LOWERINGCOSTS BY IMPROVINGEFFICIENCIES IN BIOMASSFUELED BOILERS:NEW MATERIALS

AND COATINGS TO REDUCE

CORROSION

This project has received funding from the Europe-an Union’s Horizon 2020 research and innovation programme under grant agreement No 815147.

This project has received funding from the Europe-an Union’s Horizon 2020 research and innovation programme under grant agreement No 815147.

PROJECT FACTSDuration: 48 months

Start date: 01-03-2019End date: 28-02-2023

Composition: 15 partners from 7 countries6 key scientific centres9 key industries

Overall budget: 4.9 M€EU contribution: 4.9 M€Program: H2020-EU.3.3.2. - Low-cost, low-carbon energy supplyTopic: LC-SC3-RES-11-2018 - Developing solutions to reduce the cost and increase performance of renewable technologiesFunding scheme: RIA - Research and Innovation actionCall for proposal: H2020-LC-SC3-2018-RES-two-stages

CONTACTBelenus Project coordinatorDr. Francisco Javier Pérez Trujillo+34 913 944 215fjperez@ucm.es

Belenus ProjectComplutense University of MadridFaculty of ChemistryChemical and Materials Engineering DepartmentAvda. Complutense s/n - Madrid 28040 (Spain)contact@belenus-project.euhttps://belenus-project.eu

Belenus Project Impacts Expected: Capex, Opex and Plant Lifetime Total Gains

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CAPEX

BELENUS CAPEXCurrent CAPEX

(Fuel conversion system: boiler

turbine, water-steam

cycle)PILLAR 2.NEW WELDING AND BENDING STRATEGIES

PILLAR 1.NEW SURFACE ENGINEERING

0,09%

0,94%

-1,03%OPEX

PILLAR 1.NEW SURFACE ENGINEERING

PILLAR 2.NEW WELDING AND BENDING STRATEGIES

PILLAR 3.ON-LINE CORROSION MONITORING SYSTEM

(Equipment replacement,

schedule mainte-nance,

O&M labour, fuel costs)

BELENUS OPEXCurrent OPEX

LIFETIME

Current CurrentBELENUS BELENUS

Annual Operational

HoursPlant

Lifetime

8,0008,400

20yrs

25yrs

+5% +5

PILLAR 1.NEW SURFACE ENGINEERING

Increased of reliability of critical

components in boiler and steam tubes leading to longer lifetimes

Plant life extension of 5 years

PILLAR 2.NEW WELDING AND BENDING STRATEGIES

PILLAR 3.ON-LINE CORROSION MONITORING SYSTEM

40%

4%

6%

30%

WHAT IS BELENUS?The BELENUS project will improve materials to combat corrosion and new assembly strategies in biomass plants which will reduce the cost of electricity production.

The project started in March 2019 and is being developed by a Euro-pean consortium composed of fiveteen partners from seven Eu ropean countries: Spain, Portugal, Germany, Sweden, Finland, United Kingdom and France.

This consortium consists of a multidisciplinary team with extensive ex-perience in strategic fields within bioenergy sector, which will innovate developments capable of pushing the technology forward into the market. The project is led by Universidad Complutense de Madrid and is receiving funding from the European Comission (EC) under Horizon “2020” framework programme.

WHICH ARE THE PROJECT’S TARGETS?The primary goal of BELENUS is to lower bioenergy CAPEX and OPEX by an average of 1.03% and 40% respectively. This will be addressed by preventing or mitigating corrosion as the main limiting factor, through a holistic approach to prevent corrosion in the boiler:

SOCIAL

ENVIRONMENTALTECHNOLOGICAL BREAKTHROUGHS

ECONOMICAL

1BIOMASS HIGHLY CORROSION RESISTANT COATINGS AND INNOVATIVE BASE MATERIALS

3ONLINE CORROSION MONITORING SYSTEM

2NEW WELDING AND BENDING STRATEGIES

JOB CREATION

SOCIAL ACCEPTANCE

RURAL AREASPOPULATION

CAPEX

OPEXEFFICIENTY+

FLEXIBILITY

LIFETIME

CIRCULARECONOMY

TOXICITYWASTE

VALORISATION

SHARE OFBIOENERGY

WHAT IS THE FOLLOWED METHODOLOGY?To assure effective management, the BELENUS project is divided into nine work packages.

WP1 - FORESIGHT & DEFINITION OF REQUIREMENTS

To coordinate key decision making, including specific biomass and coating selection as well as harmonization of test procedures by creating a unified test protocol.

WP2 - BIOMASS CORROSION RESISTANT COATINGS: DEPOSITION AND OPTIMISATION

To develop and optimize new biomass corrosion resistant coatings including modified slurry aluminide coatings, thick HVOF and/or HVAF thermal spray, and overlay laser and welding coatings.

