Cofiring in large scale CFB - Experience gained from

experiments with the worlds largest biofuel fired CFB of

Alholmens Kraft, Finland
Pasi Vainikka, VTT Processes, Finland
2nd World Conference and Technology Exhibition on Biomass for Energy, Industry and Climate Protection
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FP5 Project partners
Maximum biomass use and efficiency in large-scale co-firing (BIOMAX)
VTT Processes, Finland Alholmens Kraft, Finland Kvaerner Power, Finland
CIRCE Foundation, Spain Elsam Engineering, Denmark Abo Akademi
University, Finland
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Contents
Alholmens Kraft CHP plant general features
The experiment matrix
Fuel properties
Emissions of SO
2
and SO
2
autoreductions achieved
Emissions of NO
Deposition measurements
Composition of deposits
Means to avoid chlorine deposition
Protective elements
Protective elements from fuel blending
Source:
Kvaerner Power Oy
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The boiler
Annual proportion of fuels:
Peat 50%
Wood fuels 25% (LR, Bark)
Coal 25%
2.5 years of successful
operation in open electricity
market
Operates with anything from
100% coal to 100% biofuel
Combusts the fuels in any given
combination while staying within
the emission limits
Consumes a truck load of peat
in 7 minutes
30,000 truck deliveries annually
Furnace measures 8.5m by
24m and is 40m in height
550MW
th
194kg/s, 165bar, 545C
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The Process
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The experiment matrix
X - - 32 50 18 16
X - - 32 50 18 15
X - - 28 25 47 14
- - - 26 25 49 13
- 48 - 42 10 - 12
- 60 - 40 - - 11
- - 90 - 10 - 10
- - 100 - - - 9
- - 37 - - 63 8
- - - 39 - 61 7
- - - 33 24 43 6
- - 25 25 - 50 5
- - - 44 56 - 4
- - 24 - 50 26 3
- - - - 5 95 2
- - - - 43 57 1
Lime
Wood
chips
Logging
residue
Bark Coal Peat
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Fuel properties
9.6 8.1-10.2 9.2 22.5 10.9 LHV
19.6 21.1 21.9 27.0 20.5 HHV
HEATING VALUE (MJ/kg)
0.004 0.014 0.010 0.010 0.020 Cl
0.014 0.06 0.04 0.3 0.15 S
34.4 41.0 40.2 8.2 33.3 O
1.5 0.4 0.7 2 1.5 N
5.8 6.0 5.6 4.5 5.2 H
55.0 50.0 51.0 73.0 53.1 C
ULTIMATE ANALYSIS OF DRY SOLIDS (wt-%)
3.3 2.5 2.5 12 6.8 Ash (wt-%, D.S.)
41.7 40-52 48-52 12 41.8 Total moisture
WC LR Bark Coal Peat FUELS
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Sources of contributing elements
0
2
4
6
8
10
12
14
1
0
0
%
L
R
5
0
%
L
R
+
5
0
%
B
a
r
k
4
0
%
L
R
+
4
0
%
B
a
r
k
+
2
0
%
P
e
a
t
2
0
%
L
R
+
4
0
%
B
a
r
k
+
4
0
%
P
e
a
t
1
0
%
L
R
+
4
0
%
B
a
r
k
+
5
0
%
P
e
a
t
1
5
%
L
R
+
2
5
%
B
a
r
k
+
4
5
%
P
e
a
t
+
1
5
%
C
o
a
l
3
0
%
L
R
+
3
5
%
P
e
a
t
+
3
5
%
C
o
a
l
1
0
0
%
C
o
a
l
w
t
-
%
Ca*0.5 K Zn*10 P Na Al Si*0.5
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Sources of contributing elements
0.00
0.04
0.08
0.12
0.16
0.20
1
0
0
%
L
R
5
0
%
L
R
+
5
0
%
B
a
r
k
4
0
%
L
R
+
4
0
%
B
a
r
k
+
2
0
%
P
e
a
t
2
0
%
L
R
+
4
0
%
B
a
r
k
+
4
0
%
P
e
a
t
1
0
%
L
R
+
4
0
%
B
a
r
k
+
5
0
%
P
e
a
t
1
5
%
L
R
+
2
5
%
B
a
r
k
+
4
5
%
P
e
a
t
+
1
5
%
C
o
a
l
3
0
%
L
R
+
3
5
%
P
e
a
t
+
3
5
%
C
o
a
l
w
t
-
%
0
1
2
3
4
S
/
C
l

