2. Desain dan Modelling vvv pada CFB.pptx

Desain dan Modelling

1. I Nyoman Suprapta Winaya TARAHAN 15 - 19 APRIL 2017 COMBUSTION in CFB BOILER “ 2. Desain dan Modelling Pembakaran pada CFB Combustion ”

2. Paten Fluidized Bed Pertama “Manufacturing Fuel Gas” Fritz Winkler, Luwigshafen -am-Rhine Applied : 1923 Granted: 1928 Assigned to I.G. Farbenidustrie Aktiengesellschaft Fritz Winkler, pada tanggal 16 Desember 1921 di Jerman memperkenalkan suatu aliran gas hasil pembakaran yang dihembuskan di bawah sebuah wadah yang terdiri dari partikel – partikel batu arang. Kejadian ini menandai dimulainya hal yang sangat penting di dalam teknologi moderen. Winkler melihat partikel – partikel diangkat oleh tarikan gas, dan masa partikel dilihat seperti cairan yang mendidih. 12/05/2017 2

3. “Process of Producing Chemical Reactions” William W. Odell, Pittsburgh* Applied : 1926 (Original)** Granted: 1934 Assigned to Standard Oil Development Company *Odell was with the US Bureau of Mines **Originally Rejected Due to Winkler Filing, Application Refiled with Legal Assistance of Standard Oil Paten Fluidized Bed Pertama 12/05/2017 3

4. S O VIET DEVE L O P MENT a t Mos c o w Ene r gy In s ti t u t e 194 5 - F r om H A C e me n e n k o , LH Cidel k o v ski, ” P ar tic ular i t i es and e xp e r i e n c es f r om the a p p li c a t i on of flu i di z ed b e d ” , T e p l oe n e r g e t i k a No 3, 1954 T o burn fine r e s i dual part i cl es of l o w - r e a c t iv e f u els. No c oo l i ng tub e s i n the s e f i g u r e s !

5. CHI N E SE DEV E L OPMENT S t arting a t T singhua Uni v e r sity 1 9 69 with a 1 4 t/h b o ile r . 1 9 80 the r e w e r e o v er 20 FBC boile r s in China The figu r e sh o w s a 1 3 t/h p o w er boiler f r om 1 9 80 Z h a n g X u Y i P r oc 6 t h I n t . Co n g. On F B C US D oE, 1 9 8 .

6. EU R OP E A N - NO R TH AM E RIC A N DE V E L OPME N T OF B FB 1 9 7 - 1985 One of the la s t boile r s in this pe r iod: Geo r g e t o wn FBC 50 t/h b oile r , 1 9 80 ( F O S TER WH E EL E R)

7. REMARKS TERHADAP BFB BFB w as not further used f or c oal c ombu s tion f r om the 1 9 8 s be c ause of 1. 2. 3. e r os i on on i n- bed he a t t r an s f er tubes u n f a v ou r able u n f a v ou r able sulphur c a p tu r e and c ombu s tion e f fici e nc y . s c al e - up p r operti e s Fi g u re from B. Br o a d f i e l d , P .F. Li p ari, R.S. Sl on e , En gine e ri n g s t ud i e s o f a tmo s ph e ric FBC e l e ctric p o we r p la n ts in t h e U SA, VDI Beric h te N r 322, 197 8 .

8. CFB: THE FI R S T SUGG E S TION The ad v a nt a g e of high v elocity fluidi z a tion f or che m i c al r ea c ti o ns w as o b se r v ed b y L e wis and G illiland who issued their p at e n t 1 9 40 -50. L e wis 1941- 44 w as the fi r s t t o p r op o se a C F B r e a c t or “ R e a ction b e t w e e n s o lids and g ases” Lewi s , W .K . , ( S t a nd a r d Oil D e v . C o ) , “ R ea c t ion b e t w e e n soli d s a n d g ases ” , U S P at e n t 2, 3 4 3 ,7 8 , ( P a t e nt ed Ma r c h , 1 9 4 4 , a pp li c a t ion A u g u s t 1 9 4 1 ) .

