Advanced CFB Technology for Large Scale

Biomass Firing Power Plants

11.3.2013, IDA Energy: Biomass Combustion – Challenges in Fluid Bed and Grate-firing

Teemu Nevalainen

• Fluidized Bed Technology and Biomass Fuels

• Advanced Boiler Design Features for Biomass Firing

• Key References for Large Scale Biomass Firing

– Cofiring Peat and Biomass Fuels

– Clean Biomass Fuels

– Challenging Biomass Fuels

Presentation Outline

1

Foster Wheeler AG

• Employees

• Order backlog

• New orders booked

• Operating revenues

• Consolidated EBITDA

Approx. 12,000

USD 3.6 billion

USD 4.3 billion

USD 4.5 billion

USD 283 million

• Established in 1884, known as Foster Wheeler since 1927.

• Foster Wheeler is a global engineering and construction contractor and powerequipment supplier, with a reputation for delivering technically-advanced, reliable facilities and equipment with world-class quality and safety.

• Traded on NASDAQ National Market in New York.

Key figures, 2011

2

Foster Wheeler AG, Business Groups

The Global Engineering & Construction (E&C) Group

The Global Power Group

Designs and constructs leading-edge processing facilities for the

upstream oil & gas, liquefied natural gas (LNG), gas-to-liquids,

refining, chemicals and petrochemicals, power, environmental,

pharmaceutical, biotechnology and healthcare industries.

Has world-leading expertise in combustion technology, and

designs, manufactures, supplies and erects steam generating,

flue gas cleaning and auxiliary equipment for power stations and

industrial markets worldwide. The group also provides a range of

environmental products and aftermarket parts and services.

3

Foster Wheeler Global Power Group

Products & Service

Steam generators

• Circulating fluid bed

• Pulverized coal

• Oil & gas

• Bubbling fluid bed

• Grate and MSW

• Package

• HRSG

• Metallurgical waste heat

• Solar

Aftermarket services

• Engineered and replacement

pressure parts

• Weld overlay and refractory upgrades

• Replacement parts

• Cyclone burner retrofits

• Coal mill service and

upgrade

• Boiler and HRSG

maintenence

Environmental products

• Circulating fluid bed

scrubbers

• Fabric filters

• SCR and SNCR systems

• Low NOx combustion

systems

• Coal/air control system

upgrades

• Biomass combustion retrofits

Auxiliary equipment

• Condensers

• Feedwater heaters

• Biomass gasifiers

Plant operation

• Start-up

• Operation and

maintenence services

4

World Leader in Fluidized Bed Combustion

(CFB) Technology

5

• First BFB boilers delivered in the 1970s, and world’s first CFB supplied in 1979.

• World’s first once-through supercritical CFB started operation in 2009 in Lagisza, Poland.

• Flexi-Burn™ - air/oxy flexible CFB commercially available by the of end 2012.

• CFB fuel flexibility and multifuel capability provide for efficient utilization of fossile and renewable fuels.

• Meets tough emission regulations without additional flue gas cleaning systems.

136 - Bubbling fluidized bed (BFB) boilers 402 - Circulating fluid bed (CFB) boilers

• 347 delivered

• 55 under construction

• Biggest unit in operation 460 MWe

• 135 delivered

• 1 under construction

11 - Atmospheric fluidized bed gasifires

• 11 delivered

PKE Lagisza, Poland Äänevoima Oy, Finland Lahti Energia, Finland

• CFB technology was established under Graf-Wulff GmbH since 1989.

• High experience in Bag House and ESP technology.

• Low in operating and investment costs.

• Operated in coal-, oil- and solid waste-fired plants.

• Nearly unlimited in removal efficiencies (98-99%) for most multi-pollutants.

• Presently designed for flue gas flow from 10,000 to 4,000,000 m³/h.

• Operating range from 50 – 100% (down to 30% on special request).

