Fluidized Bed Combustion of Biomass and Waste-derived ... · Fluidized Bed Combustion of Biomass...
Transcript of Fluidized Bed Combustion of Biomass and Waste-derived ... · Fluidized Bed Combustion of Biomass...
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Fluidized Bed Combustion of Biomass and Waste-derived Fuels –
Current Status and Challenges
Mikko HupaÅbo Akademi University
Turku, Finland
Waste-To-Energy Research and Technology Council, WTERT 2005 Fall Meeting at Columbia University
New York City, October 20-21, 2005
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Åbo Akademi University
Turku
FINLAND
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Åbo Akademi UniversityProcess Chemistry Centre
- Combustion chemistry- Wood and paper making chemistry- Sensors and process analysis- Kinetics and catalysis
20 faculty and post docs35 ongoing PhD ThesesIntense collaboration with industry
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Fluidized Bed Combustion of Biomass and Waste-derived Fuels –
Current Status and Challenges
• Introduction• Status of the FBC technology• Current research• Fluidized bed gasification• Conclusions
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Bubbling Fluidized Bed Combustion
Air
Air
Fuel
Fuel: Fresh, Partly Pyrolysed, Char
Bed material:Quartz, Limestone; fresh, calcined, sulphated
Void Space
Ash
Flue Gas + Fly Ash
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Circulating Fluidized Bed Combustion
Air
Air
Fuel
Fuel: Fresh, Partly Pyrolysed, Char
Limestone:Fresh, Calcined, Sulphated
Void Space
Ash
Flue Gas + Fly AshCyclone
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Fluidized Bed Combustion Systems
BFBC: Bubbling Fluidized Bed Boilers- fluidization velocity 1-3 m/s- reactive fuels (wood and biomasses)
CFBC: Circulating Fluidized Bed Boilers- fluidization velocity 6-10 m/s- less reactive fuels (coal, oil shale, petroleum coke)
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Fluidized bed boilers – common features
+ low combustion temperature+ flexible to fuel quality and variations+ high combustion efficiency+ low NO+ easy SO2 reduction
- ash components may cause bed sintering- residual ash may be difficult to dispose
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Commercial status
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Number of FB devices worldwide (2004)
0
200
400
600
800
1975 1980 1985 1990 1995 2000Year
Cum
ulat
ive
num
ber CFBC
BFBCPFBCFBG
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Capacity of FB devices worldwide (2004)
0
20 000
40 000
60 000
80 000
1975 1980 1985 1990 1995 2000by year
Cum
ul. c
apac
ity [M
Wth
]
CFBCBFBCPFBCFBG
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
LUVO
Superheatersand reheaters
Boilertubes
Fuelfeed Fu
rnac
eEconomizers
Steamdrum
Airfeed
Cyc
lone
Ashhoppers
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Alholmen CFBCJakobstad, Finland
550 MW (545 C)
Peat, Bark, REF, Forest Residue, Sawdust, Coal, Oil
Boiler Efficiency 92 %
NOx 50 mg/MJ SO2 100 mg/MJParticulate 30 mg/m3n
Kvaerner Power Oy - 2001
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Mälarenergi AB, Västerås
157 MWth
170 bar540 C
wood residuespeatcoal
Foster Wheeler2002
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Capacity of CFBCs worldwide (2005)
0
200
400
600
800
1000
1975 1980 1985 1990 1995 2000 2005 2010Year
Cap
acity
[MW
th]
Duisburg IGermany
Robert son Texas-New Mexico
Gardanne France
Poludniowy Koncern Energet yczny (PKE)Poland
Thermal Power (MWth) of the CFBCs Worldwide
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
• 150 MWth range: 50+ units operating
• 300 MWth range: 10 operating + 10 under construction
• 400 MWth+ range: 100 units commisioned/under constr.
Boilers in by Chinese Companies Zhongyang Luo, Kefa Zen (2005)
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Capacity of FB devices worldwide (2004)
0
20 000
40 000
60 000
80 000
1975 1980 1985 1990 1995 2000by year
Cum
ul. c
apac
ity [M
Wth
]
CFBCBFBCPFBCFBG
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Capacity of FB devices worldwide (2004)
0
40 000
80 000
120 000
160 000
1975 1980 1985 1990 1995 2000by year
Cum
ul. c
apac
ity [M
Wth
]
CFBCBFBCPFBCFBG
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Capacity of FB devices worldwide (2004)
0
40 000
80 000
120 000
160 000
1975 1980 1985 1990 1995 2000by year
Cum
ul. c
apac
ity [M
Wth
]
ChinaCFBCBFBCPFBCFBG
CFBC in China by Chinese companies
(estimate)
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Fuels
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Biofuels – Waste derived fuels –“Opportunity fuels” for FBC?
Forest residuesAnnual cropsPruningsShells, husks & hullsOlive stonesRDF (refuse derived fuels)Waste sludgesMBM (meat and bone meal)Chicken litterCoal SlurryPet coke
Åbo Akademi Fuel Data Bank
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Biofuels – Waste derived fuels –“Opportunity fuels” for FBC?
