems Air and Gas SystemsAir and Gas Systems
nn Basics of BoilerBasics of Boilernn Feature of Feature of PaitonPaiton BoilerBoiler
Major SpecificationMajor Specification Coal PropertyCoal Property Design for SubDesign for Sub--bituminous Coalbituminous Coal
nn OperationOperation
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 55
MHI BUSINESSCONFIDENTIAL
PurposePurpose ::
Condenser
Feed Water
High PressureHigh TemperatureSteam
Exhaust Steam
To generate high pressure and high temperature steamTo generate high pressure and high temperature steamto operate steam turbineto operate steam turbine
TURBINE
Boiler=
SteamGenerator
Make-up Water
Typical Relation
Basics of Boiler
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 66
MHI BUSINESSCONFIDENTIAL
CombustionReaction
Water
Fuel
Air
Steam
Flue Gas
Input Materials Output Materials
Fuel energy
Process of Steam Generation
Basics of Boiler
Heat transfer
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 77
MHI BUSINESSCONFIDENTIAL
Wat
er
Fuel
Air
Com
bust
ion
Flue Gas
Furn
ace
Supe
rhea
ter
Econ
omiz
er
Air
heat
er
Reh
eate
rSt
eam
Typical Scheme of Boiler System
Basics of Boiler
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 88
MHI BUSINESSCONFIDENTIAL
SuperheatedSteam
Saturated Steam
Heated by fuel combustion
Water wallSH
Superheated Steam
Basics of Boiler
Water
SteamSteamturbineturbine
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 99
MHI BUSINESSCONFIDENTIAL
Compressed WaterCompressed Water
Pres
sure
(MPa
(g))
Superheated SteamSuperheated Steam
Temperature ()
Water boils at 100Water boils at 100 in thein theatmosphere.atmosphere.
Saturation Pressure and Temperature
0 100 200 300 4000
10
20
Basics of Boiler
BoundaryBoundary= Saturation= Saturation
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 1010
MHI BUSINESSCONFIDENTIAL
Pressure and Enthalpy Chart
Pressure (MPa)
Enth
alpy
(kca
l/kg)
0
200
400
600
800
1000
0 10 20 30 40
Water
600
500
400
300200
SaturationSaturation(Steam/Water)(Steam/Water)
Basics of Boiler
Critical pressure22.1 MPa
Supercritical
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 1111
MHI BUSINESSCONFIDENTIAL
Pressure (MPa)
Enth
alpy
(kca
l/kg)
0
200
400
600
800
1000
0 10 20 30 40
Water
600
500
400
300
200
Basics of Boiler
Supercritical Sliding Pressure Operation
SaturationSaturation(Water/Steam)(Water/Steam)
35% 50% 75% BMCREco. Inlet
Economizer
Water Wall
Superheater
100%
SH Outlet
W.W Inlet
W.W Outlet
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 1212
MHI BUSINESSCONFIDENTIAL
Comparison of Drum Type Boiler and Once-through Boiler
to Steam TurbineSH
Furnace Eco
SteamDrum
BFPBCP
SH
Furnace
Eco
WaterSeparator
BFP
to Steam Turbine
Basics of Boiler
Higher Grade(Higher steam condition)BaseTube Material
Less(Better plant heat rate)Base
Environmental Impact
Approx. 3% Better (Higher Steam Condition)Base
Plant Heat Rate(Required heat input per 1kW )
Better(Less Heat Capacity)BaseLoad Change Rate
System Schematic
SupercriticalSub-criticalOperating Press.Once-Through boilerDrum type boilerBoiler Type
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 1313
MHI BUSINESSCONFIDENTIAL
Comparison of Drum Type Boiler and Once-through BoilerTube Materials of Pressure Parts
Furnace
SA-213T91 9Cr
ASME Code Case 21992.25Cr
SA-213T22 2Cr
ASME Code Case 2328-118Cr
SA-213T12 1Cr
SA-210C Carbon Steel
2ryRH
1ry RH
3ry SH
2ry SH
1ry SHEcoMaterialMaterial
Pressure Parts
Paiton (One-through Boiler)
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 1414
MHI BUSINESSCONFIDENTIAL
3ry SH2ry SH
Panel
Inlet Stub
Outlet Stub
Inlet Stub
Stainless Steel
Alloy Steel ASME Code Case 2199 2.25Cr
SA-213TP347H18Cr
SA-213T91 9Cr
SA-213T22 2Cr
ASME Code Case 2328-1 (18Cr
SA-213T12 1Cr
Outlet StubPanel
MaterialMaterial
T Plant (Drum Type Boiler) Paiton (One-through Boiler)Tube Materials of Pressure Parts
Comparison of Drum Type Boiler and Once-through Boiler
Basics of Boiler
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 1515
MHI BUSINESSCONFIDENTIAL
Supercritical Sliding Pressure Operation Boilers in Japan
Soma Joint EPCO. Shinchi P/S (1995)1,000MW 24.1MPa538/566
Tohoku EPCO. Haramachi P/S (1997)1,000MW 24.5MPa566/593
Tokyo EPCO. Hirono P/S (2004)600MW 24.5MPa600/600
Chubu EPCO. Hekinan P/S (1991)700MW 24.1MPa538/566
Vertical Water Wall
Kobe steel IPP Kobe P/S (2002)700MW 24.1MPa538/566
Chugoku EPCO. Misumi P/S (1998)1,000MW 24.5MPa600/600
Kyushu EPCO. Matsuura P/S (1989)700MW 24.1MPa538/566
Kansai EPCO. Maizuru P/S (2004)900MW 24.5MPa595/595
Basics of Boiler
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 1616
MHI BUSINESSCONFIDENTIAL
Global Supply Record for Vertical Water Wall BoilerNo.1 Share / 5 countries /
32,896MW / 45units
Since 1989,As of September 2010
( ): COD
SC : SupercriticalUSC : Ultra-Supercritical
Chugoku EPCO Misumi #1101000MW 24.5MPa600/600 (1998),and other 9 units for other customers
Japan 10 unitsChina 32 units (by Licensee)
Jaypee Nigrie #1, #2700MW 24.5MPa566/593 (2011),
and other 9 units for other customers
Paiton856MW 24.1MPa538/566 (2012)
Indonesia 1 unit
CFE Pacifico #1700MW 24.2MPa538/566 (2010)
Mexico 1 unitIndia 11 units
(by L&T-MHI Boiler Pvt. Ltd. as Joint Venture)
Henung Yuhuan #1 to #41001000MW 26.4MPa600/600 (2006),
and other 28 units for other customers
Basics of Boiler
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 1717
MHI BUSINESSCONFIDENTIAL
Availability of Supercritical Sliding Pressure Operation Boiler (Vertical Water Wall)
