Biomass Combustion
With State Of The Art Bubbling Bed
Steam Generators
Ingo Tschanun
Martin Mineur
Austria
1/20
Options Previous Next
Power-Gen Europe 2003
1. Preamble
Austrian Energy & Environment AG (AE&E) is Austria’s largest systems supplier for thermal
energy production and environmental engineering. AE&E is the concentrate of 150 years in
successful tradition of the two predecessor companies Simmering-Graz-Pauker and Waagner-
Biro. The ATB Beteiligungs GmbH Wien, a holding company of private entrepreneurs, owns
the company.
The Business Unit Biomass, located at Vienna, is the centre of competence for future-oriented
green power solutions in the field of the thermal utilization of renewable fuels by means of
biomass-fired power stations, and has been able to assure a technological top position.
The company was and is a worldwide supplier of fluidised bed technology. The reference list
comprises plants with steam generating capacities from 9 t/h to 290 t/h and a fuel range from
coal, biomass, sludges, RDF to various industrial wastes.
Biomass fuel exists in various forms, traditionally as wood, bark, harvesting residues and
organic waste resulting from agricultural industry. In the new type of biomass the carbon
content for incineration is contained in the so-called “renewable energy sources” – residual
material and residues like industrial waste, tailings, sewage sludge and RDF.
Our main combustion technology for these biomass fuels is the bubbling fluidised bed
combustion named “EcoFluid” with our special design features.
We would like to present some examples of biomass-fired plants with different fuels and
plants under different stages of construction or operation. This will comprise of operating
results, experience made during initial operation, and plants under construction as well as in
start up condition and a preview of market development.
2/20
Options Previous Next
Power-Gen Europe 2003
The plant is approved according to the 17th BImSchV, a very strong German decree for waste
combustion, which sets emission limits as well as operating conditions. The most important
operation conditions that are required are 6% minimum oxygen content in the dry flue gas and
2 seconds residence time above 850°C for the flue gas in the post combustion chamber.
3/20
Options Previous Next
Power-Gen Europe 2003
The air distributor in open design of AE&E enables the drain of bed material with impurities
over the whole bed cross-section during operation.
To keep the bed- and post-combustion chamber temperature with these low heating values in
the required range for the operation conditions, a marked staging of the combustion air is
foreseen. This air staging enables the control of the heat release in a distinct area and sets the
dimensions of the bed and the post combustion chamber.
The customer tightened up the already strong emission limits of the 17th BImSchV decree.
For example, the reference O2-content for the emission limits in the flue gas was lowered
from 11% to 6%. The residence time at 850°C was increased from two to three seconds.
The emission values for CO, NO2 and organic matter have to be obtained with the fluidised
bed combustion without secondary measures.
Plant description
The design figures of the steam generator are listed in the table below:
Live Steam Flow 8,6 t/h
Live Steam Pressure 40 bar
Live Steam Temperature 400°C
Boiler Efficiency (average operation value) 87%
The steam generator is a bottom supported 4-pass type with natural circulation, where three
passes are integrated in the evaporator waterwalls. The fluidised bed is situated in the lower
part of the boiler. Due to erosion protection and thermal reasons, the waterwalls in the
fluidised bed and post-combustion chamber are covered with refractory material. The primary
air enters the bed via the open type air distributor and bubble caps.
The temperature of the fluidised bed is controlled in the range between 750°C and 800°C.
This temperature can be supported with the hot gas generator when the heating value is very
low.
The secondary air is distributed over the cross-section of the post-combustion chamber inlet.
This results in a staged combustion and a temperature increase to 870°C up to 950°C at the
maximum. This temperature can be limited with the installed flue gas recirculation. In the
opposite case, the freeboard burner ensures the minimum temperature of 850°C.
4/20
Options Previous Next
Power-Gen Europe 2003
The third pass contains two superheaters and one evaporator bundle. To avoid high
temperature corrosion, the final superheater is arranged in parallel flow. The fourth pass, built
as carbon steel casing, contains the flue gas air heater and the economizer, which cools the
flue gases down to 180°C.
As the flue gas contains acid gases, the feedwater is preheated to 130°C in a heat exchanger in
the steam drum.
5/20
Options Previous Next
Power-Gen Europe 2003
6/20
Options Previous Next
Power-Gen Europe 2003
Operating Results of the VERA – Plant from the Years 1998 to 2002:
The following charts show the trend of the operation results from the year 1998 to 2002.
The first three diagrams show the development of the fuel input. The amount of sludge was
increasing because the wastewater treatment plant accepted additional foreign sludge and
residues.
The portion of screenings decreased because of optimising the dewatering equipment.
The volume of digester gas increased due to the additional organic residues in the wastewater
treatment plant, improved digesting process and a raised takeover capacity of the VERA
plant.
.
7/20
Options Previous Next
Power-Gen Europe 2003
7.000
120.000
6.000
100.000
Sludge-Quantity [t]
5.000
Screenings [t]
80.000
4.000
60.000
3.000
40.000
2.000
20.000 1.000
0 0
98 99 00 01 02 98 99 00 01 02
The delivered electric power increased according to the chart below because of the raised
amount of sludge and gas. An additional reason is the increase of plant efficiency caused by
other improvements like the lowered oxygen content in the fluidised bed combustion.
