Advanced solutions for Energy from Waste. Frank Ligthart Sales Director, Valmet

Transcription

1 Advanced solutions for Energy from Waste Frank Ligthart Sales Director, Valmet

2 Valmet solutions for Energy from Waste (EfW) Valmet Valmet s concept for Energy from Waste Valmet fluidized bed combustion for EfW Valmet fluidized bed gasification for EfW Summary

3 Global supplier of services and technologies for the pulp, paper and energy industries. Services Mill and plant improvements Spare parts Maintenance services Life-cycle services Pulp and Energy Technologies and solutions for Pulp production Energy production Biomass conversion Paper Technologies and solutions for Board production Tissue production Paper production Valmet has a turnover of 3 billion and was reborn through the demerger of Metso Group on December 31, December Valmet

4 Valmet s concept for Energy from Waste

5 Can we afford to Waste a valuable resource? High efficiency and fuel flexible Energy-from- Waste solutions from Valmet 5 11 June, 2014 Valmet Author / Title

6 Valmet solutions part of an integrated concept Sorting Heat and electricity Maximizing energy business Residual waste Maximizing recycling business Recyclates Pretreatment in MRF or MBT Industrial waste Refuse derived fuel Wet waste RDF Power plant - highest energy efficiency Multifuel capability sludge, biowaste, biomass, agro, coal Biodrying or AD 6 Date Author Title Wet biowaste Biogas Ethanol

7 Valmet s high efficiency solutions for EfW Fluidized bed combustion EPC RDF combustion plants 10 MW e Gasification with hot gas cleanup 7

8 Valmet fluidized bed combustion for EfW

9 Extensive experience in Energy from Waste Installed 28 fluidized bed boilers for RDF since BFB boilers MWth t/a 7 CFB boilers MWth t/a

10 Valmet Circulating Fluidized Bed combustion technology (CFB) for EfW Strong track record More than 70 units in operation, with 7 for EfW Superior fuel flexibility RDF, biomass, agro, sludges and coal all in one boiler Proven high reliability Higher than 99% High boiler efficiency 91-92% High steam parameters 75 bar / 520 ºC High electrical efficiency > 28% Excellent environmental performance Low NOx and almost zero UBC in ash Relatively low maintenance cost No moving parts in furnace June, 2014 Valmet Author / Title

11 Valmet CFB for Refuse Derived Fuel (RDF) Special design features Empty pass with Water sootblowing Replaceable superheaters Refractory covered furnace Reliable fuel feeding equipment Flue gas cooling down <620 C Effective removal of bottom ash, sieving & recycling Final superheater in loop seal, outside fluegases June, 2014 Valmet Author / Title

12 Challenge: High temp corrosion due to Chlorine (Cl) in RDF Solution: Loop seal superheater Final superheater in loop seal is effectively isolated from fluegases Gas atmosphere much less corrosive compared to furnace or back pass Double layer tube design for RDF application to avoid alkali chlorine condensation Allows steam temperature up to 520 ºC with limited corrosion risk Outside surface T ~ 700 C Inside T = C

13 Challenge: Mid temp corrosion due to Lead (Pb) in RDF Solution: Easily replaceable superheaters Superheaters in backpass of the boiler are easily replaceable within less than 5 days per bundle Minimizes downtime of the boiler when Pb induced corrosion cannot be fully prevented

14 Challenge: High content of foreign material in RDF Solution: Grid design and bed ash recirculation Effective bottom ash removal, sieving & recycling Minimizing bed material usage by recirculation

15 Valmet CFB for RDF Main references EON Norrköping, Sweden Stora Enso Langerbrugge, Belgium SAICA El Burgo de Ebro, Spain Mälarenergi Västerås, Sweden 75 MW th, 65 bar, 470 C MSW, industrial waste, recycled wood, sewage sludge 125 MW th 60 bar, 475 C RDF, untreated and treated wood, coal, gas 140 MW th 75 bar, 520 C Paper processing rejects (plastics), mill sludges 155 MW th 75 bar, 470 C MSW, industrial waste, recycled wood, wood, peat Start-up 2002 Start-up 2010 Start-up 2011 Start-up 2014 Tero Luomaharju

16 Competitive and reliable energy for municipality Valmet CFB for utility E.ON CHP plant operated by E.ON to provide electricty to grid, industrial process steam and district heat to city of Norrköping Sorted MSW and industrial waste, which is converted to ca. 200 ktpa RDF on site to feed the Valmet CFB Valmet CFB technology was selected to reliably combust a mix of refuse derived fuel (RDF), recycled wood and ca. 20% District sewage sludge heat and electricity from MSW & CIW June, 2014 Valmet Author / Title E.ON, Norrköping, Sweden Start-up 2002

