AG Processing Inc.
Hastings, Nebraska

Plant Owner
AG Processing Inc.

Location
Hastings, Nebraska

Contract Order: 2006

Commercial Operation: 2009

B&W Scope

• Coal-fired internal recirculation circulating fluidized-bed (IR-CFB) boiler from outlet of coal bunkers to outlet of tubular air heater including:
• FD fan and motor
• Tubular air heater
• Steam coil air heater
• Multi-cyclone dust collector
• Ash recycle/reinjection system
• Limestone injection system
• Coal feeding system
• Start-up burners
• Refractory lined lower furnace with erosion protection at the Reduced Diameter Zone (RDZ) transition
• Segmented U-beam primary particle collectors with watercooled support system
• Bed drain screw coolers
• Bed drain solids conditioning equipment including a screener and crusher
• Sootblower boiler cleaning system.
• Attemperator and spray water control station
• Flues and ducts
• Ammonia forwarding, control and injection system
• Instrumentation
• Technical advisory services during startup and commissioning

Boiler Specifications

• Boiler type: Internal recirculation CFB design
• Design fuel: Powder River Basin coal
• Startup fuel: Natural gas
• Steam flow: 311,000 lb/h (37.8 kg/s)
• Steam pressure: 150 psig (1034 kPa)
• Steam temperature: 440F (227C)

Environmental Equipment

• Selective non-catalytic reduction (SNCR) NOx emissions control system

Project/Boiler Facts

• Low pressure and temperature steam from the boiler is supplied primarily for soy bean processing.
• The addition of limestone to the circulating bed reduces SO₂ emissions from the boiler.
• Low furnace temperatures, staged combustion and SNCR system limit NOx emissions.
• Unique two-stage solids collection system using U-beams and multi-cyclone dust collector (MDC) provides superior collection efficiency. The recycling of solids collected by the MDC improves combustion efficiency and limestone utilization.
• The U-beam and MDC solids collection system requires significantly less maintenance than hot cyclones.
• A patented RDZ design with silicon carbide tiles at the top edge of the furnace refractory is used to minimize tube erosion at the interface