EFB Combustion - Power Gen Asia 2014 VF

AREVA Renewables

Presentation title – Presenter/ref. - 19 April 2023 - p.1Presentation title – Presenter/ref. - 19 April 2023 - p.1

AREVA Renewables

Efficient Combustion of Empty Fruit Bunch with minimum Fuel preparation

Ramesh ChivukulaHead – Technical Kuala Lumpur, 10 Sept 2014

AREVA Renewables

Presentation title – Presenter/ref. - 19 April 2023 - p.3

Agenda

Introduction & Potential for EFB

Factors to be considered while combusting EFB

Typical Parameters

AREVA solution

Summary and Conclusion

Short presentation of AREVA activities in bioenergy

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• Malaysia is one of the world’s largest producers of Palm oil

4 million hectares of land under cultivation annually around 75 million tons of FFB processed 16 million tons of EFB produced

• One of the significant issues in the palm fruit processing industries/mills is to manage large amount of wastes generated during the process.

• Today the Palm wastes and other wastes from the Palm Oil Industries are mostly

used as land fills, discarded as waste, either burned in the open air or left to settle in waste ponds

Palm oil production and Empty Fruit Bunch wastes issues

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The following are the biomass products from Palm tree, that are suitable for combustion in a boiler to generate steam and thereby electricity:

• Empty Fruit Bunch [EFB] (See Fig: 1) Largest quantities of Palm oil Wastes are mainly “Empty fruit Bunch“ Highly fibrous, high in moisture and also contains oil residues. Very difficult to either shred the EFB into small sizes or to directly combust in the

boilers.

• Palm Fibre (See Fig:2)

• Palm Kernel Shell (See Fig: 3)

Biomass from palm wastes

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Fig -1: EFB from Palm oil Industry

Fig -2: Palm Fiber from Palm oil Industry

Fig -3 : Palm Shell from Palm oil Industry

Photo caption - © Copyright

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Potential Power Generation from EFB in Malaysia

• Minimum potential : ~ 500 MW

• Present generation : less than 100 MW

• That too with low / medium performance

• Many plants planned but not built

• Few plants using alternate fuels like Palm Kernel

shells, Palm Fibres

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Critical Factors in design of EFB Boiler

• Chlorine content

• Alkali content

• Fuel size and volumetric flow

• High volatiles / Moisture in fuel

AREVA’s Boiler and Grate design attends to each of the above challenges.

1

2

3

4

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Effects of Chlorine


• Accelerated corrosion especially in super-heater area

• Chlorine corrosion will further be increased with presence of SO2

• Extent of Chlorine corrosion depends on Temperature, Concentration of Chlorine , presence of Sulphur and Alkali metals

1

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Effects of Alkalies


High Alkali & alkaline earth constituents results in deposit formation, which is a complex process depending on

Mineral characteristics of Fuel Fuel Chemistry Combustion Chemistry Particle Transport Fluid Dynamics Condensation

Deposit formation results in:• Reduction in heat transfer rates• Fouling• Accelerated rate of fire side corrosion

2

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Fuel Size and Volumetric Flow


The bulk density of EFB is very low.

This necessitates handling of large quantity of fuel for firing in the boiler.

Also it is very fibrous, oil content and high moisture levels, make it unwieldy for shredding in a shredder.

3

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High Volatiles and Moisture in the Fuel

High Volatiles result in lower ignition temperature and more combustion in upper furnace

High moisture reduces available heating value & inhibits proper combustion. Combustion air staging more pronounced to maintain Furnace temp where moisture is being vaporized. AREVA boiler can accept EFB with moisture up to 55 %

4

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Typical Parameters of EFB Boiler

Parameters

Boiler Capacity Up to 80 tph

Main Steam Press Up to 67 kg/cm2(a)

Main Steam Temp Up to 435 deg C

Fuel Considered 100 % Prepared EFB

Moisture content Up to 55 %

Fuel size Up to 150mm

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Typical Fuel composition


Fuel EFB- RAW EFB- Pressed

Proximate Analysis

Moisture % mass 68 50Ash % mass 1.1 1.72Volatile Matter % mass 17.7 27.66Fixed Carbon % mass 13.2 20.62Ultimate Analysis Carbon % mass 13.2 20.62Hydrogen % mass 2.1 3.28Nitrogen % mass 0.6 0.94Sulfur % mass 0.1 0.16Ash % mass 1.1 1.72Moisture % mass 68 50Oxygen % mass 14.7 22.97Chlorine % mass 0.2 0.31

Other Characteristics

Bulk Density kg/m3 250 250HHV kcal/kg 1376 2150LHV kcal/kg 869 1686

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15

Step-grate

AIR COOLED MECHANICAL

GRATE

It is cheaper and easier to operate than the water

cooled grate

MODULAR GRATE

One or more standard grates can be

connected to build biomass boilers in many

sizes Economically

interesting

THREE-PASS DESIGN

It reduces furnace outlet temperature (FOT) leading to

reduction in fouling

It limits corrosion especially for fuel that have a high chlorine and alkali content

(ex: EFB)

REDUCTION OF SUPER-HEATED

STEAM

TEMPERATURE

AIR DISTRIBUTION SYSTEM IN THE GRATE

Control of the air fed individually to various zones of the grate: low percentage of unburnt material (< 4 %)

AIR STAGING

It reduces NOx generation

AREVA Solution- Special Design Features of the Boiler


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Minimum Fuel Preparation

Fuel Preparation - No fuel shredding is required for the AREVA solution

For other technologies in the Market, shredding is required Main aim of Shredding is to reducing fuel size and facilitate combustion Shredding of EFB will lead to

· Higher investment· Higher auxiliary energy consumption· Higher operating costs (frequent change of blades due to EFB’s high abrasive

properties)

AREVA solution: No shredding required, grate and boiler design adapted accordingly.

