Patent Grant
9423122
Our invention relates to a circulating fluidized bed boiler. In more detail, the circulating fluidized bed boiler of the present invention is preferably a once through utility (OTU) boiler, for example, for power generation or industrial steam production. As the size of boilers increases, the relation of the wall surface area to the volume of the furnace usually becomes disadvantageous, which may cause problems, for example, in positioning of the different devices and conduits related to the furnace, as well as feed the feeding and mixing of different materials. The present invention especially relates to solving problems related to large circulating fluidized bed (CFB) boilers.
Our invention relates to a circulating fluidized bed boiler. In more detail, the circulating fluidized bed boiler of the present invention is preferably a once through utility (OTU) boiler, for example, for power generation or industrial steam production. As the size of boilers increases, the relation of the wall surface area to the volume of the furnace usually becomes disadvantageous, which may cause problems, for example, in positioning of the different devices and conduits related to the furnace, as well as feed and mixing of different materials. The present invention especially relates to solving problems related to large circulating fluidized bed (CFB) boilers.
Generally speaking, a circulating fluidized bed boiler comprises a furnace for combusting fuel, an outlet channel connected to the upper section of the furnace for the discharge of flue gas out of the furnace, a solids separator for receiving the flue gas via the outlet channel from the furnace, and for separating solid particles from the flue gas. The CFB boiler further comprises at the lower portion of the solids separator, a return channel for taking the hot solids separated by means of the solids separator to the lower section of the furnace, and at the upper portion of the solids separator, a flue gas duet for removing cleaned flue gas to the backpass of the boiler, to gas cleaning devices and, further, through the stack to the environment.
The outlet channel, solids separator, and the return channel form a so-called external hot circulation, in which the hot solids entrained in the flue gas are first taken out of the furnace, then treated in the separator, and finally, returned to the furnace. Most often, somewhere in the external circulation, in flow communication with the solids return channel, a fluidized bed heat exchanger is arranged. The heat exchanger may be supported to the lower portion of the solids separator such that the return channel takes the solids from the heat exchanger to the lower section of the furnace. Or, the heat exchanger may be supported by a side wall of the furnace, such that the return channel takes the solids from the solids separator to the heat exchange chamber. As to the fluidized bed heat exchangers, they may also be arranged in the internal circulation, i.e., for receiving the solids from the bed material flowing down along the furnace walls. And, naturally, there are also fluidized bed heat exchangers that may receive solids from either the internal or the external circulation, or simultaneously, from both circulations.
The lower section of the furnace is provided with feeds for feeding fuel, inert bed material, and possibly sulfur binder to the furnace, and, finally, the bottom of the furnace is provided with feeds for feeding oxide-containing fluidizing gas into the furnace, in other words, a gas inlet channel, a wind box, and nozzles.
Published PCT International Application No. WO 2007/128383 A2 discusses a fluidized bed heat exchanger structure for a CFB boiler. The CFB boiler of the PCT publication, or in fact, the fluidized bed heat exchanger, comprises two heat exchange chambers arranged in series in communication with the return channel, such that a first fluidized bed heat exchange chamber supported below the solids separator receives hot solids directly, actually, via a gas seal, from the solids separator, and then, in normal conditions, discharges the cooled solids to a second fluidized bed heat exchange chamber arranged in connection with the wall of the lower section of the furnace. Finally, the cooled solids are returned to the furnace from the second heat exchange chamber.
In accordance with the teachings of the PCT publication, the upper heat exchange chamber is also provided with a return for returning cooled solids from the upper heat exchange chamber directly to the furnace. Both heat exchange chambers have internal heat exchange surfaces arranged within the heat exchange chambers for cooling the solids before they are returned to the lower section of the furnace. In other words, the two heat exchange chambers discussed above are connected in series in the external solids circulation of a CFB boiler.
It is a specific feature of the second, i.e., the lower heat exchange chamber, of the above-mentioned PCT publication that the heat exchange chambers may receive hot solids, not only from the first heat exchange chamber, but also, from the internal circulation, i.e., the second heat exchange chamber is provided with an inlet arranged in the wall of the lower section of the furnace such that hot solids flowing down along the boiler walls are able to enter the second fluidized bed heat exchange chamber. Further, the heat exchanger arrangement of the PCT publication is provided with an overflow for allowing overflow of solids from the first heat exchange chamber directly to the second heat exchange chamber, in a case that the solids flowing into the first heat exchange chamber is larger than the discharge flowing out of the first heat exchange chamber. In connection with this discussion concerning the heat exchangers, it should be understood that a large CFB boiler is usually provided with several parallel solids separators and heat exchangers connected to their return channel either on one side of the boiler or on both sides thereof, but, for clarity reasons, both above and in the following description of the invention, mainly, only one heat exchange arrangement with one solids separator, is discussed.
