FUEL FLEXIBILITY, EFFICIENCIES AND PAY-BACK OF ADVANCED ENERGY PLANTS!!

Transcription

1 FUEL FLEXIBILITY, EFFICIENCIES AND PAY-BACK OF ADVANCED ENERGY PLANTS!!

2 POLYTECHNIK BIOMASS ENERGY

3 POLYTECHNIK BIOMASS ENERGY! Family business! Headquarters in Austria! Honoured with Austria s coat of Arms! Export rate: >95%! Around 250 employees! First boiler in 1965! Installing 150 to 200 MW every year! 30 to 50 boilers per annum ($70 to $80 million)! >3,000 reference plants! Polytechnik owns and operates wood waste and biomass fuelled energy plants! Integrated Management Systems: ISO 9001, ISO 14001, OHSAS 18001! Offices and representations in over 20 countries worldwide! Only European biomass boiler supplier with an established office in Australasia Head office in Weissenbach/Austria! Secretary of State Dr. Harald Mahrer with Polytechnik s! business owners Lukas Schirnhofer und CEO Leo Schirnhofer!

4 POLYTECHNIK BIOMASS ENERGY! Tailored wood waste and biomass combustion and gasification solutions! 8 different combustion solutions! Over 100 different furnace designs! Boilers from 300 kw to 30 MW th per unit! Heat transfer medium hot water steam thermal oil air flue gas! Energy plants up to 60 MW th! Power plants from 200 kw e to 20 MW e both, organic and steam rankine cycle! Cogeneration! Trigeneration! Emission control systems! Fuel storage and handling systems! Ash handling equipment! Fans! Energy and heat recovery systems

5 WOOD FUELS

6 Wood Fuels

7 Wood / Biomass Classification & CV BANZ Technical Guide 1 20 Semi dry wood chip vs. green hog fuel / bark For the same energy output 50% of weight (t/h) or 75% of volume required (m 3 /h) Type / traded form Size Moisture Ash Lower heating value LHV/NCV (MJ/kg) to 33% MC WB 12 GJ/t 57 to 61% MC WB Bulk density Energy density Ash content 1% 3% 5% 10% 6 GJ/t Additional data EN 14961: Fuel moisture wb (%)

8 Fuel Qualities / Fuel Analysis VERY GOOD STANDARD LOW SPECIAL Schools, small heat plants Medium scale heat plants Sawmill, heat and CHP plants Wood waste plants Effect on emissions Other side effects Moisture % < 30 < > 55 CO (low loads) Ash % d.b. < 1,0 < 3,0 < 10,0 < 20,0 Dust (fly ash) Nitrogen, N < 0,1 < 0,3 < 0,5 > 0,5 NOx (SNCR; low loads) Sulfur, S < 0,02 < 0,03 < 0,05 > 0,05 SO2 (dry absorption) Heating value, bulk density, energy density, dew point, residence time, grate area Calorific value, wear, manual cleaning, aux. power consumption, ash disposal costs Acid dew point, back/cold end corrosion Chlorine, Cl < 0,01 < 0,03 < 0,05 > 0,05 HCl (dry absorption); Dioxines and Furanes High temperature corrosion and fouling of heating surfaces (with K); similar effects of Fluorine Potassium, K Sodium, Na Lead, Pb Zinc, Zn mg/kg d.b. < 500 < 2000 < 3000 > 3000 PM1 (Aerosoles) Ash melting point, high temp. corrosion, fouling and slagging PM1 (Aerosoles) Ash disposal costs

9 Fuel Quality Pro high quality Con high quality Pro low quality Con low quality Biomass landfill site Cheaper boiler plant Expensive fuel Cheap fuel Boiler plant investment cost Lower service and maintenance cost Fuel cost increase with demand Unlimited availability Higher service and maintenance cost Uncontrolled Limited fuel availability Few experienced boiler suppliers

