Progress in commercial scale CFB gasification for waste and biomass

Symposium on Renewable Energy and Products from Biomass and Waste CIUDEN (Cubillos de Sil, León, Spain)12-13 May 2015

Juhani Isaksson, Valmet Power

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Valmet CFB Gasification

GeneralWhat kind of gasification we are talking about

Metso International BioenergySeminar Juhani Isaksson4

PRESSURE OXIDISIER PROCESS ASH FUEL SIZE APPLICATION

Atmospheric Air Fixed bed Slagging CoalSMALL0 – 10 MW

Combustionengines

Pressurized Oxygen BFB Non-slagging BiofuelMEDIUM

5-50 MW

Combustible gas for industrial

furnaces

Steam CFB OilLARGE50 -300

MW

Fossil fuel replacement by

bio/waste in power plants

Entrained flow Gas

HUGE 200 -2000

MWIGCC

Transport reactor Waste Transport fuels

Flame gasification Synthetic NG

Valmet CFB gasifier - operating principle

Date Author Title INTERNAL5

2 Center tube3 Gas out5, 5.1 Grid6 Bottom ash removal7, 7.1 Gasification air fan,

air pre-heat

8 Start burner9 Fuel day silo10 Bed material silo11 Circulating bed

TechnologyAbout fuel: Dryness

20 May, 20156

0

2

4

6

8

20 40G

as h

eat v

alue

hot

MJ/

m3n

Fuel Moisture

Gas heat value MJ/m3n hot( incl. sensible heat )

Fuel moisture ( waste ) 20% 30% 40%

Gasifier max output 100 89 77

Waste fuel: HHV dry 22,5 MJ/kg, Ash 7,6% CFB gasifier

Biomass Gasification for Power – Case Vaasa

Biomass gasification in VaasaDrivers for the project

European CO2-emission tradingNational feed-in tariff for power production using forest biomassFossil fuel tax for heat productionMarket and policy trendto decrease the use of coal

Existing high efficiency production unitwas decided to be convertedinto biomass use rather than construct a new one

TargetsReduction of fossil CO2- emissionsCost efficient production of power and heatChange large amount of coal to local biomass fuelMaintain 100 % coal firing possibility

Valmet scope in Vaskiluodon Voima’sgasification project Full scope services with total plant optimization

– Fuel receiving and handling – Drying – Gasification – Boiler modifications – Automation, electrification and instrumentation

Wet biomass

Existing PC boiler

Instrumentation, electrification and automation

Biomass receivingand pre-handling Large-scale belt dryer CFB gasifier

140 MWfuel

Product gas

Dried biomass

First year availability

20 May, 2015 © Valmet | Author / Title10

Fuel handling

Flame detection

Burner impeller damage

Air preheater imbalance

Air damper leakage

Torch test mailfunction

Reasons for unavailability (total 3 %)

90 h30 h

First operational year 2013/2014 availability was 97 %

60 h

20 May, 2015 © Valmet | Author / Title11

200

225

250

275

300

325

350

375

400

425

450

0 % 10 % 20 % 30 % 40 % 50 % 60 %

NO

xm

g/N

m3

6% O

2

Gasifier share of total fuel input

High O2Low O2

Biomass gasification in VaasaOperational experienceNOx content of boiler flue gases

Biomass gasification in VaasaOperational experience

Summary of the operational features and experience- 2 years of commercial operation- The gasifier plant has been easy to operate, responds promptly and

consistently to operational changes- No tar accumulation has been observed- No corrosion so far at the main boiler, monitoring program is ongoing- Gas firing has decreased the NOx content in the boiler flue gas- Decrease of fossil CO2-emissions on a typical year 230 000 t- Safe operation without accidents

Summary – Vaasa biomass gasifier

A major, cost effective power plant fuel conversion from coal to wood biomass

Short implementation time

Existing, pulverised fuel fired boiler was utilised with minimal changes

Thermal integration utilises low temperature heat from the power plant for fuel drying

Up to 40 % fuel to power efficiency for wood biomass in condensing mode

Waste Gasification for Power – Case Lahti

Valmet Waste GasificationKymijärvi II – Process Concept

15

Valmet Waste GasificationKymijärvi II - Project Milestones

16

Environmental Permit 27.4.2007

Building Permit 6.11.2009

Delivery Contract 26.11.2009

First Gasification 15.12.2011

Turbine Synchronization 3.02.2012

Take Over 27.06.2012

Over 18 500 hours of commercial operation.