The starting point in the development of the fluidized bed heat exchanger of the PCT publication discussed above was to be able to construct a heat exchange arrangement that may be used in almost all possible applications due to its versatile controlling possibilities. A problem the construction of the PCT publication solved related to the traditional location of the fluidized bed heat exchange chambers on the outside walls of the lower section of the furnace. While the CFB boilers grew, it was not possible to increase the size of the fluidized bed heat exchange chambers accordingly, as increasing the height of a heat exchange chamber resulted in the increase of pressure losses in the fluidization air, and an increase in the width of the heat exchanger was not possible due to a lack of space. Thus, the growing size of the CFB boilers was taken into account in the PCT publication by arranging the heat exchangers one on top of the other, whereby requirements relating to both the available space and the acceptable pressure Josses were taken into account. And, finally, the adjustability or controllability of the heat exchange arrangement was ensured by providing the arrangement with equipment giving a possibility to run the arrangement in several different ways.
When all the above-discussed and other considerations were taken into account in the design of the heat exchange arrangement, however, the construction of the arrangement became less optimal for some specific applications. Such applications are cases when no extensive control is required, or cases when the connection of the heat exchange chambers in series is not desired, for some reason. In other words, the prior art arrangement has a few drawbacks or problems.
First, since the upper heat exchange chamber is supposed to discharge the cooled solids to the lower one, the channel between the heat exchange chambers runs between the upper heat exchange chamber and the furnace forcing positioning of the first/upper heat exchange chamber substantially far from the furnace wall. This also means that the solids separator has to be positioned far from the furnace, as the upper heat exchange chamber is normally positioned right below the separator, and supported from the separator.
Second, as the lower heat exchange chamber is supposed to be able to receive all the cooled solids from the upper heat exchange chamber, and possibly, also some additional solids from the internal circulation, it is clear that the volume of the lower heat exchange chamber should at least correspond to the one of the upper heat exchange chamber. As already discussed above in connection with the PCT publication (WO 2007/128883 A2), neither the height nor the width (in a direction parallel to the furnace wall) of the lower heat exchanger can be chosen freely, but both the pressure loss in the fluidization, and the space occupied by the heat exchange chamber have to be considered. The above consideration results in that the dimensions of the lower heat exchange chamber are substantially equal with the upper one. Thereby, there is very little room in connection with the lower section of the furnace for the equipment necessary for running the boiler, such as, for example, the start-up burner, a temperature measuring device for measuring the lower furnace temperature, a pressure measurement device for measuring the bed pressure, and feeds for introducing fuel, bed material, secondary air, additives, recirculated flue gas (if in use), etc.
Third, due to the various running alternatives, i.e., control options in the prior art boiler, there are conduits and channels for each alternative. For instance, the upper heat exchange chamber has one inlet from the separator, and several outlet channels and lift channels. One lift channel and outlet channel leading to the lower heat exchanger, another lift channel and outlet channel leading to the furnace, and overflow channels leading to both the lower heat exchange chamber and to the furnace. In addition to the channels, rather complicated fluidization means and controllers for adjusting the fluidizations are also required at the bottom of the upper heat exchange chamber. If, and when, the various channels and conduits require bellows to separate components in different temperatures, the bellows, again, occupy space, and also increase the costs of the heat exchanger arrangement together with the already numerous channels, conduits, fluidization equipment, and control systems that have been discussed above. And, still further, all of the channels and conduits need to be either made of water/steam tube walls and connected to the rest of the steam/water system, or made of a refractory material. Irrespective of the manufacture, this adds to the expenses as constructing the channels of water/steam tube walls or refractory material is a complicated and time-consuming task.
For the above reasons, it has been found necessary to improve the construction of a CFB boiler and its heat exchanger arrangement.
An object of the present invention is to provide a circulating fluidized bed boiler, in which problems and drawbacks of the prior art discussed above are minimized.
A further object of the present invention is to provide a simpler heat exchanger arrangement as compared to the prior art.
Yet another, further object of the present invention is to provide a heat exchanger arrangement that offers the boiler designer more alternatives in positioning various components of the boiler system in the lower section of the furnace.
