A New Generation of

Pulverized Coal Technology

A LONG HISTORY WITH

PULVERIZED COAL STEAM
GENERATORS
For over half a century, Foster Wheeler has been designing and manufacturing
utility pulverized coal (PC) steam generators. Our utility steam generators have
proven themselves with over 50 million hours of operation, up to 1,100 MWe in size,
and have the capability of burning a wide range of coals from anthracite to subbituminous fuels as well as petroleum coke.
Our natural circulation boilers are designed to be inherently safe by naturally
increasing water flow as tube heat flow increases, under normal or upset scenarios,
without relying on pumps, back-up systems or mechanical equipment.
The natural circulation characteristic is also included in our supercritical once-through
BENSON Vertical Tube (BVT) technology, offered as a design option on all our utility
PC steam generators.
Our units feature many other time tested advanced design features like low NOx
firing systems, MBF and ball mills, SCR systems, split and series back pass resulting in
improved reliability, low emissions and peak plant performance.

ST. JOHNS UNITS 1 & 2 SUPPLIED

BY FOSTER WHEELER TO
JACKSONVILLE ELECTRIC AUTHORITY
IN OPERATION SINCE 1987

FW PCs STAND OUT DUE TO THEIR TIME TESTED DESIGN FEATURES

OUR STATE-OF-THE-ART LOW NOx COMBUSTION SYSTEMS DELIVER HIGH COMBUSTION
EFFICIENCY AND THE LOWEST EMISSIONS
FWs Wall-Fired Vortex Series

FWs Arch-Fired Preheat Burners

Highly Reliable Low NOx Burners

Low NOx Burners for Low Volatile Fuels

Only three moving components

No radial vanes to bind
Independent swirl & air flow control for burner-to-burner biasing
Four port silhouette burner tip for optimized velocity control
Refractory lined elbow, outer barrel and anti roping vanes to handle high ash
abrasive coals

Multi-level air staging for the lowest NOx emissions

Fuel preheating for improved combustion efficiency
Air separating cyclone burners for easy Ignition
Natural hot gas recirculation for flame stability
Unit turndown to 40% load without support oil

Real Time Fuel/Air Monitoring and Control for Optimum Combustion Efficiency, Reliability and Low Emissions

Electrostatic Charge Technology (ECT)

Adjustable Riffle Distributor

Automatically detects coal slugging that can lead to fires and load reductions
Pinpoints distribution problems that cause uneven temperature profiles, localized slagging
and elevated unburned carbon
Rugged long-life tungsten carbide probes
Intuitive graphical interface

FWS MBF Coal Pulverizers are

Designed and Built to Handle
Abrasive High Ash Coals

Ceramic or high chrome composite grinding rollers and table segments

Refractory lined classifier housing & mill discharge assembly
Refractory lined roller coal shields
Individually tensioned, fixed rollers
Three point maintenance access
Low internal fuel air velocities
3

On-line biasing of coal flow between coal pipes

Compatible with common industry riffle distributors
Available for 2 or 3 way distribution

FW PCs Have Proven Themselves On High Ash Coals

Start-Up Year(s)

