8 th SGC International Seminar on Gasificaton October 15 th -16 th, 2014 Malmö, Sweden

Transcription

1 8 th SGC International Seminar on Gasificaton October 15 th -16 th, 2014 Malmö, Sweden Commercial Experiences of Waste and Biofuel Gasification - Valmet CFB Gasification Juhani Isaksson, Valmet Power

2 Valmet CFB Gasification Valmet Valmet CFB Gasification Valmet CFB Gasification for Waste Case Lahti Valmet CFB Gasification for biomass Case Vaskiluoto Outlook and Summary

3 Global supplier of services and technologies for the pulp, paper and energy industries. Services Mill and plant improvements Spare parts Maintenance services Life-cycle services Pulp and Energy Technologies and solutions for Pulp production Energy production Biomass conversion Paper Technologies and solutions for Board production Tissue production Paper production Valmet has a turnover of 3 billion and was reborn through the demerger of Metso Group on December 31, December Valmet

4 Valmet CFB Gasification

5 Gasification is a part of combustion Combustion Gasification

6 Valmet CFB gasifier - operating principle 2 Center tube 3 Gas out 5, 5.1 Grid 6 Bottom ash removal 7, 7.1 Gasification air fan, air pre-heat 8 Start burner 9 Fuel day silo 10 Bed material silo 11 Circulating bed 6 Date Author Title INTERNAL

7 Valmet CFB gasifier CFB Gasifier Cyclone CFB reactor Fuel feeding Size (300) MWth Product gas/ gasification air - heat exchanger Fuel Biomass, waste Gasification media Air Operating temperature C Operating pressure 5-30 kpa(g) Product gas heating value 3-7 MJ/nm 3 (LHV) Product gas line Bottom ash removal 7

8 8 Valmet CFB gasifier early reference At Värö, Södra Cell, Sweden, a Valmet CFB gasifier has been used to fire the lime kiln with bark/wood => Over 20 years of industrial experience The oil used in a lime kiln is the only user of fossil fuel in a modern pulp mill By replacing fossil fuels, a pulp mill can be CO 2 neutral

9 Valmet Power - gasification offering Product gas for industrial kilns Woody biomass, bark, peat also waste MW fuel units Typically includes a dryer Dusty product gas Also other types of kilns possible Gas cleaning if needed Product gas for power boilers Woody biomass, bark, peat Superior electricity efficiency Existing boilers MW fuel units Typically includes a dryer Gas cleaning if needed Product gas from waste for power production Waste-derived fuel MW fuel High electricity efficiency Typically a new gas boiler (existing boiler is also an option) Gas filtering -> clean product gas Indirect gasification of biofuels Suitable for clean biofuels Suitable for cases HIGH HEATING VALUE GAS is needed (SNG, refinery feed motors) 9

10 Valmet CFB Gasification for Waste Case Lahti

11 Valmet Waste Gasification Lahti Energia areal view Stack Old power station Turbine Gasifier APC Boiler Gas cleanup Conveyor October, 2014 Valmet Author / Title

12 Lahti Waste Gasification plant Design fuel Design fuel Fuel LHV SRF from MSW and C+IW MJ/kg, dry Moisture < 30 w-% Ash < 15 w-%, dry Cl < 0.6 w-%, dry Na + K < 0.3 w-%, dry Hg < 0.1 mg/kg, dry October, 2014 Valmet Author / Title

13 Lahti Waste Gasification plant Highest efficiency for Energy-from-Waste World s largest waste (SRF) gasification power plant Processes 250 ktpa of Refuse Derived Fuel (SRF) to produce: 50 MW of electricity 90 MW of district heat CHP efficiency of 87,5 % Total investment ca. 160m Lahti Energia, Lahti, Finland Start-up October, 2014 Valmet Author / Title CO2 emissions reduced up to 50 %