In order to solve the above-mentioned problems of the prior art, our invention provides a circulating fluidized bed boiler (CFB) with a novel heat exchanger arrangement. The CFB boiler comprises a furnace for combusting solid carbonaceous fuel in a fast fluidized bed, the furnace having walls made of water/steam tube panels and used for evaporating the water fed therein, a solids separator arranged adjacent to a sidewall of the furnace for separating solids entrained with exhaust gas discharged via an outlet channel from an upper portion of the furnace, a gas seal for conveying at least a portion of the separated solids to a first fluidized bed heat exchange chamber arranged downstream of the gas seal and having internal heat exchange surfaces, a first lift channel, having a lower end connected to a bottom portion of the first fluidized bed heat exchange chamber and an upper end connected to an upper end of a first return channel for discharging solids from the first fluidized bed heat exchange chamber and taking the cooled solids to a lower portion of the furnace, a second fluidized bed heat exchange chamber arranged adjacent to a lower sidewall of the furnace and having internal heat exchange surfaces, an inlet channel arranged between the second fluidized bed heat exchange chamber and the furnace for introducing hot solids from the furnace to the second heat exchange chamber, a second lift channel having a lower end connected to a bottom portion of the second fluidized bed heat exchange chamber and an upper end connected to discharge the solids to the lower portion of the furnace, the first fluidized bed heat exchange chamber being positioned above the second fluidized bed heat exchange chamber, wherein the first heat exchange chamber has two first lift channels and two first return channels arranged at the lateral sides thereof such that the second heat exchange chamber is situated between the lower ends of the two first return channels.
Other features of the present invention will be discussed in more detail as follows.
The advantages gained by the construction and the design of the CFB boiler of the present invention are as follows;
The present invention is described in more detail in the following with reference to the attached drawings, of which
Most often, somewhere in the external circulation, a fluidized bed heat exchanger (36) is arranged. The fluidized bed heat exchanger may be supported to the lower portion of the solids separator 16 such that the return channel 18 takes the solids from the heat exchanger to the lower section of the furnace 12. Or, the fluidized bed heat exchanger may be supported by the side wall of the furnace 12 such that the return channel 18 takes the solids from the solids separator 16 to the heat exchange chamber. The prior art also shows fluidized bed heat exchange chambers arranged outside the furnace wall in the internal circulation, which means that the fluidized bed heat exchange chamber receives solids flowing down along the furnace walls, cools the solids, and returns them back to the furnace.
In operation, the heat exchanger of
In the arrangement of
Further,
Normally, the walls of the furnace 12, as well as the walls of the solids separator 16, of the fluidized bed heat exchange chambers 36, 38, and also, of some conduits and channels, are made of water tube panels (sometimes called membrane walls) serving as so-called evaporating surfaces or as water heating surfaces, in which water tube panels, the high-pressure feed water of the boiler steam cycle, heated in an economizer (not shown in
As has already been explained above, however, the heat exchanger arrangement of
First, since the upper heat exchange chamber 36 is supposed to discharge the cooled solids to the lower one 38, the channel between the heat exchangers runs between the upper heat exchanger 36 and the furnace 12 forcing positioning of the first heat exchanger 36 substantially far from the furnace 12. This also means that the solids separator 16 has to be positioned far from the furnace 12, as the heat exchange chamber 36 is normally positioned right below the solids separator 16, and is supported by the separator 16.
Second, as the lower heat exchange chamber 38 is supposed to be able to receive all of the cooled solids from the upper heat exchange chamber 36, and possibly, also some additional solids from the internal circulation, it is clear that the volume of the lower heat exchange chamber 38 should be at least that of the upper heat exchange chamber. As has already been discussed above in the PCT publication (WO 2007/128883 A2), neither the height nor the width of the lower heat exchanger 38 can be chosen freely, but both the pressure loss in the fluidization, and the space occupied by the heat exchanger have to be optimized. This results in that the dimensions of the lower heat exchange chamber 38 are substantially equal to the upper one 36. Thereby, there is very little room in connection with the lower section of the furnace 12 for the equipment necessary for running the boiler 10, such as, for example, the start-up burner, a measuring device for measuring the lower furnace temperature, a measuring device for measuring the bed pressure, and feeds for introducing fuel, bed material, secondary air, additives, recirculated flue gas (if applicable), etc.
Third, due to the various running alternatives, conduits and channels are necessary for each alternative. For instance, the upper heat exchange chamber 36 has one inlet from the separator 16, and several outlet channels and lift channels. One lift channel and outlet channel leading to the lower heat exchanger 38, another lift channel and outlet channel leading to the furnace 12, and an overflow channel leading to the lower heat exchange chamber 38. In addition to the channels, rather complicated fluidization means and controller for adjusting the fluidization also are required at the bottom of the upper heat exchange chamber 36. If, and when, the various channels and conduits require bellows to separate components in different temperatures, the bellows, again, occupy space, and also increase the costs of the heat exchanger arrangement together with the numerous channels, conduits, fluidization equipment, and control systems that have already been discussed above.
A solution to at least some of the above-mentioned drawbacks and problems is illustrated in
A lower fluidized bed heat exchange chamber 74 is arranged below the upper fluidized bed heat exchange chamber 72, and, preferably, in connection with the wall of the furnace lower section. Further, the lower heat exchange chamber 74 is situated between the return channels 86 of the upper heat exchange chamber 72, in fact, between the lower ends of the return channels 86. The lower heat exchange chamber 74 is provided with an inlet channel 90 for receiving hot solids directly from the furnace 12 via an opening 92 in the, preferably oblique, furnace wall 94. The lower heat exchange chamber 74 further has internal heat exchange surfaces 96, bottom nozzles 98, and a wind box 100 below the bottom from where fluidization air 102 is blown into the fluidized bed heat exchange chamber 74. The lower fluidized bed heat exchanger 74 further has a lift channel 104 along which solids from the chamber 74 are discharged into the lower section of the furnace 12. The lift channel 104 needs its own nozzles, wind box, and air feed to be able to lift the solids into the lift channel 104.
The advantages of the present invention may be seen in both
As to the heat exchange surfaces of the fluidized bed heat exchange chambers 72, 74, it is normal practice that the internal surfaces 76 and 96 (
One alternative to utilize the wall surfaces of the heat exchange chambers 72, 74 is to arrange such in the water circulation, i.e., for preheating the water to be fed into the steam cycle of the furnace 12. For instance, one option is to feed water via an economizer in the flue gas conduit to the walls of the lower fluidized bed heat exchange chamber 74, and then, to introduce the preheated water to the evaporator tubes in the furnace walls. A further option is to take the feed water after the lower heat exchange chamber 74 to the walls of the upper heat exchange chamber 72, and only thereafter introduce the preheated water to the evaporator panels of the furnace 12. A yet further option is to take the feed water after the lower heat exchange chamber 74 to the walls of the discharge conduit that leads from the upper heat exchange chamber 72 to the furnace 12, and, thereafter, to the walls of the upper heat exchange chamber 72. This way, the feed water path from the feed water pump to the evaporator tubes in the furnace walls is as follows: feed water pump—economizer—lower heat exchange chamber walls—return channel walls 86′ —upper heat exchange chamber walls—water/steam tube panels of the furnace 12. The feed water path may also be provided with water cooled hanger tubes between the economizer and the lower heat exchange chamber 74 walls. As a further option, it is also possible that the walls of the upper heat exchange chamber 72 may be steam cooled, and, optionally, integrated with the steam cooled separator.
The invention has been described above in connection with exemplary arrangements, but the invention also comprises various combinations or modifications of the disclosed embodiments. Especially, the number of separators and heat exchangers may vary from what is disclosed in
| Number | Date | Country | Kind |
|---|---|---|---|
| 20115181 | Feb 2011 | FI | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/FI2012/050172 | 2/22/2012 | WO | 00 | 7/8/2013 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2012/113985 | 8/30/2012 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 5463968 | Abdulally | Nov 1995 | A |
| 6631698 | Hyppanen et al. | Oct 2003 | B1 |
| 8807053 | Kauppinen | Aug 2014 | B2 |
| 20090293818 | Kauppinen | Dec 2009 | A1 |
| 20110220038 | Kauppinen et al. | Sep 2011 | A1 |
| Number | Date | Country |
|---|---|---|
| H09-243019 | Sep 1997 | JP |
| 2009-536312 | Oct 2009 | JP |
| 2007128883 | Nov 2007 | WO |
| 2010052372 | May 2010 | WO |
| Entry |
|---|
| Japanese Office Action dated Aug. 26, 2014, issued in counterpart Japanese Patent Application No. 2013-552998, with an English translation. |
| Finnish Office Action dated Jan. 31, 2012, issued in corresponding Finnish Patent Application No. 20115181. |
| Notification of and International Search Report completed Jul. 4, 2012, and mailed on Jul. 13, 2012, in corresponding International Patent Application No. PCT/US2012/050172. |
| Written Opinion mailed on Jul. 13, 2012, in corresponding International Patent Application No. PCT/US2012/050172. |
| Number | Date | Country | |
|---|---|---|---|
| 20130284120 A1 | Oct 2013 | US |
