Modern recovery boiler design criteria

Engineering and pricing of large recovery boiler were studied in this work. Engineering was carried out with Anita 4.2 which is an engineering program of Andritz. Key initial values were chosen with previous studies. Primary target of this work was to find out the consequences that furnace dimensions and furnace screen vertical part has to boiler pricing. Boilers that were engineered had different rate of furnace width and depth and different heat transfer plate count. Boiler balances were invariable. Boilers with different vertical screen construction were also calculated. First variation was boiler with vertical screen up to furnace roof. Other variation was to connect vertical screen to Pre-boiler generating bank inlet tubes. Total prices were calculated to engineered boilers. Pricing was sort out to heat transfers, high pressure pipes, steel structures, auxiliary equipments and civil/structural costs. This study did not notice parts of the boiler which costs do not vary with the construction of the boiler. Heat transfers had the largest share of costs. Boiler building had the most significant differences between the boilers. Furnace screen had also significant role especially to costs of the boiler building.

Development of Furnace Model for Bubbling Fluidized Bed Boiler

The aim of this thesis was to develop a model, which can predict heat transfer, heat release distribution and vertical temperature profile of gas phase in the furnace of a bubbling fluidized bed (BFB) boiler. The model is based on three separate model components that take care of heat transfer, heat release distribution and mass and energy balance calculations taking into account the boiler design and operating conditions. The model was successfully validated by solving the model parameters on the basis of commercial size BFB boiler test run information and by performing parametric studies with the model. Implementation of the developed model for the Foster Wheeler BFB design procedures will require model validation with existing BFB database and possibly more detailed measurements at the commercial size BFB boilers.

Heat transfer in superheaters of the bubbling fluidized bed boiler conversions

It is often reasonable to convert old boiler to bubbling fluidized bed boiler instead of building a new one. Converted boiler consists of old and new heat surfaces which must be fitted to operate together. Prediction of heat transfer in not so ideal conditions sets challenges for designers. Two converted boilers situated in Poland were studied on the grounds of acceptance tests and further studies. Calculation of boiler process was performed with boiler design program. Main interest was heat transfer in superheaters and factors affecting it. Theory for heat transfer is presented according to information found from literature. Results obtained from experimental studies and calculations have been compared. With correct definitions calculated parameters corresponded well to measured data at boiler maximum design load. However overload situations revealed to be difficult to model at least without considering changes in the combustion process which requires readjustments to the design program input values.

Soodakattilalaitoksen ohjeiston kehittäminen ja tuotteistaminen

Soodakattila on osa selluloosatehdasta. Selluloosatehtaan tehokkuuden ja ympäristöystävällisyyden ratkaisevin tekijä ovat työntekijät. Puutteellisten ja vanhentuneiden ohjeiden avulla tehtaan operaattorit eivät pysty kehittämään omaa osaamistaan ja edelleen tehostamaan laitoksen toimintaa. Työntekijöiden toiminnan tukeminen päivittäisissä työtehtävissä onkin tehokas tapa parantaa niin soodakattilan kuin koko selluloosatehtaan energia- ja ympäristötaloutta. Työssä on tarkasteltu nykyistä soodakattilan käyttöohjeistoa ja selvitetty dokumentaation käyttäjäryhmät sekä näiden pohjalta laadittu uudistetun ohjeen sisältövaihtoehdot ja tekotavat. Työn tuloksena on havaittu, että ohjeen uudistaminen on helpointa toteuttaa ohjausjärjestelmään yhdistettyinä intranet-sivustona. Sivuston käyttöönotolla on saatavissa kustannussäästöjä, jotka seuraavat toiminnan tehostumisesta, ympäristöhaittojen vähenemisestä, laitoksen ylläpidon helpottumisesta, käyttövarmuuden parantumisesta ja nopeammasta käyttöönotosta. Työssä on esitetty ehdotus Andritz Oy:n sähköiseksi dokumentointitavaksi sekä listattu siihen liittyviä liiketoimintamahdollisuuksia.

Asiantuntijajärjestelmä kattilakonseptin valintaan

Polttoaine asettaa puitteet kattilasuunnittelulle. Kiertoleijukattilakonseptin valinta kytkeytyy kiinteästi mitoitusarvoihin ja polttoaineen ominaisuuksiin. Asiakkaan vaatimuk-set kattilalle asettavat lähtökohdan kattilasuunnittelulle. Suorituskyky, kustannukset ja luotettavuus ovat asiakaslähtöisiä tekijöitä, joiden painotukset vaikuttavat kattilakonseptin valintaan. Korkeat lämpötilat tulistimien alueella tekevät tulistinjärjestelystä vaikean ja määräävän osan kattilakonseptin valintaa. Konvektiotulistimien altistuminen kuumille savukaasuille tekee niistä herkkiä likaantumiselle ja korroosiolle. Mitoitusarvojen ja tulistimien rakenteen oikeanlaisella valinnalla voidaan näitä polttoaineperäisiä ongelmia ehkäistä. Lisäksi kiertoleijukattiloissa käytetyt tulipesän ulkopuoliset tulistimet soveltuvat konvektiotulistimia korkeammille lämpötiloille huonolaatuisillakin polttoaineilla. Tässä työssä rakennettu asiantuntijajärjestelmä valitsee alustavan kattilakonseptin mitoitusta varten käyttäjän antamien vähäisten lähtötietojen pohjalta.

Fouling tendency in biomass-fired boilers

Although it is well known that firing biomass fuels leads to increased deposition buildup on heat transfer surfaces in boiler compared with firing coal, existing empirical knowledge about combustion of different types of biofuels is limited. The aim of this study is to give greater awareness and understanding of the circumstances which are able to decrease considerably deposition build up on heat transfer surfaces when firing different types of biofuels. The crucial part of this thesis is experimental investigation of fouling tendency while firing biomass fuels, such as straw, bark, and peat having different chemical composition. In order to give comprehensive overview of ash deposition phenomena the number of not less important issues such as mechanisms of ash deposition, effect of fouling on heat transfer, and design of boilers subjected to ash buildup were examined as well. The answers obtained in this study may be a step towards a better knowledge of firing biofuels as separately as in mixtures, and may provide solutions for successful combustion technique of biomass fuels.

A three dimensional study of heat transfer in a supercritical circulating fluidized bed combustor

From the boiler design point of view, it is imperative to know and understand the operation of the boiler. Since comprehensive measurement of a large furnace is impossible, the furnace can be modeled in order to study its behavior and phenomena. This requires the used model to be validated to correspond with the physical furnace behavior. In this thesis, a three dimensional furnace model is validated to match a bituminous coal utilizing, supercritical once-through circulating fluidized bed combustor based on measurement data. The validated model is used for analyzing the furnace heat transfer. Other heat transfer analysis methods are energy balance method based on tube surface temperature measurements and a method based on measured temperature difference between the tube crest and the fin. The latter method was developed in the thesis using Fluent-software. In the theory part, literature is reviewed and the fundamental aspects of circulating fluidized bed are discussed. These aspects are solid particle behavior in fluidization known as hydrodynamics, behavior of fuel and combustion and heat transfer. Fundamental aspects of modeling are also presented.

Esisuunnitteluohjelmiston kehitys BFB-höyrykattiloille

Tämä diplomityö käsittelee Andritz Oy:n BFB-voimalaitosten tarjoustoimintaan kehitettävää esisuunnitteluohjelmistoa. Tässä työssä on esitelty kattiloiden tarjoustoimintaan liittyviä seikkoja etenkin laskennan ja tekniikan näkökulmasta. Työssä on myös koottu tietoa polttoaineista ja BFB-kattiloiden suunnittelusta ja mitoituksesta. Työn aikana kehitettiin ohjelmisto, jolla on mahdollista luoda eri BFB-kattila tarjousprojekteja. Projekteille on mahdollista luoda useita eri taselaskelmia eri lähtöarvoilla ja useilla eri polttoaineilla, sekä niiden seoksilla. Ohjelmakehityksessä painotettiin suunnittelun joustavuutta eri konfiguraatioille, mahdollisimman tarkkaa laskentaa ja ylläpidon merkitystä. Ohjelmistokehityksessä päätettiin käyttää Microsoft Excel ohjelmistoa laskentaympäristönä. Tällöin pystyttiin luomaan käyttäjille tuttu käyttöympäristö ja mahdollistaa vanhojen hyväksi todettujen laskentapohjien käyttö apuna kehityksessä. Tämä mahdollistaa myös ylläpidon toimialueen ammattilaisten toimesta jatkossa.

Steam boilers; instruction paper with examination questions.

Types of steam boilers; Boiler details; Boiler fittings; Boiler design; Boiler feeding and feedwater problems; Combustion, firing and draft; Economic combustion of coal; Automatic furnaces and mechanical stokers.

Locomotive boilers and engines; a practical treatise on locomotive boiler and engine design, construction, and operation,

Mode of access: Internet.

Prediction of heat transfer on kraft recovery boiler

Työssä tutkittiin Andritz-Ahlstrom toimittamien soodakattiloiden lämmönsiirtoa ANITA 2.20- suunnitteluohjelmalla feedback- laskentaa apuna käyttäen. Data laskentaan saatiin kattiloiden takuukokeissa mitatuista arvoista. Mittaukset on suoritettiin Andritz-Ahlstromin henkilökunnan toimesta tehdashenkilökunnan avustuksella. Feedback -laskenta tapahtui mittaustulosten perusteella, joten tiettyä virhettä luonnollisesti esiintyi. Aluksi laskettiin taseet molempien ekojen yli erikseen sekä molemmat yhdessä Excel-taulukkolaskentaohjelmalla. Täältä saatiin oletettu savukaasuvirtaus kattilassa. Tämän jälkeen lämpöpintoja muokattiin todellisuutta vastaaviksi yleislikaisuuskerrointa muuttamalla (overall fouling factor). Kertoimet ovat liikkuivat noin 0.4 ja 1.6 välillä riipuen kattilan tyypistä ja ANITAn oletuksesta lämpöpintojen likaisuudelle. Havaittin että yhtä varsinaista syytä lämpöpintojen eroavaisuuteen oletetusta ei saatu. Syitä toiminnan poikkeamiseen oli monia. Mm. etukammion koolla havaittiin olevan suurtakin vaikutusta tulistimien, etenkin savukaasuvirrassa ensimmäisen tulistimen toimintaan. Yleisesti todettiin muiden tulistimien vastaavan oletettua toimintaa. Keittopinnan ja ekonomiserien toimintaa tutkittiin hivenen suppeammin ja havaittiin niiden toimivan huomattavasti stabiilimmin kuin tulistimien. Likaisuus kertoimet oletetusta vaihtelivat noin ±20 %.

