solid recovered fuels - a sustainable option for spain ...combined heat and power plant stavenhagen...

SRFSRF--CHP Plant CHP Plant StavenhagenStavenhagen

Contracting Solution for EnergyContracting Solution for Energy--Supply of a FoodSupply of a Food--Production SiteProduction Site

Solid Recovered Fuels -

a sustainable option for Spain

Thomas Hegner

www.nehlsen.com

International SRF Conference, Madrid, November 17th 2009

The Client: Unilever Production Site The Client: Unilever Production Site StavenhagenStavenhagen

Total area: 200.000 m²

Area covered: 32.600 m²

325 Employees

Procuring 150.000 t potatoes

from 100 farmers

40.000 t products

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TheThe SupplierSupplier: Nehlsen: Nehlsen

Nehlsen AG

Waste Management Contracting Security

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Nehlsen Nehlsen ContractingContracting

� 124 Employees

� 6 Locations

� Main business:

� Development of wte-projects

� MBT-plant engineering

� Site management SRF-CHP

� Site management biomass treatment plants

� Site management biomass-to-fuel plants

� Energy contracting

� Logistic services

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CHP Plant StavenhagenCHP Plant Stavenhagen

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Combined Heat and Power Plant Combined Heat and Power Plant StavenhagenStavenhagen

� Construction of plant for the power supply for the Unilever plant (Pfanni) in

Stavenhagen (Germany)

� Processing 150.000 t/a of potatoes, 14 Mio. m³/a of natural gas have

previously been needed

� Target: Lowering energy costs to ensure the competitiveness of the location

� Technology: Building a SRF-fired CHP at the location Stavenhagen

� Tool: Usage of approx. 95.000 t/a SRF to supply Pfanni with steam and

electricity

Steam

200.000 t/y

Power

12 - 14

GWh/y

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TheThe StavenhagenStavenhagen--ProjectProject

SRF-demand: approx. 11t/h

approx. 20 trucks daily

SRF storage capacity:

approx. 2.000 t

SRF plant

Thermal capacity: 49,5 MW

SRF throughput: 95.000 t/yr

(at 14,2 MJ/kg heating value )

Grate ash: 20.000 t/yr

Filter residues: 5.600 t/yr

Steam: 200.000 t/yr

Power: 22.500 MWh/yr(Local grid)

14.400 MWh/a(Pfanni)

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Food Food ProductionProduction Site of Site of PfanniPfanni

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SRF SRF –– OOriginrigin and Potentialand Potential

Transport MSW to MBT Rosenow

Delivery SRF from Nehlsen

MBT Rosenow – separation into refuse

with high calorific value and residue for

landfill

Landfill Rosenow, landfilling of residue

Thermal utilisate of SRF in Stavenhagen

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FuelFuel SpecificationSpecification II

1% by weightceramic, stones, porcelain, sand,

ferrous metals, non-ferrous-metals

Contraries

250x250mmfoilLength x Width

250x50x25mmLength x Width x Height

Size

1813 (10)MJ/kgCalorific value

Physical quality characteristics

MaximumMinimumUnitDescription

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FuelFuel SpecificationSpecification IIII

31,21mg/kgMercury

400250200mg/kgFluorine

1,51,00,8% by weight Chlorine

1,00,80,6% by weightSulphur

Quality characteristics of micro elements (maximum allowance)

2520% by weightAshes

2520% by weightWater

Basic composition (benchmark)

Maximum80%

Percentile

AverageUnit*Element

*dry material

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Basic Design of SRF Basic Design of SRF CHPCHP--PlantPlant

HIGH PRESSURESTEAM 42 bar

DELIVERY OFSRF SRF SILO

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FlueFlue--GasGas CleaningCleaning SystemSystem

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Interfaces Interfaces SteamSteam SupplySupply Nehlsen Nehlsen -- PfanniPfanni

PfanniProduction

Bleaching

75 °C

Peeling

Drying

Mashed potatoes

Drying

Boiling

11 bar

Steam

(food processing quality)16 bar

SuperheatedSteam

42 bar

Extraction Steam

16 bar

Steam-to-Steam

generators

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Commissioning ProceduresCommissioning Procedures

