Waste to Energy Conference, Vienna 2017

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1 Processing of household waste and energy recovery from the high calorific fraction by incineration together with sewage sludge in the fluidized bed furnace in Simmeringer Haide Waste to Energy Conference, Vienna 2017

2 Processing of household waste and energy recovery from the high calorific fraction by incineration together with sewage sludge in the fluidized bed furnace in Simmeringer Haide Waste to Energy Conference, Vienna 2017

3 Content Company Wien Energie BFB Boiler 4 (WSO4) process description design data operational experience Development of a 3D computational particle fluid dynamics model What is computational particle fluid dynamics Project description Sneak preview on results Summary

4 Wien Energie As Austria s largest energy service company, Wien Energie safeguards the reliable, uninterrupted supply of energy and all of the associated services to the city of Vienna and the surrounding area around the clock. Wien Energie is one of the largest employers in the Greater Vienna metropolitan area. The associated portfolio of services ranges from the production of energy recycling waste to providing energy advice helping to improve energy efficiency and energy services facility management telecommunications Wien Energie Confidentiality Notice 4

5 Key performance indicators Turnover Investment Headcount EUR 2,056.7 million EUR 74 million 2,652 employees Supplying electricity, natural gas and heating to Two million people 230,000 businesses and industrial facilities 4,500 farms Wien Energie Confidentiality Notice 5

6 Waste Wien Energie Waste incineration is carried out at four locations: Spittelau, Flötzersteig, Pfaffenau, Simmeringer Haide with grate furnaces, fluidized bed furnaces and rotary kiln Fluidized bed oven #4 (WSO4) at Simmeringer Haide is designed for the incineration of household waste & sludge ~13 % of municipal solid waste of Vienna Reserve capacity for the sludge combustion 9/21/17 Wien Energie 6

7 Pre-processing of the MSW for Municipal department Vienna Waste is collected by municipal department Shredded and sieved with partly iron removal Delivered to Wien Energy Thermally treated by Wien Energie Residuals (ash, bed ash etc.) returned to municipal department for further treatment 9/21/17 Wien Energie 7

8 Why fluidized bed system? Advantages of BFB technology High fuel flexibility Low NOx and CO emission Sulfur separation in bed possible Low melting and sintering of inorganic matter due to low bed temperatures (<660 C) Inorganic matter can be discharged in a low oxidized state due to in-bed separation of inorganic matter Wien Energie 8

9 Basic Flow Sheet WSO 4 9/21/17 Wien Energie 9

10 Rowitec Fluidized bed Design Fuel input Flue gas to freeboard Inorganic matter Rotating fluidized bed Primary air 9/21/17 Wien Energie 10

11 Design data WSO4 Fuel Parameter Unit Design Range Municipal solid waste Throughput t/h 12 <16 Lower heating value MJ/kg Water content % Ash content % Dewatered sewage sludge Throughput t/h db 6,84 <6,84 Dry substance % Organic dry substance % Hygroscopic water in the dry substance % 4,5 1-5 Heating value of the organic dry substance MJ/kg Oil (heavy, extra light, waste oil) For heat up and temperature control 9/21/17 Wien Energie 11

12 Design data boiler WSO4 Parameter Unit Value Pressure live steam bar abs 54 Temperature live steam C 354 Maximum steam production t/h 49,5 Maximum temperature after oven C Ash content in the flue gas g/nm³ 40 Flue gas temperature after boiler at the beginning of the operation C 180 Flue gas temperature after boiler before shut down C 210 9/21/17 Wien Energie 12

13 Operational data Air emissions Air emissions, continuous measurement WSO Values corrected for reference conditions in mg/m³, 11 % O2, dry, with subtracion of confidence intervals. No correction to 11 % oxygen is made for values with O2 < 11 %. half hourly average min max average * limit value HHA daily average acc. notification from authorities min max average ** limit value DA acc. notification from authorities CO 0,0 58,5 5, ,4 12,0 7,3 50 VOC 0,0 7,8 0,3 10 0,3 1,0 0,5 10 HCl 0,0 5,8 0,1 10 0,0 0,3 0,1 10 NO 2 4,3 92,7 32, ,5 35,7 34,1 70 SO 2 0,0 24,4 0,8 50 0,3 1,6 0,8 50 Dust 0,0 8,6 0,0 10 0,0 0,1 0,0 10 arithmetic average of HHA ** monthly average calculated with operating hours, amount of flue gas and pollutants Werksleitung SH/Ing. Pawelka/MB 9/21/17 Wien Energie 13

14 Operational experience WSO4 Emission limits are undercut significantly Design data concerning yearly waste amount are fulfilled The operation suffers from inorganic fouling in the oven Limitation of availability High service costs 9/21/17 Wien Energie 14

15 Inorganic fouling in the oven mixing chamber excess air area 2nd secondary air 1st secondary air waste chutes 2x recirculated flue gas understoichiometric area primary air 9/21/17 Wien Energie 15

16 Inorganic fouling Typical crystal structure of fouling Crystal structure Formula SH Corundium a-al 2 O 3 % 64,0 Hercynite FeAl 2 O 4 % 13,3 Diopside CaMg(SiO 3 ) 2 % 5,2 Aluminium Al % 4,7 Gehlenite Ca 2 Al 2 SiO 7 % 3,8 Akermanite Ca 2 MgSi 2 O 7 % 2,9 Silicon Si % 2,6 Quarz SiO 2 % 1,8 Hematite Fe 3 O 4 % 1, Wien Energie 16

17 Countermeasures for fouling Development of an online cleaning device to remove fouling Change of the air staging (primary measures) Development of a 3D Computational particle fluid dynamic model in cooperation with and 9/21/17 Wien Energie 17

18 What is Computational Particle Fluid Dynamics (CPFD) 3D oven model meshed in reference volumes Mass & energy balances incl. chemical reactions (ε g ρ g ) + +ε t g ρ g u g - = δm p (ε g ρ g u g ) +,ε t g ρ g u g u g - = p + F + ε g ρ g g + (ε g τ g ) f t + 'fu p* + up 'fa p * = 0 Gas phase is included Particles are included as particle swarm to reduce calculation time δm p = ' f dm p dt dm pdu- p dt p a p = D p &u( g u( p + 1 ρ p p + g 1 ε p ρ p τ F = $ f &m p )C D,u g u p / 1 ρ p p3 + u p dm p dt 7 dm pdu p dt p 9/21/17 Wien Energie 18

19 Project description Reactor model Fuel model reaction kinetics flue gas outlet Validation using different operational conditions secondary air Optimization of the operation waste sewage sludge primary air recirculated flue gas recirculated flue gas bottom air 9/21/17 Wien Energie 19

20 Sneak preview CPFD results 9/21/17 Wien Energie 20

21 Summary Combustion of MSW and sewage sludge is carried out in a BFB Boiler Operation fulfills emission limits Design capacity is fulfilled Operation suffers from inorganic fouling in the oven area Development of a CPFD simulation is ongoing A rebuild of the air staging is ongoing which can be reported next year 9/21/17 Wien Energie 21

22 Bed ash course fraction 9/21/17 Wien Energie 22

23 Bed ash - fine fraction Wien Energie 23

24 Questions? Wien Energie

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