Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A · DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Your partner for
steam power -
Burmeister & Wain Energy A/S
Presentation of BWE
Utilisation of Multi fuel boilers for
enhancement of energy efficiency
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Company founded in 1843
• First steam boiler supplied in 1852
• First Benson once-through boiler in 1952
• World record - above 47% in efficiency for a coal
fired utility boiler in 1999
• Contract for Porto Tolle 3x660 MW USC
History of BWE
• Part of Lentjes Group in 1980
• Part of Deutsche Babcock in 1991
• Part of FLS Miljø in 1997
• Part of the Italian STF S.p.A. Group in 2002
• BWE India founded in 2009
Recent History
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
STF Headquarter
and workshop
TOTAL AREA: 160,000 m2
MANUFACTURING AREA: 32,000 m2
Magenta - Milan
ITALY
ENERGY INDIA
Chennai
INDIA
Lyngby
DENMARK
BURMEISTER & WAIN ENERGY A/S
Company structure
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
BWE Staff
Total number of employees: 137 persons
• 85% of the total staff are engineers or technicians
• 61% of the total staff holds a degree in engineering
14.0%
6.5%
8.5%
49.0%
22.0%
Administration
Sales
Operation
Engineering
Service
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Advanced Ultra Super Critical steam boilers
• Grate fired biomass boilers
• Pulverized biomass fired boilers
• SCR – Selective Catalyst Reactors (deNOx)
• Low-NOx firing systems and circular burners
• Regenerative Air Heaters and Gas-Gas Heaters
• Critical piping
• Erection and commissioning
• Upgrading of existing boilers to improved
performance
• Boiler service
• Training
BWE – Products and services
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Heat Recovery Steam Generators:
• Horizontal gas flow arrangement
• Natural & forced circulation
• Benson Once-through
• Industrial Boilers:
• Package type
• Steam drum type
• Heat Transfer Products:
• Water steam condensers
• Feed water heaters
• Heat exchangers
STF - Products
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
BWE Energy India
BWE Energy India started operating in October 2009
and covers the fast growing South Asian market.
The office is located in Chennai -
one of the largest engineering hubs in India.
BWE Energy India takes care of:
• Sales and operation of BWE and STF products
• Procurement and sourcing of materials and
engineering services within the area Chennai
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Net efficiency above 47% on coal
• Fuel flexible - coal, HFO, NG, Orimulsion, peat and
wood dust
• Pressure ~ 280 to 320 bars
• Temperature ~ 580 to 620 °C
• Single or double reheat
• Excellent performance and reliability record
• Three USC units in operation until now:
NVV3 415 MWe (coal)
SVS3 415 MWe (NG)
AVV2 415 MWe (NG/HFO/wood dust/coal)
Clean Coal Technology
Ultra Super Critical Boilers
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Increasing Plant Efficiency
• Increasing steam parameters 250-300 bar, 600/610 °C
• Reducing pressure loss of the water/steam cycle
- valves wide open – sliding pressure
- proper design of the boiler
- reduced length of steam lines to turbine
• Reducing auxiliary power consumption
by variable speed drives (VSD)
• Increasing boiler efficiency
1950 19701960 19901980 20202000 2010
30
32
34
36
38
40
42
44
46
48
52
50
54
56
58
60
%
Net Efficiency (LHV)
Commissioning Year
Esbjerg 3Nordjyllandsværket
Avedøre 2
Fynsv. 7
“250 MW”
Studstrup 3/4Ensted 3
Line of Steel
Line of Super Alloys
Evolution of Danish Utility Plants
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
1950 19701960 19901980 20202000 2010
30
32
34
36
38
40
42
44
46
48
52
50
54
56
58
60
%
Net Efficiency (LHV)
Commissioning Year
Esbjerg 3Nordjyllandsværket
Avedøre 2
Fynsv. 7
“250 MW”
Studstrup 3/4Ensted 3
Line of Steel
Line of Super Alloys
Efficiency Increase in Denmark
Efficiency
future > 700 C
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Increasing Boiler Efficiency
• Reducing flue gas exit temperature (115°C) by
means of an effective air preheater and basket
design
• Reducing Unburned Carbon (UBC) in the fly
ash by effective and improved combustion
(<4%)
• Reducing air excess and thereby obtaining a
reduced flue gas loss (λ=1.15 using T-firing)
• Reducing air preheater leakage (<6%) by
means of improved sealing system, single train
and quad sector design.