Plant Owner

Plant & Unit

Country

Capacity
MWe

Fuel

%
Fuel Ash

Abono #1 & #2

Spain

355 - 556

Bituminous Coal

30%

1974, 1984

Hidroelectrica del
Cantabrico

1972, 1981, 1984

Endesa, SA

Compostilla II - #3, #4, #5

Spain

320 - 350

Anthracite Coal

28%

1980

ENECO, SA

Puente Nuevo #3

Spain

315

Coal

49%

1964

Termicas del Norte

Espana, SA

Guardo #2

Spain

350

Coal

29%

1995, 1996

CFE - Mexico

Carbon II - #1/2

Mexico

385

Coal

43%

2000, 2000

Shandong Rizhou

Rizhou #1 & #2

China

350

Coal

31%

1996, 1997

Shandong Electric

Zouxian #5 & #6

China

660

Coal

29%

NOT ALL SUPERCRITICAL TECHNOLOGIES

ARE THE SAME

ADVANCING UTILITY PC TECHNOLOGY

The Longview Power Project
GOING SUPERCRITICAL

Foster Wheelers BENSON Vertical Tube (BVT) supercritical steam

technology has significant advantages over conventional spiral
technology. Since the evaporator tubes are vertical along the entire
furnace height, the furnace walls are easier to fabricate, erect and
repair.
In addition, the steam flow of BVT technology is much lower in each
tube than spiral technology, resulting in a lower steam pressure
loss which further improves plant efficiency. BVT technology also
features a self cooling characteristic which can limit the temperature
rise of tubes receiving higher heat flows for longer tube life.
To further improve the life of the furnace, evaporator tubes which
receive high heat are rifled resulting in a spiral ridge along the length
of the tube. After years of research, the ridge geometry has been
perfected so that a film of liquid water will coat the tube wall to
provide effective cooling at much higher steam qualities and tube
metal temperatures than conventional smooth tube technology.
For ease of operation, BVT supercritical technology utilizes inline tangential steam/water separators which allow the steam
generators evaporator to automatically transition from circulating to
once-through steam mode during unit start-up and shut-down, while
providing a wide range of operation in the once-through mode.

We have coupled our proven wall-fired

pulverized coal (PC) steam generators
with advanced BENSON vertical-tube
(BVT) supercritical steam technology.
Supercritical steam technology can
achieve plant efficiencies well beyond
conventional subcritical drum-type units,
thereby producing more electricity and
less emissions from a steam power
plant. By coupling these technologies
together, we offer a steam generator
design balanced with both proven and
advanced design features, such as:

Steam Pressure Drop

Across Evaporator at
100% Boiler Load (bar)
25

20.2

20
15
9.1

10

S
 imple vertical tube furnace
construction which is easier
to fabricate, build and repair

5
0

Conventional Spiral
Technology

B
 uilt-in self cooling characteristic
for maximum furnace life

Advanced BVT
Technology

G
 enerous furnace volumes for
complete combustion of the fuel
MBF

and ball mill pulverizers
for the widest solid fuel range

Foster Wheelers Advanced

BVT Steam Generator Technology

S
 taged low NOx combustion
systems
SCR for the lowest NOx emissions

LONGVIEW PROJECT
SUMMARY

Small tubes for self cooling effect

Simple support system
Low pressure drop
Easy to maintain
Lower cost to build

Plant Location:
Customer:
FW Full Release:
Plant Start-Up:

Plant Electrical Output (Gross/Net)

770 MWe/695 MWe

Net Plant Efficiency (LHV/HHV)

40.8%/39.1%

Net Plant Heat Rate (LHV/HHV)

8370/8733 Btu/kWh

Steam Flow (SH/RH)

616/507 kg/s

4876/4012 kpph

Steam Pressure (SH/RH)

258/55 bar

3735/802 psig

Steam Temperature (SH/RH)

569/567 C

1056/1052 F

Feedwater Temperature

298 C

569 F

Maidsville, WV, USA

Longview Power, LCC
December 2007
Spring 2011

Fuel West Virginia

Bituminous Coal

FWS SUBCRITICAL NATURAL CIRCULATION WALL FIRED PCs

Designed and Built For Long Life and High Reliability
Natural circulation furnace
circuitry self compensates
for heat flux unbalances
Optimized furnace size yields
high combustion efficiency
and minimizes flame
impingement on furnace
walls
Low NOx Vortex Series
burners maximize carbon
burnout, with minimal NOx
production
Evenly spaced burners on
furnace walls provide uniform
gas temperature at furnace
exit
Direct firing system from
silo to burner offers safe
fuel storage and simple fuel
controls

Wall Fired
Subcritical Natural
Circulation Steam
Generator
Springerville Generating Station Units 3 & 4
Location:
Springerville, Arizona, USA
Customer:
Bechtel Power Corp./
Salt River Project (SRP)
Start-Up Year: 2006, 2009
Capacity:
2 x 400 MWe
Fuel:
PRB Coal

Quezon Power Plant

Location:
Quezon, Philippines
Customer:
Quezon Power Limited Co.
Start-Up Year: 2000
Capacity:
1 x 486 MWe
Fuel:
Coal, Oil

Santee Cooper Cross Station

Location:
Moncks Corner, North Carolina, USA
Customer:
Santee Cooper
Start-Up Year: 1999
Capacity:
1 x 550 MWe
Fuel:
Bituminous Coal

Wide tube spacing and in-line

tubes to prevent ash bridging
Low gas velocities for low
erosion
Refractory and erosion shield
protection in high wear areas
Patented induct heater for
economical SCR ammonia
vaporization
Flue gas or steam bypass for
efficient reheat temperature
control
Robust MBF coal mills to
handle abrasive high ash
coals