35 60.000
Delivered electr. Power [MWh]
30
50.000
Digester Gas [Mio m³]
25
40.000
20
30.000
15
20.000
10
10.000
5
0 0
98 99 00 01 02 98 99 00 01 02
The consumption of utilities for the operation of the fluidised bed could also be lowered in
this operating period.
In a test program the temperature profile in the furnace, that is bed area, freeboard and post
combustion chamber was varied and the NOx emissions were tracked to find the optimal
conditions regarding NOx formation.
These test showed as a result, that temperatures around 900°C in the freeboard and post
combustion chamber in a combination with bed temperatures lower than 800°C showed the
best result in relation to the NOx emissions. These temperatures together with the lowered
excess air (5,5% Oxygen in dry flue gas) leads to average NOx emission values of 30 to
40 mg/sm3. It has to be pointed out, that these results were achieved without employing the
SNCR system.
The flow of the flue gas recirculation takes control of the temperatures above the bed.
8/20
Options Previous Next
Power-Gen Europe 2003
As there is no flue gas recirculation into the fluidising air installed, the control of the bed
temperatures is more complicated. The solution is a combination of a minimum fluidising
airflow, variation of the heating value of the sludge (possible in this special case) and a water
injection into the bed that serves as a temperature limiter.
These measures resulted in a remarkable cutback in the consumption of denoxing agent as
shown in the chart below. Today the SNCR is only in operation during a failure of other
components like e.g. the FGR – fan.
1200 90000
80000
1000
70000
50000
600
40000
400 30000
20000
200
10000
0 0
98 99 00 01 02 98 99 00 01 02
Another result of these improvements is that the make up sand consumption is minimised to
refills after shut downs for revision. At higher temperatures around 900°C the bed material
and the ash tend to build up agglomerations. These agglomerations in a size range up to a fist
had to be drained with the bed material and were separated in a drum screen from the fine bed
material. This leads to a loss of bed material that has to be replaced with make up sand.
The improved bed temperature control avoids this effect. At present, the bed drain is only in
service if the bed pressure increases due to the sand contained in the sludge.
20.000
18.000
16.000
Ash Quantity [t]
14.000
12.000
10.000
8.000
6.000
4.000
2.000
0
98 99 00 01 02
9/20
Options Previous Next
Power-Gen Europe 2003
The avoidance of the adding of make up sand has two positive impacts to the operating cost
of the plant. One is the direct costs for the sand supply and the other one is the reduction of
ash disposal costs for the drained bed material.
The successful combination of a well-designed plant and a highly dedicated operator showed
these remarkable results that will be ended with a chart showing the favourable trend of the
emissions of the plant.
100%
90%
80%
70%
60%
50%
40%
30%
100%
90%
80%
70%
60%
50%
40%
30%
20%
17. BImSchV
10% Operation Licence
Average 1998
0% Average 1999
Average 2000
Hg
HCl Average 2001
HF
PCDD/ Average 2002
PCDF Cd,TI
Sb..Sn
10/20
Options Previous Next
Power-Gen Europe 2003
The plant is approved according to the SEPA (Scottish Environmental Protection Agency), a
special regulation in Scotland, which sets emission limits for renewable fuels.
The emissions relate to 11 % O2 content in dry flue gas and are half hour mean values.
Pollutants according regulations Emission limit
Carbon monoxide CO 200 mg/m3n
Sulphur dioxide SO2 300 mg/m3n
Nitrogen oxides NOx as NO2 300 mg/m3n
Unburned organic carbon Corg 20 mg/m3n
11/20
Options Previous Next
Power-Gen Europe 2003
Dust 25 mg/m3n
Hydro chloride HCl 150 mg/m3n
Dioxins and Furans PCDD/F 0,5 ng/m3n
Unburned matter in bed ash < 5 % (w)
Unburned matter in fly ash < 5 % (w)
The emission values for CO, NO2, SO2, unburned and organic matter have to be obtained
with the fluidised bed combustion.
Plant description
The design figures of the steam generator are listed in the table below:
Live Steam Flow 46,6 t/h
Live Steam Pressure 62 bar
Live Steam Temperature 460°C
Boiler Efficiency (actual average operation value) 89,5%
The steam generator is a bottom supported 4-pass type with natural circulation, where three
passes are integrated in the evaporator waterwalls. The bubbling fluidised bed and the post-
combustion chamber are the first pass. The waterwalls in the fluidised bed and a part of the
post-combustion chamber are covered with refractory material due to erosion protection and
thermal reasons. The second pass is a radiation chamber to cool down the flue gas before
entering the convection surfaces. The third pass contains the superheater bundles.
The fourth pass, built as carbon steel casing, contains the economizer, which cools the flue
gases down to 160°C.
The process characteristics of the EcoFluid bubbling bed are a substoichiometric air supply
through the air distributor to control the bed temperature. A proper designed secondary air
system feeds the balance of the required combustion air above the fluidised bed and results in
a good burnout in the post-combustion chamber. In addition, a flue-gas recirculation system
mixes flue-gas into the post combustion chamber as well as into the primary air. This enables
very good temperature control in the furnace according to legal and process requirements and
leads to lowest emissions.
