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25.11.2016 Caluwe, Inc – Spanner wood chip CHP 1
Caluwe, Inc. – Biomass Heat & Power Solutions
- Commercial-Scale Dry-Chip
Combined Heat & Power System
and Chip-Drying Technology
By Marc Caluwe
9 Wheatland street, Burlington MA 01803
83 Alexander Road, Billerica MA 01821
781-308-8583 - [email protected]
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Caluwe, Inc. – Biomass Heat & Power Solutions
1993 – 2005: Product Testing & Certification; Apragaz (B) and TUV-SÜD (US)
2005 - Present: Caluwe, Inc. - Import, Distribution and Sales:
- Hydronic wood stoves and fireplace inserts: Walltherm (I) & Spartherm (D)
- Hydronic wood fired cook stoves: Pertinger (I) & Lacunza (Es)
- Pellet Boilers: Windhager (A)
- Wood Chip Boilers: Heizomat (D)
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Pellet Boilers: Windhager (A) >> US & Canada
25.11.2016 Caluwe, Inc – Spanner wood chip CHP 4
Pellet Boilers: Windhager (A) >> US & Canada
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Wood Chip Boilers: Heizomat (D) >> US
Fixed Grate + Rotating Agitator
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Wood Chip Boilers: Heizomat (D) >> US
Moving
Chain
Grate
www.holz-kraft.de
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Commercial-Scale
Dry-Chip Combined Heat & Power System
and Chip-Drying Technology
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> Wood-Power-Modules > Wood-Power-Systems > Wood-Power-Plants > Drying-Systems
Spanner Re² GmbH
Wood Chips > Gasification > Electric Power & Thermal Heat
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Spanner SK.
k.s.
Slovakia
40 Employees
Spanner RE²
GmbH
Neufahrn in Ndb,
Germany
> 120 Employees
OTTO SPANNER
GmbH
Bayerbach, Germany
> 200 Employees
Automotive Renewables
SPANNER Group
Ursatronics GmbH
Berlin, Germany
40 Employees
Electronics
Otto Spanner GmbH in Bayerbach, Germany
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Spanner Re² GmbH in Neufahrn,
Germany
Caluwe, Inc – Spanner wood chip CHP
In 2004 Otto Spanner GmbH founded the daughter company Spanner Re² GmbH. With this decision the group aimed at achieving more independence from the automotive industry as well as at opening up a new business field: The mission of Spanner Re² is the development and commercial exploitation of innovative, economically attractive regenerative power generation technologies. • 120 employees at the company’s headquarters in
Neufahrn/Landshut/Germany • internationally active in seven countries • 7,000 m² production area • ISO 9001-2006 certified
Otto Spanner GmbH has been a successful player in the metal working industry for many years: The company has been a stable medium-sized partner of major industry brands for more than 50 years. Long standing customers like BMW, Porsche or Rational have come to appreciate the company’s reliability and corporate philosophy based on trust and honesty.
Geschäftsbereiche:
Innovative HOLZ-
KRAFT®-Anlagen
Kompakte Industrie-
Heizzentralen
Effektive
Hackschnitzel-
Trocknungsanlagen
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2004:
Gründung des regenerativen Sektor
der Spanner Gruppe
2006:
Gründung der Tochtergesellschaft
Spanner Re² GmbH
Business units:
Innovative Wood-
Power-Plants
Compact industrial
heating systems
Efficient wood chip
drying systems
2004:
Start of the Renewables sector of
Spanner group
2006:
Foundation of daughter
Spanner Re² GmbH
The Spanner Wood-Power-Plant is an intelligent system to produce electricity
and heat out of conventional wood-chips. The compact Wood-Power single plant and also the whole Wood-Power-Systems have proven themselves many
times in practice.
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The Spanner Wood-Power®-Plant
Caluwe, Inc – Spanner wood chip CHP
Uses cheap wood chips
Highly efficient combined heat and power
Use your power yourself and save cost
Feed eco power into the grid and earn revenue
CHP unit Gasification unit
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Operating principle of the Spanner Wood-Power®-Plant
(Face Lift = Post Reformer)
GM Vortec Engine
4 Stroke V8 – 5.7 Liter
1,520 RPM
CHP unit
Gasification unit
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Operating principle of the Spanner Wood-Power®-Plant
(Face Lift = Post Reformer)
Caluwe, Inc – Spanner wood chip CHP
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REFORMER Process
Caluwe, Inc – Spanner wood chip CHP
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EMISSIONS
Caluwe, Inc – Spanner wood chip CHP
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Technical data Spanner Wood-Power®-Plant
Electric power 10 kW (2016) 30 kW 45 kW
Thermal Heat 25 kW
(85,300BTU/hr)
73 kW
(249,000 BTU/hr)
108 kW
(368,000 BTU/hr)
Wood chip consumption 10 kg/h 30 kg/h 45 kg/h
Wood chip consumption for 7.000
operating hours 60 tATRO 180 tATRO 270 tATRO
Required space min 7.5 x 5 m
Required room height 2.6 – 3.4 m depending on wood chip intake
Max output limited for
Net metering in Germany
ATRO-t means
0% WC !
