CFBC Boiler Bed Material
CFBC Boiler Bed Material
CFBC (Circulating Fluidized Bed Combustion) Boiler Bed Material is a specially engineered refractory product essential for stable, efficient operation of CFBC boilers. It forms the “bed” in which fuel is combusted and is designed to support perfect fluidization, high heat transfer, and minimal maintenance in demanding industrial settings
Composition and Properties
- Core Components: High-purity silica (SiO₂, typically 60–70%), moderate alumina (Al₂O₃, about 30–40%), and very low iron (Fe₂O₃ < 1.5–2.5%). Low alkali content (<1% Na₂O + K₂O), free from dust, excessive fines, or oversized particles.
- Physical Form: Sub-angular to rounded granular shape, dense texture, beige or off-white color. Available as granules or powder as per specifications.
- Particle Size: Controlled between 0.85–2.36mm (sometimes as low as 0.6mm or as high as 2.8mm, matching the boiler and fuel requirements).
- Bulk Density: 950–1,100kg/m³ (occasionally up to 1,200kg/m³ depending on supplier and batch).
- Fusion Temperature (Refractoriness): >1,300°C (up to 1,400°C), ensuring resistance to melting or agglomeration at high operational temperatures typical in CFBC.
- Hardness: Ranges from 6.8–7.2 on Mohs scale—highly resistant to abrasion and attrition.
- Moisture: Very low, highly dried, as moisture may compromise fluidization.
- Magnetic Separation: Processed through powerful magnetic separators to eliminate all free iron particles, ensuring chemical stability in the aggressive combustion environment.
Key Benefits & Functions
- Perfect Fluidization: Engineered for accurate particle size and density, ensuring stable and uniform bed movement. Reduces risk of agglomeration, channeling, or poor combustion.
- Thermal and Mechanical Stability: High resistance to thermal shock and abrasion, supporting extended service life, minimizing erosion of boiler tubes, and reducing maintenance needs.
- Clinker and Slag Resistance: Chemical composition is optimized to resist clinker (slag) formation even at demanding temperatures and variable fuel chemistries.
- Enhanced Combustion Efficiency: Ensures uniform heat transfer, stable temperature distribution, and maximum fuel burn efficiency, resulting in improved boiler performance and lower emissions.
- Compatibility: Suitable for diverse fuels—coal, lignite, biomass, petcoke, industrial waste etc. Adaptable to specific system requirements with custom sizing and packaging.
- Eco-friendly: Manufactured to minimize environmental impact, with low replacement rates due to durability.
Applications
- Industries: Used in power generation (thermal plants), cement, chemicals, waste-to-energy, and other industries utilizing CFBC and FBC technology.
- Function: Maintains the operational “bed” in the combustion chamber—where forced air fluidizes the particles, allowing for intense and complete combustion.
Packaging and Supply
- Packaging: Frequently supplied in 40–50kg HDPE or BOPP bags, 1MT jumbo bags, and in bulk for large installations.
- Customization: Suppliers can adjust grain size and chemistry as per customer or boiler OEM requirements.
Key Benefits & Functions
- Perfect Fluidization: The size, purity, and sphericity of particles ensure smooth fluid bed movement, optimal combustion, and heat transfer.
- Thermal & Mechanical Stability: High resistance to abrasion and thermal shock, minimizing bed material loss and boiler tube erosion.
- Clinker Prevention: Chemically engineered to minimize slagging or clinker formation, ensuring consistent boiler operation.
- Extended Bed Life: Low impurity levels and calibrated hardness lead to longer intervals between material replacement.
- Fuel Flexibility: Successfully supports combustion of coal, lignite, biomass, petcoke, and various industrial wastes.
Typical Grade & Pricing (India, 2025)
|
Grade/Spec
|
Typical Value
|
|---|---|
|
Bulk Density
|
950–1,100kg/m³
|
|
Particle Size
|
0.85–2.36mm (customizable)
|
|
Fusion Temp
|
>1,300°C (up to 1,400°C)
|
|
Fe₂O₃
|
≤1.5–2.5%
|
|
Packaging
|
40–50kg/1MT bag, bulk
|
|
Cost
|
₹1,500–₹5,500/tonne
|
|
Brand Examples
|
GLM, Shine, Jainco
|
Summary Table: CFBC Boiler Bed Material Properties
|
Grade/Spec
|
Typical Value
|
|---|---|
|
Composition
|
SiO₂ 60–70%, Al₂O₃ 30–40%, Low Fe₂O₃
|
|
Particle Size
|
0.85–2.36mm
|
|
Bulk Density
|
950–1,100kg/m³
|
|
Fusion Temp
|
>1,300°C (up to 1,400°C)
|
|
Form
|
Granular, sub-angular/rounded
|
|
Resistance
|
Thermal shock, abrasion, chemical
|
|
Packaging
|
40–50kg bags, 1MT jumbo, bulk
|
|
Price (India)
|
₹1,500–₹5,500/tonne
|
Essential Facts
- Quality and specification matching are critical: the wrong grade can cause poor fluidization, bed agglomeration, excessive tube wear, or efficiency loss.
- Manufactured to conform to OEM, BHEL, ASTM, or BS standards, often with batch-wise quality test certificates.
Summary
CFBC boiler bed material is a heat-resistant, chemically pure, and physically engineered aggregate—mainly silica and alumina—available in tightly controlled sizes and grades. It is indispensable for smooth, efficient, and safe operation of CFBC boilers, contributing directly to fuel efficiency, maintenance reduction, and reliable energy production