12/20
Options Previous Next
Power-Gen Europe 2003
The requirements regarding the combustion, at the minimum 850°C for two seconds and a
minimum O2 content of 6% (vol) in the dry flue gas, as well as the ash properties regarding
agglomeration tendencies require these good temperature control possibilities.
The secondary air, which is the bigger part of the combustion air, is taken from the fuel
storage house. This avoids smell harassment in the surrounding area and the contaminated air
is disposed according to the regulations.
Together with the fuel, incombustible parts like stones, glass and metals come as tramp
material to the fluidised bed, where they collect and hinder the fluidization. To prevent this,
an open type air distributor in AE&E – design is built in and the bed material is consciously
drained and cleaned.
Start-up of the plant is carried out with two burners firing fuel oil No.2. They are not used
above minimum load of the boiler.
13/20
Options Previous Next
Power-Gen Europe 2003
As an additional benefit, the owner of the plant has the target to sell the fly ash with its high
content of potassium and phosphor as a fertilizer. For this reason, "impurities" like sand and
Ca(OH)2 from the flue gas cleaning have to be minimized.
A clear evidence of the successful handling of this difficult fuel in the Westfield plant can be
seen in the fact that the same client has chosen AE&E for a follow up contract for a chicken
litter fired power plant in the Netherlands in a consortium with Siemens. This plant will burn
chicken litter with a lower heating value of 6 to 10 MJ/kg. Feathers and meat meal are
optional fuels for mixing.
The generating capacity of the boiler will be 130 t/h with 66 barg and 478°C. The Plant will
deliver 31, 5 MW of green electric power to the grid.
The project will start after reaching the purchase agreement for the electric power and the
financial closing.
15/20
Options Previous Next
Power-Gen Europe 2003
A flue gas air heater for the primary air is installed to minimise the support firing at the very
low heating values. In addition, a natural gas fired hot gas generator is installed to support the
bed temperature if required.
Plant description
The design figures of the steam generator are listed in the table below:
Live Steam Flow 65,0 t/h
Live Steam Pressure 80 bar
Live Steam Temperature 480°C
Boiler Efficiency (average operation value) 87,5%
The steam generator is of the standard EcoFluid design. The final superheater has due to the
high live steam temperature a protection against chlorine corrosion. This protection is a thin
layer of refractory on the five platen - type superheaters in the radiation pass. This protection
is a standard design in municipal waste burning boilers.
16/20
Options Previous Next
Power-Gen Europe 2003
The plant is in final erection status and commissioning will take place in April and May 2003.
17/20
Options Previous Next
Power-Gen Europe 2003
18/20
Options Previous Next
Power-Gen Europe 2003
The emission limits affected by the fluidised bed combustion relate to 11 % O2 content in dry
flue gas and are half hour mean values.
Pollutants according regulations Emission limit
Carbon monoxide CO 50 mg/m3n
Unburned organic carbon Corg 8 mg/m3n
The flue gas cleaning plant has to fulfil very strong emission limits. Therefore, it consists of a
bag filter with hydrated lime and activated carbon injection, 2- stage wet scrubber and a SCR
and is in the scope of AE&E too.
Plant description
The design figures of the steam generator are listed in the table below:
Live Steam Flow operation 25 – 51,7 t/h
Live Steam Pressure 43 barg
Live Steam Temperature 400°C
The steam generator has some special design features. It is a bottom supported 5-pass type
with natural circulation. The evaporator waterwalls contain three passes. The fluidised bed is
in the first pass. The second pass is a radiation chamber to cool down the flue gases before
entering the convection surfaces. At the entrance of the third pass, an evaporator bank serves
as a cooling trap in front of the superheaters. The last superheater in the third pass can be
bypassed on the steam side to keep the required temperatures in the cyclone that is situated
between the third and fourth pass. The cyclone separates fly ash at high temperature to reduce
reformation of dioxins and the portion of contaminated ash.
The fourth and fifth passes are built as carbon steel casing. The fourth pass contains two
superheaters and two economiser bundles. The fifth pass contains three economiser bundles,
which cool the flue gases down to 170°C.
As the fuel preparation and supply is essential for a plant firing this kind of fuel mix, much
attention is given to the design of this part of the plant.
Trucks will dump the already processed fuel into a bunker and a grapple crane will bring it to
a vibrating screen and a shredder. As the fuel preparation and the mixing are essential for
good combustion conditions, the storage bunker is sized for 4 days full load capacity. Another
grapple crane will mix the fuel and supplies it to the metering system for the combustion.
19/20
Options Previous
Power-Gen Europe 2003
7. Market Development
The business unit Biomass concentrates on the projects arising of the EU directives
2000/76/EC Incineration of waste and 2001/77/EC on the promotion of electricity produced
from renewable energy sources in the internal electricity market. These directives result in
various national guidelines creating a market for biomass and waste burning power plants.
With the EcoFluid combustion system, AE&E is well prepared to fulfil the requirements for
these plants in the EC an the candidate countries
20/20