Biofuel and Biomass firing

technologies

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DALKIA’s experience: More than 600,000t of biomass
p.a. (More than 80 plants)
North
Zone Europe
Europe duzone
Nord

Estonia :
5 heating plants
North Atlantic 25 MW (th)
ZoneZone 60,000 t of wood

Lithuania :
Atlantique 8 heating plants
100 MW (th)
Nord 250,000 t of wood

Germany
Leinefelde CHP : 2.1 MWe
60,000 t of wood

France : Czech Republic (cofiring)

60 heating
Zone
Olomouc CHP :Pecos
41 MWe
plants Krnoc CHP : 6.3 MWe
150 MW (th) 50,000 t of wood
180,000 t of
wood Pecos Zone

Spain (project) :
San pere : 6 MWe
65,000 t of wood
Chile (project) :
Masisa CHP : 6,5 MWe
180,000 t of wood Brazil (project) :
UTE : 3 x 12 MWe
3 x 160,000 t of wood
South Zone
Zone sud Direction du d é veloppement
Development Zone
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 Part 1

Biomass as Fuel

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 Types of biomass

ƒ Some examples of bio-fuels (2 main categories):

ƒ Wood and waste from wood industry
ƒ Wood chips, Sawdust, Shavings, Barks, Pellets, Logs
ƒ Etc…
ƒ Agricultural products and waste
ƒ Straw
ƒ Seeds
ƒ Hemp
ƒ Fast-growing trees (willows, poplars)
ƒ Grasses
ƒ Etc…
ƒ Co-fired fuels:
ƒ Peat, coal, sludge, etc...
ƒ But also: Straw + wood, etc..

Significant variety and possible combination which

generate for each of them there own technical challenge 4
 The full chain of biomass
Fuel receiving/preparation/storage block diagram

Straw

Bark
Sawdust
Other wood
Industry residue
Forest exploitation
residues
Recycled wood

Logs

Rejected fuel

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Continuous availability of the primary energy.
One example: Straw

ƒ Different kinds: Wheat, barley, rye, rape, etc..

ƒ Rape: High Calcium rate => Limited quantity (ash melting
point)
ƒ Yield per ha: 4.5 to 12 t/ha depending on kind.
ƒ Ratio grain/straw: 0.5 to 1.1 => Various straw yields
ƒ Quantity availability: +/-5% depending on weather
ƒ Logistics:
ƒ Distance of the resources (max 100km), roads, size of
bales, density (100 to 300kg/m3),storage (short
harvesting) , loading lorries, access to field, etc..
ƒ Other markets for the fuel

Critical to anticipate the variability of the resource

and to have a local understanding of it 6
 Additional information required
about the primary energy
ƒ Physical and chemical characteristics
(Using representative samples):
ƒ CV range
ƒ Potential uneven combustion
ƒ Moisture (And CV)
ƒ Overweight fuel handling
ƒ Reduced boiler capacity (=> burn more expensive fuel)
ƒ Reduced efficiency
ƒ Excessive flue gas on flue gas treatment
ƒ Ash content
ƒ Overweight ash removal systems
ƒ Increased costs and wear

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 Additional information required
about the primary energy
ƒ Physical and chemical characteristics
(Using representative samples):
ƒ Temperature of ash fusibility (K, P, Mg) and alkaline
components (K, Na, Ca)
ƒ Bed /gate impact
ƒ Fouling impact
ƒ ESP impact
ƒ Impact of fertiliser, pesticides, salts (Cl, S)...
ƒ High temperature corrosion
ƒ Corrosion if low temperature feedwater/DHN water (<85C)
ƒ Mechanical characteristics:
ƒ The upstream preparation condition
ƒ (Risk of stones (Screws..), metal, plastics (HCl),.., Uniformity,
Seasonality, Storage,..))
ƒ Granulometry
ƒ (Max, min, average)
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Solution: Improve the fuel quality with supplier
 Storage (Long term and on site)

ƒ Risk of fire (Regulations)

ƒ Risk of fermentation (Methanisation)
ƒ Impact LCV and ash content
ƒ Impact of rainfall and wind (dust)
ƒ Undesirable elements (stones, plastics, metal parts,..)
ƒ Quantity
ƒ Tendency to freeze (due to the high moisture content)
ƒ Design of storage (drain, ground quality, walls, fire protection,…)
ƒ On site unloading/loading and boiler feeding:
ƒ Automatic or manual
ƒ Mixing on long term storage (crane, loader, etc…)
ƒ Etc…

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 Storage: Biofuel storages
Biofuel is stored in the plants in open or covered storages. Fuel amount is from
3 to 7 days plant operation.