Reliability (%) = (Calendar date hours(h)- forced outage hours (h)) / (Calendar date hours(h))
0%
20%
40%
60%
80%
100%A
vaila
bilit
yA
vaila
bilit
y
MisuMisumimi1,000MW1,000MW
HaramachiHaramachi1,000MW1,000MW
ShinchiShinchi1,000MW1,000MW
MatsuuraMatsuura700MW700MW
Basics of Boiler
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 1818
MHI BUSINESSCONFIDENTIAL
Outline
nn SummarySummary
nn Design of Design of PaitonPaiton BoilerBoiler Combustion SystemsCombustion Systems Vertical Water WallVertical Water Wall Pressure PartsPressure Parts Boiler Expansion SystemsBoiler Expansion Systems Air and Gas SystemsAir and Gas Systems
nn Basics of BoilerBasics of Boilernn Feature of Feature of PaitonPaiton BoilerBoiler
Major SpecificationMajor Specification Coal PropertyCoal Property Design for SubDesign for Sub--bituminous Coalbituminous Coal
nn OperationOperation
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 1919
MHI BUSINESSCONFIDENTIAL
4.66Gcal/m2hFuel Heat Input (*1) / Plan Area
421.65m2Plan Area
29,414mmWidth55,149mmHeight
21,369m3Volume
0.089Gcal/m3hFuel Heat Input (*2) / Volume
14,335mmDepth
Furnace
25.78MPa(g)SH OutletPressure
4.85MPa(g)RH Outlet
542SH OutletTemperature
568RH Outlet
2,695t/hSteam Flow815MWNet Power Output
PaitonUnit
Major Specification
(*1)Include combustion air sensible heat and H2,H2O latent heat (HHV)
(*2)Exclude combustion air sensible heat and H2,H2O latent heat (HHV)
Feature of Paiton Boiler
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 2020
MHI BUSINESSCONFIDENTIAL
Material and Design Code
MHI StandardJIS or EquivalentNon Pressure Parts
ASME Pressure Vessel Code Section
ASME Pressure Vessel Code Section ,ASME Code Case
Pressure Parts
DesignMaterial
Feature of Paiton Boiler
ASME Pressure Vessel Code Section NFPA Code 85B, D E
Design for Implosion, Explosion
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 2121
MHI BUSINESSCONFIDENTIAL
Outline
nn SummarySummary
nn Design of Design of PaitonPaiton BoilerBoiler Combustion SystemsCombustion Systems Vertical Water WallVertical Water Wall Pressure PartsPressure Parts Boiler Expansion SystemsBoiler Expansion Systems Air and Gas SystemsAir and Gas Systems
nn Basics of BoilerBasics of Boilernn Feature of Feature of PaitonPaiton BoilerBoiler
Major SpecificationMajor Specification Coal PropertyCoal Property Design for SubDesign for Sub--bituminous Coalbituminous Coal
nn OperationOperation
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 2222
MHI BUSINESSCONFIDENTIAL
ASTM* Coal Rank (*American Society for Testing and Materials)
40
60
80
100
16000Gross Calorific Value Moist Mineral Matter Free(BTU/Lb)
Dry
Min
eral
-Mat
ter F
ree
Fixe
d C
arbo
n (%
)
BituminousBituminous LigniteLigniteSubSub--BituminousBituminous
MahakamMelawan
50
70
90
3060008000100001200014000
AnthraciteAnthracite
Pasir Roto South
Loa jananEnviro
Pasir Roto North
Feature of Paiton Boiler
Coals for PaitonProject are classified into Sub-Bituminous coal.
Performancecoal
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 2323
MHI BUSINESSCONFIDENTIAL
40
60
80
100
37200Gross Calorific Value Moist Mineral Matter Free (kJ/kg)
Dry
Min
eral
-Mat
ter F
ree
Fixe
d C
arbo
n (%
)
BituminousBituminous LigniteLigniteSubSub--BituminousBituminous
MahakamMelawan
50
70
90
301400018600233002790032600
AnthraciteAnthracite
Pasir Roto South
Loa jananEnviro
Pasir Roto North
Feature of Paiton Boiler
ASTM* Coal Rank (*American Society for Testing and Materials)
Coals for PaitonProject are classified into Sub-Bituminous coal.
Performancecoal
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 2424
MHI BUSINESSCONFIDENTIAL
Sub-bituminous coal (Paiton)
Bituminous coal
5.22.51.72547
0.961.05.20.80.25.210.120
0.84120041
16.70.96
PerformanceCoal
35201018402.51.8354.03.0352.0150.5120020182.5
Range Design CoalRange
UnitItem
AS: As ReceivedAD: Air Dry Base
DB: Dry BaseDSF: Dry Ash Free
1.95.3kg/106kcalAsh Loading1.13.8kg/106kcalAl2O3SiO2 (DB)0.72.5kg/106kcalQuartz(SiO2) (DB)Erosion
Characteristic
2132%Total Moisture (AR)4353HGICoal Fineness
0.861.07Fuel Ratio (AD)0.91.8%Nitrogen N (DAF)NOx Emission
Characteristic
1.95.3kg/106kcalAsh Loading0.82.7%Na2OK2O (DB)0.21.8%Na2O (DB)Fouling
Characteristic
1.95.28kg/106kcalAsh Loading0.10.3%Total Sulfur (AD)12.520%Fe2O3 (DB)0.311.5Base/Acid Ratio(*1) (DB)
12001320Ash Softening Temperature
Slagging Characteristic
40.543.5%Volatile Matter (AD)13.417.6C/H Ratio (DAF)0.861.07Fuel Ratio (AD)
Combustion Characteristic
() The ratio of basic substances (Fe2O3, CaO,MgO,Na2O,K2O) to acid substances (SiO2, Al2O3, TiO2)
Coal Property
Feature of Paiton Boiler
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BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 2525
MHI BUSINESSCONFIDENTIAL
Sub-bituminous coal (Paiton)
Bituminous coal
5.22.51.72547
0.961.05.20.80.25.210.120
0.84120041
16.70.96
PerformanceCoal
35201018402.51.8354.03.0352.0150.5120020182.5
Range Design CoalRange
UnitItem
1.95.3kg/106kcalAsh Loading1.13.8kg/106kcalAl2O3SiO20.72.5kg/106kcalQuartz(SiO2)Erosion
Characteristic
2132%Total Moisture (As Received)4353HGICoal Fineness
0.861.07Fuel Ratio0.91.8%Nitrogen N (Dry Ash Free)NOx Emission
Characteristic
1.95.3kg/106kcalAsh Loading0.82.7%Na2OK2O (in Ash)0.21.8%Na2O (in Ash)Fouling
Characteristic
1.95.28kg/106kcalAsh Loading0.10.3%Total Sulfur12.520%Fe2O3(in Ash)0.311.5Base/Acid Ratio(*1)
12001320Ash Softening Temperature
