advanced cfb technology for large scale biomass firing
DESCRIPTION
CFBC boiler_BiomassTRANSCRIPT
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Advanced CFB Technology for Large Scale
Biomass Firing Power Plants
11.3.2013, IDA Energy: Biomass Combustion – Challenges in Fluid Bed and Grate-firing
Teemu Nevalainen
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• Fluidized Bed Technology and Biomass Fuels
• Advanced Boiler Design Features for Biomass Firing
• Key References for Large Scale Biomass Firing
– Cofiring Peat and Biomass Fuels
– Clean Biomass Fuels
– Challenging Biomass Fuels
Presentation Outline
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Foster Wheeler AG
• Employees
• Order backlog
• New orders booked
• Operating revenues
• Consolidated EBITDA
Approx. 12,000
USD 3.6 billion
USD 4.3 billion
USD 4.5 billion
USD 283 million
• Established in 1884, known as Foster Wheeler since 1927.
• Foster Wheeler is a global engineering and construction contractor and powerequipment supplier, with a reputation for delivering technically-advanced, reliable facilities and equipment with world-class quality and safety.
• Traded on NASDAQ National Market in New York.
Key figures, 2011
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Foster Wheeler AG, Business Groups
The Global Engineering & Construction (E&C) Group
The Global Power Group
Designs and constructs leading-edge processing facilities for the
upstream oil & gas, liquefied natural gas (LNG), gas-to-liquids,
refining, chemicals and petrochemicals, power, environmental,
pharmaceutical, biotechnology and healthcare industries.
Has world-leading expertise in combustion technology, and
designs, manufactures, supplies and erects steam generating,
flue gas cleaning and auxiliary equipment for power stations and
industrial markets worldwide. The group also provides a range of
environmental products and aftermarket parts and services.
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Foster Wheeler Global Power Group
Products & Service
Steam generators
• Circulating fluid bed
• Pulverized coal
• Oil & gas
• Bubbling fluid bed
• Grate and MSW
• Package
• HRSG
• Metallurgical waste heat
• Solar
Aftermarket services
• Engineered and replacement
pressure parts
• Weld overlay and refractory upgrades
• Replacement parts
• Cyclone burner retrofits
• Coal mill service and
upgrade
• Boiler and HRSG
maintenence
Environmental products
• Circulating fluid bed
scrubbers
• Fabric filters
• SCR and SNCR systems
• Low NOx combustion
systems
• Coal/air control system
upgrades
• Biomass combustion retrofits
Auxiliary equipment
• Condensers
• Feedwater heaters
• Biomass gasifiers
Plant operation
• Start-up
• Operation and
maintenence services
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World Leader in Fluidized Bed Combustion
(CFB) Technology
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• 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 2012.
• CFB fuel flexibility and multifuel capability provide for efficient utilization of fossile and renewable fuels.
• Meets tough emission regulations without additional flue gas cleaning systems.
136 - Bubbling fluidized bed (BFB) boilers 402 - Circulating fluid bed (CFB) boilers
• 347 delivered
• 55 under construction
• Biggest unit in operation 460 MWe
• 135 delivered
• 1 under construction
11 - Atmospheric fluidized bed gasifires
• 11 delivered
PKE Lagisza, Poland Äänevoima Oy, Finland Lahti Energia, Finland
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• CFB technology was established under Graf-Wulff GmbH since 1989.
• High experience in Bag House and ESP technology.
• Low in operating and investment costs.
• Operated in coal-, oil- and solid waste-fired plants.
• Nearly unlimited in removal efficiencies (98-99%) for most multi-pollutants.
• Presently designed for flue gas flow from 10,000 to 4,000,000 m³/h.
• Operating range from 50 – 100% (down to 30% on special request).