Forest residues EmissionsAnnual cropsPrunings Bed sinteringShells, husks & hullsOlive stones Fouling & corrosionRDF (refuse derived fuels)Waste sludgesMBM (meat and bone meal)Chicken litter Fuel Mixtures!Coal SlurryPet coke
Åbo Akademi Fuel Data Bank
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Emissions
100 %
100 ppm
1 %
1 ppm
1 ppb (µg/kg)
1 ng/kg
1 pg/kg -15
CO2 Carbon Dioxide
CO Carbon Monoxide / CxHy Hydrocarbons
PAH Polyaromatic Hydrocarbons
As, Cr, Ni, V, Pb, Cd, Hg,... Heavy Metals
Dioxins, Furans
SO2 Sulfur Dioxide / NOx Nitrgen Oxides-5
-10
0
Flue Gas Emission Components
100 %
100 ppm
1 %
1 ppm
1 ppb (µg/kg)
1 ng/kg
1 pg/kg -15
CO2 Carbon Dioxide
CO Carbon Monoxide / CxHy Hydrocarbons
PAH Polyaromatic Hydrocarbons
As, Cr, Ni, V, Pb, Cd, Hg,... Heavy Metals
Dioxins, Furans
SO2 Sulfur Dioxide / NOx Nitrgen Oxides-5
-10
0
Flue Gas Emission Components
Aerosol Aerosol ParticlesParticles
EU Directive on Incineration of Waste Containing Fuels
Acidic Gases• HCl 10 mg/m3n (on-line)• HF 1.0 mg/m3n (on-line)• SO2 50 mg/m3n (on-line)• NOx 200 mg/m3n (on-line)
Dust 10 mg/m3n (on-line)
Metals, ”EDD”• Hg 0.05 mg/m3n (twice a year)• Cd+Tl 0.05 mg/m3n (twice a year)• Sb+As+Co+Cr+
Cu+Pb+Mn+Ni+V 0.5 mg/m3n (twice a year)
(0.05 mg/m3n in flue gases ≈ 0,4 mg/kg dry fuel)
Dioxins and furans 0.1 ng/m3n (measurement twice a year)
Recovered Wood Fuel Metal Contents (ppmw = mg metal/kg fuel)
heavy metals
0.00
50.00
100.00
150.00
200.00
250.00
300.00
350.00
As Cd Co Cr Cu Hg Mn Ni Pb Sb Tl V Zn
mg/
kg fu
el
Rest fraction, analysedLeached in HClLeached in AcetateLeached in H2OUntreated Fuel
corrected value
As Cd Co Cr Cu Hg Mn Ni Pb Sb Tl V Zn
ppmw
300
200
100
0
Fouling and corrosion
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
BFBC for Biomass Fuels
Rice huskEucalyptus bark
Steam temperature for BFBCs worldwide (2005)
100
200
300
400
500
600
700
1975 1980 1985 1990 1995 2000 2005 2010Year
Tem
pera
ture
[°C
]
Ash Elements in Spruce Tissues(J. Werkelin 2005)
Five Spruce Tissues
Wood Bark Twigs Needles Shoots
Ash Elements in Spruce Tissues(J. Werkelin 2005)
Corrosion Test by Alkali Salts
Beforeheat treatment After heat treatment
Prepared for SEM
Corosion Analysis by SEM
450°C500°C
525°C550°C575°C600°C
Salt 0Salt 5
Salt 6Salt 7
Salt 8Salt 9
Salt 10
0
20
40
60
80
100
Cor
rosi
on l
ayer
thic
knes
s m
Steel: ATime: 168 h
Corrosion due to Alkali Salts
120
140
(Skrifvars et al. 2005)
Steel: BTime: 168 h
Corrosion due to Alkali Salts
450°C500°C525°C550°C575°C
600°C
01020304050607080
90100
Cor
rosi
on la
yer t
hikc
ness
m
Salt 5Salt 6
Salt 7Salt 8
Salt 9Salt 10
Salt 0
(Skrifvars et al. 2005)
450°C500°C 525°C550°C575°C 600°C
0102030405060708090
100
Cor
rosi
on la
yer t
hick
ness
μm
Steel: CTime: 168 h
Corrosion due to Alkali Salts
Salt 5Salt 6
Salt 7Salt 8
Salt 9Salt 10
Salt 0
(Skrifvars et al. 2005)
Gasification
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
CFB Gasifier
850 °C
900 °C
BOTTOM ASH COOLING SCREW
HOT LOW CALORIFICGAS (750 - 650 °C)
UNIFLOW CYCLONE
FUEL FEED
REACTOR
BOTTOM ASH
GASIFICATION AIR FAN
COOLING WATER
AIR PREHEATER
RET
UR
N L
EG
Foster Wheeler
BIOMASS GASIFICATION - COAL BOILER - LAHTI PROJECT
Bottomash
Gasifier
Coal
540 蚓 /170 bar
Processing
Biomass
Fly ash
Pulverized coal flames
Gas flame
Natural Gas
50 MW
300 GWh/a -15 % fuel input
1050 GWh/a -50 %
350 MW
650 GWh/a -35 %
Power* 600 GWh/aDistrict Heat* 1000 GWh/a
CO2 Reduction -10 %
Foster Wheeler
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Conclusions (i)
• FBC rapidly expanding – now especially in China
• CFBC - upto 1000 MWth- novel cyclones and superheaters
• BFBC - interesting for reactive fuels
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Conclusions (ii)
• PFBC well demonstrated in 800 MWth class• FB gasifiers promising for producing gas to co-
firing
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Conclusions (iii)
• Waste derived fuels great potential for FBC• Challenge to boiler manufacturers & operators:
– Emission control (heavy metals)– Bed sintering and fouling control– Corrosion control– Multifuel firing and fuel interaction
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi
Aknowledgements
B. Leckner, L-E. Åmand (Chalmers), H. Tran (Toronto)
C. Mueller, R. Backman, B-J. Skrifvars, M. Zevenhoven, P. Yrjas, S. Kallio, P. Kilpinen, J. Konttinen, M. Theis, J. Werkelin (Åbo)
Kvaerner Power, Foster-Wheeler, Vattenfall, Metsä-Botnia, Andritz, International Paper
Tekes, Academy of Finland
WTERT 2005 Fall Meeting at Columbia University, October 20, 2005 Mikko Hupa, Åbo Akademi