Combination of FGS and dedusting 68 number of world wide installed systems

• 68 delivered

• 2 under commissioning

• Biggest unit in operation 3,100,000 m³/h

• approx. 70 % with CFB-scrubber and

Bag House

• approx. 30 % with CFB-scrubber and ESP

• approx. 50 % coal fired boilers

• approx. 40 % garbage and waste fired boilers

• approx. 10 % biomass and RDF,

fuel oil and fuel oil residue fired boilers

Distributing / application areas

6

Basin Electric, USA Refinery, Germany EVN, Austria

World Leader in Circulating Fluid Bed Scrubbing

(CFB) Technology

Fluidized Bed Technology and Biomass Fuels

7

• Fuel flexibility is a special advantage

– Wide range for design coals

– Broad range for biomass, waste, etc

– Hard-to-Burn fuels (petcoke etc)

• Excellent emission performance

– No DeSOx / DeNOx –plants required

• High availability & competitive price

Key Advantages of CFB

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• Biomass has an important role in reducing the environmental

effects 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 co-firing in

larger fossil fired power plants!

Biomass as Energy Source

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Biomass Fuels

10

Oth e r in d u s tria l

wo o d re s id u e s

Sa w-d u s t

Cu tte r s h a v in g s

Grin d in gp o wd e r

Ba rk

E n e rg yE . A la ka n g a s

HIERARCHY OF T HE WOOD-DERIVED F UEL S DEF INIT IONS

T imb e r o r p u lp wo o d fo r fo re s t in d u s try

FORESTRY Dire c t wo o d fu e ls

INDUSTRY In d ire c t wo o d fu e ls

SOCIETYRe c o v e r e d wo o d fu e ls

CONSUMERS OF WOOD

AND PAPER PRODUCT SF OREST INDUST RY

F OREST CHIPS

Wh o le tre e

De limb e d tre e s

Stu mp s

Ch ip s

Pu lp c h ip s

F o r p a p e rin d u s try

B ille ts

Pe lle ts Briq u e tte s

Ch ip s

Ch ip s c ru s h e d

Ch ip sF IEL DS

SHORT ROT AT ION

F OREST(willo w)

RAW MAT ERIAL

T imb e r

Pu lp wo o d

Re g e n e ra tio n

s ta n d s (lo g g in g re s id u e s )

Yo u n g s ta n d sT h in n in g s

(wh o le tre e s )

WOOD F UEL S

Un me r c h a n ta b le wo o d

CONVERSION PROCESSES ( COMBUSTION, GASIFICATION, PRODUCTION OF LIQUID BIOFUELS)

Pro d u c tio n o f re fin e d

wo o d fu e ls

Gre e n c h ip s

Bro wn c h ip s B la c k liq u o r

B io b a s e d

s lu d g e s

mix e d

with b a rk

Un tre a te d wo o d

Bu ild in g o f n e w h o u s e s

Pu lp a n d p a p e r

in d u s try

Me c h a n ic a l wo o d

in d u s try

Ch e mic a lly

tre a te d wo o d

Us e d p a p e r a n d b o a rd

Re c o v e re d p a p e r fo r

re c y c lin g

Cru s h e d o r c h ip p e d

re c o v e re d wo o d

Cru s h e d

p a p e r

L IQUID INDUST RIAL

WOOD F UEL S CONST RUCT ION

WOOD "o ld wo o d " o r

u s e d wo o d p ro d u c ts

NOT re c y c la b le

p a p e r

Wo o d a n d

p a p e r p ro d u c ts

SOL ID INDUST RIAL WOOD RESIDUES/

BY-PRODUCT Su n tre a te d wo o d

Ch ip s

s o rtin g

R a w m a te ria l u se

M e c h a n ic a l h a n d lin g (ch ip p in g , cru s h in g , p e lle tizin g , b riq u e ttin g )

C h e m ic a l tre a tm e n t in fo re st in d u stry

P a in tin g e tc . h a n d lin g o f w o o d

F u e l fo r co n v e rsio n p ro ce ss

E n d p ro d u cts (w o o d a n d p a p e r)

De wa te rin g

+ AGRO Biomass

All fuels have they

own Characteristics:

• Chemical characteristics

– Na,K

– Cl, P

– Ash content

– Etc..