• Reducing APH bypass by increasing mill outlet
temp. (90 - 110 °C) and low air/coal ratio 1.65
kg/kg).
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Mono components / single train based on:
• One FD-fan axial single stage blade control
• One PA-fan radial incl. VSD
• One air heater (two drives)
• One FGR-fan radial (optional) incl. VSD
• One ID-fan axial blade control (radial fans
for high ash coals)
Proven high availability
Reduced duct work and flue gas exposed dampers
Reduced pressure loss flue gas side
Reduced cost
Single train – mono component design
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Single train – mono component design
• Air – fuel control for individual burners
• No damper in main flue gas path
• One mill each burner level
Air and flue gas system
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Improved APH design
Single train – mono components
• Reduced leakage
Quad sector
• Reduced leakage PA sector in between SA
sectors
Improved sealing system
• Reduced leakage
Improved basket design
• Reduced pressure loss
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Combustion and furnace
Air stagging
- Burner PA (primary air)
- Burner SA (secondary air)
- Burner TA (tertiary air)
- OBA (over burner air)
- OFA (over fire air)
T-firing no CO corrosion
Uniform heat absorption
Air excess down to λ=1.15 (increase of boiler efficiency)
Residence time 1.6 – 2 sec. before screen
Furnace exit temperature 1250 C
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Fuel flexibility
• In addition to the increase of efficiency, the Danish power industry had to
face the issues related to fuel flexibility
• The energy model of Denmark had to adapt to the primary energy market in
order to:
– Be independent from large sources of primary energy that may “capture” the
power industry
– Adapt to new possibility of sources of cheap primary energy
– Follow the trend of demand for cleaner technology and renewable energy
– Be load flexible in order to maximise the use of wind energy
– Combine all the above points
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Fuel flexibility
Be independent from large sources of primary energy that may
“capture” the power industry
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Fuel flexibility
Adapt to new possibility of sources of cheap primary energy
Avedøre Power
Station Unit 2
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Fuel flexibility
Follow the trend of demand for cleaner technology and renewable
energy
Avedøre Power
Station Unit 2
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
0
50
100
150
200
1994 '00 '05 '09
Coal Oil Natural Gas Wind Power Other
PJ
Electricity Production by Fuel in DK
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Composition of Fuels in
District Heating Production
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
0%
10%
20%
30%
40%
50%
60%
1980 '85 '90 '95 '00 '05 '09
Oil Natural Gas Renewable Energy and Waste
Fuels Other than Coal
in Electricity Production
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Unit 3: Clean Coal Technology
Nordjylland Power Station
More than 50,000 h of operational hours have
proven:
• Plant efficiency >47%
• High Availability
• Double reheat
Year Availability *
2004 93.7%
2005 95.7%
2006 88.0%
2007 99.5%
* Calculated without planned maintenance
Plant owner: Vattenfall
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Avedøre Power Station Unit 2
BWE Solutions for co-firing
Co-firing into an existing power station
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Avedøre II (2001)
Client: DONG Energy A/S (Denmark)
CHP - 485 MWe & 545 MJ/s heat (1067 t/h steam)
Tangential firing
USC Tower boiler
HP 305 bar & 582 C
Avedøre II (2001) / DONG Energy A/S
CHP / 485 MWe & 545 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Multi fuel concept
• Avedøre Power Station unit 2
design:
• 100% on coal
• 100% on natural gas
• 100% on heavy fuel oil (HFO)
• 70% on biomass (wood pellets)
• USC combined with
2 x 50MW gas turbine
Increased output 150MWe
Total plant efficiency 51%
HRSG FW-preheater
Bio
Boiler
(straw)
USC
boiler
(gas/oil/
wood)
Gas-turbine
Steam turbine
Plant concept by DONG Energy, visited by delegations during COP15
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Multi-fuel unit:
• 800 MJ/s USC boiler supplied by BWE for gas, oil, coal or wood pellets (70%)
• 105 MJ/s straw-fired biomass boiler
• 2*50 MWe gas turbines
• Connected to the Copenhagen area district heating system
