Industrial-scale R&D in Challenging Times

Transcription

1 Industrial-scale R&D in Challenging Times 1

2 Presented by: Ralf Koralewska Contents 1. R&D Topics 2. Grate-based Combustion Technology 3. Energy Concepts 4. Residue Quality 5. Conclusions 2

3 R&D Topics Fuels - Waste treatment / RDF - High calorific fuels - Sewage sludge co-combustion Residue quality - Dry discharge - Residue recovery - SYNCOM-Plus - Fly ash / boiler ash recirculation Flue-gas quality - CO reduction - NO x reduction / VLN - SYNCOM Energy efficiency - Efficiency - Boiler design - Energy concepts - Corrosion Clients wish Sustainability Best available technique No landfills Waste management concepts Environmental compatibility Costs Combustion system - Grate development - Combustion control / MICC - Fuzzy control - Simulations / CFD 3

4 Combustion Technology Typical Lower Heating Values of Untreated MSW in Different Countries P. REP. OF CHINA REP. OF KOREA BRAZIL TAIWAN, R.O.C. REP. OF SINGAPORE JAPAN EUROPE U.S.A. SWITZERLAND GERMANY FRANCE SCANDINAVIA Possible range of application of the MARTIN reverse-acting grate up to 20,000 kj/kg 1,000 3,000 5,000 7,000 9,000 11,000 13,000 15,000 17,000 19,000 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 kj/kg 4

5 Combustion Technology Fuel-bed Temperature Measurements / Modeling IR camera Temperature [ C] 65 x31 x21 x11 x32 x22 x12 x33 x23 x13 x34 x24 x14 x35 x25 x15 Insertable thermocouples Temp FR primary air zones Temperature probes Ball instrument 09/06/2010 NAWTEC 18 5

6 Combustion Technology Industrial-scale RDF Trials 13,000 kj/kg 5,589 BTU/lb 17,000 kj/kg 7,309 BTU/lb 19,000 kj/kg 8,169 BTU/lb 6

7 Combustion Technology RDF Trials Grate Bar Temperature Measurements 70 Temperature [ C] T UFA 54 C 14 C 10 Normal LHV LHV LHV 0 operation 13,000 kj/kg 17,000 kj/kg 19,000 kj/kg 11:30 00:00 12:29 00:59 13:29 01:59 14:29 02:59 15:29 03:59 16:29 04:59 17:29 05:59 Front grate bar Grate step 4 Grate step 8 7

8 Combustion Technology IR Camera Fuel-bed Temperature / Combustion Control 8

9 Combustion Technology MARTIN Infrared Combustion Control Control and Monitoring System Visualization and operation level CMS system bus Automation level External Automation station system bus PID open loop control Basic backup program furnace temperature MARTIN IR IR camera IPC plant bus Fuzzy logic closed loop control master controller for CMS IR camera control Long-term data logging Remote data transmission interface Ready for operating mode concept No direct connection to field I/O MARTIN I/O External plant bus Field 09/06/ NAWTEC 18 9

10 Combustion Technology MICC Fuzzy Control EfW Plant Arnoldstein, A 100% Percentage of measuring points [%] Anzahl der Meßwerte (%) 98% 96% 94% 92% 90% 88% 86% 84% 82% 80% 78% 76% 74% 72% 70% Steam set point 113% <±5% <±8% <±10% >±10% Fuzzy - Betrieb QD 40 t/h Warranty Gew ährleistung Fuzzy Fuzzy PID - Betrieb 07./ Set point deviation of steam output 10

11 Combustion Technology MICC Operating Mode Concept Superordinate operational interests Waste throughput Energy recovery Basic Gross heat release Process steam Steam flow NO x Solid residue quality Solid residue quantity Electricity Heat for district heating Furnace temperature Waste throughput Service period Selection of operating modes according to operator s needs MICC provides switch between different operating modes Adaptation to plant-specific boundary conditions Subsequent adjustment / optimization with minimum effort 11

