Kymijärvi II Plant High-efficiency use of SRF in power production through gasification. Janne Savelainen CEO, Lahti Energy Ltd.

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1 Kymijärvi II Plant High-efficiency use of SRF in power production through gasification Janne Savelainen CEO, Lahti Energy Ltd.

2 Lahti Energy - Forerunner Lahti Energy Ltd. operates in the Lahti region in Finland Founded in 1907 Net sales 180 million euros, 250 employees Power production is based on CHP Two major CHP power plants Kymijärvi I (coal-fired, 350 MW) and Kymijärvi II (SRF gas-fired, 160 MW) Our core business is to generate electricity and to use the process heat for district heating District heating network over 600 km long 90% of the people in Lahti area use our district heating

3 13/06/2013 Lahti GreenCity Strong environment-friendly profile Goal to reduce CO₂ emissions by half by 2025 Political support for CHP and non-fossil fuels Local waste management company utilises and recycles 94% of all waste in the area Only 6% to landfill Production of SRF since 1998 Lahti Energy has gasified SRF and cofired it in the Kymijärvi I coal burner since inhabitants 100 km from capital Helsinki

4 13/06/2013 Gasification In 2012, gas-fired Kymijärvi II Commercial operations for over a year 50 MW (300 GWh) electricity, 90 MW (600 GWh) district heat Gas produced from tons of solid recovered fuel No need for additional fossil fuels Natural choice for Lahti Energy Plenty of experience on gasification with Kymijärvi I Good quality SRF readily available in the area Over all efficiency as high as 80% Cost 160 million euro Building project was well executed

5 13/06/2013 New fuel, new technology plenty of electricity The fuel is gasified The gas is cooled down and then cleaned The clean gas is fired in the boiler NOTE: We do not burn waste Clean gas enables high steam parameters (540 C/121 bar) which enable proper production of electricity and district heating

6 Valuable Waste Why waste it?

7 13/06/2013 All Aspects of Waste to Energy Incineration is not the only choice anymore Kymijärvi II proves it Co-firing in coal boilers also works well as demonstrated in Kymijärvi I All emissions were reduced Gasification is not meant to be a solution to waste management problems However, if all SRF is taken out of the mixture, the remains are remarkably smaller Incineration plants could be designed and calculated for worse material Savings in building costs, benefits to the society Introducing a new approach in the field of waste-to-energy: VALUABLE WASTE

8 13/06/2013 Waste More than just heat SRF compares to all other fuels in the production of Lahti Energy We pay a price to the supplier according to energy content and that encourages suppliers to refine the waste collection process Fuels at Kymijärvi plants 2012 vs Diminishing need for fossil fuels % 11% 12% 8% 5% 60% 9% 76% Coal Natural gas Bio fuels SRF Coal Natural gas Bio fuels SRF

9 13/06/2013 Because of Kymijärvi II A new supply chain was born around waste Fuel payments have created a new market for fuel preparation The quality of SRF has increased Benefits other SRF users, as well Tight quality control increases also material recycling, i.e. metals Our fuel suppliers have been able to invest in new machinery Operations created approx. 100 new jobs in the supply chain The use of coal in Lahti has diminished and thus, also emissions In 2012, specific emission CO₂ reduced by 30% compared to 2011

10 The Technology is Here Let s Finally Start Using It!

11 Lahti film power plant technology

12 Metso Waste Gasification Juhani Isaksson Metso Power Oy PowerGen Europe 2013

13 Kymijärvi II Long lasting co-operation Environmental permit application Lahti Energia/VTT Development 2000 => Environmental permit approved Pre-engineering 2/2009 9/2009 METSO Pre-qualification Contract Commercial operation 4/2012 Final conclusions in 2013 Metso Gasification development team Lahti contacted Metso STEAMAX for reducing conditions 2007 => Metso Gas Cleaning Concept development in Värö METSO/VTT tests 2008 Delivery Project Demonstration 13 Metso

14 Kymijärvi II Plant technology Metso delivery 2 x 80 MW th gasifiers tn SRF/a Gas cooling and filtration Gas boiler 121 bar, 540 C - 50 MW e & 90 MW heat - η e = 31 % (net) SCR, dry APC Plant automation Waste fuel receiving & handling Gasifier and gas cooler Gas boiler and APC Old PC boiler Architecture study of the plant 14 Metso

15 Kymijärvi II Plant technology Process: The trick Gasify waste at C Cool it down to about 400 C - corrosive components, will be in solid form Resulting gas is clean - Possible to use high steam parameters without risk of corrosion Burn clean gas in a gas-fired boiler (540 C, 121 bar) Final emission control after the boiler 15 Metso

16 Kymijärvi II Plant technology The trick Cooler design Avoid risk of corrosion in the cooler, temperature low enough in the cooler structure Condensate harmful components on particles, gas temperature controlled Avoid tar condensation, temperature high enough Still reasonable size! Operational window to filter out corrosive compounds High-temperature ceramic fiber filters Filters endure high temperatures Tar condensation needs to be avoided 16 Metso

17 Performance values are achieved Commercial production since may 2012 Design capacity achieved Low parasitic load Fuel flexibility seen in practise - Forest residues - SRF Demolition wood Plastics - Natural gas for start-ups only 17 Metso

18 Low emissions proven At stack (red. 11 % O 2 ) Final emission control: DeNox catalyst Sodium bicarbonate injection Activated carbon injection Bag house * NOx, SO 2, HCl are usually close to limit to minimize the cost of additives 18 Metso

19 Stable operation in varying conditions Stable flame - No need for support fuel - Over 35% moisture content Excellent combustion - 2s, 850 C - Very low CO, with low O 2 Process recovers from interruptions - Load changes - Fuel feeding blockages Reliable fluidization - No problems with sintering 19 Metso

20 Basic idea works - No corrosion detected Gas cooler and boiler inspected Gas cooler walls - Thicknesses measured after h are the same than original ones - Smooth steel surface below fouling layer - Manufacturing tracks are still visible - No visible marks of corrosion anywhere Gas boiler - Thicknesses measured after h are the same than original ones - Smooth pipe surfaces - Manufacturing tracks are still visible - No visible marks of corrosion anywhere 20 Metso

21 Main areas of further development Hot gas filter elements - There have been some broken elements - Product development of filter elements - Process condition optimization Instruments in product gas - Tar condensation is a challenge - Avoiding cold bridges is essential Plant fine tuning - Operation parametres - Utilities consumption - Work practices 21 Metso

22 Metso Waste gasification Eligible for the UK ACT ROC band Demonstrated in a large scale WID-compliant solution Metso s extensive gasification experience High net electrical efficiency (R1 > 0,65) Ready for the market 22 Metso

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