Institute of Thermal Technology Konarskiego 18, 44-100 Gliwice, POLAND

New Challenges in Eco-designing of Energy Consuming Installations

in Particular Small Combustion Installations

(1) Institute of Thermal Technology, Silesian University of Technology in Gliwice, Poland(2) Department of Chemical and Processing Apparatus Silesian University of Technology in Gliwice, Poland

krystyna.kubica@polsl.pl

Krystyna Kubica(1), Andrzej Szlęk(1), Robert Kubica (2)

International Forum of R&D for Eco-innovation

Katowice, 22-23 October 2009

Small Combustion Installation - definition

What is a “small scale combustion installation”?

A combustion unit of less than 50 MWth thermal

capacity, traditionally not regulated at the EU level

– Sectors: residential, commercial/ institutional, industrial– Technologies/Fuels: gas, oil, coal, wood..– Types of installation: of which there are a large number

Importance of Small Combustion Installations

Contribution to total emissions (RAINS model results)

Pollutant Year

1990 1995 2010

Oxides of nitrogen 4.5% 5% 7%

Sulfur dioxide 11% 8% 7%

Ammonia About 0.5% - 1%

NMVOC(1) 7% 7% 7%

PM2.5(2) 25% 25% 19%

PM10(2) 22% 20% 15%

Source: IIASA, 2004

(1)  Contributions vary widely from country to country, e.g. 1% - 3% in the Netherlands or Italy,

10%-15% in Austria and 25%-30% in Sweden,

(2)  Contributions vary widely from country to country, e.g. 2%-4% in the Netherlands and 40%-

50% in Austria and Sweden

Importance of Small Combustion Installations

● Emission of PAHs from residential use of solid fuels and biomass accounts for about half of the total emission of PAHs in EU [COM(2003) 423 final]; in Poland about 84% in 2006Dębski et al., 2009; http://emissions.ios.edu.pl/kcie/Download/Raport_EMEP_2006_PL.pdf

● Emission of PCDD/F from those activities accounts for one third of dioxin emissions in the EU (Quass U., et al., 2000); in Poland about 43% (of national total) Dębski et al.,2009; http://emissions.ios.edu.pl/kcie/Download/Raport_EMEP_2006_PL.pdf

0%

5%

10%

15%

20%

25%

30%

FR PL NO DE FI SE ES GB PT IT CZ AT GR LT LV HU NL IE DK EE BE SL SK CH LU

2000 2010 2020

Emission of PM10 (2000-2020) from non-industrial SCIs in different countries; Pye S. at al.; Costs and

environmental effectiveness …. AEAT/ED48256/Draft Final Report 2004

Importance of Small Combustion InstallationsMercury emissions

65%

11%

21%

3%

Industrial

Comm_Inst

Residential

AFF

63%8%

2%

27%

Solid

Liquid

Gaseous

Biomass

Pye S., Jones G., Stewart R., Woodfield M., Kubica K., Kubica R., Pacyna J. 2005; Pye S., Jones G., Stewart R., Woodfield M., Kubica K., Kubica R., Pacyna J. 2005; Costs and Costs and

environmental effectiveness of options for reducing mercury environmental effectiveness of options for reducing mercury ……, AEAT/ED48706/Final report, AEAT/ED48706/Final report v v22

Non-industrial SCI Non-industrial SCI sourcessources All SCI sourcesAll SCI sources

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

CommInst Residential AFF CommInst Residential AFF CommInst Residential AFF

2002 2010 2020

Hg

em

issio

n (

ton

ne

s)

Biomass

Gaseous

Liquid

Solid

Projections by sector and fuelProjections by sector and fuel

WWhy essential improving of SCIs quality?hy essential improving of SCIs quality?

