Welcome to Biomass Heating Systems Presented by Andreas Wintzer. Viessmann Werke
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1 Welcome to Biomass Heating Systems Presented by Andreas Wintzer
2 Biomass Heating Systems 1. Wood fundamentals 2. Boiler 3. Extraction systems 4. System Design 5. Emissions
3 What is CO 2 neutral? Burning wood releases the same amount of CO 2 as it absorbed for it s growth and as it would release if it would be left to rot.
4 Biomass supports regional sustainability Biomass fuel is usually harvested in close proximity to the boiler plants Biomass fuel is a new value stream for the struggling forest industry - creates jobs Money spent on wood fuel is a direct investment into the local economy
5 How is burning wood sustainable? A mixed hard and softwood forest can produce approximately 1.5 to 2.5 tons of wood chips per acre/year Regional foresters have usually road cuttings and trees where they bring it to landfill and pay for it can be used as fuel
6 Useable Fuels Viessmann offers biomass boilers for most woody biomass Forest wood and plantation wood: Mature wood from trunks and branches, untreated and chopped Compressed wood, pellets: untreated wood with limited bark content, compressed by machine Remnants from derived timber products: Usually a mixture of untreated and treated wood in form of shavings, chips, sawdust Used wood: Essentially untreated wood that has been used prior to its energetic utilization (e.g. pallets)
7 Fuels Wood Chips water content with air dry material Water content in % January December January December
8 Wood Pellets Wood Pellets are small size briquettes which are usually sold in bags or in bulk per ton. The used raw material is usually dry wood waste from sawmills, wood manufacturing plants etc. Wood pellets are produced without any additives such as binders and glues. The untreated natural wood waste is compressed under high pressure and temperature.
9 Pellet Quality Good quality pellets: smooth surface low dust content uniform size sink in water Bad quality pellets: rough surface high dust content high variety in size swim in water
10 Bolewood Chips Advantages Quality/cost compromise between whole tree & mill residue chips Disadvantages More bark/dirt (ash) than mill residue chips Foil 10
11 Whole Tree Chips Advantages Cost of material Disadvantages Quality/size inconsistency Bark/dirt (ash) Corrosive gasses from leaves/needles Foil 11
12 Foil 12 Mill Residue Chips Best quality, highest price.
13 Pellet usage per hour Pellet with 7900 BTU/lb With 150 KW x 3412 BTU / KW = BTU BTU / 7900 BTU / lb = 64.8 lb or 29.5 kg Storage facility mostly looked at 5-7 days 29.5 kg x 24 h x 7 days = 4956 Kg needed for 100% load 7 days Foil 13
14 Wood chip usage per hour Wood chips with 30% and 5946 BTU/lb 150 KW x 3412 BTU / KW = BTU BTU / 5946 BTU / lb = 86.0 lb or 39 kg Storage facility mostly looked at 5-7 days 39 kg x 24 h x 7 days = 6552 Kg needed for 100% load 7 days Wood chips with 50% and 4247 BTU/lb 55 Kg x 24 h x 7 days = 9240 kg needed for 100% load 7 days Foil 14
15 Ash Content Wood Fuels Energy Source Ash Content % by Weight Ash Sintering Point in C ( F) Wood Chips (2170) Wood Chips with adherent bark (2189) Bark (2215) Shavings Ca (2192) Quality Pellets 0.5 Ca (2192) Debris Wood Wheat Straw (1828) Miscanthus (1582) Barley Straw (1328) Wheat (1224)
16 Fuel Quality What is clinker? If ash is heated above it s sintering (softening) point it changes the state of aggregation and turns doughy or viscous When cooled turns solid again and sticks to refractory and grate elements Foil 16
17 Fuel Quality Water does not burn! Wet fuels decrease efficiency Wet fuels need heavy duty extraction systems Wet fuels need substantially bigger storage facilities Wet fuels need more expensive heating equipment The more Ash the more cleaning is necessary The lower the sinter point the more problems with clinker
18 Conclusion Fuel The fuel quality determines the heat value, the efficiency, the amount of ash (cleaning and maintenance) and the life expectancy of the boiler To make it easy Bad fuel bad performance Good fuel good performance Foil 18
19 Biomass Heating Systems 2. Boiler
20 Rotary Combustion Boiler 500 MBH to 1,800 MBH (150kW- 540kW) Possible Fuels: Wood briquettes Off Cuts Wood Chips Wood Pellets For dry wood fuels with a water content < 35%.
