Fraunhofer IFF Energy Utilization Program - Presentation Indonesia

Frank Mueller, FMC, Magdeburg, [email protected]

Ralf Opierzynski, Fraunhofer IFF, [email protected]

Technology cooperationTechnology cooperation

Background

Fluidized bed technology

Energetic utilization – pilot plants

Concept for technology and know-how transfer

Annex

The The FraunhoferFraunhofer IFF approach onIFF approach on

decentralized energy utilization of waste and biomass using decentralized energy utilization of waste and biomass using

fluidized bed combustion technologyfluidized bed combustion technology

Opportunities for cooperationOpportunities for cooperation




Main Fraunhofer IFF Magdeburg building

Virtual Development and Training Centre

The Fraunhofer IFF is an autonomous research organization within the Fraunhofer-Gesellschaft.




PartnershipPartnership

Capacity & Capacity & Institution Institution BuildingBuilding

R & DR & DIndustry Industry

ApplicationsApplications

From know how transfer to long term cooperation From know how transfer to long term cooperation -- Fluidized bed technologyFluidized bed technology

Selected other areas

a. Renewable energies and smart grids

b. ICT supported Sustainability Management in industries

b. Logistic und automation,

c. VR for planning processes

d. Technical Vocational Education & Training

e. …

Fluidized bed applications




• Green Productivity Project (GPP I / II)(Indonesia, Thailand, Philippines, Vietnam / 1999 – 2005)www.epa-for-industry.de

• Training on Cleaner Production Technology (CPT I / II / III / IV)(Indonesia, Thailand, Philippines, Vietnam / 2000 - 2003)

• Web Based Training: Life Cycle Oriented Plant Management(LCPM) (Vietnam, Indonesia, Thailand / 2001 - 2005)

• Information Technology and Communication in the Field of Sustainable Environmental Protection for Resource Intensive Enterprises (ASIA IT&C FORCE, Thailand / 2002 – 2004)www.asia-itc-force.de)

• Technology Transfer – Fluidized Bed Gasification Plant (Biomass / Hanoi, Vietnam / 2006)

Selected Project References Asia ISelected Project References Asia I




• Technology Partnership and Training Cooperation in European Management Information Systems to Enhance theCompetitiveness of Thai SMEs (SPF TEAMS SME; Thailand / 2006 – 2007, www.teams-sme.de)

• European-Malaysian Alliance and Capacity Building ofMalaysian Intermediary Institutions in European MIS to Enhance Corporate Social Responsibility in Export OrientedMalaysian SMEs (EMIT CSR (Malaysia / 2007 – 2008, www.emit-csr.de)

• Empowering Asian Business Intermediaries throughKnowledge-based Networking focused on SustainabilityManagement (EMP-ASIA; Thailand, Vietnam / 2007 – 2009, www.empasia.org)

Selected Project References Asia IISelected Project References Asia II




Biomass / Residues

Combustion Gasification Fermentation

HeatGas Cleaning and Gas Conditioning

Organic Rankine Cycle

Gas Engine or Turbine Fuel Cell

Syngas Biogas

Bioethanol Production

MembraneReactor

IFF Process and Plant Engineering IFF Process and Plant Engineering –– Areas Areas

• ProBio• WISA

• COST 543

• Intell-FC

• Templin• Wolmirstedt

• Stackelitz

IFF R&D IFF R&D ActivitiesActivitiesIFF Engineering IFF Engineering ActivitiesActivities




Fluidized bed technology systems consist of a vertical pipe with an air distribution plate.

The air distribution plate is covered by a bed material, usually quartz sand (yellow), mixed with the fuel (green).

As air (gray) flows through the nozzles, it entrains the bed material with the combustible material into a fluidized state where the fuel is converted (flue gas - white ).

New fuel is gradually fed into the fluidized bed from the side.

Fluidized bed technology Fluidized bed technology -- principleprinciple

Air

Air distribution plate

Flue gas (high temp.)

Fuel




Advantages for energy conversion processes, i.e. combustion and Advantages for energy conversion processes, i.e. combustion and gasification:gasification:

Use of a broad range of fuels with regard to lumpiness (broad grain size), type of fuel / heterogeneity, moisture content and content of contaminants (S, Cl)

High combustion/gasifier performance with low space requirements

Excellent mass and heat transfer conditions associated with process

Excellent possibilities to intervene for process optimization at high dynamics.