12 Combustion Technology Very Low NO x Concept NO x referred 11% O 2 12

13 Combustion Technology Very Low NO x Air Schemes VLN?=1.5 λ=1.5 Conventionel?=1.5 λ=1.8 V VLN gas, wet?=1.1 λ=1.2?=1.1 λ=1.8 λ=0.15?=0.1 λ=0.15?=0.1? λ=0.35?=0.1 λ=0.35?=1.3 λ=1.2 V V flue gas, VLN gas, wet boiler end, wet = 20%?=1.3 λ=1.1 V VLN gas, wet 13

14 Combustion Technology / Energy Concepts Modeling / Simulation CFD modeling Boiler / power plant simulation 14

15 Energy Concepts Measures for Major Increases in Energy Efficiency Increased steam parameters - Pressure / temperature of superheated steam Reduced flue gas heat losses - Temperature at boiler outlet - Excess air rate Improved steam condensation conditions - Water instead of air condensers Optimized thermal cycles - Intermediate superheating - External superheating Reduced in-plant consumption - SNCR instead of SCR - Excess air rate 15

16 Energy Concepts References Net electrical efficiency of 17 % Net electrical efficiency of 25 % Sao Paulo 1959 Toulon 1984/1993 Power (40 bar/400 C) Heat Net electrical efficiency of 42 % Combined heat and power overall efficiency > 90 % Brescia 1998/2004 Power (74 bar/480 C) Heat Net electrical efficiency of 30 % Bilbao 2004 Power (100 bar/540 C) Malmö 2003/2008 Power (40 bar/400 C) Heat (flue gas condensation) Amsterdam 1992/2007 Power (135 bar/440 C) Heat 16

17 Residue Quality SYNCOM-Plus Material Flows Bottom ash Sludge Fine fraction < 5 mm Recirculation Granulate > 2 mm Recovery 17

18 Residue Quality SYNCOM-Plus Concept 18

19 Residue Quality SYNCOM-Plus Industrial-scale Pilot Plant EfW Plant Arnoldstein, A Screening machine Decanter centrifuge Dumpers Recirculation of fine fraction / sludge 19

20 Residue Quality Dry Bottom Ash Discharge Concept 20

21 Residue Quality Dry Bottom Ash Discharge Monthey concept EfW Plant Monthey, CH 21

22 Residue Quality Dry Bottom Ash Discharge Pilot Plant / Industrial-scale Components Pilot plant Air separator with hood Cyclone separator / overfire air fan 22

23 Residue Quality Fly Ash Treatment Concept BSH Umweltservice AG, Switzerland 23

24 Residue Quality Fly Ash Treatment Industrial-scale Trials Recirculation of approx. 30 mt treated fly ash per week 24

25 Ideas about Future Waste Management Promote reuse and recycling Avoid landfilling and composting / MBT of MSW Landfill tax 5 bar steam 26% of heat Flue gas ECO 2 4% of heat Condensing scrubber 6% of heat Promote energy efficiency 0.7bar steam G Low tempe 19% of hea Incentives for green electricity and heat e city of heat) Back pressure Condenser 45% of heat District heating medium Absorption heat pump 45% of heat Return from Promote innovation Adapt to local environment Sensible innovation policy MBT = Mechanical-Biological Treatment MSW = (mixed) Municipal Solid Waste (residual waste after recycling) 25

26 Conclusions Sustainability, recycling, resource conservation and global warming are the greatest global challenges facing us, including waste management EfW is an essential component of all modern waste management concepts Further development and optimization of existing EfW technologies and concepts are needed due to international requirements Innovative technologies must first be developed and comprehensively investigated 26

27 Contacts If you have questions or require further information, please feel free to contact us at MARTIN GmbH für Umwelt- und Energietechnik Leopoldstr. 248 D München Tel: Fax: mail@martingmbh.de Internet: 27

28 Thank you for your attention! MARTIN, MARTIN Rückschub and SYNCOM are registered trademarks in selected countries. The MARTIN technologies described in this presentation are protected by numerous patents in many countries. 28