To sum – upTo sum – up::

▪ solid fuels (coal fuels) – main energy source in many countries; low energetic

efficiency of appliances, lack or low efficiency of flue gas cleaning systems

▪ emission factors for small sources can exceed many times the factors of the

same pollutants for industry (PM, HMs, CO, SO, NO, VOCs and POPs,

particularly PAHs, PCDDs/Fs,)

▪ low flue gases exhaust, location in residential areas; the influence on the local

air quality and human health might be greater than their share in total

emissions

and

▪ implementation of EU Policies

EU Strategy - Environmental and Climate Action

CAFE - CAFE - Clean Air for EuropeClean Air for Europe, DG , DG Environment EC - Environment EC - Thematic Strategy on Air Pollution COM(2005) 446 final Brussels, 21.9.2005

Small combustion sources burning coal and wood: one of the sources for particulate matter (PM) pollution to be addressed with priority

The Strategy sets specific long-term target to decrease emissions (for 2020):▪ primary PM2.5 (particles emitted directly into the air) by 59% compared with the year 2000.

The establishment of standards for small heating installations is also envisaged through the new Directive Energy-using Products

The Climate action and renewable energy package - 28 January 2008 sets up three ambitious quantitative targets described as 3x20:

▪ reduce greenhouse gases at least 20% by 2020 (compared with 1990 levels),

▪ reduce energy consumption by 20% through increased energy efficiency,

▪ meet 20% of our energy needs from renewable sources.

EU Energy policy and SCIs – the products for domestic sector

Directive on Eco-design for Energy-using Products (EuP) (2005)

EuP Directive implementation

Directive 2005/32/EC of the European Parliament

Framework Directive for the setting of eco-design requirements for Energy

using Products; 6 July 2005 (Official Journal of the European Union)

Scope of the Directive:– In principle, all Energy using Products– Specific product categories for eco-design requirements

to be defined ( 20 studies launched – 20 Lots, managed by DG TREN EC)

– Measures of action: Setting of eco-design requirements (Implementing Measures)

EuP Preparatory Study – Lot 15 Solid Fuel SCIs ECODESIGN (EC DG XII)

Current state of SCIs – Energy using Products for domestic sector

SCIs – final design product, SCIs – final design product, a a standalone standalone appliance appliance ≤≤ 0,5 MWth output 0,5 MWth output

Small Combustion Installations – solid fuelsSmall Combustion Installations – solid fuels

Solid fuels are divided in two main categories (the EMEP/Corinair Emission

Inventory Guidebook):■ Solid mineral fuels: anthracite, hard coal, brown coal, patent fuels, brown coal

briquettes, coke, charcoal, peat;

■ Solid biomass fuels: wood (log, pellets, chips), wood wastes, agricultural wastes used

as fuels (straw, straw pellets corncobs, etc).

Solid fuel SCIs a design for a specific fuel type!

FuelsOTHERS

Volatile matter contents;

Biomass 80%

Coal 35%

The combustion process organisation

3 categories of the combustion process

organisation:

counter-current flow; over-fire, overfeed appliances, manually fuelled, the combustion air is leaded in the opposite direction to the fuel stream and the flame is guided in the opposite direction to the fuel stream also – old type of stove, fireplace, insert

cross-current flow; cross-current flow; under-fire, manually fuelled, with distribution of air i.e., primary and secondary air supply for the process (the combustion air is leaded in the opposite direction to the fuel stream, the flame and the flue gas removal is in the middle of the furnace chamber) – semi-automatic and automatic fuelled boilers ,

co-current flow; upper-fire, underfed stoker boiler, automatic fuelled, the combustion air and fuel are leaded in the same direction and the flame is guided in the same direction as the fuel – automatic fuelled coal and biomass boiler

From Kubica K., (2003/1); “Environment Pollutants.., in Thermochemical Transformation of Coal and Biomass; pp 145-232, ISBN 83-913434-1-3, Publication, Copyright by IChPW and IGSMiE PAN; Zabrze-Kraków; 2003, (in Polish)

