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New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant

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A special issue of Energies (ISSN 1996-1073). This special issue belongs to the section "I3: Energy Chemistry".

Deadline for manuscript submissions: closed (25 January 2023) | Viewed by 22913

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Special Issue Editors

Prof. Dr. Xiaofeng Lu

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Guest Editor

Key Laboratory of Low-Grade Energy Utilization Technologies and Systems, Chongqing University, Ministry of Education of PRC, Chongqing 400044, China
Interests: the primary focus of the present research concerns engineering applications in various low-pollution combustion processes and advanced technologies in coal-fired power plants; especially in the large-scale circulation of fluidized bed combustion boilers; based on the fundamentals of energy and environmental issues

Prof. Dr. Rafał Kobyłecki

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Guest Editor

1. Department of Advanced Energy Technologies, Czestochowa University of Technology, Dabrowskiego 71, 42-200 Czestochowa, Poland
2. International Energy Agency – Fluidized Bed Conversion (Executive Committee Alternative Member in Poland), Paris, France
Interests: environmentally friendly energy conversion technologies; hydrodynamics and heat transfer in fluidized bed systems; construction; operation and optimization of CFB boilers; fluidized bed combustion and thermal treatment of solid fuels
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Prof. Dr. Artur Blaszczuk

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Guest Editor

Department of Advanced Energy Technologies, Czestochowa University of Technology, Dabrowskiego 71, 42-200 Czestochowa, Poland
Interests: heat transfer in fluidized bed; heat exchangers; bed hydrodynamics; fluidization regimes; population mass balance; CFB boilers; fuzzy logic
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Dr. Dongfang Li

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Guest Editor

1. State Key Laboratory of Complex Nonferrous Metal Resources Clean Utilization, Faculty of Metallurgical and Energy Engineering, Kunming University of Science and Technology, Kunming 650093, China
2. Pusan CFBC Research Center, Pusan National University, Busan, Korea
Interests: fluidized bed; CFB; gas–solid reaction; emission control; heat transfer

Special Issue Information

Dear Colleagues,

The application of circulating fluidized bed boiler (CFBB) technology has been under rapid development in the recent decades, due to its various advantages in fuel flexibility, emission control and efficiency. The uniformity in large-scale CFBBs, not only regarding fluidization, but also chemical reaction and heat transfer, still requires further investigation. Improvements to CFBB technology are also required due to the urgent demand for the reduction in costs and the strengthened environmental regulations of, for example, NOx, SOx, carbon dioxide and dust. Moreover, it is significant and vital to share the valuable experience attained from operating over several years, and R&D among different plants and parties. The Guest Editors invite submissions for the Special Issue of Energies on the following subject: “New Frontiers in Circulating a Fluidized Bed Boiler and Thermal Power Plant".

This Special Issue focuses on the new developments in design and the operation of a large circulating fluidized bed boiler. The topics of interest include, but are not limited to:

The fundamentals of fluidization, including the numerical simulation of combustion, and heat transfer and pollution control in large industrial CFBBs;
The design and operation technologies of large CFB boilers, especially supercritical CFB boilers;
New technologies for the auxiliary system for a CFB boiler;
New technologies for the control of pollutants and ultra-low emissions;
Flexible and deep load regulation;
Coal flexibility and co-combustion;
The security of heat transfer surfaces;
The hydrodynamics of water wall tubes;
Anti-wear technology;
Waste heat recovery and utilization;
Energy-saving technologies;
Ash characterization and utilization;
CFB combustion of high-sodium coal, biomass, industrial waste, municipal sludge and municipal waste.

Prof. Dr. Xiaofeng Lu
Prof. Dr. Rafał Kobyłecki
Prof. Dr. Artur Blaszczuk
Dr. Dongfang Li
Guest Editors

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Keywords

CFB
boiler
fluidized bed combustion
supercritical CFB boiler
CFB power plant

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Published Papers (12 papers)

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Research

15 pages, 5993 KiB

Open AccessArticle

Study on the Effect of Secondary Air Layout on CO Reduction Performance in a 75 t/h Biomass CFB Boiler Burning Wheat Straw

by Jun Zhang, Yanmin Li, Lin Mei, Xiaoliang Yu, Xun Lv, Jinping Wang, Jin Yan and Rongyue Sun