• 570 MWe for power
• 545 MJ/s & 485 MWe
Avedøre II (2001) / DONG Energy A/S
CHP / 485 MWe & 545 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Avedøre II: Combustion system
Air staging:
• Burner PA (primary air)
• Burner SA (secondary air)
• Burner TA (tertiary air)
• OBA (over burner air)
• OFA (over fire air)
Wood pellets:
• Mill air/wood ratio: 2 kg/kg
• Mill inlet temperature: approx . 60oC
Avedøre II (2001) / DONG Energy A/S
CHP / 485 MWe & 545 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Wood pellet mill – a modified coal mill
Capacity 45 – 50 t/h
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Originally commissioned on gas/oil in 2001
• Burners converted (2003):
• Gas/Oil/Coal => Gas/Oil/Wood/Coal pellets
• The wood pellets are pulverized in traditional roller mills
• 3 of 4 burner levels (12 of 16 BWE burners) can burn 100% wood
(70% of heat input)
• The 4th level can only burn oil/gas/coal
• The thermal input is up to 560 MJ/s on wood – equivalent to approx. 250 MWe
resulting from biomass (reduction of efficiency of approx. 2%)
• Efficiency on gas only, approx 49%
• Expected efficiency on coal only, 47%
• Efficiency on gas/biomass approx 45%
Avedøre II (2001) / DONG Energy A/S
CHP / 485 MWe & 545 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Work to be performed (in a coal fired power plant) for co-firing:
• Burners change or adaptation
• Possible new gravimetric feeders
• Primary air system modification (increase of cold primary air flow)
• Set up of mills and classifier
• Modification in bunkers’ feeding system
• Investment level equivalent to:
- 20-25 K Euro/MWe (without changing the mills)
- 60-70 K Euro/MWe (in case of mill change)
• Plant shutdown period: approx. 3 months (with burner change)
Avedøre II (2001) / DONG Energy A/S
CHP / 485 MWe & 545 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Operation issues:
• Unattached flames
• Uneven PF distribution out of mill
• Back fire (due to blocking in PF pipes)
Solutions:
• Modified mill operation (classifier speed, air/wood ratio)
• Unattached flames accepted (possible with T-firing)
• Adjusted pressure loss in PF piping (built in orifices)
Avedøre II: Biomass combustion
Avedøre II (2001) / DONG Energy A/S
CHP / 485 MWe & 545 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• 8 years of successful operation with biomass firing
• In 2010 the consumption of wood pellets was 642,000 tons
• This is equivalent to 50% of the total fuel consumption at full load
• The corresponding CO2 reduction is approx. 950,000 tons
Avedøre II (2001) / DONG Energy A/S
CHP / 485 MWe & 545 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Herning Power Station
BWE Solutions for co-firing
Repowering of an existing power station
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Herning Power Station (1982)
Client: DONG Energy A/S (Denmark)
CHP - 89 MWe & 174 MJ/s heat
425 t/h of steam (equivalent to
approx 125 MWe in case of full electricity
conversion)
Wall firing & bottom grate
Drum boiler – 115 bar & 525 C
Herning Power Station(1982) / DONG Energy A/S
CHP / 89 MWe & 174 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Herning Power Station (1982) / DONG Energy A/S
CHP / 89 MWe & 174 MJ/s heat
• Original boiler supply and upgrades by BWE
• 1982: Original boiler supply
• 2000: Coal/Oil => Gas/Oil
• 2002: Gas/Oil => Wood chips/Gas/Oil
• 2009: Wood chips/Gas/Oil =>
Wood chips/Wood pellets/Gas/Oil
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Herning Power station (1982) / DONG Energy A/S
CHP / 89 MWe & 174 MJ/s heat
1982 Coal/Oil 2002 Biomass/Gas/Oil
2009 Biomass
2000 Gas/Oil
4 x 2 coal/oil burners
The original boiler design
was operated for 20 years
4 x 2 gas/oil burners
The first retrofit included 8
new WR oil and gas
burners
3 x 2 gas/oil burners
The retrofit enables about
45% load on biomass
1 x 2 gas/oil burners
2 x 2 gas/oil/wood dust burners
1 x vibration grate for wood
chips
biomass load up to 90%
1 x vibration grate for wood
chips
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Biomass conversion 1:
Cut of boiler bottom and installation of a grate
Result: Low NOx emission and reduced CO2 emission
• Biomass conversion 2:
Replace gas/oil burners with PF burners for wood pellets
Result: Lower NOx emission and no CO2 emission
• Investment level (phase 1 + 2) (170-190 K Eur/MWe)
• Approx. schedule project 6 months (downtime – phase 1+2 )
Herning Power Station (1982) / DONG Energy A/S