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Efficiency data Spanner Wood-Power®-Plant
Electric power 10 kW (2016) 30 kW 45 kW
Thermal Heat 25 kW (85,300
BTU/hr)
73 kW
(249,000 BTU/hr)
108 kW
(368,000 BTU/hr)
Thermal Efficiency NA NA 56.3%
Electrical Efficiency NA NA 26.7%
Total Efficiency NA NA 83%
Installed units
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Sold and installed units
12 24
42 62
120 140
12 36
78
140
260
400
0
50
100
150
200
250
300
350
400
450
2009 2010 2011 2012 2013 2014
Auslieferungen im Jahr
Feldbestand zum Jahresende
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Sold per year
Installed units at year end
Installed units
in Germany
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Holz-Kraft locations
Site visits by appointment
Regular site tours
Corporate headquarters at
Neufahrn (NB.)
Caluwe, Inc – Spanner wood chip CHP
Most important aspect:
The CHP unit needs to run as many
hours per year as possible: >7,000
hours/year
HOW?
- Correct sing of the THERMAL LOAD >> UNDERSIZE CHP output !
- Fuel quality = quality of the wood chips >> result in less breakdowns
>> CAN‘T BURN WATER !
>> WATER IS USED TO EXTINGISH A FIRE !
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Correct sizing of the THERMAL LOAD
- Size for SUMMER CONDITIONS !
- UNDERSIZE output
- Look into COOLING applications for summer (Absorbtion chiller)
Why?
- The CHP unit needs to be able to use the Thermal Heat (Hot Water)
„somewhere“ >> Process Heat or Heating/Cooling a building
- If you can not use the Thermal Heat, then the CHP unit will overheat
and shut down (just like your car engine with broken radiator)
- Do not „dump“ the heat !
Dumping Heat = Annual Operational hours go down = No financial pay
back
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Do not „dump“ the heat !
Dumping Heat = you loose THERMAL ENERGY = No financial pay
back
HOW?
Incorporate Thermal Storage
10,000 gallons of water = 83,500 Lbs of water
Assume a usefull deltaT = 20C = 36F
83,500 Lbs x 36F = 3,006,000 BTU
3,006,000 BTU / 3412 = 881 kW devided by 108 kWt = 8+ hours of storage
10,000 gallons of water = 83,500 Lbs of water
Assume a usefull deltaT = 20C = 36F
83,500 Lbs x 36F = 3,006,000 BTU
3,006,000 BTU / 3412 = 881 kW devided by 73 kWt = 12+ hours of storage
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45 kWe
30 kWe
Required wood chip quality
13% water contents max., 15% moisture contents max.
30% fine portion
max.
• Higher fine portion increases fault susceptibility
• Highter fine portion increases ash discharge
No foreign substances
• Sand causes slagging
• Screws, nails, stones cause plant damage
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Requiredwood chip quality: G30 – G40
YOU
Can‘t
BURN
WATER !
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Fuel comparison
Customer: Huber Prepared roadside and
landscape conservation wood
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Fuel comparison
Customer: Wäsler Dried and sieved mixed woods
Customer: Baumgartner Dried and sieved forest timber
remains
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Calorific Value (Heating Value) of wood & wood chips
@ 13% WC
Or 15% MC
You double your heating value by drying
The wood chips and you cut down on the
amount of wood chips
2.12 kWh/kg or
3,255 BTU/Lb
4.45 kWh/kg or
6,830 BTU/Lb
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Cost of wood chips at 15% MC and 25% MC
MC WC MC WC
Wood Chips G30/50
$145/ton
Wood Chips G30/50
$120/ton
WET Wood Chips
G30/50
$50/ton ???
Info:
Biomasseverband OÖ
4021 Linz, Auf der Gugl 3
Biomasseverband-ooe.at
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Wood chip drying
Wood chip drying technology
How much does it cost to dry wood chips ?
Caluwe, Inc – Spanner wood chip CHP
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How much does it cost to dry wood chips ?
<<<<< Required Thermal Heat
<<<<< Required Electric Power
Required Total Energy for drying?