21 Rotary Combustion Boiler Construction features Rotation Blower Swirl combustion zone 3-pass chamber Exhaust blower Flue gases Secondary air intake De-Ashing Auger FlueGas Recirculation system Low Lying Ash Pan Primary air intake Fuel Auger supply
22 Rotary Combustion Boiler Fuel supply and combustion zone Primary air dampers Continous feed auger Fuel Bed
23 Rotary Combustion Boiler Combustion chamber with air barrier
24 Rotary Combustion Boiler Fully automatic de-ashing system
25 Rotary Combustion Boiler Fully automatic de-ashing system
26 Underfeed Combustion Boiler 1,300 MBH to 4,300 MBH (390 to 1250 kw) Wood Fuels with a moisture content of <50%
27 Underfeed Combustion Boiler Fuel supply Fuel Supply
28 Underfeed Combustion Boiler Fuel supply and ignition Automatic ignition device Ignites fuel up to 45% moisture content Idle mode available Fire trough with inner grate Even allocation of primary air to the entire fire bed Pre dries the fuel
29 Underfeed Combustion Boiler Fuel grates Fuel grates
30 Underfeed Combustion Boiler Fuel grates Stationary combustion grate Evenly allocates the fuel coming from the trough to degasify the fuel. Moving annealing grate Very slow movements ensures complete release of carbon and hydrogen in the fuel with Low lying ash pan with de-ashing auger
31 Underfeed Combustion Boiler 3-pass heat exchanger High temperature zone With injection of secondary air the woodgas is combusted completely. The optimum amount of secondary air ensures low CO emissions and low stack temperatures
32 Conclusion Boiler Two different types Pyrot : MBTU with max Water content of 35% and Ash content of max 1.5% Pyrotec: MBTU with max Water content of 50% and Ash content of max 3% Foil 32
33 Biomass Heating Systems 3. Extraction system
34 Fuel Transport Spring Operated Extraction System (AF) This extraction system is suitable for square and round fuel bunkers. As long as the silo is full the spring arms are closely attached to the centre plate. The spring extraction system can be mounted perpendicular to the silo floor or on an angle up to 15 degrees.
35 Horizontal Extraction System (AH) The two sweeping arm consist of either one or two (depending on extraction diameter) joint arm(s) and a spring steel extension which is positioned at the outside of the arms. The stirring device is being engaged in depency of the filling level of the extraction system (controlled by optical sensor). The extraction auger itself is engaged by its own drive unit which works independently of the stirring device.
36 Horizontal Extraction System (AH)
37 Walking Floor Extraction System (AS)
38 Drive on Walking Floor NESEA Conference Presentation: Central Plant Energy Sources Part 3 Foil 38
39 Extraction Auger for Pellets (AE-L)
40 Fuel Transport Trough Conveyor Augers
41 Infeed Auger With Slide Gate
42 Conclusion Extraction system Almost everything is possible but should always be in shortest distance to the boiler Fuel needs to be transported to the boiler and there are multiple solutions Foil 42
43 Biomass Heating Systems 4. System Design
44 System Design Heating circuits Biomass boiler Fossil fuel boiler Thermal storage tank
45 Short Amortization Period Low initial investment DO NOT OVERSIZE THE BOILER Use large storage tanks to cut peaks Recommended 10 litre storage volume per 1 kw of burner output (1 Litre per 340 BTU boiler output) Simple plant design Small number of boilers Short distances from silo to boiler room
46 Use of accumulator tanks Biomass boilers take longer to adjust output to heat demands Igniting wood takes longer than igniting gas or oil Once a pile of wood chips burn you can not simply you can not simply turn the fire off The use of a hot water storage tank Boosts heat availability Covers brief peak demand requirements Absorbs excess heat when boiler shuts of for later use Creates a clear separation of the heat generation and heat dissipation Allows optimal connection of other means of heating (solar and redundancy boilers
47 System Design Design Fuel Bunker - Sizing Dimension of fuel storage is determined by Yearly Fuel Requirement Supply Situation Truck load capacity The Fuel Storage should hold a multiple of truck loads in order to keep applicable delivery charges as low as possible. A capacity for 5-7 days of operation is sufficient and will most likely be the most cost effective solution.