Combination of FGS and dedusting 68 number of world wide installed systems
• 68 delivered
• 2 under commissioning
• Biggest unit in operation 3,100,000 m³/h
• approx. 70 % with CFB-scrubber and
Bag House
• approx. 30 % with CFB-scrubber and ESP
• approx. 50 % coal fired boilers
• approx. 40 % garbage and waste fired boilers
• approx. 10 % biomass and RDF,
fuel oil and fuel oil residue fired boilers
Distributing / application areas
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Basin Electric, USA Refinery, Germany EVN, Austria
World Leader in Circulating Fluid Bed Scrubbing
(CFB) Technology
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Fluidized Bed Technology and Biomass Fuels
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• Fuel flexibility is a special advantage
– Wide range for design coals
– Broad range for biomass, waste, etc
– Hard-to-Burn fuels (petcoke etc)
• Excellent emission performance
– No DeSOx / DeNOx –plants required
• High availability & competitive price
Key Advantages of CFB
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• Biomass has an important role in reducing the environmental
effects of energy production
• Biomass fuel market has changed to global and makes
possible large scale power generation of biomass alone
• In addition to the traditional clean and recycled biomasses, the
trend today shows increasing interest to applying agricultural
biomass & waste
• For the boiler supplier is important to understand bio fuel origin
and treatment processes as well as the actual ranges of fuel
and ash properties
• CFB is IDEAL TECHNOLOGY for large scale power
generation for broad range of biomass alone or co-firing in
larger fossil fired power plants!
Biomass as Energy Source
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Biomass Fuels
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Oth e r in d u s tria l
wo o d re s id u e s
Sa w-d u s t
Cu tte r s h a v in g s
Grin d in gp o wd e r
Ba rk
E n e rg yE . A la ka n g a s
HIERARCHY OF T HE WOOD-DERIVED F UEL S DEF INIT IONS
T imb e r o r p u lp wo o d fo r fo re s t in d u s try
FORESTRY Dire c t wo o d fu e ls
INDUSTRY In d ire c t wo o d fu e ls
SOCIETYRe c o v e r e d wo o d fu e ls
CONSUMERS OF WOOD
AND PAPER PRODUCT SF OREST INDUST RY
F OREST CHIPS
Wh o le tre e
De limb e d tre e s
Stu mp s
Ch ip s
Pu lp c h ip s
F o r p a p e rin d u s try
B ille ts
Pe lle ts Briq u e tte s
Ch ip s
Ch ip s c ru s h e d
Ch ip sF IEL DS
SHORT ROT AT ION
F OREST(willo w)
RAW MAT ERIAL
T imb e r
Pu lp wo o d
Re g e n e ra tio n
s ta n d s (lo g g in g re s id u e s )
Yo u n g s ta n d sT h in n in g s
(wh o le tre e s )
WOOD F UEL S
Un me r c h a n ta b le wo o d
CONVERSION PROCESSES ( COMBUSTION, GASIFICATION, PRODUCTION OF LIQUID BIOFUELS)
Pro d u c tio n o f re fin e d
wo o d fu e ls
Gre e n c h ip s
Bro wn c h ip s B la c k liq u o r
B io b a s e d
s lu d g e s
mix e d
with b a rk
Un tre a te d wo o d
Bu ild in g o f n e w h o u s e s
Pu lp a n d p a p e r
in d u s try
Me c h a n ic a l wo o d
in d u s try
Ch e mic a lly
tre a te d wo o d
Us e d p a p e r a n d b o a rd
Re c o v e re d p a p e r fo r
re c y c lin g
Cru s h e d o r c h ip p e d
re c o v e re d wo o d
Cru s h e d
p a p e r
L IQUID INDUST RIAL
WOOD F UEL S CONST RUCT ION
WOOD "o ld wo o d " o r
u s e d wo o d p ro d u c ts
NOT re c y c la b le
p a p e r
Wo o d a n d
p a p e r p ro d u c ts
SOL ID INDUST RIAL WOOD RESIDUES/
BY-PRODUCT Su n tre a te d wo o d
Ch ip s
s o rtin g
R a w m a te ria l u se
M e c h a n ic a l h a n d lin g (ch ip p in g , cru s h in g , p e lle tizin g , b riq u e ttin g )
C h e m ic a l tre a tm e n t in fo re st in d u stry
P a in tin g e tc . h a n d lin g o f w o o d
F u e l fo r co n v e rsio n p ro ce ss
E n d p ro d u cts (w o o d a n d p a p e r)
De wa te rin g
+ AGRO Biomass
All fuels have they
own Characteristics:
• Chemical characteristics
– Na,K
– Cl, P
– Ash content
– Etc..
