WasteBoostTM

Superheating Supplied by Gasification

Ole Hedegaard MadsenDirector Technology & Marketing

ohm@volund.dk

Agenda

Introduction

Proven technology – but still improving!

Reno NordReno Nord – super thermal efficiency

Gasification

Harboøre Plant

WasteBoost™

External steam superheater

FTG Gärstad, Sweden – a case story

What is on the horizon

Modern combustion systems = Waste Fired Power Plants

Water cooled combustion grates

Water cooled wear zone and sealing

New furnace development

CFD advanced design tool for calculating heat and mass transfer

Optimizing secondary and over fire air systems

Waste fired boilers – corrosion!

Protect you investment = Inconel®

ACC advanced combustion control systems

Get the highest electrical out put

Proven technology – but still improving!

Waste Fired Power Plants

High Energy Efficiency

el = 27 %

Th = 97 %

Modern Design

RenoReno Nord Nord

Limitation of Electrical Efficiency

Electrical Efficiency:Temperatures

Excess Air

Steam Data

Corrosion caused by:Increasing:

Steam temperature.

Flue gas temperature.

Particle impact.

High velocity.

500600700800900100011001200

Flue Gas Temperature [°C]

250

300

350

400

450

500

550

600

Meta

l Tem

pera

tu

High Corrosion Area

Low Corrosion Area

Fin centre tempeature

WasteBoost™ - superheating of the steam parameters

with a VølundSystems™ biomass gasifier.

Gasification principles

Numerous concepts!

Few of these tested in pilot or full scale!

Few of these with a decent log of operating hours!

Few of these with power production!

Babcock & Wilcox Vølund = Harboøre CHP

Up-draft gasification

• A new technology based on an old

concept

• A B&W Vølund research area

since 1988

• Licensed to:

• JFE Engineering Corp. - Japan

• RELAX Umwelttechnik -

Germany

Product gas

Drying

Pyrolysis

Reduction

Oxidation

Ash Steam/Air

Fuel

The Harboøre CHP plant

• First of a kind – focus on having

the overall concept working –

not optimization of the

performance

• Fuel: Woodchips. Moisture

content: 35-55 %

• 3.5 MWfuel / 1 MWe

• Commissioned in 1996

• Originally designed for district

heating

• CHP capability added in 2000

Gasifier

Stack

Wood-

chips

Air Ash

Flue gas

Gas fired Boiler Scrubber

Tar storage

Gascooler/

Cleaner

Gas engines

Tarwatc

WaterTar in Raw gas:

Tar: 40 - 100 g/Nm3dry

Light tar: 70-100 g/Nm3dry

Tar in cleaned gas:

Tar (condensable): < 2 mg/Nm3dry

Gasifier

Gascooler/

Cleaner

Gas engines

Gas fired Boiler Scrubber

Tar storage Tar fired Boiler

Tarwatc

Stack

Wood-

chips

Air Ash

Flue gas

WaterProductgas 2003:

Hh 6.5-7 MJ/Nm3dry

18-19 % H2

27-30 % CO

7-10 % CO2

3-5 % CH4

< 0.5 % O2

Gasifier

Gascooler/

Cleaner

Gas engines

Gas fired Boiler Scrubber

Tarwatc

Stack

Wood-

chips

Air Ash

Flue gas

Water

Wastewater as condensate without

additional treatment:

0.1-0.2 m3/h

pH 5-7

COD 10 - 100 mg O2/l

Ntotal 1 - 100 mg/l

Acetic acid 1 - 15 mg/l

Water

Thermal treatment of waste water

contaminated with organics.

Gasifier

Gascooler/

Cleaner

Gas engines

Gas fired Boiler Scrubber

Tar storage Tar fired Boiler

Tarwatc

Stack

Wood-

chips

Air Ash

Flue gas

Water

Tar:28-30 MJ/kg

Gasifier

Gascooler/

Cleaner

Gas engines

Gas fired Boiler Scrubber

Tar storage Tar fired Boiler

Tarwatc

Stack

Wood-

chips

Air Ash

Flue gas

Water

Ash

Ash:1 % (w/wdry)

TOC: 0.1 – 1.0 %dry

PAH: < 0.5 mg/kgdry

Dioxin: below detection limit

WasteBoost™ = High Electrical Production

Tin = 400°C 752 F

Tout = 520°C 968 F

Basic principle

Gasification

Syn gas

HF Oil = tar

Waste Wood

Excellent ash

Syn gas

External Super

Heating

No risk of corrosion

Integrated system

Incineration of Tar

Water

The principle

The Waste Fired Power Plant Gärstad, Sweden

The Waste Fired Power Plant Gärstad, Sweden

External

Super

Heater

Condenser

(optional)