Caluwe, Inc – Spanner wood chip CHP
144 kWhth = 0.144 MWhth >>> @ $20/MWhth >>> $2.88 per m3 or yard + electric
If you need 2 or 3 m3 or yards for a ton
of chips then the total drying cost per
ton $8 to $12
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Cost of wood chips at 15% MC and 25% MC
MC WC MC WC
Wood Chips G30/50
$145/ton
Wood Chips G30/50
$120/ton
Info:
Biomasseverband OÖ
4021 Linz, Auf der Gugl 3
Biomasseverband-ooe.at
WET Wood Chips
G30/50
$50/ton
+$12 for drying
= $62/ton
For 300 or 350
Tons per year
You save
$25,000 per year
= 3 to 4 year pay
back for dryer
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Wood chip drying technology Wood chips for use in a Wood-Power-Plant must not exceed a water
content of 13 % resp. a moisture content of 15 %!
However: Fresh material (from the forest) has a moisture contents of over
100 %
By simple storage (natural predrying) of wood chips, moisture contents
cannot be decreased to < 40 %
Therefore wood chips have to be technically dried to achieve the required
moisture content of < 15 %.
Spanner Re² offers a range of drying units:
Bin drying
Slanted floor drying
Mobile silo
Container drying
Waggon drying
Double bin drying
Push floor drying
Caluwe, Inc – Spanner wood chip CHP
Drying conveyor
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For approx. 6 – 10 m³/day or rather 3000 m³ per year Fully automatic drying system >> you dry the amount of wood chips you need Continuous drying Optional: remote control Dimensions: 3,5 m x 2,4 m x 1,7 m (LxBxH)
Caluwe, Inc – Spanner wood chip CHP
Bin drying, compact unit
for 4000 – 5000 m³ loose cubic meters of wood chips per year
The drying in containers is recommended if large quantities of wood chips are to be dried and to be further transported immediately afterwards.
Very simple, cost efficient construction
In the floor area wood chip discharge and an air permeable construction can be combined
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Dimensions: individual concerning customers request
Depending on the available heat, it is possible to dry the wood chips in two bins simultaneously double bin drying (following page)
Caluwe, Inc – Spanner wood chip CHP
Double bin drying Very simple, cost efficient construction
In the floor area wood chip discharge and an air permeable construction can be combined
dimensions: 2,5 m x 2,5 m (base floor) per bunker
Depending on what the customer wants, we offer the system with different storage capacities and heat output
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Advantages: • Combined drying / bin solution in alternate operation • Low time & work effort • Minimum dust • Low floor space required
Caluwe, Inc – Spanner wood chip CHP
Container drying
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Advantages:
• Also serves as intermediate storage
• Simple logistics
• Batch operation
• Suitable for small amounts
• Low time & work effort
• No cover needed in normal rain or snow
For approx. 11-22 m³/day
Drying in containers is recommended if large quantities of wood chips are to be dried and to be further transported immediately afterwards.
For this, large roll-off containers are used for the transport on trucks. The advantage of the container is its large capacity of 22 m³ and more.
Two containers can be combined for double bin drying
Filling amount = container size
Caluwe, Inc – Spanner wood chip CHP
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• For approx. 15 – 20 m³/day or rather 5500 m³ per year
• The big difference: permanent drying resp. Discharge of wood chips
• A storage bin for dry wood chips is required !!!!!!
• Fan and heat exchanger press warm air through the floor from below
• Drying time is adjusted by means of temperature comparisons above and below the wood chips
Push floor drying
• Dimensions: 6 m x 2,4 m x 3 m
Caluwe, Inc – Spanner wood chip CHP
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Transportation logistics: in 2 x 20‘ steel containers per gasification unit
Due to the ready-to-install components in the 20 ft. Containers or rather in the concrete garages, the Wood-Power-Module is very easy to transport! This also lower the time between delivery and implementing
The Spanner Wood-Power – Modular concept
Caluwe, Inc – Spanner wood chip CHP
The Spanner Wood-Power – Modular concept
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• The wood-power-modules consist of the wood-
power-plant (gasifier and cogeneration unit) and is
pre-installed in a sound-absorbing, robust, fireproof
and cheap ferroconcrete ready-to-install garage or
container.
• The interior design is adapted to the special needs
and requirements!
• This solution is used, where no matching room for
the wood-power-plant exists, the existing room
cannot be modified, or the plant should be adapted
as a space-saving solution besides the building.
Space-saving and ready-to-install solutions Wood-power-unit in a container (picture above) Wood-power-unit in a concrete garage (picture below)
Adaptable to every amount of needed heat and electricity
Caluwe, Inc – Spanner wood chip CHP
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The Spanner Wood-Power-System Solutions the complete system solution
Therefore, the internal process guarantees the necessary wood-chip quality out of untreated and humid conventional wood chips. By use of this whole system solution, the maintenance-friendly and continuous operation will get much more easier.
