Massachusetts Statewide Wood Energy Team Worcester County ...€¦ · 31.03.2017 Caluwe, Inc...

31.03.2017 Caluwe, Inc – Spanner wood chip CHP 1

Commercial-Scale Dry Wood Chips

Combined Heat & Power System

and Chip-Drying Technology

By Marc Caluwe

9 Wheatland street, Burlington MA 01803

83 Alexander Road, Billerica MA 01821

781-308-8583 - [email protected]

Massachusetts Statewide Wood Energy Team

Worcester County Modern Wood Heat Tour

April 30-2017


Caluwe, Inc. – Biomass Heat & Power Solutions

1993 – 2005: Product Testing & Certification; Apragaz (B) and TUV-SÜD (US)

2005 - Present: Caluwe, Inc. - Import, Distribution and Sales:

- Hydronic wood stoves and fireplace inserts: Walltherm (I) & Spartherm (D)

- Hydronic wood fired cook stoves: Pertinger (I) & Lacunza (Es)

- Pellet Boilers: Windhager (A) >>> USA & Canada

- Wood Chip Boilers: Heizomat (D) >>> USA & Canada

- Biomass CHP: Spanner Re² (D) & Burkhardt Energy (D) >>> USA &

Canada

Overview of activities


Caluwe, Inc. – Biomass Heat & Power Solutions

- Emission control systems: Catalytic, ESP’s Cyclones >>> USA & Canada

- Wood chip storage bins with integrated drying system: From green/wet to

25% MC in 4 days >>> 8'x8' - 10'x10' - 12'x12' - 16'x16' - 20'x20'

- Thermal Storage Tanks: From 120 gallons up to 20,000 gallons

- Installation & Service: MA, Southern ME & NH

- Heat sale contracts to government & municipal entities (MA only)

Wood chip boilers / CHP (similar to Solar PV > roof lease)

Overview of activities


Pellet Boilers: Windhager (A) >> US & Canada


Wood Chip Boilers: Heizomat (D) >> US

Fixed Grate + Rotating Agitator


Wood Chip Boilers: Heizomat (D) >> US

Moving

Chain

Grate


Typical wood chip boiler configuration


Cyclone

Emission control via

Cyclones


Electrostatic Precipitator - ESP


K+W Airject ESP


1 Ionization chamber

2 Collector chamber

3 High Voltage

Electrode

4 Wire Steel Brush

5 Cleaning

6 Ash box



Carola Clean Air ESP


Fly-ash collection box




Questions so far ?


Cost for the different fuels


wood chips SOURCE

From logging operations

-Logging companies

Cost point per Ton

$50/ton for green bole chips

From Urban wood waste

-Tree care companies

- Landscaping companies

- Municipalities

Cost point per Ton

$35/ton for green bole chips


Heating Oil #2 price history


Questions so far ?

31.03.2017 22Caluwe, Inc – Spanner wood chip CHP

Commercial-Scale

Biomass

Combined Heat & Power Systems

www.holz-kraft.de


www.burkhardt-energy.com

Commercial-Scale

Biomass

Combined Heat & Power Systems

http://www.holz-kraft.de/


905,000 BTU/hr

Thermal


Electrical output 50 kW

‚Thermal output 110 kW (375,000 BTU/hr)

www.holz-kraft.de


Commercial-Scale

Dry-Chip Combined Heat & Power System

and Chip-Drying Technology


> Wood-Power-Modules> Wood-Power-Systems> Wood-Power-Plants> Drying-Systems

Spanner Re² GmbH

Wood Chips > Gasification > Electric Power & Thermal Heat


Spanner SK.

k.s.

