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31.03.2017 Caluwe, Inc – Spanner wood chip CHP 1
Commercial-Scale Dry Wood Chips
Combined Heat & Power System
and Chip-Drying Technology
By Marc Caluwe
9 Wheatland street, Burlington MA 01803
83 Alexander Road, Billerica MA 01821
781-308-8583 - [email protected]
Massachusetts Statewide Wood Energy Team
Worcester County Modern Wood Heat Tour
April 30-2017
31.03.2017 Caluwe, Inc – Spanner wood chip CHP 2
Caluwe, Inc. – Biomass Heat & Power Solutions
1993 – 2005: Product Testing & Certification; Apragaz (B) and TUV-SÜD (US)
2005 - Present: Caluwe, Inc. - Import, Distribution and Sales:
- Hydronic wood stoves and fireplace inserts: Walltherm (I) & Spartherm (D)
- Hydronic wood fired cook stoves: Pertinger (I) & Lacunza (Es)
- Pellet Boilers: Windhager (A) >>> USA & Canada
- Wood Chip Boilers: Heizomat (D) >>> USA & Canada
- Biomass CHP: Spanner Re² (D) & Burkhardt Energy (D) >>> USA &
Canada
Overview of activities
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Caluwe, Inc. – Biomass Heat & Power Solutions
- Emission control systems: Catalytic, ESP’s Cyclones >>> USA & Canada
- Wood chip storage bins with integrated drying system: From green/wet to
25% MC in 4 days >>> 8'x8' - 10'x10' - 12'x12' - 16'x16' - 20'x20'
- Thermal Storage Tanks: From 120 gallons up to 20,000 gallons
- Installation & Service: MA, Southern ME & NH
- Heat sale contracts to government & municipal entities (MA only)
Wood chip boilers / CHP (similar to Solar PV > roof lease)
Overview of activities
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Pellet Boilers: Windhager (A) >> US & Canada
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Pellet Boilers: Windhager (A) >> US & Canada
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Wood Chip Boilers: Heizomat (D) >> US
Fixed Grate + Rotating Agitator
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Wood Chip Boilers: Heizomat (D) >> US
Moving
Chain
Grate
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Typical wood chip boiler configuration
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Cyclone
Emission control via
Cyclones
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Electrostatic Precipitator - ESP
Emission control via
K+W Airject ESP
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Electrostatic Precipitator - ESP
Emission control via
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Electrostatic Precipitator - ESP
Emission control via
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Electrostatic Precipitator - ESP
Emission control via
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1 Ionization chamber
2 Collector chamber
3 High Voltage
Electrode
4 Wire Steel Brush
5 Cleaning
6 Ash box
Emission control via
Electrostatic Precipitator - ESP
Carola Clean Air ESP
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Emission control via
Electrostatic Precipitator - ESP
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Fly-ash collection box
Electrostatic Precipitator - ESP
Emission control via
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Questions so far ?
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Cost for the different fuels
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wood chips SOURCE
From logging operations
-Logging companies
Cost point per Ton
$50/ton for green bole chips
From Urban wood waste
-Tree care companies
- Landscaping companies
- Municipalities
Cost point per Ton
$35/ton for green bole chips
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Heating Oil #2 price history
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Questions so far ?
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Commercial-Scale
Biomass
Combined Heat & Power Systems
www.holz-kraft.de
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www.burkhardt-energy.com
Commercial-Scale
Biomass
Combined Heat & Power Systems
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905,000 BTU/hr
Thermal
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Electrical output 50 kW
‚Thermal output 110 kW (375,000 BTU/hr)
www.holz-kraft.de
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Commercial-Scale
Dry-Chip Combined Heat & Power System
and Chip-Drying Technology
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> Wood-Power-Modules> Wood-Power-Systems> Wood-Power-Plants> Drying-Systems
Spanner Re² GmbH
Wood Chips > Gasification > Electric Power & Thermal Heat
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Spanner SK.
k.s.