Straw storage 300 tons

Vibrating bin storages 2x40m3 Wood chips storage 2000 m3
with screw conveyors for 400 with rail-mounted grab and
kW boilers belt conveyor

Wood chip storage with moving floor

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 Fuel handling

Mixing station Milling ice pieces Extraction of metal pieces

ƒ Mixing capability on site

(If various fuels, straw, Crushing screening
moisture..)
ƒ Ice protection
ƒ Metal removal
ƒ Screening
ƒ Large element removal
ƒ Crushing
ƒ ATEX requirements
ƒ Etc…
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 Fuel handling

ƒ Technical recommendations:
ƒ Oversize installations (Crusher (60% of MCR), conveyors (200% of
MCR),….etc…)
ƒ Magnet
ƒ Avoid elbows / steep slopes
ƒ Size front silo for 30-60 min. of boiler operation on MCR (if BFB,
CFB)
ƒ Doors, stairs and platforms for maintenance and supervision.
ƒ Etc..

ƒ Typical cause for unavailability:

ƒ Screw damage =>design, fuel quality, prefer chain conveyors
ƒ Accelerated wear (Chute,..)=> fuel quality, design
ƒ Chain conveyor feeding the boiler => light design, wet fuel
ƒ screw/conveyor for ash => foreign bodies, high ash content
ƒ Vitrification =>low ash melting point, high furnace temp.
ƒ Etc.. 12
 Energy metering for the fuel

ƒ Weight
ƒ LCV
ƒ Ash
ƒ (removed dry/wet, sand input- from bed or fuel, fly ash, bottom
ash, etc…)
ƒ Moisture content
ƒ (conductivity, sampling…)
ƒ Size screening
ƒ Undesirable element (Metal, ice, snow, stones, etc…)
ƒ Etc..
ƒ Can be difficult if:
ƒ Mainly if fuel quality is inconsistent and/or various kind of
fuels are used
ƒ More than one supplier (depending on invoicing method)
ƒ Large plant meaning many samples
ƒ Method of invoicing ( inlet/outlet boiler )?
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 Part 2

Technologies and
compatibility with
Biomass

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 Classification of solid fuels: Biomass is a challenging fuel

35
CONSUMER PDF
PETROLEUM COKE
MIXED PLASTICS
POLYOLEFIN COLORED COLORED
PLASTICS OR PRINTED OR PRINTED CONSUMER PDF
(PE, PP, PC...) PLASTICS, MIXED WOOD AND PLASTICS
CLEAN PLASTICS

Biofuels
BITUMINOUS
COALS RF
20 PELLETS

PDF PDF PLY- CHIP-

LHV, MJ/kg

INDUSTRIAL COMMERCIAL WOOD BOARD PVC

PVC
BROWN
COALS,
LIGNITE
DEMOLITION
10 WOOD BIOMASS WOOD

FIBER RESIDUE RDF

PEAT

BARK
CONSUMER PDF MSW
PAPER AND WOOD

5
0 1 2 5 10
STANDARD
DESIGN NO CHALLENGE SOME CHALLENGES MULTIPLE CHALLENGES

Boiler Designs 15
 Challenging fuels
ƒ Too dusty fuel (sawdust, straw, …)
ƒ Fouling in boiler-house and around fuel handling station; ATEX regulation;
ƒ Risk of fire and explosion (in boiler, ducts and flue gas treatment)
ƒ Incomplete combustion in the furnace (for grates) and of combustion in the
second pass
ƒ colder bed if BFB, CFB
ƒ Too wet fuel
ƒ Tendency to freeze, bridging
ƒ Overload in fuel receiving station, conveyors
ƒ Reduced boiler capacity (fuel volume limited, excessive flue gas temperature,
need top up with expensive fuel..)
ƒ Reduced efficiency (Incomplete combustion with grate or spreader stocker if not
homogenous)
ƒ Too dry fuel
ƒ Hazard of overheatind and damaging grate
ƒ Ash melting /Vitrification:
ƒ Bed and refractory agglomeration
ƒ Sand agglomeration if BFB, CFB
ƒ Recirculation may be needed (to control the oxygen level and regulate the
combustion –BFB)
ƒ Ash content
ƒ Overload fuel removing system 16
ƒ Foreign bodies
 Boiler sizing