Slagging Characteristic
40.543.5%Volatile Matter (Air Dry Base)13.417.6C/H Ratio0.861.07Fuel Ratio
Combustion Characteristic
() The ratio of basic substances (Fe2O3, CaO,MgO,Na2O,K2O) to acid substances (SiO2, Al2O3, TiO2)
Coal Property
Feature of Paiton Boiler
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 2626
MHI BUSINESSCONFIDENTIAL
Outline
nn SummarySummary
nn Design of Design of PaitonPaiton BoilerBoiler Combustion SystemsCombustion Systems Vertical Water WallVertical Water Wall Pressure PartsPressure Parts Boiler Expansion SystemsBoiler Expansion Systems Air and Gas SystemsAir and Gas Systems
nn Basics of BoilerBasics of Boilernn Feature of Feature of PaitonPaiton BoilerBoiler
Major SpecificationMajor Specification Coal PropertyCoal Property Design for SubDesign for Sub--bituminous Coalbituminous Coal
nn OperationOperation
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 2727
MHI BUSINESSCONFIDENTIAL
SlaggingSlaggingcharacteristiccharacteristic
Design Considerations for Sub-bituminous Coal
Feature of Paiton Boiler
Low calorific valueLow calorific value
High spontaneous High spontaneous combustibilitycombustibility
High moisture contentHigh moisture contentCoal FinenessCoal Fineness
Coal Property of Coal Property of subsub--bituminous bituminous coalcoal
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 2828
MHI BUSINESSCONFIDENTIAL
SlaggingSlaggingcharacteristiccharacteristic
Feature of Paiton Boiler
Low calorific valueLow calorific value
High spontaneous High spontaneous combustibilitycombustibility
High moisture contentHigh moisture contentCoal FinenessCoal Fineness
Coal Property of Coal Property of subsub--bituminous bituminous coalcoal
Design Considerations for Sub-bituminous Coal
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 2929
MHI BUSINESSCONFIDENTIAL
Feature of Paiton Boiler
lHigh spontaneous combustibilityDecrease Pulverizer Outlet Air Temperature
60
Sub-Bituminous Coal (Paiton)
77
Bituminous Coal
Pulv
eriz
erO
utle
t Air
Tem
p.(
)
50
100
0
Design Considerations for Sub-bituminous Coal
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 3030
MHI BUSINESSCONFIDENTIAL
Feature of Paiton Boiler
lHigh moisture contentIncrease Pulverizer Inlet Air Temperature
Sub-Bituminous Coal (Paiton)
255
Bituminous Coal
Pulv
eriz
erIn
let A
ir Te
mp.
(
)
100
200
300241
0
Design Considerations for Sub-bituminous Coal
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 3131
MHI BUSINESSCONFIDENTIAL
Feature of Paiton Boiler
lLow calorific value (More coal flow)Larger capacity pulverizer is selected.
Sub-Bituminous Coal (Paiton)
108 t/h
Bituminous Coal
Pulv
eriz
erC
apac
ity
(t/h)
50
100
150
95 t/h
0
Design Considerations for Sub-bituminous Coal
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 3232
MHI BUSINESSCONFIDENTIAL
Proper arrangement of Wall Deslagger
Wall Deslagger : 68
Half Retractable Sootblower : 10
Long Retractable Sootblower : 26
Features of Paiton Boiler
lSlagging characteristicDesign Considerations for Sub-bituminous Coal
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 3333
MHI BUSINESSCONFIDENTIAL
Outline
nn SummarySummary
nn Design of Design of PaitonPaiton BoilerBoiler Combustion SystemsCombustion Systems Vertical Water WallVertical Water Wall Pressure PartsPressure Parts Boiler Expansion SystemsBoiler Expansion Systems Air and Gas SystemsAir and Gas Systems
nn Basics of BoilerBasics of Boilernn Feature of Feature of PaitonPaiton BoilerBoiler
Major SpecificationMajor Specification Coal PropertyCoal Property Design for SubDesign for Sub--bituminous Coalbituminous Coal
nn OperationOperation
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 3434
MHI BUSINESSCONFIDENTIAL
Boiler Front
Fixed SeparatorPulverizer
In-Furnace DeNOx System MACT* (*Mitubishi Advanced Combustion Technology)
Circular Corner Firing CCF
Low NOxA-PM* Burner(*Advanced Pollution minimum)
Combustion Systems
Combustion Systems
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 3535
MHI BUSINESSCONFIDENTIAL
Plan View
2. High Combustion StabilityMutual supporting combustion byadjacent burner
1. High Efficient CombustionBetter mixing of fuel and airLong flame path by effective use of furnace
Circular Corner Firing (CCF)
Combustion Systems
Side View
3. Low NOx Emission4. Less Furnace slaggingUniform combustion without peak heat flux.
l Twin furnacel Eight(8) burnersl No division walll Two concentric circles are
formed by circular firing.
- Main Structure -
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 3636
MHI BUSINESSCONFIDENTIAL
Coal Fired Supercritical Pressure Operation Boiler-CCF Units (Twin Furnace)-
CoalMar.2003600MWChina FPC USA CP #413
CoalSep.2000600MWChina FPC USA CP #28
Coal.2000600MWTaiwan Mailiao FPCC #69
CoalMar.2000600MWChina FPC USA CP #17
CoalAug.2004900MWKansai EPC Maizuru #114
Coal.2002600MWTaiwan Mailiao FPCC #712
Coal.2002600MWTaiwan Mailiao FP #411
CoalJan.2000600MWChina FPC USA CP #310
CoalSep.1999600MWTaiwan Mailiao FP #26
CoalJun.1999600MWTaiwan Mailiao FP #15
CoalJul.19981000MWChugoku EPC Misumi #14
CoalJul.19971000MWTohoku EPC Haranomachi #13
CoalJul.19951000MWSoma Kyodo PC Shinchi #22
CoalOct.1991700MWChubu EPC Hekinan #11
FuelCommercialOperationCapacityPlant NameNo.
Combustion Systems
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 3737
MHI BUSINESSCONFIDENTIAL
A-PM Burner (1/2)
Conc. flame surface is extended
Stable Ignition
Conc.
Weak
Conc.
