POWER-GEN EUROPE 2015, June 9, 2015 Amsterdam, Netherlands

Transcription

1 ADVANCED UTILITY CFB TECHNOLOGY FOR CHALLENGING NEW SOLID BIOMASS FUELS Timo Eriksson, Vesna Barišić, Kalle Nuortimo, Timo Jäntti Amec Foster Wheeler Energia Oy POWER-GEN EUROPE 2015, June 9, 2015 Amsterdam, Netherlands

2 Presentation Outline Properties of New Non-Conventional Biomass Fuels Being Introduced to Global Market Characterization of Biomass Fuels for CFB Combustion Large Scale CFB for Biomass Combustion ABC Technology Recent CFB References for Biomass Combustion Introduction of New Large-Scale CFB Boiler Design for Non-Conventional Solid Biomass Fuels 2

3 3 Properties of New Non- Conventional Biomass Fuels Being Introduced to Global Market

4 Available Non-conventional Biomass Fuels Challenging Biomass Introduced to Utility Power Plant Fuel Markets USA Juliaflora Soya stalk Ground nut shell Cotton stalk Wheat stalk Mesquite EU Wheat stalk Pakistan Sugar cane bagasse Middle East Juliaflora India Sugar cane bagasse Mustard stalk Coconut shell Soya stalk Ground nut shell Cotton stalk Wheat stalk Bamboo China Sugar cane bagasse Soya stalk Ground nut shell Cotton stalk Wheat stalk Bamboo South America Sugar cane bagasse (Brazil, Mexico) Juliaflora Coffee husk Soya stalk (Brazil, Argentina) Acacia Africa Elephant grass Juliaflora Coffee husk Rubber wood Acacia Invader bush Shea tree South East Asia Rubber wood Sugar cane bagasse (Thailand) Eucalyptus (Australia, New Guinea, Indonesia) Rice husk Coffee husk Coconut shell ( Indonesia, Philippines) Acacia (Australia) Bamboo (Bangladesh, Indonesia, Thailand) 4

5 Special Properties of Biomass Fuels Low energy density Large variation range in all properties, especially in moisture Alkali and chlorine contents In biomass, alkalis (mainly K) volatile and reactive during combustion Handling and blending of fuels from numerous sources Traded in many different sizes and shapes Excessive dust concentration may cause handling and process issues. Poor flow characteristics due to sticks and oversized particles Seasonal supply of annual biomass Interaction between ash elements in multifuel combustion Agglomeration, fouling and corrosion risks to be evaluated! Non-combustible contaminants

6 Biomass Ash Biomass ash composition strongly depends on the species and part of the biomass plant: stem wood, bark, branches, tops and needles have different ash compositions. The nutrients available, soil quality, fertilizers and weather conditions also have significant impact on the ash composition. Deviations of tens of percent from the mean value of each element are common in biomass ashes. Agglomeration = gathering of small particles into large size clusters 6

7 Biomass Properties Woody Biomass Fuels Variation in main elements and heat value (dry) typically small Ash is typically rich in calcium (CaO 30-50%), potassium (K 2 O up to 15%) and magnesium (MgO 4-10%). Some wood species rich in SiO 2 Wood Chips (Stem Wood) Wood Pellets (Stem Wood) Mesquite Pellets Rubber Wood Chips Shea Tree Pellets HHV dry MJ/kg LHV dry MJ/kg LHV wet MJ/kg Bulk density kg/m N/A N/A 760 Proximate analysis Moisture, total %-w Fixed carbon dry %-w 16.7 N/A Volatiles dry %-w 81.4 N/A Ash dry %-w Fuel ratio FC/VM Ultimate analysis C dry %-w H dry %-w N dry %-w <0.3 < S dry %-w <0.02 < Ash forming elements Cl dry mg/kg Ca, total dry mg/kg Mg, total dry mg/kg Na, acid soluble (1 dry mg/kg K, acid soluble (1 dry mg/kg Na, total dry mg/kg K, total dry mg/kg P, total dry mg/kg Si, total dry mg/kg Al, total dry mg/kg Fe, total dry mg/kg Notes: 1) Acetic acid soluble 7

8 Biomass Properties Agro Biomass Fuels Major differences in ash forming elements Concentrations of alkali, phosphorous and chlorine typically much higher in most agros than in wood Agglomeration, fouling, corrosion and erosion risks to be considered Palm Kernel Shell Sunflower Pellets Straw Pellets Straw, Fluff Fruit Husk Pellets Sugar Cane Bagasse HHV dry MJ/kg LHV dry MJ/kg LHV wet MJ/kg Bulk density kg/m Proximate analysis Moisture, total %-w Fixed carbon dry %-w Volatiles dry %-w Ash dry %-w Fuel ratio FC/VM Ultimate analysis C dry %-w H dry %-w N dry %-w S dry %-w Ash forming elements Cl dry mg/kg Ca, total dry mg/kg Mg, total dry mg/kg Na, acid soluble (1 dry mg/kg 32 < < K, acid soluble (1 dry mg/kg Na, total dry mg/kg < K, total dry mg/kg P, total dry mg/kg Si, total dry mg/kg Al, total dry mg/kg Fe, total dry mg/kg Notes: 1) Acetic acid soluble 8