Slovakia
40 Employees
Spanner RE²
GmbH
Neufahrn in Ndb,
Germany
> 120 Employees
OTTO SPANNER
GmbH
Bayerbach, Germany
> 200 Employees
Automotive Renewables
SPANNER Group
Ursatronics GmbH
Berlin, Germany
40 Employees
Electronics
Otto Spanner GmbH in Bayerbach, Germany
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Spanner Re² GmbH in Neufahrn,
Germany
Caluwe, Inc – Spanner wood chip CHP
In 2004 Otto Spanner GmbH founded the daughtercompany Spanner Re² GmbH. With this decision the groupaimed at achieving more independence from theautomotive industry as well as at opening up a newbusiness field: The mission of Spanner Re² is thedevelopment and commercial exploitation of innovative,economically attractive regenerative power generationtechnologies.• 120 employees at the company’s headquarters in
Neufahrn/Landshut/Germany• internationally active in seven countries• 7,000 m² production area• ISO 9001-2006 certified
Otto Spanner GmbH has been a successful player in themetal working industry for many years: The company hasbeen a stable medium-sized partner of major industrybrands for more than 50 years. Long standing customerslike BMW, Porsche or Rational have come to appreciatethe company’s reliability and corporate philosophy basedon trust and honesty.
Geschäftsbereiche:
Innovative HOLZ-
KRAFT®-Anlagen
Kompakte Industrie-
Heizzentralen
Effektive
Hackschnitzel-
Trocknungsanlagen
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2004:
Gründung des regenerativen Sektor
der Spanner Gruppe
2006:
Gründung der Tochtergesellschaft
Spanner Re² GmbH
Business units:
Innovative Wood-
Power-Plants
Compact industrial
heating systems
Efficient wood chip
drying systems
2004:
Start of the Renewables sector of
Spanner group
2006:
Foundation of daughter
Spanner Re² GmbH
The Spanner Wood-Power-Plant is an intelligent system to produce electricity
and heat out of conventional wood-chips. The compact Wood-Power single plant and also the whole Wood-Power-Systems have proven themselves many
times in practice.
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The Spanner Wood-Power®-Plant
Caluwe, Inc – Spanner wood chip CHP
✓ Uses cheap wood chips
✓ Highly efficient combined heat and power
✓ Use your power yourself and save cost
✓ Feed eco power into the grid and earn revenue
CHP unit Gasification unit
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Operating principle of the Spanner Wood-Power®-Plant
(Face Lift = Post Reformer)
GM Vortec Engine
4 Stroke V8 – 5.7 Liter
1,520 RPM
CHP unit
Gasification unit
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Operating principle of the Spanner Wood-Power®-Plant
(Face Lift = Post Reformer)
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REFORMER Process
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EMISSIONS
Caluwe, Inc – Spanner wood chip CHP
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Technical data Spanner Wood-Power®-Plant
Electric power 9 kW (2016) 30 kW 45 kW
Thermal Heat25 kW
(85,300BTU/hr)
73 kW
(249,000 BTU/hr)
108 kW
(368,000 BTU/hr)
Wood chip consumption 10 kg/h 30 kg/h 45 kg/h
Wood chip consumption for 7.000
operating hours60 tATRO 180 tATRO 270 tATRO
Required space min 7.5 x 5 m
Required room height 2.6 – 3.4 m depending on wood chip intake
Max output limited for
Net metering in Germany
ATRO-t means
0% WC !
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Efficiency data Spanner Wood-Power®-Plant
Electric power 9 kW (2016) 30 kW 45 kW
Thermal Heat25 kW (85,300
BTU/hr)
73 kW
(249,000 BTU/hr)
108 kW
(368,000 BTU/hr)
Thermal Efficiency NA NA 56.3%
Electrical Efficiency NA NA 26.7%
Total Efficiency NA NA 83%
Installed units
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Sold and installed units
1224
4262
120140
1236
78
140
260
400
0
50
100
150
200
250
300
350
400
450
2009 2010 2011 2012 2013 2014
Auslieferungen im Jahr
Feldbestand zum Jahresende
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Sold per year
Installed units at year end
Installed units
in Germany
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Holz-Kraft locations
Site visits by appointment
Regular site tours
Corporate headquarters at
Neufahrn (NB.)
