Fluidized Bed Combustion of Biomass and Waste-derived Fuels Current Status and Challenges

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1 Waste-To-Energy Research and Technology Council, WTERT 2005 Fall Meeting at Columbia University New York City, October 20-21, 2005 Fluidized Bed Combustion of Biomass and Waste-derived Fuels Current Status and Challenges Mikko Hupa Åbo Akademi University Turku, Finland

2 Åbo Akademi University Turku FINLAND

3 Åbo Akademi University Process Chemistry Centre - Combustion chemistry - Wood and paper making chemistry - Sensors and process analysis - Kinetics and catalysis 20 faculty and post docs 35 ongoing PhD Theses Intense collaboration with industry

4 Fluidized Bed Combustion of Biomass and Waste-derived Fuels Current Status and Challenges Introduction Status of the FBC technology Current research Fluidized bed gasification Conclusions

5 Bubbling Fluidized Bed Combustion Flue Gas + Fly Ash Fuel: Fresh, Partly Pyrolysed, Char Air Fuel Air Bed material: Quartz, Limestone; fresh, calcined, sulphated Void Space Ash

6 Circulating Fluidized Bed Combustion Cyclone Air Fuel Air Flue Gas + Fly Ash Fuel: Fresh, Partly Pyrolysed, Char Limestone: Fresh, Calcined, Sulphated Void Space Ash

7 Fluidized Bed Combustion Systems BFBC: Bubbling Fluidized Bed Boilers - fluidization velocity 1-3 m/s - reactive fuels (wood and biomasses) CFBC: Circulating Fluidized Bed Boilers - fluidization velocity 6-10 m/s - less reactive fuels (coal, oil shale, petroleum coke)

8 Fluidized bed boilers common features + low combustion temperature + flexible to fuel quality and variations + high combustion efficiency + low NO + easy SO2 reduction - ash components may cause bed sintering - residual ash may be difficult to dispose

9 Commercial status

10 Cumulative number Number of FB devices worldwide (2004) CFBC BFBC PFBC FBG Year

11 Cumul. capacity [MW th] Capacity of FB devices worldwide (2004) CFBC BFBC PFBC FBG by year

12 Steam drum Superheaters and reheaters Boiler tubes Fuel feed Air feed Furnace Cyclone Economizers Ash hoppers LUVO

13 Alholmen CFBC Jakobstad, Finland 550 MW (545 C) Peat, Bark, REF, Forest Residue, Sawdust, Coal, Oil Boiler Efficiency 92 % NO x SO 2 Particulate 50 mg/mj 100 mg/mj 30 mg/m 3 n Kvaerner Power Oy

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16 Mälarenergi AB, Västerås 157 MWth 170 bar 540 C wood residues peat coal Foster Wheeler 2002

17 Capacity [MW th] Thermal Power (MWth) of the CFBCs Worldwide Capacity of CFBCs worldwide (2005) Poludniowy Koncern Energet yczny (PKE) Poland Gardanne France Robert son Texas-New Mexico Duisburg I Germany Year

18 Boilers in by Chinese Companies Zhongyang Luo, Kefa Zen (2005) 150 MW th range: 50+ units operating 300 MW th range: 10 operating + 10 under construction 400 MW th + range: 100 units commisioned/under constr.

19 Cumul. capacity [MW th] Capacity of FB devices worldwide (2004) CFBC BFBC PFBC FBG by year

20 Cumul. capacity [MW th] Capacity of FB devices worldwide (2004) CFBC BFBC PFBC FBG by year

21 Cumul. capacity [MW th] Capacity of FB devices worldwide (2004) China CFBC BFBC PFBC FBG CFBC in China by Chinese companies (estimate) by year

22 Fuels

23 Biofuels Waste derived fuels Opportunity fuels for FBC? Forest residues Annual crops Prunings Shells, husks & hulls Olive stones RDF (refuse derived fuels) Waste sludges MBM (meat and bone meal) Chicken litter Coal Slurry Pet coke Åbo Akademi Fuel Data Bank

24 Biofuels Waste derived fuels Opportunity fuels for FBC? Forest residues Annual crops Prunings Shells, husks & hulls Olive stones RDF (refuse derived fuels) Waste sludges MBM (meat and bone meal) Chicken litter Coal Slurry Pet coke Emissions Bed sintering Fouling & corrosion Fuel Mixtures! Åbo Akademi Fuel Data Bank

25 Emissions

26 Flue Gas Emission Components 100 % 0 CO 2 Carbon Dioxide 1 % CO Carbon Monoxide / C x H y Hydrocarbons 100 ppm -5 SO 2 Sulfur Dioxide / NO x Nitrgen Oxides 1 ppm PAH Polyaromatic Hydrocarbons 1 ppb (µg/kg) -10 As, Cr, Ni, V, Pb, Cd, Hg,... Heavy Metals 1 ng/kg Dioxins, Furans 1 pg/kg -15