CoalCoal
A-PM Burner : Advanced - Pollution Minimum Burner
Aux.2
AA
Aux.1
Oil / AirCoal
Coal
Aux.1
Aux.1
Oil / AirCoal
Coal
Aux.1
Aux.1
Oil / AirCoal
Coal
AA
AA
AA
Oil / Air
Coal
Coal
AA : Additional Air
Aux.1(U)
Combustion Systems
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 3838
MHI BUSINESSCONFIDENTIAL
ConcFlame
A-PM Burner (2/2)N
Ox
(ppm
)
Primary Air / Coal Ratio0
A-PM Burner
7834
Single Flame Burner
A
C1 C2
WeakFlame
C0
Combustion Systems
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 3939
MHI BUSINESSCONFIDENTIAL
Main Burner
AdditionalAir
Furnaceoutlet
CombustionCompletionZone
ReductiveDeNOxZone
Main BurnerCombustionZone
Stable and Low NOxCombustionwith A-PM Burner
Combustion Air
40%
60%
- In-Furnace DeNOx System- MACT (Mitsubishi Advance Combustion Technology)
Combustion Systems
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 4040
MHI BUSINESSCONFIDENTIAL
Fixed Separator and Pulverizer (1/2)
Combustion Systems
Hot AirHot Air
Raw Raw CoalCoal
Pulverized Pulverized CoalCoal
Coarse CoalCoarse Coal
Fine CoalFine Coal
RollerRoller
Grinding Grinding TableTable
Hydraulic Hydraulic Loading Loading DeviceDevice
FixedFixedSeparatorSeparator
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 4141
MHI BUSINESSCONFIDENTIAL
Pulverizer and Coal Pipe ArrangementFixed Separator and Pulverizer (2/2)
Pulverize
r : 6 units
Coal Pipe
BoilerFront
Combustion Systems
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 4242
MHI BUSINESSCONFIDENTIAL
Boiler Front
Fixed SeparatorPulverizer
In-Furnace DeNOx System MACT* (*Mitubishi Advanced Combustion Technology)
Circular Corner Firing CCF
Low NOxA-PM* Burner(*Advanced Pollution minimum)
Combustion Systems
Combustion Systems
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 4343
MHI BUSINESSCONFIDENTIAL
Outline
nn SummarySummary
nn Design of Design of PaitonPaiton BoilerBoiler Combustion SystemsCombustion Systems Vertical Water WallVertical Water Wall Pressure PartsPressure Parts Boiler Expansion SystemsBoiler Expansion Systems Air and Gas SystemsAir and Gas Systems
nn Basics of BoilerBasics of Boilernn Feature of Feature of PaitonPaiton BoilerBoiler
Major SpecificationMajor Specification Coal PropertyCoal Property Design for SubDesign for Sub--bituminous Coalbituminous Coal
nn OperationOperation
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 4444
MHI BUSINESSCONFIDENTIAL
Smooth Tube
Film Boiling
Nucleate Boiling
Nucleate Boiling
(Spiral Wall)Rifled Tube
(Vertical Wall)
Vertical Water Wall
Boiling Phenomenon
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 4545
MHI BUSINESSCONFIDENTIAL
Spiral Water WallVertical Water Wall (Paiton)
Vertical Water Wall
Smooth TubeRifled Tube
Boiler Type
(1)(1) Simple StructureSimple Structure
(2)(2) Low Low P at Water WallP at Water Wall
(3)(3) Easy Removal of SlagEasy Removal of Slag
Merits of Vertical Water WallMerits of Vertical Water Wall
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 4646
MHI BUSINESSCONFIDENTIAL
Smooth TubeMass Velocity 1,500 kg/m2s Mass Velocity 3,100 kg/m2s
Film Boiling
Nucleate Boiling
Nucleate Boiling
PwwPww --5 kg/cm5 kg/cm22
(Spiral Wall)Rifled Tube
(Vertical Wall)
Vertical Water Wall
Boiling Phenomenon
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 4747
MHI BUSINESSCONFIDENTIAL
700
600
500
400
0.0 0.2 0.4 0.6 0.8 1.0Steam Quality
2,000kg/m2s
3,000
3,500
Tube
Met
al T
empe
ratu
re (
)
Maximum Allowable Temp.
Steam Quality = ( Steam Flow ) / ( Steam Flow + Liquid Flow )
Smooth Tube
Design3,100 kg/m2s
2,000 2,500Rifled Tube
Design1,500 kg/m2s
WaterWater
Furnace Hopper Burner Zone Upper Furnace
SteamSteam
Vertical Water Wall
Steam Quality and Tube Metal Temperature
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 4848
MHI BUSINESSCONFIDENTIAL
8P
Vertical Water Wall
Spiral Water Wall
n 30 deg. Incline
n Half pcs. of tubes
4P
30
Vertical Water Wall
Spiral Water Wall
For smooth tube, For smooth tube, Sufficient mass Sufficient mass velocity is required.velocity is required.
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 4949
MHI BUSINESSCONFIDENTIAL
Horizontal Buckstay
Support Structure of Spiral Water Wall
Holder
Vertical Tie
Holder
Lug
Vertical Water Wall
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 5050
MHI BUSINESSCONFIDENTIAL
Keeper Lug
Horizontal Buckstay
Support Structure of Vertical Water Wall
HolderHolder
Vertical Water Wall
Horizontal tie
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 5151
MHI BUSINESSCONFIDENTIAL
Fall easilyAdhere on the shelf of tube fin
Vertical Water Wall Spiral Water WallEasy Removal of Slag
Vertical Water Wall
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 5252
MHI BUSINESSCONFIDENTIAL
Spiral Water WallVertical Water Wall (Paiton)
Vertical Water Wall
Smooth TubeRifled Tube
(1)(1) Simple StructureSimple Structure
(2)(2) Low Low P at Water WallP at Water Wall
(3)(3) Easy Removal of SlagEasy Removal of Slag
Merits of Vertical Water WallMerits of Vertical Water Wall
Spiral Spiral water wall has been awater wall has been adopteddopted previously.previously.Now, MHI has deNow, MHI has deveveloplopeded and adopted vertical and adopted vertical water wall with rifled tube over 20 years, water wall with rifled tube over 20 years, considering above merits.considering above merits.
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 5353
MHI BUSINESSCONFIDENTIAL
Outline
nn SummarySummary
nn Design of Design of PaitonPaiton BoilerBoiler Combustion SystemsCombustion Systems Vertical Water WallVertical Water Wall Pressure PartsPressure Parts Boiler Expansion SystemsBoiler Expansion Systems Air and Gas SystemsAir and Gas Systems
nn Basics of BoilerBasics of Boilernn Feature of Feature of PaitonPaiton BoilerBoiler
Major SpecificationMajor Specification Coal PropertyCoal Property Design for SubDesign for Sub--bituminous Coalbituminous Coal
nn OperationOperation
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 5454
MHI BUSINESSCONFIDENTIAL
Economizer
Water Wall
2ry Superheater
2ry Reheater3ry Superheater
1ry Reheater
Pressure Parts
Pressure Parts Arrangement
1ry Superheater
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 5555
MHI BUSINESSCONFIDENTIAL
Arrangement and Flow Diagram (1/12)
EcoEcoInlet PipeInlet Pipe
Eco InletEco InletHeaderHeader
Furnace Furnace Inlet PipeInlet Pipe
Furnace Furnace Inlet PipeInlet Pipe
EcoEcoInlet PipeInlet Pipe
Eco Inlet HeaderEco Inlet Header
Eco Outlet Eco Outlet HeaderHeader
Eco Outlet Eco Outlet HeaderHeader
Pressure Parts
IntermediateIntermediateHeaderHeader
Intermediate Intermediate HeaderHeader
Economizer
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 5656
MHI BUSINESSCONFIDENTIAL
Economizer
Pressure Parts
IntermediateHeader
Outlet Header
Roof Tube
Inlet Header
IntermediateHeader
Design considerations
u Counter flow for more efficient heat transfer
u Intermediate HDR for temp. equalization
u Heating surface area is designed considering Eco. outlet temp.
u Sufficient Eco. outlet subcool is ensured.