Slovakia

40 Employees

Spanner RE²

GmbH

Neufahrn in Ndb,

Germany

> 120 Employees

OTTO SPANNER

GmbH

Bayerbach, Germany

> 200 Employees

Automotive Renewables

SPANNER Group

Ursatronics GmbH

Berlin, Germany

40 Employees

Electronics

Otto Spanner GmbH in Bayerbach, Germany

31.03.2017 30

Spanner Re² GmbH in Neufahrn,

Germany

Caluwe, Inc – Spanner wood chip CHP

In 2004 Otto Spanner GmbH founded the daughtercompany Spanner Re² GmbH. With this decision the groupaimed at achieving more independence from theautomotive industry as well as at opening up a newbusiness field: The mission of Spanner Re² is thedevelopment and commercial exploitation of innovative,economically attractive regenerative power generationtechnologies.• 120 employees at the company’s headquarters in

Neufahrn/Landshut/Germany• internationally active in seven countries• 7,000 m² production area• ISO 9001-2006 certified

Otto Spanner GmbH has been a successful player in themetal working industry for many years: The company hasbeen a stable medium-sized partner of major industrybrands for more than 50 years. Long standing customerslike BMW, Porsche or Rational have come to appreciatethe company’s reliability and corporate philosophy basedon trust and honesty.

Geschäftsbereiche:

Innovative HOLZ-

KRAFT®-Anlagen

Kompakte Industrie-

Heizzentralen

Effektive

Hackschnitzel-

Trocknungsanlagen


2004:

Gründung des regenerativen Sektor

der Spanner Gruppe

2006:

Gründung der Tochtergesellschaft

Spanner Re² GmbH

Business units:

Innovative Wood-

Power-Plants

Compact industrial

heating systems

Efficient wood chip

drying systems

2004:

Start of the Renewables sector of

Spanner group

2006:

Foundation of daughter

Spanner Re² GmbH

The Spanner Wood-Power-Plant is an intelligent system to produce electricity

and heat out of conventional wood-chips. The compact Wood-Power single plant and also the whole Wood-Power-Systems have proven themselves many

times in practice.

31.03.2017 32

The Spanner Wood-Power®-Plant


✓ Uses cheap wood chips

✓ Highly efficient combined heat and power

✓ Use your power yourself and save cost

✓ Feed eco power into the grid and earn revenue

CHP unit Gasification unit


Operating principle of the Spanner Wood-Power®-Plant

(Face Lift = Post Reformer)

GM Vortec Engine

4 Stroke V8 – 5.7 Liter

1,520 RPM

CHP unit

Gasification unit

31.03.2017 34

Operating principle of the Spanner Wood-Power®-Plant

(Face Lift = Post Reformer)


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REFORMER Process


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EMISSIONS



Technical data Spanner Wood-Power®-Plant

Electric power 9 kW (2016) 30 kW 45 kW

Thermal Heat25 kW

(85,300BTU/hr)

73 kW

(249,000 BTU/hr)

108 kW

(368,000 BTU/hr)

Wood chip consumption 10 kg/h 30 kg/h 45 kg/h

Wood chip consumption for 7.000

operating hours60 tATRO 180 tATRO 270 tATRO

Required space min 7.5 x 5 m

Required room height 2.6 – 3.4 m depending on wood chip intake

Max output limited for

Net metering in Germany

ATRO-t means

0% WC !


Efficiency data Spanner Wood-Power®-Plant

Electric power 9 kW (2016) 30 kW 45 kW

Thermal Heat25 kW (85,300

BTU/hr)

73 kW

(249,000 BTU/hr)

108 kW

(368,000 BTU/hr)

Thermal Efficiency NA NA 56.3%

Electrical Efficiency NA NA 26.7%

Total Efficiency NA NA 83%

Installed units


Sold and installed units

1224

4262

120140

1236

78

140

260

400

0

50

100

150

200

250

300

350

400

450

2009 2010 2011 2012 2013 2014

Auslieferungen im Jahr

Feldbestand zum Jahresende


Sold per year

Installed units at year end

Installed units

in Germany

31.03.2017 41

Holz-Kraft locations

Site visits by appointment

Regular site tours

Corporate headquarters at

Neufahrn (NB.)



