BIOMASS and WASTE to ENERY

Transcription

1 Power Stations Boiler Plants Hot Gas Generators Firing Systems Heat Recovery Service Customised Casting BIOMASS and WASTE to ENERY Overview of some critical technological issues RICHARD KABLITZ GMBH Intelligent technologies for energy recovery Speaker: Roman Koeppl, Export Manager Monday, March 26,

2 Agenda I. Introduction II. Critical technical issues to consider III. Examples Monday, March 26,

3 About R. Kablitz was founded in 1901 For > 100 years Kablitz builds moving grates for multi-fuel combustion and cast plate heat exchangers, all produced in its own foundry For > 25 years Kablitz builds complete plants worldwide as subsupplier or general contractor Kablitz builds steam boiler plants, thermal oil heaters, hot gas generators and power and CHP plants or combinations thereof Monday, March 26,

4 Why Waste to Energy? DON T WASTE THE WASTE Reduction of dependency on fossil fuels In UK much waste still is dumped in landfills or exported to EU Landfills are not eco-friendly and a waste of resources, waste slowly degrades and pollutes the environment Waste hierarchy in the policies: 1. Prevent waste 2. Re-use / re-cycle -> Sorting required 3. Waste to Energy 4. Landfill is only a last option Monday, March 26,

5 Fuels Fresh and Waste Wood 1. Fuels Natural, untreated Wood, Bark, Landscaping Wood, Wood Chips Industrial Wood, Waste Wood (AI - AIV) Wood Granulate, Saw Dust and Fibres Monday, March 26,

6 Fuels - Agricultural Waste Rice Husks, Olive Stones or Pomace, Peach Kernels, Sunflower Seed Husks, Nut Shells, Coffee Grounds, Sansa Farm wastes (Cow manure, chicken litter,...) Empty Fruit Bunches (EFB), Palm Shells and Kernels (PKS), Bagasse, Straw Monday, March 26,

7 Fuels - Waste and Coal Solid Sorted Waste, RDF/SRF/Fluff Paper Mill Wastes (Pulp, Rejects,...) Coal Monday, March 26,

8 Steam Turbine (MAN) Hot Water & Steam Hot Gas (Dieffenbacher) Thermal Oil Heater & ORC (Turboden) Monday, March 26,

9 Typical Flow Sheet of a W2E Plant Fuel bunker and preparation Furnace & Boiler Flue gas treatment Feed water system Turbine-Gen-Set Heat plant Monday, March 26,

10 Agenda I. Introduction II. Critical technical issues to consider III. Examples Monday, March 26,

11 Know your Fuel Especially when dealing with the various waste fuels the plant suppliers need a full fuel analysis: Characteristics Moisture Calorific value Ash content Ash melting temperature Chlorine [Cl] Nitrogen [N] Sulphur [S] Potassium [K] Sodium [Na] Heavy metals Influences Suitability for storage, plant design, self ignition danger Plant design, fuel usage Dust emissions, firing technology Availability, Safety, firing technology HCl-, Dioxine, Furane, High temperature chlorine corrosion NOx-, N 2 O Emissions SOx-Emissions, Acid dew point corrosion Corrosion (Superheater), decrease of the ash melting point Corrosion (Superheater), decrease of the ash melting point Emissions, Corrosion Always remember: you do not know what kind of fuel you have in 10 or 15 years! Monday, March 26,

12 Multifuel Combustion: It is possible to combine different combstion systems in a plant: Grate: wood chips, RDF and other large fuel parts Dust / granulate burner: fine particles < 3 mm Auxiliary burners: light oil or natural gas LA Monday, March 26,

13 Multi-stage Combustion for Multi-fuels Kablitz multi-stage combustion design allows operators to adjust the plant to a large variety of fuels Recirculation Flue Gas Combustion air Monday, March 26,

14 Combustion Diagram: Make sure that even with the worst fuel you can get full power Monday, March 26,

15 > 2 s 2 Seconds Rule -> valid for combustion of waste - Flue gas temperature in boiler after last air injection must be > 850 C for more than 2 seconds - When T < 850 C only oil/gas burners may operate (usually only during startup and shutdown) >850 C Last air injection, begin of retention time measurement ~980 C Monday, March 26,

16 SNCR If there is alot of Nitrogen in the fuel, NOx will be emitted -> SNCR If the flue gas temperature is too high, the NH 3 radicals from the urea build NOx If the flue gas temperature is too low, the NH3 radicals don t react and the NH3 gets emitted as ammonia slip Mehldau & Steinfath Monday, March 26,