Valmet Waste Gasification

17

Emisssion Limit Measured

NOx 200 mg/m3n 161 mg/m3n SO2 50 mg/m3n 7 mg/m3n CO 50 mg/m3n < 2 mg/m3n Dust 10 mg/m3n < 2 mg/m3n HCl 10 mg/m3n < 1 mg/m3n HF 1 mg/m3n < 0,5 mg/m3n TOC 10 mg/m3n < 1 mg/m3n PCDD/F compounds

0,1 ng/m3n < 0,002 ng/m3n

Hg 0,05 mg/m3n < 0,0001 mg/m3n Cd+Tl 0,05 mg/m3n < 0,0003 mg/m3n Sb+As+Co+ Cr+Cu+Mn+ Ni+Pb+V

Total 0,5 mg/m3n

< 0,03 mg/m3n

* NOx, SO2, HCl are usually close to limit to minimize the cost of additives

Final emission control: DeNox – catalyst

Sodiumbicarbonate injection

Activated carbon injection

Bag house

Final emission control: DeNox – catalyst

Sodiumbicarbonate injection

Activated carbon injection

Bag house

Emissions at Kymijärvi II Plant

(Guarantee test)

Date Author TitleINTERNAL18

KYMIJÄRVI II Gasification Plant, Environmental Bookkeeping Reports

Kymijärvi II, fuels 2014

REF from household waste 119251 t 463 384 MWhRecyled wood 131505 t 500 131 MWhNG ( Start up/ Back up) 45 591 MWh

__________________________________________________________Total solid fuel 250 756 t 963 515 MWh

Kymijärvi II, Production 2014Electricity 241 GWhDistrict heat 514 GWh

Kymijärvi II, ResiduesGasifier Hot Gas Filter Bag HouseBottom Ash Ash Ash16 200 t 17 292 t 2 376 t

Valmet Waste Gasification

Date Author TitleINTERNAL19

Valmet Waste GasificationKYMIJÄRVI II Gasification Plant, Environmental Bookkeeping Reports

Kymijärvi II, Waste Gasification Plant, Annual Environmental Load to Air

UNIT 2012 2013 2014*

Particles t 0,02 0,03 0,17

Carbon Dioxide (CO2)t 52 505 106 800 84 602

Nitrogen Oxides (NOx/NO2) t 155,3 238,85 364,85

Sulphur Oxides (SOx/SO2) t 31,59 57 85,31

Carbon monoxide (CO)t 0,15 0,15 0,08

Hydrochlorides (HCl)t 3,36 8,5 15,53

Fluor and Inorganic Compounds (HF) kg 260 331,96 417,84

Total Organic Carbon (TOC) t 0,82 0,85 0,75

Arsenic (As) kg 0,87 1,44 2,32

Cadmium (Cd) kg 0 1,33 1,97

Cobalt (Co) kg 0 3,43 3,9

Chromium (Cr) kg 0,87 1,55 1,74

Copper ( Cu) kg 1,73 1,44 1,58

Mercury (Hg) kg 0 0,22 0,25

Manganese (Mn) kg 0,87 0,77 0,84

Nickel (Ni) kg 2,6 0,22 0,24

Lead (Pb) kg 0,87 0,22 0,29

Antimony (Sb) kg 0,87 1,44 1,63

Thallium (Tl) kg 0 0,11 0,12

Vanadium (V) kg 0,87 0,66 0,74

Dioxin and FuranPCDD + PCDF) (TEQ)

g 0 0 0* year 2014 numbers subject to final check for the period of November/December

• As annual average the emissions are 20 -99 % belowthe permit limits.