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Questions so far ?
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Sizing of a biomass CHP system
Most important aspect:
The CHP unit needs to run as many
hours per year as possible: >7,000
hours/year
HOW?
- Correct sing of the THERMAL LOAD >> UNDERSIZE CHP output !
- Fuel quality = quality of the wood chips >> result in less breakdowns
>> CAN‘T BURN WATER !
>> WATER IS USED TO EXTINGISH A FIRE !
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365 days per year
X 24 hours per day
>>> 8,760 hours per year
Correct sizing of the THERMAL LOAD
- Size for SUMMER CONDITIONS !
- UNDERSIZE output
- Look into COOLING applications for summer (Absorbtion chiller)
Why?
- The CHP unit needs to be able to use the Thermal Heat (Hot Water)
„somewhere“ >> Process Heat or Heating/Cooling a building
- If you can not use the Thermal Heat, then the CHP unit will overheat
and shut down (just like your car engine with broken radiator)
- Do not „dump“ the heat !
Dumping Heat = Annual Operational hours go down = No financial pay
back
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Do not „dump“ the heat !
Dumping Heat = you loose THERMAL ENERGY = No financial pay
back
HOW?
Incorporate Thermal Storage
10,000 gallons of water = 83,500 Lbs of water
Assume a usefull deltaT = 20C = 36F
83,500 Lbs x 36F = 3,006,000 BTU
3,006,000 BTU / 3412 = 881 kW devided by 108 kWt = 8+ hours of storage
10,000 gallons of water = 83,500 Lbs of water
Assume a usefull deltaT = 20C = 36F
83,500 Lbs x 36F = 3,006,000 BTU
3,006,000 BTU / 3412 = 881 kW devided by 73 kWt = 12+ hours of storage
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45 kWe
30 kWe
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Required fuel quality
Required wood chip quality
13% water contents max., 15% moisture contents max.
30% fine portion
max.
• Higher fine portion increases fault susceptibility
• Highter fine portion increases ash discharge
No foreign substances
• Sand causes slagging
• Screws, nails, stones cause plant damage
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Requiredwood chip quality: G30 – G40
YOU
Can‘t
BURN
WATER !
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Fuel comparison
Customer: HuberPrepared roadside and
landscape conservation wood
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Fuel comparison
Customer: WäslerDried and sieved mixed woods
Customer: BaumgartnerDried and sieved forest timber
remains
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Calorific Value (Heating Value) of wood & wood chips
@ 13% WC
Or 15% MC
You double your heating value by drying
The wood chips and you cut down on the
amount of wood chips
2.12 kWh/kg or
3,255 BTU/Lb
4.45 kWh/kg or
6,830 BTU/Lb
Hardwood = another commonly used word for deciduous, broadleaf trees
Softwood = usually refers to coniferous trees
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Cost of wood chips at 15% MC and 25% MC
MC WC MC WC
Wood Chips G30/50
$145/ton
Wood Chips G30/50
$120/ton
GREEN Wood Chips
G30/50
$50/ton ???
Info:
Biomasseverband OÖ
4021 Linz, Auf der Gugl 3
Biomasseverband-ooe.at
Wood Chips G30/50
$65 to $85/ton
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Wood chip drying
Wood chip drying technology
How much does it cost to dry wood chips ?
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THERMO-HYGROMETER
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How much does it cost to dry wood chips ?
<<<<< Required Thermal Heat
<<<<< Required Electric Power
Required Total Energy for drying?
