Burmeister & Wain Energy A/S - Sinotech

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

mailto:[email protected]

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


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


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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


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• 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


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• 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


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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


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• 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


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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


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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


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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).


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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


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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


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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


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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


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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


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Fuel flexibility

Be independent from large sources of primary energy that may

“capture” the power industry


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Fuel flexibility

Adapt to new possibility of sources of cheap primary energy

Avedøre Power

Station Unit 2


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Fuel flexibility

Follow the trend of demand for cleaner technology and renewable

energy

Avedøre Power

Station Unit 2


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0

50

100

150

200

1994 '00 '05 '09

Coal Oil Natural Gas Wind Power Other

PJ

Electricity Production by Fuel in DK


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Composition of Fuels in

District Heating Production


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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


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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


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Avedøre Power Station Unit 2

BWE Solutions for co-firing

Co-firing into an existing power station


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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


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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


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• 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




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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




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Wood pellet mill – a modified coal mill

Capacity 45 – 50 t/h


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• 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%




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• 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)




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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




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• 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




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Herning Power Station


Repowering of an existing power station


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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



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Herning Power Station (1982) / DONG Energy A/S


• 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


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Herning Power station (1982) / DONG Energy A/S


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


The retrofit enables about

45% load on biomass


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


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• 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 )




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• 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)




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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)




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PF combustion system




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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)




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Amager Power Station Unit 1


New build for multi-fuel


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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



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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


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• 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




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• 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




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Operation issues:

• Unstable mill operation (blocking of mills – high pressure loss)

Solution:

• Modification of classifier design (reduction of re-circulated

material)


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• 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


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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


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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.


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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


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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


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Advantages of using pellets


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• 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?


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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


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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


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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


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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


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• 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:


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• 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


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• 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


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• 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


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• 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


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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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