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The biomass gasification plant to
Vaskiluodon Voima in Vaasa
Claes Breitholtz
Research engineer
and two more ongoing
gasification projects
© Metso
The pilot phase is over
SolanderSymposium 2011 Claes Breitholtz2 Source: Lahti Energia
Technology has been available since the 1970’s
“Let’s finally start using it!”
Janne Savelainen – Lahti Energia
© Metso3
Metso is a global supplier of sustainable technology and services
• Our customers operate in
the following industries:
- Mining
- Construction
- Power generation
- Oil and gas
- Recycling
- Pulp and paper
• About 29,000 employees in more
than 50 countries.
• 2010 net sales EUR 5.6 billion.
• Our shares are listed on NASDAQ
OMX Helsinki Ltd.
SolanderSymposium 2011 Claes Breitholtz
© Metso
Metso Power Wide scope of fuel-flexible power technology
4
Heating plants
ProfilersIntelligent control
valves ESD valves
Power solutions
Automation systemsGasification
Recovery boilers
Boiler plants
Automation systems
Automation Rebuilds and upgradesEnvironmental systems
Modular power plants
SolanderSymposium 2011 Claes Breitholtz
© Metso
Metso’s Solution for Gasification CFB gasification: Reaction temperature
5
0
500
1000
1500
2000
2500
0,1 1 10
Air coefficient
Tem
pera
ture
(C
)
GASIFICATION COMBUSTION
DRY FUEL
WET FUEL
CFB gasification-
Operational area
SolanderSymposium 2011 Claes Breitholtz
© Metso
Metso’s evolution in gasification
SolanderSymposium 2011 Claes Breitholtz6
TAMPELLA POWER
ENVIROPOWER
GÖTAVERKEN
Tampere pilot plant
•15 MWth pressurized FB gasifier
• Biomass and coal gasification development
• Hot gas cleaning development
METSO
CFB GASIFIER
NEW DEVELOPMENT ACTIVITY• Fuel drying technology
• Gas cleaning
• Biomass gasification for limekilns
• Biomass gasification for power production
• Waste gasification
METSO CFB /BFB
Boiler experience
First generation
Atmospheric CFB gasification development
• Värö lime kiln gasifier 1987
Second generation
© Metso
Gasification technologiesPosition of Metso CFB gasification
SolanderSymposium 2011 Claes Breitholtz7
PRESSURE OXIDISIER PROCESS ASH FUEL SIZE APPLICATION
Atmospheric Air Fixed bed Slagging Coal
SMALL
0 – 10
MW
Combustion
engines
Pressurized Oxygen BFB Non-slagging Biofuel
MEDIUM
5-50
MW
Combustible gas
for industrial
furnaces
Steam CFB Oil
LARGE
50 -200
MW
Fossil fuel
replacement by
bio/waste in
power plants
Entrained
flowGas
HUGE
200 -2000
MW
IGCC
Transport
reactorWaste Transport fuels
Flame
gasificationSynthetic NG
© Metso
Metso’s Solution for Gasification CFB Gasifier
8
Product gas for
(lime) kilns
• Sawdust, forest
residues, fresh wood,
bark
• 20 – 80 MWfuel units
• Typically includes a
dryer
• Dusty product gas
• Also other types of
kilns possible
Product gas for
power boilers
• Woody biomass, bark,
peat, straw…
• Superior electricity
efficiency
• (Existing) power
boilers
• 50 – 150 MWfuel units
• Typically includes a
dryer
• (Gas filtering)
Product gas from
waste for power
production
• Waste-derived fuel
• High electricity
efficiency
• Typically a new gas
boiler
• Gas filtering -> clean
product gas
• 50 – 100 MWfuel units
or multiple units
connected to a boiler
SolanderSymposium 2011 Claes Breitholtz
Vaskiluodon Voima Oy gasification project
Replacing coal with biomass for electricity
production in an existing boiler
© Metso
Vaskiluoto coal-fired power plant in Vaasa
• In operation since 1982
• Thermal capacity
- 560 MW
• Production
- electricity 230 MW
- district heating 170 MW
• Coal consumption
400,000 – 500,000 t/a
• Produces approximately 90% of
the district heat needs in Vaasa
region
SolanderSymposium 2011 Claes Breitholtz10
© Metso
Vaskiluodon Voima Oy gasification project
Enables to replace a large share of coal with biomass
• 140 MW biomass gasifier and dryer
• Adjoined to the existing
560 MW coal-fired power plant
• Up to 40 percent replacement of coal
Schedule
• Contract signed June 2011
• Plant operational 12/2012
Total project cost < 40 M€
SolanderSymposium 2011 Claes Breitholtz11
© Metso
Biomass gasification into the existing coal-fired plant
SolanderSymposium 2011 Claes Breitholtz12
Relatively low
investment
cost
Integrated drying processOriginal coal capacity
available
Short delivery time and
minimized production
interference
© Metso
Typical gasification applicationsExample:100 MW of biofuel available at the district
• Cofiring is an efficient way to use biomass
SolanderSymposium 2011 Claes Breitholtz13
100 MW, fuelSmall boiler
efficiency 25 %25 MW
green electricity
100 MW, fuelLarge boiler
efficiency 40 %40 MW
green electricity
+
160 MW
coal electricity400 MW coal
The final outcome is 60 %
more green electricity !
