LARGE-SCALE Pääotsikko BIOMASS GASIFICATION PLANT INTEGRATED TO A PC-BOILER

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1 Fuel conversion at the Vaasa power plant: LARGE-SCALE Pääotsikko BIOMASS GASIFICATION PLANT INTEGRATED TO A PC-BOILER Power-Gen Europe 2012, Cologne, Alaotsikko Germany June 12 14, 2012 Tekijä Mauri Blomberg and Ville Hankalin 1

2 Large-scale biomass gasification plant integrated to a pc-boiler Contents: 1. Vaskiluodon Voima Oy, Vaasa power plant 2. Background of the project 3. The gasification plant project 4. Procurement of biomass 5. Metso and gasification technology 6. Vaskiluoto gasification plant 2

3 Vaskiluodon Voima Oy Vaskiluodon Voima was established in the late 1960s and is equally owned by the energy companies EPV Energia Oy and Pohjolan Voima Oy. Company s power plants, situated in Vaasa and Seinäjoki, together generate TWh/a of electricity and around 1,000 GWh/a of district heat. The power plants production covers approximately 90% of the district heating needs of the cities of Vaasa and Seinäjoki. The Vaasa power plant is coal-fired, and the Seinäjoki plant uses biomass and peat as fuel. Vaasa Power Plant FINLAND Seinäjoki Power Plant 3

4 Vaasa power plant Vaskiluoto 2 Vaskiluoto 2 Coal-fired power plant Investments made in phases: Coal-fired boiler 1982 Desulphurization plant 1993 New turbine plant 1998 In technical terms, the plant is fit for use until 2030 Technical specifications: Electricity output 230 MW District heating output 175 MW Production: Electricity TWh/a District heating GWh/a; currently covering approximately 90% of the Vaasa area s district heating demand 4

5 Vaskiluoto 2 - Process Diagram FGD -PLANT BOILER PLANT TURBINE PLANT 43 bar / 570 C 250 MWe LIMESTONE SILO 190 kg / s 185 bar / 536 C HP IP LP G CONDENSER GAVO LUVO ABSORBER ESP FEED WATER 175 MW dh VAASA GYPSUM DEWATERING GYPSUM SILO FLY- ASH SILO 80 t/h COAL MILLS 4 PCS COAL SILOS DISTRICT HEATING NETWORK t/a 5

6 1. Vaskiluodon Voima Oy, Vaasa power plant 2. Background of the project 3. The gasification plant project 4. Procurement of biomass 5. Metso and gasification technology 6. Vaskiluoto gasification plant 6

7 Fuel conversion - from coal to biomass Main drivers for the project + European emissions trading system and feed-in tariff for forest biomass + Taxation of fossil fuels used for district heating + National pressure to decrease the use of coal in CHP-plants + The possibility to extend the lifecycle of the existing power plant Reduction in emissions Domestic biomass to replace coal Cost-efficient electricity and heat production Possibility of producing competitively condensing power remains 7

8 Fuel conversion - from coal to biomass Chosen technology - Gasification Integration of a biomass gasification plant to the existing boiler was seen as the best option for Vaasa power plant: + CFB gasification technology enables use of a wide range of biomass and other fuels + A retrofit investment that is a relatively inexpensive solution + The existing coal-fired boiler can be utilized + Short project time and the need for only a few weeks outage of the existing power plant - Technical risks of a new technology - Some process risks with the existing coal-fired boiler 8

9 Analyzed technological risks Analyzed risks for utilization of the gasification technology Dimensioning and design of the large CFB gasifier Control of wet forest biomass drying and its effects on gasification Increase in energy consumption Combustion of lean gas in an existing boiler originally designed for pulverized coal Increase in flue gas flow and its effect on the capacity of the boiler Effects on combustion control and possible effect on staged low-nox combustion Possible hot corrosion on superheaters Possible uneven distribution of feed water in furnace spiral tubes Possible effect on availability of the existing plant Effect of new fuels on SCR-plant catalyst and increased need for regeneration 9

10 1. Vaskiluodon Voima Oy, Vaasa power plant 2. Background of the project 3. The gasification plant project 4. Procurement of biomass 5. Metso and gasification technology 6. Vaskiluoto gasification plant

11 The gasification plant project key data Schedule for the project Signing of the main equipment contract: May 6, 2011 Foundation works ready by April 6, 2012, at the latest Equipment installations completed by September 1, 2012, at the latest Hand-over of the gasification plant to Vaskiluodon Voima: by December 31, 2012, at the latest Project budget Total budget of below 40 million euros Main equipment supplier Metso Power Oy 11

