The Ajka Biomass Project

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Grant McDowell
5 years ago
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1 The Ajka Biomass Project Dr. Albin Zsebik /László Kovács Technical University of Budapest/ Bakonyi Power Plant Ltd. Ajka

2 The Ajka biomass project RES, RES-E in the EU and Hungary The Bakony Power Plant Ltd. The Ajka Biomass project Photo gallery

3 Key EU objectives Previous target (1997): 12% RES by 2010 Last proposal Renewable Energy Road Map ( ): 20% RES by 2020 (34% RES-E)

4 Bakony Power Plant Ltd. in brief 1943 Commissioning of the Ajka coal fired plant 1980s Retrofit of the boiler park 1990s Introducing hybrid-fluid combustion system 1991 Integration with the Inota coal fired plant 1992 Establishment of Bakony Power Plant Ltd Integration with the local coal mines 1997 Privatisation Hungarian investors

5 Difficulties after the Millennium Long term power purchase agreement terminated in 2001 incompetitive production with the old coal fired inefficient units on the liberalised power market Exemption to comply with environmental regulation to be expired at the end of 2004 sulphurous local coal, to keep up with emmission limits would have needed huge, uneconomical investment

6 The answer: The Biomass Project RES-E is a marketable product Conversion can be made and environmental emmission limits can be kept with modest investments

7 The Biomass Project Schedule Project planning and technical design 2003 Acquiring applicable permits Hungarian energy office Environmental authority Securing biomass through long term contracts with biomass producers (mainly forestries) Technical modification construction Converting two boilers for biomass (woodchips) firing Investment cost: ~4 million EURO Test run Commissioning commercial operation March 2004

8 Hybrid-fluid combustion system Fuel bunker Conveyor belts Steam parameters: Flow - 98 t/h Temperature o C Pressure - 70 bar From the chopping machine and the inner coal storage area SH 2 SH 3 SH 1/b Fuel feed system SH 1/a EF ECO UB AB AH FM EV Legends: FM - Fluid mill UB - Upper burners Fluid bed FF - Fluid fan FDF - Forced-draft fan EV - Exhaust ventillator Slag pipes EF - Electrofilter AH - Air heater SH - Superheaters Slag disposal AB - Auxiliary burners IALB -Igniting, auxiliary and layer burners IALB FF Natural gas FDF Scheme of hybrid-fluid boiler Stack

9 Operational experiences Biomass market and logistics Limited storing capacity and handling area at the plant Timing of biomass transports (road and rail) Difficulties in perfect fuel mixing and boiler feeding Hectic biomass market increasing prices Answers: Organising cluster of producers energy forest plantation Transforming wood residue into energy Joint investment into bundling technology

10 Operational experiences Biomass quality Homogenisation of fuel components is a key Optimal size of woodchips a + b + c = 10 cm Low wet content Higher LHV Less slag and flying ash No pulsation occures in the furnace Lower ignition temperature -easier start up than in case of coal

11 Operational experiences Adapting different biomasses Agricultural wastes Unfavourable experience in case of bran, straw and some other material Significant fouling on the heating surfaces due to low melting point fluid bed solidifies Successful application of sunflower Bundled forest residues (20,000 t in 2007) Rape seed pellet (byproduct of biodiesel prod.) Different kind of reeds Biomass from energy plantations

12 Biofuel consumption Biomass (t/yr) Wood (soft+hard) Woodchips (soft + hard) Agricultural waste (bran, sunflower crust, corn grain, etc.) Summary

13 RES-E production (GWh) Generated RES-E Net electrical output Efficiency ( % ) 25,23 24,63 23,78 25

14 Fluegas emmission figures Component Limit value Solid particles (mg/nm 3 ) 50 22,6 11,5 12,9 CO (mg/nm 3 ) , NO x (mg/nm 3 ) , SO 2 (mg/nm 3 )