Development of fuel flexible heat and power

production based on fluidized bed technology

Jouni Hämäläinen, Technology manager, VTT

E-mail: jouni.hamalainen@vtt.fi

Pre-Conference for Baltic Sea Region Conference 2010

Jyväskylä, Finland, 30th of November 2010

Jyväskylän Paviljonki

214/12/2010

VTT Technical Research Centre of Finland

VTT IS

the largest multitechnological applied research

organisation in Northern Europe

VTT HAS

polytechnic R&D covering different fields of

technology from electronics to building

technology

clients and partners: industrial and business

enterprises, organisations, universities and

research institutes

VTT CREATES

new technology and science-based innovations in

co-operation with domestic and foreign partners

Turnover 280 M€ (budget for 2010)

Personnel 2,900 (1.1.2010)

78% with higher academic

degree

6,500 customers

Established 1942

VTT has been granted

ISO9001:2000 certificate.

314/12/2010

VTT - Diverse and sustainable energy research

Provides almost 400 energy experts

Provides modern experimental facilities, pilot plants and calculation tools

Synergy with other VTT competencies

Networks - national & international

Key focus of technology developments: Cost-effective and zero-emission heat and power production

Bioenergy - especially combined heat and power (CHP) Wind power – especially for cold climate conditions Nuclear energy – safety, plant life management, nuclear

waste management and geological disposal, Generation IV nuclear technologies

Efficient and optimized use of biomass resources Focus on forest residues and waste

Clean fossil fuels Carbon Capture and Storage (CCS) in Fluidized Bed

Combustion (FBC) Synthetic fuels for transportation, energy savings through

use of electricity in hybrid cars

VTT pursues versatile energy research, from nuclear to renewables. Energy economy, energy

systems and reduction of emissions also form a crucial part of our energy research.

414/12/2010

World primary energy demand until 2030. Ref. Coal in the

IEA World Energy Outlook 2006 - The Importance of Clean

Coal Technologies in China, Brian Ricketts Coal Energy

Analyst, IEA.

~ 40% increase

between 2005 and 2030

Total primary energy supply (2006)

Totally 67%

Total electricity generation (2006)

Totally 81%

World energy today and

forecast

514/12/2010

CO2 reduction in energy production

The approaches to CO2 emission

reduction in the energy production are

as follows:

Use of CO2 neutral energy sources:

biomass, nuclear power, wind, solar etc.

Use of fuels with lower CO2 impact:

shift from coal to natural gas

Biomass for power or Co-firing of

fossil fuels with CO2-neutral fuels

provides a technically and economically

feasible solution for CO2 reduction up to

certain degree.

Increase of efficiency provides emission cuts proportional to the rise in efficiency

CCS, Carbon Capture and Storage technologies, potential for near zero emission

power production from fossil fuels.

614/12/2010

Content of the presentation

G

ALKALISILICATES,SULPHATES

ALKALICHLORIDES

O

SULPHUR DIOXIDE, Al-SILICATES

C

FOREST RESIDUE PEAT

Co-combustion

Heat transfersurface

Lack of protecting

compounds

Low ash content

ALKALICHLORIDES

BARK/FOREST RESIDUE

By M. Aho, VTT

1. Shortlly about fluidized bed combustion (FBC) technology and VTT’s activities in

FBC related research and development especially in biomass fuel combustion

2. Some recent results achieved and new innovation based on our expertise

3. New applications and tools for improving power plant performance in biomass

combustion

4. Conclusions

Research activities and developing

technologies for biomass combustion

is more or less understanding high

temperature chemistry of ash behaviour

The understanding of that will lead to

solutions for plant designs and power

plant operators. Target of this presentation

is to give a view that interaction of fuel

mixture (or use additives) really has an

effect of combustion and ash behaviour

process

714/12/2010

Source: Metso Power

Fluidised Bed Combustion (FBC) technology has advantage to burn simultaneously various kind of fuels from coal to biomass and mixtures of different fuels

Variations in fuel particle size or in moisture content does not have a large effect on combustion process because of stability of fluid bed behaviour (huge amount of bed material in process = stabilize combustion)

However, the fuels spectrum has come and will come more wider in the future. Challenge is to optimise fuel mixture to prevent unwanted fuel ash behaviour (deposition and corrosion) during combustion or to find another ways to control combustion chemistry.

The fuel flexibility of the technology will give great advantage in the markets

Fluidized bed combustion technology

Targets of development in FBC technology

scaling up and increasing efficiency

improving environmental performance

widening (still) the fuel flexibility, agrobiomass, short

rotation energy crops

814/12/2010

1. Fluidized bed combustion characterisation test services

High-class, unique experimental pilot and bench scale FB testing environment

Well-established procedures for testing, analysing and reporting

2. Challenging fuels and ash chemistry in multifuel operation

Advanced sampling techniques, control, manipulation and modelling tools for ash chemistry

Effects of fuel quality and combustion conditions on ash related problems

Novel tools for fouling and high temperature corrosion monitoring, boiler economy evaluation and process simulations

Boiler availability and diagnostics at different operation conditions

3. In-furnace phenomena in air and oxyfuel fluidized bed combustion

World-class oxyfuel FB combustion research facilities

Combining of experimental results and process knowledge into rigorous combustion modelling tools

Fluidized bed combustion reseach at VTT

On this R&D&I field we have

turnover about 5 milj.€ at VTT

in Jyväskylä

- Direct industrial funding 30%

- Funding from public sources 45%

- VTT’s own funding 25%

914/12/2010

Fuel capacity ~50 kW

Riser height 8 m, diameter 17 cm

Option for fuel feed with two separate feeding lines

Option for fuel additive feed with a separate feeding line

Option for gas and solid matter sampling as a function of riser height

Fly ash sampling after both cyclones

Deposit probe measurements

Particle size analyses

Combustion conditions fully controlled

Several lab or pilot scale combustion

units: example CFB reactor

R&D topics in combustion

Understanding in furnace phenomena under FB combustion

Combustion profiles

Gas, solids, temperature

Heat transfer inside combustor

Emission formation

Ash behaviour characteristics

Aerosol sampling inside furnace

Formation and analysis of deposition

Combustion control studies

1014/12/2010

Major challenges in biomass combustionThere already exists lot of experience and knowledge about forest fuel

combustion (Scandinavian fuels). The trend today is, however, towards

agrobiomass fuels, fast growing, short rotation biomass fuels like

Miscanthus sinensis

Eucalyptus, bagasse

Rice husk, willow and other energy wood feedstocks

Industrial by-products, etc…

In general the major challenges with biomass

fuels are in fuel feeding and burning properties

Stability of fuel mass flow

Ash behaviour due to high alkalines,

chlorine etc.

However, the “new” biomass fuel fractions

has specific characteristics due to higher

alkaline, chlorine, potassium and some

heavy metal content → boiler design for

those fuel will be the future challenge –

but very feasible

In cooperation with industry VTT is developing and demonstrating new designs for boilers andnew concepts for energy markets

1114/12/2010

To stack

Sampling port

Sampling port

Sampling port

Gas cooling

Bagfilter

Gas probe

Observationport

Cyclone

Gas sample

Temperature control

Tertiary air optional

Tertiary air optional

Tertiary air (preheated)

Fuel container 2Fuel container 1

Secondary air(preheated)

Nitrogen

Air

Additivecontainer

Primary gas heating

Heating zone 2/Cooling zone 2

Heating zone 3

Heating zone 4

Heating zone 1/Cooling zone 1

BEDmade of quarz

PC control and data logging system

Obervation port

Obervation port

Obervation port

Obervation port/Deposit probe

Deposit probe

VTT’s expertise on this field Offering pilot scale R&D devices to study combustion phenomena

- Stable combustion conditions achievable

- In furnace sampling of gas, solid, aerosols. Measurement of temperature

and pressure profiles – able to go inside the process

- High-level sampling technologies for fine particulates at high temperature

- Development of modelling tools for ash behaviour chemistry

CorroStop®: Method for preventing chlorine deposition

on the heat-transferring surfaces of a boiler. Aho, Martti Pat.

WO2006134227

CorroStop – water soluble liquids

- Aluminium sulphate Al2(SO4)3 and ferric sulphate

Fe2(SO4)3 as 25 % water solutions

0

100

200

300

400

500

600

0.01 0.1 1 10

Particle Diameter Dp [µm]

dm

/dlo

g(D

p)

[mg

/Nm

³]

0

100

200

300

400

500

600

700

0.01 0.1 1 10

Particle Diameter Dp [µm]

dm

/dlo

g(D

p)

[mg

/Nm

³]

AEROSOLS FROM ALKALINE CHLORIDES CAN

BE BIND IN NON-HARMFUL PHASE USING ADDITIVES

Before After

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Based on understanding of ash chemistry VTT has got a trademark for CINDY CFBC®-Chemically active (coal) minerals are able to effect on biomass or waste derived aerosols

Biomass or waste Coal CINDY CFBC®

Chemically reactive mostly inert alkalines cocombustion process

alkalines etc. → no corrosive FUEL INTERACTION!

0

100

200

300

400

500

600

0.01 0.1 1 10

Particle Diameter Dp [µm]

dm

/dlo

g(D

p)

[mg

/Nm

³]

0

1000

2000

3000

4000

5000

6000

0.01 0.1 1 10

Particle Diameter Dp [µm]d

m/d

log

(Dp

) [m

g/N

m³]

0

500

1000

1500

2000

2500

0.01 0.1 1 10

Particle Diameter Dp [µm]

dm

/dlo

g(D

p)

[mg

/Nm

³]

Corrosive

alkaline salts

@ 780°C

Sorption + chemical reaction:

Al2Si2O5(OH)4 …

2KCl + Al2Si2O7 + H2O K2O·Al2Si2O7 + 2HCl

1314/12/2010

15 %

20 %

25 %

30 %

35 %

40 %

45 %

50 %

350 400 450 500 550 600 650 700

Steam temperature, °C

Ele

ctr

ic e

ffic

ien

cy,

%

Grate fired CHP waste incinerator

420°C, 60bar

Fluidised bed CHP plant for waste

470°C, 65bar

Ultra super critical pulverised coal fired condensing

power plant, 700°C, 330bar

Super critical coal fired condencing power plant, fluidised bed

580°C, 275bar

Grate firing for MSW

Fluidised bed for SRF

Biomass

combustion

Coal fired condencing mode

power plants

Grate fired CHP plant for biomass

500°C, 70bar

ADCOF TARGET AREA:

Fluidised bed CHP plant for biomass,

520°C, 120bar

15 %

20 %

25 %

30 %

35 %

40 %

45 %

50 %

350 400 450 500 550 600 650 700

Steam temperature, °C

Ele

ctr

ic e

ffic

ien

cy,

%

Grate fired CHP waste incinerator

420°C, 60bar

Fluidised bed CHP plant for waste

470°C, 65bar

Ultra super critical pulverised coal fired condensing

power plant, 700°C, 330bar

Super critical coal fired condencing power plant, fluidised bed

580°C, 275bar

Grate firing for MSW

Fluidised bed for SRF

Biomass

combustion

Coal fired condencing mode

power plants

Grate fired CHP plant for biomass

500°C, 70bar

ADCOF TARGET AREA:

Fluidised bed CHP plant for biomass,

520°C, 120bar

®DOUBLING THE ELECTRIC EFFICIENCY IN WASTE-TO-

ENERGY by utilising the capability of coal ash to adsorb:

and chemically react with the waste-originated salts ending to a complete absence

of halogen salts in the combustion gases wherefrom the energy can be recovered with

electric efficiency of 40%.

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Development of monitoring tools for power plant operators to

improve plant performance

Development of on line-monitoring, diagnostic and calculation methods to optimize multifuel operation at power plants

On-line monitoring of ash deposition

Long-term measurements of corrosion characteristics

Methods for process analysis to improve plant operation (availability and reliability)

Currently in semicommercial application, installed on several power plants by VTT

New innovations and patents on analysis of fluid bed behaviour and on-line measurement of heat transfer inside the furnace

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Information to customer:

• On-line deposition monitoring

• Monthly reporting system

• HelpDesk-service

Technical concept for power plant monitoring toolbox

On-line monitoring probe

Probe cooling unit

Measurement system Monitoring toolboxMultifuel boiler

• On-line deposition data

• Process data from customers

automation system

• Connection to combustion

process and plant automation

and control system

1614/12/2010

Conclusions

Ten years ago we did not have lot of experience about burning of forest

residues – the first experience revealed problems with fouling of heating

surfaces and risk of high temperature corrosion.

The next step was new designs for biomass boilers (external superheates

into loop seal ie. not to direct contact to flue gas path etc).

Nowadays the use of more challenging biomass sources is increasing –

eucalyptus, agrobiomass fuels, fast growing energy wood etc. These new

fuels have lot of new challenges due to ash related understanding.

Lot of new understanding is however available and hopefully after 10

years we are able to say that agrobiomass fuels and fas growing energ

wood was a challenge in 2010 but now we have …..

1714/12/2010

Thank You for your attentionFurther questions or contact

Jouni Hämäläinen tel. +358 40 5211066 or

jouni.hamalainen@vtt.fi

VTT creates business from technology