Fuel Impact on Boiler Concept - outlook

2012-11-12, Vrme- och Kraftkonferensen 2012 Morgondagens energisystem Juha Sarkki Edgardo Coda

Presentation Outline

Focus: why Biomass & why CFB CFB Fuel Flexibility & Biomass Fuels Boiler Design Features for Biomass Firing Key References for Biomass Firing Clean Biomass Fuels Challenging Biomass Fuels Advanced Bio CFB technologies

Biomass as Energy Source & Market Drivers

Biomass has an important role in reducing the environmental effects (CO2) of energy production Biomass fuel market has changed to global and makes possible large scale power generation of biomass alone In addition to the traditional clean and recycled biomasses, the trend today shows increasing interest to applying agricultural biomass & waste For the boiler supplier is important to understand bio fuel origin and treatment processes as well as the actual ranges of fuel and ash properties CFB is IDEAL TECHNOLOGY for large scale power generation for broad range of biomass alone or cofiring in larger fossil fired power plants!

Key Advantages of CFB for Biomass Firing

Fuel flexibility is a special advantage

Wide range for biomass fuels Mixes of wood, agro, waste, etc Mixes of biomass fuels, coal

Excellent emission performance

Inherently low emissions No DeSOx / DeNOx plants required

High availability & competitive price

CFB Fuel Flexibility & Biomass Fuels

Fuel Flexibility in CFB

Coal
Anthracite Bituminous Subbituminous Lignite

Wood Residue
Bark Chips Sawdust Forest Residue

Recycled Wood Tire Derived Fuel Solid Recovered Fuel

Waste Coal
Bituminous Gob Anthracite Culm Coal Slurry

Agricultural Waste
Straw Olive Waste Sunflower Husk Rapeseed Dried Fruits ...

Waste Paper

Gas
Natural Off gases

Petroleum Coke
Delayed Fluid

Oil Sludge
Paper mill De-inking Municipal

Oil Shale

Peat

Biomass Properties
Timber pellets Timber chips 20-50 7,5-13,9 130-280 0,55 0,4-5,3 <0,1 <0,05 0,1-0,3 <0,05 Saw dust 45-60 6-10 300-350 0,45-0,7 0,4-0,5 <0,05 <0,03 0,1-0,3 <0,04 Bagasse Straw briquette pellets 8 16 650 2,9 6 <0,05 <0,03 0,4-0,7 <0,05 12 14,7 650 Peat Recycled RDF wood fluff 25 14 300-400 1,4 5 0,1 0,1 0,1-0,5 <0,3 25 13 100 0,4 10-20 0,1-0,5 0,3-1,2 0,4-1 <0,5

Moisture % Lower Heating Value MJ/kg Bulk Density kg/m3 Energy density MWh/m3 Ash % ds S % ds Cl % ds Alkali % ds P % ds

5-10 17 650 3 0,9 <0,1 <0,03 0,1-0,3 <0,05

50 9,3 340

2,7 0,9 7 5,1 0,01-0,03 0,22 0,1-0,8 0,02-0,06 0,3-1,7 0,1 0,05-0,8 <0,35

High concentrations of alkalis and chlorine increase risk for agglomeration, fouling and corrosion

Prediction tools for fuel effects and corrosion estimation

Agglomeration
10 9

Fouling

Corrosion

A. - agro biomass

Probability Index

8 7 6

4 3
MEDIUM
Bitumin. Stem A. 1 A. 2 A. 3 A. 4 A. 5 A. 6 A. 7 Straw A. 8 A. 9 Olive Waste

2 1 0

WOOD COAL

HERBACEOUS BIOMASS

FRUIT

Agglomeration, Fouling and Corrosion probabilities for selected fuels based on FW AFC model
7

LOW

HIGH

VERY HIGH

Boiler Design Features for Biomass Firing

Design Features for challenging fuels

Integrated Water/Steam Cooled Solid Separator and Return Leg

Features to control Fouling & Corrosion - Correct flue gas temperature - Correct design for convective heat transfer surfaces

Features to control Agglomeration & Fouling Effective temperature control

Conservative flue gas velocity During Operation: - Fuel quality management - FW SmartBoiler datalog & Diagnostic tools

Possibility to use Additives with worst quality agros

Active Bed Material

Step Grid

Final SH & RH as INTREX

Factors Effecting for Boiler Concept

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Additives and alternative bed materials against Agglomeration, Fouling and Corrosion
Schematic representation of mechanisms observed between fuel ash, bed materials, and additives

non-fouling (FA)

fouling/non-corrosive

fouling/corrosive

Sulfur

limestone

kaolinite

agglomerating

coating

melt

non-agglomerating (BA)
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The role of alloying elements and temperature against fire-side Cl-induced corrosion
400 350 300 250 200 150 100 T = 520 C 50 0 0.01 0.1 1 Log (Cl wt-% in deposit) 10 Alloy A (18.5% Cr, 10% Ni) Alloy B (25% Cr, 20% Ni) Alloy C (22.5% Cr, 25% Ni) Alloy D (23%Cr, 50.8% Ni) T = 650 C

