Fluidised Bed Hot Air Generator

Technology

Inside a fluidized bed, fuels mixed with inert solids such as ash or sand/Special media is combusted. Specific velocity air is passed into the bed, creating strong turbulence inside the bed and causing the solid particles to behave like a fluid and mix uniformly. Fluidized bed reactors are capable of combusting solid fuels at 95% efficiency or higher, generating heat/Gas at a high rate, which can in turn be used to produce steam.

SYSTEM ASPECTS
The system comprises of fluidized bed furnace, nozzles, chambers for ash settling, ash removal mechanisms, cyclones, fuel feeding devices, hoppers, elevator, fluidization air blower, pneumatic fuel feeding blower, instrumentation & control equipment, operation panel board, motors & electrical components.

BIOMASS / SOLID FUEL DATA
Biomass / Solid Fuel Size                      0 – 6 mm
Moisture content                                  < 15 %
Ash content                                         Up-to 30%

APPLICABLE FUELS

  • Wood Wastes (Bar, Chips, Saw Dust etc.)
  • Agriculture wastes (Husks, Ground nut shell, Cotton Stack etc.,)
  • Lignite / Coal / Solid waste

Process

This system is operated by auto control procedures. The fluidized media is incited slowly for fluidization by start-up of fluidization air blower. The speed is regulated primarily & increased incrementally. Pneumatic fuel feeding is started & furnace is ignited. The fuel feeding is continued to achieve full combustion & required temperature. The control philosophy includes variables like air flow rate, feed rate, furnace pressure, combustion temperature etc. Ash is removed intermittently through settlers and cyclones.

The (FBC) Fluidised Bed Combustion fired HAG system consists of a fluidized bed furnace , settling chamber and high efficiency cyclones. Hot air with minor dust particals having size lower than 20 microns from our hot air generator, enters the process.The total system is automatic.

  1. FBC Furnace with Wind Box
    Agro waste / Coal / Lignite fired FBC system comprising of a Nozzle plate with attached Air Plenum, a side structure frame bolted with Nozzle plate.Graded cast iron Nozzles fitted on top of the Nozzle plate and Sand drain pockets are provided for the removal of heavy unwanted silica particles.
  1. Fuel Feeding with Screw Conveyor System
    M.S. Fabricated Fuel feeding venturi system is provided for feeding the fuel inside the furnace through S.F.D.Fan air.
  1. Refractory Material
    All the standard / special shaped refractory bricks for furnace walls along with fixtures and holders are provided. The required Insulation bricks Mortar cements will be provided by us. ( for Furnace area Refractory work only.)
  1. Instrumentation nd Safety Interlocks
    The system offered is extremely simple and convenient to operate. Alarms and safety interlocks have been provided to ensure correct working of the HAG. The following are a few of the safety inter locks.
  • Unless process suction fan is switched on, F.D.Fan / S.F.D.Fan / Fuel Feeders will not operate.
  • In case of high hot air temperature, audio/visual alarms are activated on the panel.
  • In case of high bed temperature audio/visual alarms are actived on the panel and fuel feeder speed is lowered down to minimum.
  1. Control Panel
    The panel is PLC based, having sophisticated but user friendly controls enabling the operator to run the HAG in automatic or manual mode as desired. The control panel consists of main MCCB, invertors for fans and feeders with individual MCBs, announciation module with hooter, PID controllers, indicating lamps and one auxiliary contact.

Advantages of Fluidized Bed hot air generator

The fluidized Bed HAG system is capable of combusting several types of fuel such as coal, corncobs, wood scraps, and precipitates from waste water treatment, at high efficiency. In addition, the emission control system of toxic gases such as sulfur dioxide and oxides of nitrogen in this technology is easy to operate, inexpensive, and efficient.

  1. Efficient Advantages:
  • Virtually complete combustion at low excess air level.
  • Increased energy recovery potential and system efficiency.
  • Odor elimination.
  • Minimal Maintenance.
  • Minimized temperature variations due to fluctuations in feed.
  • Lower capital costs.
  • Fully Automated system, which maintain automatically all the operating parameters of the system according to fuel.
  1. Favorable Ash Properties:
    The high combustion efficiency of a fluidized bed results in a reduced amount of inorganic material as fine ash. Low combustion temperatures in the fluidized bed minimize the formation of toxic materials that might carry over with the ash.
  1. Operating Flexibility:
    Radhe Fluidized Bed systems have demonstrated the ability to operate under a wide range of load conditions. The low fuel inventory present in the unit makes it very responsive to varying loads. The fluidized bed also maintains efficiency during system turndown.
  1. Operating Costs:
    The lack of moving part in a fluidized bed reduces maintenance costs and down time. RF units have achieved operatabilities above 98% and have kept operating cost relatively low given the difficult fuels they are burning.
  1. Environmentally Sound Energy Production from Waste:
    Fluidized bed combustion is an environmentally favorable, proven technology for disposal of solid wastes and generation of energy. The combustion of RF’s vast experience in developing solutions for a wide variety of application, with the favorable characteristics of fluidized bed combustion make RF the leader in providing environmentally sound waste disposal solutions. The effective cyclone design is able to reduce suspended matter content to below 20 micron in the hot air.
  1. Waste Fuel Diversity:
    RF systems have operated on fuels as diverse as agricultural waste, municipal solid waste, wood waste and coal. Fluidized bed systems are also capable of efficiently combusting fuels of varying consistency. RF units have demonstrated the ability to handle a variety of wastes within a single combustor.
  1. Low Emission:
    Emissions from a fluidized bed unit are inherently lower than conventional technologies for the following reasons.
  • Low combustion temperatures and low excess air within the bed reduces the formation of certain emissions such as Nox.
  • High combustion efficiency results in flue gases that contain low amount of CO.

Features:

  • No ash slagging problem. There is no ash slagging problem because combustion temperature is low and stable & due to bed in constant fluidization.
  • Low Nox Formation. Nox formation is negligible because of low combustion temperature.High Combustion Efficiency up-to 98%.
  • Easy Start-up and Shut-down.
  • Constantly running and continuous ash discharge.
  • Operate with multi fuels.
  • Temperature fluctuation is very minor, due to highly atomized PLC base control.

Applications:

The fluidized bed combustion technology has wide range of applications, notably in Hot Air Generator, Spray Dryer, Incinerator, Power Generation.

Applicable Industries

  • Ceramics Industries
  • Chemicals Industries
  • Rubber Industries
  • Food Processing Unit
  • Pharmaceuticals
  • Paper & Pulp Industries
  • Textile Processing Unit
  • Various Dryers
  • Other Industries where Heat is required

Model List

Model
Thermal output (Kcal/hr)
Liquid fuel replacement (Liter/hr)
RF-1000
8,60,000
75 – 95
RF-1400
12,04,000
110 – 140
RF-1900
16,34,000
150 – 190
RF-2300
19,78,000
180 – 230
RF-2900
24,94,000
220 – 285
RF-3400
29,24,000
270 – 340
RF-3800
32,68,000
300 – 380
RF-4700
40,42,000
380 – 475
RF-5600
48,16,000
450 – 565
RF-7500
64,50,000
600 – 750
RF-9500
81,70,000
750 – 940
RF-10500
90,30,000
650 – 850

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