Applications:Applications:

Energetic utilization of solid matters (fossil fuel, biomass, residues, silage, sewage sluge, etc.)

Waste processing e.g. incineration plant

Product drying and coating

Product treatment e.g. coffee roasting (food industry)

Product design e.g. medical pills production (pharmaceutical-industry)

Application and advantages of the fluidized bed technologyApplication and advantages of the fluidized bed technology




Advantages for small and medium applications (1Advantages for small and medium applications (1--20 MW) 20 MW)

Low capacityClose to place of consumptionCHP (combined heat and power)

• High degree of fuel utilization • Reduced resource consumption

and greenhouse gas emissions• Small fuel source radius• Low transport costs• Low grid costs and losses• High investment certainty• Regional value added

Decentralized energy utilization plants based on fluidized bed technology




residues and waste materials (self-sustaining energy supply of production

processes and/or network supply)

electricity

(heating/cooling of industrial, commercialand municipal processes)

thermal energybiomass

energy transformation

process development plant engineering plant control

Process and plant engineering know howProcess and plant engineering know how




Energetic utilization of biomass Energetic utilization of biomass –– plant plant WolmirstedtWolmirstedt

Technology: Fluidized bed combustionCombined heat and power with ORC-process4,3 MW firing thermal capacityFuel: wood residues from forest and industryFuel input: 1 t/h

Power: 500 kWel / 2.400 kWtherm. (ORC)Heat: heating network Bodelschwingh-HausE-power: sale to the public grid (EEG)

Start of operation: 2007




Technology: Fluidized bed combustionSteam cycle process110 MW firing thermal capacityFuel: community wasteFuel input: 20 t/h; 150.000 t/a

Power: Max. 20 MWel - max. 90 MWtherm.

Heat: district heating networkE-power: sale to the public grid


source: www.stadtwerke-neumuenster.de

Energetic utilization of municipal waste – plant Neumünster







Consequences for technology applicationConsequences for technology application

Localization of technology to applications

Market conditions (materials, demands on products, production process, prices, financial conditions)

Local conditions (climate, culture …)

Interdisciplinary qualified experts and specialist

Institutionalized capacities and R&D (further development, ToT …)

Adaptation by local businesses

The Fraunhofer IFF approach on decentralized energy utilization of waste and biomass using fluidized bed combustion technology

Example




Scope and potential results of the IFF technology cooperation moScope and potential results of the IFF technology cooperation modeldel

1. Enable Indonesian engineers / organizations to utilize the full technological potential of fluidized bed technology for the benefit of their country (training of specialists and training of trainers)

2. Apply the technology for market driven and environmentally friendly applications in Indonesia (design, construct and operate power plants)

3. Support sustainable and decentralized energy supply

4. Advance science and technology development through international and local research (R&D activities on fuel utilization and technology applications)

5. Long term partnership and international R&D cooperation




Duration: 3 to 5 years depending on specificationProject team: Fraunhofer IFF Magdeburg, Germany, Hamburg University of Technology (TUHH),

Indonesian partners (private or public), private or public investors (Indonesian, international)Budget: Depending on specification – range 10 - 13 Mio EUR - turn key

Program Program organizationorganization

Realization of the first combustion plant with CHP and ORC-process:1.Planning, engineering and construction of fluidized bed combustion plant, e.g. 4 - 6 MW firing thermal capacity (approx. 1 t/h fuel input), fuel possibilities: municipal waste, biomass or residues from forestry or industry2.Qualification of plant operators and technicians

Fluidized bed Fluidized bed combustion combustion application application

Set up of infrastructure for engineering research and education purposes:1.Engineering, construction and operation of semi-industrial scale BFBC (bubbling fluidized bed combustor) including measurement and analysis systems2.Laboratory set up for fuel analysis (e.g. calorimeter, dry chamber, proximate and ash analyzer), and fuel conditioning (e.g. grinder, sieve apparatus) as well as work shop facilities.