17 Corrosion: Acid dew point corrosion Caused by much water and Sulfur in the fuel Solution: High feed water temperature High temperature chlorine corrosion Convection heating surfaces High level of Chlorine in fuel Solution: reduce flue gas temperatures before superheaters Low steam parameters Cladding Monday, March 26,

18 High temperature Corrosion Cl - Corrosion Diagram: Always consider the corrosion diagram Keep superheaters out of the corrosion areas Monday, March 26,

19 Flue Gas Treatment Everything depends on the fuel Biomass, waste wood AI/II: -> Usually only dust removal required -> Centrifugal separators, ESP, baghouse filter Waste wood AIII/IV, RDF: Flue gas treatment must be compliant to Waste Incineration Directive (WID) / 17. BImSchV Regulation (Germany), that means reactors, additive and activated carbon injection, bag-house filter, in future also catalysts -> high invest costs, impact on total invest is less in larger plants Important: Often additionally local regulations apply! Monday, March 26,

20 Refractory material Insist on a suitable refractory material. Here: Refractory consisting of special SiC-plates for waste-to-energy plants. (example: Wiesbaden) Monday, March 26,

21 Characteristics: Characteristics of membrane wall boilers: - up to 150 t/h live steam power - up to 110 bars - up to 510 C Characteristics of smoke tube boilers: - up to ca. 25 MW boiler output - up to 38 bars and 455 C - compact design - suitable for superheated steam, saturated steam and hot water generation Monday, March 26,

22 Steam Boilers: Recomended boiler for Waste to Energy: Main Advantage of horizontal boiler design: Very maintenance friendly, easy access to heating surfaces Horizontal boiler for Waste to Energy (tail end boiler) Monday, March 26,

23 Thermal Oil Heaters: Thermal oil heaters with meander convection part Characteristics: - up to 50 MW thermal power - up to 20 bars - up to approx. 400 C oil temperature - Critical with waste fuel -> risk of high-temperature corrosion! Thermal oil heaters in membrane wall design, suitable for low quality fuel Monday, March 26,

24 Things you shouldn t miss: - Boiler island should have 10-15% reserves in its design to be able to supply full power in any case - Choose a furnace that is flexible in regards of fuels, that can accept a sufficiently large variation in water-content, LHV, grain size, metals and inert material in the fuel - In case of power plant: part load characteristics (down to which part load will you get full live steam temperature?) - Flue gas velocity in the boiler -> less velocity -> less erosion Monday, March 26,

25 Summary: - Know your fuel, make analysis - Multi-fuel furnace - Always be aware of the corrosion problem - Use recirculation gas to control the combustion - Choose the right boiler design Monday, March 26,

26 Agenda: I. Introduction II. Critical technical issues to consider III. Examples Monday, March 26,

27 Examples: Reference Project: Chilton, UK Location: Fuel: Fuel Bandwidth: Installed Combustion Capacity: Electric Power: Live Steam Mass Flow: Live Steam Pressure: Live Steam Temperature: Feed Water Temperature: Combustion Air Preheating: Year of Commissioning: United Kingdom Wood Chips 4,4 4,8 kwh/kg Reciprocating Grate: 53,6 MW 17,6 MW 67,0 t/h 86 bar(a) 495 C 190 C 150 C 2012 Monday, March 26,

28 Examples: Monday, March 26,

29 Waste-to-Energy steam boilers Project: Location: Electrical output: Heat output: Steam mass flow: Steam pressure: Wiesbaden Germany 10,0 MW 24,0 MW 49 t/h 42 bar(a) Steam temperature: 425 C Installed combustion capacity: Fuel: Year of commissioning: Reciprocating grate: 38,4 MW Wood waste grade 1 to Monday, March 26,

30 Waste Steam Boiler Plants Water Tube Boilers Reference Project: Buchen Location: Germany Monday, March 26, Fuel: Fuel Bandwidth: Installed Combustion Capacity: Electric Power: Live Steam Mass Flow: Live Steam Pressure: Live Steam Temperature: Feed Water Temperature: Year of Commissioning: Waste Wood AI AIV 17. BImSchV 1,8 4,5 kwh/kg Reciprocating Grate: 27 MW, Auxiliary Burner: 12 MW 7,1 MW 30 t/h 66 bar(a) 425 C 105 C 2003

