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Foster Wheeler Atmospheric Gasification Technology:
Development and Latest ExperiencesBrief Summary
Matti HiltunenFoster Wheeler Energia Oy
Finland
TopicsRome, Palazzo dei Congressi, May 10, 2004
• Update of recent projects
– Lahti plant, Finland
– Corenso plant, Finland
– Ruien plant, Belgium
• Gasification of recycled fuels
– Clean gas production
– Lahti Slip Stream Tests
Lahti Gasification PlantRome, Palazzo dei Congressi, May 10, 2004
Rome, Palazzo dei Congressi, May 10, 2004
Lahti Fuels
Lahti Operating Experiences 1998-2003Rome, Palazzo dei Congressi, May 10, 2004
• Operation of the gasifier and the gas burners has been stable• Stability of the steam cycle and coal burners good• No deposit formation or high temperature corrosion observed on the heat transfer surfaces
• Operating data 1998 - 2002– Operating time 27 000 hours– Energy produced 1700 GWh– Fuels gasified 498 000 ton– Availability of the gasifier 97.5 %
Gasifier Effect to Main Boiler Emissions Rome, Palazzo dei Congressi, May 10, 2004
NOx Decrease by 10 mg/MJ (= 5 to 10 %)SOx Decrease by 20 - 25 mg/MJCO No changeHCl Increase by 5 mg/MJ , base level lowParticulates Decrease by 15 mg/m3nHeavy metals Increase in some elements, base level lowDioxins, etc. No change
Corenso Design Rome, Palazzo dei Congressi, May 10, 2004
Original designGasifier Boiler40 MW 40 MW product gas
68 MW HFO
Reject consumption 18 000 ton/aEnergy produced 165 GWh/aSubstituting 16 500 ton HFO/aAluminium recovered 2 100 ton/a
Increased effectThe effect of the gasifier was increased to 50MW.
Rome, Palazzo dei Congressi, May 10, 2004
Corenso FuelRome, Palazzo dei Congressi, May 10, 2004
Corenso Operating ExperienceRome, Palazzo dei Congressi, May 10, 2004
• Commercial operation since autumn 2001• Operating hours appr. 12 500 h • Feeding of light reject into dense fluidized bed• Aluminium handling: operating windows are ensured• FW spring hammers as a solution to keep the furnace clean• Cl emissions in control• Availability equal to normal power plant availabilities
Ruien DesignRome, Palazzo dei Congressi, May 10, 2004
• 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
Ruien GasifierRome, Palazzo dei Congressi, May 10, 2004
RUIEN
BRYSSEL
Ruien FuelsRome, Palazzo dei Congressi, May 10, 2004
• Bark• Demolition wood
• Crushed wood based boards, chip boards, etc.
• Moisture 25-30 %
Ruien Process PerformanceRome, Palazzo dei Congressi, May 10, 2004
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
Clean Gas ConceptRome, Palazzo dei Congressi, May 10, 2004
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 boiler
Fuel feed system
Lahti Slip Stream TestsRome, Palazzo dei Congressi, May 10, 2004
• To demonstrate the performance of the Clean Gas Concept, a long term product gas cooling and filtration tests including product gas combustion tests for different fuel mixtures was arranged
• Connected to the commercial 70 MWth CFB gasifier in Lahti firing a blend of wood and wastes
• In the slip stream plant 5% of the syngas produced in the CFB gasifier was cooled and filtered
• The long term testing was stopped in April 2004, after more than 3300 hours of operation.
Lahti Slip Stream TestsRome, Palazzo dei Congressi, May 10, 2004
Pulsing N2
Sorbent feeder
Syn
gas
duct
from
gas
ifier
Syngas cooler
Filter
Syngas combustor
LLV Slip stream unit
Combustion air
Ash discharge systems
Filter by-pass line
Lahti Slip Stream TestsRome, Palazzo dei Congressi, May 10, 2004
In the Lahti slip stream tests it was demonstrated that
• By cleaning the waste derived product gas before the boiler, the amount of harmful components in the gas (heavy metals, alkalies, chlorine, dust, etc.) can be reduced significantly.
• The cleaned product gas can be safely burned in a high efficiency boiler with high steam temperatures
• The combustion of the cleaned gas was also environmentally safe: e.g.the emissions of heavy metals and dioxines were clearly below the WID limits