Biomass & Waste Co-firing Experience at Vattenfall

Transcription

1 Society of Thermal Engineers of Serbia POWER PLANTS 2012 International Conference Zlatibor, Serbia October 30 November 02, 2012 Biomass & Waste Co-firing Experience at Vattenfall Dr.-Eng. Daniel Seibt Head of Power Plant Engineering Ronald Rost Head of Sales Vattenfall Europe PowerConsult GmbH, Vetschau, Germany

2 Introduction

3 Vattenfall Group Organisation involved Business Units Board of Directors Chief Executive Officer Staff functions Chief Financial Officer Business Division Asset Development Business Division Production Business Division Asset Optimisation and Trading Business Division Distribution and Sales Business Division Renewables R&D Projects Lignite Asset Optimisation Continental Customer Service Onshore Wind Development Engineering Nuclear Asset Optimisation Nordic Sales B2C Offshore Wind Development Thermal Projects Hydro Trading Sales B2B Generation Wind Nuclear and Hydro Projects Thermal Operations Heat Biomass Project Governance & Improvement Distribution Energy related services Shared Services 3 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

4 Vattenfall Engineering Key Facts Approx. 1,000 employees Turnover: 154 MEUR Technical, management and environmental engineering and consulting services for the energy sector Active all over the world with focus on Europe Providing services through: Vattenfall Europe PowerConsult GmbH, Germany Vattenfall Europe PowerConsult East d.o.o., Serbia 4 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

5 Biomass use at Vattenfall

6 Biomass at Vattenfall has a long history of working with biomass in producing heat and electricity and plans to increase co-firing of biomass in coal power plants to reduce fossil emissions of CO 2. Vattenfall has currently more than 40 heat and power plants fuelled in full or in part by biomass. uses more than 3 million tonnes of biomass per year, an amount that is steadily increasing. intends to allocate significant resources and efforts to build a substantial, highly reliable and sustainable biomass supply chain. is one of the world s leading companies in the sector. 6 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

7 Biomass Plants of Vattenfall (existing and planned) Heinola Kärsämäki Laukaa Myllykoski (Vamy Oy) Pulkkila Puulaakso CHP Uurainen Vanaja (Hämeenlinna) Aschersleben Boxberg Jänschwalde Lippendorf Moabit MVB MVR Reuter C Rüdersdorf Schwarze Pumpe Sellessen T.A. Lauta Tiefstack VERA Märkisches Viertel Klingenberg Buggenum Hemweg Lelystad Amagerværket Fynsværket Askersund Båtsmannen Bollmora Ekobacken Fagersta Fisksätra Götene Grängesberg Gustavsberg Haparanda Hästhagen Hemse Idbäcken Nyköping Johannisberg Jordbro Kalix Klinte Knivsta Kvarnberget Ludvika Mölnvik Motala Munksund Överkalix Övertorneå Skavsta Slite Storvreta Uppsala CHP/waste plant Vänersborgs fjärrvärme Värmdö marknadsplats 7 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

8 Biomass Importance of Sustainability Importance of Sustainability for Biomass Market Development - Vattenfall s Strategy Investment in low-emitting energy Biomass plays an important role in Vattenfall s ambition on renewable energy, especially within the next 10 years Biomass co-firing quickly reduces fossil CO 2 emissions by substituting hard coal Biomass growth plan Need to secure long term supply of biomass in large volumes, develop a sustainable supply chain The biomass growth plan will five-fold Vattenfall s use of energy biomass by 2015 and will ten-fold by 2020 Biomass portfolio Vattenfall will build a biomass portfolio with a mix of sourcing agreements, sourcing contracts and upstream investments Vattenfall is evaluating and negotiating supply agreements and partnerships in following regions Europe, North-America, Africa, Russia Biomass is a cornerstone of Vattenfall's strategy for near term CO 2 reduction efforts 9 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