31 Power Stations Boiler Plants Hot Gas Generators Firing Systems Heat Recovery Service Customised Casting Thank You RICHARD KABLITZ GMBH Intelligent technologies for energy recovery Bahnhofstr , Lauda-Königshofen Germany Tel: +49 (9343) Fax: Monday, March 26,

32 Biomass steam boilers Vertical water tube steam boiler Project: Location: Electrical output: Heat output: Steam mass flow: Steam pressure: Pemuco Chile 12,1 MW 60 t/h at 1,2 bar(g) 60 t/h 76 bar(a) Steam temperature: 485 C Installed combustion capacity: Fuel: Year of commissioning: Reciprocating grate: 55,0 MW Forest residues, eucalyptus bark, coal 2014 Monday, March 26,

33 Biomass Thermal Oil Heater Plants Thermal Oil Heaters Reference Project: Menznau Location: Fuel: Fuel Bandwidth: Installed Combustion Capacity: Thermal Oil Output: Thermal Oil Temperature: Switzerland Wood Chips, Production Wood, 2,7 4,0 kwh/kg Reciprocating Grate: 40 MW Granulate: 12 MW Dust: 25 MW Design: 57 MW 25 MW 285 C / 255 C Hot Gas: 30 MW / 350 C Year of Commissioning: 2009 Monday, March 26,

34 Hot Gas Generators Reference Project: Sanem Location: Fuel: Fuel Bandwidth: Installed Combustion Capacity: Luxembourg Bark, Production Wood (MDF), Saw Dust, Shavings 2,6-3,5 kwh/kg Reciprocating Grate: 15 MW, Granulate Burner: 3 x 5 = 15 MW Hot Gas: 25 MW / 350 C Year of Commissioning: 2010 Monday, March 26,

35 Biomass CHP and Energy Centers Steam Turbine Power Plants Reference Project: Rosenheim Location: Fuel: Installed Combustion Capacity: Electric Power: Live Steam Mass Stream: Live Steam Pressure: Germany Waste wood, Industrial wood Reciprocating grate: 20 MW Dust/Granulate burner: 3 x 5 = 15 MW 6,0 MW 30 t/h 66 bar(a) Feed Water Temperature: 107 C Year of Commissioning: 2001 Monday, March 26,

36 Biomass CHP and Energy Centers Steam Turbine Power Plants Reference Project: Goch Location: Germany Monday, March 26, Fuel: Fuel Bandwidth: Installed Combustion Capacity: Electric Power: Live Steam mass flow: Live Steam Pressure: Wood Chips, Landscaping Wood 1,5-3,2 kwh/kg Reciprocating Grate: 28 MW 5,0 7,2 MW 30 t/h 65 bar(a) Live Steam Temp.: 480 C Year of Commissioning: 2012

37 Biomass CHP and Energy Centers ORC Power Plants Reference Project: Aschaffenburg Location: Fuel: Fuel Bandwidth: Installed Combustion Capacity: Electric Power: Heat Output: Thermal Oil Output: Year of Commissioning: Germany Wood Chips, Landscaping Wood 1,7-3,5 kwh/kg Reciprocating Grate: 11,7 MW 1,1 MW 8,0 MW 9,4 MW 2009 Monday, March 26,

38 Examples: Reference Project: Rosières en Santerre Monday, March 26, 2018 Location: Fuel: Fuel Bandwidth: Installed Combustion Capacity: Heat Output: Saturated Steam mass flow: Saturated Steam Pressure: Saturated Steam Temperature: Feed Water Temperature: Year of Commissioning: France Wood Chips 1,9-3,1 kwh/kg Reciprocating Grate: 19,9 MW 18 MW 28 t/h 18 bar(a) 207 C 105 C

39 Biomass CHP and Energy Centers Steam boiler: Domat/Ems Block 3, CH Monday, March 26,

40 Biomass CHP and Energy Centers Thermal oil boiler: Tomsk, RU Monday, March 26,

41 Biomass CHP and Energy Centers Thermal oil heater and hot gas generator: Genk, BE Grate, Fuel Feeder, Kablitz Turbo System and steel works Monday, March 26,

42 Examples: Four grates are in position Monday, March 26,

43 Examples: Monday, March 26,

44 Examples: Monday, March 26,

45 Examples: Monday, March 26,

46 Examples: Assembly after 4 Months Monday, March 26,