BIOMASS and WASTE to ENERY Peach Kernels, Sunflower Seed Husks, Nut Shells, Coffee Grounds, Sansa...

Power Stations

Boiler Plants

Hot Gas Generators

Firing Systems

Heat Recovery

Service

Customised Casting

Monday, March 26, 2018 1

RICHARD KABLITZ GMBH Intelligent technologies for energy recovery Speaker: Roman Koeppl, Export Manager

Richard Kablitz GmbH Biomass & Waste to Energy

BIOMASS and WASTE to ENERY

Overview of some critical technological issues

Agenda


I. Introduction

II. Critical technical issues to consider

III. Examples


About Richard Kablitz GmbH


R. Kablitz was founded in 1901

For > 100 years Kablitz builds moving grates for multi-fuel combustion and cast plate heat exchangers, all produced in its own foundry

For > 25 years Kablitz builds complete plants worldwide as subsupplier or general contractor

Kablitz builds steam boiler plants, thermal oil heaters, hot gas generators and power and CHP plants or combinations thereof



Biomass & Waste to Energy


Why Waste to Energy?

DON‘T WASTE THE WASTE

Reduction of dependency on fossil fuels

In UK much waste still is dumped in landfills or exported to EU

Landfills are not eco-friendly and a waste of resources, waste

slowly degrades and pollutes the environment

Waste hierarchy in the policies:

1. Prevent waste

2. Re-use / re-cycle -> Sorting required

3. Waste to Energy

4. Landfill is only a last option

Fuels – Fresh and Waste Wood • 1. Fuels


Natural, untreated Wood, Bark, Landscaping

Wood, Wood Chips

Industrial Wood,

Waste Wood

(AI - AIV)

Wood Granulate, Saw Dust and

Fibres


Fuels - Agricultural Waste


Rice Husks, Olive Stones or

Pomace, Peach Kernels,

Sunflower Seed Husks, Nut

Shells, Coffee Grounds, Sansa

Farm wastes

(Cow manure, chicken litter, ...)

Empty Fruit Bunches (EFB), Palm Shells and Kernels (PKS),

Bagasse, Straw



Solid Sorted Waste,

RDF/SRF/Fluff

Paper Mill Wastes

(Pulp, Rejects, ...)

Coal

Fuels - Waste and Coal





Steam Turbine (MAN) Hot Water & Steam Thermal Oil Heater & ORC (Turboden) Hot Gas (Dieffenbacher)

Typical Flow Sheet of a W2E Plant

Monday, March 26, 2018 9 Richard Kablitz GmbH


Fuel bunker and

preparation

Furnace & Boiler Flue gas treatment

Turbine-Gen-Set Feed water system Heat plant

Agenda


I. Introduction


III. Examples



Know your Fuel


Especially when dealing with the various waste fuels the plant suppliers need a

full fuel analysis:

Always remember: you do not know what kind of fuel you have in 10 or 15 years!

Characteristics Influences

Moisture Suitability for storage, plant design, self ignition danger

Calorific value Plant design, fuel usage

Ash content Dust emissions, firing technology

Ash melting temperature Availability, Safety, firing technology

Chlorine [Cl] HCl-, Dioxine, Furane, High temperature chlorine corrosion

Nitrogen [N] NOx-, N2O Emissions

Sulphur [S] SOx-Emissions, Acid dew point corrosion

Potassium [K] Corrosion (Superheater), decrease of the ash melting point

Sodium [Na] Corrosion (Superheater), decrease of the ash melting point

Heavy metals Emissions, Corrosion


Multifuel Combustion:

LA 2.2.03

It is possible to combine different combstion systems in a plant:

Grate: wood chips, RDF and other large fuel parts

Dust / granulate burner: fine particles < 3 mm

Auxiliary burners: light oil or natural gas


Monday, March 26, 2018 Richard Kablitz GmbH

Biomass & Waste to Energy 13

Multi-stage Combustion for Multi-fuels

Combustion air

Recirculation Flue Gas

Kablitz multi-stage

combustion design allows

operators to adjust the plant

to a large variety of fuels



Combustion Diagram:

Make sure that even

with the worst fuel you

can get full power

-> valid for combustion of waste - Flue gas temperature in boiler

after last air injection must be > 850°C for more than 2 seconds

- When T < 850°C only oil/gas burners may operate (usually only during startup and shutdown)



~980°C Last air injection,

begin of retention

time measurement

>850°C

> 2

s

„2 Seconds Rule“


If there is alot of Nitrogen in the fuel, NOx will be emitted -> SNCR

If the flue gas temperature is too high, the NH3 radicals from the urea build NOx

If the flue gas temperature is too low, the NH3 radicals don‘t react and the NH3 gets emitted as „ammonia slip“

SNCR


Mehldau & Steinfath

Monday, March 26, 2018

Acid dew point corrosion

Caused by much water and Sulfur in the fuel

Solution: High feed water temperature

High temperature chlorine corrosion

Convection heating surfaces

High level of Chlorine in fuel

Solution:

reduce flue gas temperatures before superheaters

Low steam parameters

Cladding

Corrosion:

17 Richard Kablitz GmbH



Cl - Corrosion Diagram: High temperature Corrosion


Always consider the

corrosion diagram

Keep superheaters

out of the corrosion

areas

18

Flue Gas Treatment Everything depends on the fuel

• Biomass, waste wood AI/II: -> Usually only dust removal required

-> Centrifugal separators, ESP, baghouse filter

• Waste wood AIII/IV, RDF: Flue gas treatment must be compliant to Waste Incineration Directive (WID) / 17. BImSchV Regulation (Germany), that means reactors, additive and activated carbon injection, bag-house filter, in future also catalysts

-> high invest costs, impact on total invest is less in larger plants

• Important: Often additionally local regulations apply!





Refractory material

Insist on a suitable refractory material. Here: Refractory consisting of

special SiC-plates for waste-to-energy plants.

(example: Wiesbaden)

Characteristics: Characteristics of membrane wall boilers:

- up to 150 t/h live steam power

- up to 110 bars

- up to 510°C

Characteristics of smoke tube boilers:

- up to ca. 25 MW boiler output

- up to 38 bars and 455°C

- compact design

- suitable for superheated steam, saturated steam and

hot water generation



Steam Boilers:

Horizontal boiler for Waste to Energy (tail end boiler)



Main Advantage of horizontal

boiler design:

Very maintenance friendly, easy

access to heating surfaces

Recomended boiler for Waste to Energy:

Thermal oil heaters in

membrane wall design,

suitable for low quality fuel

Thermal oil heaters with meander convection part

Thermal Oil Heaters:



Characteristics:

- up to 50 MW thermal power

- up to 20 bars

- up to approx. 400°C oil temperature

- Critical with waste fuel

-> risk of high-temperature corrosion!


Things you shouldn‘t miss:



- Boiler island should have 10-15% reserves in its design to be able to supply

full power in any case

- Choose a furnace that is flexible in regards of fuels, that can accept a

sufficiently large variation in water-content, LHV, grain size, metals and inert

material in the fuel

- In case of power plant: part load characteristics (down to which part load will

you get full live steam temperature?)

- Flue gas velocity in the boiler -> less velocity -> less erosion


Summary:



- Know your fuel, make analysis

- Multi-fuel furnace

- Always be aware of the corrosion problem

- Use recirculation gas to control the combustion

- Choose the right boiler design


Agenda:



I. Introduction


III. Examples


Reference Project: Chilton, UK

Location: United Kingdom

Fuel: Wood Chips

Fuel Bandwidth: 4,4 – 4,8 kWh/kg

Installed Combustion Capacity:

Reciprocating Grate: 53,6 MW

Electric Power: 17,6 MW

Live Steam Mass Flow:

67,0 t/h

Live Steam Pressure: 86 bar(a)

Live Steam Temperature:

495°C

Feed Water Temperature:

190°C

Combustion Air Preheating:

150°C

Year of Commissioning:

2012

Examples:




Examples:



Waste-to-Energy steam boilers



Project: Wiesbaden

Location: Germany

Electrical output: 10,0 MW

Heat output: 24,0 MW

Steam mass flow: 49 t/h

Steam pressure: 42 bar(a)

Steam temperature: 425 °C

Installed combustion capacity:

Reciprocating grate: 38,4 MW

Fuel: Wood waste grade 1 to 4

Year of commissioning:

2013

Waste Steam Boiler Plants


Water Tube Boilers

Reference Project: Buchen

Location: Germany

Fuel: Waste Wood AI – AIV 17. BImSchV



Reciprocating Grate: 27 MW, Auxiliary Burner: 12 MW


Live Steam Mass Flow:

30 t/h

Live Steam Pressure:

66 bar(a)

Live Steam Temperature:

425°C


105 °C


2003


Power Stations

Boiler Plants

Hot Gas Generators

Firing Systems

Heat Recovery

Service

Customised Casting

Thank You RICHARD KABLITZ GMBH Intelligent technologies for energy recovery


Bahnhofstr. 72-78, 97922 Lauda-Königshofen

Germany

Tel: +49 (9343) 7901-0 | Fax: -996 [email protected] | www.kablitz.com


http://www.kablitz.com/

Biomass steam boilers



Vertical water tube steam boiler

Project: Pemuco

Location: Chile

Electrical output: 12,1 MW

Heat output: 60 t/h at 1,2 bar(g)

Steam mass flow: 60 t/h

Steam pressure: 76 bar(a)

Steam temperature: 485 °C

Installed combustion capacity:

Reciprocating grate: 55,0 MW

Fuel: Forest residues, eucalyptus bark, coal

Year of commissioning:

2014

Biomass Thermal Oil Heater Plants


Reference Project: Menznau

Thermal Oil Heaters

Location: Switzerland

Fuel: Wood Chips, Production Wood,



Reciprocating Grate: 40 MW Granulate: 12 MW Dust: 25 MW Design: 57 MW

Thermal Oil Output: 25 MW

Thermal Oil Temperature:

285°C / 255°C

Hot Gas: 30 MW / 350°C


2009


Hot Gas Generators


Reference Project: Sanem

Location: Luxembourg

Fuel: Bark, Production Wood (MDF), Saw Dust, Shavings

Fuel Bandwidth: 2,6 - 3,5 kWh/kg


Reciprocating Grate: 15 MW, Granulate Burner: 3 x 5 = 15 MW

Hot Gas: 25 MW / 350°C


2010


Biomass CHP and Energy Centers


Reference Project: Rosenheim

Steam Turbine Power Plants

Location: Germany

Fuel: Waste wood, Industrial wood


Reciprocating grate: 20 MW Dust/Granulate burner: 3 x 5 = 15 MW


Live Steam Mass Stream: 30 t/h

Live Steam Pressure: 66 bar(a)

Feed Water Temperature: 107 °C

Year of Commissioning: 2001




Steam Turbine Power Plants Reference Project: Goch

Location: Germany

Fuel: Wood Chips, Landscaping Wood



Reciprocating Grate: 28 MW

Electric Power: 5,0 – 7,2 MW

Live Steam mass flow:

30 t/h

Live Steam Pressure:

65 bar(a)

Live Steam Temp.: 480°C


2012




ORC Power Plants Reference Project: Aschaffenburg

Location: Germany

Fuel: Wood Chips, Landscaping Wood





Heat Output: 8,0 MW

Thermal Oil Output:

9,4 MW


2009



Location: France

Fuel: Wood Chips




Heat Output: 18 MW

Saturated Steam mass flow:

28 t/h

Saturated Steam Pressure:

18 bar(a)

Saturated Steam Temperature:

207°C


105 °C


2012

Examples:

Reference Project: Rosières en Santerre





Steam boiler: Domat/Ems Block 3, CH




Thermal oil boiler: Tomsk, RU




Thermal oil heater and

hot gas generator:

Genk, BE

Grate, Fuel Feeder, Kablitz Turbo System and steel works Richard Kablitz GmbH



Examples:

Four grates are in position




Examples:



Assembly after 4 Months


Examples:



BIOMASS and WASTE to ENERY Peach Kernels, Sunflower Seed Husks, Nut Shells, Coffee Grounds, Sansa...

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Transcript of BIOMASS and WASTE to ENERY Peach Kernels, Sunflower Seed Husks, Nut Shells, Coffee Grounds, Sansa...