bwe presentation for_cleantech_group_final[1]

Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A · DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · info@bwe.dk

Your partner for

steam power -

STF S.p.A group

Presentation of BWE

Modern technologies in utilisation

of biomass in large power plants

Paolo Danesi - VP sales BWE A/S

Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · info@bwe.dk

STF Headquarter

and workshop

TOTAL AREA: 160,000 m2

MANUFACTURING AREA: 32,000 m2

Magenta - Milan

ENERGY INDIA

Chennai

Lyngby

DENMARK

BURMEISTER & WAIN ENERGY A/S

Company structure

• Company founded in 1937

• Located in Magenta (Milano), Italy

• STF is an historical and leading name in Power field

• Supplier of large size equipment and complete units for

power plants

• 1997-98 - Design & supply of HP FWH (289 bar design pressure) for TorValdaliga Sud Steam Power Plant

• 1999 - 1st HRSG for Pietrafitta CCPP

• 2002 - Acquisition of BWE Burmeister & Wain Energy A/S

• 2008 - Contract for Porto Tolle (Italy) , 3 x 660 MW UltraSuperCritical Boiler

• 2009 - Establishment of BWE Energy India PVT Ltd

STF GROUP

Historic Overview

• Company founded in 1843

• First steam boiler supplied in 1852

• First Benson once-through boiler in 1952

• World record - above 47% in efficiency for a coal

fired utility boiler in 1999

• Contract for Porto Tolle 3x660 MW USC

History of BWE

• Part of Lentjes Group in 1980

• Part of Deutsche Babcock in 1991

• Part of FLS Miljø in 1997

• Part of the Italian STF S.p.A. Group in 2002

• BWE India founded in 2009

Recent History

BWE Energy India

BWE Energy India started operating in October 2009

and covers the fast growing South Asian market.

The office is located in Chennai -

one of the largest engineering hubs in India.

BWE Energy India takes care of:

• Sales and operation of BWE and STF products

• Procurement and sourcing of materials and

engineering services within the area

Chennai

STF GROUP

Location of STF

STF Power Limited - UK

STF GmbH - Germany

STF Slovakia s.r.o.

STF Hungary kft.

BWE Energy India PVT LTD

STF Egypt Branch

STF S.p.A. - Italy

BWE A/S - Denmark

Branch

Local Company

Lead center

STF Enerji Lim. Sirkety (Turkey)

STF GROUP

Field of application

COAL GAS RENEWABLES NUCLEAR

HIGH EFFICIENCY ULTRA SUPERCRITICAL

COAL BOILER

HEAT RECOVERY STEAM GENERATOR

BIOMASS

HEAT TRANSFER PRODUCTS

Heat Recovery Steam Generators

Heat Transfer Products

Industrial Boilers

Nuclear Division

Biomass Boilers

SC & USC Boilers

Air Preheaters & Gas Gas Heaters

STF GROUP

Products

• Heat Recovery Steam Generators:

• Horizontal gas flow arrangement

• Natural & forced circulation

• Benson Once-through

• Industrial Boilers:

• Package type

• Steam drum type

• Heat Transfer Products:

• Water steam condensers

• Feed water heaters

• Heat exchangers

STF - Products

• Advanced Ultra Super Critical steam boilers

• Grate fired biomass boilers

• Pulverized biomass fired boilers

• SCR – Selective Catalyst Reactors (deNOx)

• Low-NOx firing systems and circular burners

• Regenerative Air Heaters and Gas-Gas Heaters

• Critical piping

• Erection and commissioning

• Upgrading of existing boilers to improved

performance

• Boiler service

• Training

BWE – Products and services

• Net efficiency above 47% on coal

• Fuel flexible - coal, HFO, NG, Orimulsion, peat and

wood dust

• Pressure ~ 280 to 320 bars

• Temperature ~ 580 to 620 °C

• Single or double reheat

• Excellent performance and reliability record

• Three USC units in operation until now:

NVV3 415 MWe (coal)

SVS3 415MWe (NG)

AVV2 415MWe (NG/HFO/wood dust)

Clean Coal Technology

Ultra Super Critical Boilers

Vibrating grate boiler for straw and wood chips

50- 120 Mj/s

Biomass boiler – products overview

Screen

HP1.3 HP1.2

3 mills

OFA OFA

burners

Conversion to biomass for large

Fossil fuel power station

Multi fuel hybrid power station

15 - 400+ MWe , PF type boiler

BWE has been one of the pioneer in biomass combustion technologies due

to the demand of the Danish/Scandinavian market for such solution.

The drivers of the involvement of BWE in the biomass project are deriving

from different side all related to environmental concerns

Experience in biomass

Driver Technology Project

Availability of straw to

be disposed

Straw combustion Various

Ban of coal for large

combustion plant and

introduction of subsidy

for the use of biomass

Large biomass

combustion plant

(mainly pellet)

Avedore

Large availability of

Conversion of fossil

fuel plant to biomass

combustion

Herning power plant

boiler conversion

Demand for fuel

flexibility (fossil and

biomass)

Co combustion Amager boiler

Avedøre Power Station Unit 2

BWE Solutions for co-firing

Large hybrid fossil/biomass power station

Avedøre II (2001)

Client: DONG Energy A/S (Denmark)

CHP - 485 MWe & 545 MJ/s heat (1067 t/h steam)

Tangential firing

USC Tower boiler

HP 305 bar & 582°C

Avedøre II (2001) / DONG Energy A/S

CHP / 485 MWe & 545 MJ/s heat

• Multi-fuel unit:

• 800 MJ/s USC boiler supplied by BWE for gas, oil, coal or wood pellets (70%)