Questions so far ?


Sizing of a biomass CHP system

Most important aspect:

The CHP unit needs to run as many

hours per year as possible: >7,000

hours/year

HOW?

- Correct sing of the THERMAL LOAD >> UNDERSIZE CHP output !

- Fuel quality = quality of the wood chips >> result in less breakdowns

>> CAN‘T BURN WATER !

>> WATER IS USED TO EXTINGISH A FIRE !


365 days per year

X 24 hours per day

>>> 8,760 hours per year

Correct sizing of the THERMAL LOAD

- Size for SUMMER CONDITIONS !

- UNDERSIZE output

- Look into COOLING applications for summer (Absorbtion chiller)

Why?

- The CHP unit needs to be able to use the Thermal Heat (Hot Water)

„somewhere“ >> Process Heat or Heating/Cooling a building

- If you can not use the Thermal Heat, then the CHP unit will overheat

and shut down (just like your car engine with broken radiator)

- Do not „dump“ the heat !

Dumping Heat = Annual Operational hours go down = No financial pay

back


Do not „dump“ the heat !

Dumping Heat = you loose THERMAL ENERGY = No financial pay

back

HOW?

Incorporate Thermal Storage

10,000 gallons of water = 83,500 Lbs of water

Assume a usefull deltaT = 20C = 36F

83,500 Lbs x 36F = 3,006,000 BTU

3,006,000 BTU / 3412 = 881 kW devided by 108 kWt = 8+ hours of storage

10,000 gallons of water = 83,500 Lbs of water


83,500 Lbs x 36F = 3,006,000 BTU

3,006,000 BTU / 3412 = 881 kW devided by 73 kWt = 12+ hours of storage


45 kWe

30 kWe


Required fuel quality

Required wood chip quality

13% water contents max., 15% moisture contents max.

30% fine portion

max.

• Higher fine portion increases fault susceptibility

• Highter fine portion increases ash discharge

No foreign substances

• Sand causes slagging

• Screws, nails, stones cause plant damage


Requiredwood chip quality: G30 – G40

YOU

Can‘t

BURN

WATER !


Fuel comparison

Customer: HuberPrepared roadside and

landscape conservation wood


Fuel comparison

Customer: WäslerDried and sieved mixed woods

Customer: BaumgartnerDried and sieved forest timber

remains


Calorific Value (Heating Value) of wood & wood chips

@ 13% WC

Or 15% MC

You double your heating value by drying

The wood chips and you cut down on the

amount of wood chips

2.12 kWh/kg or

3,255 BTU/Lb

4.45 kWh/kg or

6,830 BTU/Lb

Hardwood = another commonly used word for deciduous, broadleaf trees

Softwood = usually refers to coniferous trees


Cost of wood chips at 15% MC and 25% MC

MC WC MC WC

Wood Chips G30/50

$145/ton

Wood Chips G30/50

$120/ton

GREEN Wood Chips

G30/50

$50/ton ???

Info:

Biomasseverband OÖ

4021 Linz, Auf der Gugl 3

Biomasseverband-ooe.at

Wood Chips G30/50

$65 to $85/ton

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Wood chip drying

Wood chip drying technology

How much does it cost to dry wood chips ?


31.03.2017 54

THERMO-HYGROMETER


31.03.2017 55

How much does it cost to dry wood chips ?

<<<<< Required Thermal Heat

<<<<< Required Electric Power

Required Total Energy for drying?


