S f h A CFB T h l f U ili S lState-of-the-Art CFB Technology for Utility-Scale Biomass Power Plants
Vesna Barišić1*, Edgardo Coda Zabetta1, and Bogusław Krztoń2
1Foster Wheeler – R&D Department, Finland2F t Wh l E i P l k Gl b l S l & M k ti P l d2Foster Wheeler Energia Polska, Global Sales & Marketing, Poland
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Contents
• Foster Wheeler Global Power Group References
• Challenges in Biomass Combustion
• Advanced Biomass CFB (ABC) Technology
• Conclusions
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
World Leader in Fluidized Bed Combustion (CFB) Technology
• 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
Fl i B ™ i / fl ibl CFB i ll il bl b th f d 2010• Flexi-Burn™ - air/oxy flexible CFB commercially available by the of end 2010
370 CIRCULATING FLUIDIZED BED (CFB) BOILERS• 328 in operation• 42 under construction• Biggest unit in operation 460 MWe• Sizes up to 800 MWe available
143 BUBBLING FLUIDIZED BED (BFB) BOILERS• 143 in operation
11 ATMOSPHERIC FLUIDIZED BED GASIFIRES• 11 in operation
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Pioneering Supercritical Once-Through and Flexi- BurnTM
CFB Technology
The world’s largest and first Supercritical Once-
Th h CFB ith th it f 460 MW t PKE’
gy
Through CFB with the capacity of 460 MWe at PKE’s
Lagisza plant in Poland is in operation since 2009
Capacity 460 MWe (966 3 MWth)Capacity 460 MWe (966.3 MWth)
Steam flow 361 kg/s
Steam pressure 282 bar
Steam temperature 563 °C
Fuel Bituminous Coal,Coal Slurry
• CFB technology is commercially available in 600 – 800 MWe scale
• Flexi-Burn™ CFB development and validation up to 300 MWe
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Growth in Biomass Utilization in Energy Production
• Incentives against CO2 emissions promote renewable fuels => biomassg 2 p
• Public institutions subsidize and support biomass projects
• Regulatory organisms do not release permits to fire fossil fuels
investors look into biomass
• Traditional biomass (wood-based) is costly and unavailable
• Agriculture residues are locally/globally available, and more economic
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
CFB Technology Ideally Suited for Large-Scale Biomass Power Plants
• Supreme fuel flexibility and multi-fuel firing
L i i• Low emissions
• High availability and efficiency
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Challenges in Biomass and Waste Combustion- Complex Ash Chemistry-Complex Ash Chemistry
Ash 279 g/kg150
Si Al Fe Ca Mg K Na P Ash concentration
Ash 279 g/kg
125
150
kg fu
el, d
ry]
8
10
12
14
75
100
centration
[g/k
0
2
4
6
8
25
50Conc
0
Stem Wood
Forest Residue
Recycled Wood
0
Coal Peat Stem Wood
Forest Residue
Sunflower Husk
Wheat Straw
Olive Waste
Rapeseed Waste
Recycled Wood
RDF
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Fossil Fuel Biomass Fuel Waste Fuel
Challenges in Biomass and Waste Combustion- Complex Ash Chemistry-Complex Ash Chemistry
30
y] Na, week acid soluble K, week acid soluble Sulfur Chlorine Phosphorous
20
25
[g/kg fuel, d
ry
Na, week acid soluble K, week acid soluble Sulfur Chlorine Phosphorous
10
15
oncentration
[
5
10Co
0Coal Peat Stem
WoodForest Residue
Sunflower Husk
Wheat Straw
Olive Waste
Rapeseed Waste
Recycled Wood
RDF
il l i l l
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Fossil Fuel Biomass Fuel Waste Fuel
Challenges in Biomass and Waste Combustion– Fuel Model –Fuel Model
9
10
7
8
9
dex
Agglomeration Fouling Corrosion
VERY
HIGH
4
5
6
obability In
MHIGH
1
2
3Pro
LOW
MED
IUM
0Coal Peat Stem
WoodForest Residue
Sunflower Husk
Wheat Straw
Olive Waste
Rapeseed Waste
Recycled Wood
RDF
Fossil Fuel Biomass Fuel Waste Fuel
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Fossil Fuel Biomass Fuel Waste Fuel
Selected Design Options for Biomass and Waste
Intelligent cleaning- steam blowersempty pass- acustic blowers- water guns- spring hummers
easy HXs
StepGridIntrex
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
(possibly chemical countermeasures)
Chemical Countermeasures– Alternative Bed Materials and Additives –Alternative Bed Materials and Additives
fouling/corrosivenon‐fouling (FA) fouling/non‐corrosive
Su
limestone
ulfuragglomerating
kaolinite
( )
agglomerating
coating melt
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
non‐agglomerating (BA)
Advanced Biomass CFB Technology
Control of Fouling & Corrosion
Correct f lue gas temperature
Integrated Steam Cooled Solid Separator and Return Leg
During Operation
Fuel quality management
Correct design for convective heat transfer surfaces
Features to Control
FW SmartBoiler datalog & Diagnostic tools
Agglomeration & Fouling
Optional additives with worst quality agros
Active Bed Material
Conservative f lue gas velocity
Ef fective temperature control
Step Grid Final SH & RH as INTREX• ABC projects in progress:– Konin (Poland), 154 MWth, 215 ton/h, 97 bar(a), 540 °C
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Konin (Poland), 154 MWth, 215 ton/h, 97 bar(a), 540 C– Połaniec (Poland), 447 MWth, 158/135 kg/s, 128/20 bar(a), 535/535 °C
Połaniec (GDZ Suez Energia Polska S.A., Połaniec, Poland)(190/447 Mwe/th, 158/135 kg/s, 128/20 bar(a), 535/535 °C)( g ( ) )
• Project schedule
– Contract awarded in April 2010
– Delivery 2012
• Fuel• Fuel
– 80%wt virgin wood
– 20%wt agro-biomass: wt g
straw,
sunflower husk,
dried fruits (marc),
palm kernel
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Conclusions
• Foster Wheelers Advanced Bio CFB (ABC) Technology provides state-of-the-art solutions for effective CO2 reduction in large-scale power generation with a broad ranges of biomass and waste fuels.