9. CFB: THE FI R S T SUGG E S TION The ad v a nt a g e of high v elocity fluidi z a tion f or che m i c al r ea c ti o ns w as o b se r v ed b y L e wis and G illiland who issued their p at e n t 1 9 40 -50. L e wis 1941- 44 w as the fi r s t t o p r op o se a C F B r e a c t or “ R e a ction b e t w e e n s o lids and g ases” Lewi s , W .K . , ( S t a nd a r d Oil D e v . C o ) , “ R ea c t ion b e t w e e n soli d s a n d g ases ” , U S P at e n t 2, 3 4 3 ,7 8 , ( P a t e nt ed Ma r c h , 1 9 4 4 , a pp li c a t ion A u g u s t 1 9 4 1 ) .

10. FI R S T C OMBU S TION CFB S t ahl, B e cu w e 197 2 -74 Rhone P r o g il, F r anc e : P r ocedu r e f or c ombu s tion of indu s trial or hou s ehold w a st es

11. A F A S T AND S L O W BED BO I LER, J . Y erushalm i , S.Erlich, EPRI, ( M a r ch) 1 9 7 7- 7 8 , U S4 1 3 6 4 6

12. P R OC E SS F OR B U RNING CA R BON A C E OUS M A T E R IA L S Col l i n , Fl i n k , R e h , M e t all g esel l s c haf t , ( M a y) 1977 - 7 9 , US 4111 15 8, US 41657 1 7 • • Prima r y - se c onda r y air Suspension density ab o v e se c onda r y air 10- 40 k g /m 3 . Gas v elocity 5 - 15 m / s Co n tinous so l ids density g r adie n t f r om the bo t t om of the fluidi z ed bed t o the t op o f the r e a c t o r . P arti c le si z e 3 0-25 μm • • •

13. THE ”SQ U ARE” C Y C L ONE: Ce n trifu g al sepa r at o r , T Hyppänen and R K ui v ala i nen, A . Ahl s t r öm Co. Finland US 52 8 13 9 8, 19 9 2 - 94

14. THE ORIGINAL L U R GI CF . C OMBU S T OR P r op o sed 197 6 f or c ombu s tion of oil shale in Sw ed e n and South Afri c a. L. P la ss , G D a ra d i m o s , H Be isswe n g e r, D eve o p me n t of t h e circ u la t i n g a t h m o s ph e ric f l u i d ized b e d t o a n e n v iro n me n t – co n se r v o n g comb u s ti o n tech n olog y , VGB Kr a f tw e r k s tech n ologie 67 ( 5), 399 - 405 (1 9 87 ) .

15. THE CFB P R OC E SS A C C ORDI N G <1 9 95 I . Abd ul a ll y e t a l. , The 5 t h I n t . P ow er Gene r a ti on E x h i b iti on & Co n f . , O r l a n do F l , 1992 . T O F O S TER WHEELER “ The Fo s t e r W he e l e r process is ch a r a c t er i z e d by the pr e sen c e of a pronoun c ed bed i n the bot t om f e w f e et of the furn a ce and a re l a t iv e ly solid s -l e an fre e boa r d above i t . An a l t e rn a t i ve pro c ess, i . e . , f a st flu i di z ed or high l y exp a nded bed, is ch a r a c t er i z e d by hav i ng the solids spr e ad over a s ubstan t i a l he i ght of the furn a ce with the abs e nce of a prono u nc e d bed at the bottom of the fur n a c e … .. ”

16. CFB M ANU F A C T U R E R S AND THE I R RE L A T I O N S - U S t - ish c o a l, R en fr e w ( Bab c o ck) Bri - M e t a l l g ese l lsc h a ft ( L u r gi ) 1989 Pu 1995 1996 Li c e n se t o D o n g f a n g 1 9 95 - T e c h n ology t r a n s f er 2 03 Etc V a l m e t 2 00 Al st om Dongfang Harbin Shanghai M e tso 1 9 8 7 , 1 9 93 (Lu r gi li c e n se) A BB (1989 ) C omb u s tion E n gi n e e r i ng Kvae r ner 2 03 E n vi r oth e rm Ge n e r at or Götaverken 1996/9 7 L u r g i L e n t jes (1993 ) B a b c o c k, EV T , 2 07 A E & E L e n tjes 20 1 1 Do o sa n Lent j e s T a m pella A h l s t r öm 1 9 81 CFB A h l s t r o m - P y r o p o w er F o s t er Whe e l e r B F B 1 9 7 8 - 1 9 90 Geo r ge t own CF B 19 8 8 - 1995 Pu r c h ase B HEL - Dorr O li v er C h i n a 1 9 6 5 - L u r gi p a t e n t lice n se L u r gi p a t e n t lice n se M e t a l l g ese l lsc h a ft ( L u r gi 1970 s fi r s t C FB p a t e n ts D u i sbu r g 1 9 83 K ee ler U K 1 9 70 R iv e s ville 1 9 - 76 U SSR 1 9 4 - 60 C F B C a t cr a c k e r: Le wis Gil l il a n d 1 9 50 P e troleum & Chem i c al indu s t r y Wi n kl e r ga sif ie r 1 9 22 65 69th I E A -F B C T echn i c al Me e t i ng, Ai x - e n - P r o ven c e, S e p t e m ber 2014

