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Offer:
general contracting of complete power generation units,
general contracting of waste incineration plants and biomass combustion
plants,
design and turn-key delivery of flue gas desulfurization plants based on
absorption methods, including wet lime and semi-dry methods,
design and manufacturing of steam and hot water boilers fired with fossil
fuels, including PC boilers for sub- and supercritical steam parameters,
CFB boilers, stoker fired boilers.
design and manufacturing of boilers for waste incineration and biomass
combustion,
design and manufacturing of heat recovery steam generators,
design and turn-key delivery of NOx reduction systems, including system based
on selective catalytic reduction (SCR),
design and manufacturing of dust removal equipment, including electrostatic
precipitators,
diagnostics, consulting as well as repairs and modernization of boilers, boiler
auxiliaries and FGD plants,
production of boiler components and auxiliaries, including firing systems,
air heaters, flue gas and air ducts, steel structures and other equipment
and plants.
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ENVIRONMENTAL
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KIS.VZ.200132
_____________ ...;;;, C;.;_ IR.;;...; C:..: U:..: LA ;;....;.;;.. :T;.;.. IN.;,..;; G FLUIDIZED BED BOILERS
Siersza Power Plant. Two CFB boilers OFz-425
2
Due to their low flue gas
temperature in fluidized bed
which causes the reduction of
NOx emissions as well as due to
the addition of sorbent limiting
the formation of sulfur
compounds, fluidized bed boilers
became an alternative solution
for plants operating with
conventional boilers equipped
with low-emission furnaces or
flue gas desulfurization systems.
The advantages of fluidized bed
boilers include
o reduction of NOx emission -
combustion temperature
800C - 900C;
o reduction of sulfur oxides
emission by c.a. 90 - 95% -
addition of sorbent to the
furnace;
o possibility of firing with various
low-grade solid fuels;
o operation of the boiler within
the large range of loads
without auxiliary fuel.
-
Basing on the engineering and experience of
Alstom Power (former EVT Stuttgart),
RAFAKO S.A. designs and delivers
circulating fluidized bed boilers. The
construction of this type of boilers enables
the circulation of a dense mass consisting of
ash, fuel and sorbent particles from the
furnace chamber through external cyclones
back to the furnace chamber. The
Company works also on biomass
combustion in CFB boilers.
0Fz-450A boiler in i:eran
CHP Plant, Warsaw
In 1993, RAFAKO SA signed a turnkey
contract for the first of two fluidized bed
boilers foreseen as a replacement for three
conventional OP-230 units.
0Fz-450A has a classical two-pass profile.
The first pass consists of furnace chamber
made of membrane walls A partition wall
incorporated into the evaporator circuit as
well as second stage platen superheater
made of "double super omega" tubes are
installed within the furnace chamber. After
separation of ash m two cyclones (coarse
fraction is recirculated to the furnace
chamber via downcomer) flue gas goes to
the second pass consisting of steam
superheater, economizer and tubular air
heater. From the latter, flue gas is directed to
the chimney through electrostatic precipitator
and flue gas fans. 0Fz-450A features the
cyclones made of steel sheets covered with a
layer of coating protecting against
temperature and erosive activity of
circulating ash particles.
Zeran CHP Plant, Warsaw, Poland
OFz-4508 in ieran
CHP Plant, Warsaw
In 2001 second CFB boiler was
commissionned at Zeran CHP
Plant When compared with the A
boiler, a number of modifications
were introduced both in pressure
and furnace systems. The main
modification consists in
installation of so called "tubular"
cyclones incorporated into the
boiler steam system. Cyclones
simultaneously act as separators
and heat exchange surfaces.
Within the numerous advantages
of this systems we shall mention
the reduction of heat exchange
surfaces in convective pass,
possibility of use of considerably
simpler expansion joints between
cyclones and double loop as well
as shortening of start-up time
due to the brickwork which is
much thinner than in case of
steel sheet cyclone solutions.
The putting of the boiler into
operation is planned for August
2001'
0Fz-450A
CIRCULATING FLUIDIZED BED BOILERS ___ _
"Tubular' cyclone. Manufacturing workshop of RAFAKO S.A.