9 Biomass traditional product large future market Biomass seen as a Fuel Development over Time Wood chips (residues) Wood chips (logs) White pellets/ briquettes Black pellets/ Briquettes Steam explosion Torrefaction Carbonization R&D stage Fuel Development today 10 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

10 Vattenfall Experiences in Biomass Co-Firing CHP Station Zeran, Poland 350 MW e / 1561 MW th Fuels: hard coal, wood chips, agric. residues, operated by Vattenfall Heat Poland CHP Station Amagervaerket, Denmark 438 MW e / 1203 GWh th Fuels: hard coal, biomass, operated by Vattenfall Heat Nordic CHP Station Fynsvaerket, Denmark 656 MW e / 2139 GWh th Fuels: hard coal, biomass, operated by Vattenfall Heat Nordic CHP Station Uppsala, Sweden 200 MW e / 1500 GWh th Fuels: peat, biomass, waste, oil; operated by Vattenfall Heat Nordic CHP Station Reuter, Germany 153 MW e Fuels: hard coal, wood chips; operated by Vattenfall Europe Heat 11 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

11 Biomass Co-firing CHP Moabit

12 Project Motivation Climate protection agreement between the city state of Berlin and Vattenfall, signed on 8 October 2009 Agreement about sustainable procurement of wood was signed on 15 th April 2011 Moabit s Wood Co-Firing impact on the commitment is shown in the chart below: Forecast of Vattenfall s CO2 emissions in Berlin ~ 1.2 mln t CO 2 current forecast target Moabit can deliver a CO 2 reduction up to t/a from 2014 (Commercial Operation date) on 13 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

13 Security of wood chips delivery for Moabit Supply of wood chips is only possibly by barges due to the permitting process 100 % of wood chips (265,000 t/a, approx. 40 % water content) can be provided by local sourcing, with possibility of the use of forest residues (tops and branches) and logs Additional international volumes could be provided For a secured supply of local wood chips, a hub (for transfer of local wood chips in barges) is necessary 14 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt *gmt green metric tons

14 Location Historic CHP site in the city of Berlin 15 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

15 CHP Moabit - Location in the Berlin district heating system CHP Moabit Buch 5 MW ( MW el x35 MW th ) An der Kappe 0.1 MW Lichterfelde 450 MW Blankenburger Straße Schulstraße 0,1 MW Görschstraße 0,1 MW Prenzlauer Promenade Reuter West Scharnhorststraße 600 MW Velodrom Reuter 1 MW 165 MW Lichtenberg Mitte Charlottenburg 36 MW 440 MW 215 MW Treptow** 0,2 MW Wilmersdorf Klingenberg 280 MW Bayernring 188 MW Kodak- Hanseatica Friedrichshagen Adlershof 1 MW System West System Ost 0.2 MW Köpenick 10 MW Altglienicke Cogeneration power plant* Block cogeneration power plant* Heat only plants * Installed electrical power ** Molten-Carbonate-Fuel Cell 16 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

16 CHP Moabit Main process flow of Unit A Furnace with "integrated" Environmental Protection Biomass Secondary Air Coal Bunker Foreign Ash Bunker Lime stone Silo Wood I Primary Air CFB Vortex Combustion Chamber Nozzle Grate Return Cyclones Fluid. Bed Cooler Bed Ash Cooler Flue Gas Downstream -Heating Surfaces Ash Air Electrostatic Precipitator Flue Gas Ash Steam Fresh Air Fan Induced Draft Fan Tube Air Preheater Flue Gas Chimney from CFB Turbine Highpressure to CFB Mediumpressure Heating Condenser Lowpressure part Generator Cooling Tower Cooling Water Main Condenser Berlin-Spandau Ship Canal Transformer Ash Silo Heat exchanger Power Water Flow Return to Consumer District Heating Network 17 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

17 CHP Moabit Installed Electrical and Thermal Capacity Installed Electric Power Unit A (coal/lignite) Gas Turbines 5-7 (light heating oil) 151 MW 100 MW 51 MW (17 MW each) Thermal Site Output Unit A HOB 1-3 (light heating oil) 241 MW th 136 MW th 105 MW th (35 MW each) 18 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

