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Power Stations
Boiler Plants
Hot Gas Generators
Firing Systems
Heat Recovery
Service
Customised Casting
Monday, March 26, 2018 1
RICHARD KABLITZ GMBH Intelligent technologies for energy recovery Speaker: Roman Koeppl, Export Manager
Richard Kablitz GmbH Biomass & Waste to Energy
BIOMASS and WASTE to ENERY
Overview of some critical technological issues
Agenda
Monday, March 26, 2018 2
I. Introduction
II. Critical technical issues to consider
III. Examples
Richard Kablitz GmbH Biomass & Waste to Energy
About Richard Kablitz GmbH
Monday, March 26, 2018 3
R. Kablitz was founded in 1901
For > 100 years Kablitz builds moving grates for multi-fuel combustion and cast plate heat exchangers, all produced in its own foundry
For > 25 years Kablitz builds complete plants worldwide as subsupplier or general contractor
Kablitz builds steam boiler plants, thermal oil heaters, hot gas generators and power and CHP plants or combinations thereof
Richard Kablitz GmbH Biomass & Waste to Energy
Monday, March 26, 2018 4
Biomass & Waste to Energy
Richard Kablitz GmbH Biomass & Waste to Energy
Why Waste to Energy?
DON‘T WASTE THE WASTE
Reduction of dependency on fossil fuels
In UK much waste still is dumped in landfills or exported to EU
Landfills are not eco-friendly and a waste of resources, waste
slowly degrades and pollutes the environment
Waste hierarchy in the policies:
1. Prevent waste
2. Re-use / re-cycle -> Sorting required
3. Waste to Energy
4. Landfill is only a last option
Fuels – Fresh and Waste Wood • 1. Fuels
Monday, March 26, 2018 5
Natural, untreated Wood, Bark, Landscaping
Wood, Wood Chips
Industrial Wood,
Waste Wood
(AI - AIV)
Wood Granulate, Saw Dust and
Fibres
Richard Kablitz GmbH Biomass & Waste to Energy
Fuels - Agricultural Waste
Monday, March 26, 2018 6
Rice Husks, Olive Stones or
Pomace, Peach Kernels,
Sunflower Seed Husks, Nut
Shells, Coffee Grounds, Sansa
Farm wastes
(Cow manure, chicken litter, ...)
Empty Fruit Bunches (EFB), Palm Shells and Kernels (PKS),
Bagasse, Straw
Richard Kablitz GmbH Biomass & Waste to Energy
Monday, March 26, 2018 7
Solid Sorted Waste,
RDF/SRF/Fluff
Paper Mill Wastes
(Pulp, Rejects, ...)
Coal
Fuels - Waste and Coal
Richard Kablitz GmbH Biomass & Waste to Energy
Monday, March 26, 2018 8
Biomass & Waste to Energy
Richard Kablitz GmbH Biomass & Waste to Energy
Steam Turbine (MAN) Hot Water & Steam Thermal Oil Heater & ORC (Turboden) Hot Gas (Dieffenbacher)
Typical Flow Sheet of a W2E Plant
Monday, March 26, 2018 9 Richard Kablitz GmbH
Biomass & Waste to Energy
Fuel bunker and
preparation
Furnace & Boiler Flue gas treatment
Turbine-Gen-Set Feed water system Heat plant
Agenda
Monday, March 26, 2018 10
I. Introduction
II. Critical technical issues to consider
III. Examples
Richard Kablitz GmbH Biomass & Waste to Energy
Monday, March 26, 2018 11
Know your Fuel
Richard Kablitz GmbH Biomass & Waste to Energy
Especially when dealing with the various waste fuels the plant suppliers need a
full fuel analysis:
Always remember: you do not know what kind of fuel you have in 10 or 15 years!