WP3 - LAB SCALE TESTING, CHARACTERISATION AND MONITORING

a. To carry out lab testing under fireside atmospheres as well as steam side conditions at atmospheric and supercritical pressures,also including erosion resistanceand mechanical properties.

b. To develop a fireside corrosion monitoring system by implementing ceramic-based electrochemical sensors.

WP4 - PILOT SCALE TESTING AND CHARACTERISATION

a. To characterize the selected biomass types.b. To obtain gas and ash compositions while burning biomass.c. To test the coating/material systems in 2 biomass pilot plants (0.5 kWth and 10 kWth).

WP5 - NEW WELDING AND STRUCTURAL INTEGRITY STRATEGIES: ASSEMBLY OF BOILER STRUCTURES

To define and develop innovative welding, bending and joining strategies for coated boiler parts through the study of the influence of these processes in coated boiler structures enabling the generation of assembled structures for further execution of mechanical and corrosion testing.

WP6 - MODELLING AND VALIDATION OF MATERIAL LIFE PREDICTION & COST AND LIFE CYCLE ANALYSIS

a. To develop a methodology for lifetime prediction;b. To carry out cost and life cycle analysis of the best coating-materials systems;c. To calculate the OPEX and CAPEX reduction based on material cost savings and lifetime increase

WP7 - TESTING AND MONITORING AT OPERATION PLANT CONDITIONS UNDER SMALL AND MEDIUM- SCALE CHP PARAMETERS

To validate BELENUS coating/material and corrosion monitoring systems by testing in operating biomass plants.

WP8 - DISSEMINATION. EXPLOITATION. IP AND SOCIAL ASSESMENT

a. To disseminate and communicate the project's outputs to all target audiences to maximize visibility.b. To define an exploitation plan to ensure market penetration.c. To assess social acceptance.

WP9 - PROJECT MANAGEMENT

To coordinate and manage all project-related actions in order to guarantee its successful execution and the adequate advance of the project in terms of schedule, resources, scope and expected impacts.

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WHICH IMPACTS ARE EXPECTED? • To develop new material systems, based on coatings deposited

on established or under development ferritic/martensitic steels and austenitic steels, with superheater tubing wall thickness losses lower than 0.1 mm per year.

• To increase the durability of the tube joints in the boiler by 20% by carrying them out through new welding strategies adapted to the new materials and coatings.

• To achieve reliable monitoring of high temperature corrosion up to 8,400 hours by developing an innovative on-line sensor to anticipate plant component failures and, thus, increasing the maintenance intervals.

• To achieve a 1.03% reduction of CAPEX by obtaining individual gains with the novel solutions proposed in the project: 0.94% with the new surface engineering: biomass corrosion highly resistant coatings on creep resistance materials and 0.09% with the new strategies of welding and bending for coated tubes.

• To reduce the total OPEX of the plant a 40% by obtaining in-dividual gains with the novel solutions proposed in the project: 30% with the new surface engineering: biomass corrosion highly resistant coatings on creep resistance materials, 6% with the new strategies of welding and bending for coated tubes and 4% with new online corrosion monitoring system specifically designed for biomass CHP plants.

• To increase efficiency up to 40-42% in small and medium-scale CHP biomass plants by reaching super-critical conditions at 580-625°C due to the new BELENUS solution capacity in pre-venting or mitigating corrosion.

• To raise the plant lifetime by: a) increasing 5 % of the operational hours of boiler components and SH tubes, reaching more than 8,400 hours per year, saving up to 11 days of annual mainte-nance (meaning a potentially increase of income of approx. 1.1M€ in power generation); b) increasing 5 years (25%) the total plant lifetime through the new corrosion protection systems.

• To reduce fuel costs by 10-15% by employing waste biomass and also reducing consumption by increasing efficiency.

• To increase the flexibility of the plant by allowing the use of different types of biomass.

• To increase and improve “co-firing” of biomass and coal in exist-ing coal plants with some adjustments as a cost-effective option.

1. WHAT IS BIOMASS AND HOW IS IT TRANSFORMED INTO HEAT AND ELECTRICITY?

Heat from biomass combustion is used to produce superheated steam in the boiler, which turns a turbine and alternator, generating electricity.

2. CORROSION IS CONSIDERED THE MOST SERIUS PROBLEM IN BIOMASS PLANTS

Aggressive biomass and waste derived combustion products cause excessive fireside corrosion leading to uneconomically short boiler tubing operating lifetime.

3. WHAT IS BELENUS?

The BELENUS project will improve materials against corrosion and optimise assembly strategies in the biomass plants which can reduce the cost of electricity generation.

The four year BELENUS project commenced in March 2019 with a consortium comprising partners from seven EU countries: Spain, Portugal, Germany, Sweden, Finland, United Kingdom and France.

4. WHAT IS THE BELENUS´ OVERALL CONCEPT?

CHALLENGES BELENUS SOLUTIONS

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CORROSION RESISTANCE

COATING MATERIAL SYSTEMS RESISTANT TO A VARIETY OF HIGHLY CORROSIVE BIOMASS TYPES

ACCURATE AND LONG LASTING ONLINE CORROSION MONITORING SYSTEM

BASE- MATERIAL

SOLUTIONS

VALIDATION OF NEW FERRITIC

MARTENSITICALLOYS

NEW WELDING STRATEGIES C0M8INE0 WITH HOT&COLD BENDING FOR COATED STRUCTURES

VALIDATION OF SOLUTIONS TESTING IN LAB. PILOT SCALE & OPERATING PLANT CONDITIONS

EC

ON

OM

ICA

L C

HA

LLE

NG

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REDUCE CAPEX & OPEX

FUEL COST REDUCCTION

30% OUTAGE TIME SAVING DUE TO LOWER REPLACEMENT NEED

HIGHER PLANT EFFICIENCY BY INCREASING OPERATING TEMPERATURES (SUPERCRITICAL CONDITIONS)

≥8400 OPERATIONAL HOURS/YEAR PLANT LIFETIME INCREASED BY 5 YEARS

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TAL

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ALL

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TRANSITION TO A CIRCULAR

ECONOMY

SMALL & MEDIUM-SCALE BIOMASS PLANTS IN BIOMASS RICH RURAL ZONES

WASTE VALORISATION

AGRICULTURAL, FORESTRY AND INDUSTRIAL, WASTE WOOD TRANSFORMED TO ENERGY

LOWER GHG EMISSIONS

INCREASE THE SHARE OF RENEWABLE

ENERGYCO-FIRING SOLUTIONS

REDUCE MATERIAL WASTAGE DUE TO

CORROSION

SO

CIA

L C

HA

LLE

NG

ES RAISE RURAL

POPULATIONDECENTRALISED ENERGY PRODUCTION WITH SMALL AND

MEDIUM SCALE CHP

SOCIAL ACCEPTANCE

NON FOOD BIOMASS FEEDSTOCK

LOWER ELECTRICITY COST

ECOMOMIC GROWTH IN RURAL AREAS

JOB CREATION NEW JOBS WILL ARISE IN THE BIOMASS ENERGY SECTOR

TRL 1

Technology readiness level (TRL)

TRL 2

TRL 3

TRL 4

TRL 5

TRL 6

TRL 7

TRL 8

TRL 9

BELENUS FRAMEWORK

Technology concept formulated

Technologyvalidated in lab

Technology demonstratedin relevant environment

System completeand qualified

Basic principlesobserved

Experimental proofof concept

Technologyvalidated in relevant

environment

System prototype demonstration in

operational enviroment

Actual systemproven in operational

enviroment

5. WHICH IMPACTS ARE EXPECTED?

The primary goal of BELENUS is to lower bioenergy capital expenditure (CAPEX) and operational expenditure (OPEX) leading to Levelized Cost of Electricity (LCOE) reduction by means three technological breakthroughs:

SOCIAL

ENVIRONMENTALTECHNOLOGICAL BREAKTHROUGHS

ECONOMICAL

1BIOMASS HIGHLY CORROSION RESISTANT COATINGS AND INNOVATIVE BASE MATERIALS

3ONLINE CORROSION MONITORING SYSTEM

2NEW WELDING AND BENDING STRATEGIES

JOB CREATION

SOCIAL ACCEPTANCE

RURAL AREASPOPULATION

CAPEX

OPEXEFFICIENTY+

FLEXIBILITY

LIFETIME

CIRCULARECONOMY

TOXICITYWASTE

VALORISATION

SHARE OFBIOENERGY

CAPEX

BELENUS CAPEXCurrent CAPEX

(Fuel conversion system: boiler

turbine, water-steam

cycle)PILLAR 2.NEW WELDING AND BENDING STRATEGIES

PILLAR 1.NEW SURFACE ENGINEERING

0,09%

0,94%

-1,03%OPEX

PILLAR 1.NEW SURFACE ENGINEERING

PILLAR 2.NEW WELDING AND BENDING STRATEGIES

PILLAR 3.ON-LINE CORROSION MONITORING SYSTEM

(Equipment replacement,

schedule maintenance, O&M labour, fuel costs)

BELENUS OPEXCurrent OPEX

LIFETIME

Current CurrentBELENUS BELENUS

Annual Operational

HoursPlant

Lifetime

8,0008,400

20yrs

25yrs

+5% +5

PILLAR 1.NEW SURFACE ENGINEERING

Increased of reliability of critical

components in boiler and steam tubes leading to longer lifetimes

Plant life extension of 5 years

PILLAR 2.NEW WELDING AND BENDING STRATEGIES

PILLAR 3.ON-LINE CORROSION MONITORING SYSTEM

40%

4%

6%

30%

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 815147.

https://belenus-project.eu