a
t
o
m
i
c

r
a
t
i
o
S Cl S/Cl atomic ratio
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0.0
0.2
0.4
0.6
0.8
1.0
l
r
1
0
0
l
r
9
0
/
c
1
0
w
c
6
0
/
b
4
0
w
c
4
8
/
b
4
2
/
c
1
0
p
6
3
/
l
r
3
7
p
5
4
/
b
2
3
/
l
r
2
3
p
6
1
/
b
3
9
p
4
3
/
b
3
3
/
c
2
3
c
5
6
/
b
4
4
p
9
5
/
c
5
p
4
9
/
b
2
6
/
c
2
5
p
2
6
/
c
5
0
/
l
r
2
4
p
5
7
/
c
4
3
c
1
0
0
p
4
7
/
b
2
8
/
c
2
5
+
L
c
5
0
/
b
3
2
/
p
1
8
+
L
c
5
0
/
b
3
2
/
p
1
8
+
L
+
F
A
S
O
2
e
m
i
s
s
i
o
n
0
0.1
0.2
0.3
S
u
l
p
h
u
r

c
o
n
t
e
n
t

(
w
t
-
%
)
Sulphur content
SO2 emission
VTT TECHNICAL RESEARCH CENTRE OF FINLAND
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0 10 20 30 40 50 60 70 80 90 100
Share of biomass in fuel blend (%)
S
O
2
r
e
d
u
c
t
i
o
n
S02 reduction
SO2 reduction with
limestone feeding
VTT TECHNICAL RESEARCH CENTRE OF FINLAND
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Sources of contributing elements:
TGA test
75
80
85
90
95
100
200 300 400 500 600 700 800 900
Temperature (C)
W
e
i
g
h
t
-
%

(
%
)
~20% fall
Logging residue chips, ashed in 500 C
Courtesy of Markku Orjala
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Sources of contributing elements:
TGA test
75
80
85
90
95
100
200 300 400 500 600 700 800 900
Temperature (C)
W
e
i
g
h
t
-
%

(
%
)
Peat, ashed in 500 C
Courtesy of Markku Orjala
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0.0
0.2
0.4
0.6
0.8
1.0
l
r
1
0
0
l
r
9
0
/
c
1
0
w
c
4
8
/
b
4
2
/
c
1
0
w
c
6
0
/
b
4
0
p
5
4
/
b
2
3
/
l
r
2
3
p
6
3
/
l
r
3
7
c
5
6
/
b
4
4
p
6
1
/
b
3
9
p
4
3
/
b
3
3
/
c
2
3
p
2
6
/
c
5
0
/
l
r
2
4
p
4
7
/
b
2
8
/
c
2
5
+
L
p
4
7
/
b
2
8
/
c
2
5
c
5
0
/
b
3
2
/
p
1
8
+
L
c
5
0
/
b
3
2
/
p
1
8
+
L
+
F
A
p
9
5
/
c
5
p
5
7
/
c
4
3
c
1
0
0
N
O
x
e
m
i
s
s
i
o
n
0.0
0.5
1.0
1.5
2.0
N
i
t
r
o
g
e
n

c
o
n
t
e
n
t

(
w
t
-
%
)
Nitrogen content
NOx emission
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MP2: flue gas 510-550C
probe 350C
MP1: flue gas 700-750C
probe 540C
Deposit probe locations
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Radial variation in composition and temperature
NOTE THE
TEMPERATURE
INCREASE ON THE
EDGE OF DEPOSIT
Courtesy of Pasi Makkonen
C
o
u
r
t
e
s
y

o
f

M
a
r
t
t
i
A
h
o
0
4
8
12
16
20
24
28
Wind 50 angle Lee
w
t
-
%
Na2O K2O Cl
W
t
-
%
N2O
Cl K2O
Wind 50 Lee
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Boundary conditions: Temperature
10CrMo910
R
2
= 0.79
X20CrMoV121
R
2
= 0.88
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
350 370 390 410 430 450 470 490 510 530 550
STEAM TEMPERATURE, C
E
S
T
I
M
A
T
E
D