Characteristics Influences
Moisture Suitability for storage, plant design, self ignition danger
Calorific value Plant design, fuel usage
Ash content Dust emissions, firing technology
Ash melting temperature Availability, Safety, firing technology
Chlorine [Cl] HCl-, Dioxine, Furane, High temperature chlorine corrosion
Nitrogen [N] NOx-, N2O Emissions
Sulphur [S] SOx-Emissions, Acid dew point corrosion
Potassium [K] Corrosion (Superheater), decrease of the ash melting point
Sodium [Na] Corrosion (Superheater), decrease of the ash melting point
Heavy metals Emissions, Corrosion
Monday, March 26, 2018 12
Multifuel Combustion:
LA 2.2.03
It is possible to combine different combstion systems in a plant:
Grate: wood chips, RDF and other large fuel parts
Dust / granulate burner: fine particles < 3 mm
Auxiliary burners: light oil or natural gas
Richard Kablitz GmbH Biomass & Waste to Energy
Monday, March 26, 2018 Richard Kablitz GmbH
Biomass & Waste to Energy 13
Multi-stage Combustion for Multi-fuels
Combustion air
Recirculation Flue Gas
Kablitz multi-stage
combustion design allows
operators to adjust the plant
to a large variety of fuels
Monday, March 26, 2018 Richard Kablitz GmbH
Biomass & Waste to Energy 14
Combustion Diagram:
Make sure that even
with the worst fuel you
can get full power
-> valid for combustion of waste - Flue gas temperature in boiler
after last air injection must be > 850°C for more than 2 seconds
- When T < 850°C only oil/gas burners may operate (usually only during startup and shutdown)
Monday, March 26, 2018 Richard Kablitz GmbH
Biomass & Waste to Energy 15
~980°C Last air injection,
begin of retention
time measurement
>850°C
> 2
s
„2 Seconds Rule“
Monday, March 26, 2018 16
If there is alot of Nitrogen in the fuel, NOx will be emitted -> SNCR
If the flue gas temperature is too high, the NH3 radicals from the urea build NOx
If the flue gas temperature is too low, the NH3 radicals don‘t react and the NH3 gets emitted as „ammonia slip“
SNCR
Richard Kablitz GmbH Biomass & Waste to Energy
Mehldau & Steinfath
Monday, March 26, 2018
Acid dew point corrosion
Caused by much water and Sulfur in the fuel
Solution: High feed water temperature
High temperature chlorine corrosion
Convection heating surfaces
High level of Chlorine in fuel
Solution:
reduce flue gas temperatures before superheaters
Low steam parameters
Cladding
Corrosion:
17 Richard Kablitz GmbH
Biomass & Waste to Energy
Monday, March 26, 2018
Cl - Corrosion Diagram: High temperature Corrosion
Richard Kablitz GmbH Biomass & Waste to Energy
Always consider the
corrosion diagram
Keep superheaters
out of the corrosion
areas
18
Flue Gas Treatment Everything depends on the fuel
• Biomass, waste wood AI/II: -> Usually only dust removal required
-> Centrifugal separators, ESP, baghouse filter
• Waste wood AIII/IV, RDF: Flue gas treatment must be compliant to Waste Incineration Directive (WID) / 17. BImSchV Regulation (Germany), that means reactors, additive and activated carbon injection, bag-house filter, in future also catalysts
-> high invest costs, impact on total invest is less in larger plants
• Important: Often additionally local regulations apply!
Monday, March 26, 2018 Richard Kablitz GmbH
Biomass & Waste to Energy 19
Monday, March 26, 2018 Richard Kablitz GmbH
Biomass & Waste to Energy 20
Refractory material
Insist on a suitable refractory material. Here: Refractory consisting of
special SiC-plates for waste-to-energy plants.
(example: Wiesbaden)
Characteristics: Characteristics of membrane wall boilers:
- up to 150 t/h live steam power
- up to 110 bars
- up to 510°C
Characteristics of smoke tube boilers:
- up to ca. 25 MW boiler output
- up to 38 bars and 455°C
- compact design
- suitable for superheated steam, saturated steam and
hot water generation
Monday, March 26, 2018 Richard Kablitz GmbH
Biomass & Waste to Energy 21
Steam Boilers:
Horizontal boiler for Waste to Energy (tail end boiler)
Monday, March 26, 2018 Richard Kablitz GmbH
Biomass & Waste to Energy 22
Main Advantage of horizontal
boiler design:
Very maintenance friendly, easy
access to heating surfaces
Recomended boiler for Waste to Energy:
Thermal oil heaters in
membrane wall design,
suitable for low quality fuel
Thermal oil heaters with meander convection part
Thermal Oil Heaters:
Monday, March 26, 2018 Richard Kablitz GmbH
Biomass & Waste to Energy 23
Characteristics:
- up to 50 MW thermal power
- up to 20 bars
- up to approx. 400°C oil temperature
- Critical with waste fuel
-> risk of high-temperature corrosion!
