State-of-the-Art CFB Technology for Utility-Scale Biomass Power Plants Vesna Barišić 1*, Edgardo Coda Zabetta 1, and Bogusław Krztoń 2 1 Foster Wheeler R&D Department, Finland 2 Foster Wheeler Energia Polska, Global l Sales & Marketing, Poland * vesna.barisic@fwfin.fwc.com
Contents Foster Wheeler Global Power Group References Challenges in Biomass Combustion Advanced Biomass CFB (ABC) Technology Conclusions
World Leader in Fluidized Bed Combustion (CFB) Technology First BFB boilers delivered in the 1970s, and world s first CFB supplied in 1979 World s first once-through supercritical CFB started operation in 2009 in Lagisza, Poland Flexi-Burn -air/oxy flexible CFB commercially available by the of end 2010 370 CIRCULATING FLUIDIZED BED (CFB) BOILERS 328 in operation 42 under construction Biggest unit in operation 460 MWe Sizes up to 800 MWe available 143 BUBBLING FLUIDIZED BED (BFB) BOILERS 143 in operation 11 ATMOSPHERIC FLUIDIZED BED GASIFIRES 11 in operation
Pioneering Supercritical Once-Through and Flexi- Burn TM CFB Technology The world s largest and first Supercritical Once- Throughh CFB with the capacity of 460 MWe at PKE s Lagisza plant in Poland is in operation since 2009 Capacity Steam flow Steam pressure 460 MWe (966.3 MWth) 361 kg/s 282 bar Steam temperature 563 C Fuel Bituminous Coal, Coal Slurry CFB technology is commercially available in 600 800 MWe scale Flexi-Burn CFB development and validation up to 300 MWe
Growth in Biomass Utilization in Energy Production Incentives against CO 2 emissions promote renewable fuels => biomass Public institutions subsidize and support biomass projects Regulatory organisms do not release permits to fire fossil fuels investors look into biomass Traditional biomass (wood-based) is costly and unavailable Agriculture residues are locally/globally available, and more economic
CFB Technology Ideally Suited for Large-Scale Biomass Power Plants Supreme fuel flexibility and multi-fuel firing Low emissions High availability and efficiency
Challenges in Biomass and Waste Combustion - Complex Ash Chemistry- 150 Ash 279 g/kg Si Al Fe Ca Mg K Na P Ash concentration Conc centration [g/k kg fuel, dry] 125 100 75 50 14 12 10 8 6 4 2 0 Stem Wood Forest Residue Recycled Wood 25 0 Coal Peat Stem Wood Forest Residue Sunflower Husk Wheat Straw Olive Waste Rapeseed Waste Recycled Wood RDF Fossil Fuel Biomass Fuel Waste Fuel
Challenges in Biomass and Waste Combustion - Complex Ash Chemistry- Co oncentration [g/kg fuel, dry y] 30 25 20 15 10 Na, week acid soluble K, week acid soluble Sulfur Chlorine Phosphorous 5 0 Coal Peat Stem Wood Forest Residue Sunflower Husk Wheat Straw Olive Waste Rapeseed Waste Recycled Wood RDF Fossil Fuel Biomass Fuel Waste Fuel
Challenges in Biomass and Waste Combustion Fuel Model 10 dex Pro obability In 9 8 7 6 5 4 3 2 1 Agglomeration Fouling Corrosion VERY HIGH LOW MEDIUM M HIGH 0 Coal Peat Stem Wood Forest Residue Sunflower Husk Wheat Straw Olive Waste Rapeseed Waste Recycled Wood RDF Fossil Fuel BiomassFuel Waste Fuel
Selected Design Options for Biomass and Waste empty pass easy HXs Intelligent cleaning - steam blowers - acustic blowers - water guns - spring hummers StepGrid Intrex (possibly chemical countermeasures)
Chemical Countermeasures Alternative Bed Materials and Additives non fouling (FA) fouling/non corrosive fouling/corrosive limestone Su ulfur kaolinite agglomerating coating melt non agglomerating (BA)