• Physical characteristics
– Combustion
– Sizing
– Etc.
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Biomass Properties
• High concentrations of alkalis and chlorine increase risk for agglomeration, fouling and
corrosion
Timber Timber Saw Bagasse Straw Peat Recycled RDF
pellets chips dust briquette pellets wood fluff
Moisture % 5-10 20-50 45-60 8 12 50 25 25
Lower Heating Value
MJ/kg 17 7,5-13,9 6-10 16 14,7 9,3 14 13
Bulk Density kg/m3 650 130-280 300-350 650 650 340 300-400 100
Energy density
MWh/m3 3 0,55 0,45-0,7 2,9 2,7 0,9 1,4 0,4
Ash % ds 0,9 0,4-5,3 0,4-0,5 6 7 5,1 5 10-20
S % ds <0,1 <0,1 <0,05 <0,05 0,01-0,03 0,22 0,1 0,1-0,5
Cl % ds <0,03 <0,05 <0,03 <0,03 0,1-0,8 0,02-0,06 0,1 0,3-1,2
Alkali % ds 0,1-0,3 0,1-0,3 0,1-0,3 0,4-0,7 0,3-1,7 0,1 0,1-0,5 0,4-1
P % ds <0,05 <0,05 <0,04 <0,05 0,05-0,8 <0,35 <0,3 <0,5
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Advanced Boiler Design Features for
Biomass Firing
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• Fuel Characterization
– Physical & Chemical characteristics
– Fouling characteristics
– Corrosion characteristics
• Plant Requirements
– Electricity / Industrial
– Steam data
– Emissions
– Legistlation
• Investment Factors
– Investment cost
– Operation cost
– Fuel flexibility
– Availability
Factors Effecting for Boiler Design
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Key Design Features of Foster Wheeler Advanced Bio CFB
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Features to control Fouling & Corrosion
Features to control
Agglomeration & Fouling
- Correct flue gas temperature
- Correct design for convective heat
transfer surfaces
Conservative flue gas velocity
Integrated Water/Steam Cooled
Solid Separator and Return Leg
Step Grid Final SH & RH as INTREX
Active Bed Material
During Operation:
- Fuel quality management
- FW SmartBoiler datalog &
Diagnostic tools
Effective temperature control
Possibility to use Additives
with worst quality agros
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Key References for Large Scale Biomass
Firing
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Large Scale CFB for Cofiring Peat and Clean Biomass Jyväskylä, Finland
458 MWth, 160/143 kg/s, 164/40.5 bar(a), 560/560°C
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Fuel Peat Wood Chips
Moisture [%]ar 50.0 50.0
Ash [%]dry 5.0 2.0
Nitrogen [%]dry 1.2 0.3
Sulfur [%]dry 0.3 0.0
Chlorine [ppm]dry < 500 < 200
LHV [MJ/kg]ar 8.3 7.3
Performance Peat
Flue gas Texit [˚C] 90
Boiler efficiency [%] 94.1
NOx [mg/m3n] 150
SO2 [mg/m3n] 200
CO [mg/m3n] 200
Dust [mg/m3n] 30
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Large Scale CFB for Clean Biomass (CHP) Kaukas, Finland
385 MWth, 125 MWe-net, 110 MWDH, 149 kg/s, 115 bar(a), 550 °C
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Fuel Biomass Peat
Moisture [%]ar 48 50
Ash [%]dry 2.5 5
Nitrogen [%]dry 0.6 1.9
Sulfur [%]dry 0.05 0.2
LHV [MJ/kg]ar 9.2 8.5
Performance Biomass
Flue gas Texit [˚C] 149
Boiler efficiency [%] 91
NOx [mg/m3n] 150
SO2 [mg/m3n] 200
CO [mg/m3n] 200
Dust [mg/m3n] 20
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Large Scale and High Efficiency Advanced Bio CFB Concept for 20-30%-w Agro with Clean Biomass up to scale 400MWe
568/566ºC, 179-190/43.6 bar(a),
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• Natural Circulation available up
to 400MWe (~179bar)
– Limiting factor for scale in EU is
drum manufacturing capability
(up to scale ~350MWe)