17 CYMIC boiler Circulating Fluidized Bed (CFB) technology E.ON Värme Sverige Norrköping, Sweden Steam 75 MW th 27 kg/s 65 bar(g) 470 C Fuels MSW, Industrial waste, Sewage sludge, Recycled wood 17

18 E.ON Norrköping RDF quality going to the CFB boiler 65 w-% MSW, 35 w-% industrial waste Heating value MJ/kg Moisture % Chlorine % in DS June, 2014 Valmet Author / Title

19 Competitive and reliable energy for paper mill Valmet CFB for paper maker Stora Enso CFB boiler plant provides paper mill with process steam, heat and power Stora Enso, Gent, Belgium Start-up 2010 Stora Enso selected Valmet multi-fuel CFB to use flexible and competitive recovered fuel mix With at the same time highest reliability and full coal backup Fuels: Refuse derived fuel (RDF) Recycled wood Virgin biomass De-inking sludge (20%) Coal as back-up fuel June, 2014 Valmet Author / Title Flexible fuel mix and high reliability > 99%

20 CYMIC boiler Circulating Fluidized Bed (CFB) technology Stora Enso Langerbrugge, Gent, Belgium Steam 125 MW th 45 kg/s 60 bar 475 C Fuels RDF, Recycled wood, Coal (backup), Virgin biomass, De-inking sludge 20

21 Stora Enso Langerbrugge CFB for RDF Operational experience: high boiler efficiency and burnout RDF share, energy % 100 Measured boiler efficiency, % 91.2 Bottom ash / fly ash share, w-% 58/42 TOC in bottom ash, w-% < 0.1 TOC in fly ash, w-% 0.2 Flue gas O2-content, % wet 3.8 Full superheating range, % of MCR s at 850C area without support fuel, % of MCR

22 Stora Enso Langerbrugge CFB for RDF Operational experience: near zero emissions Component Unit* Guaranteed daily average Measured (RDF+ Recycled wood) NO as NO 2 mg/nm 3 < CO mg/nm 3 <50 <10 Particulate mg/nm 3 <10 0,1 SO 2 mg/nm 3 <50 n.d. HCl mg/nm 3 <10 0,1 HF mg/nm 3 <1 n.d. Heavy metals mg/nm 3 <0,5 <0,008 PCDD/F ng/nm 3 <0,1 <0,1 *(dry, actual O 2 ) 22

23 CFB for RDF: Boiler availability and reliability EON Norrköping * November 2005: New fluidized bed heat exchanger design was taken into use * ) Operation h Unavailability h Availability 1) % 78,0 82,6 88,6 88,7 87,7 87,4 89,1 Reliability 2) % 87,0 91,8 97,0 97,5 96,4 96,9 97,2 Stora Enso Langerbrugge Operation h Unavailability h Availability 1) % 95,0 93,8 Reliability 2) % 99,0 99,9 1) 2) Operating time 8760 h Operating time 8760 h Planned outage

24 Largest CFB for waste in the world Valmet CFB for municipal utility Mälarenergi CHP plant will process 480 ktpa of sorted MSW and CIW, to be converted to RDF on site Designed to allow shift in the future to biomass fuels CHP plant will export 50 MWe power and 130 MW district heat The investment will give us a greater fuel mix flexibility. We chose Valmet because they fulfilled our requirements regarding price, technology, availability and experience., says Kenneth Jönsson, President, Mälarenergi AB June, 2014 Valmet Author / Title Mälarenergi, Västerås, Sweden Start-up 2014 World s largest CFB for EfW

25 CYMIC boiler Circulating Fluidized Bed (CFB) technology Mälarenergi AB, Västerås Sweden Steam 155 MW th 56 kg/s 74 bar 470 C Fuels MSW, C+I waste, Recycled wood, Virgin wood, Peat, Sewage sludge 25

26 Modular RecycPower11-CFB 10 MWe,net Customer benefits of EPC/Turnkey delivery and standardization Modular plant design EPC delivery Shop assembled modules CFB combustion RDF, bio, coal and sludges 10,5 MWe,net from 100 ktpa CHP per requirements Compact footprint 33m x 33m x 33m Steam drum Stack Boiler Ash silo Economizer Boiler silo Bag House Feed water tank module Benefits to customer Fast project implementation Multi-fuel capability Solid bankability Make-up water tank module Condenser module Heat exchanger module Turbine generator April, 2014 Valmet Matti Järvinen / Power Plants