9 9 Characterization of Biomass Fuels for CFB Combustion

10 Characterization of Biomass Fuels for CFB Combustion Detailed characterization method developed at Amec Foster Wheeler enables full assessment of fuel properties Standard physicochemical analyses such as proximate and ultimate analysis, heating value, bulk density, and particle size Concentration of ash-forming elements preferably performed with Inductively Coupled Plasma Optical Emission Spectroscopy (ICP-OES) on fully digested biomass without prior ashing Selective leaching of ash-forming elements with two solutions of increasing ph which allows an estimate of chemical forms present in the fuel Characterization tests for pellets including durability Thermogravimetric determination of the burning profile In-house developed methods such as combustion test and sintering test For new biomass types, pilot test in test rigs Bench-scale defluidization reactor Small-scale (~0.1 MW) pilot CFB Large-scale (~1 MW) pilot CFB 10

11 Characterization of Biomass Fuels for CFB Combustion Utilization of the results from the characterization tests Comparison with data from an in-house database, which contains nearly 1500 biomass samples, and experience of the large fleet of operating biomass boilers Input for models and tools providing quantitative or semiquantitative estimates for agglomeration, fouling and corrosion Design boilers with the highest efficiency and availability & Operate them in the most economical way 11

12 12 Large Scale CFB for Biomass Combustion ABC Technology

13 Advanced Bio CFB Concept Konin (Poland), 154 MW th, 215 t/h, 97 bar(a), 540 C Połaniec (Poland), 447 MW th, 569/486 t/h, 127/20 bar(a), 535/535 C Lund (Sweden), 110 MW th, 154 t/h, 113 bar(a), 540 C Cost-optimized design, adopted e.g. to: Capacity Steam parameters Fuel selection Emission limits Additives Load range Further developed for nonconventional biomass fuels 13

14 14 Recent CFB References for Biomass Combustion

15 Amec Foster Wheeler Biomass References Recent Boilers with Biomass as Primary Fuel Del. year Customer MWth Fuels 1/ Monbetsu Biomass, Japan United Renewable Energy, Japan Biomass, coal Biomass 2015 Oji Engineering Green Energy Hokuriku, Japan 19 Biomass Kirisima Mokushitsu Hatsuden, Japan Miyazaki shinrin Hatsudensyo, Japan Biomass Biomass 2015 Oji Green Energy, Nichian, Japan 69 Biomass, coal Oji Green Energy, Ebetsu, Japan Green Biomass Factory, Tsuno, Japan Biomass, coal Biomass 2015 GS E&C, Danjing, South Korea 256 Biomass, coal, wood pellets Nihon Kaisui, Akou, Japan Kraftringen Energi AB, Örtofta, Lund, Sweden Biomass Biomass, demolition wood, peat 2013 Green Energy, Ooita, Japan 19 Biomass Asahi Kasei Chemicals, Japan GDF SUEZ, Polaniec, Poland Biomass, coal Wood chips, agro biomass 2012 ZE PAK, S.A., Konin, Poland 154 Wood, crop waste Kawasaki Biomass Power Co., Kanagawa, Japan Prokon Nord Energiesysteme GmbH, Oostrozebeke, Belgium Wood chips Demolition wood 2010 E.ON Värme Sverige AB, Norrköping, Sweden 85 RDF, demolition wood Jyväskylän Energia Oy, Jyväskylä, Finland Kaukaan Voima Oy, Lappeenranta, Finland Peat, forest residue Biomass, peat Söderenergi AB, Södertälje, Sweden Nippon Paper Industries, Asahikawa, Japan HVC-HH, Alkmaar, Netherlands Biomass, REF pellets, demolition wood Biomass, coal Demolition wood Söderenergi AB Södertälje, Sweden 2006 Siemens AG Austria, Wien, Simmering, Austria 61 Forest chips 2006 Prokon Nord, Hamburg, Germany 63 Recycled wood 2005 Harpen Energie Contracting GmbH, Bergkamen, Germany 58 Recycled wood, forest residue 2005 Stora Enso Kvarnsveden AB, Borlänge, Sweden 130 Bark, sewer sludge, bit. coal Totally approx. 120 biomass-fired units sold 15

16 CFB for Demolition Wood and Virgin Biomass Kraftringen Energi AB, CHP Plant in Örtofta, Lund, Sweden CHP 110 MW th, 35 MW e, main steam 154 t/h, 540 C, 113 bar, a Designed to burn max. 50 % demolition wood with wood chips, peat, saw dust, bark, salix and stump chips CFB furnace 8.8 m x 5.5 m x 28 m Load burner due to demolition wood Two water-cooled high-efficiency solids separators Step grid No specific additives INTREX TM SH

