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CIRCULATING FLUIDIZED BED BOILER FED DIRECTLY WITH SLURRY CONTAINING 33 % WATER [PHASE 5] : MEASUREMENT

Ziel

Construction of, and measurements on Lurgi circulating fluidized bed boiler to burn tailings from settling basins in the form of a slurry containing 30-35 % water in order to generate 115 MW of electricity. The present contract covers phase 5 of the project (measurement).
After conducting the whole electric and mechanic tests on the different boiler devices, the auxiliary equipment and the turbogenerator, the first load build-up of the unit was carried out during the last week of July 1990. The first coupling of the alternator was realized on July 28, 1990. After thr gradual load build-up and the regulation control, the 125 MWe unit could operate at full load as soon as August 22, 1990, i.e. only three weeks after the first coupling.
After a period of probative running with control of the operational characteristics of the installation, the boiler was commissioned on November 20, 1990 for dry coal firing.
During the period before commissioning, some improvements have been carried out concerning in particular :

- starting-up time refractorization of the wind box and adddition of two oil burners in replacement of the gas lances,
- heating of steam lines at cold starts by installation of a mini HP by-pass.

Coal pulp could be injected into the boiler with satisfying results as soon as November 15, 1990.
The boiler is a success as regards gaseous pollutant emissions.
SO2 emissions are around 250 mg/Nm3 for a Ca/S rate of 1.9.
NOx emissions do not exceed 330 mg/Nm3 with an average value of 170 mg/Nm3.
As a reminder, the guaranteed values are 330 mg/Nm3 for SO2 and 300 mg/Nm3 for NOx.
Load variation tests show that the boiler can stand load variations of 4 to 5 MW/mm.
The use of external heat exchangers provides a great flexibility for the regulation of reheated and superheated steam temperatures (good sensibility of needle valves).
The slurry recovered will be carried by truck to the power station where it will be taken to a slurry preparation shop to prepare an optimal mixture of coal and water. The slurry will be transferred from the shop to storage basins, from which it will be pumped by variable-flow pumps to feed the boiler directly. In the case of certain basins, an existing coal pipeline may be used for transportation to the power stations, and the slurry will then be prepared at the basin.
The boiler that is to burn the slurry is a CFB boiler with recirculation of solids recovered in the cyclones, either directly in the bed, or through two outside exchangers that allow regulation of the bed temperature in relation to operating rates and also regulation of the superheated steam temperature.
It will replace an obsolete boiler in an existing 125 MWe unit. Additional to the slurry preparation and transportation equipment and the CFB boiler, the project covers auxiliary equipment (dedusters, stack, control system) which will complete the installation.
The following are the characteristics of the new boiler: Superheated steam 367 t/h at 134 bar and 545 deg. C
Reheated steam 338 t/h at 29,8 bar and 540 deg. C
Thermal power 315 MW th (input)
288 MW th (output)

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