10 $8 to > $20 / GJ - High Quality Fuel $8/GJ& Wood waste

11 $4 to $7 / GJ - Hog Fuel

12 $2 to $5 / GJ - Wood Waste Biomass landfill site Uncontrolled Uncontrolled

13 Fuel Handling

14 Fuel Storage!

15 Fuel Flexibility

16 EFFICIENT WOOD ENERGY

17 Combustion of High Moisture Content Fuel

18 Wood / Biomass Combustion Wood Carbon: ~ 50% Volatile: >85% CV: 4 to 17 GJ/t Coal Carbon: 80 to 90% Volatile: 10 to 40% CV: 18 to >30 GJ/t

19 Efficient Wood Combustion Systems 4 Stages Temperature Air and gas staging Turbulence Gas residence time Sufficient air Adiabatic conditions Heat load Drying Gasification Combustion De-ashing < 800 C in gasification zone, and > 850 C in combustion zone PA, SA, TA & FGR zones = low NOx when mixing gas with oxygen - secondary and tertiary air, not primary air! > 2 seconds in high temperature zone > 850 C but <1,000 C Oxygen / Lambda < 1 in gasification zone, and 1.2 to 1.6 after combustion (low CO) No cold surfaces in the gasification and combustion zone = refractory Low thermal load on furnace and grate

20 Efficient Wood Energy Plants Combustion air temperature! Moisture Content! Flue gas temperature! Flue gas recirculation! Radiation losses! Excess O2! Ash unburned carbon! Carbon monoxide! ƞ Control System!

21 CONTROL SYSTEM

22 Advanced Combustion Control - Standard Standard Boiler Control PID_Power + PID_O2 + PID_REZI Power Setpoint Power Actual Value Power / Output (Flow Temp. or Steam Pressure) Primary air fan(s) fuel, grate(s) movement O2 Setpoint O2 Actual Value Oxygen in Flue-gas Secondary air fan (s) Flow Temp.Setpoint Flow Temp Actual Value Furnace temperature Recirculation fan(s)

23 Combustion Control - MPC Model Predictive Control Power Mp-PL1(PI) PA fan(s) 1 Mp-PL2(PI) PA fan(s) 2 O 2 in fluegas M o Mp-SL (PI) SA fan(s) d Furnace Temperature e l Mp-RR (PI) Recirculation fan(s) Lambda in the combustion zone Mp-Br (PI) Fuel feed, grate

24 Combustion Control Standard vs. MPC Fuel savings: 4% Furnace Temperature swings reduced by 80% Steam pressure swings reduced by 85% Oxygen swings reduced by 60% Polytechnik s MPC the world s leading control system Complete Combustion = no CO

25 INVESTMENT COST

26 Investment Cost of Energy Plants Basic vs. state-of-the-art

27 Investment Cost of a 4 MW Heat Plant Basic Advanced Basic Main savings : Fuel flexibility and storage Service and maintenance: de-ashing, automatic cleaning, access, control system, etc. Efficiency / emissions: furnace size, combustion and control system Health and safety: fire protection, accessibility, insulation, de-ashing, etc.

28 Example Fuel Storage and Handling Basic vs. state-of-the-art

29 Example Furnace & Automatic Cleaning Basic vs. state-of-the-art

30 Example De-ashing Basic vs. state-of-the-art

31 Example Plant Access Basic vs. state-of-the-art

32 Example Insulation & Heat Losses Basic vs. state-of-the-art

33 INVESTMENT VS. RUNNING COST

34 Energy Plant Utilisation Continuous drying kiln Dairy Plants Glasshouse District Heating / Hospital Schools

35 20 % Heat Plant Utilisation 1 MW 1.) Water-cooled grate, 2 pass, ram stoker feed, automatic" furnace and grate de-ashing" Utilisation of 25%, output 80%" = 800 kwh for 2,150 hrs. or 200 kwh for 8,600 hrs.) 2.) Air cooled grate, 1 pass, auger feed, automatic" grate de-ashing" U t I l I z a t I o n 3.) Underfeed stoker, 1 pass, auger feed, automatic" de-ashing" Most expensive boiler design" becomes cheapest option after 4.7 to 5.5 years