17. The designs a r e app r oaching ea c h othe r . Th e r e r e m ains s o me individual f e a tu r es such as se e n bel o w: Bo t t om par t s with e x t e r nal h e a t e x cha n g e r s V almet (p r evi o usly Me t so ) A l stom F o ster Wh e e l er

18. R E CE N T INTE R E S T • S c ale up • O x y - fuel, high o x yg en c once n t r a tion • Other C O 2 lo o ping c a p tu r e method s : C a lcium lo o pin g , Ch e mi c al

19. S C A L E - UP OF A C FB BOILER F R OM 3 00 T O 6 M W e Dimensions in m 16 8 50 40 30 30 600 MW 300 MW

20. AN O X Y- FUEL C FB BOILER @ 6 % O 2 8 7 300 MW CFB Air vs oxy (60%) Dimensions in m 40 50 30 14

21. HISTORI PERKEMBANGAN PALING AKHIR 12/05/2017 21 LECKNER 2016

22. STATUS CIRCULATING FLUDIZED BED (CFB) Public Utility Regulatory Policy Act (1978)- Independent Power Producers Qualifying Facility Status for Fluidized Bed-Friendly Fuels CFB Boiler Installed Capacities grow to 300 MW (Sub-Critical), 460 MW (Supercritical) at Lagiza- Katowice area of southern Poland The bigest capacity today: 600-MW supercritical CFB (SC CFB) at the Baima power plant China Fuels: Coal Coal Waste Pet Coke Biomass MSW 12/05/2017 22

23. 1 ) 2 ) cyc lon e s ec ond a r y a i r b e d fu e l pri m a r y a i r DUA GENERASI CFB : 1. C y c lone sep a rator 2. I nner se p a r a t or TIPE DESAIN CIRCULATING FLUDIZED BED (CFB)

24. KAPASITAS UNIT ( M W e ) 6 SE C O N D GE N E R A T I O N D ES I G N 5 5 5 Lagi s z a 4 5 4 3 5 F I R ST GE N E R A T I ON DESIGN JEA 3 Tu r o w 5 2 5 Tu r o w 1 2 1 5 N PS ima 1 5 K okkola K uhmo Pilot pl a nt Thai Kr aft 1 9 7 1 9 7 5 1 9 8 1 9 8 5 1 9 9 1 9 9 5 2 2 5 ….... 2 14 TAHUN AWAL OPERASI N o v a Scotia Vaski l uodon V o K ajaani T r i-State L e y kam Pilot pl a nt Pihla v a K auttua TREND PERKEMBANGAN CFB Baima

25. INTERNATIONAL CFB CONFERENCE CFB-1, Halifax, Canada, 1985 CFB-2, Compiegne, France, 1988 CFB-3, Nagoya, Japan, 1990 CFB-4, Hidden Valley, USA, 1993 CFB-5, Beijing, China, 1996 CFB-6, Würzburg, Germany, 1999 CFB-7, Niagara Falls, Canada, 2002 CFB-8, Hangzhou, China, 2005 CFB-9, Hamburg, Germany, 2008 CFB-10, Sunriver, USA, 2011 CFB-11, Beijing, China, 2014 CFB-12, Krakow, Poland, 2016..........September 30... 12/05/2017 25

26. m m Boi l e r Te m p e r a t u re F u el F u el si z i n g A sh / s l a g i n g PF H i g h : 1 1 00 - 1 4 o C H ard co a l 3 1 - 3 3 Li g n i t e < . 3 m m M e lt ed/ y es C F B Lo w : 8 - 9 o C H ard co a l , l i g n i t e, b i o m a ss , w a s t es 3 - 3 N o t m e l t ed / n o PERBANDINGAN BOILER PULVERIZED FUEL (PF) DAN CIRCULATING FLUIDIZED BED (CFB)