0Fz-450A and OFz-4508 technical data:
Boiler nominal capacity 315 MW
1
Maximum continuous rating 450 t/h
Outlet steam temperature 510
oc
Outlet steam pressure 10 MPa
Feedwater temperature 205
oc
Efficiency (0Fz-450NB) 92,2 I 92,0 %
OFz-4508
Fuel characteristics:
Type
Calorific value
Moisture
Ash
Sulfur
0Fz-450A OFz-4508
hard coal
22 - 28 18 - 24 MJ/kg
8-15 8-15%
7- 18
0.6- 0.8
15-25 %
0.6-1 %
Volatile particles vdat 34.4 30 %
Fuel consumption
Start-up fuel
16.38 kg/s
heavy fuel oil
Guaranteed emission levels of pollutants
so2 200 m g m ~
NOx 200 m g m ~
co 0Fz-450A 250 m g m ~
OFz-4508 *150 m g m ~
Ash 50 m g m ~
(for dry flue gas with 6% oxygen contents)
* within the load range from 70% to 1 00%. In
case of lower loads CO emission shall not
exceed 250 m g m ~
Silhouettes of the CFB boilers, Zeran CHP Plant
3
4
II
OFz-230 boiler
in Bielsko-Biata II CHP
The design of this fluidized bed
boiler takes into account the fact
that a conventional pulverized
fuel fired OP-230 boiler was
previously designed for Bielsko
CHP Plant.
The majority of systems was
already delivered to the site or
under the final phase of design,
manufacturing or shipping.
A considerable part of these
element s was used in th8 new
boiler. The decision to modify the
type of the boiler was motivated
by environmental requirements.
All these factors resulted in a
fluidized bed boiler having a non-
typical profile. Cyclones are
installed on both sides of furnace
chamber and the drum location
follows the axis of the boiler.
OFz-230 boiler was put into
operation in 1997.
----
--~ .:;;:-;;;,..._ __
Silhouette of the OFz-230 boiler, Bielsko-Biata II CHP Plant
Technical data:
Boiler nominal capacity 177 I 165 MW
1
Maximum continuous rating 230 t/h
Outlet steam temperature 540
oc
Outlet steam pressure 13.8 MPa
Feedwater temperature 158/205
oc
Efficiency 91 %
Guaranteed emission levels of pollutants
S02 300 m g m ~
NOx 250 mg/ m ~
CO 250 mg/ ~
Ash 50 mg/ ~
(for dry flue gas with 6% oxygen contents)
Fuel characteristics:
Type hard coal with the addition of mine
sludge:
Calorific value
Moisture
Ash
Sulfur
Volatile particles vdaf
Fuel consumption
Start-up fuel
16- 18.8 MJ/kg
10- 15 %
31-36 %
1.7 %
30 %
ca. 10 kg/s
fuel oil
OFz-230 boiler - Bielsko-Bia/a II CHP Plant, Poland
CIRCULATING FLUIDIZED BED BOILERS __ --
---------------------------
Two OFz-75 boilers
in "Polpharma"
Pharmaceutical Plant,
Starogard Gdanski
In 1993 "Polpharma" Starogard
Pharmaceutical Plant and
RAFAKO SA signed a contract
for turnkey construction of heat
and power generating plant
equipped with two fluidized bed
boilers and one 12 MWe
turbogenerator. The heat was to
cover the heating and process
needs of "Polpharma" plant
OFz-75 has a three-pass profile
arranged in a so called
"bacpack" system. Cyclone
separator is installed in the front
part of the boiler and the duct
connecting the separator with
second pass is installed above
furnace chamber. Outlet live
steam superheater is also
located in this duct Second pass
adjoining the furnace chamber
contains steam superheater and
economizer bundles. Tubular air
heater is located in the third
pass.
Guaranteed emission levels of
pollutants
so
2
400 m g m ~
NOX 300 m g m ~
co 250 m g m ~
Ash 50 m g m ~
(for dry flue gas with 6% oxygen
contents)
Technical data:
Boiler nominal capacity 60.2 MW
1
Maximum continuous rating 75 t/h
Outlet steam temperature 455
oc
Outlet steam pressure 4.5 MPa
Feedwater temperature 105
oc
Efficiency 91.5 %
Fuel characteristics:
Type- hard coal:
Calorific value 17-20.1 MJ/kg
Moisture 10- 17 %
Ash 20-30 %
Sulfur 1.0 %
Volatile particles ydat 30 %
Fuel consumption ca. 4 kg/s
Start-up fuel fuel oil
Silhouette ofthe OFz-75 boiler, Polpharma Plant, Starogard Gdanski
OFz-75 boilers- ,Polpharma" Pharmaceutical Plant, Starogard Gdanski, Poland
5
61
Two OFz-425 boilers
in Siersza Power Plant
These fluidized bed boilers were
delivered to replace conventional
OP-140 boilers using the latter's
support structure and reinforced
foundations. OFz-425 is a drum
boiler with reheat and rotary air
heaters. It is fired with the mixture
of hard coal and flotation sludge
(1 0% thermal share).
The boilers were commissionned
in 2001 and 2002 respectively.