Monday, March 26, 2018
Things you shouldn‘t miss:
24 Richard Kablitz GmbH
Biomass & Waste to Energy
- Boiler island should have 10-15% reserves in its design to be able to supply
full power in any case
- Choose a furnace that is flexible in regards of fuels, that can accept a
sufficiently large variation in water-content, LHV, grain size, metals and inert
material in the fuel
- In case of power plant: part load characteristics (down to which part load will
you get full live steam temperature?)
- Flue gas velocity in the boiler -> less velocity -> less erosion
Monday, March 26, 2018
Summary:
25 Richard Kablitz GmbH
Biomass & Waste to Energy
- Know your fuel, make analysis
- Multi-fuel furnace
- Always be aware of the corrosion problem
- Use recirculation gas to control the combustion
- Choose the right boiler design
Monday, March 26, 2018
Agenda:
26 Richard Kablitz GmbH
Biomass & Waste to Energy
I. Introduction
II. Critical technical issues to consider
III. Examples
Monday, March 26, 2018
Reference Project: Chilton, UK
Location: United Kingdom
Fuel: Wood Chips
Fuel Bandwidth: 4,4 – 4,8 kWh/kg
Installed Combustion Capacity:
Reciprocating Grate: 53,6 MW
Electric Power: 17,6 MW
Live Steam Mass Flow:
67,0 t/h
Live Steam Pressure: 86 bar(a)
Live Steam Temperature:
495°C
Feed Water Temperature:
190°C
Combustion Air Preheating:
150°C
Year of Commissioning:
2012
Examples:
27 Richard Kablitz GmbH
Biomass & Waste to Energy
Monday, March 26, 2018
Examples:
28 Richard Kablitz GmbH
Biomass & Waste to Energy
Waste-to-Energy steam boilers
Monday, March 26, 2018 Richard Kablitz GmbH
Biomass & Waste to Energy 29
Project: Wiesbaden
Location: Germany
Electrical output: 10,0 MW
Heat output: 24,0 MW
Steam mass flow: 49 t/h
Steam pressure: 42 bar(a)
Steam temperature: 425 °C
Installed combustion capacity:
Reciprocating grate: 38,4 MW
Fuel: Wood waste grade 1 to 4
Year of commissioning:
2013
Waste Steam Boiler Plants
Monday, March 26, 2018 30
Water Tube Boilers
Reference Project: Buchen
Location: Germany
Fuel: Waste Wood AI – AIV 17. BImSchV
Fuel Bandwidth: 1,8 – 4,5 kWh/kg
Installed Combustion Capacity:
Reciprocating Grate: 27 MW, Auxiliary Burner: 12 MW
Electric Power: 7,1 MW
Live Steam Mass Flow:
30 t/h
Live Steam Pressure:
66 bar(a)
Live Steam Temperature:
425°C
Feed Water Temperature:
105 °C
Year of Commissioning:
2003
Richard Kablitz GmbH Biomass & Waste to Energy
Power Stations
Boiler Plants
Hot Gas Generators
Firing Systems
Heat Recovery
Service
Customised Casting
Thank You RICHARD KABLITZ GMBH Intelligent technologies for energy recovery
Monday, March 26, 2018 31
Bahnhofstr. 72-78, 97922 Lauda-Königshofen
Germany
Tel: +49 (9343) 7901-0 | Fax: -996 [email protected] | www.kablitz.com
Richard Kablitz GmbH Biomass & Waste to Energy
Biomass steam boilers
Monday, March 26, 2018 Richard Kablitz GmbH
Biomass & Waste to Energy 32
Vertical water tube steam boiler
Project: Pemuco
Location: Chile
Electrical output: 12,1 MW
Heat output: 60 t/h at 1,2 bar(g)
Steam mass flow: 60 t/h
Steam pressure: 76 bar(a)
Steam temperature: 485 °C
Installed combustion capacity:
Reciprocating grate: 55,0 MW
Fuel: Forest residues, eucalyptus bark, coal
Year of commissioning:
2014
Biomass Thermal Oil Heater Plants
Monday, March 26, 2018 33
Reference Project: Menznau
Thermal Oil Heaters
Location: Switzerland
Fuel: Wood Chips, Production Wood,