Energies 2023, 16(8), 3312; https://doi.org/10.3390/en16083312 - 7 Apr 2023

Viewed by 1631

Abstract

Biomass fuels play an important role in the field of fluidized bed combustion, but due to the diversity and uncertainty of fuels, there are usually some problems of high CO emission that cannot be directly solved by combustion adjustment. In this paper, a 75 t/h biomass fluidized bed was taken as the research object. It was observed from the field test that the gas incomplete combustion loss reached 12.13% when mono-combustion of wheat straw was conducted, and the CO concentration in the exhaust gas exceeded 30k ppm. Combined with the CPFD numerical simulation, the combustion characteristics and influence of secondary air layout on CO reduction performance were discussed in detail. The results revealed that the gas temperature gradually increased along furnace height under the initial condition, and the maximum temperature was more than 1000 °C at furnace outlet. The air curtain of the secondary air jets was insufficient, and the wheat straw rose rapidly as it entered into the furnace. By arranging adjacent secondary air ports above each fuel-feeding inlet, the residence time of particles in the furnace could be significantly increased, thus, the furnace temperature distribution was more reasonable and the CO emission was reduced by 58.6%. Full article

(This article belongs to the Special Issue New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant)

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17 pages, 10458 KiB

Open AccessArticle

An Experimental Study on SO₂ Emission and Ash Deposition Characteristics of High Alkali Red Mud under Large Proportional Co-Combustion Conditions in Fluidized Bed

by Xiaoliang Yu, Jin Yan, Rongyue Sun, Lin Mei, Yanmin Li, Shuyuan Wang, Fan Wang and Yicheng Gu

Energies 2023, 16(6), 2584; https://doi.org/10.3390/en16062584 - 9 Mar 2023

Viewed by 1346

Abstract

As an industrial solid waste, the discharge of a large amount of red mud (RM) causes serious environmental problems; thus, a large proportion of RM co-combustion has been proposed to solve the consumption problem. In this paper, an experiment with various proportions of RM co-combustion was conducted on a 0.2 t/h circulating fluidized bed (CFB) boiler. Desulfurization performance, combustion characteristics, and ash deposition characteristics were analyzed, especially under the large proportional co-combustion conditions. As the study results showed, the desulfurization efficiency was positively correlated with the RM co-combustion proportion. When the RM co-combustion proportion reached 50%, the desulfurization efficiency was over 94%. After a period of cyclic combustion, the highest desulfurization efficiency exceeded 99.5%. The smaller size of RM was beneficial to improve the combustion efficiency and the combustion stability. However, a large area of sintering formed on the top of the heating surface in the furnace, which was lighter than the sintering of high alkali fuels such as Zhundong coal. Meanwhile, the content of sulfates, such as Na₂SO₄ and CaSO_4, in the ash increased, which clearly proves that RM has the desulfurization effect. Therefore, a large proportion of co-combustion could meet the requirements of in-situ desulfurization and realize the resource utilization of RM. Full article

(This article belongs to the Special Issue New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant)

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13 pages, 2510 KiB

Open AccessArticle

Study on Gas–Solid Two–Phase Flow Characteristics of One–Furnace with Two–Tower Semi–Dry Desulfurization in Circulating Fluidized Bed Boiler

by Xueshen Wang, Zheng Gan, Shengwei Xin and Chunzhen Yang

Energies 2023, 16(4), 1971; https://doi.org/10.3390/en16041971 - 16 Feb 2023

Viewed by 1483

Abstract

A single–phase flow model was used to analyze the uniformity of the flow field in the desulfurization tower under different baffle combinations, and a multiphase flow model was used to explain the gas and solid two–phase flow characteristics and chemical reaction characteristics in the tower. The stability of the flow behavior of gas and solids in one furnace and two towers was discussed. The results show that the installation of shielding plates at appropriate positions in the tower for sulfur removal is beneficial to enhance the uniform distribution of flow in space, reduce the pulsation interference of bed pressure in the tower, keep the state of gas and solid flow unchanged, and maintain the efficiency of desulfurization at a high level. Reducing the instability of gas–solid two–phase flow is the basis of ensuring the stable switching between single and double towers. Full article

(This article belongs to the Special Issue New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant)

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28 pages, 8105 KiB

Open AccessArticle

Investigation of Supercritical Power Plant Boiler Combustion Process Optimization through CFD and Genetic Algorithm Methods