4-Apr 12-Apr 16-Apr

1-Feb

4-Apr

7-Jul

5-Jun

21-May

25-Jul

Jan-07

Mar-07

Apr-07

May-07

Jul-07

Aug-07

Sep-07

chec

ksco

ldst

art-u

pw

arm

sta

rt -u

p

test

ing

auto

mat

iccr

ane

star

t fin

al b

low

1st S

RF d

eliv

ery

end fi

nal b

low

furn

ace

igniti

onst

art t

est r

unen

d test

run

scheduled actual

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Performance of the plant during first quarter 2008Performance of the plant during first quarter 2008F

ull

loa

d o

pera

ting h

ours

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ScheduledScheduled and and ActualActual Power Power SupplySupply to EEXto EEX

Fahrplan / Ausspeisung I/2008

0,00

1.000,00

2.000,00

3.000,00

4.000,00

5.000,00

6.000,00

7.000,00

8.000,00

01.

Mrz

02.

Mrz

02.

Mrz

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Mrz

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Mrz

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Mrz

06.

Mrz

07.

Mrz

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Mrz

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Mrz

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Mrz

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Mrz

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Mrz

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Mrz

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Mrz

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Mrz

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Mrz

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Mrz

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Mrz

29.

Mrz

30.

Mrz

31.

Mrz

Datum

kW

h

Messwerte

Fahrplanactual

scheduled

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ProjectProject abstractabstract

waste

water

elect

ricity

heat

cold

heat

stea

m

800,000 liter fuel oil per year

1,000,000 m³ natural gas pro year

1,000,000 kWh electricity per year

CO2 - reduction

4,000 t/a

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⇒ As a result of the good fuel efficiency, the combined

process steam and power generation reduces CO2 emissions

⇒ CO2 saving > 10,000 – 15,000 t/a

⇒ Protection of fossil resources

GHGGHG--EffectsEffects

Supported by the EU promotional

programme:

„EFRE - Europäischer Fonds

für regionale Entwicklung“

Supported by the EU promotional Supported by the EU promotional

programme:programme:

„„EFRE EFRE -- EuropEuropääischerischer FondsFonds

ffüürr regionaleregionale EntwicklungEntwicklung““

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RecentRecent Facts and Facts and FiguresFigures

• In approx. 15.000 operating hours (availability almost 90 %)

since commissioning (end of July 2007)

• 360.000 t steam and 25 GWh electric power have been

delivered

• approx. 27 million m³ natural gas have been substituted

• about 25 non planned shut downs had to be managed

(most of them caused by failures in the supply network)

• first revision showed no problems in the furnace

• waste composition impacts on furnace and boiler

performance

• emissions well below 17. BImSchV (German Immission

Regulation, factor 5 to 10)

• District heating and another client will be supplied with steam

and heat (according to current schedule as of July 2010)

Nehlsen Heizkraftwerke GmbH & Co. KG

Schultetusstraße 43b

17153 Stavenhagen

Tel.: +49-39954-2462-20

Fax: +49-39954-2462-16

[email protected]

www.nehlsen.com

ThanksThanks forfor listeninglistening

Thomas Hegner

Karl-Heinz Plepla

www.nehlsen.com


Nehlsen

WZV

Pfanni

Immergut

WVS

process heating Pfanni

network heating WZV

process heating IG

network heating WVS

600 kW

45 t/h

6 t/h1800 kW

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Typical Annual Performance Heat Supply Typical Annual Performance Heat Supply -- StavenhagenStavenhagen

provision of base load by Nehlsen

5.200 MWh

3.500 MWh 2.300 MWh

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COCO22--balance > balance > IncinerationIncineration of SRF in CHPof SRF in CHP

Pfanni

production

SRF-CHP-plant regional

power grid

200.000 t steam

131.100 MWh/a14.400 MWh/a

power supply367.000 MWh/a

out of 95.000 t/a SRF

10.000 MWh/a

fuel oil

23.500 MWh/a

feed

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SRFSRF--ProductionProduction

Waste

Organic

Fraction (16%)SRF (54%)

Secondary Raw

Material (10%)

MBT

Composting Plastics Glass Metals

Water

(20%)

solid recovered fuels - a sustainable option for spain ...combined heat and power plant stavenhagen...

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