ExCo55 Doc 05.03 Experiences from the Lahti and Rien Plants · –CO2 reduction 120.000 t/a,...

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Experiences from the Lahti and RuienPlants

25th of May 2005Timo Anttikoski

Foster Wheeler Energia Oy

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IEA Bioenergy ExCo 55Copenhagen 25 May 2005

• Circulating fluidized bed (CFB) boilers- Up to 600 MWe, all solid fuels

• Bubbling fluidized bed (BFB) boilers- Up to 100 MWe, biomass, & other

high volatile fuels

• Atmospheric CFB gasifiers

• Heat recovery steam generators (HRSGs)- For gas turbines up to 250 MWe

Foster Wheeler Global Power GroupProducts

• Pulverized coal-fired (PC) boilers- Up to 1,000 MWe

• Waste heat boilers (WHBs)- For metallurgical and

waste incinerating processes

• Package boilers

• Condensers and heat exchangers

- Repairs and spare parts- Boiler modifications- Process improvements- Emergency service- Coal mills, burners- Environmental retrofits (BFB, SCR, SNCR, etc.)- OM&S agreements

• Complete boiler islands/power plants- EPC deliveries

• Service

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EC

Ch

orz

ów

Elc

ho

The world leader in fluidized bed boiler technology

227 CFB BOILERS DELIVERED TO DATE

• 202 in operation• 25 under construction• Largest unit currently in operation: 300 MWe• Largest unit contracted: 460 MWe

Over 40 years experience in fluidized bed combustion

• First BFB boilers delivered in the 1970s, based on work started in the 1960s• World’s first CFB for power generation supplied in 1979; second-generation technology in 1992• World’s first once-through supercritical CFB project won in 2003• Benefits: simple construction, reliable, excellent efficiency and availability, multifuel capability• Meets tough emission regulations without additional flue gas cleaning systems

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Foster Wheeler Gasifier Concept

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Foster Wheeler Atmospheric CFB/BFB Gasification

• Developed in the end of 1970’s - in the beginning of 1980’s

• Driving force the dramatical increase in oil price

• First commercial applications produced gas for lime kilns (4 units)

• Foster Wheeler has supplied 7 commercial scale CFB/BFB gasifiersproducing low heat value gas for different applications

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Foster Wheeler Atmospheric Gasifier References

Hans Ahlstrom Laboratory, Finland 3 Misc. Test unit 1981

Oy W. Schauman Ab, Finland 35 Lime kiln fuel 1983

Norrsundet Bruks Ab, Sweden 25 Bark Lime kiln fuel 1984

ASSI Karlsborg, Sweden 27 Bark Lime kiln fuel 1984

Portucel, Rodao, Portugal 15 Bark Lime kiln fuel 1985

Kemira Oy, Vuorikemia, Finland 4 1986

Lahden Lämpövoima Oy, Finland 40-70 Biofuels 1997

Corenso United Ltd., Finland 40 2000Aluminious plastic waste Cyclone cleanedgas to boiler

Electrabel, Belgium 50 Biofuels 2002

Customer MW Fuel Application Year

Coal, peat

Bark, sawdust

Test unit, clean gas

Hot raw gas to boiler

Hot raw gas to boiler

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Foster Wheeler CFB Gasifier

850 °C

900 °C

BOTTOM ASH COOLING SCREW

HOT LOW CALORIFICGAS (750 - 650 °C)

UNIFLOW CYCLONE

BIOFUEL FEED

REACTOR

BOTTOM ASH

GASIFICATION AIR FAN

COOLING WATER

AIR PREHEATER

RE

TU

RN

LE

G

850 °C

900 °C



UNIFLOW CYCLONE

BIOFUEL FEED

REACTOR

BOTTOM ASH

GASIFICATION AIR FAN850 °C

900 °C



UNIFLOW CYCLONE

BIOFUEL FEED

REACTOR

BOTTOM ASH

GASIFICATION AIR FAN

COOLING WATER

AIR PREHEATER

RE

TU

RN

LE

G

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• Concepts– Gasification à combustion of raw product gas– NEW: gasification + gas cooling and filtration à combustion of clean

product gas

• Energy production– Co-combustion of raw gas / clean gas in existing PC boiler– NEW: stand alone plant with steam turbine island

• Size of gasifier– Raw gas 20 – 150 MWfuel– Clean gas 20 – 80 MWfuel

• References– Lahti Energia 40 – 70 MW (raw gas, co-firing)– Corenso Varkaus 50 MW (raw gas, stand alone)– Electrabel Ruien, Belgia 50 MW (raw gas, co-firing)

Status of FW Fluidized Bed Gasification

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Fuel: Status:

Wood, bark, chips, saw dust Commercial

REF, plastics, (RDF) Commercial

Coal, straw, peat, RDF Demonstrated

ASR (Automotive ShredderResidue), other special wastes Under development

Fuels Used in FW CFB Gasifiers

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ReferencesLahti & Ruien

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Power Station Kymijärvi, Lahti Finland

GASIFIER

MAIN BOILER

(OLD PC BOILER)

BIOFUEL PREPARATION PLANT

COAL BUNKERS & MILLS

COAL YARD

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Bottomash

Gasifier

Coal

540 °C/170 bar

Processing

Biomass

Fly ash

Pulverized coal flames

Gas flame

Natural Gas

50 MW

350 GWh/a -15 % fuel input

1850 GWh/a -80 %

360 MW

100 GWh/a -5 %

Power* 600 GWh/aDistrict Heat* 1000 GWh/a

Lahti Gasifier Process

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IEA Bioenergy ExCo 55Copenhagen 25 May 2005 Lahti Gasifier