by Gavirineni Naveen Kumar and Edison Gundabattini

Energies 2022, 15(23), 9076; https://doi.org/10.3390/en15239076 - 30 Nov 2022

Cited by 7 | Viewed by 2602

Abstract

One of the main energy sources utilized to produce power is coal. Due to the lack of combustion enhancement, the main issue with coal-based power plants is that they produce significant amount of pollutants. The major problem of slagging formation within the boiler; it sticks to the water tube walls, superheater, and reheater. Slagging might decrease the heat transferred from the combustion area to the water or steam inside the tubes, increasing the amount of coal and extra air. The abrupt fall of slag on the tube surface into the water-filled seal-trough at the bottom of the furnace might occasionally cause boiler explosions. In order to maximize heat transmission to the water and steam tubes by reducing or eliminating slag formation on the tube surface, the work presented here proposes an appropriate computational fluid dynamics (CFD) technique with a genetic algorithm (GA) integrated with conventional supercritical power plant operation. Coal usage and surplus air demand are both decreased concurrently. By controlling the velocity and temperatures of primary air and secondary air, the devised technique could optimize the flue gas temperature within the furnace to prevent ash from melting and clinging to the water and steam tube surfaces. Heat transmission in the furnace increased from 5945.876 W/m² to 87,513.9 W/m² as a result of the regulated slag accumulation. In addition to reducing CO₂ emissions by 8.55 tonnes per hour and saving close to nine tonnes of coal per hour, the boiler’s efficiency increased from 82.397% to 85.104%. Full article

(This article belongs to the Special Issue New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant)

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15 pages, 3191 KiB

Open AccessArticle

Safety Analysis on the Heating Surfaces in the 660 MW Ultra-Supercritical CFB Boiler under Sudden Electricity Failure

by Boyu Deng, Tuo Zhou, Shuangming Zhang, Haowen Wu, Xiaoguo Jiang, Man Zhang and Hairui Yang

Energies 2022, 15(21), 7982; https://doi.org/10.3390/en15217982 - 27 Oct 2022

Cited by 2 | Viewed by 1552

Abstract

Ultra-supercritical circulating fluidized bed (CFB) boilers are taking up an increasing proportion of the CFB boiler fleet in China, making the safety concern about the heating surfaces in this type of boilers under sudden electricity failure draw more and more attention from the industry. For the time being, however, few studies have made efforts to resolve this concern. Given this, the physical process in a 660 MW ultra-supercritical boiler during the electricity failure accident was precited with a comprehensive model composed of mass and energy conservation equations in this work. The tube temperature of the boiler components with the highest safety risk, i.e., the water wall and a superheater, was obtained to evaluate the safety of the heating surfaces. The results revealed that the tube temperature (about 516 °C and 544 °C) would be obviously lower than the maximum permissible temperature of the tube material (600 °C and 630 °C) even when electricity could be restored at the power plant, indicating that the heating surfaces in the 660 MW ultra-supercritical CFB boilers would generally be recognized to be safe under sudden electricity failure. Full article

(This article belongs to the Special Issue New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant)

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22 pages, 9573 KiB

Open AccessArticle

Experimental Research on the Flow and Heat Transfer Characteristics of Subcritical and Supercritical Water in the Vertical Upward Smooth and Rifled Tubes

by Xiaocheng Du, Weiteng Li, Xirong Zhang, Jingrong Chen, Tingyu Chen and Dong Yang

Energies 2022, 15(21), 7941; https://doi.org/10.3390/en15217941 - 26 Oct 2022

Cited by 3 | Viewed by 1475

Abstract

Experiments were conducted to investigate the heat transfer and flow characteristics of the vertical upward smooth and rifled tubes from subcritical to supercritical pressure. The distributions of wall temperature and heat transfer coefficient (HTC) were obtained, and the HTC correlations and friction resistance coefficient correlations were fitted with experimental data. In addition, the influences of heat flux and type of tube on heat transfer performance were analyzed. The research shows that heat flux has different influences on the heat transfer characteristics under different pressures. The increase in heat flux improves the heat transfer characteristics in the nucleate boiling region, yet it leads to the advance in heat transfer deterioration. However, for supercritical water, the increase in heat flux reduces the heat transfer ability. In addition, using the rifled tube not only improves the heat transfer performance, but also inhibits the occurrence of heat transfer deterioration. The fitted correlations have great predictive ability for the heat transfer coefficient and friction resistance coefficient, and the average relative fitting errors are limited to 20%. Full article

(This article belongs to the Special Issue New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant)

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12 pages, 2542 KiB

Open AccessArticle

Discussion on the Feasibility of Deep Peak Regulation for Ultra-Supercritical Circulating Fluidized Bed Boiler

by Shengwei Xin, Hu Wang, Jianbo Li, Gang Wang, Quanhai Wang, Peiqing Cao, Peng Zhang and Xiaofeng Lu