----
Technical data:
Boiler nominal capacity 336.3 MW
1
Maximum continuous rating 425 t/h
Outlet steam temperature 560
oc
Outlet steam pressure 16.1 MPa
Secondary steam temperature 560
oc
Secondary steam pressure 4.0 I 3.8 MPa
Feedwater temperature 250
oc
Efficiency 91 %
Guaranteed emission levels of pollutants
S0
2
337.5 m g m ~
NOX
co
Ash
307.8 m g m ~
271 m g m ~
50 m g m ~
(for dry flue gas with 6% oxygen contents)
Fuel characteristics:
Type - hard coal
Calorific value
Moisture
Ash
Sulfur
Volatile particles vdat
Fuel consumption
Start-up fuel
15-16.7 MJ/kg
21.7-25 %
20.6-27 %
2.4-3 %
30 %
22.2 kg/s
fuel oil
Silhouette of the OFz-425 boiler, Siersza Power Plant
Siersza Power Plant, Poland - erection of the OFz-425 CFB boilers
Apart from circulating fluidized
bed boilers RAFAKO SA also
offers bubbling bed boilers. Such
boilers may be operated in small
and medium sized heat and
power generating plants. OF-125
and OF-140 boilers
manufactured for Czech
Komofany CHP Plant may serve
as an example of this solution.
OF-125, OF-140 boilers
in Komofany CHP
Plant, Czech Republic
In Komofany CHP Plant , five
stoker fired boilers were subject
to modernization with bubbling
fluidized bed technology. This
modernization was carried out by
Elektrim I Mostostal Zabrze
consortium on the basis of
deliveries from RAFAKO SA The
scope of works included the
installation of fluidization box,
necessary heat exchange
bundles and boiler auxiliary
equipment. The works were
completed in 1997.
KomoTany CHP Plant, Czech Republic
BUBBLING BED BOILERS ___ -
Successful modernization of the first five
boilers served as a basis for the decision to
modernize further five units. This task was
carried out by Elektrim I RAFAKO consortium.
The offer was enlarged by installation of
membrane walls and increase of capacity
from 125 to 140 t/h
OF-140 is a drum boiler with natural
circulation in furnace chamber wall tubes and
assisted circulation (using circulation pumps)
in evaporator coils located in fluidized bed.
The boiler is equipped with fluidized furnace
being an intermediate solution between
bubbling and circulating furnace.
Combustion air is heated in tubular air heater
and delivered - via primary air fan - to
fluidization chamber and then - via secondary
air fan - to furnace chamber located above
fluidization chamber. The heat contained in
flue gas leaving the furnace chamber is
recovered in superheaters installed in
interconnecting pass and in ECO and air
heater bundles located in the second pass of
the boiler. Flue gas cleaned in fabric filters is
directed to the chimney.
-----
Silhouette of the OF-140 boiler,
Komofany CHP Plant
Technical data:
Boiler nominal capacity
Maximum continuous rating
Minimum continuous rating
Steam temperature
Steam pressure
Efficiency
140 t/h
71 t/h
490
oc
7.5 MPa
91 .5 %
Guaranteed emission levels of pollutants
S0
2
soo m g l m ~
NOx 400 m g m ~
CO 250 m g m ~
Ash 50 m g l m ~
(for dry flue gas with 6% oxygen contents)
Fuel characteristics:
Type lignite
Calorific value 9.5- 15 MJikg
Moisture 25-33 %
Ash 19- 30 %
Sulfur 1.1 - 2.7 %
7
Technical data specification of CFB boilers
designed and delivered by RAFAKO S.A.
Parameter Uni ts
Boiler nominal capacity
MWt
Maximum continuous rating
t/h
Live steam temperature
oc
Live steam pressure MPa
Quantity of reheated steam t/h
Reheated steam temperature
oc
Reheated steam pressure MPa
Feedwater temperature
oc
Boiler efficiency %
Emission
802 m l m ~
(for dry flue
NOX m l m ~
gas with
co m l m ~
0 2 = 6%)
ash m l m ~
Wd MJikg
w %
Coal
p
%
s %
volatile particles Vdat %
Number of cyclones pes.
Bed temperature
oc
depth mm
Furnace chamber dimensions width mm
height mm
Number of fuel inlets pes.