Horizontal Horizontal PartPart
Hanger Hanger PartPart
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 5757
MHI BUSINESSCONFIDENTIAL
A
A
Eco Tube
Eco Tube
Spiral Fin
Eco Intermediate HDR
Eco Hanger Tube
Eco Hanger TubeEco Intermediate HDR
A-A
Support Assembly
Clevis
Economizer horizontal part
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 5858
MHI BUSINESSCONFIDENTIAL
Water Wall(Furnace)
Furnace InletFurnace InletManifoldManifold
Furnace Outlet Furnace Outlet HeaderHeader
Furnace InletFurnace InletManifoldManifold
Furnace Furnace Outlet Outlet HeaderHeader
Pressure Parts
Arrangement and Flow Diagram (2/12)
Furnace Furnace Intermediate Intermediate ManifoldManifold
Furnace Furnace Intermediate Intermediate manifoldmanifold
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 5959
MHI BUSINESSCONFIDENTIAL
Water Wall(Roof)
Roof Inlet Roof Inlet ManifoldManifold
Roof Inlet Roof Inlet HeaderHeader
Roof Inlet Roof Inlet ManifoldManifold
Roof Outlet Roof Outlet HeaderHeader
Roof Outlet Roof Outlet HeaderHeader
Roof Inlet Roof Inlet HeaderHeader
Pressure Parts
Arrangement and Flow Diagram (2/12)
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 6060
MHI BUSINESSCONFIDENTIAL
Water Wall(Passage Side Wall)(Rear Wall Hanger)
Outlet HeaderOutlet Header
Outlet HeaderOutlet Header
Inlet HeaderInlet Header
Passage Side WallPassage Side WallInlet ManifoldInlet Manifold
RearRear Wall HangerWall HangerInlet ManifoldInlet Manifold
Rear Wall HangerRear Wall Hanger Inlet ManifoldInlet ManifoldPassage Side Wall Inlet ManifoldPassage Side Wall Inlet Manifold
Inlet HeaderInlet Header
Arrangement and Flow Diagram (4/12)
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 6161
MHI BUSINESSCONFIDENTIAL
Water Wall(Back Pass)
Outlet HeaderOutlet Header
Back PassBack PassInlet PipeInlet Pipe
Inlet HeaderInlet Header
Inlet ManifoldInlet Manifold
Water SeparatorWater SeparatorInlet PipeInlet Pipe
Water SeparatorWater SeparatorInlet PipeInlet PipeInlet HeaderInlet Header
Back PassBack PassInlet PipeInlet Pipe
InletInletManifoldManifold
Outlet HeaderOutlet Header
Arrangement and Flow Diagram (5/12)
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 6262
MHI BUSINESSCONFIDENTIAL
Water Wall2RY PASS FRONTWALL OUTLET HDR.
RIGHT SIDE ONLY
SM
OO
TH T
UB
E
LEFT SIDE ONLY
RIF
LE T
UB
ESM
OO
TH
TUB
E
MEM
BRANE
MEM
BRANE
FURNACE INLET PIPE
+16500
+45120
ROOF INLET HDR.
+64200
SIDE WALL OUTLET HDR.
PASSAGE SIDE WALLOUTLET HDR.
SECONDARY PASS SIDEWALLOUTLET HDR.
FIN FIN
FIN ROOF OUTLET HDR.
SIDE WALLSIDE WALL INLET HDR.
1st TUBE OF PASSAGE SIDE WALLFROM BOILER FRONT TO BEINCLUDED WITH FURNACESIDE WALL TUBE PANEL.
C L O
F F
UR
NA
CE
SECONDARY PASS SIDE WALL
PRIMARY SH INLETHDR.
SECONDARY PASS SIDE WALLINLET HDR.
MEM
BRAN
E
PRIMARY RH INLETHDR.
1st TUBE OF PASSAGE SIDE WALLFROM BOILER REAR TO BE INCLUDEDWITH FURNACE SIDE WALL TUBE PANEL.
FURNACE INTER MEDIATEHDR. (SIDE)
PASSAGE SIDE WALLINLET HDR.REAR WALL HANGER
TUBE
REAR WALL HANGERINLET HDR
OUTSIDE WELDINGGROOVE
FRONT WALL OUTLET HDR. REAR WALL HANGEROUTLET HDR.
2RY PASS REARWALL OUTLET HDR.
2RY PASS DIVISION WALLOUTLET HDR
2RY PASS DIVISION WALLINLET HDR
Rifled TubeRifled Tube
Pressure Parts
Design considerations
u Plan area is designed considering the coal slagging characteristic
u Furnace size is designed so that 2ry SH outlet gas temp is below the ash softening temp.
u Rifled tube is used at furnace lower wall
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 6363
MHI BUSINESSCONFIDENTIAL
Water Wall
Adjustment of heat absorptionAdjustment of heat absorptionpp InIn--tube orifice tube orifice
Variation of orifice diameterVariation of orifice diameter
pp Intermediate HDR and manifoldIntermediate HDR and manifold
Elimination of temp. differenceElimination of temp. differencein upper wall tubesin upper wall tubes
Pressure Parts
Heat absorption in each tube is not equal.
p Heat distribution in furnace
p Burner shaded part
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 6464
MHI BUSINESSCONFIDENTIAL
Water Separator& Drain Tank
1ry SH1ry SHInlet PipeInlet Pipe WSWS
DrainDrainTankTank
WaterWaterSeparatorSeparator
Drain TankDrain Tank
1ry SH1ry SHInlet PipeInlet Pipe
Arrangement and Flow Diagram (6/12)
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 6565
MHI BUSINESSCONFIDENTIAL
Water Separator
3310mm (Shell)Height
1000mmOutside diameter
SA-387-11-2 (Shell)
Material
120mm (Shell)Thickness
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 6666
MHI BUSINESSCONFIDENTIAL
Water Separator Drain Tank
16.4m (Shell)Height
1000mmOutside diameter
SA-387-11-2(Shell)
Material
120mm (Shell)Thickness
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 6767
MHI BUSINESSCONFIDENTIAL
1ry SH1ry SH--DeSHDeSH
1ry Superheater
2ry SH2ry SHInlet PipeInlet Pipe
1ry SH1ry SHInlet HeaderInlet Header
2ry SH2ry SHInlet PipeInlet Pipe
1ry 1ry SHSH--DeSHDeSH
1ry SH1ry SHOutlet HeaderOutlet Header
1ry SH 1ry SH InletInletHeaderHeader
1ry SH 1ry SH OutletOutletHeaderHeader
Arrangement and Flow Diagram (7/12)
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 6868
MHI BUSINESSCONFIDENTIAL
Outlet Header
Roof Tube
Inlet Header
Pressure Parts
1ry Superheater
Design considerationsu Counter flow for more
efficient heat transfer.