ƒ Must run for a minimum of 8000 hours a year

ƒ For economical reasons (high investment)
ƒ Sized on summer needs (DHN) or base load for industry
ƒ Prefer CHP to condensation
ƒ Take into account technical minimum of other boiler(s)
ƒ Availability of the biomass ressource
ƒ Flexibility
ƒ No peak lopping or fast response time capability
ƒ High inertia ( up to 30% for grate, spreader stoker boilers)
ƒ Time needed for start and stop depend on size and technology (esp. if sand bed)
ƒ Minimum load
ƒ Depends on boiler size, technology and fuel. (Varies from 30 to 60%)
ƒ But Steam parameters may change below a certain point (e.g:70%)
ƒ Can be multi-fuel boiler
ƒ To secure the fuel supply
ƒ Fossil fuel needed for BFB /CFB
ƒ Compatibility with fuel
ƒ The smaller boilers are adapted for higher fuel quality (dry wood logs, pellets, wood
chips)
ƒ Heat or power generation
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 Combustion technology

ƒ Fixed or moving grate

ƒ Spreader stoker
ƒ Fluidised bed (BFB, CFB) (> 15/20MW)
ƒ Cigar burners (10 /30 MW)
ƒ Gasification.

ƒ Mix (examples):
ƒ Straw with cigar + grate for wood (up to 100%)
ƒ Straw for grate + spreader for wood (up to 50%)
ƒ Sludge injection in chute of grate boiler
ƒ Etc..

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 Combustion technology : Grate/ BFB -CFB /Cigar

Moving/fixed grates Rotating grate with Volcan furnace

Cigar burner and grate with straw disintegrator

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 Combustion technologies
Comparison of existing systems
BFB or CFB Mobile grid Burner
with placed feed Spreader stoker

Fuel flexibility +++ ++ +

Fuel granulometry o ++ +

Efficiency ++ o +

Auxiliary electrical consumption - + +

Ash & residues + - o

Reactives / Sand +/- -/+ -/+

Emissions (CO / NOx) -/+ o/- +/o

Load follow-up ++ - ++

Price - + + 20
 Boilers 40-400 kWth.
Wood logs boilers
Wood logs boilers

Upside down flame (“gasifier effect ”)

Pellets or chips boilers

Mobile grate Under feed stoker

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 400 kWth biomass boiler-house

Gas extraction
Screw
boiler conveyor
Multicyclone

Feed hopper
Flying ash Bottom ash removal Screw feeder to boiler’s
collector combustion chamber
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Combustion technology : Size of boilers

Range of use Capacity Type of boilers

Domestic boilers 15-40 kW th ƒThermal-fireplaces

ƒWood thermal-stoves
ƒWood boilers
ƒPellets boilers
ƒUpside down flame (gasified effect)

Boilers for big houses 40-400 kW th ƒUpside down flame (gasified effect)
ƒFixed grate
ƒUnder feed stoker fireplace (hearth)
ƒPellets boilers

District heating boilers 0,4 – 20 MW th ƒMoving grate

ƒSpreader stoker
ƒBubbling fluidised bed (>15MW)
ƒCigar (>10MW)
Industrial boilers for power and/or 1-80 MW th ƒMoving grate
heat production ƒSpreader stoker
ƒCigar (<30MW)
ƒBubbling fluidised bed (BFB)
ƒCirculate fluidised bed (CFB)
ƒGasification

Industrial boilers for power and/or 80-300 MW th ƒBubbling fluidised bed (BFB)
heat production ƒCirculating fluidised bed (CFB)