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RUIEN PROCESS

Bottomash

Gasifier

Coal

540 °C/180 bar

Processing

Biomass

Fly ash

Pulverized coal flames

Gas flame

50 MW

100.000 ton/year

500.000 ton/year

540 MW

CO2 Reduction –120.000 ton

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IEA Bioenergy ExCo 55Copenhagen 25 May 2005Electrabel Ruien Gasifier

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Electrabel Ruien Gasifier

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Ruien Design

• Biomass gasifier producing “green electricity” in co-combustion with coal in an existing PC boiler

• Using of renewable fuels to cut CO2 emissions

• Design 50 MWth with 50 % fuel moisture (86 MWth with 20 % fuel moisture)

• Electric efficiency 34 % (Boiler 36 %, gasifier 98 %)

• Produced “green” electricity 17 MWe

• Annual production 120 GWh

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RUIEN GASIFIER REACTOR

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RUIEN CYCLONE

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RUIEN GASIFIER REACTOR

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RUIEN, AIRHEATER

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RUIEN, PRODUCT GAS BURNER

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Experiences from Lahti & Ruien

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Lahti fuels

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Lahti fuel conveyor

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Lahti Fuels

6348 49

3925

14

9

9 1515

3136

15

2329

34 31 38

5 147 11 11 11

0 %

20 %

40 %

60 %

80 %

100 %

225GWh

342GWh

295GWh

445GWh

407GWh

415GWh

1998 1999 2000 2001 2002 2003

YEAR

Rlw. Sleepers

Tires

Paper

Plastic

REF

Wood w. glue

Wood

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LAHTI OPERATIONAL EXPERIENCES 1998-2003

• Stable operation of the Gasifier and Gas Burners

• Coal combustion in the main boiler has not been disturbed by thegasifier

• No additional fouling or corrosion in the main boiler has been noticed compared to coal combustion

• Main boiler fly ash composition and utilization has not been changed

• Main boiler availability has not been worsened by the Gasifier

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Gasifier Effects To Main Boiler Emissions

NOx Decrease 10 mg/MJ (= 5 ... 10 %)

SOx Decrease 20 - 25 mg/MJ

CO No change

HCl Increase 5 mg/MJ , base level low

Particles Decrease 15 mg/m3n

Heavy metals Slight increase, base level low

Dioxines No change

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Ruien Fuels

• Bark

• Demolition wood

• Crushed wood based boards, chip boards, etc.

• Moisture 25-30 %

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Ruien Process Performance

The gasifier in operation since May 2003

Environmental benefits– NOx & SOx reduced– CO & dust emission about the same or slightly reduced– Trace metals & dioxins no change– CO2 reduction 120.000 t/a, substituting of coal 50.000 t/a

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RUIEN, GASIFIER CAPACITY

0

10

20

30

40

50

60

70

80

90

100

60 50 40 30 20

Moisture of the fuel %

Heats to the boiler

MW

Carbon dust

Gas sensible

Gas chemical

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Lahti & Ruien Summary

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Gasifier - PC Boiler Combustion Offers

• Lower environmental emissions– use of coal is reduced =>– lower CO2, SO2 and NOx emissions

• Better fuel flexibility• Possibility to use local fuel (biomass, REF, plastics, etc.) resources in high

efficiency steam cycle• Low investment and operation costs• Utilization of existing power plant capacity• Only small modifications to the main boiler• High plant availability: If problems in the gasification system, still possible to

get full output from the main boiler

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Future gasifier concepts

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Main boiler feed water

Main boiler furnace

Recycled fuels

CFB Gasifier

Pulsing gas

Cooling water

Flare

LP Steam

Filters

Fly ash

Bed materials

Gas cooler

Fuel feed system

Clean Gas Concept for REF/RDF

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Power Production Efficiency in Clean Gas Co-Combustion Concept

Vaasa, Vaskiluodon voima

Condensing power plant:

Waste to power 35...40 %

CHP plant:

Waste to power 30…35 %

Vantaa, Vantaan Energia

Gasifier

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Clean Gas Concept & CO-Combustion in PC BoilerOffers

• Possibility to utilize waste fuels in existing PC boilers

– To replace coal => CO2 Reduction

– To utilize high steam parametres => High electrical power production

– Utilization of the existing boiler & turbine => Significantly lower investment costs compared to stand alone waste incineration plant

– Effective emission control => Effective chlorine and heavy metal removal, effective combustion in the PC boiler furnace, no dioxineformation, utilization of the existing PC boiler flue gas treatment, coal ash and waste ash will be separated from each others

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Stand Alone Gasification Plant for RDF

RDF gasifier

Fuel gas boiler

Gas cooling and cleaning

Bag filter

Electricity, district heat

Steam turbine

RDF fuel

Flue gas

HP steam

Stack

Bottom ash

Auxiliary fuel (natural gas/oil)

Filter ash Fly ash

Additive feed

Additive feed

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REF feeding

Gas fired boiler GasifierGas coolerGas

filtration

Turbine

Stand Alone Gasification Plant for RDF

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Electricity Production 160 MWfuel

ηe = 36 %

40 MWe

57 MWe

53 MWe

ηe = 25 %

ηe = 33 %

Gasification

120 bar, 540 ºC

CFB combustion

65 bar, 465 ºC

Grate firing

40 bar, 400 ºC

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ExCo55 Doc 05.03 Experiences from the Lahti and Rien Plants · –CO2 reduction 120.000 t/a,...

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