Caluwe, Inc – Spanner wood chip CHP
144 kWhth = 0.144 MWhth >>> @ $20/MWhth >>> $2.88 per m3 or yard + electric
If you need 2 or 3 m3 or yards for a ton
of chips then the total drying cost per
ton $8 to $12
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Cost of wood chips at 15% MC and 25% MC
MC WC MC WC
Wood Chips G30/50
$145/ton
Wood Chips G30/50
$120/ton
Info:
Biomasseverband OÖ
4021 Linz, Auf der Gugl 3
Biomasseverband-ooe.at
GREEN Wood Chips
G30/50
$50/ton
+$12 for drying
= $62/ton
For 300 or 350
Tons per year
You save
$25,000 per year
= 3 to 4 year pay
back for dryer
Wood Chips G30/50
$65 to $85/ton
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Wood chip drying technologyWood chips for use in a Wood-Power-Plant must not exceed a water
content of 13 % resp. a moisture content of 15 %!
However: Fresh material (from the forest) has a moisture contents of over
100 %
By simple storage (natural predrying) of wood chips, moisture contents
cannot be decreased to < 40 %
Therefore wood chips have to be technically dried to achieve the required
moisture content of < 15 %.
Spanner Re² offers a range of drying units:
Bin drying
Slanted floor drying
Mobile silo
Container drying
Waggon drying
Double bin drying
Push floor drying
Caluwe, Inc – Spanner wood chip CHP
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Wood chip dryers
Drying conveyor
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For approx. 6 – 10 m³/day or rather 3000 m³ per year ✓ Fully automatic drying system >> you dry the amount of wood chips you need✓ Continuous drying✓ Optional: remote control
Dimensions: 3,5 m x 2,4 m x 1,7 m (LxBxH)
Caluwe, Inc – Spanner wood chip CHP
Bin drying, compact unit
for 4000 – 5000 m³ loose cubic meters of wood chips per year
The drying in containers is recommended if large quantities of wood chips are to be dried and to be further transported immediately afterwards.
✓ Very simple, cost efficient construction
✓ In the floor area wood chip discharge and an air permeable construction can be combined
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Dimensions: individual concerning customers request
Depending on the available heat, it is possible to dry the wood chips in two bins simultaneously double bin drying (following page)
Caluwe, Inc – Spanner wood chip CHP
Double bin drying✓ Very simple, cost efficient construction
✓ In the floor area wood chip discharge and an air permeable construction can be combined
dimensions: 2,5 m x 2,5 m (base floor) per bunker
Depending on what the customer wants, we offer the system with different storage capacities and heat output
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Advantages:• Combined drying / bin solution in alternate operation• Low time & work effort• Minimum dust• Low floor space required
Caluwe, Inc – Spanner wood chip CHP
Container drying
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Advantages:
• Also serves as intermediate storage
• Simple logistics
• Batch operation
• Suitable for small amounts
• Low time & work effort
• No cover needed in normal rain or snow
For approx. 11-22 m³/day
Drying in containers is recommended if large quantities of wood chips are to be dried and to be further transported immediately afterwards.
For this, large roll-off containers are used for the transport on trucks. The advantage of the container is its large capacity of 22 m³ and more.
Two containers can be combined for double bin drying
Filling amount = container size
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• For approx. 15 – 20 m³/day or rather 5500 m³ per year
• The big difference: permanent drying resp. Discharge of wood chips
• A storage bin for dry wood chips is required !!!!!!
• Fan and heat exchanger press warm air through the floor from below
• Drying time is adjusted by means of temperature comparisons above and below the wood chips
Push floor drying
• Dimensions: 6 m x 2,4 m x 3 m
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Integrated drying system: Push floor >> belt dryer
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Questions so far ?
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Transportation logistics: in 2 x 20‘ steel containers per gasification unit
Due to the ready-to-install components in the 20 ft. Containers or rather in theconcrete garages, the Wood-Power-Module is very easy to transport! This also lower the time between delivery and implementing
The Spanner Wood-Power – Modular concept
Caluwe, Inc – Spanner wood chip CHP
The Spanner Wood-Power – Modular concept
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• The wood-power-modules consist of the wood-
power-plant (gasifier and cogeneration unit) and is
pre-installed in a sound-absorbing, robust, fireproof
and cheap ferroconcrete ready-to-install garage or
container.
• The interior design is adapted to the special needs
and requirements!