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 Efficiency depends on

ƒ Load
ƒ Boiler size
ƒ Fuel (Moisture: +10% => About -1% efficiency)
ƒ Technology and manufacturer
ƒ Method of calculation (through fuel or losses)
ƒ Scope (deaerator, blowdown, etc…)

ƒ Power consumption:
ƒ For grate, spreader stokers technologies:
15-25 kWe/MWth (pumps, FD, ID, ESP, fuel handling )
ƒ For BFB, CFB technologies:
25-35 kWe/MWth (air booster, flue gas recycling etc.
ƒ NB: Traditional gas boiler house: About 10 kWe/MWth

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 Heat and Power generation

ƒ Hot water and process Steam

ƒ Pressure depends on the application (DHN, etc..)
ƒ No specific problem with P&T

ƒ Steam parameters for power generation

ƒ according to the turbine characteristics and the outlet levels for the
customer process
ƒ To risk of fouling (ash melting point)
ƒ To risk of corrosion
ƒ Typical parameters:
ƒ Plant < 16 MWt P = 24-45 bara; T=350-440°C
ƒ Plant between 15 and 70 MW P = 40/65 bara ; T = 420- 540 °C
ƒ Plant > 70 MW : P = 90 bara ; T : 540 °C
ƒ With Straw, parameters can reach 90bar/540C or 200bar/560C
ƒ CHP or condensation mode
ƒ Stability of parameters for ST

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 Greenfield or retrofit ?

ƒ A retrofit can half the investment cost

ƒ Risk of the lifecycle of the remaining parts
ƒ Difficult interface with existing plant during construction
ƒ There may not be enough space
ƒ From coal or other boilers
ƒ Requires experienced boiler manufacturer
ƒ A Greenfield
ƒ Guarantees latest technology for all plant
ƒ Dedicated plant

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 Fuel drying

ƒ Drum dryer or Mat dryer

ƒ Often quite problematic=>Not recommended in general
ƒ Operational issues
ƒ Space required with flue gas temperature >170C
ƒ Displace useful heat (>140C required) if steam or hot water is
used.
ƒ NB: Technologies in appendix

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 Availability

ƒ BFB or CFB:
ƒ 8200 hours p.a.

ƒ Grate
ƒ 8050 hours p.a

ƒ NB:
ƒ Depends on reliability, easy access for maintenance,..
ƒ Reduced availability on the first year
ƒ 12 or 24 months availability guaranteed

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 Investment and O&M

ƒ Investment:
ƒ Technologies
ƒ Steam parameters
ƒ Level of manning and automation
ƒ Turnkey or EPCM
ƒ Market (Appetite of suppliers, steel,..)

ƒ Operation
ƒ Design and technologies

Depends a lot on fuel, technology and contractual risk organisation

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 Ash: A critical issue

ƒ Typical ash content (On dry)

ƒ 3% wood, 8% bark, etc…
ƒ Technologies:
ƒ Multi-cyclone (<4 MW) ,
ƒ ESP (except agriculture biomass),
ƒ bag filters (Risk: CaO + H2O).
ƒ Ash from
ƒ Bottom ash, Second pass ash and fly ash
ƒ 70/30% depending on technology
ƒ 10% unburned
ƒ Good design of ash removal systems is key for reliable operation
ƒ (hoppers, screws, cooling system, screening, Containers, silos)
ƒ Prefer recycling to landfill
ƒ Classified as non-hazardous waste
ƒ But as waste….
ƒ Certification + (N+P2O5+K2O )<7% for fertilizer

ƒ Cost issue
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 Conclusion: Biomass projects are good and worth
doing with:

ƒ “Local” source of fuel

ƒ Close partnership with supplier(s)

ƒ good understanding of the fuel supply chain for design and operation

ƒ Appropriateness of fuel/technology:
ƒ Biomass is not “exact science” nor perfect
ƒ (stones, metal, CV, ash, moisture,…)
ƒ Design based on good knowledge of the real fuel quality
ƒ Success can be ensured by operationally experienced parties for the
design and the operation of a plant using:
ƒ technologies and design of plant which are reliable, mature and easy
to O&M
ƒ compatible with the fuel
ƒ compatible with the energy demand

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