Corrosion experiences in Kymijärvi II plant

Date Author Title INTERNAL20

Cooler

Temperature low enough to avoid corrosion in cooler

Temperature high enough to avoid clogging

Condensing of corrosive components into dust

Filter

High enough filtration efficiency for corrosive components

Avoid tar condensation

Boiler

No hot corrosion with high steam parameters (540 C 121 bar) found during 3 years of operation.

Valmet Waste Gasification

Gas

ifier

Coo

ler

Date Author Title INTERNAL21

SH III 2011 2012 2013 2014Pos. [mm] [mm] [mm] [mm]

1 5,6 5,5 5,8 5,82 5,4 5,4 5,9 5,93 5,6 5,6 6,1 6,14 5,4 5,4 5,6 5,75 5,7 5,5 5,8 5,96 5,7 5,6 6,2 5,97 5,4 5,4 5,9 5,98 5,6 5,6 6,1 6,29 5,6 5,4 5,8 5,8

10 5,4 5,4 5,8 5,811 5,5 5,5 5,7 5,812 5,6 5,6 6,0 5,913 5,7 5,7 6,1 614 5,8 5,6 6,3 6,115 5,6 5,6 5,9 5,916 5,6 5,5 5,9 617 5,6 5,6 6,2 6,118 5,7 5,7 6,0 6,119 5,5 5,4 6,0 5,820 5,5 5,5 5,9 6

61 5,7 5,7 6,1 6,162 5,6 5,6 5,8 5,863 5,8 5,5 5,6 6,164 5,5 5,6 5,8 5,965 5,6 5,6 5,9 5,966 5,4 5,3 5,8 5,867 5,6 5,6 6,1 668 5,6 5,6 5,9 5,969 5,6 5,5 6,0 5,970 5,4 5,4 5,8 5,671 5,3 5,5 5,9 5,972 5,5 5,6 5,8 5,873 5,6 5,6 5,9 5,974 5,5 5,4 5,8 5,975 5,6 5,5 5,8 5,976 5,5 5,5 5,8 5,777 5,4 5,6 5,8 5,978 5,6 5,7 5,9 5,979 5,7 5,5 5,8 5,980 5,5 5,6 6,0 5,981 5,5 5,5 5,7 5,8

Valmet Waste GasificationCorrosion at Lahti => No Corrosion

Date Author Title INTERNAL22

Valmet Waste GasificationHot gas cleaning in Kymijärvi II

Initially random but frequent filter element failures. Root course was found to be local

overheating (up to 900 C).

Corrected by new shut down / start up procedure.

Slow dp increase in filter over time. Reasons are accumulation of material

on the surface and inside filter media.

Filter recovery system developed and installed in 2013 => complete dprecovery reached.

Lifetime of filter elements At the moment over 50% original filters

still in use.

Replacement cycle 3-5 years

Valmet Waste GasificationKymijärvi II – an Operational Power Plant

20 May 2015 © Valmet | Author / Title23

• Capacity targets demonstrated

• All environmental requirements fullfilled

• Availability targets reached

Co-firing is an efficient way to use biomass or waste

Example:100 MW of fuel available at the district

24

100 MW, fuel Small boiler,efficiency 25 %

25 MW electricity

100 MW, fuel Large boiler,efficiency 40 %

40 MW electricity+ 160 MW coal electricity400 MW coal

The final outcome is 60 % more electricity.

Relatively low investment cost, ca 1/3 of a similar-sized new biomass power plant

An integrated drying process brings flexibility to the fuel range

Full original coal capacity still available,

A reliable way to utilize renewable energy

Short delivery time and minimized interference to ongoing energy production

Why slip steam Gasifier ?