Fuel Bandwidth: 2,7 – 4,0 kWh/kg
Installed Combustion Capacity:
Reciprocating Grate: 40 MW Granulate: 12 MW Dust: 25 MW Design: 57 MW
Thermal Oil Output: 25 MW
Thermal Oil Temperature:
285°C / 255°C
Hot Gas: 30 MW / 350°C
Year of Commissioning:
2009
Richard Kablitz GmbH Biomass & Waste to Energy
Hot Gas Generators
Monday, March 26, 2018 34
Reference Project: Sanem
Location: Luxembourg
Fuel: Bark, Production Wood (MDF), Saw Dust, Shavings
Fuel Bandwidth: 2,6 - 3,5 kWh/kg
Installed Combustion Capacity:
Reciprocating Grate: 15 MW, Granulate Burner: 3 x 5 = 15 MW
Hot Gas: 25 MW / 350°C
Year of Commissioning:
2010
Richard Kablitz GmbH Biomass & Waste to Energy
Biomass CHP and Energy Centers
Monday, March 26, 2018 35
Reference Project: Rosenheim
Steam Turbine Power Plants
Location: Germany
Fuel: Waste wood, Industrial wood
Installed Combustion Capacity:
Reciprocating grate: 20 MW Dust/Granulate burner: 3 x 5 = 15 MW
Electric Power: 6,0 MW
Live Steam Mass Stream: 30 t/h
Live Steam Pressure: 66 bar(a)
Feed Water Temperature: 107 °C
Year of Commissioning: 2001
Richard Kablitz GmbH Biomass & Waste to Energy
Biomass CHP and Energy Centers
Monday, March 26, 2018 36
Steam Turbine Power Plants Reference Project: Goch
Location: Germany
Fuel: Wood Chips, Landscaping Wood
Fuel Bandwidth: 1,5 - 3,2 kWh/kg
Installed Combustion Capacity:
Reciprocating Grate: 28 MW
Electric Power: 5,0 – 7,2 MW
Live Steam mass flow:
30 t/h
Live Steam Pressure:
65 bar(a)
Live Steam Temp.: 480°C
Year of Commissioning:
2012
Richard Kablitz GmbH Biomass & Waste to Energy
Biomass CHP and Energy Centers
Monday, March 26, 2018 37
ORC Power Plants Reference Project: Aschaffenburg
Location: Germany
Fuel: Wood Chips, Landscaping Wood
Fuel Bandwidth: 1,7 - 3,5 kWh/kg
Installed Combustion Capacity:
Reciprocating Grate: 11,7 MW
Electric Power: 1,1 MW
Heat Output: 8,0 MW
Thermal Oil Output:
9,4 MW
Year of Commissioning:
2009
Richard Kablitz GmbH Biomass & Waste to Energy
Monday, March 26, 2018
Location: France
Fuel: Wood Chips
Fuel Bandwidth: 1,9 - 3,1 kWh/kg
Installed Combustion Capacity:
Reciprocating Grate: 19,9 MW
Heat Output: 18 MW
Saturated Steam mass flow:
28 t/h
Saturated Steam Pressure:
18 bar(a)
Saturated Steam Temperature:
207°C
Feed Water Temperature:
105 °C
Year of Commissioning:
2012
Examples:
Reference Project: Rosières en Santerre
38 Richard Kablitz GmbH
Biomass & Waste to Energy
Biomass CHP and Energy Centers
Monday, March 26, 2018 39
Steam boiler: Domat/Ems Block 3, CH
Richard Kablitz GmbH Biomass & Waste to Energy
Biomass CHP and Energy Centers
Monday, March 26, 2018 40
Thermal oil boiler: Tomsk, RU
Richard Kablitz GmbH Biomass & Waste to Energy
Biomass CHP and Energy Centers
Monday, March 26, 2018 41
Thermal oil heater and
hot gas generator:
Genk, BE
Grate, Fuel Feeder, Kablitz Turbo System and steel works Richard Kablitz GmbH
Biomass & Waste to Energy
Monday, March 26, 2018
Examples:
Four grates are in position
42 Richard Kablitz GmbH
Biomass & Waste to Energy
Monday, March 26, 2018
Examples:
43 Richard Kablitz GmbH
Biomass & Waste to Energy
Monday, March 26, 2018
Examples:
44 Richard Kablitz GmbH
Biomass & Waste to Energy
Monday, March 26, 2018
Examples:
45 Richard Kablitz GmbH
Biomass & Waste to Energy
Assembly after 4 Months
Monday, March 26, 2018
Examples:
46 Richard Kablitz GmbH
Biomass & Waste to Energy