THE 12 th EUROPEAN GASIFICATION CONFERENCE. Vaskiluoto CFB Gasificaton Plant. March 10 13, 2014 Rotterdam, The Netherlands

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1 THE 12 th EUROPEAN GASIFICATION CONFERENCE March 10 13, 2014 Rotterdam, The Netherlands Vaskiluoto CFB Gasificaton Plant Juhani Isaksson, Valmet Power

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3 3 12 March, 2014 Valmet Author / Title

4 Valmet Power - gasification offering Product gas for industrial kilns Product gas for power boilers Product gas from waste for power production Indirect gasification of biofuels Sawdust, forest residues, fresh wood, bark MW fuel units Typically includes a dryer Dusty product gas Also other types of kilns possible Woody biomass, bark, peat, straw Superior electricity efficiency (Existing) power boilers MW fuel units Typically includes a dryer (Gas filtering) Waste-derived fuel High electricity efficiency Typically a new gas boiler Gas filtering -> clean product gas MW fuel units or multiple units connected to a boiler Suitable for clean biofuels Suitable for cases HIGH HEATING VALUE GAS is needed 8 SNG, refinery feed motors) 4

5 Cofiring is an efficient way to use biomass Example:100 MW of biofuel available at the district 100 MW, fuel Small boiler, efficiency 25 % 25 MW green electricity 100 MW, fuel 400 MW coal Large boiler, efficiency 40 % 40 MW green electricity MW coal electricity The final outcome is 60 % more green electricity! 5

6 Valmet scope in Vaskiluodon Voima s gasification project Full scope services with total plant optimization Fuel receiving and handling Drying Gasification Boiler modifications Automation, electrification and instrumentation Instrumentation, electrification and automation Product gas Dried biomass Wet biomass Biomass receiving and pre-handling Large-scale belt dryer CFB gasifier 140 MW fuel Existing PC boiler

7 VASKILUOTO GASIFICATION PLANT PC BOILER CFB GASIFIER FUEL STORAGE AND HANDLING DRYER 7 Date Author Title INTERNAL

8 Valmet CFB gasifier CFB Gasifier Cyclone CFB reactor Fuel feeding Size Fuel (300) MWth Biomass, waste Product gas/ gasification air - heat exchanger Gasification media Air Operating temperature C Operating pressure 5-30 kpa(g) Product gas heating value 3-7 MJ/nm 3 (LHV) Product gas line Bottom ash removal 8

9 Biomass dryer Vaskiluodon Voima Vaasa, Finland Start-up 2012 Process Materal Gasification (140 MW) Forest resudues (chips) Size 274 m 2 / ft 2 Layer type Heat source Capacity Single Water/glycol-50% C / F 10 metric tons/h of evaporated water 9

10 Gas heat value hot MJ/m3n Fuel Moisture vs. Gasifier output Fuel moisture ( waste ) 20% 30% 40% Gasifier max output Waste fuel: HHV dry 22,5 MJ/kg, Ash 7,6% CFB gasifier Gas heat value MJ/m3n hot ( incl. sensible heat ) Fuel Moisture 10 Date Author Title

11 Vaskiluoto Biomass Gasification plant and the main experiences of the project Matti Tiilikka Project manager Vaskiluodon Voima Oy 11

12 Vaskiluoto Power Plant Vaskiluoto 2 Investments: Boiler plant 1982 Desulphurization plant 1993 New turbine plant 1998 In technical terms, the plant is fit for use until 2030 Main figures: Electricity output 230 MW District heat output 175 MW Vaskiluodon Voima Oy 12

13 Main project drivers Main drivers for the project: To replace large amount (25-40%) of coal with renewable CO2-neutral fuel. The gasification plant will be run on full capacity and coal firing will be reduced on boiler part loads. To extend the lifetime of the existing power plant unit To achieve capability to use multiple fuels (fuel cost optimization) To guarantee a cost-effective district heating solution

14 Investment cost and benefits Total investment cost 40 M. State investment subsidy 10,8 M (Ministry of Employment and the Economy) Cost savings: Reduction of CO2-emission cost, reduction of CO2-emissions up to t/yr. Feed-in tariffs of renewable energy Reduction of the environmental taxes of district heating Other benefits: Low total cost compared with the construction of a totally new biofuel power plant Gasification compared with wood pellet firing: higher cost of pellet production (around +50%) and pellet milling is avoided Local fuels - Positive effects to the local economy, 15 M /a. The new activities will employ 100 people in fuel logistics Vaskiluodon Voima Oy 14

15 Project implementation Main Schedule Environmental permit Binding promise of the investment subsidy Contract with Metso Power Oy Start of the foundation work (4 months) Start of the equipment installation (11 months) Planned five weeks outage in August 2012 (15 months) Start of test runs October 2012 (17 months) Start of the commercial use January 2013 (20 months) Vaskiluodon Voima Oy

16 Project experiences Total project costs did stay in the frames of the budget Installation time: The time schedule was very tight. That pressed final installation work to late autumn and made the test running period quite challenging. Even so, the boiler modifications were made as planned during 5 weeks outage. The site safety was organised fine and there was only one minor accident on site. Test run: Only minor effects on PC-boiler operation, no boiler trips great! The fuel unloading pockets were designed with high separating walls and some types of trucks have had difficulties to operate between those walls. In the fuel sampling system there has been jamming with wet and cold peat. Temperature differences on the body material of air heaters have caused distortion and damaged bellows of the gas ducts. Vaskiluodon Voima Oy 16

17 Operation experiences There has been no instabilities in the boiler evaporator. NOx -emission level has been under the limits of environmental permit (500 mg/m3(n)) after the modification the emission level is around 350 mg/m3 and has been around 400 mg/m3 last year. The warranty values are likely to be fulfilled. Warranty tests will be carried out in March The dyer has functioned fine. We have seen that investment quite successful also because biofuels have been abnormal wet this year. The potential risk of the hot corrosion of the superheaters was noticed and therefore a theoretical study was made by Metso. As a result it was decided to keep the rate of biofuel always under the rate of coal. Vaskiluodon Voima Oy 17

18 Live steam pressure Temperature and flow Load following with coal Reduction for nights Gasifier load ( MW) March, 2014 Valmet Author / Title

19 NOx mg/nm3 6% O2 NOx content of boiler flue gases Low O2 High O % 10 % 20 % 30 % 40 % 50 % 60 % Gasifier share of total fuel input March, 2014 Valmet Author / Title

20 SO2 mg/nm3 6% O2 SO 2 content - before sulphur removal % 10 % 15 % 20 % 25 % 30 % 35 % 40 % 45 % 50 % 55 % Gasifier share of total March, 2014 Valmet Author / Title

21 First year availability First operational year 2013/2014 availability was 97 % Distribution of causes for unavailability (total 3 %) Torch test mailfunction Air damper leakage Air preheater imbalance Burner impeller damage Flame detection Fuel handling 0.0 % 20.0 % 40.0 % 60.0 % March, 2014 Valmet Author / Title

22 Dryer (Titanic) We are very pleased about the final results of this project and like to thank all our suppliers for the fine co-operation! Vaskiluodon Voima Oy 22

23 For further information contact: