FOSTER WHEELER

CFB COMBUSTION TECHNOLOGY

FW is the Leading Global Supplier of CFB Technology

Over 369 Units Sold

330 MWe Subcritical Units in Operation
460 MWe Supercritical Unit in Operation
600 MWe Supercritical Start-Up in 2015

Units in Service Over 30 Years

Total Fleet logged over 30 Million Hours of Operation
Widest Fuel Experience in Industry
High Availability Demonstrated
Offering Unit Sizes to 800 MWe

Mong Duong 1 Boiler Size is Within FWs CFB Experience

700
Samcheok
Korea

Bo
oiler Capac
city (MWe)

600
Lagisza
Poland

500
400

JEA
USA
Turow 1
Poland

300
Nova Scotia
Canada

200
100
Pilot Plant
Finland

0
1970

1975

Oriental
Chemicals
Korea

1980

Tri-State
USA
General
Motors
USA

1985

MONG DUONG 1

1990

1995

2000

Start-Up Year

2005

2010

2015

2020

Foster Wheeler CFBs Burn a Wide Range of Fuels

And:
Waste Coal
Bituminous Gob
Anthracite Culm

Agricultural Waste
Rice Husks
Bagasse Pith

Peat
Tire Derived Fuel
Refuse Derived Fuel
Refinery Bottoms
Oil
Natural Gas

Schematic Diagram of a Typical Foster Wheeler CFB Boiler

Cyclone

Stack

Ground
Limestone

Furnace
e

Baghouse/ESP

Crushed
Fuel

Fly Ash
ID Fan
Secondary Air Fan
Bottom Ash
Primary Air Fan

Circulating Fluidized Bed Technology Offers Many Advantages

Feature

Benefit

Low Furnace
Temperature

Eliminates Need for Expensive Scrubber

by Allowing In-Furnace Sulfur Capture
Keeps Uncontrolled NOx Low By
Eliminating Oxidation of Air Nitrogen
Eliminates Need for Expensive SCR by
Allowing Use of SNCR
Allows Combustion of Fuels with Low
Melting Point Ash (Biofuels).

Hot Circulating
Solids

Velocit : 4
Velocity
4.5
5 - 6 m/s

Fuel Flexibility Allows Stable

Combustion Despite Wide Variation in
Fuel Quality
Simple Fuel Feed System

Secondary Air

Vigorous Mixing for Excellent Sulfur

Capture

Limestone: < 1 mm
Fuel: < 15 mm

Uniform Heat Flux

Long Solids
Residence
Time

Temperature: 825-925 C

High Combustion Efficiency

Primary Air

High Sorbent (Limestone) Utilization

Foster Wheeler Has Several Anthracite Fired CFB Boilers

ANTHRACITE FIRED CFB PLANT

Gilberton

COUNTRY

START-UP YEAR

USA

1988

Foster Wheeler CFB Boilers

Have Been Burning Anthracite for Over 22 Years.

Foster Wheelers Experience with Anthracite

(and Vietnamese Anthracite) Is Considered in the Boiler Design

Selection of Fuel Particle Size

Selection of Furnace Temperature

Selection of Excess Air Level

Determine Fuel Distribution Requirements (No. of Fuel Feed Points)

Characterize Uncontrolled NOx and CO Emissions as Function of Load,

Furnace Temperature
Temperature, Excess Air Level
Level.

Estimation of SO2 Emission and Limestone Consumption (Emission

Guarantee and Limestone System Sizing)

Estimation of Split Between Fly Ash and Bottom Ash (Ash Cooler Sizing)

Erosion Protection Requirement

Concept Design
Mong Duong 1 4 x 250 MWe CFB Boilers

Design Basis Steam Conditions

Boiler Load

BMCR

RO

75%RO

60%RO

kg/hr

916,188

848,322

614,582

483,998

MPa(a)

17.40

17.27

12.44

9.88

Main Steam Temperature

541

541

541

541

Feedwater Temperature

295.9

290.4

274.2

261.2

Spray Water Temperature

295.9

290.4

274.2

261.2

kg/hr

731,046

681,723

508,124

406,647

MPa(g)

4.679

4.364

3.303

2.668

Reheat Inlet Temperature

347.8

342.46

350.6

355.2

Reheat Outlet Temperature

540

540

540

--

Main Steam Flow

Main Steam Pressure

Reheat Steam Flow

Reheat Inlet Pressure

Design Basis Fuel Properties

Performance
Coal

Coal

Range Coal
Minimum
Maximum

Proximate Analysis, (As Received)

Moisture
Ash
Volatile Matter
Fixed Carbon

wt. %
wt. %
wt %
wt.
wt. %

8.50
33.33
6 44
6.44
51.73

6.50
31.66
5 93
5.93
45.30

12.00
34.50
7 18
7.18
57.07

Ultimate Analysis, (As Received)