NaturalAnthracite

Bituminous

coal

Natural

Wood logs

Manufactured

Biomass

Manufactured

Lignite briquettes

Coal briquettes

Peat briquettes

Output range (kW)

Solid Fuel SCIs

Stoves / Roomheaters

Fireplaces / Inserts

Boilers

Cookers

Direct

Cooking

IndirectHeating

< 50

< 50

< 50

< 50

50 <…< 500

Open

Closed

Manual fuel feed

Automatic fuel feed

Key s secondary parameters

Fossil

Bales/straw

PelletsBriquettes

Wood chips

Fuel type: Typical fuelPossible fuel

Functionality: PrimarySecondary

Manual fuel feed

Automatic fuel feed

Manual fuel feed

Automatic fuel feed

Manual fuel feed

Automatic fuel feed

Categorisation of small combustion installations; http://www.ecosolidfuel.org

Quality of SCIs - Test Standard Overview http://www.ecosolidfuel.org

Standard Applies to Functional parameters Emissions

Heat output

Efficiency CO Dust

TSP

OGC NOx

EN303-5 Boilers <300kW Y Y Y Y Y Y

EN12089 Residential Boilers <50kW

Y Y Y N.D. N.D. N.D.

EN13240 Roomheaters Y Y Y N.D. N.D. N.D.

EN13229 Inset appliances Y Y Y N.D. N.D. N.D.

EN14785 Residential space heaters

Y Y Y N.D. N.D. N.D.

EN12815 Residential Cookers Y Y Y N.D. N.D. N.D.

EN15250 Slow heat release appliances

Y Y Y N.D. N.D. N.D.

EN 15270 Pellet burners for small heating boilers

Y Y Y N.D. N.D. N.D.

Historical improvement of CO and dust emissions from biomass and coal SCIs; http://www.ecosolidfuel.org

0

100

200

300

400

500

600

700

1985 - 1996 1996-1999 2000-2005 2005-2008

Period [year]

Effic

ienc

y, T

SP, N

Ox

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

CO

Efficiency [%] TSP [mg/m3] NOX [mg/m3] CO [mg/m3]

Pollutants emission for coal and wood boilers

COVOC

PM (TSP)PAHs

PCDD/F

Boilers (mechanic fuelled)

Boilers (manual fuelled)

Stove0

1000

2000

3000

4000

5000

6000

7000

CO, V

OC, P

M [g/

GJ], P

AHs [

mg/G

J], PC

DD/F

[ng/G

J] .

Figure 2 Emission factor of pollutants for wood fuelled residental heating appliances

COVOC

PM (TSP)PAHs

PCDD/F

Boilers (mechanic fuelled)

Boilers (manual fuelled)

Stove0

1000

2000

3000

4000

5000

6000

CO, V

OC, P

M [g/

GJ], P

AHs [

mg/G

J], PC

DD/F

[ng/G

J] .

Figure 1: Emission factor of pollutants for coal fulled residental heating appliances

http://ies.jrc.ec.europa.eu/uploads/fileadmin/Documentation/Reports/Emissions_and_Health/EUR_2006-2007/EUR_23214_EN.pd

Direct heating appliances efficiency and emissions data measured under test standard conditions http://www.ecosolidfuel.org

Average Range Average Range Average Range Average Range

55 40.2 ÷ 63.6 2033 1750 ÷ 2333 - - - -

40 30 ÷ 53 2766 1631 ÷ 4163 - - - -

75.4 66.9 ÷ 80.3 1859.8 541.8 ÷ 5411.7 59.6 36.0 ÷ 74.0 - -

No secondary air (4 appliances) 72.8 71 ÷ 74.5 2400 1547 ÷ 3091 n.d. n.d. n.d. n.d.