27 Valmet Circulating Fluid Bed combustion for EfW Summary benefits Well proven technology Highest combustion efficiency High steam parameters High electrical efficiency Multifuel capability Proven high reliability Relatively low maintenance cost Lowest primary fluegas emissions Good quality ash June, 2014 Valmet Author / Title

28 Valmet fluidized bed gasification for EfW

29 Valmet Waste gasification CFB gasifier Size Fuel Reactor Medium MW th Biomass, waste, peat Uncooled, refractory lined CFB Atmospheric air Temperature C Fuel gas 5-7 MJ/nm3 29

30 Valmet Waste Gasification Concept Gasification Steam generation 121 bar/540 C Flue gas cleaning RDF handling Hot gas cleanup June, 2014 Valmet Author / Title

31 Valmet Waste Gasification Hot gas filtration Fuel gas is cooled and filtered in rigid candle filter elements Nitrogen to pulse cleaning Filtrated gas out Removes corrosive compounds and heavy metals Results in clean gas for combustion Dirty gas in 31

32 Highest efficiency for Energy-from-Waste Valmet Gasification plant for municipal utility Lahti Energy World s largest waste (RDF) gasification power plant CFB gasification plant converts waste into clean fuel gas for combustion in the steam boiler Processes 250 ktpa of Refuse Derived Fuel (RDF) to produce: 50 MW of electricity 90 MW of district heat CHP efficiency of 87,5 % Total investment ca. 160m June, 2014 Valmet Author / Title CO2 emissions reduced by 30 % Lahti Energia, Lahti, Finland Start-up 2012

33 Valmet Waste Gasification Lahti Energia areal view Stack Old power station Turbine Gasifier APC Boiler Gas cleanup Conveyor June, 2014 Valmet Author / Title

34 Lahti gasification plant Design fuel Design fuel Fuel LHV RDF from MSW and C+IW MJ/kg, dry Moisture < 30 w-% Ash < 15 w-%, dry Cl < 0.6 w-%, dry Na + K < 0.3 w-%, dry Hg < 0.1 mg/kg, dry June, 2014 Valmet Author / Title

35 Valmet Waste Gasification Operational experience Gasification RDF end 2011 Commercial May 2012 > operating hours Capacity demonstrated Gasifier operation reliable Stable and good combustion Compliance with WID No corrosion detected 35

36 Lahti gasification plant Lesson learned from first years Availability in first year ca. 80% Fuel quality is important for high availability Metal content in fuel very high causing jamming fuel feeding systems Fuel moisture content higher than design sometimes limiting output Candle filter element failures, causing some unavailability Clean burn system installed in May 2013 to keep candle filters clean, significantly improving availability June, 2014 Valmet Author / Title

37 Valmet Waste gasification Co-firing waste in existing power plant Co-firing of clean gas from waste gasification in existing utility boiler Hot gas cleanup removes corrosive and harmful compounds from gas Minimum impact on boiler operation, corrosion, ash quality and emissions Full capacity on main solid fuel maintained Minimum boiler modifications needed, including new gas burners Utilizing existing, efficient power plant infrastructure minimizes investment and maximizes energy recovery Add-on gasifier and hot gas cleanup Existing utility boiler Valmet can provide all on EPC basis, including boiler modifications June, 2014 Valmet Author / Title

38 Valmet Waste gasification Summary benefits Waste is turned into a fuel gas that can be cleaned before combustion Combustion of clean gas, instead of waste allows high steam parameters and highest electrical efficiency for EfW Demonstrated at large scale in standalone EfW plant Possibility to co-fire waste in existing utility boiler with relatively low investment June, 2014 Valmet Author / Title

39 Summary

40 Power production efficiency comparison Comparison for 80 MW RDF plant (ca. 170 ktpa) Conventional incineration 400 C / 40 bar < 20% 16 MWe CFB combustion 520 C / 75 bar > 28% 22,4 MWe + 40% power CFB gasification 540 C / 120 bar > 31% 24,8 MWe + 56% power June, 2014 Valmet Author / Title

41 Valmet solutions for Energy from Waste Provide many benefits Maximizing recycling of valuable materials Removal metals and other materials before combustion Maximizing energy recovery Highest electrical efficiency for Energy from Waste Maximizing fuel flexibility Co-firing of wet biowaste, sewage sludge, biomass or coal Minimizing environmental impact BAT with lowest primary emissions and low carbon in ash June, 2014 Valmet Author / Title

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