Modeling of water/steam circulation in Circulating Fluidized Bed boiler

A distinctive design feature of steam boiler with natural circulation is the presence of the steam drum which plays a role of the separator of vapor from the flow of water-and-steam mixture coming into steam drum from the furnace tubes. Steam drum with unheated downcomer tubes, deducing from it, and riser (screen/furnace tubes) inside the furnace is a closed circulation loop in which movement of water (downcomer tubes) and water-and-steam mixture (riser tubes) is organized. The movement of the working fluid is appears due to occurrence of the natural pressure, determined by the difference in hydrostatic pressure and the mass of water and water-and-steam mixtures in downcomer and riser tubes and called the driving pressure of the natural circulation:

Influence of mixed fuels combustion on boiler operation

The aim of this work is to study the effect of different fuel mixtures on the operation of circulating fluidized bed (CFB) boiler. The applicability of heat balance modeling software IPSEpro to simulate CFB boiler operation is also investigated. The work discusses various types of boilers and methods of boiler operation. The fuel properties and the possible fuel influence on the boiler efficiency are described. Various biofuel types that are possible to use in combination with other fuels are presented. Some examples of the fuel mixtures use are given. A CFB boiler model has been constructed using IPSEpro and applied to analyze boiler operation outside design conditions. In the simulations, the effect of different load levels and moisture contents for the fuel mixture has been studied.

Modeling of water/steam circulation in Circulating Fluidized Bed boiler

A distinctive design feature of steam boiler with natural circulation is the presence of the steam drum which plays a role of the separator of vapor from the flow of water-and-steam mixture coming into steam drum from the furnace tubes. Steam drum with unheated downcomer tubes, deducing from it, and riser (screen/furnace tubes) inside the furnace is a closed circulation loop in which movement of water (downcomer tubes) and water-and-steam mixture (riser tubes) is organized. The movement of the working fluid is appears due to occurrence of the natural pressure, determined by the difference in hydrostatic pressure and the mass of water and water-and-steam mixtures in downcomer and riser tubes and called the driving pressure of the natural circulation: S drive = H steam (ρ down + ρ mix) g where: ρ down - density of water in downcomer tubes; ρ mix - density of water in riser tubes; H steam - height of steam content section; g - acceleration of gravity. In steam boilers with natural circulation the circulation rate is usually between 10 and 30. Thus, consumption of water in the circulation circuit “circulation rate times” more than steam output of the boiler. There are two aspects of the design of natural water circulation loops. One is to ensure a sufficient mass flux of circulating water to avoid burnout of evaporator tubes. The other is to avoid tube wall temperature fluctuation and tube vibration due to oscillation of circulation velocity. The design criteria are therefore reduced, in principle, to those of critical heat flux, critical flow rate for burnout, and flow instability. In practical design, however, the circulation velocity and the void fraction at the evaporator tube outlet are used as the design criteria (Seikan I., et. al., 1999). This study has been made with assumption that the heat flux in the furnace of the boiler even all the time. The target of the study was to define the circulation rate of the boiler, thus average heat flux do not change it. I would like to acknowledge professionals from “Foster Wheeler” company for good and comfortable cooperation.

The Plastic Capacity of Boiler Supporting Headers

The goal of this thesis was to make a dimensioning tool to determine the plastic capacity of the boiler supporting header. The capacity of the header is traditionally determined by using FE-method during the project phase. By using the dimensioning tool the goal is to ensure the capacity already in the proposal phase. The study began by analyzing the headers of the ongoing projects by using FE-method. For the analytical solution a plain header was analyzed without the effects of branches or lug. The calibration of parameters in the analytical solution was made using these results. In the analytical solution the plastic capacity of the plastic hinges in the header was defined. The stresses caused by the internal pressure as well as the normal and shear forces caused by the external loading reduced the plastic moment. The final capacity was determined by using the principle of virtual work. The weakening effect of the branches was taken into account by using pressure areas. Also the capacity of the punching shear was defined. The results from the FE-analyses and the analytical solution correlate with each other. The results from the analytical solution are conservative but give correct enough results when considering the accuracy of the used method.