36 40 % Heat Plant Utilisation 1 MW 1.) Water-cooled grate, 2 pass,! ram stoker feed, automatic! furnace and grate de-ashing!! Utilisation of 50%, output 80%! = 800 kwh for 4,300 hrs. or 400 kwh for 8,600 hrs.)! 2.) Air cooled grate, 1 pass,! auger feed, automatic! grate de-ashing!! U t I l I z a t I o n! 3.) Underfeed stoker, 1 pass,! auger feed, automatic! de-ashing!! Most expensive boiler design! becomes cheapest option! after 2.3 to 2.8 years!

37 64 % Heat Plant Utilisation 1 MW 1.) Water-cooled grate, 2 pass,! ram stoker feed, automatic! furnace and grate de-ashing!! Utilisation of 80%, output 80%! = 800 kwh for 6,880 hrs. or 640 kwh for 8,600 hrs.)! 2.) Air cooled grate, 1 pass,! auger feed, automatic! grate de-ashing!! U t I l I z a t I o n! 3.) Underfeed stoker, 1 pass,! auger feed, automatic! de-ashing!! Most expensive boiler design! becomes cheapest option! after 1.3 to 1.8 years!

38 64 % Heat Plant Utilisation 10 MW NEW and advanced utilisation of 80% running at 80% load! = 8 MWh for 6,680hrs or 6.4 MWh for 8,600h)! 10 year financing of 80%! U t I l I z a t I o n! vs. 2 ND HAND

39 Successful Wood Energy Plants Fuel flexibility size moisture ash U t I l I z a t I o n High plant utilization Wood waste & residues = cheap fuel! Viable and economic biomass boiler plant

40 REFERENCE PLANTS

41 Hot Water Boiler Plant 400m 3 " heat storage tank

42 Hot Water Boiler Plant 900 kw

43 Visualisation

44 2014 EECA Award Winning Plant setting a new standard for biomass energy use in New Zealand.

45 Fuel - $4 to $6 / GJ fuel

46 Fuel - $4 to $6 / GJ fuel

47 Greenhouse Victoria / AUS old brown coal briquette system

48 1.6 MW HW Plant in Australia

49 1.6 MW HW Plant in Australia

50 2 MW HW Plant in Australia

51 Fuels $1 to $4 / GJ ROI < 3 Years

52 Nursery - Christchurch Average emissions: > 500 mg/m 3 Resource Consent: < 230 mg/m 3 Europe Limit: < 10 to 20 mg/m 3 520

53 Nursery - Christchurch

54 New Boiler at 100% Load

55 Hydraulic System

56 Constant Boiler Load

57 30 MW Energy Plant with 100% Efficiency

58 30 MW Energy Plant with 100% Efficiency

59 Dairy Plant and District Heating Energy plant of the dairy plant

60 Fuel Storage

61 Steam Boiler Plant - Austria MW

62 Steam Boiler Plant France MW

63 Trigeneration - Spain

64 Trigeneration - Spain 500 kw

65 Thermal Oil Boiler 4.8 MW

66 Thermal Oil Boiler 4.8 MW

67 Cogeneration - Germany ESP Boiler Furnace Economiser Fuel Bunker

68 Thermal Oil Boiler 4.8 MW / ORC kw e

69 Cogeneration - Austria

70 District Heating 10.5 MW th / ORC 1.1 MW e

71 Cogeneration France 42.2 MW / 7.5 MW STG

72 CONTACT: CHRISTIAN JIRKOWSKY GENERAL MANAGER POLYTECHNIK BIOMASS ENERGY LTD 81 ST ANDREWS ROAD HAVELOCK NORTH 4130 NEW ZEALAND DDI: T: M: F: E: C.JIRKOWSKY@POLYTECHNIK.CO.NZ