The Wood-Power-System consists of a cascade of • The needed amount of Wood-Power-Plants • The efficient wood-chips dryer and the whole
logistic • The intelligent impurity removal • The wood-chips bunker • And the whole waste material logistic
inclusive ash-container
Ash-container
Wood-chips drying system; bunker Wood-chips bunker
and Wood-Power-Plants
Wood-chips drying system
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Your advantages: Nine out of ten plants are operating every time this
ensures a permanent and save heat and electricity supply Cheap and robust wear parts for a max. efficiency simple
repair and maintenance work by every car mechanic In case of substituting dieselgenerators: ROI within three
years! Fast delivery times! Your option: relocation after a few years could be done very
simple!
Inform and react: Within four months* you could be your own energy supplier
*from ordering with payment receipt until the first electricity and heat production
The Spanner Wood-Power-System Solutions
Caluwe, Inc – Spanner wood chip CHP
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HK 19 Wood-Power-System: Wood-Power-System combined with a double-bin dryer and the ash logistics
Example: HK 19 Wood-Power-System
HK 19 Wood-Power-System: Wood-Power-System combined with the ash logistics, the bunker for the wood-chips and the drying system
Plant-Type HK 19 (1) El. power: 19 kW Th. power: 45 kW
Caluwe, Inc – Spanner wood chip CHP
Example: HK 135 Wood-Power-System
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The unit consists of a cascade of three Wood-Power-Plants (cogeneration unit and wood-gasifier) and of a fully automatic wood-chip preparation (drying-system and sieve-system).
Plant-Type HK 45 (3) El. Power 135 kW Th. Power 324 kW
Caluwe, Inc – Spanner wood chip CHP
The Spanner Wood-Power-System Solutions
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Example here: Plant-type: HK 45 (10) El. power: 450 MW Th. power: 1,08 MW
Adaptable to every amount of needed heat and electricity
Caluwe, Inc – Spanner wood chip CHP
The Spanner Wood-Power-System Solutions
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Adaptable to every amount of needed heat and electricity
Example here: Plant-type: HK 45 (20) El. power: 900 MW Th. power: 2,16 MW
Caluwe, Inc – Spanner wood chip CHP
Example: Wood-Power-System in Latvia
Feeding in the electricity into the district heating system in Latvia
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Plant-Type HK 45 (22) El. power 1 MW Th. power 2,4 MW
Caluwe, Inc – Spanner wood chip CHP
Typical applications in Germany
Forestry
• Forest owners
• Thinning operations
• Saw mills
Local heating networks
• Swimming pools
• Industrial business
• Public buildings, e.g. schools or town halls
• Remote districts and hamlets
Agriculture
• Piglet weaner stations
• Organic milk producers
• Nurseries and hothouses
• Agricultural business with holiday accomodation
Hotel & real estate industry
• Agricultural business with holiday accomodation
• Guesthouses in rural areas
• Holiday farms and wellness hotels
• Youth hostels
25.11.2016 48 Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours (91% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours
(91% operational)
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours (91% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours (86% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
District Heating network
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours
(86% operational)
District Heating network Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours (80% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours
(80% operational)
Caluwe, Inc – Spanner wood chip CHP
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Annual operating hours
(96% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
Caluwe, Inc – Spanner wood chip CHP
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Annual operating hours
(96% operational)
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours (91% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours
(91% operational)
Caluwe, Inc – Spanner wood chip CHP
25.11.2016 65
>>> Annual operating hours (91% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours
(91% operational)
Caluwe, Inc – Spanner wood chip CHP
DHW load
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>>> 2,855 Ft = 952 yds
6 1 >>> Annual operating hours (74% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
District Heating network
Caluwe, Inc – Spanner wood chip CHP
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(13,230 Gal) !?
SYSTEM is OVERSIZED
for summer, but needs the
thermal heat in winter
Annual operating hours (74% operational) >>>
District Heating network
Thermal Storage 10,000 gallons of water = 83,500 Lbs of water
Assume a usefull deltaT = 20C = 36F
83,500 Lbs x 36F = 3,006,000 BTU
3,006,000 BTU / 3412 = 881 kW devided by 216 kWt = 4 hours
5.5 hours of
Thermal storage
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours (57% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
Caluwe, Inc – Spanner wood chip CHP
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!!! (22,750 Gal)
SYSTEM is
OVERSIZED
for summer
>>> Annual operating hours
(57% operational)
Thermal Storage 10,000 gallons of water = 83,500 Lbs of water
Usefull deltaT = 20C = 36F
83,500 Lbs x 36F = 3,006,000 BTU
3,006,000 BTU / 3412 = 881 kW devided by 73 kWt = 12 hours
27 hours of
Thermal storage
Caluwe, Inc – Spanner wood chip CHP
www.holz-kraft.de
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woodchipboilersr.us
Borealiswoodpower.com
Thank you for your attention
Caluwe, Inc – Spanner wood chip CHP