Summary and Outlook

Valmet Power – CFB gasification references

Date Author Title INTERNAL27

[CELLRANGE]Waste

Gasification

[CELLRANGE]Coal

Replacement

[CELLRANGE]Oil Replacement

[CELLRANGE]Oil Replacement

0

100

200

300

400

500

600

700

2012 2013 2016 2017

Start up year

Cap

acity

/ M

W

Cumulative

Valmet CFB Gasification

28

Commercially proven solutions:

Partial or complete fuel change in existing power plants

High efficiency WtE technology for electricity production

Firing of Industrial Process with gasified Biofuels or Waste

Dryer (Titanic)

“We are very pleased about the final results of this project and like to thank all our suppliers for the fine co-operation!” Matti Tiilikka, Vaskiluodon Voima

29Vaskiluodon Voima Oy

Date Author TitleINTERNAL31

KYMIJÄRVI II Gasification Plant, Environmental Bookkeeping Reports

Kymijärvi II, fuels 2014

REF from household waste 119251 t 463 384 MWhRecyled wood 131505 t 500 131 MWhNG ( Start up/ Back up) 45 591 MWh

__________________________________________________________Total solid fuel 250 756 t 963 515 MWh

Kymijärvi II, Production 2014Electricity 241 GWhDistrict heat 514 GWh

Kymijärvi II, ResiduesGasifier Hot Gas Filter Bag HouseBottom Ash Ash Ash16 200 t 17 292 t 2 376 t

Valmet Waste Gasification

Date Author TitleINTERNAL32

Valmet Waste GasificationKYMIJÄRVI II Gasification Plant, Environmental Bookkeeping Reports

Kymijärvi II, Waste Gasification Plant, Annual Environmental Load to Air

UNIT 2012 2013 2014*

Particles t 0,02 0,03 0,17

Carbon Dioxide (CO2)t 52 505 106 800 84 602

Nitrogen Oxides (NOx/NO2) t 155,3 238,85 364,85

Sulphur Oxides (SOx/SO2) t 31,59 57 85,31

Carbon monoxide (CO)t 0,15 0,15 0,08

Hydrochlorides (HCl)t 3,36 8,5 15,53

Fluor and Inorganic Compounds (HF) kg 260 331,96 417,84

Total Organic Carbon (TOC) t 0,82 0,85 0,75

Arsenic (As) kg 0,87 1,44 2,32

Cadmium (Cd) kg 0 1,33 1,97

Cobalt (Co) kg 0 3,43 3,9

Chromium (Cr) kg 0,87 1,55 1,74

Copper ( Cu) kg 1,73 1,44 1,58

Mercury (Hg) kg 0 0,22 0,25

Manganese (Mn) kg 0,87 0,77 0,84

Nickel (Ni) kg 2,6 0,22 0,24

Lead (Pb) kg 0,87 0,22 0,29

Antimony (Sb) kg 0,87 1,44 1,63

Thallium (Tl) kg 0 0,11 0,12

Vanadium (V) kg 0,87 0,66 0,74

Dioxin and FuranPCDD + PCDF) (TEQ)

g 0 0 0* year 2014 numbers subject to final check for the period of November/December

• As annual average the emissions are 20 -99 % belowthe permit limits.

Valmet Waste gasificationA New Option for Co-Firing Co-firing of cleaned gas from waste gasification in existing boiler Hot gas cleanup removes corrosive and harmful compounds from

gas Minimum impact on boiler operation, corrosion, ash quality and

emissions Full capacity on main solid fuel maintained Minimum boiler modifications needed

– only new gas burners

Utilization of existing powerplant infrastructure => Minimum additional Investment

20 May 2015 © Valmet | Author / Title33

Add-on gasifier andhot gas cleanup

Existing utility boiler

DIRECTIVES

Date Author Title INTERNAL34

DIRECTIVE 2010/75/EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 24 November 2010 on industrial emissions (integrated pollution prevention and control)

SPECIAL PROVISIONS FOR WASTE INCINERATION PLANTSAND WASTE CO-INCINERATION PLANTS

Article 42Scope1.

This Chapter shall apply to waste incineration plants and waste co-incineration plants which incinerate or co-incinerate solid or liquid waste.

This Chapter shall not apply to gasification or pyrolysis plants, if the gases resulting from this thermal treatment of waste are purified to such an extent that they are no longer a waste prior to their incineration and they can cause

emissions no higher than those resulting from the burning of natural gas.

What is this in praxis ?