8 sgc international seminar on gasificatonconference.sgc.se/ckfinder/userfiles/files/4_1_ juhani...

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

Commercial Experiences of Waste and

Biofuel Gasification -

Valmet CFB Gasification

Juhani Isaksson, Valmet Power


Valmet


Valmet CFB Gasification for Waste – Case Lahti

Valmet CFB Gasification for biomass – Case Vaskiluoto

Outlook and Summary

1

2

3

4

5

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

December 31 2013 © Valmet | 3

Valmet has a turnover of €3 billion and was reborn through

the demerger of Metso Group on December 31, 2013.

Gasification is a part of combustion

Combustion

Gasification

Valmet CFB gasifier - operating principle

Date Author Title INTERNAL6

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

Valmet CFB gasifier

CFB Gasifier

Size 20 – 140 (300) MWth

Fuel Biomass, waste

Gasification media Air

Operating

temperature

750 – 900 C

Operating pressure 5-30 kPa(g)

Product gas

heating value

3-7 MJ/nm3 (LHV)

7

Fuel feeding CFB reactor

Bottom ash removal

Cyclone

Product gas line

Product gas/

gasification air

- heat exchanger

Valmet CFB gasifier early reference

At Värö, Södra Cell, Sweden, a

Valmet CFB gasifier has been

used 1987 -2014 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 CO2 neutral

8

Valmet Power - gasification offering

9

Product gas for

industrial kilns

•Woody biomass,

bark, peat also waste

•20 – 110 MWfuel 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

• 50 – 300 MWfuel

units

• Typically includes a

dryer

• Gas cleaning if

needed

Product gas from

waste for power

production

• Waste-derived fuel

• 50 – 150 MWfuel

• 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)

Valmet CFB Gasification for WasteCase Lahti

Valmet Waste GasificationLahti Energia – areal view

10 October, 2014 © Valmet | Author / Title11

Gasifier

Gas

cleanup

Boiler

Old power

station

Conveyor

Stack

APC

Turbine

Lahti Waste Gasification plantDesign fuel

Design fuel

FuelSRF from MSW and

C+IW

LHV 18 – 24 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


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 2012


CO2

emissions

reduced

up to 50 %

Lahti Waste Gasification plant

Lahti Project Milestones

14

Environmental Permit 27.4.2007

Building Permit 6.11.2009

Delivery Contract 26.11.2009

First Gasification 15.12.2011

Turbine Syncronisation 3.02.2012

Take Over 27.06.2012

Over 16 000 hours of operation until end

September 2014

Valmet Waste Gasification


Lahti Project -Operational experience

15

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


Fuel variations in Lahti

16

0,0

5,0

10,0

15,0

20,0

25,0

30,0

35,0

40,0

28.12.2013

5.1.2014

12.1.2014

20.1.2014

30.1.2014

5.2.2014

12.2.2014

20.2.2014

27.2.2014

6.3.2014

13.3.2014

21.3.2014

27.3.2014

3.4.2014

21.4.2014

28.4.2014

4.5.2014

11.5.2014

18.5.2014

25.5.2014

MOISTURE VARIATIONS

Low emissions provenAt stack (red. 11 % O2)

17

Emisssion Limit Measured

NOx 200 mg/m3n 161 mg/m

3n

SO2 50 mg/m3n 7 mg/m

3n

CO 50 mg/m3n < 2 mg/m

3n

Dust 10 mg/m3n < 2 mg/m

3n

HCl 10 mg/m3n < 1 mg/m

3n

HF 1 mg/m3n < 0,5 mg/m

3n

TOC 10 mg/m3n < 1 mg/m

3n

PCDD/F

compounds0,1 ng/m

3n < 0,002 ng/m

3n

Hg 0,05 mg/m3n < 0,0001 mg/m

3n

Cd+Tl 0,05 mg/m3n < 0,0003 mg/m

3n

Sb+As+Co+

Cr+Cu+Mn+

Ni+Pb+V

Total 0,5

mg/m3n

< 0,03 mg/m3n

* NOx, SO2, HCl are usually close to limit to minimize the cost of additives

Final emission control:

DeNox – catalyst

Sodiumbicarbonate injection

Activated carbon injection

Bag house

Valmet Waste gasificationCo-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

10/10/2014

www.lahtienergia.fi

Valmet CFB Gasification for BiomassCase Vaskiluoto

Cofiring is an efficient way to use biomass

Example:100 MW of biofuel available at the district

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100 MW, fuelSmall boiler,

efficiency 25 %25 MW

green electricity

100 MW, fuelLarge boiler,

efficiency 40 %40 MW

green electricity

+

160 MW

coal electricity400 MW coal

The final outcome is 60 %

more green electricity !

Valmet scope in Vaskiluodon Voima’sgasification project

Full scope services with total plant optimization

– Fuel receiving and handling

– Drying

– Gasification

– Boiler modifications

– Automation, electrification and instrumentation

Wet biomass

Existing PC boiler

Instrumentation,

electrification

and automation

Biomass receiving

and pre-handlingLarge-scale belt dryer CFB gasifier

140 MWfuel

Product gas

Dried biomass

Vaskiluoto Biomass Gasification plant

and the main experiences of the project

11.3.2013

Matti Tiilikka

Project manager

Vaskiluodon Voima Oy 23

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


Vaskiluoto Power Plant

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 230 000 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


Project implementation

Main Schedule

Environmental permit 10.8.2010

Binding promise of the investment subsidy 8.4.2011

Contract with Metso Power Oy 6.5.2011

Start of the foundation work 1.9.2011 (4 months)

Start of the equipment installation 1.4.2012 (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

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.

28Vaskiluodon Voima Oy

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 2013.

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.


VASKILUOTO GASIFICATION PLANT


FUEL STORAGE

AND HANDLING

PC BOILER

CFB

GASIFIER

DRYER


Gasifier load

(70 – 132 MW)

Live steam pressure

Temperature and flow

Load following with coal

Reduction for nights

NOx content of boiler flue gases


200

225

250

275

300

325

350

375

400

425

450

0 % 10 % 20 % 30 % 40 % 50 % 60 %

NO

xm

g/N

m3 6

% O

2

Gasifier share of total fuel input

High O2Low O2

SO2 content - before sulphur removal


0

50

100

150

200

250

300

350

400

450

500

550

5 % 10 % 15 % 20 % 25 % 30 % 35 % 40 % 45 % 50 % 55 %

SO

2

m

g/N

m3 6

% O

2

Gasifier share of total

First year availability


0,0 % 20,0 % 40,0 % 60,0 %

Fuel handling

Flame detection

Burner impeller damage

Air preheater imbalance

Air damper leakage

Torch test failure

Distribution of causes for unavailability (total 3 %)

First operational year 2013/2014 availability was 97 %

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!


Outlook and Summary

Recent Reference – Case OKI


OKI –

PROJECT

SITE

100 % Coal Replacement TestVaskiluoto 29.09.2.2014


24 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)


39

Commercial

operation

4/2012

Commercial

Operation

1/2013

Start Up

20162/2014 OKI

5/2011 VaKa

A Proven Product with real life References

12/09 KyVo II

40

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!


8 sgc international seminar on gasificatonconference.sgc.se/ckfinder/userfiles/files/4_1_ juhani...

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