The document discusses Thermax Limited's internal recirculation circulating fluidized bed (IR-CFB) boiler technology. Some key benefits of IR-CFB boilers include higher separation efficiency across smaller particle sizes, uniform furnace temperatures, thin refractory, and lower operating and maintenance costs compared to other CFB designs. IR-CFB boilers also offer benefits such as high heat transfer rates, extended turndown ratios without auxiliary fuels, low auxiliary power needs, and fast shutdown times. The technology is supported by the operational experience of multiple installed IR-CFB boilers.

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Babcock & Wilcox's
IR-CFB Boiler Technology
Papertech -2010, Hyderabad
Thursday 17, June 2010
S. P. Ganeshan
Divisional Manager, Thermax Limited, Boilers & Heaters Group

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To be a globally respected high performance
organization offering sustainable solutions in
energy and environment
Thermax - Vision

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IR - CFB TECHNOLOGY

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Technology Partnerships for CFBC BOILERS

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Internal Recirculation – Circulating Fluidized Bed
Boiler (IR-CFB)
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U-Beam Separators
41
2
3Flue
Gas
&
Solid
Flow
Flue
Gas
•1. Sidewall
• membrane panel
•2. U-beam - SS309H/
•SS 253MA
•3. Seal baffle
•4. Refractory

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U-Beams

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U-Beam Separators – for High
capacity units
• Sidewall membrane panel
• U-beam - SS309H / SS310H/RA253MA
• Seal baffle
• Refractory
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CFBC TECHNOLOGY
IMPROVEMENTS

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Reduced Diameter Zone (RDZ)
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WHY IR - CFBC?
– HIGHER SEPARATION EFFICIENCY EVEN AT LOWER PARTICLE SIZE.
– HIGH FURNACE DENSITY
– UNIFORM FURNACE TEMPERATURE THROUGHOUT THE FURNACE.
– THIN REFRACTORY.
– TYPICAL BUBBLE CAPS TO AVOID BACK SHIFTING
– LOWER OPERATING & MAINTENANCE COST

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Overall Grade Separation Efficiency Comparison
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•IR-CFB Two Stage Solids Collection vs Hot Cyclone CFB Collection
Particle Size, Micron
Efficiency,%
100
90
80
70
60
50
40
0 20 40 60 80 100 120
Cyclone-
Based
CFB
IR-CFB

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IR-CFB Boilers - Furnace Density Profile

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IR-CFB Furnace Predicted Temperature Profiles
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Benefits:
• Low NOX
• SO2 capture across
furnace height

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(Refractory highlighted in yellow)
Thin Cooled Refractory
90% less refractory in IR-
CFB
NO hot expansion joints
as compared to hot
cyclone type CFB’s
Low gas velocity through
U-beam collector significantly
reduces need for refractory

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–High upper furnace heat transfer rate and precise
furnace temperature control
• Result of high efficiency solids collection and
solids recycle control from the MDC
–Extended turndown ratio (no oil/gas)
• 100% to 20% MCR
–Low auxiliary power requirements
• Due to low flue gas ∆P and no fluidizing blower
IR-CFB Features / Benefits
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–Fast shut down / cool down
• 80%+ of bed material is drained during cool
down. Can shutdown / cool / enter / re-start
within a 24 hour period compared to 2 to 3
times longer for competitor CFB designs.
–Low Maintenance Costs
• No refractory or hot expansion joints, ‘RDZ’ at
lower furnace refractory interface, no fluidized
sealing system, low furnace exit velocity, low
gas velocity in convective heating surfaces,...
IR-CFB Features / Benefits
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IR-CFB Boiler (110 Tons/Hr) at Kanoria Chemicals,
(Renukoot, Uttar Pradesh)

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IR-CFB Boiler at BILT (Chandrapur, Maharashtra)

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IR-CFB Boiler Technology -- Concluding Remarks
• IR-CFB facilitates Efficient boiler operation with precise process
control ensured with two-stage solids separation system with
controllable secondary recycle
• Internal recycle of the bulk of circulating solids and a wide range of
furnace velocity allows a flexible, compact, cost-effective and high
performance CFB boiler design suitable for multiple fuel firing
applications
• Lessons learned from the operating units led to development of IR-
CFB boiler technology suitable to various fuels / Indian conditions.
• Operational experience, a significant commercial reference list, and
technical developments illustrate the superiority of IR-CFB boiler
technology and trends of IR-CFB technology