CHP / 89 MWe & 174 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• 9 years of successful operation with biomass firing
• The annual consumption of wood chips is approx. 280-290,000 tons
• This was equivalent to 70% of the total fuel consumption
• Now the capability is 100% of the fuel consumption
• The CO2 reduction is 325,000 at 100% load compared to 100% at coal firing
• CO emission < 200 mg/Nm³ (dry, 6% H2O)
• NOx emission < 300 mg/Nm³ (dry, 6% H2O)
Herning Power Station (1982) / DONG Energy A/S
CHP / 89 MWe & 174 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Combined grate and PF fired utility boiler
Heat input:
• Grate wood chips (45% moisture) 130 MJ/s
• PF wood pellets 125 MJ/s
• Natural gas 288 MJ/s (100% load)
Herning Power Station (1982) / DONG Energy A/S
CHP / 89 MWe & 174 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
PF combustion system
Herning Power Station (1982) / DONG Energy A/S
CHP / 89 MWe & 174 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Commissioning
Operation issues:
• Unattached flames
• Lack of flame signal
• High flue gas temperature (after APH)
Solutions:
• Modified biomass feeding system
• Change of trip criteria (burner trip)
• Possible modification of boiler to reduce flue gas temperature (not
decided)
Herning Power Station (1982) / DONG Energy A/S
CHP / 89 MWe & 174 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Amager Power Station Unit 1
BWE Solutions for co-firing
New build for multi-fuel
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
HP2
Screen
RH2
HP1.3 HP1.2
HP1.1
ECO2
ECO1
3 mills
OFA OFA
OFA
ESP
FD
APH
4 x 3
burners
deSOx
deNOx
RH1.2
RH1.1
PA
fans
Amager I (2009)
Client: Vattenfall A/S (Denmark)
CHP - 71 MWe & 250 MJ/s heat (500 t/h
steam ≈ equivalent to 150 MWe)
Front-wall fired
Fitted into existing building
HP part 185 bar & 540 C
PA
cooler
HP2
Screen
RH2
HP1.3 HP1.2
HP1.1
ECO2
ECO1
3 mills
OFA OFA
OFA
ESP
FD
APH
4 x 3
burners
deSOx
deNOx
RH1.2
RH1.1
PA
fans
Amager I (2009) / Vattenfall A/S
CHP / 71 MWe & 250 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Amager I (2009) / Vattenfall A/S
CHP / 71 MWe & 250 MJ/s heat
Boiler design:
• Increased pitch super heater banks
• Austenitic steel 1st pass
(due to straw pellets)
• ECO out of boiler envelope
Combustion system design:
• 100% on coal (350 MJ/s, two levels)
• 100% on heavy fuel oil (HFO)
• 100% on wood pellets
(350 MJ/s, three levels)
• 90% straw pellets
Reduced flue gas temperature by PA coolers
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Multi-fuel boiler supplied by BWE
• Steam parameters adapted to the Copenhagen steam based district heating system
• 350 MJ/s thermal input by coal, oil or wood pellets
• 320 MJ/s thermal input by straw pellets
• 3 roller mills for coal or for biomass pellets
• 3 front-wall burner levels each with 4 BWE low-NOx burners
• Only one fuel type per mill at any time
• Investment level 320-350 K Eur MWe equivalent (boiler only)
• Delivery time approx 30 months
Amager I (2009) / Vattenfall A/S
CHP / 71 MWe & 250 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• The plant was commissioned in 2009
• Projected consumption of wood pellets is 40,000 tons/yr
• Projected consumption of straw pellets is 110,000 tons/yr
• Biomass use is equivalent to 35% of expected thermal input
• The corresponding CO2 reduction is approx. 220,000 tons
Amager I (2009) / Vattenfall A/S
CHP / 71 MWe & 250 MJ/s heat
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Amager I (2009) / Vattenfall A/S
CHP / 71 MWe & 250 MJ/s heat
Operation issues:
• Unstable mill operation (blocking of mills – high pressure loss)
Solution:
• Modification of classifier design (reduction of re-circulated
material)
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Only one fuel type per mill at any time; i.e. no co-milling
0
50
100
150
200
250
300
350
100% 100% 100% 91% 100% 100% 85% 100% 100%
Fuel input
Fu
el in
pu
t [M
J/s
]Coal Wood
Straw
20 m%
50 m%
40 m%
Co-firing
40 m%
Straw
Wood
Coal
Mass percentageCoal
AMV1 options:
Technical factors to consider
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Porto Tolle: Co-combustion
Coal fired USC 3 x 660 MW:
• Injection through centre tube in the PF burner
• 5% wood chips (33 MWe)
• 5% RDF (Refuse Derived Fuel from waste)
coal biomass/rdf
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Hazira: multi fuel boiler
for a steel mill complex
Essar steel mill complex BWE has awarded a contract for the supply of two
drum type boilers for power and steam production for the Hazira steel mill
complex (Gujarat-India) .