144 kWhth = 0.144 MWhth >>> @ $20/MWhth >>> $2.88 per m3 or yard + electric

If you need 2 or 3 m3 or yards for a ton

of chips then the total drying cost per

ton $8 to $12


Cost of wood chips at 15% MC and 25% MC

MC WC MC WC

Wood Chips G30/50

$145/ton

Wood Chips G30/50

$120/ton

Info:

Biomasseverband OÖ

4021 Linz, Auf der Gugl 3

Biomasseverband-ooe.at

GREEN Wood Chips

G30/50

$50/ton

+$12 for drying

= $62/ton

For 300 or 350

Tons per year

You save

$25,000 per year

= 3 to 4 year pay

back for dryer

Wood Chips G30/50

$65 to $85/ton

31.03.2017 57

Wood chip drying technologyWood chips for use in a Wood-Power-Plant must not exceed a water

content of 13 % resp. a moisture content of 15 %!

However: Fresh material (from the forest) has a moisture contents of over

100 %

By simple storage (natural predrying) of wood chips, moisture contents

cannot be decreased to < 40 %

Therefore wood chips have to be technically dried to achieve the required

moisture content of < 15 %.

Spanner Re² offers a range of drying units:

Bin drying

Slanted floor drying

Mobile silo

Container drying

Waggon drying

Double bin drying

Push floor drying



Wood chip dryers

Drying conveyor

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For approx. 6 – 10 m³/day or rather 3000 m³ per year ✓ Fully automatic drying system >> you dry the amount of wood chips you need✓ Continuous drying✓ Optional: remote control

Dimensions: 3,5 m x 2,4 m x 1,7 m (LxBxH)


Bin drying, compact unit

for 4000 – 5000 m³ loose cubic meters of wood chips per year

The drying in containers is recommended if large quantities of wood chips are to be dried and to be further transported immediately afterwards.

✓ Very simple, cost efficient construction

✓ In the floor area wood chip discharge and an air permeable construction can be combined

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Dimensions: individual concerning customers request

Depending on the available heat, it is possible to dry the wood chips in two bins simultaneously double bin drying (following page)


Double bin drying✓ Very simple, cost efficient construction

✓ In the floor area wood chip discharge and an air permeable construction can be combined

dimensions: 2,5 m x 2,5 m (base floor) per bunker

Depending on what the customer wants, we offer the system with different storage capacities and heat output

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Advantages:• Combined drying / bin solution in alternate operation• Low time & work effort• Minimum dust• Low floor space required


Container drying

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Advantages:

• Also serves as intermediate storage

• Simple logistics

• Batch operation

• Suitable for small amounts

• Low time & work effort

• No cover needed in normal rain or snow

For approx. 11-22 m³/day

Drying in containers is recommended if large quantities of wood chips are to be dried and to be further transported immediately afterwards.

For this, large roll-off containers are used for the transport on trucks. The advantage of the container is its large capacity of 22 m³ and more.

Two containers can be combined for double bin drying

Filling amount = container size


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• For approx. 15 – 20 m³/day or rather 5500 m³ per year

• The big difference: permanent drying resp. Discharge of wood chips

• A storage bin for dry wood chips is required !!!!!!

• Fan and heat exchanger press warm air through the floor from below

• Drying time is adjusted by means of temperature comparisons above and below the wood chips

Push floor drying

• Dimensions: 6 m x 2,4 m x 3 m


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Integrated drying system: Push floor >> belt dryer



Questions so far ?

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Transportation logistics: in 2 x 20‘ steel containers per gasification unit

Due to the ready-to-install components in the 20 ft. Containers or rather in theconcrete garages, the Wood-Power-Module is very easy to transport! This also lower the time between delivery and implementing

The Spanner Wood-Power – Modular concept


The Spanner Wood-Power – Modular concept

31.03.201767

• The wood-power-modules consist of the wood-

power-plant (gasifier and cogeneration unit) and is

pre-installed in a sound-absorbing, robust, fireproof

and cheap ferroconcrete ready-to-install garage or

container.

• The interior design is adapted to the special needs

and requirements!