18 CHP Moabit Project Features CFB Boiler 240 MW th for bituminous coal (designed for max. 40 % lignite) Substitution of 50 % of combustion heat capacity by virgin wood (chips/pellets) already 10 % wood co-firing realised by earlier project Co-firing of ~ 40 t/h Biomass from the vicinity around Berlin and international markets Construction of a plant for unloading, transport, intermediate storage and dosing of biomass Wood delivery via ship throughout the whole year from nearby BEHALA facility Intermediate storage of 9,000 m 3 Heat exchange system to be tied-in into water steam cycle 19 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

19 CHP Moabit Fuel Features Biomass types: virgin wood chips, wood pellets Water content: % Particle size: mm Density: kg/m³ Ash content: % Heating Value (raw): 9 18 MJ/kg 20 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

20 CHP Moabit - Location Map 21 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

21 Expectations - Reduction of Coal and CO 2 Planned CO 2 - reduction at the site: Additional Fuel Virgin Wood (woodchips or white pellets): up to t/a (depending on wood quality) Reduction CO 2 : up to 280,000 t/a Reduction Coal: up to 120,000 t/a 23 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

22 Procurement Packages Lot 1 Crane Lot 2 Bulk Material Handling Lot 3 Special Conveyer Lot 4 Fire protection Lot 5 Electrical Equipment Lot 6 Instrumentation & Control Lot 7 Steel and Metal Construction Lot 8 Fuel dosing Lot 9 Heat exchange system Lot 10 Civil works 27 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

23 Project timeline 02/ / / / /2014 Project Analysis Project Planning Establishment Realization Handover Conclusion 29 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

24 HSE HAZID Activities Overview HSE Manager established HAZID Workshop conducted with cross competency participants HSE Risks identified and integrated into Risk Register Several interviews/workshops conducted with risk responsible persons Knowledge exchange with HSE Managers of other projects performed HSE requirements to be fulfilled by suppliers have been included in the ITT First proposals have been evaluated and meet HSE requirements Several HSE documents have been developed and approved: HSE Masterplan HAZID Study HSE Design Plan HSE Construction Plan SiGePlan 31 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

25 Technical Aspects

26 View of CHP Moabit Red brick historical parts 33 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

27 CHP Moabit New unloading area Semiautomatic crane is used for ship unloading Separation of oversized particles by classifier to protect the SICON Belt Conveying of Biomass to the storage site by closed conveying system (SICON) 34 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

28 CHP Moabit New Biomass unloading and handling 35 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

29 Transport to intermediate storage 36 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

30 Transport to intermediate storage Biomass will be transported to the storage by the closed conveying system Beladung Entleerung Antrieb 37 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

31 Biomass handling and storage in a former turbine hall 38 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

32 Temporary Storage Biomass flow will be divided into two flows in the receiving area of the former turbine hall 1) direct supply of the CFB Boiler (180 m³/h) 2) storage of the remaining biomass (320 m³/h) Full automatic crane will be used for fuel handling - Storage - Removal from storage - Relocating of biomass inside the storage Storage area is divided into Sections each Section consist of 6 Fields 39 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

33 Temporary Storage The full automatic crane is capable to time-staple the stored biomass => possibility to demonstrate to the authority the storage period of max. 1 week Removal of biomass according to the boiler demand and the FIFO principle (storage period max. 7 days) Monitoring of the storage area by Infrared (IR ) camera and selective removal of biomass with a temperatures > 60 C 40 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

34 Fire Protection Main focus: Construction of biomass plant in the area of the existing plant requires different adjustment in inventory (expansion of fire monitoring, fire protection roof of machine hall) Monitoring of temporary storage with IR cameras and specification of alarm temperatures Installation of spray levels divided into sections above biomass storage Automatic spraying units in the tunnel area and from conveyor bridge to feed regulating Dry extinguishing system along the pocket belt conveyor, in the building of coarse grain resistance and in machine hall Installation of combustion gas detectors and expansion of fire detection system 42 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

