357MMBtu/hr (105 MWth) RENEWABLE ENERGY FROM CATTLE MANURE Panda Ethanol required a source of economical, reliable and renewable steam for its new ethanol plant in Hereford, Texas. Using fossil fuels for the production of green Ethanol was not fitting in with the eco-friendly image of Ethanol production and therefore Panda Ethanol was looking to reduce the carbon footprint of the Ethanol production. Outotec Bubling fluizided bed boiler is designed to convert one billion pounds of cattle manure a year into usable energy for an ethanol plant. By using CHALLENGES • High fuel moisture content • High fuel alkaline content • Large amount of non-combustible “tramp” material in the fuel SOLUTION • Outotec Bubbling Fluidized Bed boiler island • Supplied to the client as a “metering bin-to-stack” solution BENEFITS • Stable operation with varying fuel quality • Reduced slagging potential due to low operating temperatures • Online bed recycling system removes tramp material and re-injects clean bed media automatically. a renewable fuel (cattle manure) to create a renewable fuel (ethanol), Panda is eliminating exposure to natural gas pricing volatility, conserving the energy equivalent of 1,000 barrels of oil a day and creating a significant market advantage in their ethanol production costs. In addition, by disposing of the manure in a clean environmentally friendly manner, Panda is addressing the environmental hazards related to field application of cattle manure in the Hereford, Texas region.
Transcript
357MMBtu/hr (105 MWth) RENEWABLEENERGY FROM CATTLE MANUREPanda Ethanol required a source of economical, reliable and renewable steam for its new ethanol plant in Hereford, Texas. Using fossil fuels for the production of green Ethanol was not fitting in with the eco-friendly image of Ethanol production and therefore Panda Ethanol was looking to reduce the carbon footprint of the Ethanol production. Outotec Bubling fluizided bed boiler is designed to convert one billion pounds of cattle manure a year into usable energy for an ethanol plant. By using
CHALLENGES• High fuel moisture content• High fuel alkaline content• Large amount of
non-combustible “tramp” material in the fuel
SOLUTION• Outotec Bubbling Fluidized
Bed boiler island• Supplied to the client as
a “metering bin-to-stack” solution
BENEFITS• Stable operation with varying
fuel quality• Reduced slagging potential
due to low operating temperatures
• Online bed recycling system removes tramp material and re-injects clean bed media automatically.
a renewable fuel (cattle manure) to create a renewable fuel (ethanol), Panda is eliminating exposure to natural gas pricing volatility, conserving the energy equivalent of 1,000 barrels of oil a day and creating a significant market advantage in their ethanol production costs. In addition, by disposing of the manure in a clean environmentally friendly manner, Panda is addressing the environmental hazards related to field application of cattle manure in the Hereford, Texas region.
Outotec provides leading technologies and services for the sustainable use of Earth’s natural resources. As the global leader in minerals and metals processing technology, we have developed many breakthrough technologies over the decades for our customers in metals and mining industry. We also provide innovative solutions for industrial water treatment, the utilization of alternative energy sources and the chemical industry. Outotec shares are listed on NASDAQ Helsinki. www.outotec.com
The system is designed to operate on 100% cattle manure, or a mixture of manure and many other fuels. Outotec’s bubbling fluidized bed energy system is the first commercially successful system to operate on 100% cattle manure.
In this process, relatively wet cattle manure is introduced into a bubbling sand bed which is maintained at a precise temperature. This bed effectively drives off the moisture and converts the organic materials into a usable energy in the form of hot gas. The gas is run through a specially designed boiler that produces steam for use in the ethanol process. The result is a clean, odor-free conversion of cattle manure, or other biomass materials, into clean usable steam.
Initial heat for starting up the renewable energy system is provided by overbed and underbed burners fired by natural gas. Air from the 900 HP forced draft (FD) fan fluidizes the bed media such that it bubbles like a boiling pot of water. Fuel entering this hot, bubbling bed area, first releases its moisture, then oxidizes in the combustion chamber to release its thermal energy. Hot flue gas rises above the bed into the upper vapor space. NOx abatement occurs inside the main vessel’s upper vapor space via nozzles that spray ammonia into the flue gas, which then reacts with nitrous oxides to form nitrogen, carbon-dioxide and water. Any remaining, inert fuel contaminants, such as metal or rock are removed from the bed continuously during normal operation via Outotec’s proprietary bed material cleaning, handling, and storage system.
Energy is recovered from the sensible heat produced via a boiler design proprietary to Outotec. This boiler produces over 267,000 lbs/hr of saturated steam at 155
psi. Any remaining energy that cannot be utilized for steam production is recovered in the economizer, which pre-heats the incoming water to the boiler.
Lastly, a 350 HP induced draft fan pulls clean flue gas from the baghouse and disperses it via the stack. Emissions are monitored via a continuous emissions monitoring system (CEMS), which measures carbon monoxide, oxygen, nitrogen oxides, sulfur dioxides, and opacity.
Flue gas cleanup is first accomplished via hydrated lime injection into a dry scrubber. The partially-cleaned flue gas continues into a pulse-jet fabric filter baghouse, in which over 99% of the particulate matter is removed.
BFB PLANT FACTS:
Fuel Throughput 1500 tpd of cattle manure
Ash quantity Approximately 55%
Boiler Steam Generation capacity Pressure Temperature Economizer Inlet Temp
267,000 lbs/hr 155 psia 360°F 280°F
Flue Gas Cleaning Gas quantity Flue Gas Exit Temp
502,000 lbs/hr 293°F
Ash Silo Capacity Approx seven (7) days of operation
Emissions
NOx, SOx, PM, HCl, CO, Opacity complies with all standards for the state of Texas.