• Once Through Benson available
up to 400MWe (~179-190bar)
– Lower Investment cost in scale
~350-400MWe
– Limiting factor for steam
pressure is corrosion resistance
of evaporator panel wall
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Advanced Bio CFB Concept for 20%-w Agro Polaniec CFB, Poland
447 MWth, 190MWe, 535/535ºC, 127/20 bar(a)
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Fuel
80% Wood Chips
&
20% AGRO (Straw, Sunflower etc)
Moisture [%]ar 35.9
Ash [%]dry 2.8
Nitrogen [%]dry 0.25
Sulfur [%]dry 0.05
LHV [MJ/kg]ar 10.5
Emissions
NOx [mg/m3n] 150
SO2 [mg/m3n] 150
CO [mg/m3n] 50
Dust [mg/m3n] 20
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Individual Biomass Fuels
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Unit Wood
chips
Straw Sun
flower
Dry Fruits Palm
Kernel
Form - Chips Pellet /
Briquettes
Pellet Pellet Crushed
LHV as received MJ/kg 10.1 14.8 18.6 16.8 17.9
Total moisture % 42.4 13.0 7.9 10.0 9.7
Content in dry fuel
Ash % 0.5 6.9 3.1 3.3 2.2
Sulphur (S) % 0.04 0.15 0.14 0.09 0.04
Chlorine (Cl) mg/kg < 200 <2000 < 700 < 300 < 300
Alkalis (Na+K) mg/kg <1 500 <27 000 <20 000 <5 000 <2 200
Phosphor (P) mg/kg < 400 <2 000 <3 000 <2 100 < 400
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Fuel Feeding
21
Day silos
Holding capacity total 1.5 h
Feeding chutes
4 pcs at FW
4 pcs at RW
2 drag chain conveyors
(RW/FW)
Four robbing screws per line
Eight feeding points
~60 MW per feeding point
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Multifuel CFB for Waste and Clean Biomass (CHP) Igelsta (Söderenergi AB, Södertälje, Sweden)
240 MWth, 73 MWe-net, 209 MWDH, 92 kg/s, 90 bar, 540°C
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Emissions 6%O2, dry
NOx [mg/MJ] 35*
SO2 [mg/m3n] 75
CO [mg/m3n] 50*
Dust [mg/m3n] 10
NH3 ppm 10
TOC [mg/m3n] 10
HCl / HF [mg/m3n] 10 / 1
Cd+Tl / Hg / HMs [mg/m3n] 0.05 / 0.05 / 0.5
PCDD+F [ng/m3n] 0.1
*) only at 100% load with Mix 1, 2, and 3
Fuel Mix 1 Mix 2 Mix 3
Biomass [%]LHV 75 30 100
Rec.wood [%]LHV 0 70 0
REF pellets [%]LHV 25 0 0
Moisture [%]ar 44.3 35.6 50.0
Ash [%]dry 6.5 4.7 4.0
Nitrogen [%]dry 0.6 0.8 0.5
Sulfur [%]dry 0.09 0.08 0.06
Chlorine [ppm]dry 1200 800 200
LHV [MJ/kg]ar 9.7 11.0 8.3
Total plant efficiency ~110%LHV 90%HHV
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• Despite of focus in bioenergy, other renewables and
nuclear, coal will remain important global fuel
• Co-firing biomass in larger fossil steam plants
enables high efficiency bioenergy production
• Co-firing provides flexibility to robust use biomass
depending on its seasonal availability
• Boiler Scale up to 800MWe is technically feasible
with a 20% share of Clean biomass with Clean coal
• Boiler Scale up to 600MWe is technically feasible
with a 50% share of Clean biomass with Clean coal
Co-Combustion of 50% Biomass with Coal
600MWe Scale with Supercritical Steam Parameters
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• FW has Extensive knowledge of Biomass
firing (195 FB units sold) and has modern
CFB Design with High fuel flexibility
meeting the most stringent emission
requirements
• Some biomass is easy, other is more
challenging. Biggest challenges are related
for agglomeration, fouling, and corrosion.
• Correct Fuel Characterization is the Key
issue in boiler Design.
• CFB Boiler Technology available for broad
variety of biomass/waste fuels with high
efficiency
Foster Wheeler CFB Technology & Summary
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