• The two Drum Boilers are designed to fire a number of different fuels.
• Main fuels are COREX Gas and COREX Coal besides a variety of other
coal types.
• The boilers are, however, also capable of firing:
• COREX Coal Fines,
• Corex Coal Dust,
• HFO and LDO.
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Key figures steam generator:
150 MWe power production
HP steam data: 487 t/h, 141 bar, 540 C
RH steam data: 462 t/h, 33 bar, 540 C
Boiler efficiency: 93.8 %
• The 20 Multi Fuel Burners makes it possible to fire 100 % Coal, Coal Fines,
Dust or Gas or any reasonable combination of the four.
• In order to obtain the best possible combustion of all fuels, only one fuel is
introduced in one burner at a time.
• In this case the need of a flexible boiler derives from the necessity to burn
all the “by products” of a steel mill complex
Hazira: multi fuel boiler
for a steel mill complex
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Parameter Unit Natural gas Natural gas LFO Coal Wood pellets Source/comment:
Boiler type --- CCGTBWE USC BOILER
TOWER TYPE T-FIRED MULTI-FUEL BOILER
Steam data
- main steam pressure bar n.a. 300 turbine
dependent 300 turbine
dependent BWE design
- main steam temperature °C n.a. 600 540 600 565 BWE design
- RH steam temperature °C n.a. 610 540 610 565 BWE design
Plant size MWe 600 600 600 600 600 Gross output in fully condensing mode
Net cycle efficicency % 55,0 46,0 44,0 45,0 43,0 Assuming direct seawater cooling on condenser
Heat input MJ/s 1.091 1.304 1.364 1.333 1.395
Fuel cost US$/MT 700 700 510 120 n.a. KKPTC
EUR/MT 490,1 490,1 357,1 84,0 n.a.
Fuel LHV MJ/kg 49 49 41 26 17 BWE assumption
Energy cost EUR/GJ 10,00 10,00 8,71 3,23 6,50 Wood pellets energy price is approximately 2*coal
Turnkey unit cost EUR/kWe 800 1500 1500 1500 1500 BWE internal estimates
Plant size turnkey cost mEUR 480 900 900 900 900 On gross electrical output
Boiler island cost % n.a. 20-25 20-25 20-25 20-25 In percentage of EPC cost
Lifetime Years 30 30 40 40 40 BWE estimate - not used
Internal Interst Rate % p.a. 6 6 6 6 6 BWE estimate - not used
PV factor --- 13,8 13,8 15,0 15,0 15,0
Yearly equivalent full load hours 7.500 7.500 7.500 7.500 7.500 BWE assumption
Yearly output GWh 4.500 4.500 4.500 4.500 4.500
OPEX excluding fuel EUR/MWh 5,00 7,00 7,00 8,00 8,00 BWE internal estimates
mEUR/year 22,50 31,50 31,50 36,00 36,00
Fuel cost GJ/year 29.454.545 35.217.391 36.818.182 36.000.000 37.674.419
mEUR/year 294,60 352,24 320,65 116,33 244,88
Total operating cost mEUR/year 317,10 383,74 352,15 152,33 280,88
Gross CO2 emissions kg/kg fuel 2,75 2,75 2,85 2,40 1,65
Net CO2 emissions kg/kg fuel 2,75 2,75 2,85 2,40 1,65 By political definition CO2 emission from biomass is 0
CO2 emissions MT/year 1.653.061 1.976.486 2.559.313 3.323.077 3.656.635 By political definition CO2 emission from biomass is 0
kg/MWh 367 439 569 738 813 By political definition CO2 emission from biomass is 0
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Advantages of using pellets
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Substantially increase in heating value (LHV)/ volume
( approx. x 4 compared with green chips)
• Reduced transport costs
• Simplified transportation / handling
• Reduction of biological activity / stable storing
• Homogenous manageable fuel for power plants
• Wood pellets is a well-defined commodity product with standardized quality
parameters.