27. C OM B U S T ON A N D FUE L S q A , MW / m q v, MW / m T y p e o f b oi l e r P a r a m ete r C FB B FB P C Su r f a ce th e r m a l l oa d : 2 1 . 8 - 2 . 5 1 . 2 - 1 . 5 3 . - 5 . 5 V o l u me th e r m a l l oa d 3 . 2 - . 4 I . 1 - . 2 . 08 - . 2 PERBANDINGAN BOILER PULVERIZED FUEL (PF) DAN CIRCULATING FLUIDIZED BED (CFB)

28. C o m pou n d P F C FB C a O S iO 2 S O 3 Al 2 O 3 Fe 2 O 3 M g O N a 2 O L OI 2 - 1 2 40 - 55 . 5 - 6 13 - 30 4 - 1 7 1 . 8 - 8 . 3 - . 7 . 7 - 15 25 26 10 . 8 9 . 6 15 . 4 . 8 . 4 2 - 1 2 PERBANDINGAN ABU HSIL PEMBAKARAN BOILER PF DAN CFB

29. Model of combustion and dispersion of carbon solids

30. Commercial scaling-up requires a model that simultaneously assesses carbon combustion and horizontal solid dispersion. Model of combustion and dispersion of carbon solids

31. Commercial scale-up requirements 1. Combustion rate : Reaction rate constant, k , can be controlled by changing temperature, oxygen concentration, superficial gas velocity and mass of fuel. The parameter k is determined as :

32. C = Carbon loading in the bed D h = Horizontal solid dispersion coefficient (m 2 /s) k = First order reaction rate constant (1/s) L = Width of combustor (m) 2. Horizontal dispersion: D h /kL 2 [-] Commercial scale-up requirements

33.   Horizontal dispersion of carbon deposit over bed material is governed by deposit combustion rate, solid dispersion rate and horizontal scale of combustor. Carbon mixing Carbon combustion High reaction rate, poor mixing, large scale Carbon mixin g Carbon combustion Slow reaction rate, good mixing, small scale Commercial scale-up requirements

34. One-dimensional Bubbling Bed Horizontal solid mixing is assumed to be uniform because its small horizontal cross-sectional area The bubbling fluidized bed model proposed by Kunii and Levenspiel is used to simulate the carbon combustion 2. Vertical solid mixing is also assumed to be uniform because vigorous solid mixing induced by rising bubbles Consequently, only a one-dimensional concentration profile of the gaseous component is examined.

35. Model of carbon deposit combustion The change concentration in the bubble: The change concentration in the emulsion: The fluidized bed consists of two phases: bubble and emulsion The change in concentration in the bubble ( C b ) and that in the emulsion ( C e ) along the bed height is determined as

36. Two-dimensional model In the two-dimensional bubbling fluidized bed reactor, horizontal dispersion of the carbon takes place. The mass flow rate of carbon by solid dispersion in each cell is calculable as At both ends of the reactor, the carbon mass flow through the wall is zero; consequently, the mass flow of carbon is

37. Experimental works Measurement of the combustion rate of carbon in a one-dimensional combustor Measurement of the horizontal CO 2 concentration profile in a two-dimensional combustor during continuous combustion of carbon

38. Effect of operating conditions and oxygen concentration on k Measurement of the combustion rate of carbon

39. Calculated O 2 concentration profile along bed height by one-dimensional model (temperature = 943 K, t = 0)

40. Horizontal profile of CO 2 concentration at upper surface of bed: comparison of experimental results and those of the two-dimensional model High combustion rate Low combustion rate Calc. O 2 : 5 % Calc. O 2 : 21 % Calc. O 2 : 21 % Carbon-loaded solid

41. Model of calculations CO Gas: CO 2 C Carbon-loaded solids Carbon feed + Horizontal difussion of carbon L H L W Carbon concentration The carbon material balance is : Carbon concentration + Carbon feed: Carbon capture x feed rate x time Horizontal dispersion coefficient: Shi and Fan, 1984 Kunii and Levenspeil 1991 Difussion:

42. Carbon material balance CO 2 Gas O 2 Carbon-loaded solids Carbon feed - Horizontal dispersion of carbon deposit L H L W Carbon combustion rate: The carbon material balance : Carbon combustion + Carbon feed: Carbon capture x fuel feed rate Horizontal dispersion coef., D h : 0.0003 m 2 /s 1-dimensional model