• Physical characteristics

– Combustion

– Sizing

– Etc.

Biomass Properties

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

corrosion

Timber Timber Saw Bagasse Straw Peat Recycled RDF

pellets chips dust briquette pellets wood fluff

Moisture % 5-10 20-50 45-60 8 12 50 25 25

Lower Heating Value

MJ/kg 17 7,5-13,9 6-10 16 14,7 9,3 14 13

Bulk Density kg/m3 650 130-280 300-350 650 650 340 300-400 100

Energy density

MWh/m3 3 0,55 0,45-0,7 2,9 2,7 0,9 1,4 0,4

Ash % ds 0,9 0,4-5,3 0,4-0,5 6 7 5,1 5 10-20

S % ds <0,1 <0,1 <0,05 <0,05 0,01-0,03 0,22 0,1 0,1-0,5

Cl % ds <0,03 <0,05 <0,03 <0,03 0,1-0,8 0,02-0,06 0,1 0,3-1,2

Alkali % ds 0,1-0,3 0,1-0,3 0,1-0,3 0,4-0,7 0,3-1,7 0,1 0,1-0,5 0,4-1

P % ds <0,05 <0,05 <0,04 <0,05 0,05-0,8 <0,35 <0,3 <0,5

Advanced Boiler Design Features for

Biomass Firing

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• Fuel Characterization

– Physical & Chemical characteristics

– Fouling characteristics

– Corrosion characteristics

• Plant Requirements

– Electricity / Industrial

– Steam data

– Emissions

– Legistlation

• Investment Factors

– Investment cost

– Operation cost

– Fuel flexibility

– Availability

Factors Effecting for Boiler Design

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Key Design Features of Foster Wheeler Advanced Bio CFB

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Features to control Fouling & Corrosion

Features to control

Agglomeration & Fouling

- Correct flue gas temperature

- Correct design for convective heat

transfer surfaces

Conservative flue gas velocity

Integrated Water/Steam Cooled

Solid Separator and Return Leg

Step Grid Final SH & RH as INTREX

Active Bed Material

During Operation:

- Fuel quality management

- FW SmartBoiler datalog &

Diagnostic tools

Effective temperature control

Possibility to use Additives

with worst quality agros

Key References for Large Scale Biomass

Firing

15

Large Scale CFB for Cofiring Peat and Clean Biomass Jyväskylä, Finland

458 MWth, 160/143 kg/s, 164/40.5 bar(a), 560/560°C

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Fuel Peat Wood Chips

Moisture [%]ar 50.0 50.0

Ash [%]dry 5.0 2.0

Nitrogen [%]dry 1.2 0.3

Sulfur [%]dry 0.3 0.0

Chlorine [ppm]dry < 500 < 200

LHV [MJ/kg]ar 8.3 7.3

Performance Peat

Flue gas Texit [˚C] 90

Boiler efficiency [%] 94.1

NOx [mg/m3n] 150

SO2 [mg/m3n] 200

CO [mg/m3n] 200

Dust [mg/m3n] 30

Large Scale CFB for Clean Biomass (CHP) Kaukas, Finland

385 MWth, 125 MWe-net, 110 MWDH, 149 kg/s, 115 bar(a), 550 °C

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Fuel Biomass Peat

Moisture [%]ar 48 50

Ash [%]dry 2.5 5

Nitrogen [%]dry 0.6 1.9

Sulfur [%]dry 0.05 0.2

LHV [MJ/kg]ar 9.2 8.5

Performance Biomass

Flue gas Texit [˚C] 149

Boiler efficiency [%] 91

NOx [mg/m3n] 150

SO2 [mg/m3n] 200

CO [mg/m3n] 200

Dust [mg/m3n] 20

Large Scale and High Efficiency Advanced Bio CFB Concept for 20-30%-w Agro with Clean Biomass up to scale 400MWe

568/566ºC, 179-190/43.6 bar(a),

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• 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