• 105 MJ/s straw-fired biomass boiler

• 2*50 MWe gas turbines

• Connected to the Copenhagen area district heating system

• 570 MWe for power

• 545 MJ/s & 485 MWe

Multi fuel concept

• Avedøre Power Station unit 2

design:

• 100% on coal

• 100% on natural gas

• 100% on heavy fuel oil (HFO)

• 70% on biomass (wood pellets)

• USC combined with

2 x 50MW gas turbine

Increased output 150MWe

Total plant efficiency 51%

HRSG FW-preheater

Boiler

(straw)

boiler

(gas/oil/

Gas-turbine

Steam turbine

Plant concept by DONG Energy, visited by delegations during COP15

• Originally commissioned on gas/oil in 2001

• Burners converted (2003):

• Gas/Oil => Gas/Oil/ Wood pellets

• The wood pellets are pulverized in traditional roller mills

• 3 of 4 burner levels (12 of 16 BWE burners) can burn 100% wood

(70% of heat input)

• The 4th level can only burn oil/gas

• The thermal input is up to 560 MJ/s on wood – equivalent to approx. 250 MWe resulting

from biomass

Avedøre II: Combustion system

Air staging:

• Burner PA (primary air)

• Burner SA (secondary air)

• Burner TA (tertiary air)

• OBA (over burner air)

• OFA (over fire air)

Wood pellets:

• Mill air/wood ratio: 2 kg/kg

• Mill inlet temperature: approx . 60oC

• 8 years of successful operation with biomass firing

• Consumption of wood pellets in 2010 was 620,000 tons/yr

• The corresponding CO2 reduction was about 1,000,000 tons per

Herning Power Station

Repowering of an existing power station

Herning Power Station (1982)

Client: DONG Energy A/S (Denmark)

CHP - 89 MWe & 174 MJ/s heat

425 t/h of steam (equivalent to

approx 125 MWe in case of full electricity

conversion)

Wall firing & bottom grate

Drum boiler – 115 bar & 525°C

Herning Power Station(1982) / DONG Energy A/S

Herning Power station (1982) / DONG Energy A/S

1982 Coal/Oil 2002 Biomass/Gas/Oil

2009 Biomass

2000 Gas/Oil

4 x 2 coal/oil burners

The original boiler design

was operated for 20 years

4 x 2 gas/oil burners

The first retrofit included 8

new WR oil and gas

burners

The retrofit enables about

45% load on biomass

2 x 2 gas/oil/wood dust burners

1 x vibration grate for wood

biomass load up to 90%

• 7 years of successful operation with biomass firing

• In 2006 the consumption of wood chips was 206,000 tons

• This was equivalent to 70% of the total fuel consumption

• Now the capability is 100% of the fuel consumption

• The CO2 reduction will be >200,000 tons per year

• CO emission < 200 mg/Nm³ (dry, 6% H2O)

• NOx emission < 300 mg/Nm³ (dry, 6% H2O)

Herning Power Station (1982) / DONG Energy A/S

PF combustion system

Herning Power Station (1982) / DONG Energy A/S

Amager Power Station Unit 1

New build for multi-fuel

Screen

HP1.3 HP1.2

3 mills

OFA OFA

burners

Amager I (2009)

Client: Vattenfall A/S (Denmark)

CHP - 71 MWe & 250 MJ/s heat (500 t/h

steam ≈ equivalent to 150 MWe)

Front-wall fired

Fitted into existing building

HP part 185 bar & 540°C

cooler

Screen

HP1.3 HP1.2

3 mills

OFA OFA

burners

Amager I (2009) / Vattenfall A/S

Boiler design:

• Increased pitch super heater banks

• Austenitic steel 1st pass

(due to straw pellets)

• ECO out of boiler envelope

Combustion system design:

• 100% on coal (350 MJ/s, two levels)

• 100% on heavy fuel oil (HFO)

• 100% on wood pellets

(350 MJ/s, three levels)

• 90% straw pellets

Reduced flue gas temperature by PA coolers

• Only one fuel type per mill at any time; i.e. no co-milling

100% 100% 100% 91% 100% 100% 85% 100% 100%

Fuel input

]Coal Wood

Co-firing

Mass percentageCoal

AMV1 options:

• The plant was commissioned in 2009

• Projected consumption of wood pellets is 40,000 tons/yr

• Projected consumption of straw pellets is 110,000 tons/yr

• Biomass use is equivalent to 35% of expected thermal input

• The corresponding CO2 reduction is approx. 220,000 tons

Porto Tolle: Co-combustion

Coal fired USC 3 x 660 MW:

• Injection through centre tube in the PF burner

• 5% wood chips (33 MWe)

• 5% RDF (Refuse Derived Fuel from waste)

coal biomass/rdf

• Grate firing is used in smaller boilers.

• The fuel preparation for grate firing is reduced compared

to burner firing, where the fuel is dried and pulverized.

• Fuel can be straw, wood chips combination of the two

Grate Fired Biomass Boilers

• Fuel input up to 150 MW

• Steam temperature up to 540 °C

• Steam pressure up to 120 Bar

• Natural circulated Drum

Boiler size & type:

Vibration Grate Firing:

• 4½ - pass drum type boiler

• BWE straw firing system

• Fuel: straw from cereals

Boiler concept:

Plant concept:

• 50 MJ/s (heat input) straw fired steam boiler

Emlichheim

50 MJ/s straw; 18,55 kg/s steam; 122 Bar; 522 °C; 190 °C feedwater

Emlichheim

• 4½ - pass drum type boiler

• BWE straw firing system

• Fuel: straw from cereals

• Aux.: wood chips

Boiler Concept

102.3 MJ/s (heat input) straw fired steam boiler in UK

Sleaford plant concept

Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A · DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · info@bwe.dk

Your partner for

steam power -

Tak for opmærksomheden !!

BWE A/S - STF S.p.A group

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