• Easy – inexpensive adaption of existing boilers from fossil fuels to bio fuel pellets
• Co-firing, Bio fuel pellets and coal in power stations
Why pelletize?
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Benefits and drivers of pelletizing for the target groups
• Industrial boilers / Municipal heating stations
Re-use of existing furnaces and firing systems for solid fossil fuel
• Power plants
Quick and inexpensive conversion from coal to CO2 neutral Biofuel pellets
Co-firing possible
Green fuel pellets –
benefits and drivers
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Green fuel pellets –
density and possibilities
Sawmill wood
waste
Wood chips (wet)Sawdust /
Ground wood chips Pellets
Density
Specific
energy
content
300 kgs/m3 160 kgs/m3 650 kgs/m3
55% 12% 8%Moisture %
2.0 MWh/ton 4.4 MWh/ton 4.8 MWh/ton
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Green fuel pellets
Bio
ma
ss
,
Wet
Bio
ma
ss
pe
lle
ts
Truck
Truck
Rail
Ocean
100 km
500 - 700 km
2000 - 3000 km
15,000 km
Transportation comparison / energy equivalents
Transportation benefits of pellets
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
The history of biofuel pellet
consumption 1980 - 2009
1980 1990 2000 2006 2007
16 mill. tons (est)
16
2
4
6
8
10
12
14
Million tons
6,5 mill. tons
9.5 mill. tons
3.0 mill. tons
0.75 mill. tons
0.10 mill. tons
20122009
7.5 mill. tons
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Grate firing is used in smaller boilers.
• The fuel preparation for grate firing is reduced compared
to burner firing, where the fuel is dried and pulverized.
Grate Fired Biomass Boilers
• Fuel input up to 150 MW
• Steam temperature up to 540 °C
• Steam pressure up to 120 Bar
• Natural circulated Drum
Boiler size & type:
Vibration Grate Firing:
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• 4½ - pass drum type boiler
• BWE straw firing system
• Fuel: straw from cereals
Boiler concept:
Plant concept:
• 50 MJ/s (heat input) straw fired steam boiler
Emlichheim
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• New pressure parts for improved performance
• Conversion to other fuels
• Installation of equipment for harmful emission reduction
• Lifetime extension
• New control systems
and conversionRehabilitation, modification
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Air Heaters of bi-, tri- or quad sector designs for steam boilers
• Gas-Gas Heaters for environmental plants
• Upgrading of existing units with new effective sealing systems (active leakage
control)
• Modification of existing air heaters for SCR application
• New cleaning systems
• New heating surface in mild or corten
steel or with vitreous enamel coating
Regenerative Gas-Gas Heaters
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
• Reduced NOx emission
• Increased fuel flexibility with multi fuel burners
• Increased load flexibility
• Higher combustion efficiency
• Simultaneously meeting NOx and UBC requirements
The Wide Range (WR) combustion systems offer fuel and
load flexible systems that can be implemented as part of a
new plant or adapted to existing plants as retrofits.
WR Combustion Systems
Group
Burmeister & Wain Energy A/S · Lundtoftegårdsvej 93A· DK-2800 Kgs. Lyngby · Denmark · Tel/fax +45 39 45 20 00/+45 39 45 20 05 · [email protected]
Recent & Active Contracts
Plant Scope Client Duration
Hazira 2 x 150 MWe Multifuel boilers Essar Power 2010-2012
Fusina APH Rehabilitation Enel/Italy 2010
Honam GGH Halla E&E/Korea 2010-2011
Brindisi Sud APH Rehabilitation Enel/Italy 2010
Asnæs # 2 FGD plant (400MWe) DONG Energy/Denmark 2008-2009
Porto Tolle # 1-3 3 x 660 MWe USC boiler islands Enel/Italy 2011-2015
San Filippo del Mela GGH Termokimik/Italy 2008-2009
BEKW Emlichheim Straw fired boiler 50MJ/s BE Bioenergie GmbH 2011-2013
Studstrup # 3&4 2 SCR plants Elsam/Denmark 2005-2008
Amager # 1 GGH Vattenfall/Denmark 2006-2009
Amager # 1 HP-piping Vattenfall/Denmark 2006-2009
Amager # 1 Benson Boiler (500t/h) Vattenfall/Denmark 2005-2009
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