u Heating surface area is decided so that necessary total heat absorption of SH is obtained.
u The height is within the effective area of soot blowing.Horizontal Horizontal
PartPart
Terminal Terminal PartPart
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 6969
MHI BUSINESSCONFIDENTIAL
2ry Superheater
3ry SH3ry SHInlet PipeInlet Pipe
2ry SH2ry SH--DeSHDeSH
2ry SH2ry SHInlet HeaderInlet Header
2ry SH2ry SH--DeSHDeSH
3ry SH3ry SHInlet PipeInlet Pipe
2ry SH2ry SHInlet HeaderInlet Header
2ry SH2ry SHOutlet HeaderOutlet Header
Arrangement and Flow Diagram (8/12)
Pressure Parts
2ry SH2ry SHOutlet HeaderOutlet Header
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 7070
MHI BUSINESSCONFIDENTIAL
Outlet HeaderInlet Header
2ry Superheater
Roof Tube
Girdling Tube
Pressure Parts
u Panel type, which absorbs the radiant heat from furnace effectively.
u Heating surface area is designed based on the furnace size.
u 2ry SH outlet gas temp. is designed below the ash softening temp.
u Girdling tube and wrapper tube are provided for anti-vibration.
Design considerations
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 7171
MHI BUSINESSCONFIDENTIAL
Girdling tube / 2ry SH Wrapper tube
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 7272
MHI BUSINESSCONFIDENTIAL
3ry Superheater
3ry SH3ry SHInlet HeaderInlet Header
3ry SH3ry SHOutlet HeaderOutlet Header
MainSteam
MainSteam3ry SH3ry SH
Outlet HeaderOutlet Header
Arrangement and Flow Diagram (9/12)
Pressure Parts
3ry SH3ry SHInlet HeaderInlet Header
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 7373
MHI BUSINESSCONFIDENTIAL
Girdling Tube
Outlet HeaderInlet Header
3ry Superheater
Roof Tube
Pressure Parts
u Platen type, which absorbsthe radiant heat from furnace and convectionheat from flue gas.
u Heating surface area isdesigned based on the furnace size.
u Girdling tube and spacer tube are provided for anti-vibration.
Design considerations
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 7474
MHI BUSINESSCONFIDENTIAL
1ry SH Inlet HDR
Spacer tube
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 7575
MHI BUSINESSCONFIDENTIAL
1ry Reheater
2ry RH2ry RHInlet PipeInlet Pipe
1ry RH1ry RHOutlet HeaderOutlet HeaderRHRH--DeSHDeSH
LTRLTR 1ry RH1ry RHInlet HeaderInlet Header
1ry RH Outlet Header1ry RH Outlet Header
2ry RH2ry RHInlet PipeInlet Pipe
RHRH--DeSHDeSHLTRLTR
1ry RH1ry RHInletInlet
HeaderHeader
Arrangement and Flow Diagram (10/12)
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 7676
MHI BUSINESSCONFIDENTIAL
Outlet Header
Inlet Header
1ry Reheater
Pressure Parts
u Counter flow for moreefficient heat transfer
u Heating surface area isdecided so that necessarytotal heat absorption of RHis obtained.
u The height is within theeffective area of soot blowing.
Design considerations
Horizontal Horizontal PartPart
Terminal Terminal PartPart
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 7777
MHI BUSINESSCONFIDENTIAL
2ry Reheater
2ry RH2ry RHOutlet HeaderOutlet Header
2ry RH2ry RHInlet HeaderInlet Header
2ry RH2ry RHInlet HeaderInlet Header
2ry RH2ry RHOutlet HeaderOutlet Header
Arrangement and Flow Diagram (11/12)
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 7878
MHI BUSINESSCONFIDENTIAL
Inlet Header Outlet Header
2ry Reheater
Roof Tube
Pressure Parts
u Pendant type, which absorbsthe convection heat from fluegas.
u Heating surface area is designedbased on the furnace size.
u Spacer tube are provided foranti-vibration.
Design considerations
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 7979
MHI BUSINESSCONFIDENTIAL
2ry SH2ry SH2ry2ryRHRH
3ry3rySHSH
EcoEco
WSWS
ECOECO 1ry RH1ry RH 2ry RH2ry RHWSWSBack PassBack PassFurnaceFurnace RoofRoofPassage Side WallPassage Side WallRear Wall HangerRear Wall Hanger
Arrangement and Flow Diagram (12/12)
Pressure Parts
1ry1ryRHRH
1ry 1ry SHSH
3ry SH3ry SH2ry SH
1ry SH1ry SH
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 8080
MHI BUSINESSCONFIDENTIAL
Eco - Furnace31.49
28.00
Roof, PSW30.11 Back Pass
28.77WS 1ry SH
28.61 2ry SH29.80
27.563ry SH
SH out27.05
5.84RH
654
Design Pressure Diagram
26
24
25
27
28
29
30
31
32
33
Pres
sure
(MPa
)
654
Operating Pressure
Predicted Performance + MSV Inlet OperatingPress.5%Predicted Performance
IncludedNot Included
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 8181
MHI BUSINESSCONFIDENTIAL
250
600
550
500
450
400
350
300
250
600
550
500
450
400
350
300
Design Temperature DiagramTe
mpe
ratu
re
Operating Temperature 350
582
513550
3ry SH
454450WS 1ry SH
467
2ry SH
391
450Back Pass450
Eco - Furnace350
FurnaceInterm.
HDR 450ECOInterm.HDR
362
Roof, PSW
1ry SH InletHDR 533
496RH
IncludedNot Included
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 8282
MHI BUSINESSCONFIDENTIAL
SH Outlet DesignPress.27.05
Spring Loaded
3.97
%29.52
30.74
PCV
2.99
%
26.24
27.05
Safety Valve DesignPr
essu
re (M
Pa)
33
32
31
30
29
28
27
26
26
24
34
SH outletWS outlet
SH Outlet Press.25.80
Operating PressureWS Outlet Press.