WoodchipsMoist 45 %

Hn 9,15 MJ/kgwet

Flow 7500 kg/h

LHV 19,1 MW

Air

3300 Nm3w/h

25 °C

Ash

42 kgdry/h

Flue gas

Flow 38000

Nm3/h

O2 6,4 %wet

Airpre-

heater

Air

27700 Nm3/h

120 °C

Water

800 kg/h

Steam out

430 °C and 17 Bar

Enthalpy 108 MW

Moist air

120 °C

4300 Nm3wet

0,71 MWTemp. 75°C

Gas flow 7050 Nm3dry/h

Heavy tar 400 kg/h

Light tar 410 kg/h

Particles 1-2 g/Nm3

LHV 19,7 MW

250°C

1,12 MW

Steam in

210 °C and 19 Bar

Enthalpy 91 MW

117 ton/h = 32,5 kg/s

3,7 MW

180°C

50°C

16.9 MW

External

Super

Heater

Condenser

(optional)

WoodchipsMoist 45 %

Hn 9,15 MJ/kgwet

Flow 9000 kg/h

LHV 22,9 MW

Air

3940 Nm3w/h

25 °C

Ash

50 kgdry/h

Flue gas

Flow 34200

Nm3/h

O2 6,4 %wet

Air

preheater

Air

27700 Nm3/h

120 °C

Water

800 kg/h

Moist air

120 °C

5100 Nm3wet

0,77 MW

1,12 MW

3,7 MW

50°C

16.9 MW

Steam out

430 °C and 17 Bar

Enthalpy 108 MW

Steam in

210 °C and 19 Bar

Enthalpy 91 MW

117 ton/h

Gas

Cooler

75°C

33°C

Light tar 520 kg/h

Water 2700 kg/hHn 0 MJ/kg

Flue gas +9000 Nm3/hwet

2,3 MW

Tar 200 kg/h

Hn 28,3 MJ/kg

LHV 1,6 MW

External

Super

Heater

Condenser

(optional)

WoodchipsMoist 45 %

Hn 9,15 MJ/kgwet

Flow 9000 kg/h

LHV 22,9 MW

Air

3940 Nm3w/h

25 °C

Ash

50 kgdry/h

Flue gas

Flow 34200

Nm3/h

O2 6,4 %wet

Air

preheater

Air

27700 Nm3/h

120 °C

Water

800 kg/h

Moist air

120 °C

5100 Nm3wet

0,77 MW

1,12 MW

3,7 MW

50°C

16.9 MW

Steam out

430 °C and 17 Bar

Enthalpy 108 MW

Steam in

210 °C and 19 Bar

Enthalpy 91 MW

117 ton/h

Gas

Cooler

75°C

33°C

Light tar 520 kg/h

Water 2700 kg/hHn 0 MJ/kg

Flue gas +9000 Nm3/hwet

2,3 MW

Tar 200 kg/h

Hn 28,3 MJ/kg

LHV 1,6 MW

Tar is proven as substitute for heavy fuel oil

200 kg Tar per hour results in:

1400 tonnes per year (7000 hour/year)

40 000 GJ per year

1 000 tonnes heavy fuel oil (40 MJ/kg) per year

saving 5 mill. SEK (5 SEK/kg heavy fuel oil)

additional fuel 4.2 mill. SEK (400 SEK/tonnes wood

chips)

Utilization of Tar

Potential Opportunities

Gasifier operating 7000 hours per year

Electricity 20 MW 140.000 MWh

Heat 72 MW 500.000 MWh

Tar (Heavy Fuel Oil substitute ) 200 kg/h 1000 ton

Advantages WasteBoost™

Multi Fuel = Flexibility

Wood chips

Waste wood

Others ?

External Gas Fired super heater

No corrosion – High temperatures

No ash mixing

Gasification Reactor

Rapid control of production

Bio oil = 15 % of Qin

Cost effectiveSmall foot print

Simple system

Easy integration

Applications

Conventional CHP plant

Small plant with high electrical efficiency

External super heater for W-t-E

WasteBoost™

Co-firing Systems for PC Power Plants

No ash mixing

Utilization of heavy tar

Bio oil

Production of hydrogen

Fuel cells