L
I
F
E
T
I
M
E
,

a



'
10CrMo910 X20CrMoV121 SS2338 Esshete 1250 AC 66 Predicted
CORROSION DETECTION LIMIT
Courtesy of Pasi Makkonen
Dr Salmenoja: ~450C is a threshold temperature for chlorine induced corrosion
supports findings of Dr Makkonen
This corresponds to 400-415C steam temperature
On average, ~415C is reached after 1st superheater in T
LS
>500C CFB/BFB
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Composition in 50 angle 350C probe
0
5
10
15
20
Na2O Al2O3 SiO2 SO3 Cl K2O CaO
W
t
-
%

i
n

d
e
p
o
s
i
t
s
Biomass Biomass + 10% Coal Biomass + 55% Coal
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Means to avoid chlorine corrosion: Sulphur
0
10
20
30
40
50
60
70
80
2.0 2.5 3.0 3.5 4.0 4.5
S/Cl atomicratio
H
C
l

-
c
o
n
v
e
r
s
i
o
n
,

%
100%load
45%load
100%load
withlimestonefeeding
0
10
20
30
40
50
60
70
80
0.0 0.5 1.0 1.5 2.0 2.5
S/Cl effectiveatomicratio
H
C
l

-
c
o
n
v
e
r
s
i
o
n
,

%
100%load
45%load
100%load
withlimestonefeeding
Sulphation of alkali chlorides:
2KCl + SO
2
+ O
2
+ H
2
O K
2
SO
4
+ 2HCl
Gas phase effect!
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Means to avoid chlorine deposition: Aluminosilicates
Kaolin, Al
2
O
3
2SiO
2
, was fed to the bed (BFB)
Dosing: 25, 50 and 80wt-% of the ash flow
Fuel 20% AGW + 80% Bark
0
15
30
45
60
75
No additive 0.25 x Ash flow 0.5 x Ash flow 0.8 x Ash flow
HCl-conversion, %
Cl in deposits x 10, wt-%
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Means to avoid chlorine corrosion: Coal minerals
Alumininosilicates can also react with alkalis liberating HCl:
Al
2
Si
2
O
7
2H
2
O Al
2
O
3
2SiO
2
Al
2
O
3
2SiO
2
+ 2KCl + H
2
O K
2
O Al
2
O
3
2SiO
2
+ 2HCl
The most abundant mineral is kaolinite (above) and illite (or range of aluminosilicates)
The key issue is whether there is alkali metal bound already in the aluminosilicate
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The objective
Fe K Cl
Fe K Cl
Fe Na K
O Al Si
S Ca Cl
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Heat transfer
surface
Lack of
protecting
compounds
Low ash
content
R
I
S
K
Y
C
OMPO
U
N
D
S
ALKALI
CHLORIDES
Cl releases
corrosion
BARK/FOREST RESIDUE
CASE 1. BARK/FOREST RESIDUE
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CASE 2. PROTECTING POWER OF COAL
FOREST RESIDUE COAL
Co-combustion
P
R
O
T
E
C
T
ING RE
A
C
T
I
O
N
S
ALKALI
SILICATES,
SULPHATES
ALKALI
CHLORIDES
R
I
S
K
Y
COMP
O
U
N
S
SULPHUR DIOXIDE,
Al-SILICATES
P
R
OTECTIVE
S
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Conclusions
In CFB conditions high SO
2
autoreduction can be achieved by cofiring
biomass with peat and/or coal due to high Ca content of wood fuels
In CFB conditions peat/wood/coal cofiring produces less NOx than pure
coal or wood fuel firing
Chlorine bearing deposit formation can be avoided by appropriate fuel
blending. Protective elements can be supplied in the boiler in peat
and/or coal ash
As a result of fuel blending, change in the composition of fuel ash can
dramatically change ash melting behaviour
S/Cl atomic ratio in fuel is not an appropriate parameter in describing
corrosion propensity of fuel blends in biomass cofiring. Instead,
estimation for this ratio in gas phase could be used as a guideline
With higher shares of peat and especially coal, the effect of aluminium
silicates should also be assessed
The amount of nitrous oxide, N2O, increases steeply when coal is
blended to the biomass blend. This could be an issue if there will be
emission limits for this compound in the future