The pressed EFB of size 150 mm x 150 mm x 25 mm can be fired directly in the Boiler


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Minimum Fuel preparation

Only Pressing to reduce moisture content

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EFB Feeding System

One of the key concerns of Palm wastes (Especially EFB) is the inability to flow freely due the fibrous nature.

Our boiler is capable of accepting coarse EFB with minimum preparation, thereby reducing the preparation cost considerably.

We have envisaged an automatic crane system capable of feeding the EFB / palm fibre to the fuel hopper, which is transported through the chain conveyor and gate arrangement to the grate.

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Simple Fuel Feeding System


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GRATE SYSTEM


OVERVIEW OF THE AREVA STEP GRATE

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GRATE SYSTEM DETAILS

Grate members inside the Boiler

Grate members on the shaft

Different zones of the Grate

Hydraulic system for the Grate

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ASH HANDLING SYSTEM

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Summary of Challenges of EFB & Appropriate AREVA solution

EFB characteristics AREVA solution

Low energy density: • Low bulk density (180-250 kg/m3)• High moisture content (~ 68%)• Low calorific value (LHV ~ 850 kcal/kg) • Pressing EFB moisture down to ~ 55% needs

no shredding • Simple Fuel feeding system - Grab Crane• Design at lower steam temperature (< 435°C)

to reduce metal temperature • Use of alloys more resistant to corrosion on

most exposed parts • Boiler 3-pass design to reduce fouling• Air staging for better combustion and control

of NOx emissions

• High abrasive and entanglement properties (fibrous nature)

• High Chlorine content (0.1-0.5%)

• High Alkali content (K, Na)

• High volatile content

.

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Nucléaire et renouvelables :deux énergies complémentaires pour un mix

avec moins de CO2, économique et fiable.

AREVA supply solutions for power generation with less carbon

41,521

Backlog Sales revenue

9,240Nuclear operations 9,042Renewables operations 69

Employees

45,340

(in millions of euros)

• Number 1 worldwide in nuclear power Products and services to ensure nuclear reactor safety and

performance throughout the lifecycle An integrated model covering every stage of the fuel cycle, reactor

design and construction, and operating services

• A major player in renewable energies Advanced technology solutions: offshore wind, bioenergy and energy

storage

AREVA SHORT

PRESENTATION

2013 Key Figures

Bioenergy Asia August 2014 24

AREVA Renewables

AREVA Bioenergy, the key partner for a wide range of projects


PROCUREMENT• Best available technology

• Procurement optimization excellence

DEVELOPMENT

• Technical support• Feasibility study

INVESTMENT FINANCING

• Bank guarantees• Connecting investors and sponsors

Engineering• Engineering expertise

• Plant optimization• Boiler expertise

CONSTRUCTION

• EPC guarantees• Project excellence

MAINTENANCE

• Full documentation• Training

Our Key AssetsLeader in Bioenergy

38 years of experience

Huge track record with 2.5GW of bioenergy power projects worldwide

Strong engineering expertise

Wide offering from EPC to technologies

Strong focus on safety and execution excellence

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PRESENTATION

AREVA Renewables

Development InvestmentDesign &

EngineeringProcurement

Erection and Commissioning

- Technical support to define best possible solution for customer

-Thermal cycle optimization - Fuel assessment- Combustion technology selection

- Solution design in collaboration with customer- Engineering and design of the plant

Project Management

- Training- EPC Warranty

period

Performance & delivery guarantees

- Support for project financing

Servicing

O&M

EPC scopePre-EPC support

- Equipment procurement

- Installation, testing, commissioning and training


Cogeneration or full electricity

Output 3 to 150MWe

All types of biomass feedstock

Complete EPC services

Cogeneration or full electricity

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PRESENTATION AREVA Bioenergy turnkey bioenergy power plants

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More than 2.5 GW worldwide, the largest biomass installed base

EUROPE

LATIN AMERICA

ASIA

BELGIUM: 4.5 MWe 1 biomass power plant

FRANCE: 27 MWe 2 biomass power plants


BRAZIL: 2,307 Mwe219 biomass plants

CHILE: 12 MWe 1 biomass power plant

THE NETHERLANDS: 50 MWe 1 biomass power plants

GERMANY: 16 MWe 4 biogas power plants

INDIA: 27 MWe3 biomass power plants

THAILAND : 40 MWe 4 biomass power plants

PHILIPPINES: 12 MWe 1 biomass power plants

AREVA SHORT

PRESENTATION

AREVA Renewables

Presentation title – Presenter/ref. - 19 April 2023 - p.28Presentation title – Presenter/ref. - 19 April 2023 - p.28

EFB Combustion - Power Gen Asia 2014 VF

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