12 The gasification plant layout Fuel sampling Fuel crushing and sieving Forest chip dryer Gasifier Fuel receiving Fuel storage silos 12

13 1. Vaskiluodon Voima Oy, Vaasa power plant 2. Background of the project 3. The gasification plant project 4. Procurement of biomass 5. Metso and gasification technology 6. Vaskiluoto gasification plant

14 Procurement of biomass The fuel for the gasification plant is procured within 100 kilometers of the plant: Forest residue chips 90% (50 100%) Straw and reed canary grass 0% (0 5%) Peat 10% (0 50%) Amount: 30 trailer-trucks a day 900 GWh/a 14

15 1. Vaskiluodon Voima Oy, Vaasa power plant 2. Background of the project 3. The gasification plant project 4. Procurement of biomass 5. Metso and gasification technology 6. Vaskiluoto gasification plant 15 Metso

16 Metso A Wide Scope of Fuel-Flexible Power Technology Boiler plants Modular power plants Heating plants Automation systems Gasification Power solutions Recovery boilers Environmental systems Automation Rebuilds and upgrades Profilers Intelligent control valves ESD valves Automation systems 16 Metso

17 Metso s CFB gasification Three applications - Solution for biomass applications in lime kilns or other type of industrial kilns to replaces fossil fuel (Värö/Södra Cell). - Solution for biomass applications in power boilers, with some or all fossil fuels replaced with biomass (Vaskiluodon Voima). Instrumentation, electrification and automation Dried biomass Product gas Wet biomass Biomass receiving and pre-handling Large-scale belt dryer CFB gasifier 140 MW fuel Existing PC boiler - Solution for difficult fuels such as waste-derived fuels. Product gas is cleaned from harmful components prior to combustion (Lahti Energia). 17 Metso

18 1. Vaskiluodon Voima Oy, Vaasa power plant 2. Background of the project 3. The gasification plant project 4. Procurement of biomass 5. Metso and gasification technology 6. Vaskiluoto gasification plant 18 Metso

19 Metso s gasification plant for Vaskiluodon Voima Metso s scope Full scope - Fuel receiving and handling - Drying - Gasification - Boiler modifications - Automation, electrification and instrumentation Instrumentation, electrification and automation Product gas Wet biomass Dried biomass Biomass receiving and pre-handling Large-scale belt dryer CFB gasifier 140 MW fuel Existing PC boiler 19 Metso

20 Metso s gasification plant for Vaskiluodon Voima CFB gasifier CFB Gasifier - O.D. ~6 m - Height ~36 m Bed material - sand 2 fuel feeding lines 2 bottom-ash screws The largest CFB gasifier for biomass fuels in the world MW th Cyclone Product gas/ gasification air - heat exchanger Product gas line CFB reactor Fuel feeding Bottom ash removal 20 Metso

21 Metso s gasification plant for Vaskiluodon Voima Dryer and boiler modifications Dryer - Hot water 85 o C, evaporations capacity >10 tn/h - Drying area 237 m 2, one layer - Fuel moisture content 47 w-% PC-boiler - 16 PC burners (100 % load), 4 new burners - Live steam 535 o C, 185 bar (reheat 570 o C, 46 bar) Instrumentation, electrification and automation Product gas Wet biomass Dried biomass Biomass receiving and pre-handling 21 Metso Large-scale belt dryer CFB gasifier 140 MW fuel Existing PC boiler

22 Metso s gasification plant for Vaskiluodon Voima Analyzed technological risks Metso s experience of CFB boilers and grid design Low-temperature district heating water for drying Metso s catalyst experience from biomass-fired boilers 22 Metso

23 Material Temp, C Metso s gasification plant for Vaskiluodon Voima Analyzed technological risks Reduced pressure drop in the flue gas duct via a few minor modifications based on flow modeling Furnace modeling in collaboration with Vaskiluodon Voima and the burner supplier Water and steam flows have been studied in detail, careful design Metso s SteaMax corrosion calculation tool: specification of corrosion-safe operation models 100% load with coal still available all the time Max material temperature for low alloyed steel vs flue gas temperature Vaskiluodon Voima, Power Boiler PRIMARY SH 1,2,3 REHEATER SH 1 RE HEATER TERT SH 1,2 SEC SH 640 SH Metso Flue Gas Temp, C

24 Metso s gasification plant for Vaskiluodon Voima On-site work has been started Photo: Vaskiluodon Voima 24 Metso

25 Thank you for your attention! Mauri Blomberg Managing director Vaskiluodon Voima Oy Ville Hankalin Product engineer Metso Power Oy Metso s stand #6 E201 25

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