14 Valmet Waste Gasification Lahti Project Milestones Environmental Permit Building Permit Delivery Contract First Gasification Turbine Syncronisation Take Over Over hours of operation until end September

15 Valmet Waste Gasification Lahti Project -Operational experience Stable and easy to control operation Compliance with WID No corrosion detected Capacity demonstrated Gasifier operation reliable First year availability too low Changes in filter operational modes Product Gas Cooler changes Fuel properties improved (metal/streamers/wood) Availability now 85 % + Further improvements still ongoing as a cooperation with the Customer 15

16 Valmet Waste Gasification Fuel variations in Lahti 40,0 35,0 30,0 25,0 20,0 15,0 10,0 5,0 0,0 MOISTURE VARIATIONS 16

17 Low emissions proven At stack (red. 11 % O2) Emisssion Limit Measured NOx 200 mg/m 3 n 161 mg/m 3 n SO 2 50 mg/m 3 n 7 mg/m 3 n CO 50 mg/m 3 n < 2 mg/m 3 n Dust 10 mg/m 3 n < 2 mg/m 3 n HCl 10 mg/m 3 n < 1 mg/m 3 n HF 1 mg/m 3 n < 0,5 mg/m 3 n TOC 10 mg/m 3 n < 1 mg/m 3 n PCDD/F 0,1 ng/m 3 n < 0,002 ng/m 3 n compounds Hg 0,05 mg/m 3 n < 0,0001 mg/m 3 n Cd+Tl 0,05 mg/m 3 n < 0,0003 mg/m 3 n Sb+As+Co+ Cr+Cu+Mn+ Ni+Pb+V Total 0,5 mg/m 3 n < 0,03 mg/m 3 n * NOx, SO 2, HCl are usually close to limit to minimize the cost of additives Final emission control: DeNox catalyst Sodiumbicarbonate injection Activated carbon injection Bag house 17

18 Valmet Waste gasification Co-firing waste in existing power plant Co-firing of cleaned gas from waste gasification in existing utility boiler Hot gas cleanup removes corrosive and harmful compounds from gas Minimum impact on boiler operation, corrosion, ash quality and emissions Full capacity on main solid fuel maintained Minimum boiler modifications needed, including new gas burners Permitting? Add-on gasifier and hot gas cleanup Existing utility boiler October, 2014 Valmet Author / Title

19 10/10/2014

20 Valmet CFB Gasification for Biomass Case Vaskiluoto

21 Cofiring is an efficient way to use biomass Example:100 MW of biofuel available at the district 100 MW, fuel Small boiler, efficiency 25 % 25 MW green electricity 100 MW, fuel 400 MW coal Large boiler, efficiency 40 % 40 MW green electricity MW coal electricity The final outcome is 60 % more green electricity! 21

22 Valmet scope in Vaskiluodon Voima s gasification project Full scope services with total plant optimization Fuel receiving and handling Drying Gasification Boiler modifications Automation, electrification and instrumentation Instrumentation, electrification and automation Product gas Dried biomass Wet biomass Biomass receiving and pre-handling Large-scale belt dryer CFB gasifier 140 MW fuel Existing PC boiler

23 Vaskiluoto Biomass Gasification plant and the main experiences of the project Matti Tiilikka Project manager Vaskiluodon Voima Oy 23

24 Vaskiluoto Power Plant Vaskiluoto 2 Investments: Boiler plant 1982 Desulphurization plant 1993 New turbine plant 1998 In technical terms, the plant is fit for use until 2030 Main figures: Electricity output 230 MW District heat output 175 MW Vaskiluodon Voima Oy 24

25 Investment cost and benefits Total investment cost 40 M. State investment subsidy 10,8 M (Ministry of Employment and the Economy) Cost savings: Reduction of CO2-emission cost, reduction of CO2-emissions up to t/yr. Feed-in tariffs of renewable energy Reduction of the environmental taxes of district heating Other benefits: Low total cost compared with the construction of a totally new biofuel power plant Gasification compared with wood pellet firing: higher cost of pellet production (around +50%) and pellet milling is avoided Local fuels - Positive effects to the local economy, 15 M /a. The new activities will employ 100 people in fuel logistics Vaskiluodon Voima Oy 26