27.36
3.98
%
3.97
%
3.99
%
3.98
%
3.99
%
3.98
%
Spring Loaded
30.38
31.64
30.24
31.49
30.09
31.34
29.95
31.19
29.80
31.04
29.66
30.89
Pres
sure
(MPa
)
6.0
5.5
5.0
4.5
6.5
RH Outlet Press.4.86
RH Outlet
Operating PressureRH Inlet Press. 5.03
RH inlet
RH Design Press.5.90
Spring Loaded
3.87
%
5.46
5.68
6.07Spring Loaded
3.90
%
5.67
5.903.95
%
5.83
3.99
%
5.77
6.01
3.86
%
5.73
5.96
Reheat Steam LineReheat Steam LineMain Steam LineMain Steam LineAs per ASME Boiler & Pressure Vessel Code, Section, PG-67
Pressure Parts
WS Design Press.28.77 MFT 28.67
ANN 26.83
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 8383
MHI BUSINESSCONFIDENTIAL
1ry Reheater
2ry RH2ry RHInlet PipeInlet Pipe
1ry RH1ry RHOutlet HeaderOutlet HeaderRHRH--DeSHDeSH
LTRLTR 1ry RH1ry RHInlet HeaderInlet Header
1ry RH Outlet Header1ry RH Outlet Header
2ry RH2ry RHInlet PipeInlet Pipe
RHRH--DeSHDeSHLTRLTR
1ry RH1ry RHInletInlet
HeaderHeader
Arrangement and Flow Diagram (10/12)
Pressure Parts
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 8484
MHI BUSINESSCONFIDENTIAL
2ry SH2ry SH2ry2ryRHRH
3ry3rySHSH
EcoEco
WSWS
ECOECO 1ry RH1ry RH 2ry RH2ry RHWSWSBack PassBack PassFurnaceFurnace RoofRoofPassage Side WallPassage Side WallRear Wall HangerRear Wall Hanger
Arrangement and Flow Diagram (12/12)
Pressure Parts
1ry1ryRHRH
1ry 1ry SHSH
3ry SH3ry SH2ry SH
1ry SH1ry SH
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 8585
MHI BUSINESSCONFIDENTIAL
Outline
nn SummarySummary
nn Design of Design of PaitonPaiton BoilerBoiler Combustion SystemsCombustion Systems Vertical Water WallVertical Water Wall Pressure PartsPressure Parts Boiler Expansion SystemsBoiler Expansion Systems Air and Gas SystemsAir and Gas Systems
nn Basics of BoilerBasics of Boilernn Feature of Feature of PaitonPaiton BoilerBoiler
Major SpecificationMajor Specification Coal PropertyCoal Property Design for SubDesign for Sub--bituminous Coalbituminous Coal
nn OperationOperation
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 8686
MHI BUSINESSCONFIDENTIAL
CE
NTE
R O
F FU
RN
AC
EC L
BOILER FRONT
Furnace Bottom
Boiler Expansion Systems
Furnace Furnace HopperHopper
Drag Drag Chain Chain ConveyorConveyor
Seal Seal PlatePlate
Free
Free
FreeFree
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 8787
MHI BUSINESSCONFIDENTIAL
CORNER PLATE11
STOPPER BEAM12
BOILER STRUCTURE COLUMN13
STIFFENER14
CORNER LINK10
HOLDER9
TIE PLATE8
BUCKSTAY7
LOOSE MINERAL FIBER6
OUTER CASING5
PIN CLIPS4
INSULATION PINS3
BLOCK INSULATION(MINERAL FIBER BOARD)
2
WATER WALL TUBES1
DESCRIPTIONITEM
Buckstay Arrangement
Free
Free
Free
FreeFix
Fix
Boiler Expansion Systems
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 8888
MHI BUSINESSCONFIDENTIAL
Outline
nn SummarySummary
nn Design of Design of PaitonPaiton BoilerBoiler Combustion SystemsCombustion Systems Vertical Water WallVertical Water Wall Pressure PartsPressure Parts Boiler Expansion SystemsBoiler Expansion Systems Air and Gas SystemsAir and Gas Systems
nn Basics of BoilerBasics of Boilernn Feature of Feature of PaitonPaiton BoilerBoiler
Major SpecificationMajor Specification Coal PropertyCoal Property Design for SubDesign for Sub--bituminous Coalbituminous Coal
nn OperationOperation
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 8989
MHI BUSINESSCONFIDENTIAL
Air & Gas Systems
PAF
2ry Air
2ry Air
1ry Cold Air
PAF
1ry Cold Air
FDF
FDF
1ry Hot Air
1ry Hot Air
Pulverizer Outlet Temp. control
Pulverizer Outlet Temp. Control
Furnace(Boiler)
Air
heat
erA
ir H
eate
r
Furnace Eco.
Pulverizer
Gas
Gas
Air & Gas Systems
IDF
IDFEP
EP
FGD
Stack
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 9090
MHI BUSINESSCONFIDENTIAL
Gas side,Cold end
Soot blower Arrangement
Gas side,Hot end
369 / 145
1,683 t/h(BMCR, Design coal)
2 sets
Regenerative, RotaryVertical Trisector
Gas Temp. (Inlet / Outlet (Uncorrected))
Inlet Gas Flow
Stationary Water Washing device
Number
Type
Air Heater (1/3)
Air & Gas Systems
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 9191
MHI BUSINESSCONFIDENTIAL
Air Heater (2/3)
Gas Inlet
2ry AirOutlet
1ry AirOutlet
Air & Gas Systems
Soot Soot blowerblower
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 9292
MHI BUSINESSCONFIDENTIAL
Over View
B-side
A side
2ry Duct
1ry Duct
Gas Duct
1ry Duct
lRotating Direction
Air Heater (3/3)
Air & Gas Systems
Flue Gas Path
2ry Air Path
1ry Air Path
lRotation Speed
Approx. 1 rpm
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 9393
MHI BUSINESSCONFIDENTIAL
Fans
211Impeller StageImpeller Stage
8,580kW3,400kW2,500kWMotor CapacityMotor Capacity
Variable Blade Pitch Control
Inlet Vane Control
Variable Blade Pitch ControlControl SystemControl System
14025.525.5Inlet AirInlet Air//Gas Gas TemperatureTemperature
-540mmAq-50mmAq-50mmAqInlet PressureInlet Pressure430mmAq1,570mmAq480mmAqDischarge PressureDischarge Pressure
45,400m3/min9,900m3/min21,000m3/minCapacityCapacity222NumberNumber
Axial FlowHorizontal
CentrifugalHorizontal
Axial FlowHorizontalType
Type
IDFIDFPAFPAFFDFFDFFanFan
Air & Gas Systems
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 9494
MHI BUSINESSCONFIDENTIAL
Drive UnitDrive Unit
Seal PlateSeal Plate
Link ChainLink Chain
Lower TroughLower Trough
DewateringDewateringFurnace
FlightFlight
Dewatering sectionDewatering section
Falling of the Clinker
Chain RollerChain Roller
TransportTransport
Air & Gas Systems
Upper TroughUpper Trough
Cooling To Bottom ash storage pitTo Bottom ash storage pitCoolingCooling
Bottom Ash Handling SystemDrag Chain Conveyor
CrushCrush
GrinderGrinder
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 9595
MHI BUSINESSCONFIDENTIAL
Outline
nn SummarySummary
nn Design of Design of PaitonPaiton BoilerBoiler Combustion SystemsCombustion Systems Vertical Water WallVertical Water Wall Pressure PartsPressure Parts Boiler Expansion SystemsBoiler Expansion Systems Air and Gas SystemsAir and Gas Systems
nn Basics of BoilerBasics of Boilernn Feature of Feature of PaitonPaiton BoilerBoiler
Major SpecificationMajor Specification Coal PropertyCoal Property Design for SubDesign for Sub--bituminous Coalbituminous Coal
nn OperationOperation
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 9696
MHI BUSINESSCONFIDENTIAL
Operation
nn Operation ModeOperation Mode
nn Main Steam Temp. ControlMain Steam Temp. Control
nn Reheat Outlet Steam Temp. ControlReheat Outlet Steam Temp. Control
nn PulverizerPulverizer OperationOperation
nn NOxNOx TuningTuning
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 9797
MHI BUSINESSCONFIDENTIAL
Feed Water FlowWater Fuel Ratio (WFR)
30% 100%
Dry Mode (Once-Through Mode)
0% - 20%Load
Fuel flowPress. ControlSprayTemp. Control
System Schematics
Wet Mode (Circulation Mode)
Same system as drum type boiler.BCP is operated to re-circulate the water for the heat recovery.