With secondary air (17 appliances ) 74 67.5 ÷ 82.7 2445 789 ÷ 4293 107 103 ÷ 111 68 52 ÷ 85

Manual primary and secondary air (19 appliances) 73.2 67.5 ÷ 82.1 2580 1374 ÷ 4293 103 103 ÷ 103 85 85 ÷ 85

Automatic primary and secondary air (1 appliance) 75.1 75.1 ÷ 75.1 1889 1889 ÷ 1889 n.d. n.d. 83 83 ÷ 83

75.7 72 ÷ 78.7 1705 656.5 ÷ 2846.5 - - - -

No secondary air n.d. n.d. n.d. n.d. n.d. n.d. n.d. n.d.

With secondary air 68.4 38 ÷ 80 1515 773 ÷ 3091 77 18 ÷ 138 44 30 ÷ 75

Manual primary air (traditional + continuous burning, 9 appliances)

66 38 ÷ 80 1685 851 ÷ 3091 74 18 ÷ 138 47 30 ÷ 75

Automatic primary air (advanced + modern, 3 appliances)

77 75 ÷ 80 801 773 ÷ 1031 100 80 ÷ 138 41 39 ÷ 83

Slow heat release stove - >75 - - <1031 - <137 - <83

Kachelofen, insert for kachelofen

- >80 - - <1031 - <137 - <83

Manual primary air (traditional) 84 78 ÷ 90 1306 1238 ÷ 1375 138 138 ÷ 138 69 69 ÷ 69

Automatic primary air (advanced) n.d. n.d. n.d. n.d. n.d. n.d. n.d. n.d.EN 12815

Questionnaire responses

(41 appliances)

Questionnaire responses

(26 appliances)

Questionnaire responses (2)

Public data*

Public data (17 appliances)*

Public data*

EN 13229

EN 13240

Questionnaire responses

Public data (5 appliances)*

Public data (23 appliances)*

CO [g/GJ]

NOx [g/GJ]

VOC/OGC [g/GJ]Appliance

Test standard

Efficiency [%]

Open fireplace and open firplace insert

Closed fireplace and closed fireplace insert

Traditional Stove

Cookers

* Public data from web sites, accredited laboratory measurements, or manufacturers

SECONDARY MEASURES

New Challenges in Eco-designing of SCIs

PRIMARY MEASURES

THE ENERGY AND

ENVIRONMENTAL

PERFORMANCE OF SCIS

(PM, CO, NOx)

ECONOMIC EFFICIENCY

Decrease the energy consumption of SCIs

There are two general ways to decrease the energy consumption of SCIs:

▪ improve the efficiency of the appliance, such as by optimising the performance

of the combustion chamber and the heat exchange circuit,

▪ programmable control system, that maximises the efficiency of the heat

produced not only based on the combustion process parameters but also

according to the external environment, by reducing overheating phases, for

instance.

Improvement fuel quality - Solid fuel SCIs a design for a specific fuel type!

Improvement the environmental performance

There are two general ways to decrease the energy consumption of SCIs:

▪ primary measures - improvement the appliance efficiency, optimising the

combustion process (combustion parameters, combustion process organization),

improvement fuel quality (additives - denitrification, desulphurisation, OGC

reduction); quality of construction materials

▪ secondary measures – dedusting, OGC, NOx and SOx reduction by catalytic

afterburning (post-combustion).

R & D activities on SCIs improvement

Improve the energy and environmental performance of SCIs (capacity

<500kWth) require further scientific and basic research on:

▪ solid fuel (biomass and coal) fixed bed combustion process

▪ control (continuous) system of combustion process

▪ development of combustion catalysts

▪ development of construction material (ceramic and steel)

▪ emission abatement techniques namely dedusting, denitrification,

desulphurization systems and TOC, HM, PCDD/Fs reduction methods

▪ new harmonized method for TSP, PM10, PM2.5 determination for SCIs

It is also necessary to intensify research activities within the field of small scale of

combined heat and power plants (CHPs) fuelled with solid fuels.

Traditional solid fuels SCIs are great emitters!!!

R&D activities and implementation of BAT for SCIs

will make them really small emitters!

www.ecosolidfuel.org

Thank you for your attention!