• This solution is used, where no matching room for
the wood-power-plant exists, the existing room
cannot be modified, or the plant should be adapted
as a space-saving solution besides the building. Space-saving and ready-to-install solutionsWood-power-unit in a container (picture above) Wood-power-unit in a concrete garage (picture below)
Adaptable to every amount ofneeded heat and electricity
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The Spanner Wood-Power-System Solutionsthe complete system solution
Therefore, the internal process guarantees the necessary wood-chip quality out ofuntreated and humid conventional wood chips.By use of this whole system solution, the maintenance-friendly and continuousoperation will get much more easier.
The Wood-Power-System consists of a cascade of• The needed amount of Wood-Power-Plants• The efficient wood-chips dryer and the whole
logistic• The intelligent impurity removal• The wood-chips bunker• And the whole waste material logistic
inclusive ash-container
Ash-container
Wood-chips dryingsystem; bunkerWood-chips bunker
andWood-Power-Plants
Wood-chips drying system
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Your advantages: ✓ Nine out of ten plants are operating every time this
ensures a permanent and save heat and electricity supply✓ Cheap and robust wear parts for a max. efficiency simple
repair and maintenance work by every car mechanic✓ In case of substituting dieselgenerators: ROI within three
years!✓ Fast delivery times!✓ Your option: relocation after a few years could be done very
simple!
Inform and react: Within four months* you could be your own energy supplier
*from ordering with payment receipt until the first electricity andheat production
The Spanner Wood-Power-System Solutions
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HK 19 Wood-Power-System:Wood-Power-System combinedwith a double-bin dryer and theash logistics
Example: HK 19 Wood-Power-System
HK 19 Wood-Power-System: Wood-Power-System combinedwith the ash logistics, thebunker for the wood-chips andthe drying system
Plant-Type HK 19 (1) El. power: 19 kW Th. power: 45 kW
Caluwe, Inc – Spanner wood chip CHP
Example: HK 135 Wood-Power-System
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The unit consists of a cascade ofthree Wood-Power-Plants(cogeneration unit and wood-gasifier) and of a fully automaticwood-chip preparation (drying-system and sieve-system).
Plant-Type HK 45 (3)El. Power 135 kW Th. Power 324 kW
Caluwe, Inc – Spanner wood chip CHP
The Spanner Wood-Power-System Solutions
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Example here:Plant-type: HK 45 (10)El. power: 450 MWTh. power: 1,08 MW
Adaptable to every amount of needed heatand electricity
Caluwe, Inc – Spanner wood chip CHP
The Spanner Wood-Power-System Solutions
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Adaptable to every amount of needed heatand electricity
Example here:Plant-type: HK 45 (20)El. power: 900 MWTh. power: 2,16 MW
Caluwe, Inc – Spanner wood chip CHP
Example: Wood-Power-System in Latvia
Feeding in the electricity into the district heating system in Latvia
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Plant-Type HK 45 (22)El. power 1 MW Th. power 2,4 MW
Caluwe, Inc – Spanner wood chip CHP
Typical applications (Germany)
Forestry
• Forest owners
• Thinning operations
• Saw mills
Local heating networks
• Swimming pools
• Industrial business
• Public buildings, e.g. schools or town halls
• Remote districts and hamlets
Agriculture
• Piglet weaner stations
• Organic milk producers
• Nurseries and hothouses
• Agricultural business with holiday accomodation
Hotel & real estate industry
• Agricultural business with holiday accomodation
• Guesthouses in rural areas
• Holiday farms and wellness hotels
• Youth hostels
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>>> Annual operating hours (91% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
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>>> Annual operating hours
(91% operational)
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours (91% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours (86% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
District Heating network
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>>> Annual operating hours
(86% operational)
District Heating networkCaluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours (80% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
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>>> Annual operating hours
(80% operational)
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Annual operating hours
(96% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
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Annual operating hours
(96% operational)
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours (91% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours
(91% operational)
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours (91% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
Caluwe, Inc – Spanner wood chip CHP
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>>> Annual operating hours
(91% operational)
Caluwe, Inc – Spanner wood chip CHP
DHW load
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>>> 2,855 Ft = 952 yds
6 1 >>> Annual operating hours (74% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
District Heating network
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(13,230 Gal) !?