Carbon
Hydrogen
Sulfur
Nitrogen
Oxygen
Ash
Moisture

wt. %
wt. %
wt. %
wt. %
wt. %
wt. %
wt. %

51.48
2.04
0.55
1.00
3.10
33.33
8.50

45.30
1.88
0.45
0.83
2.68
31.66
6.50

57.07
2.16
0.73
1.17
3.52
34.50
12.00

kcal/kg
kcal/kg

4,450
4,645

4,332
4,522

4,493
4,690

HGI

50

45

60

LHV (As Received)

HHV (As Received)
Hardgrove Grindability

10

Mong Duong 1 Boiler Design Replicates Existing Boilers

SANDOW

CLECO

VCHEC

MONG DUONG 1

2 x 300 MWe
Lignite
(Since Nov-08)

2 x 300 MWe
Petcoke
(Since Jan-10)

2 x 300 MWe
High Ash Bituminous
(Scheduled Aug-11)

4 x 250 MWe
Anthracite

11

Mong Duong 1 - Plan View

SLIDE ALONG ARRANGEMENT (NOT MIRROR IMAGE)

AIR HEATER

HEAT RECOVERY
AREA

CYCLONES

FURNACE
ASH COOLERS
FUEL SILOS

LIMESTONE SILO

12

General Arrangement is Typical of Foster Wheeler CFB Boilers

VCHEC (VIRGINIA, USA)

2 x 300 MWe
1 LIMESTONE SILO

3 CYCLONES

SINGLE OPEN FURNACE

5 FUEL SILOS

2 SECONDARY AIR FANS

(ONLY ONE FAN SHOWN FOR VCHEC)

4 ASH COOLERS

13

Mong Duong 1 - Layout of Heat Transfer Surfaces

WATER COOLED CYCLONES

STEAM COOLED CROSS OVER DUCT

STEAM DRUM

STEAM COOLED CONVECTION CAGE

HANGER TUBES
FINISHING REHEATER

PRIMARY SUPERHEATER
PRIMARY REHEATER
INTERMEDIATE AND FINISHING
SUPERHEATER WINGWALLS
ECONOMIZER

FEEDWATER INLET

WATER COOLED
FURNACE WALLS

REGENERATIVE AIR HEATER

14

Patented Kick-Out at Waterwall Interface

with Lower Furnace Refractory Minimizes Tube Erosion
Offered Since 1990
Operating in over 120 Units
Worldwide
U
Up tto 330 MWe Single
Si l U
Unit
it
Experience

SANDOW (TEXAS
(TEXAS, USA)
2 x 300 MWe

15

Cyclones are Refractory Lined for Erosion Protection

16

Cooled Separators Require Less Refractory

Maintenance and Have Lower Heat Loss

STEAM/WATER
COOLED TUBES
LAGGING
INSULATING REFRACTORY
PLATE
230F

INSULATION
130F

12" TYP.
1600F

EROSION PROTECTION
REFRACTORY

PLATE AND REFRACTORY

CONSTRUCTION

17

EROSION PROTECTION
REFRACTORY

COOLED CONSTRUCTION

Each Cyclone Has A Split/Double Return Leg

CYCLONES

CLECO (LOUISIANA,
(LOUISIANA USA) 2 x 330 MWe

18

Metal Temperature Measurements for Superheater

And Reheater Tubes

19

Drum Level Control - Typical

Drum Centerline - 75 mm

Normal Drum Level

High Level Alarm

Normal + 125 mm
Normal + 250 mm
Trips with 5 Second Delay When 2 of 3
Transmitters Confirm

High Level Trip

Low Level Alarm

Normal - 200 mm
Normal - 275 mm
Trips with 5 Second Delay When 2 of 3
Transmitters Confirm

Low Level Trip

20

Five Fuel Silos Along The Furnace Front Wall

REAR WALL
FUEL SILOS
(SINGLE OUTLET)

FRONT WALL
FUEL SILOS
(DOUBLE OUTLET)