48 System Design
49 System Design Sizing Possibilities for bivalent heating systems Option 1: Wood Boiler covers 100% of heat load Typical full output operational hours Use of proper sized storage tank to downsize boiler Year around operation usually not viable if only space heating and domestic hot water required Boiler is operated at lowest possible output level (just to match heat demand requirements) During summer operation the boiler is operated via on/off (automatic ignition dramatically increases overall efficiency)
50 System Design Sizing Possibilities for bivalent heating systems Option 2: Wood Boiler should cover 70-85% of heat load Sizing of the biomass boiler to output operational hrs Use of proper sized storage tank to downsize boiler Year around operation economical viable if heat demand matches 12 hrs on minimal boiler output Boiler is operated at lowest possible output level (just to match heat demand requirements) During summer operation the boiler is operated via on/off (automatic ignition dramatically increases overall efficiency)
51 Biomass systems are extremely safe Backflash safeguard Burnback preventer Burnback safeguard Water tank Automatic fire-extinguishing system (water reservoir) Safety heat exchanger CSA certified control systems ASME certified Pressure vessel Fuel supply auger
52 Scope Of Supply Viessmann Biomass boiler with Fuel transport systems and security equipment CSA approved ASME construction with 30 / 60 psi Control panel for Biomass system with integration of communication to BMS system possible. Control panel with controlling backup boiler possible ( LON / dry contact ) Mixing valve and pump for the Biomass boiler as protection of return temperature Delivery to job site Start up required to be purchased from VI / exception Fink Maschine
53 Conclusion System Design Biomass boiler need to be sized correct for application and never oversized Integration of Backup boiler with communication to BAS system possible Boiler plant preferred to be operated by Viessmann with Master control Foil 53
54 Biomass Heating Systems 5. Emission
55 Types of emissions Compounds from imperfect oxidation Carbon Monoxide Hydrocarbons Sulphur (S), and Chlorine (Cl). Nitrogen Oxides are formed out of the nitrogen (N) content in the fuel Natural wood contains little nitrogen compared to agricultural fuels (straw, miscanthus, corn etc.) All those compounds are highly toxic
56 Types of emissions perfect oxidation Seperation of oxidation and gasification phase Lower grate with primary air ratio below 0.6 low temperatures on grate (<1700 F) prevent minerals to condensate. Oxygen deprived environment inhibits the formation of NOx. Particulate matter emissions and NOx can be cut by 50% according analysis by Verenum Switzerland, Phd Nussbaumer
57 Types of emissions perfect oxidation Secondary air creating turbulence and Lamba 1.5 with injection trough air flaps ( Pyrot ) Blower motor ( Pyrotec ) The extensive intermixture of the pyrolisis gas with oxygen results in a perfect burnout in gas burner quality The result are significantly higher efficiencies combined with very low emissions of CO andσ HC according analysis by the University of Stuttgart, Phd Baumbach 2002
58 Emission control Operation boiler with VFD blowers (Pyrotec). VFD Blowers + automatic air flaps (Pyrot). Control system modulates the burner between 30% 100%. Why not 1%-100%? At 10% modulation the flame is between amber bed and open flame. The Air ratio is at 2.62 and we have very high emission levels. We cannot guarantee the efficient burning process that we want to achieve.
59 Emission control High Annual Efficiency Requirements High boiler efficiency low air ratio λ < 2 low exhaust gas temperatures < 150ºC (300ºF) max 200 Primary secondary air flow control needed O2 Sensor required for constant prove of burning process
60 Emission Control Requirements Particulate matter has become increasingly a focus point in local, provincial/state and federal jurisdictions Particulate matter is a weakness of solid fuels Trend Particulate matter emissions are currently evaluated and will be restricted Pyrot and Pyrotec can stay below 90mg/m3 without secondary equipment Nox, CO, Hydrocarbons are produced but not controlled as of now Viable filtration systems will be necessary in some jurisdictions
61 Emission Control Technology Flue gas cyclone Filters out large particles Captures sparks Typically used on larger woodchip boilers Does not take out the small particles
62 Emission Control Technology Bag House Filters Exhaust gas is cleaned via filter bags The accumulated dust is cleaned off pneumatically, or by a shaker Low in initial cost Filter bags are not spark resistant Problems if operated under dew point (start up phase) Comparably large foot print Very high maintenance cost (filter bag exchanges)
63 Emission Control Technology Electrostatic participator Proven technology with wood boilers High availability Low remaining particle content (20mg/m3) Very high in initial cost Cost prohibitive for small boilers >500kW Comparably big foot print
64 Emission Control Technology Metal mesh particle filter Viessmann design Technology developed specially for wood boilers Not affected by moisture Low remaining particle content (20mg/m3) Very low maintenance cost Low energy use Small footprint Reasonable cost
65 Conclusion Emission Viessmann boiler stay below 90mg/m3 in particulate matter without secondary equipment If we need lower emissions we have in house options for Pyrot and external solutions for Pyrotec Foil 65
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