Tutkimuksen merkitys menestyvässä liiketoiminnassa- Innovaatiosta tuotteeksi

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1 Tutkimuksen merkitys menestyvässä liiketoiminnassa- Innovaatiosta tuotteeksi Matti Rautanen Manager, External Networks, Power-wide R&D Tutkimuksella tulevaisuuteen- seminaari Kaukolämpöpäivät, Kuopio

2 Esityksen sisältö Yleistä tuotekehityksestä Metso Powerin tuotekehityksestä Esimerkkejä Yhteenveto 2

3 Metso in a nutshell Metso is a global supplier of technology and services to customers in the process industries, including mining, construction, pulp and paper, power, and oil and gas. Our 30,000 professionals based in over 50 countries deliver sustainability and profitability to customers worldwide net sales EUR 6.6 billion Shares listed on NASDAQ OMX Helsinki Ltd. Net sales and EBITA %* Personnel by area 17% 10% 13% 5% 30% 10% 15% * before non-recurring items. 3

4 Our network Business lines organized by customer industry form a global network CUSTOMERS Metso network President and CEO, and Group Head Office Minerals Processing Solutions business line Crushing and Screening Equipment business line Services business line Flow Control business line Process Automation Systems business line Services business line Paper business line Fiber business line Power business line Services business line Mining and Construction Automation Pulp, Paper and Power 4

5 5 Power business line

6 The world s leading supplier of biomass boilers Steam, hot water and power production More than 120 grate boilers since 1994 Output 4-20 MW th Approx. 200 bubbling fluidized bed (BFB) boilers since 1979 Output MW th More than 70 circulating fluidized bed (CFB) boilers since 1980 Output MW th 6

7 Power business line products Boilers - Fluidized bed boilers for combustion of biomass, recycled fuel and coal - Modularized power and heating plants - Oil and gas boilers and boiler plants - Recovery boilers for chemical recovery Evaporators - Evaporators for black liquor concentration Environmental protection systems - Air pollution control systems for the pulp and paper, and power generation industries Services - Rebuilds and upgrades - Maintenance - Spare parts - Accessory products - Partner Services New products and technologies - LignoBoost for lignin removal - AshLeach for reducing the harmful chemicals in fly ash - Biomass gasification to replace oil and natural gas 7

8 Research and Development 8

9 9

10 From Research to Business The only source of funding Business Business with products and services on market Product Technology Competence Product development projects Technology development in own and joint projects Participation in own, consortium and public research projects The role of univ. & research institutions is significant Interest Polling of new ideas Participation in public research projects New ideas, research in universities and in institutions institutions 10

11 R&D Metso Power 11

12 Evaluation of Influence of Fuel Mixture on Corrosion Corrosion Prediction Based on Fuel Composition Case: 270 MW th BFB boiler burning biofuel, sludge and peat Question: How does a change in the fuel mixture influence on superheater corrosion? SteaMax study Metso in-house corrosion prediction calculation tool Fuel mixture including peat => no corrosion Excluding peat => increased corrosion of secondary superheater Options: Change material for a part of the secondary superheater Lower the chlorine amount in the fuel mix CorroStop additives Solution: Part of the secondary superheater was changed to stainless steel => corrosion under control 12

13 Modelling for Increased Capacity Use of CFD for Recovery Boiler Modernization Operational targets - Upgrade of the lower furnace to reduce maintenance and increase safety - Upgrade of the air system to increase capacity and improve boiler operation Use of CFD to find the optimum air supply and to verify the furnace bottom geometry Original design Improved design Air system Variations in temperature profiles Tertiary air does not penetrate deep in the furnace Temperature profile CO concentration Some CO escapes from the furnace Good air penetration and coverage Air system Temperature profile No CO escaping the furnace Even temperature profile CO concentration Result Boiler capacity increase by 12.5 % achieved and water circulation system performance, reduction efficiency and emissions as specified 13

14 CYMIC boiler Circulating Fluidized Bed (CFB) technology Kuopion Energia Kuopio Finland Steam Fuels 149 MW th 60 kg/s 130 bar 535 C Start-up 2011 Peat, wood fuel, coal 14

15 R&D Center In operation since ,000 hours of pilot operation 8,500 tonnes of tested fuels 50+ tested fuels 100+ tested fuel mixtures 150 tonnes of pyrolysis bio-oil produced BFB/CFB Pilot Fuel, additive and mechanical design testing in 4 MW th pilot boiler Pyrolysis Pilot Bio oil production testing with integrated pyrolysis process 15

16 Coal Washery Reject, case example R&D Center Case Study Development of boiler concept for high ash content coal washery reject Earlier coal washery reject has been co-combusted with good coal 20 kg sample Lab tests Waste coal reference visit for the customer 200 t of washery reject shipped to Finland Commercial concept developed and offered 16 Succesful results in the test run CFB Pilot tests in Metso R&D Center

17 Full Scale Field Tests Experimental research in customer plants Dedicated personnel and long experience in organizing measurement campaigns Real process environment representative results Modern measurement equipment Objectives: - Fuel combustibility testing Bed behavior Corrosivity Fouling Emissions Ash quality - Additive testing - Boiler optimization 17

18 Pyrolysis Oil Development 18

19 Pyrolysis Producing bio-oil from biomass Thermal decomposition of fuel without oxidizing agent Produces liquid biofuel used to substitute fuel oils Many types of biomass can be used in process Metso, UPM, Fortum and VTT have developed an integrated bio-oil production concept to provide an alternative to liquid fossil fuels Any fluidized bed boiler is a potential biorefinery! 19

20 Pyrolysis process Metso DNA automation system High pressure steam Turbine Electricity Non-condensible gas District heat Forest residue Condenser Crusher Drying Sand and coke 500 ºC Sand 800 ºC Fluidized bed boiler Pyrolyzer Bio-oil CFB or BFB 20

21 500 ºC reactor Basic principle - Fast pyrolysis Wood is decomposed in oxygen-free atmosphere by heat 800 ºC sand from fluidized bed boiler Wood pyrolyzed by heat Wood feeding Oxygen-free recirculation gas 21

22 Fast pyrolysis based bio oil production plant Fortum Joensuu, Finland In fast pyrolysis wood is decomposed in oxygen-free atmosphere solid m³/a forest chips are heated up, volatiles extracted and condensed to generate bio oil Bio oil production reactor is integrated to an existing fluidized bed boiler Annual production tons of bio oil Annual production can replace fossil oil in heating of more than private homes Start-up in the autumn of 2013 Fuel receiving, drying and crushing Pyrolyzer in the boiler building Bio-oil recovery Bio-oil tanks 22

23 Further pyrolysis development paths Biomass Catalytic pyrolysis Hydrogenation Bio-oil Gasoline substitute Fast pyrolysis Bio-oil Heat and power 23

24 Some important factors for succesful R&D and commercialization Business potential and customer benefit Good partnerships Win-win situation, opportunities for all participants Clear rules and agreements (goals, cost and work load sharing, IPR) Trust and open information sharing Different partners involved (e.g. end users, energy / end product producers, equipment manufacturers, research organisations) Long-term commitment Knowledge accumulation Long projects (e.g. pyrolysis, gasification) R&D public support and funding (e.g. Tekes, TEM, EU, etc) Synergy with existing business 24

25 25

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