• This solution is used, where no matching room for

the wood-power-plant exists, the existing room

cannot be modified, or the plant should be adapted

as a space-saving solution besides the building. Space-saving and ready-to-install solutionsWood-power-unit in a container (picture above) Wood-power-unit in a concrete garage (picture below)

Adaptable to every amount ofneeded heat and electricity


31.03.2017 68

The Spanner Wood-Power-System Solutionsthe complete system solution

Therefore, the internal process guarantees the necessary wood-chip quality out ofuntreated and humid conventional wood chips.By use of this whole system solution, the maintenance-friendly and continuousoperation will get much more easier.

The Wood-Power-System consists of a cascade of• The needed amount of Wood-Power-Plants• The efficient wood-chips dryer and the whole

logistic• The intelligent impurity removal• The wood-chips bunker• And the whole waste material logistic

inclusive ash-container

Ash-container

Wood-chips dryingsystem; bunkerWood-chips bunker

andWood-Power-Plants

Wood-chips drying system


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Your advantages: ✓ Nine out of ten plants are operating every time this

ensures a permanent and save heat and electricity supply✓ Cheap and robust wear parts for a max. efficiency simple

repair and maintenance work by every car mechanic✓ In case of substituting dieselgenerators: ROI within three

years!✓ Fast delivery times!✓ Your option: relocation after a few years could be done very

simple!

Inform and react: Within four months* you could be your own energy supplier

*from ordering with payment receipt until the first electricity andheat production

The Spanner Wood-Power-System Solutions


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HK 19 Wood-Power-System:Wood-Power-System combinedwith a double-bin dryer and theash logistics

Example: HK 19 Wood-Power-System

HK 19 Wood-Power-System: Wood-Power-System combinedwith the ash logistics, thebunker for the wood-chips andthe drying system

Plant-Type HK 19 (1) El. power: 19 kW Th. power: 45 kW


Example: HK 135 Wood-Power-System

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The unit consists of a cascade ofthree Wood-Power-Plants(cogeneration unit and wood-gasifier) and of a fully automaticwood-chip preparation (drying-system and sieve-system).

Plant-Type HK 45 (3)El. Power 135 kW Th. Power 324 kW



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Example here:Plant-type: HK 45 (10)El. power: 450 MWTh. power: 1,08 MW

Adaptable to every amount of needed heatand electricity



31.03.2017 73

Adaptable to every amount of needed heatand electricity

Example here:Plant-type: HK 45 (20)El. power: 900 MWTh. power: 2,16 MW


Example: Wood-Power-System in Latvia

Feeding in the electricity into the district heating system in Latvia

31.03.2017 74

Plant-Type HK 45 (22)El. power 1 MW Th. power 2,4 MW


Typical applications (Germany)

Forestry

• Forest owners

• Thinning operations

• Saw mills

Local heating networks

• Swimming pools

• Industrial business

• Public buildings, e.g. schools or town halls

• Remote districts and hamlets

Agriculture

• Piglet weaner stations

• Organic milk producers

• Nurseries and hothouses

• Agricultural business with holiday accomodation

Hotel & real estate industry

• Agricultural business with holiday accomodation

• Guesthouses in rural areas

• Holiday farms and wellness hotels

• Youth hostels


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>>> Annual operating hours (91% operational)

365 days per year

X 24 hours per day



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>>> Annual operating hours

(91% operational)


31.03.2017 78


365 days per year

X 24 hours per day



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365 days per year

X 24 hours per day


District Heating network


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(86% operational)

District Heating networkCaluwe, Inc – Spanner wood chip CHP

31.03.2017 86


365 days per year

X 24 hours per day



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(80% operational)


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Annual operating hours

(96% operational)

365 days per year

X 24 hours per day



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Annual operating hours

(96% operational)


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365 days per year

X 24 hours per day



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(91% operational)


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365 days per year

X 24 hours per day



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(91% operational)


DHW load

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>>> 2,855 Ft = 952 yds

6 1 >>> Annual operating hours (74% operational)

365 days per year

X 24 hours per day




31.03.2017 95

(13,230 Gal) !?