27 Flue Gas Emission Components 100 % 0 CO 2 Carbon Dioxide 1 % CO Carbon Monoxide / C x H y Hydrocarbons 100 ppm -5 SO 2 Sulfur Dioxide / NO x Nitrgen Oxides 1 ppm PAH Polyaromatic Hydrocarbons 1 ppb (µg/kg) -10 As, Cr, Ni, V, Pb, Cd, Hg,... Heavy Metals Aerosol 1 ng/kg Dioxins, Furans Particles 1 pg/kg -15

28 EU Directive on Incineration of Waste Containing Fuels Acidic Gases HCl 10 mg/m 3 n (on-line) HF 1.0 mg/m 3 n (on-line) SO 2 50 mg/m 3 n (on-line) NO x 200 mg/m 3 n (on-line) Dust 10 mg/m3n (on-line) Metals, EDD Hg 0.05 mg/m3n (twice a year) Cd+Tl 0.05 mg/m3n (twice a year) Sb+As+Co+Cr+ Cu+Pb+Mn+Ni+V 0.5 mg/m3n (twice a year) (0.05 mg/m3n in flue gases 0,4 mg/kg dry fuel) Dioxins and furans 0.1 ng/m 3 n (measurement twice a year)

29 Recovered Wood Fuel Metal Contents (ppmw = mg metal/kg fuel) heavy metals ppmw corrected value Rest fraction, analysed Leached in HCl Leached in Acetate Leached in H2O Untreated Fuel 200 mg/kg fuel As Cd Co Cr Cu Hg Mn Ni Pb Sb Tl V Zn As Cd Co Cr Cu Hg Mn Ni Pb Sb Tl V Zn

30 Fouling and corrosion

31 BFBC for Biomass Fuels Rice husk Eucalyptus bark

32 700 Steam temperature for BFBCs worldwide (2005) Temperature [ C] Year

33 Ash Elements in Spruce Tissues (J. Werkelin 2005)

34 Five Spruce Tissues Wood Bark Twigs Needles Shoots

35 Ash Elements in Spruce Tissues (J. Werkelin 2005)

36 Corrosion Test by Alkali Salts Before heat treatment After heat treatment Prepared for SEM

37 Corosion Analysis by SEM

38 Corrosion due to Alkali Salts Steel: A Time: 168 h (Skrifvars et al. 2005) 140 Corrosion layer thickness m Salt 10 Salt 9 Salt 8 Salt 7 Salt C Salt C525 C Salt C 575 C600 C

39 Corrosion due to Alkali Salts Steel: B Time: 168 h (Skrifvars et al. 2005) Corrosion layer thikcness m C 500 C525 C550 C 575 C 600 C Salt 10 Salt 9 Salt 8 Salt 7 Salt 6 Salt 5 Salt 0

40 Corrosion due to Alkali Salts Steel: C Time: 168 h Corrosion layer thickness μm C 500 C 525 C550 C 575 C 600 C Salt 10 Salt 9 Salt 8 Salt 7 Salt 6 Salt 5 Salt 0 (Skrifvars et al. 2005)

41 Gasification

42 CFB Gasifier REACTOR UNIFLOW CYCLONE 850 C GASIFICATION AIR FAN FUEL FEED 900 C RETURN LEG AIR PREHEATER COOLING WATER HOT LOW CALORIFIC GAS ( C) Foster Wheeler BOTTOM ASH COOLING SCREW WTERT 2005 Fall Meeting at Columbia BOTTOM University, ASH October 20, 2005

43 BIOMASS GASIFICATION - COAL BOILER - LAHTI PROJECT 350 MW 540 蚓 /170 bar Biomass 300 GWh/a -15 % fuel input CO 2 Reduction - 10 % Processing 50 MW Pulverized coal flames Power * 600 GWh/a District Heat * 1000 GWh/a Gasifier Gas flame Bottom ash Coal Natural Gas 1050 GWh/a -50 % 650 GWh/a -35 % Fly ash Foster Wheeler

44 Conclusions (i) FBC rapidly expanding now especially in China CFBC - upto 1000 MWth - novel cyclones and superheaters BFBC - interesting for reactive fuels

45 Conclusions (ii) PFBC well demonstrated in 800 MWth class FB gasifiers promising for producing gas to cofiring

46 Conclusions (iii) Waste derived fuels great potential for FBC Challenge to boiler manufacturers & operators: Emission control (heavy metals) Bed sintering and fouling control Corrosion control Multifuel firing and fuel interaction

47 Aknowledgements B. Leckner, L-E. Åmand (Chalmers), H. Tran (Toronto) C. Mueller, R. Backman, B-J. Skrifvars, M. Zevenhoven, P. Yrjas, S. Kallio, P. Kilpinen, J. Konttinen, M. Theis, J. Werkelin (Åbo) Kvaerner Power, Foster-Wheeler, Vattenfall, Metsä-Botnia, Andritz, International Paper Tekes, Academy of Finland

48

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