VCHEC (VIRGINIA, USA) 2 x 300 MWe

21

Mong Duong 1 Fuel Silos

Steep Silo Angles Improve

Flow

Sloped Portions of Silos are

H
Have
a St
Stainless
i l
Steel
St l Liner
Li
with a 2B Finish to Improve
Flow

Large Slot Shaped Silo

Outlet (600 mm x 1800 mm)
Improves Fuel Flow Out of
Silo

SANDOW (TEXAS, USA) 2 x 300 MWe

22

Fuel is Distributed Evenly Across the Front and Rear Walls

8 GRAVIMETRIC BELT FEEDERS

SILO 1
SILO 2

SILO 3

SILO 4

6 REAR WALL
FUEL DROPS

SILO 5
2 REAR WALL DRAG CHAINS
6 FRONT WALL FUEL CHUTES

VCHEC (VIRGINIA, USA) 2 x 300 MWe

23

The Boiler is Equipped with a Tri-Sector Regenerative Air Heater

Typical Tri-Sector Air Heater

VCHEC ((VIRGINIA, USA)) 2 x 300 MWe

24

Two Primary Air Fans Provide Air to the Furnace Grid

AIR HEATER
PRIMARY AIR DUCTS
2 x 50% PRIMARY AIR FANS

VCHEC (VIRGINIA, USA) 2 x 300 MWe

25

The Furnace Floor/Grid is Water Cooled

26

Two Secondary Air Fans Supply a 3 Level Ring Duct

DUCT SPLITS AT
AIR HEATER OUTLET

3 LEVEL RING DUCT

VCHEC (VIRGINIA, USA) 2 x 300 MWe

27

2 x 50% SECONDARY AIR FANS

(ONLY 1 SHOWN FOR VCHEC)

Ring Duct Provides Good Distribution/Control of Secondary Air

START-UP BURNERS
(UPPER RING)

3 LEVEL SECONDARY AIR

RING DUCT

UPPER SA NOZZLES
(MIDDLE RING)

LOWER SA NOZZLES
(LOWER RING)

SANDOW (TEXAS, USA) 2 x 300 MWe

28

Secondary Air Enters the Furnace Above the Grid

Through Nozzles at Various Elevations in the Lower Furnace Walls

UPPER SA NOZZLES

LOWER SA NOZZLES

FUEL CHUTE

REFRACTORY COVERED
LOWER FURNACE FRONT WALL

ARROWHEAD NOZZLE GRID

HANWHA (2 x 100 MWe)

29

Limestone is Fed Through Secondary Air Ports in the Lower Furnace

30

Rotary Feeders Meter Limestone into the Pneumatic Conveying Lines

SILO WITH TWO OUTLETS

2 x 100% VARIABLE SPEED

ROTARY FEEDERS

4 x 100% CONSTANT SPEED

ROTARY VALVES / AIRLOCKS

31

Three Blowers Provide Air for Pneumatic Conveying Of Limestone

3 x 50% LIMESTONE BLOWERS

32

Mong Duong 1 - Stripper Coolers

4 Stripper Coolers
Each Stripper Cooler Has Dedicated Blower

VCHEC (VIRGINIA,
(VIRGINIA USA) 2 x 300 MWe

Water Cooled Coils Increase Cooling Capacity

Coolers Sized to Allow Operation at BMCR with 1 Cooler Out of Service

33

Schematic of a Fluidized Bed Bottom Ash Cooler

OPTIONAL
COOLING
TUBES

34

Mong Duong 1 Start-Up Burner Location

FURNACE REAR W
F
WALL

FU
URNACE FRONT W
WALL

SIDE WALL

SIDE WALL

35

Start-Up Burners Firing into the Furnace Raise the

Furnace Bed Temperature Above the Solid Fuel Ignition Point

SANDOW (TEXAS, USA) 2 x 300 MWe

36

Conclusions

Foster Wheeler is the Worlds Leading Supplier of CFB Boilers

Foster Wheeler Understands the Combustion Characteristics of

Vietnamese Anthracite

Foster Wheeler Does not Require Additional Bench Scale or Pilot Scale
Testing to Characterize the Fuel for Mong Duong 1

The Mong Duong Boiler Design Replicates Existing FW CFB Boilers

The Predicted Performance of the Mong Duong Boilers is Based on Data

and Operational Feedback from the Replicated Existing Boilers

The Proposed Boiler is Designed to Ensure that the Boiler is Protected

Against Damage Due to Transient/Upset Conditions

All Auxiliary Systems (Fuel Feed, Air Feed, etc) are Adequately Sized to
Ensure Operation
p
of the Boiler at Full Load Across the Range
g of Fuel

Foster Wheeler Expects the Mong Duong Boilers to Demonstrate all

Guaranteed Steam Parameters and Emissions While Demonstrating High
Availability.

37

Operation of 2 Boilers to 1 Turbine

Sandow (Texas, USA) 2 x 300 MWe CFB Boilers

39

Sandow (Texas, USA) Normal Operation

42

Sandow (Texas, USA) Start-Up One Boiler in Operation

43

Sandow (Texas, USA) Start-Up Open Main Steam Stop/Check Valve

44

Sandow (Texas, USA) Start-Up Open Cold Reheat Isolation Valve

45

Sandow (Texas, USA) Start-Up Open Hot Reheat Isolation Valve

46

Sandow (Texas, USA) Start-Up Shut LP & HP Bypass Valve

47

Cm n

Thank You