SYSTEM is OVERSIZED

for summer, but needs the

thermal heat in winter

Annual operating hours (74% operational) >>>


Thermal Storage10,000 gallons of water = 83,500 Lbs of water


83,500 Lbs x 36F = 3,006,000 BTU

3,006,000 BTU / 3412 = 881 kW devided by 216 kWt = 4 hours

5.5 hours of

Thermal storage


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365 days per year

X 24 hours per day



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!!! (22,750 Gal)

SYSTEM is

OVERSIZED

for summer


(57% operational)

Thermal Storage10,000 gallons of water = 83,500 Lbs of water

Usefull deltaT = 20C = 36F

83,500 Lbs x 36F = 3,006,000 BTU

3,006,000 BTU / 3412 = 881 kW devided by 73 kWt = 12 hours

27 hours of

Thermal storage



Questions so far ?

31.03.2017 Caluwe, Inc – use of wood chips for heating 99

MA state rebate programs (MassCEC)

MassCEC – Rebate for Biomass Heating System

Rebate equals 40-50% of the total installed cost, up

to $250,000 for commercial-scale projects (>120,000 BTU/hr)

and $27,000 for small-scale projects (<120,000 BTU/hr)


MA state APS and Alternative Energy Credits

MA-APS = Alternative Portfolio Standard

AEC’s = Alternative Energy Credits (similar to SREC’s)

$15 to $30/MW for produced Thermal Energy (Heat)Or $15 to $30 per 3,412,000 BTU/hr

Or $4.41 to $8.82 per mmBTU

Or $0.015 to $0.03 per 1,000 W or 1 kW


Cost for the different fuels

Minus $4.40 AEC

Equals $4.02

Per mmBTU


Spark Spread

Spark Spread www.epa.gov/chp/my-facility-good-candidate-chp

Spark spread refers to the difference between the cost of

electricity and the cost of fuel on a per mmBTU basis. This

metric is often considered when recommending equipment retrofits that

require fuel switching. A spark spread of at least $12 per mmBTU is

considered the threshold for economic viability of Combined Heat and

Power (CHP) systems.

A spark spread of $12/mmBtu ($0.041/kWh) is typically

considered to be the threshold that is representative of an

economically attractive CHP project, meaning that projects that

exhibit spark spreads in excess of $12/mmBtu ($0.041/kWh) will have a

good potential for low payback periods and overall economic success

*The spark spread is a metric to determine the profitability of gas-fired electric generators with minimum input available. It is a

quick analysis of the market conditions of power generation, but there are limitations on it use. It considers only the cost of

electricity and fuel and does not take into consideration other costs associated with the generation of electricity, such as capital

cost, taxes and operation and maintenance (O&M) costs.


Electricity Prices in the USA (c/kWh)The cost of electricity is generally high in the Northeast, California, and the noncontiguous states of Alaska and Hawaii.

The price of electricity is low in the Northwest and Southeast.


Natural Gas Prices in the USA ($/mmBTU)In addition to a high cost of electricity, the business case for a CHP-system is improved if the cost of its fuel is low.

Figure below shows the geographic variation in natural-gas prices across different regions in the United States.

As can be seen from the figure, those areas with high electrical costs do not necessarily correspond to the areas with high natural-gas costs.


Closing remarks

Biomass Thermal is competing with:

- Wind

- Solar PV

- Solar Hot Water

All non-emitting renewable energy generators

Important for public opinion/perception:

- Biomass technology needs to be clean (PM2.5 level)

- Biomass technology needs to be efficient (>75%)

- Sustainable sourcing of biomass fuels

- Responsible use of the sourced biomass fuels

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woodchipboilersr.us

Thank you for your attention


Massachusetts Statewide Wood Energy Team Worcester County ...€¦ · 31.03.2017 Caluwe, Inc...

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Transcript of Massachusetts Statewide Wood Energy Team Worcester County ...€¦ · 31.03.2017 Caluwe, Inc...