35 Fire Protection IR Monitoring 1. Alarm temperature t > 60 C - relevant area of biomass storage is to be fed to co-firing immediately Exemplary visual analysis of IR measurement 2. Alarm temperature t > 75 C - relevant area is to be cooled down and subsequently fed to co-firing - targeted monitoring by operator 43 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

36 Transport from intermediate storage (MH II) to Boiler 44 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

37 Biomass feed-in in the boiler house 45 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

38 Waste co-incineration

39 Legal requirements in Germany acc. Recycling & Waste Act Thermal exploitation of waste must meet the following minimum conditions: Calorific value of waste 11 MJ/kg The heat created must be used Combustion efficiency of at least 75% The final residue produced is to be stored without further treatment Composition of waste with high calorific value Shredding light Dual System residues RDF (refuse-derived fuel) after mechanical and biological treatment RDF from mech.-bio. plants Industrial waste Domestic waste fraction Source A Source B Source A Source B Source A Source B Source A Source B Source A Source B share in normal operation [W-%] Calorific value [MJ/kg] , ,5 Water content [W-% mass ] Ash content [W-% mass ] Sulphur [W-% mass ] 0,6 1,5 0,5 0,2 0,5 1 0,51 0,5 0,14 0,2 Cl + F [W-%] 0,3 1,8 0,2 3 0,2 1 0,18 0,8 0,2 0,5 47 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

40 Vattenfall Experiences in Waste Co-incineration Power Station Schwarze Pumpe 1600 MW el, fuels: lignite (PC), residue derived fuel, fibre slurries; operated by Vattenfall Europe Generation Power Station Jaenschwalde 3000 MW el, fuels: lignite (PC), residue derived fuel; operated by Vattenfall Europe Generation Power Station Lippendorf 1800 MW el, fuels: lignite (PC), sewage sludge; operated by Vattenfall Europe Generation Power Station Boxberg 1900 MW el, fuels: lignite (PC), sewage sludge, animal meal; operated by Vattenfall Europe Generation 48 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

41 Waste Co-incineration at Jaenschwalde 6 x 500 MW Verbrauchs- und Erzeugungsbilanz / Tageswerte bei Kraftwerksnennleistung 3000 MW Electricity / MWh/d Housholds Limestone t/d 43 wagons/d District Heat / MWh th. /d Housholds Gypsum / t/d 75 wagons for Gypsum processing Lignite t/d wagons/d Pit water m 3 /d Ash / t/d 195 wagons/d Water / m 3 /d as CT vapour to atmosphere Residual moisture / m 3 /d ash and gypsum Water to river Spree / m 3 /d 49 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

42 Waste Co-incineration at Jaenschwalde 6 x 500 MW ANNAHME, FÖRDERUNG UND DOSIERUNG VON SEKUNDÄRBRENNSTOFF 2X 340 m 3 50 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

43 Waste Co-incineration at Jaenschwalde 6 x 500 MW ANNAHME, FÖRDERUNG UND DOSIERUNG VON SEKUNDÄRBRENNSTOFF 8000 m 3 51 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

44 Waste Co-incineration at Jaenschwalde 6 x 500 MW Einbindung des SBS in den vorhandenen Brennstoffweg 52 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

45 VPC range of services for Biomass/Waste-to-Energy projects Strategic planning Technical planning Construction Operation Waste management Site planning Project management Documentation update Disposal concept Technology selection Quality assurance Maintenance planning Market analysis Feasibility study Commissioning Revision management Materials management Logistics concept Performance tests Stock organisation Viability analysis Basic design Documentation Operational management Site concept Permit application Status assessment Risk analysis Detailed design Incident analysis Environmental impact study Tender specification Organisation and procedure Authority support Public Relations concept Contractor selection Project planning 53 Biomass and Waste co-combustion at Vattenfall - Dr. D. Seibt

46 Many Thanks for your Attention!