Energies 2022, 15(20), 7720; https://doi.org/10.3390/en15207720 - 19 Oct 2022

Cited by 7 | Viewed by 1992

Abstract

In order to meet the flexibility operation needs of coal-fired units under the goal of carbon peak and carbon neutralization, it is imperative for circulating fluidized bed (CFB) units to participate in deep peak regulation. By systematically summarizing deep peak regulation operation practice of existing SC and subcritical-parameter-levels CFB units, the feasibility of deep peak regulation technology of an ultra-supercritical (USC) CFB unit under development and being built is analyzed and demonstrated; meanwhile, the deep peak regulation capacity of the boiler is also predicted. The results show that by analyzing the structural characteristics and design performance of the USC-CFB boiler, for technical problems such as stable combustion under low load, hydrodynamic safety, denitration performance under wide load, and rapid boiler load change rate existing in deep peak regulation, technical measures were implemented by selecting advanced boiler furnace type, adopting good design technology of the secondary rising water wall and uniformity design of bed temperature and bed pressure, strengthening the reducing atmosphere inside the furnace, improving the performance of wear-resistant refractory materials, quickly controlling the furnace bed material stock under variable load, optimizing the control strategy of CFB unit, and so on. The boiler achieved good operation characteristics and good deep peak regulation performance, and the pollutant emissions can steadily achieve ultra-low emission standards. When the USC-CFB unit participates in deep peak regulation, the minimum stable combustion load of the boiler can reach 20~30% BMCR, and a boiler load change rate under 30% BMCR or above could reach 1.5~2% BMCR/min, while that below 30% BMCR could reach 1% BMCR/min. The research results can provide references for the deep peak regulation of in-service supercritical (SC) CFB units and design optimization of similar USC-CFB units. Full article

(This article belongs to the Special Issue New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant)

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26 pages, 19562 KiB

Open AccessArticle

MLD–MPC for Ultra-Supercritical Circulating Fluidized Bed Boiler Unit Using Subspace Identification

by Chen Yang, Tao Zhang, Zonglong Zhang and Li Sun

Energies 2022, 15(15), 5476; https://doi.org/10.3390/en15155476 - 28 Jul 2022

Cited by 1 | Viewed by 1915

Abstract

Before carbon capture and storage technologies can truly be promoted and applied, and nuclear or renewable energy power generation can become predominant, it is important to further develop more efficient and ultra-low emission USC units on the basis of leveraging the strengths of CFB technology. In view of this complex system with strong nonlinearity such as the boiler-turbine unit of a thermal power unit, the establishment of a model that is suitable for control is indispensable for the operation and the economics of the process. In this study the form of the nonlinear model after linearization at the steady-state point has been fully considered and an improved subspace identification method, which is based on the steady-state point deviations data, was proposed in order to identify a piecewise affine model. In addition, the construction of the excitation signal in practical applications has been fully considered. The identification results demonstrate that this method has a better adaptability to strong nonlinear systems. The identification normalized root mean square errors of each working condition were almost all less than 10%. On this basis, a framework that is widely applicable to complex system control has been established by combining with the mixed logic dynamic (MLD) model. The canonical form realization was performed in order to transfer the local models into the same state basis. The predictive control was carried out on the boiler-turbine system of a 660-MW ultra-supercritical circulating fluidized bed unit that was based on the above framework. The results indicate that the predictive control performance is closely related to the setting value of the ramp rate and, therefore, prove the effectiveness of the framework. Full article

(This article belongs to the Special Issue New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant)

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14 pages, 5679 KiB

Open AccessArticle

Fault Diagnosis of Coal Mill Based on Kernel Extreme Learning Machine with Variational Model Feature Extraction

by Hui Zhang, Cunhua Pan, Yuanxin Wang, Min Xu, Fu Zhou, Xin Yang, Lou Zhu, Chao Zhao, Yangfan Song and Hongwei Chen

Energies 2022, 15(15), 5385; https://doi.org/10.3390/en15155385 - 26 Jul 2022

Cited by 10 | Viewed by 1650

Abstract

Aiming at the typical faults in the coal mills operation process, the kernel extreme learning machine diagnosis model based on variational model feature extraction and kernel principal component analysis is offered. Firstly, the collected signals of vibration and loading force, corresponding to typical faults of coal mill, are decomposed by variational model decomposition, and the intrinsic model functions at different scales are obtained. Then, the eigenvectors consisting of feature energy and sample entropy in these functions are respectively calculated, and the kernel principal component analysis is used for noise removal and dimensionality reduction. Finally, the kernel extreme learning machine model is trained and tested with the dimension reduced feature vector as input and the corresponding coal mill state as output. The results show that the variational model decomposition extraction can improve the input features of the model compared with the single eigenvector model, and the kernel principal component analysis method can significantly reduce the information redundancy and the correlation of eigenvectors, which can effectively save time and cost, and improve the prediction performance of the model to some extent. The establishment of this model provides a new idea for the study of coal mill fault diagnosis. Full article

