presentation plant visit lucerne · hzi client event 2016: plant visit lucerne 2 key figures - 2...

Presentation Plant Visit Lucerne Perlen, March 3rd 2016

LUZERN: Overview

2 HZI Client Event 2016: Plant Visit Lucerne

Key Figures

- 2 lines, 47MW thermal each

- Waste Hu = 9-16 MJ/kg

Objectives for HZI

- Build a highly efficient and highly automated waste to

energy plant

- Many new innovative systems and control logic

- A new benchmark plant for HZI

LUZERN: Overview

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LUZERN: Bunker

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Bunker with physically

separated

compartments

LUZERN: Bunker

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Bunker with physically

separated

compartments

LUZERN: Combustion and Boiler

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First plant with INOVA grate (10° forward acting grate)

Zones 1&2 with Aquaroll, Zones 3&4 aircooled

Maintenance friendly

INOVA Grate and

Ram Feeder

LUZERN: INOVA Grate

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INOVA Grate and

Ram Feeder

R-Grate Inova Grate

Zones 4-6 (standard 5) 4

Lenght 8-12 m 10.7 m

Angle 18° 10°

Functionality

Speed variable variable

Movement discontinuous

(optional continuous)

Continuous

(slow forward, fast backward)

Stroke length fixed (150 mm) Variable (max. 300 mm)

Advantages INOVA Grate

Maintenance: Better accessibility, faster maintenance

Building: Lower building height

Price: Less expensive grate surface

R-Grate Inova Grate

LUZERN: INOVA Grate / Ram Feeder

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INOVA Grate and

Ram Feeder

Ram feeder

Ram feeder drop

Aquaroll hoses

Grate block

Pneumatic grate riddling system

INOVA Grate: Teething Troubles

LUZERN: Combustion and Boiler

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Combustion chamber:

Open geometry

New design of combustion chamber

Open design → more radiation on waste → good burn-out quality

INOVA Grate and

Ram Feeder

INOVA Grate and

Ram Feeder

LUZERN: Combustion and Boiler

10 HZI Client Event 2016: Plant Visit Lucerne

Combustion chamber:

Open geometry

1st pass is fully cladded

Fast reaction of steam on combustion conditions

Little slagging observed

1st pass:

Fully cladded

Combustion chamber:

Open geometry INOVA Grate and

Ram Feeder

LUZERN: Combustion and Boiler

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Combustion chamber:

Open geometry

Injection of secondary air and recirculated flue gas

Two stages → improved flue gas mixing, lowered peak temperatures (NOx)

Volume flows to each injection fully controlled by automated dampers

1st pass:

Fully cladded

Combustion chamber:

Open geometry

1st pass:

Fully cladded

INOVA Grate and

Ram Feeder

SA/RFG Injection

on 2 stages

RFG extraction

directly after ESP

LUZERN: Combustion and Boiler

12 HZI Client Event 2016: Plant Visit Lucerne

Combustion chamber:

Open geometry

Efficient cleaning of all empty passes with shock wave pulse generators

1st pass:

Fully cladded

Combustion chamber:

Open geometry

1st pass:

Fully cladded

Shock wave generators

in pass 1 to 3

INOVA Grate and

Ram Feeder

SA/RFG Injection

on 2 stages

SA/RFG Injection

on 2 stages

RFG extraction

directly after ESP

RFG extraction

directly after ESP

LUZERN: Combustion and Boiler

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Combustion chamber:

Open geometry

Additional sensors for combustion control (CCS+), see later

Differentiation of full and empty grate

Fire end control

1st pass:

Fully cladded

Combustion chamber:

Open geometry

SA/RFG Injection

on 2 stages

RFG extraction

directly after ESP 1st pass:

Fully cladded

RFG extraction

directly after ESP

SA/RFG Injection

on 2 stages

Additional

sensors

INOVA Grate and

Ram Feeder

Shock wave generators

in pass 1 to 3

Shock wave generators

in pass 1 to 3

LUZERN: Combustion and Boiler

14 HZI Client Event 2016: Plant Visit Lucerne

Combustion chamber:

Open geometry

1st pass:

Fully cladded

SA/RFG Injection

on 2 stages

Additional

sensors

INOVA Grate and

Ram Feeder

Shock wave generators

in pass 1 to 3

RFG extraction

directly after ESP

New control logic

Air systems run energy optimized (fan and damper control)

New HZI combustion control system (HZI-CCS)

Advanced combustion control (CCS+)

Combustion Control System

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Steam flow setpoint

Preset NCV

Adj. fire position

3 manual inputs required

Performance Examples CCS

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Narrow O2 band

Rapid load changes

Very stable steam flow After load change

no over/undershoots

Additional sensors – CCS+

Additional sensors for prediction and detection of situation on grate

Differentiate between empty and full grate

Analyse waste properties (density, LHV)

Burn-out control

Benefit

Further improve live steam stability

Proper reaction on changing waste properties

More stable combustion conditions

Less manual interactions

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Sensor Package A: Example Laser Scanner Logic

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Scans the surface of

waste on feedhopper

Waste density,

volume- and

mass-flow

Early information

about waste type

Visualisation of real data

HZI Client Event 2016: Plant Visit Lucerne

Fire End Line: Burnout control

Example: fire gets too long

► primary air flow increased

► grate speed reduced

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Visualisation of real data

Blue pyramids indicate where and how much primary air is added

HZI Client Event 2016: Plant Visit Lucerne

LUZERN: Combustion and Boiler

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Achievements

O2 Down to 3 vol% wet possible

NOx (uncontrolled) < 200 mg/Nm3 at 11% O2

TOC in bottom ash Around 0.5 wt%

Live steam stability Excellent (standard deviation: 1.5%)

Manual corrections Little (highly automated)

LUZERN: Combustion and Boiler

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LUZERN: Flue Gas Treatment

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Electrostatic Precipitator to collect fly ash; ESP ash used for Zinc recovery

Flue gas flow after ESP measured with a raw gas venturi

Raw gas

Venturi Raw gas

Venturi

ESP

LUZERN: Flue Gas Treatment

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1st stage: NaHCO3 for acid removal (HCl, SO2)

stoichiometry close to 1; Residues recycled by RESOLEST

“Xerosorb” fabric filter with integrated residue recirculation

Raw gas

Venturi

Raw gas

Venturi

Reactor 1

Bicar ESP ESP

LUZERN: Flue Gas Treatment

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Catalyst modules mounted from top

Raw gas

Venturi

Reactor 1

Bicar

Reactor 1

Bicar

SCR

Catalyst

ESP

LUZERN: Flue Gas Treatment

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Energy recovery with economizer

Used for feedwater preheating

Raw gas

Venturi

Reactor 1

Bicar

SCR

Catalyst

SCR

Catalyst economizer

ESP

LUZERN: Flue Gas Treatment

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Hydrated lime and lignite coke – “polishing” and Mercury absorption

Modular “Xerosorb” fabric filter

Raw gas

Venturi

Reactor 1

Bicar

SCR

Catalyst economizer

Reactor 2

Hydrated lime

economizer

ESP

LUZERN: Flue Gas Treatment

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Recovery of energy before stack

Energy used for condensate heating

Raw gas

Venturi

Reactor 1

Bicar

SCR

Catalyst economizer

Heat

exchanger

ESP

Reactor 2

Hydrated lime

Reactor 2

Hydrated lime

LUZERN: Flue Gas Treatment

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240 °C

135 °C

130 °C

235 °C

235 °C

80 °C

Gradual temperature

decrease

Energy recovery.

No energy losses due to

reheating of flue gases

130 °C

Emission values

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Summary

New HZI standard for new projects

Open combustion chamber &

staged secondary air injection for operation at low O2

Inova grate (partly)

New HZI CCS and CCS+ with additional sensors (also as retrofit)

Dry flue gas cleaning (Xerosorb)

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Thank you very much for your attention

HZI Client Event 2016: Plant Visit Lucerne