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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
Development and customized application of modern combustion systems
Steinmüller Engineering Conference 2016
Speakers: Paolo Schmidt-Holzmann (Department Manager Combustion Systems Proposals) Dr.-Ing. Stefan Hamel (Department Manager Combustion Systems Process)
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
Our Approach – Customization / Product Development
Engineering – Methods and Solutions
Future Development
Introduction – Changing Markets for Combustion Systems
Case Study – Lignite Firing System
Modern Combustion Systems
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
1. Introduction – Why is this topic important?
Source: Wikipedia
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
1. Introduction – Where are the main consumers – Top Ten
Lignite
Bituminous coal
SE Home Market IHI Home Market
Steinmüller Engineering Conference 2016
1. Introduction – Fuel Range Selection
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
Our Approach – Customization / Product Development
Engineering – Methods and Solutions
Future Development
Introduction – Changing Markets
Case Study – Lignite Firing System
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
2. Our Approach – How to handle the change?
Source: teneigthygroup
Customization
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
2. Our Approach – From Needs to an Optimized Solution
Very low emission
Tight time schedule
High flexibility
Low operating costs
Customized Solution
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
2. Our Approach – Customized Solution / Technical
Customized Solution
Steinmüller Engineering Conference 2016
Experience of Field Service
Individual Design of the Components of the Combustion System
One of a Kind
Design Tools
Experienced Engineers
2. Our Approach – Customized Solution / Technical Components
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
2. Our Approach – Customized solution / Scope
Customized Solution
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
2. Our Approach – Product Development / SM-V-Burner Tests
• IHI combustion test facility in Aioi, Japan
• SM-V burner combustion tests with detailed evaluation and improvement of combustion behaviour
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
Our Approach – Customization / Product Development
Engineering – Methods and Solutions
Future Development
Introduction – Changing Markets
Case Study – Lignite Firing System
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering
Client Requirements
- Change of Boundary Conditions
(legal, economic)
- Change in Fuel Quality
- Improvement of Slagging Behaviour
- Reduction of Emissions
- Increase of Efficiency
- Intention to Save Operational Costs
- ……….
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering
Client Requirements
Analysis of Plant Performance
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering – Analysis of Plant Performance
Milling and Drying
Analysis of Combustion Performance
Analysis of Plant Performance
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering
Client Requirements
Fuel Analysis
Analysis of Plant Performance
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering – Fuel Analysis
Hard Coal Lignite Peat Wood
Volatile Matter in wt.-% (dry)
LHV in MJ/kg (dry)
10 30 20 40 50 60 70 80 90 100 0
20
40
35
30
25
C, H in daf
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering – Fuel Analysis A
sh
So
fte
nin
g a
nd M
eltin
g T
em
pe
ratu
res in
°C
Range of Softening
Range of Melting
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering
Client Requirements
SE Design Tools, CFD
Fuel Analysis
Analysis of Plant Performance
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering – SE Design Tools / SM-V-Burner
Secondary air I + II
Coal / Air
Core air
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering – SE Design Tools / SM-V-Burner Design Tool
SM-V Burner:
Process Design/ Dimensioning in Excel • Automatic interface
connection to 3D CAD tool
• On-the-fly Design check
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering – CFD
Gas-/Solid Flow
Single Burner
Furnace
Solution
Furnace
Itera
tion
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering
Client Requirements
Experience
SE Design Tools, CFD
Fuel Analysis
Analysis of Plant Performance
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering – SE Experience / Boiler Types
3-Pass
2- Pass
Tower
131
m
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering – SE Experience / Furnace Types
Grate Opposite Wall Slag Tap Front Wall
Tangential CFB T-Firing Gas-/Oil
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
25 t/h
Bit. Coal
1000 t/h
Lignite
2000 t/h
Bit. Coal
2500 t/h
Lignite
3. Engineering – SE Experience / Plant Size
Cologne Cathedral
(156m)
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering
Client Requirements
Experience
CFD, SE Design Tools
Fuel Analysis
Analysis of Plant Performance
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
Our approach – Customization / Product Development
Engineering – Methods and Solutions
Future Development
Introduction – Changing Markets
Case Study – Lignite Firing System
Steinmüller Engineering Conference 2016
4. Case Study – Kostolac
Coal: Lignite
LHV: ~ 7.8 MJ/kg
W: 42-45%
A: 20-26%
Sulzer type steam generator
SH steam flow 1.000 t/h
SH pressure / temp. 186 bar/540°C
RH pressure / temp. 43.7 bar/540°C
Reduction of NOx Emissions from 450 mg/Nm³
to <191 mg/Nm³ (6% O2)
Reduction of Excess Air 1.28 to 1.15 at Furnace Exit
Maintaining Steam Temperatures
Target
Steinmüller Engineering Conference 2016
4. Case Study – Kostolac / Scope of Supply
New Over Fire Air System
Steinmüller RSM® Low-NOx burner
New Coal Dust Distribution System
Steinmüller Engineering Conference 2016
4. Case Study – Kostolac / Results
NOx reduction
from 450 mg/Nm3 (6% O2)
to 191 mg/Nm3 (6% O2)
boiler efficiency = const.
Average 175 mg/Nm³ (6% O2)
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
Our approach – Customization / Product Development
Engineering – Methods and Solutions
Future Development
Introduction – Changing Markets
Case Study – Lignite Firing System
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
5. Future Development
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
Summary
Steinmüller Engineering provides
- long term experience in: - Firing systems (solid fuel, gas, oil firing)
- Various fuels (all coals, biomass, gas, oil, refinery residues…)
- Calculation tools / Engineering methods (inhouse tools, DimBo, CFD,….)
- own technology for firing systems to reach lowest emissions: - SM-V burners for bituminous coals
- RSM® Low-NOx burners for lignite coals
- customized solutions to each client: - Adaption of SE burner and firing systems to individual clients
- Optimization of existing burner/firing systems
- overall solutions: - Firing system – Steam generator – Flue gas cleaning
Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
Thank you for your attention
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