(This article belongs to the Special Issue New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant)

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15 pages, 4294 KiB

Open AccessArticle

Simulation of Two-Phase Flow and Syngas Generation in Biomass Gasifier Based on Two-Fluid Model

by Haochuang Wu, Chen Yang, Zonglong Zhang and Qiang Zhang

Energies 2022, 15(13), 4800; https://doi.org/10.3390/en15134800 - 30 Jun 2022

Cited by 8 | Viewed by 1632

Abstract

The efficient use of renewable energy is receiving more and more attention in the context of “carbon neutrality” and “carbon peaking”. For a long time, biomass has been used less efficiently as a renewable energy source, but with the development of fluidized biomass gasification technology, it can play an increasing role in industrial production. A fluidized bed biomass gasifier has a strong nonstationary process due to its complex energy–mass exchange, and analysis of its complex reaction process and products has relied on experiments for a long time. This paper uses a Euler–Euler two-fluid model to establish a three-dimensional CFD model of the fluidized bed biomass gasifier, on which factors affecting syngas generation are analyzed. The simulation shows that increasing the initial bed temperature can effectively improve syngas production, while increasing the air equivalent is not beneficial for syngas production. Full article

(This article belongs to the Special Issue New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant)

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20 pages, 6402 KiB

Open AccessArticle

Dynamic Characteristics Analysis of a 660 MW Ultra-Supercritical Circulating Fluidized Bed Boiler

by Chen Yang, Zonglong Zhang, Haochuang Wu and Kangjie Deng

Energies 2022, 15(11), 4049; https://doi.org/10.3390/en15114049 - 31 May 2022

Cited by 8 | Viewed by 2529

Abstract

The 660 MW ultra-supercritical circulating fluidized bed (CFB) boiler, which is the maximum capacity and largest scale boiler in the world has entered construction stage in China. This study established a full-scale dynamic simulation model of the 660 MW ultra-supercritical at 100% boiler maximum continuous rating (BMCR) condition. The model consists of an air-flue gas system, a water-steam system, and an ash circulation system. The “core-annulus” of the gas-solid two-phase flow structure and “six-equation” model of water-steam two-phase flow were applied to simulate the behaviors of the gas-solid phase and water-steam system, respectively. The model was calibrated and verified at 100% BMCR condition, and the steady-state simulation results presented a high accuracy compared with the designed parameters. A dynamic simulation of three typical conditions were carried out as well, including a 5% feed water decrease, 5% air decrease, and 5% coal decrease, respectively. The results showed that the dynamic simulation model established in this study can simulate the dynamic behaviors of the 660 MW ultra-supercritical CFB boiler reasonably. Full article

(This article belongs to the Special Issue New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant)

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12 pages, 4554 KiB

Open AccessArticle

Study on the Uniformity of Secondary Air of a 660 MW Ultra-Supercritical CFB Boiler

by Li Nie, Jiayi Lu, Qigang Deng, Liming Gong, Dayong Xue, Zhongzhi Yang and Xiaofeng Lu

Energies 2022, 15(10), 3604; https://doi.org/10.3390/en15103604 - 14 May 2022

Cited by 3 | Viewed by 1838

Abstract

Based on the field test of a 600 MW supercritical circulating-fluidized bed boiler, this paper optimizes the secondary air pipe layout scheme of a 660 MW ultra-supercritical circulating fluidized bed boiler with a similar furnace structure and carried out a numerical simulation on its air distribution uniformity. The secondary air box of the 660 MW ultra-supercritical circulating-fluidized bed boiler adopts a variable section design, and the secondary air branch pipe adopts a separate air inlet mode. The experimental results showed that the oxygen concentration was uniform near the rear wall, but all exhibited a “decrease–increase–decrease” profile along the horizontal line, which indicated that the trajectory of the secondary air jet was first in the shape of bending downward and then upward. To achieve a more uniform secondary air distribution for supercritical CFB boilers, further optimization of the layout of the bellows and branch pipes should be considered. Numerical results showed that the deviation rate of the internal and lower secondary air reached 17%, and there was optimization space for the secondary air branch pipe layout of the boiler. Its uniformity can be increased by adding valves and other measures. The velocity deviation of the secondary air of the 660 MW ultra-supercritical circulating-fluidized bed boiler can be within 3% by means of separate air supply and pipe diameter change, and better uniform air supply can be achieved to reduce the speed deviation by adding valves and adjusting the combustion. Full article

(This article belongs to the Special Issue New Frontiers in Circulating Fluidized Bed Boiler and Thermal Power Plant)

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