Advanced Biomass CFB Technology Integrated Steam Cooled Solid Separator and Return Leg Control of Fouling & Corrosion Correct f lue gas temperature Correct design for convective heat transf er surf aces During Operation Features to Control Agglomeration & Fouling Active Bed Material Fuel quality management FW SmartBoiler datalog & Diagnostic tools Optional additives with worst quality agros Conservative f lue gas velocity Ef f ective temperature control ABC projects in progress: Step Grid Final SH & RH as INTREX Konin (Poland), 154 MW th, 215 ton/h, 97 bar(a), 540 C Połaniec (Poland), 447 MW th, 158/135 kg/s, 128/20 bar(a), 535/535 C
Połaniec (GDZ Suez Energia Polska S.A., Połaniec, Poland) (190/447 Mwe/th, 158/135 kg/s, 128/20 bar(a), 535/535 C) Project schedule Fuel Contract awarded in April 2010 Delivery 2012 80% wt virgin wood 20% wt agro-biomass: straw, sunflower husk, dried fruits (marc), palm kernel
Conclusions Foster Wheelers Advanced Bio CFB (ABC) Technology provides state-of-the-art solutions for effective CO 2 reduction in large-scale power generation with a broad ranges of biomass and waste fuels. ABC boilers have been recently booked by Foster Wheeler to co-fire biomass with up to 20 wt% agro-biomass including willow, oat husk, palm kernel, straw, dried fruits, sunflower, and rapeseed residues. The largest of these units (447 MW th ) is designed to produce 158 kg/s of superheated steam at 128 bar(a) and 535 C. FW s ABC technology is available for up to 300 MW e for a broad range of biomass, and up to 600 MW e co-firing 50% biomass with coal. Superheated steam can approach 180 bar(a) at 570 C for clean biomass, and 290 bar(a) at 585 C for 50% coal.
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Foster Wheeler Global Power Group References Circulating Fluidized Bed (CFB) Boilers Bubbling Fluidized Bed (BFB) Boilers Heat Recovery Steam Generators Waste Heat Boilers PC Boilers Gasifires
Foster Wheeler s CFB Fuel Flexibility Coal Anthracite Bituminous Subbituminous Lignite Waste Coal Bituminous Gob Anthracite Culm Coal Slurry Petroleum Coke Delayed Fluid Peat Wood Residue Bark Chips Sawdust Forest Residue Agricultural Waste Straw Olive Waste Sunflower Husk Rapeseed Dried Fruits... Sludge Paper mill De-inking Municipal Recycled Wood Tire Derived Fuel Solid Recovered Fuel Waste Paper Gas Natural Off gases Oil Oil Shale
Challenges in Biomass and Waste Combustion - Complex Ash Chemistry- Si Al Fe Ca Mg K Na P Ash concentration Conc centration [g/k kg fuel, dry] 150 125 100 75 50 Ash 279 g/kg Seeds of Oil/Cerial Crops Ash 3 8 % wt, dry Rich in P, K, Mg Straw/Stalk of Herbs Ash 3 17 % wt, dry Rich in Si, K, Cl Woody Biomass Ash 0.1 6 % wt, dry Rich in Ca and K Waste Fuels Higher ash content More Na, Zn, Pb, Cu,... 25 0 Coal Peat Stem Wood Forest Residue Sunflower Husk Wheat Straw Olive Waste Rapeseed Waste Recycled Wood RDF Fossil Fuel Biomass Fuel Waste Fuel
Challenges in Biomass and Waste Combustion Element/compund Alkali metals (Na, K) Earth alkali metals (Ca, Mg) Trace elements Fouling of Convective Heat Exchangers Effect on fouling Especially alkali soluble @ ph3 Especially Zn, Pb, Cu, metallic Al Aluminosilicates (e.g. kaolinite) Especially kaolinite
Challenges in Biomass and Waste Combustion Element/compund Chlorine (Cl) Chlorine Induced Corrosion Effect on corrosion Forms sticky and corrosive compunds especially with alkali Fouling or Sullfur (S) Binds alkali into less harmful sulfates Aluminosilicates (e.g. kaolinite) Binds alkali into less harmful aluminosilicates