© Metso
Vaskiluodon Voima biomass gasification plant
SolanderSymposium 2011 Claes Breitholtz14
Wet biomass
Existing PC boiler
modifications and new
burners
Instrumentation,
electrification
and automation
Biomass receiving
and pre-handling
Large-scale belt dryer CFB gasifier
140 MWfuel
Product gas
Dried biomass
© Metso
Vaskiluodon Voima, FinlandExternal Fuel Handling
Gasifier
Drying
Storage Silos
Sampling
Screening
Receiving
SolanderSymposium 2011 Claes Breitholtz15
Start-up 2012
ProcessGasification (140 MW) for
Power Generation
FuelsForest resudues (chips),
Peat
Fuel Receiving 4 x 120 m3
Receiving and
Screening
Capacity
600 m3/h
Fuel
Sampling
Automatic
5 samples / truck
Fuel Silos
and
Reclaiming
Capacity
2 x 2 500 m3
2 x 50 - 200 m3/h
Drying
Capacity
10 t/h
of evaporated water
© Metso
Metso belt dryer for biomassDouble layer
SolanderSymposium 2011 Claes Breitholtz16
WET
PRODUCT
IN
BELT
WASHING
DRY
PRODUCT
OUTFAN
FEEDING
SCREW
DRY PRODUCT
DISCHARGE SCREW
SEMI-DRY
PRODUCT INHEAT
EXCHANGER
AIR IN
AIR OUT
SEMI_DRY PRODUCT
DISCHARGE SCREWFor water evaporation
capacity up to
20 tons/h
© Metso
Fuel moisture vs. gasifier output
Fuel moisture 20%
(Design
point)
30% 40%
Gasifier max output % 100 89 77
Example case:Waste fuel, HHV dry 22,5 MJ/kg, Ash 7,6%
SolanderSymposium 2011 Claes Breitholtz17
0
1
2
3
4
5
6
7
8
20 40
Gas h
eat
valu
e h
ot
MJ/m
3n
Fuel moisture
Gas heat value MJ/m3n hot ( incl. sensible heat )
© Metso
Metso CFB Gasifier
SolanderSymposium 2011 Claes Breitholtz18
2
1
6
3
5
4
1) Fuel silo
2) Reactor
3) Cyclone
4) Productgas/ Gasification air
heat exchanger
5) Gas pipe
6) Ash removal
© Metso
Lahti Energia - solid waste gasification
• 160 (2x80) MW, 250 000 tn/a
• Total Investment 157 M€
• Start up April 2012
SolanderSymposium 2011 Claes Breitholtz20
Old PC
boiler
Waste fuel handling
Gasifier
and gas cooler
Gas boiler
and APC
1.
2. 3.
4.
5.
1. Fuel handling
2. Gasifier
3. Gas cooling
4. Gas filter
5. Gas boiler and
flue gas cleaning
© Metso
Benefits of waste gasification
SolanderSymposium 2011 Claes Breitholtz21
• High steam parameters higher efficiency- Lahti 160 MW fuel => 50 MWe + 90 MW district heat
- Lahti 120 bar, 540 C live steam
- Technology can offer even higher electricity efficiency
• Lower grade waste as a fuel lower fuel cost- Lahti fuel : Household waste (origin sorted), Industrial waste, demolition wood,
waste wood from industry
- LHV 14 -24 MJ/kg, dry ; Moisture< 30 %, Cl < 0,4 %
• Tolerance for fuel quality multiple fuel sources
• Less corrosion less expensive materials in the boiler
© Metso
Technical concept
• Gasify waste at 850-900 C
• Cool it down to about 400 C
- all corrosive components, alkalichlorides,
Pb, Zn will be in solid form
• Filter all dust out so the resulting gas is
clean
• Burn clean gas in gas fired boiler
1.