SYSTEM is OVERSIZED
for summer, but needs the
thermal heat in winter
Annual operating hours (74% operational) >>>
District Heating network
Thermal Storage10,000 gallons of water = 83,500 Lbs of water
Assume a usefull deltaT = 20C = 36F
83,500 Lbs x 36F = 3,006,000 BTU
3,006,000 BTU / 3412 = 881 kW devided by 216 kWt = 4 hours
5.5 hours of
Thermal storage
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>>> Annual operating hours (57% operational)
365 days per year
X 24 hours per day
>>> 8,760 hours per year
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!!! (22,750 Gal)
SYSTEM is
OVERSIZED
for summer
>>> Annual operating hours
(57% operational)
Thermal Storage10,000 gallons of water = 83,500 Lbs of water
Usefull deltaT = 20C = 36F
83,500 Lbs x 36F = 3,006,000 BTU
3,006,000 BTU / 3412 = 881 kW devided by 73 kWt = 12 hours
27 hours of
Thermal storage
Caluwe, Inc – Spanner wood chip CHP
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Questions so far ?
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MA state rebate programs (MassCEC)
MassCEC – Rebate for Biomass Heating System
Rebate equals 40-50% of the total installed cost, up
to $250,000 for commercial-scale projects (>120,000 BTU/hr)
and $27,000 for small-scale projects (<120,000 BTU/hr)
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MA state APS and Alternative Energy Credits
MA-APS = Alternative Portfolio Standard
AEC’s = Alternative Energy Credits (similar to SREC’s)
$15 to $30/MW for produced Thermal Energy (Heat)Or $15 to $30 per 3,412,000 BTU/hr
Or $4.41 to $8.82 per mmBTU
Or $0.015 to $0.03 per 1,000 W or 1 kW
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Cost for the different fuels
Minus $4.40 AEC
Equals $4.02
Per mmBTU
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Spark Spread
Spark Spread www.epa.gov/chp/my-facility-good-candidate-chp
Spark spread refers to the difference between the cost of
electricity and the cost of fuel on a per mmBTU basis. This
metric is often considered when recommending equipment retrofits that
require fuel switching. A spark spread of at least $12 per mmBTU is
considered the threshold for economic viability of Combined Heat and
Power (CHP) systems.
A spark spread of $12/mmBtu ($0.041/kWh) is typically
considered to be the threshold that is representative of an
economically attractive CHP project, meaning that projects that
exhibit spark spreads in excess of $12/mmBtu ($0.041/kWh) will have a
good potential for low payback periods and overall economic success
*The spark spread is a metric to determine the profitability of gas-fired electric generators with minimum input available. It is a
quick analysis of the market conditions of power generation, but there are limitations on it use. It considers only the cost of
electricity and fuel and does not take into consideration other costs associated with the generation of electricity, such as capital
cost, taxes and operation and maintenance (O&M) costs.
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Electricity Prices in the USA (c/kWh)The cost of electricity is generally high in the Northeast, California, and the noncontiguous states of Alaska and Hawaii.
The price of electricity is low in the Northwest and Southeast.
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Natural Gas Prices in the USA ($/mmBTU)In addition to a high cost of electricity, the business case for a CHP-system is improved if the cost of its fuel is low.
Figure below shows the geographic variation in natural-gas prices across different regions in the United States.
As can be seen from the figure, those areas with high electrical costs do not necessarily correspond to the areas with high natural-gas costs.
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Closing remarks
Biomass Thermal is competing with:
- Wind
- Solar PV
- Solar Hot Water
All non-emitting renewable energy generators
Important for public opinion/perception:
- Biomass technology needs to be clean (PM2.5 level)
- Biomass technology needs to be efficient (>75%)
- Sustainable sourcing of biomass fuels
- Responsible use of the sourced biomass fuels
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woodchipboilersr.us
Thank you for your attention
Caluwe, Inc – Spanner wood chip CHP