Set up of Set up of knowledge knowledge infrastructure infrastructure

Training of 6 – 10 engineers in theory and practice on:1. Solid fuel combustion, fluidized bed technology2. Distributed low and medium capacity power plants3. Operation of national train the trainer program

KnowKnow--how how transfer transfer

DescriptionDescriptionComponentsComponents




Initiation of cooperation and specification to set-up transfer program

Potential next steps / outlookPotential next steps / outlook

Study Tour Germany / Indonesia

Technology road show - practical tour on best practice examples

Duration: approx. 14 days, costs: depending on number of participants

Feasibility study

Analysis, evaluation of specific conditions, constraints and requirements

Design of a tailored transfer and cooperation program respectively business plan for private investors,

Duration: max. 12 months, approx. total costs: 120.000 EUR




AnnexAnnex




Air

Biomass,waste or

residues feed Ash

Additives

Fly ash

Thermo Oil Sorbens

Flue gas

Fluidized bedCombustion module

Boiler module Flue gascleaning module

ORC-Module

Heat (80/60°C) Power

Energetic utilization of biomass, waste and residuesEnergetic utilization of biomass, waste and residues

Combustion - CHP plant principle




Gasification - CHP plant principle

Energetic utilization of biomass, waste and residuesEnergetic utilization of biomass, waste and residues

fluidized bedgasifier

fuel gastreatment

ash

ash

fuel gascooler

fuel gas

air

heat extraction flue gas(district heating network)

air

flue gas

gas engine generatorresidual wood

preheatedair




Supervision / SteeringFinancier / Ministries

R&D and technology partner Universities, R&D centres

R&D and technology partner Universities, R&D centres

Technology and Know-how Partner (Germany)Fraunhofer IFFTechnical Universityof Hamburg…

Technology and Know-how Partner (Germany)Fraunhofer IFFTechnical Universityof Hamburg…

Coordination / Management / Controlling IFF in cooperation with local partner

Coordination / Management / Controlling IFF in cooperation with local partner

Commercialisation PartnersBiomass and residues suppliers,Energy consumer / provider,Local communities,Engineering companies

Commercialisation PartnersBiomass and residues suppliers,Energy consumer / provider,Local communities,Engineering companies

Potential project infrastructure for a national scale programPotential project infrastructure for a national scale program




Technology: Fast Internal Circulating Fluidized

Bed

Steam GasificationFuel: wood chipsFuel input: 2.3 t/h

Power: 2 MWel / 4.5 MWtherm

Heat: district heating system


source: http://www.renet.at

Energetic utilization of biomass Energetic utilization of biomass –– plant plant GGüüssingssing, Austria, Austria




Technology: Fluidized Bed Gasification and Ash

Melting

Fuel: municiple solid wasteFuel input: 8.3 t/h, in 3 processlines

Power: 4 MWel / 3x9.5 MWtherm

Heat:Ube City

Start of Operation: 2003

source: http://www.ebara.ch

Energetic utilization of Energetic utilization of municiplemuniciple solid waste solid waste –– plant plant TwinRecTwinRec, Japan, Japan




Energetic utilization of biomass Energetic utilization of biomass –– plant plant NorthamptonNorthampton , USA, USA

Technology: Circulating Fluidized BedCombustionSteam GenerationFuel: culmFuel input: 545,000 t/a

Power: 110 MWel / 277 MWtherm

primarily supplying steam to an adjacent pulp and paper mill


source: http://www.power-technology.com/projects/northampton/




Energetic utilization of biomass and waste Energetic utilization of biomass and waste –– plant plant HandeloHandelo , Sweden, Sweden

Technology: Circulating Fluidized Bed CombustionFuel: miniciple solid waste,industrialwaste,sewage sludge,rubber and demolition woodFuel input: 4000,000 t/a

Power: 11 MWel / 75 MWtherm

district heat and process steam





Improvement of the supply chain from forest to factory

Economic feasibility and cost cuttingTransparency, information and communicationEnvironmental compatibility and prevention

Primary target groups

Forestry and wood processing industriesForest and logistics service providers Forest owners

Selected services and technologies

Order management and condition monitoring Resource and inventory managementRoute planning, navigation, routing, driver‘s logMobile terminals for on site recording and information

ICT supported wood logistic chains ICT supported wood logistic chains ““from the forest to the from the forest to the factoryfactory”” focusing on its environmental orientationfocusing on its environmental orientation

Example for competences on related topics Example for competences on related topics -- wood logisticswood logistics

Documents

Fraunhofer IFF Energy Utilization Program - Presentation Indonesia