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Volume 13 | Issue 7 | Year 2026 | Article Id. IJME-V13I7P117 | DOI : https://doi.org/10.14445/23488360/IJME-V13I7P117

Experimental Investigation for Optimization of Fluidization in AFBC Boiler while Operating it at Lower Steam Generation

Chirag V. Kapuria, Reena N. Makadia, Chetankumar M. Patel

Received Revised Accepted Published
16 Sep 2025 15 Oct 2025 06 Jun 2026 30 Jul 2026

Citation :

Chirag V. Kapuria, Reena N. Makadia, Chetankumar M. Patel, "Experimental Investigation for Optimization of Fluidization in AFBC Boiler while Operating it at Lower Steam Generation," International Journal of Mechanical Engineering, vol. 13, no. 7, pp. 199-209, 2026. Crossref, https://doi.org/10.14445/23488360/IJME-V13I7P117

Abstract

An industrial-scale Atmospheric Fluidized Bed Combustion (AFBC) boiler with a capacity of 66 TPH has been developed by Aarti Industries Limited, located in the Dahej region of Gujarat. In coal-fired AFBC boilers used in chemical industries, a decrease in chemical production reduces steam demand, leading to higher energy losses and increased specific coal consumption. To maintain operation above the recommended turndown ratio, industries often vent excess steam, which ultimately increases production costs. This study focuses on reducing dry flue gas losses in boilers operating below the recommended turndown ratio. Key parameters-fluidizing air flow, bed material height, and coal conveying air pressure-were analyzed to achieve an optimal flue gas exhaust temperature of 140°C at reduced steam loads of 20, 23, and 26 TPH. The exhaust flue gas temperature was reduced from 150°C to 140°C by selecting an optimized combination of operating parameters. The flue gas temperature dropped to as low as 133°C, leading to cold-end corrosion in the boiler’s Induced Draft (ID) fans. The flue gas temperature dropped to as low as 133°C, resulting in cold-end corrosion of the boiler Induced Draft (ID) fans. Maintaining the flue gas temperature above 140°C helps prevent the formation of corrosive sulfur compounds, thereby extending the lifespan of the boiler cold-end components.

Keywords

AFBC boiler, Furnace fluidization, Windbox pressure, Steam generation pressure.

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