--
Ash removal from bed
----
0Fz-450A OFz-230
Zerari Bielsko
315 177 I 165
450 230
510 540
10 13.8
205 158 I 205
92.2 91
200 443
200 250
250 250
50 50
22 --c- 28 16--c- 18.8
8--c-15 1 0--c- 15
7--c- 18 31 .5--c- 36
0.6--c-0 8 1.7
34.4 - 30
2 2
850 849
6915 5115
13245 9955
42000 34000
4 4
central lateral
OFz-75 OFz-425 OFz-4508
Polpharma Siersza Zerari
60.2 338.5 315
75 425 450
455 560 510
4.5 16.1 10
382
560
3.5
105 250 205
91 .5 91 92.2
300 357 200
250 326 200
250 271 150*
50 50 50
17 --c- 20. 1 15 -7- 16.7 18 -7- 24
10--c- 17 21.7 -7- 25 8 -7- 15
20--c- 30 20.6 -7- 27 15 -7- 25
2.4 -7- 3 0.6 -7- 1
- 30 - 30 - 30
2 2
850 850 850
4215 8517 6915
4255 11615 13245
25000 37000 42000
2 4 4
lateral central central
* within the load range from 70% to 100%. In case of lower loads CO emission shall not exceed 250 m l m ~
CIRCULATING FLUIDIZED BED BOILERS
RAFAKO S.A. and Alstom Power reference list
Circulating fluidized bed boilers
Boiler
Live/reheated Live/reheated
Ordered in Plant name Country
Number
capacity
steam pressure steam
Fuel
of boilers
t/h
MPa temperature C
1985 Wachtberg Power Plant Germany 175 17.8 I 3.8 530 I 425 lignite
1985 Kohler CHP Plant Germany 100 10.5 535 hard coal , paper pulp
1986 Gaisburg CHP Plant Germany 150 7.3 500 hard coal
1986 Pforzheim CHP Plant Germany 90 14.3 I 2.9 540 I 535 hard coal
1987 Emile Huchet Power Plant France 367 13.413.0 545 I 540 hard coal sludge
1988 Berrenrath Power Plant Germany 2 250 9.0 510 lignite
1989 Goldenberg Power Plant Germany 400 11.5 505 lignite
1991 Wahlitz Power Plant Germany 150 11.5 535 lignite
* 1991 Lublin-Wrotk6w CHP Plant Poland 230 13.5 540 bituminous coal
1992 Gardanne Power Plant France 700 19.3 567 I 565 lignite
1992 Bielsko-Biala II CHP Plant Poland 230 13.8 540 hard coal
1993198 i:eran CHP Plant Poland 2 450 10.0 510 hard coal
1993 Tisova CHP Plant Czech Republic 350 9.4 510 lignite
1993 Polpharma Plant Poland 2 75 4.5 455 hard coal
1994 Mironowska Power Plant Ukraine 260 13.8 540 anthracite
1996 Mlada Boleslav CHP Plant Czech Republic 2 140 12.5 535 hard coal
1998 Red Hills Power Plant USA 2 753 20.3 I 4.0 568 I 540 lignite
1998 CAN Power Plant Turkey 2 462 17.5 I 3.8 543 I 542 lign1te
1998 Siersza Power Plant Poland 2 425 16.1 I 4.0 560 I 560 hard coal
Boilers designed and manufactured by RAFAKO SA are outlined in bold characters.
* design and workshop documentation - RAFAKO SA
9
CIRCULATING FLUIDIZED BED BOILERS
RAFAKO S.A. and Alstom Power reference list
Circulating fluidized bed boilers
Boiler
Live/reheated Live/reheated
Ordered 1n Plant name Country
Number
capacity
steam pressure steam
Fuel
of boilers
t/h
MPa temperature C
.,
1985 Wachtberg Power Plant Germany 175 17.8 I 3.8 530 I 425 lignite
1985 Kohler CHP Plant Germany 100 10.5 535 hard coal, paper pulp
1986 Gaisburg CHP Plant Germany 150 7.3 500 hard coal
1986 Pforzheim CHP Plant Germany 90 14.3 I 2.9 540 I 535 hard coal
1987 Emile Huchet Power Plant France 367 13.4 13.0 545 I 540 hard coal sludge
1988 Berrenrath Power Plant Germany 2 250 9.0 510 lignite
1989 Goldenberg Power Plant Germany 400 11.5 505 lignite
1991 Wahlitz Power Plant Germany 150 11.5 535 lignite
* 1991 Lublin-Wrotk6w CHP Plant Poland 230 13.5 540 bituminous coal
1992 Gardanne Power Plant France 700 19.3 567 I 565 lignite
1992 Bielsko-Biata II CHP Plant Poland 230 13.8 540 hard coal
1993198 Zerari CHP Plant Poland 2 450 10.0 510 hard coal
1993 Tisova CHP Plant Czech Republic 350 9.4 510 lignite
1993 Polpharma Plant Poland 2 75 4.5 455 hard coal
1994 Mironowska Power Plant Ukraine 260 13.8 540 anthracite
1996 Mlada Boleslav CHP Plant Czech Republic 2 140 12.5 535 hard coal
1998 Red Hills Power Plant USA 2 753 20.3 I 4.0 568 I 540 lignite
1998 CAN Power Plant Turkey 2 462 17.513.8 543 I 542 lignite
1998 Siersza Power Plant Poland 2 425 16.1 I 4.0 560 I 560 hard coal
Boilers designed and manufactured by RAFAKO SA are outlined in bold characters.
* design and workshop documentation - RAFAKO SA
9