Zouxian
Location:
Customer:
Start-Up Year:
Capacity:
Fuel:

Wall Fired
Subcritical Natural
Circulation Steam
Generator

Bruce Mansfield Units 2 & 3

Location:
Shippingport, PA, USA
Customer:
Pennsylvania Power Co.
Start-Up Year: 1977, 1980
Capacity:
2 x 800 MWe
Fuel:
Eastern Bituminous Coal

Zouxian City, Shandong Province, China

Zouxian Power Generating Company
1996
2 x 660 MWe
Bituminous Coal

FWS ADVANCED PULVERIZED COAL TECHNOLO GY FOR LOW VOLATILE FUELS

Arch-Fired OnceThrough Supercritical
Steam Generator

Double cyclone burners

creates a W flame shape
for high carbon burnout of
low volatile fuels
Burner vent-to-overfire air
system aids ignition and
minimizes NOx formation
Selective refractory covering
in lower furnace enhances
ignition and promotes
complete combustion
Direct firing system from
silo to burner offers safe
fuel storage and simple fuel
controls
Self compensating natural
circulation characteristic
to minimize temperature
unbalances

Datang Supercritical Arch-Fired PC Power Plant

Location:
Heshan City, Guangxi Province, China
Customer:
Datang Guiguan Heshan Power Gen Co, Ltd.
Start-Up Year: 2012
Capacity:
2 x 670 MWe
Fuel:
Anthracite Coal

Arch-Fired Subcritical
Natural Circulation
Steam Generator

Vertical tube wall

construction simplifies
erection, maintenance, and
repair
Low minimum load which
reduces start-up time,
auxiliary fuel and start-up
pump power consumption
For Supercritical Designs
BVT technology provides safe
self cooling protection and
simple vertical tube furnace
design
Optimized rifled tubes for
effective tube cooling
Low steam/water pressure
loss provides improved plant
efficiency

Vinh Tan Arch-Fired Units I & II

Location: Binh Thuan Province, South
Vietnam
Customer:
Vietnam Electricity (EVN)
Start-Up Year: 2013 - 2014
Capacity:
2 x 622 MWe
Fuel:
Anthracite

Nghi Son 1 Arch-Fired Project

Location:
Thanh Hoa Province, Vietnam
Customer:
Vietnam Electricity (EVN)
Start-Up Year: 2013 - 2014
Capacity:
2 x 300 MWe
Fuel:
Pulverized Anthracite Coal

10

Hanfeng Arch-Fired Boilers

Location:
Handan, Hebei Province, China
Customer:
Hanfeng Power Generating
Company Ltd.
Start-Up Year: 2000, 2001
Capacity:
2 x 716 MWe
Fuel:
Anthracite Coal

We offer a full range of steam generator equipment, aftermarket products and services to the power,
industrial, and waste-to-energy sectors. Our global manufacturing and engineering network can deliver cutting
edge products and expertise, quickly and cost competitively with best-in-class quality. Established in 1891, our
experience comes from a heritage of designing, servicing, and continually improving steam generating equipment.

Steam Generators
Circulating Fluid Bed
Pulverized Coal
Oil & Gas
Solar
Bubbling Fluid Bed
Package
Grate and MSW
Metallurgical Waste Heat
HRSG

Environmental Products
Circulating Fluid Bed Scrubbers
Fabric Filters
SCR and SNCR Systems
Low NOx Combustion Systems
Biomass Combustion Retrofits
Coal/Air Control System
Upgrades

Aftermarket Services
Condition Assessment
Engineered and Replacement
Pressure Parts
Weld Overlay and Refractory
Upgrades
Replacement Parts
Cyclone Burner Retrofits
Coal Mill Service and Upgrades
Maintenance Services
Outage Construction
Engineering Studies

Auxiliary Equipment
Condensers
Feedwater Heaters
Biomass Gasifiers
Plant Operation
Plants owned and
operated by FW
Long-term Service
Agreements

contact us
GLOBALLY
www.fwc.com
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Raffles City Beijing Office Tower
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T +86 (0) 10 8409 8855
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Shanghai 200122 China
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Madrid, Spain
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Hampton, New Jersey 08827 USA
T +1 (1) 908 730 4000
9780 Mt. Pyramid Court, Suite 260
Englewood, Colorado 80112-7060 USA
T +1 (1) 303 784 4880

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