BCP is stopped.
Boiler Operation Mode
SH
EcoBFP
to Steam Turbine
Furnace
WaterSeparator
SH
EcoBFP
to Steam Turbine
Furnace
WaterSeparator
SH
EcoBFP
to Steam Turbine
Furnace
WaterSeparator
SH
EcoBFP
to Steam Turbine
Furnace
WaterSeparator
BCPBCP
Operation
-
BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 9898
MHI BUSINESSCONFIDENTIAL
Pressure (MPa)
Enth
alpy
(kca
l/kg)
0
200
400
600
800
1000
0 10 20 30 40
Water
600
500
400
300200
SaturationSaturation(Water/Steam)(Water/Steam)
Supercritical Sliding Pressure Operation
35% 50% 80% BMCREco. Inlet
Economizer
Water Wall
Superheater
SH Outlet
W.W Inlet
W.W Outlet
Operation
W.W outlet Enthalpy in W.W outlet Enthalpy in Wet Mode (0Wet Mode (020%Load)20%Load)
W.W outlet Enthalpy in W.W outlet Enthalpy in Transition (20Transition (2030%Load)30%Load)
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MHI BUSINESSCONFIDENTIAL
SH
EcoBFP
to Steam Turbine
Furnace
WaterSeparator
Wet Mode
1ry SH Inlet Pipe1ry SH Inlet Pipe
Water SeparatorWater Separator
Furnace Inlet PipeFurnace Inlet Pipe
SH
EcoBFP
to Steam Turbine
Eco Inlet PipeEco Inlet Pipe
Furnace
WaterSeparator
BCPBCP
BCP Outlet PipeBCP Outlet Pipe
Drain TankDrain Tank
BCP Inlet PipeBCP Inlet Pipe
BCPBCP
EcoEco
Operation
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MHI BUSINESSCONFIDENTIAL
SH
EcoBFP
to Steam Turbine
Furnace
WaterSeparator
Dry Mode
1ry SH Inlet Pipe1ry SH Inlet Pipe
Water SeparatorWater Separator
EcoEco
Furnace Inlet PipeFurnace Inlet Pipe
SH
EcoBFP
to Steam Turbine
Eco Inlet PipeEco Inlet Pipe
Furnace
WaterSeparator
Operation
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MHI BUSINESSCONFIDENTIAL
Dry ModeDry ModeWet ModeWet Mode BCP is inBCP is in--service.service.
Boiler Operation Mode
Load (%)
Wat
er F
low
thro
ugh
Furn
ace
wal
l (%
)
25
25%
Boiler minimum flow for furnace wall tubes protection
0
100
25
50
75
0 50 75 100
50%
No.4
70%
No.5 Mill
35%
No.3
20%
No.1,2
Operation
BCP is stopped.BCP is stopped.
Transition Transition
3020
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MHI BUSINESSCONFIDENTIAL
Main Steam Temperature Control SystemsOperation modeOperation mode
Separate controlSeparate controlOver injectionOver injectionprotection functionprotection function
-- Supplementary Supplementary --Load changeLoad changeQuick responseQuick responseSeparate controlSeparate control
SH spraySH spray(2 Stages)(2 Stages)
N/AN/A
-- Main Main --Control avg. value ofControl avg. value offinal SH outlet steamfinal SH outlet steamtemp.temp.
Water / Fuel RatioWater / Fuel Ratio
Wet ModeWet ModeDry ModeDry ModeControlControlMatterMatter
Operation
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MHI BUSINESSCONFIDENTIAL
Stea
m T
emp.
1SH 1ry DeSH 2SH 2ry DeSH 3SH
SpraySpray
SH Desuperheater
Operation
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MHI BUSINESSCONFIDENTIAL
RH Outlet Steam Temperature Control Systems
Gas DistributionDamper (Main)
Adjustable Burner Nozzle angle(Auxiliary)
RH spray (For load changeand emergency)
RHRHPassPass
SHSHPassPass
Division WallDivision Wall
Operation
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MHI BUSINESSCONFIDENTIAL
Pulverizer Operation
Upper Limit 90%
Lower Limit 30%
PasirPasirRotoRoto
NorthNorth
Perform
ance
Perform
ance
coalcoal
Boiler Load (%)
Pulv
eriz
er L
oad
(%)
100
75
50
25
020 40 60 80 100
25%
30%
50%
100%
75%
BM
CR
3 Pulv
erizer
s
4 Pulve
rizers
5 Pulver
izers
6 Pulveri
zers
2 Pulv
erize
rs
Operation
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MHI BUSINESSCONFIDENTIAL
Operating Parameter for NOx Tuning
Low NOx High NOx
Additional AirDamper CloseOpen
Excess Air IncreaseDecrease
Coal Damper OpenClose
Auxiliary AirDamper OpenClose
Operation
Burner Nozzle Angle UpwardDownward
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MHI BUSINESSCONFIDENTIAL
SummarynBoiler design for Paiton project is
based on a lot of MHIs experiences.
nnBoiler design for Boiler design for PaPaitoniton project is project is based on design coal properties.based on design coal properties.
nnWe are looking forward to We are looking forward to demonstrating high performance demonstrating high performance and high reliability of and high reliability of PaPaitoniton Boiler.Boiler.