17 CFB for Demolition Wood and Virgin Biomass Kraftringen Energi AB In commercial operation since March 2014 In the first operation year, the average fuel mix was as follows: Forestry residues 52 % Recycled wood 22 % Bark 10 % Peat 9 % Saw dust 7 % The cumulative availability for Amec Foster Wheeler boiler scope has been over 99 %. 17

18 World's Largest CFB Firing 100 % Biomass Polaniec, Poland, 569 t/h, 447 MW th Customer: GDF Suez Energia Polska Plant start-up: Q4, 2012 Fuels: Wood biomass + max 20 % high-alkaline agro biomass Design features: CFB furnace 24 m x 7.6 m x 43 m Three steam-cooled separators Step grid Additive feeding systems INTREX SH 3 & RH 2 Electrical output, gross/net MW e 205/190 Net efficiency, LHV/HHV % 36.5/31.4 Steam flow rate, SH/RH kg/s 158/135 Steam pressure, SH/RH bar, g 126/19 Steam temperature, SH/RH C 535/535 Emission Guarantee Measured (1 NO x mg/m 3 n SO 2 mg/m 3 n CO mg/m 3 n 50 < 5 Dust mg/m 3 n ) F. van Dijen, H. Gennart, "The New 200MWe Wood-Fired CFBC at Polaniec/Poland" 18

19 CFB for 100 % Wood and Agro Biomass Pątnów-Adams-Konin (PAK), Poland 154 MW th, 55 MW e, main steam 215 t/h, 540 C, 97 bar, a Designed to burn max. 20 % agro biomass (energy willow, straw, rapeseed residues, cherry stones, oat husk) with wood chips CFB furnace 12 m x 5.9 m x 29 m Two water-cooled high-efficiency solids separators Fuel feeding through solids return chutes, with circulating material Step grid No specific additives SH 1-2 in horizontal pass INTREX SH 3-4 Commercial operation since 7/

20 CFB for PKS (Palm Kernel Shell) GS Engineering and Construction, Danjing, South Korea 253 MW th, 105 MW e, 108 kg/s, 130 bar, a, 254 C FUEL DATA Sulphur Nitrogen Moisture Ash LHV Palm Kernel Shell 0.28% d.s. 0.46% d.s. 16.4% 2.97% d.s MJ/kg Bituminous coal 0.22% d.s. 0.61% d.s. 6.4% d.s % d.s MJ/kg DESIGN PERFORMANCE, O 2 6% in dry gases Flue Gas Exit Temperature Boiler Efficiency (ASME PTC 4) Emission Guarantees - NO x - SO 2 - CO Particulate Matter (dry) 147 C 85.10% 129 mg/nm³ 116 mg/nm³ 106 mg/nm³ 6 mg/nm³ SCHEDULE Contract Award Start of Erection Commercial Operation February December August

21 21 Introduction of New Large- Scale CFB Boiler Design for Non-Conventional Solid Biomass Fuels

22 High-Efficiency CFB for 100 % Biomass Combustion 455 MW th, steam 565/515 t/h, 568/568 C, 169/36 bar, a Designed to burn virgin wood chips and pellets of varying origin, as well as saw dust and agro biomass CFB furnace 25 m x 8 m x 40 m Sliding pressure for high efficiency in load cycling operation Three steam-cooled high-efficiency solids separators Step grid Final SH/RH in INTREX Other SH/RH in 2nd pass and at the top of the furnace Third pass for economizer and slip catalyst Enables high-efficiency steam cycle with 100 % biomass 22

23 Amec Foster Wheeler CFB Technology Subcritical steam parameters available up to scale 600 MW e with 100 % biomass (and 100 % coal) firing Natural circulation evaporator (~ 175 bar) Once through Benson evaporator (~ bar) Lower investment cost in large scale High plant efficiency over the whole load range Supercritical steam parameters available up to ~600 MW e scale with coal and up to 50 % solid biomass share Supercritical (ultra-) steam parameters available up to ~800 MW e scale with coal and up to 20 % biomass share 23

24 Summary 24 Amec Foster Wheeler has experience in over 200 CFB and BFB units sold firing solid biomass fuels. Investors and plant operators are widening their fuel portfolios to include low cost, often globally sourced biomass fuels. They do not behave like conventional, well-known biomass fuels in the process. Fuel characterization, models and prediction tools are necessary to assess and control complex ashrelated challenges in combustion. Advanced Bio CFB technology has been developed further toward higher steam parameters and efficiency, with a broadening variety of solid biomass fuels.

25 Thank You! World Class delivery track record Long standing relationships Leading player across the value chain 25