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CFBC boiler_Biomass
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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
• 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
1
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
2
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.
3
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
4
World Leader in Fluidized Bed Combustion
(CFB) Technology
5
• 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
• 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
6
Basin Electric, USA Refinery, Germany EVN, Austria
World Leader in Circulating Fluid Bed Scrubbing
(CFB) Technology
Fluidized Bed Technology and Biomass Fuels
7
• 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
8
• 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
9
Biomass Fuels
10
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.
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
Advanced Boiler Design Features for
Biomass Firing
12
• 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
13
Key Design Features of Foster Wheeler Advanced Bio CFB
14
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
Key References for Large Scale Biomass
Firing
15
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
16
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
Large Scale CFB for Clean Biomass (CHP) Kaukas, Finland
385 MWth, 125 MWe-net, 110 MWDH, 149 kg/s, 115 bar(a), 550 °C
17
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
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),
18
• 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
Advanced Bio CFB Concept for 20%-w Agro Polaniec CFB, Poland
447 MWth, 190MWe, 535/535ºC, 127/20 bar(a)
19
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
Individual Biomass Fuels
20
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
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
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
22
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
• 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
23
• 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
24
www.fwc.com