• ABC boilers have been recently booked by Foster Wheeler to co-fire biomass y ywith up to 20 wt% agro-biomass including willow, oat husk, palm kernel, straw, dried fruits, sunflower, and rapeseed residues. The largest of these units (447 MWth) is designed to produce 158 kg/s of superheated steam at 128 bar(a) and 535°C535°C.
• FW’s ABC technology is available for up to 300 MWe for a broad range of biomass, and up to 600 MWe co-firing 50% biomass with coal. Superheated steam can approach 180 bar(a) at 570°C for clean biomass, and 290 bar(a) at 585°C for 50% coal.
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Thank You for Your Attention !
www.fwc.comwww.fwc.com
Better Technologygy
For a Cleaner Environment
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Supporting materialpp g
www.fwc.comwww.fwc.com
Better Technologygy
For a Cleaner Environment
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Foster Wheeler Global Power Group References
Circulating Fluidized Bed (CFB) Boilers Waste Heat Boilers
H t R St G tBubbling Fluidized Bed (BFB) Boilers PC Boilers
G ifi
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Heat Recovery Steam Generators Gasifires
Foster Wheeler’s CFB Fuel Flexibility
CoalA th it
Wood ResidueB k
Recycled Wood• Anthracite• Bituminous• Subbituminous• Lignite
• Bark• Chips• Sawdust• Forest Residue
Tire Derived Fuel
Solid Recovered Fuel
Waste Coal• Bituminous Gob• Anthracite Culm
Agricultural Waste• Straw• Olive Waste
ue
Waste Paper
• Coal Slurry
Petroleum Coke• Delayed
• Sunflower Husk• Rapeseed• Dried Fruits• ...
GasNatural“Off” gases
• Delayed• Fluid
Peat
Sludge• Paper mill• De-inking• Municipal
Oil
Oil Shale
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Challenges in Biomass and Waste Combustion- Complex Ash Chemistry-Complex Ash Chemistry
Ash 279 g/kg150
Si Al Fe Ca Mg K Na P Ash concentration
Ash 279 g/kg
125
150
kg fu
el, d
ry]
Straw/Stalk of Herbs
Waste Fuels• Higher ash content
More Na Zn Pb Cu
Seeds of Oil/Cerial Crops• Ash 3 – 8 %wt, dry• Rich in P, K, Mg
75
100
centration
[g/k
Woody Biomass
Straw/Stalk of Herbs• Ash 3 – 17 %wt, dry• Rich in Si, K, Cl
• More Na, Zn, Pb, Cu, ...
25
50Conc
Woody Biomass• Ash 0.1 – 6 %wt, dry• Rich in Ca and K
0
Coal Peat Stem Wood
Forest Residue
Sunflower Husk
Wheat Straw
Olive Waste
Rapeseed Waste
Recycled Wood
RDF
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Fossil Fuel Biomass Fuel Waste Fuel
Challenges in Biomass and Waste Combustion– Fouling of Convective Heat Exchangers –Fouling of Convective Heat Exchangers
Element/compund Effect on foulingAlkali metals (Na K)Alkali metals (Na, K)
↑↑Especially alkali soluble @ pH3
Earth alkali metals (Ca, Mg)Trace elements Especially Zn, Pb, Cu, metallic Al
↓↓Aluminosilicates (e.g. kaolinite) ↓↓ Especially kaolinite
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
Challenges in Biomass and Waste Combustion– Chlorine Induced Corrosion –Chlorine Induced Corrosion
Element/compund Effect on corrosion
Chl i (Cl) ↑↑ Forms sticky and corrosive compundsChlorine (Cl) ↑↑ Forms sticky and corrosive compunds especially with alkali
Fouling ↑↑ or ↓↓Sullfur (S) ↓↓ Binds alkali into less harmful sulfates
Aluminosilicates (e.g. kaolinite) ↓↓ Binds alkali into less harmful aluminosilicates
Power Plants 2010Vrnjačka Banja, Serbia, 26–29 October 2010