Mean oxide layer thickness [m]

High Cl concentration

Deposit from commercial CFB co-firing high share of agro with coal (408 hours)

Laboratory corrosion test results

High Cr, or high total alloying elements do not guarantee low corrosion Other material properties such as stabilizing elements and crystallographic structure gain a bigger role at temperatures > 600 C
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References for Biomass Firing

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Biomass CFB, Vsters Increased capacity with wider fuel range

180 MWth (originally 157 MWth), 170/39 bar, 540/540 C
Fuel mix Forest residues Wood chips Bark Saw dust Peat Willow Demolition wood [%]LHV [%]LHV [%]LHV [%]LHV [%]LHV [%]LHV [%]LHV 35 10 5 5 15 5 25

Emissions NOx NH3-slip SO2 CO Dust [mg/m3n] [ppm] [mg/m3n] [mg/m3n] [mg/m3n]

6%O2, dry

65 5 130 210 20

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Large Scale CFB for Clean Biomass (CHP) 125 MWe Kaukas, Finland
125 MWe-net, 110 MWDH, 149 kg/s, 115 bar(a), 550 C
Fuel Moisture Ash Nitrogen Sulfur LHV [%]ar [%]dry [%]dry [%]dry [MJ/kg]ar Biomass 48 2.5 0.6 0.05 9.2 Peat 50 5 1.9 0.2 8.5

Performance Flue gas Texit Boiler efficiency NOx SO2 CO Dust [C] [%] [mg/m3n] [mg/m3n] [mg/m3n] [mg/m3n]

Biomass 149 91 150 200 200 20

The Power Plant was the Worlds largest user of solid biomass fuels in 2010!

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Advanced Bio CFB Concept for 20%-w Agro 205 MWe Polaniec, Poland
447 MWth, 205 MWe, 535/535C, 127/20 bar(a)
Fuel Moisture Ash [%]ar [%]dry 80% Wood Chips & 20% AGRO (Straw, Sunflower etc) 35.9 2.8

Nitrogen
Sulfur LHV

[%]dry
[%]dry [MJ/kg]ar

0.25
0.05 10.5

Emissions NOx SO2 CO [mg/m3n] [mg/m3n] [mg/m3n] 150 150 50

Dust

[mg/m3n]

20

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Multifuel CFB for Waste and Clean Biomass (CHP) Igelsta (Sderenergi AB, Sdertlje)
240 MWth, 73 MWe-net, 209 MWDH, 92 kg/s, 90 bar, 540C
Fuel Biomass Rec.wood REF pellets Moisture Ash Nitrogen Sulfur Chlorine LHV [%]LHV [%]LHV [%]LHV [%]ar [%]dry [%]dry [%]dry [ppm]dry [MJ/kg]ar Mix 1 75 0 25 44.3 6.5 0.6 0.09 1200 9.7 Mix 2 30 70 0 35.6 4.7 0.8 0.08 800 11.0 Mix 3 100 0 0 50.0 4.0 0.5 0.06 200 8.3

Total plant efficiency ~110%LHV 90%HHV

Emissions NOx SO2 CO Dust NH3 TOC HCl / HF Cd+Tl / Hg / HMs PCDD+F [mg/MJ] [mg/m3n] [mg/m3n] [mg/m3n] ppm [mg/m3n] [mg/m3n] [mg/m3n] [ng/m3n]

6%O2, dry 35* 75 50* 10 10 10 10 / 1 0.05 / 0.05 / 0.5 0.1

*) only at 100% load with Mix 1, 2, and 3

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Advanced Bio CFB Technologies

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Advanced Bio CFB Technology with Pure Solid Biomass up to scale 600MWe with Sub-Critical Steam Parameters
568/566C, 175-190/43.6 bar(a)
Market Prospects today up to 300 - 400MWe CFB Technology available up to 600MWe Natural Circulation Evaporator (~175bar) Once Through Benson evaporator (~175-190bar)
Lower Investment cost in large scale High plant efficiency over the whole load range

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Large Scale and High Efficiency Advanced Bio CFB Concept for 20-30%-w Agro with Clean Biomass up to scale 400MWe
568/566C, 179-190/43.6 bar(a)
Natural Circulation available up to 400MWe (~179bar)
Limiting factor for scale in EU is drum manufacturing capability (up to scale ~350MWe)

Once Through Benson available up to 400MWe (~179-190bar)

Lower Investment cost in scale ~350-400MWe Limiting factor for steam pressure is corrosion resistance of evaporator panel wall

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Take Away,,
Biomass has an important role in reducing the environmental impact of energy production. CFB technology is an ideal Technology to be used for power generation with broad range of solid biomass fuels, comprising of 20 % agro biomass in the recent projects commissioned this year. CFB Technology with pure biomass firing available up to 600 MWe scale.
Biomass CFB scale-up
Offered today

Unit Size in MWe's

600 500 400 300 200 100 0

Historic trend Current status

State of the art

1983

1985

1989

1995

2010

2012

2015
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