26 Project implementation Main Schedule Environmental permit Binding promise of the investment subsidy Contract with Metso Power Oy Start of the foundation work (4 months) Start of the equipment installation (11 months) Planned five weeks outage in August 2012 (15 months) Start of test runs October 2012 (17 months) Start of the commercial use January 2013 (20 months) Vaskiluodon Voima Oy

27 Project experiences Total project costs did stay in the frames of the budget Installation time: The time schedule was very tight. That pressed final installation work to late autumn and made the test running period quite challenging. Even so, the boiler modifications were made as planned during 5 weeks outage. The site safety was organised fine and there was only one minor accident on site. Test run: Only minor effects on PC-boiler operation, no boiler trips great! The fuel unloading pockets were designed with high separating walls and some types of trucks have had difficulties to operate between those walls. In the fuel sampling system there has been jamming with wet and cold peat. Temperature differences on the body material of air heaters have caused distortion and damaged bellows of the gas ducts. Vaskiluodon Voima Oy 28

28 Operation experiences There has been no instabilities in the boiler evaporator. NOx -emission level has been under the limits of environmental permit (500 mg/m3(n)) after the modification the emission level is around 350 mg/m3 and has been around 400 mg/m3 last year. The warranty values are likely to be fulfilled. Warranty tests will be carried out in March The dyer has functioned fine. We have seen that investment quite successful also because biofuels have been abnormal wet this year. The potential risk of the hot corrosion of the superheaters was noticed and therefore a theoretical study was made by Valmet. As a result it was decided to keep the rate of biofuel always under the rate of coal. Vaskiluodon Voima Oy 29

29 VASKILUOTO GASIFICATION PLANT PC BOILER CFB GASIFIER FUEL STORAGE AND HANDLING DRYER 30 Date Author Title INTERNAL

30 Live steam pressure Temperature and flow Load following with coal Reduction for nights Gasifier load ( MW) October, 2014 Valmet Author / Title

31 NOx mg/nm3 6% O2 NOx content of boiler flue gases Low O2 High O % 10 % 20 % 30 % 40 % 50 % 60 % Gasifier share of total fuel input October, 2014 Valmet Author / Title

32 SO2 mg/nm3 6% O2 SO 2 content - before sulphur removal % 10 % 15 % 20 % 25 % 30 % 35 % 40 % 45 % 50 % 55 % Gasifier share of total October, 2014 Valmet Author / Title

33 First year availability First operational year 2013/2014 availability was 97 % Distribution of causes for unavailability (total 3 %) Torch test failure Air damper leakage Air preheater imbalance Burner impeller damage Flame detection Fuel handling 0,0 % 20,0 % 40,0 % 60,0 % October, 2014 Valmet Author / Title

34 Dryer (Titanic) We are very pleased about the final results of this project and like to thank all our suppliers for the fine co-operation! 35 Vaskiluodon Voima Oy

35 Outlook and Summary

36 Recent Reference Case OKI OKI PROJECT SITE 37 Date Author Title INTERNAL

37 100 % Coal Replacement Test Vaskiluoto hour test without any coal or oil Stable steam parameters (SH/RH 530/530 C) Stable combustion (CO below 10 mg/nm3) Emission reduction (SO2, NOx) October, 2014 Valmet Author / Title

38 Valmet CFB Gasification A Proven Product with real life References 2/2014 OKI Start Up /2011 VaKa Commercial Operation 1/ /09 KyVo II Commercial operation 4/

39 Valmet CFB Gasification New possibilities: Partial or complete fuel change in existing power plants High efficiency WtE technology for electricity production Firing of Industrial Process with Biofuels You name it! 40