43. Design a n d Required D a ta The de s ign and re q uired d a ta nor m a l ly w ill be spe c ify by owner or clien t . T h e basic d e sign Desi g n Data : - Fuel ultimate ana l ysis - Feed water quality da t a a nd re q uired d a ta a r e; - - Weath e r conditi o n Feed water p roperties Required Data : - Main s t eam prop e rties - Flue g as emiss i on - - Flue g as temp e rature Boiler effi c ie n cy 82

44. Com b us t ion Calculat i on • Base on the design and required data the f oll o wing data c a n be cal c ulated in t h is s tage : - - - Fuel flow rate Fan ca p a city - - C o mb u st i on air flow rate Fuel and ash ha n dling c a p a city Sorbent f l ow rate 83

45. F u r n ace D esign 86 • The f urnace de s ign i nc l ude: 1. Fu r nace cross section 2. Fu r nace height 3. Fu r nace opening 1. Furnace cross sec t ion Crit e ria - mo i sture in f u el - ash in f u el - f l u i di z ation velocity - S A penetra t ion - mai n tain f l u i d i zation in lo w er zone at pa r t load

46. F u r n ace D esign 87 2. Furnace height Crit e ria - H e ating s u r f ace - R e si d ual t ime for sulfur capture 3. Fu r nace opening Crit e ria - Fuel feed por t s - S orbent feed por t s - Bed drain ports - Fu r nace exit sec t ion

47. Cyc l o n e Se p a r at o r • The c e ntrifugal force o n the p artic l e e n tering t he c yc l one is • The drag force on t he p artic l e c a n be w ritten as • Und e r s t eady s t ate drag force = c entri f u g al f orce 89

48. Cyc l o n e Se p a r at o r • Vr c a n be con s ider e d as index of c y clone e f fi c iency, from ab o ve equation the cy c lone e f f i ci e ncy will in c rease f or : - - - - - Hi g her e ntry velocity Lar g e size of s o lid Hi g her d e nsity o f p artic l e Sm a ll r adius o f c yc l one low value of visco s ity o f gas 90

49. Cyc l o n e Se p a r at o r • The p a rti c le with a di a meter l a rger th a n theoretical cut- size of cy c lone will be colle c ted or tra p p e d by cyc l one while the small si z e will be entrained o r le a ve a c y clone • Actual o p e ration, the c ut-off size dia m eter wi l l be de f ined as d50 that mean 5 0% o f the p a rticle w hi c h h a v e a diamet e r more than d50 will be coll e c t ed or ca p tured. 91

50. Renova si & Moderni sasi (R&M) and Life Extension (LE) terhadap pembangkit yang tua adalah pilihan yang efektif untuk menjadikan pembangkit hijau Perkembangan regulasi lingkungan memaksa keberadaan utilitas boiler yang sudah lama untuk di-revamping menggunakan boiler yang ramah lingkungan seperti CFB. Boiler CFB 12/05/2017 52

51. Tidak ada desain paten yang dominan The v arious designs p r e v ailing h a v e c o n v e rg ed i n t o a f ew g r ou p s 1) F o s t er Whe e ler with its c ompact design f orms a unique t r end b y itsel f . E n vi r otherm admini s t e r s lic e nc e s t o v arious c ompanies based on the Lu r gi t e c hnol o g y . The la r g e s t manu f a c tu r er who s e design origin at ed f r om Lu r gi is Al st om. The g en e r al design with h o t or c o o led c y clones, i nt er n al win g - w all he a t t r an s f er sur f a c es, and pos s ibly a h e a t e x ch a n g er in the lo o p seal, is f oll o w ed b y a g r e a t numb e r of manu f a c tu r e r s li k e the Jac k s o n vil l e type of F o s t er Wheele r ’ s design ( e specially U S A ) , Al s t om without e x t er n al he a t e x ch a n g e r s, V almet e t c. The mo s t impor t a n t d e v elopm e n t and appli ca tion a t p r es e n t t a k es pla c e in Asia , espe c ially in China. 2) 3) 4) 69th I E A -F B C T echn i c al Me e t i ng, Ai x - e n - P r o ven c e, S e p t e m ber 2014 Desain CFB

52. TERIMA KASIH