Advanced Bio CFB Concept for 20%-w Agro Polaniec CFB, Poland

447 MWth, 190MWe, 535/535ºC, 127/20 bar(a)

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Fuel

80% Wood Chips

&

20% AGRO (Straw, Sunflower etc)

Moisture [%]ar 35.9

Ash [%]dry 2.8

Nitrogen [%]dry 0.25

Sulfur [%]dry 0.05

LHV [MJ/kg]ar 10.5

Emissions

NOx [mg/m3n] 150

SO2 [mg/m3n] 150

CO [mg/m3n] 50

Dust [mg/m3n] 20

Individual Biomass Fuels

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Unit Wood

chips

Straw Sun

flower

Dry Fruits Palm

Kernel

Form - Chips Pellet /

Briquettes

Pellet Pellet Crushed

LHV as received MJ/kg 10.1 14.8 18.6 16.8 17.9

Total moisture % 42.4 13.0 7.9 10.0 9.7

Content in dry fuel

Ash % 0.5 6.9 3.1 3.3 2.2

Sulphur (S) % 0.04 0.15 0.14 0.09 0.04

Chlorine (Cl) mg/kg < 200 <2000 < 700 < 300 < 300

Alkalis (Na+K) mg/kg <1 500 <27 000 <20 000 <5 000 <2 200

Phosphor (P) mg/kg < 400 <2 000 <3 000 <2 100 < 400

Fuel Feeding

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Day silos

Holding capacity total 1.5 h

Feeding chutes

4 pcs at FW

4 pcs at RW

2 drag chain conveyors

(RW/FW)

Four robbing screws per line

Eight feeding points

~60 MW per feeding point

Multifuel CFB for Waste and Clean Biomass (CHP) Igelsta (Söderenergi AB, Södertälje, Sweden)

240 MWth, 73 MWe-net, 209 MWDH, 92 kg/s, 90 bar, 540°C

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Emissions 6%O2, dry

NOx [mg/MJ] 35*

SO2 [mg/m3n] 75

CO [mg/m3n] 50*

Dust [mg/m3n] 10

NH3 ppm 10

TOC [mg/m3n] 10

HCl / HF [mg/m3n] 10 / 1

Cd+Tl / Hg / HMs [mg/m3n] 0.05 / 0.05 / 0.5

PCDD+F [ng/m3n] 0.1

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

Fuel Mix 1 Mix 2 Mix 3

Biomass [%]LHV 75 30 100

Rec.wood [%]LHV 0 70 0

REF pellets [%]LHV 25 0 0

Moisture [%]ar 44.3 35.6 50.0

Ash [%]dry 6.5 4.7 4.0

Nitrogen [%]dry 0.6 0.8 0.5

Sulfur [%]dry 0.09 0.08 0.06

Chlorine [ppm]dry 1200 800 200

LHV [MJ/kg]ar 9.7 11.0 8.3

Total plant efficiency ~110%LHV 90%HHV

• Despite of focus in bioenergy, other renewables and

nuclear, coal will remain important global fuel

• Co-firing biomass in larger fossil steam plants

enables high efficiency bioenergy production

• Co-firing provides flexibility to robust use biomass

depending on its seasonal availability

• Boiler Scale up to 800MWe is technically feasible

with a 20% share of Clean biomass with Clean coal

• Boiler Scale up to 600MWe is technically feasible

with a 50% share of Clean biomass with Clean coal

Co-Combustion of 50% Biomass with Coal

600MWe Scale with Supercritical Steam Parameters

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• FW has Extensive knowledge of Biomass

firing (195 FB units sold) and has modern

CFB Design with High fuel flexibility

meeting the most stringent emission

requirements

• Some biomass is easy, other is more

challenging. Biggest challenges are related

for agglomeration, fouling, and corrosion.

• Correct Fuel Characterization is the Key

issue in boiler Design.

• CFB Boiler Technology available for broad

variety of biomass/waste fuels with high

efficiency

Foster Wheeler CFB Technology & Summary

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www.fwc.com