2. 3.
4.
5.
22SolanderSymposium 2011 Claes Breitholtz
1. Fuel handling
2. Gasifier
3. Gas cooling
4. Gas filter
5. Gas boiler and
flue gas cleaning
1,E-09
1,E-08
1,E-07
1,E-06
1,E-05
1,E-04
1,E-03
350
370
390
410
430
450
470
490
510
530
550
570
590
610
630
650
670
690
710
730
750
770
790
810
830
850
870
890
910
930
950
970
990
1010
1030
1050
1070
1090
1110
1130
1150
1170
1190
Temperature [C]
log
p
AC/GAS/NaCl -
AC/GAS/KCl -
AC/GAS/ZnCl2 -
AC/GAS/PbCl2 -
Saturated steam-Na2SO4(g)
Saturated steam-K2SO4(g)
Saturated steam-ZnCl2(g)
Saturated steam-PbCl2(g)
Saturated steam-KCl(g)
Saturated steam-NaCl(g)
AC/GAS/Na2SO4
AC/GAS/K2SO4
AC/GAS/PbO
AC/GAS/ZnO
© Metso
Operational window to clean out corrosive compounds
SolanderSymposium 2011 Claes Breitholtz23
• All water walls cooled with boiler feed
water– Avoid risk of corrosion in cooler
– Condensate corrosive components on
particles
– Avoid tar condensation in cooler
• High temperature ceramic filter– Filter can tolerate high temperatures
– Tar condensation can be avoided
© Metso
GoBiGas project
Solander Symposium 2011 Claes Breitholtz25 Source: Göteborg Energi
• Production: ~20 MW bio
methane of wood pellets
• Investor: Göteborgs Energi AB
• Total cost approximately:
100 MEUR
• Schedule: In operation 2013
• Gasification and boiler island
technology: Metso/REPOTEC
• Metahanation technolgy:
Haldor Topsöe
• EPCM for metahanation:
Jacobs process
Existing boiler
GoBiGas - Phase 1
© Metso
Indirect gasification,Biomass CHP plant, Güssing
Solander Symposium 2011 Claes Breitholtz26
• Start of construction September 2000
• Start up November 2001
• Fuel Wood Chips
• Fuel Power 8 MW
• Electrical Power 2 MW
• Thermal Power 4,5 MW
• Electrical Efficiency 25 %
• Total Efficiency 80 %
• Operational hours over 55 000 h
© Metso
}
Steam
Biomethane
Air
Steam
Flue gas
Wood pellets
Bed
material
Forest residues
Tar
Sulphur rich gas
Air preheater
Hot water
Hot water
CO2 to inert
gas system/
atm
Tar
GoBiGas process
Solander Symposium 2011 Claes Breitholtz27 Source: GoBiGas
Gasification: Metso scope
Methanation
CombustorGasifier
Dryer
Bag filter
De-NOx
Fuel handling
Tar removal
ShiftTar removal
Drying
UpgradingMethanation
Sulphur
removal
CO2-
removal
© Metso
Indirect Gasification in Dual Fluidized Bed
• Fuel is feed to the BFB gasifier
• The gasifier is fluidized with
steam
• Bed material is circulated to
transport heat from the
combustor to the gasifier
• Char in fly and bottom ash from
the gasifier is burnt in the
combustor riser
• Fly ash from the combustion is
recirculated to the gasifier
Solander Symposium 2011 Claes Breitholtz28
Air
Steam
Producer gas Flue gas
Fuel
BFB
Gasifier
CF
B C
om
busto
r
© Metso
Gas Cleaning
• Cooling of producer gas
• Dust removal in a textile filter
• Removal of tars and water
solvable pollutants in a oil
scrubber
Solander Symposium 2011 Claes Breitholtz
INTERNAL
29
FilterCooler Scrubber