Maximising the available fuel portfolio – improved ... … · Test run of one working week (100 hours non-stop) Share of EFB was increased gradually to 100% – Fouling tendency

Maximising the available fuel portfolio– improved affordability

Ari Kokko

Director, Technology and R&D

Valmet

Content

Maximising the available fuel portfolio – improved affordability

CFB’s fuel flexibility

Cost of renewable fuels

Fuel research in Valmet

2

3

4

New fuels tested5

Summary6

1 Valmet’s offering in energy

© Valmet | Maximizing the available fuel portfolio2 10/10/2018

Valmet’s offering in energy

© Valmet | Maximizing the available fuel portfolio3

HYBEX (BFB technology)

• BtE and WtE

CYMIC(CFB technology)

• BtE, WtE and multifuel

Gasification

• BtE and WtE

• Power plant,

co-gasification and

lime kiln

Rebuilds and conversions

Air pollution control

Automation

10/10/2018

CYMIC

Trade name for Valmet CFB boilers

Size range 30–350 MWe

Fuel flexibility

– From high heating value and high ash fuels to

high moisture fuels

– High steam data capability with corrosive fuels

– Good in-furnace sulphur removal

CFB’s biggest benefit: Fuel flexibility


Valmet has full scale experience of following range of fuel properties:

calorific value from biomass 6.5 MJ/kg to pet coke 32 MJ/kg

moisture content up to 60% in biomass

ash content up to 65% in waste coal

sulfur content up to 6–8% in pet coke

Valmet fuel experience in CYMIC boiler


Wood Recycled wood RDF Agro Sludge

Coal Peat Lignite Pet coke Waste coal

10/10/2018

Turning from fossil fuel towards renewable fuels often creates fuel availability

problems and fuel prices are going up

New less expensive fuels are continuously coming onto market

New fuels are always technically more challenging

Price of renewable fuels tends to increase


SEK/MWh

Wood pellets

Wood chips

Recycled wood

PeatWood waste

Biomass price

trend in Sweden

Year

10/10/2018

Based on over 300 fluidized bed references and own R&D center

Valmet has extensive experience with demanding fuels


Fuel testing since 1990:

• 4 MWth CFB

• 10–100 kW tube reactors

• Cold models

• Over 9,000 fuel analysis

in fuel library

10/10/2018

Pilot equipment designed, build and easily

modified to develop different technologies

Tube reactor – Pilot – Full Scale

Both internal R&D and customer projects

– New technology piloting

– Improving the competitiveness of current technology

– Testing new fuels and fuel mixtures

– Development of research and measurement methods

Co-operation with scientific community

Energy technology R&D Center


Valmet R&D Center milestones


May 1990

First test-runs

June 1990

R&D Center

inaugurated

1990’sFuel testing

1995–2006

Loop seal superheater

development

2000’s

Multifuel capability

Emission reduction and

corrosion knowledge

Boiler component

development

2009–2013

Pyrolysis process

development

ESP and BHF

development

2012First gasification plant

2013First Pyrolysis plant

2017

Asian agro fuels testing

with customer

Asphaltene testing with

customer

2010’s

Agro-Coal-Waste

testing

Cyclone development

Marine scrubber

1982First BFB

1984First CFB

10/10/2018

JFE Engineering and Valmet supplying power plant

to Ofunato Power Inc

– 75 MWe reheat CFB (65/57 kg/s, 142/27 bar, 557/540°C)

– Fuels: PKS (60%), EFB pellets (30%) and coal (10%)

– Long term target: to have 100% EFB pellets

Need for fuel testing: EFB as a new fuel

Ofunato Power Inc project – new fuels


Oil palms Fruit bunch PKS Coal

Empty fruit bunces (EFB)

Palm kernel shells (PKS)

EFB pellets

10/10/2018

High alkali and chlorine content in the fuel increases the risk of bed agglomeration and high

temperature corrosion due to alkali-chloride deposits

JFE Engineering, Taiheiyo Cement and Valmet decided to conduct a full pilot test with EFB

– Safe limit for Na+K = 2,000 ... 3,000 mg/kg in a fuel mixture unprocessed EFB is ten times higher

EFB testing in Valmet R&D Center pilot boiler


Wood chips PKS EFB Processed EFB Coal

Moisture % 45 18 8 7 16

LHV MJ/kg 10 15 18 16 23

S % DS 0.04 0.24 0.12 0.035 0.24

Cl % DS 0.01 0.06 0.53 0.013 0.01

Ash % DS 1.5 6.0 9.1 2.6 7.1

Na mg/kg DS 160 285 340 165 700

K mg/kg DS 850 2,150 20,300 1,990 550

10/10/2018

Plant owner wanted to test processed EBF

Test run of one working week (100 hours non-stop)

Share of EFB was increased gradually to 100%

– Fouling tendency was measured with deposit probe

– Bed temperature was kept at normal level (880–900°C)

– Test point #2 is the operation point of the boiler

– Test point #5 is the long term target of boiler operation point

EFB testing in Valmet R&D Center pilot boiler


Fuel share,

% of energyTest point

1 2 3 4 5

Coal 100 10 10 10 0

PKS 0 60 30 0 0

Processed

EFB

0 30 60 90 100

Results

Alkali level in the bed remained stable no agglomeration

Deposit probe test indicated no increased risk for alkali-chloride

induced corrosion

Controllable deposit probe

Bed material sample

TP5TP3TP1

10/10/2018

Pilot test run confirmed that Ofunato design fuel mixture can be

operated safely (30% EFB with 60% PKS and 10% coal)

Test showed that a 100% share with processed EFB might be

possible

It was agreed that tests will continue when the boiler is in

operation in 2019

Positive results were achieved without lowering bed

temperature or having any additives

However to manage the corrosion risk it is necessary to have a

finishing superheater and reheater inside the bed material in a

cyclone loop seal

– Main steam temperature 557°C and 540°C for reheated steam

EFB testing – story continues


Increased demand for renewable fuels leads to higher fuel prices

Power plant owners are seeking less expensive fuel alternatives

and these fuels are always technically demanding

New fuels can be tested at Valmet R&D Center before full-scale use

EFB pellets were tested in co-operation with customer

Test showed that agro-based biomass can be fired safely

in a CFB boiler

Preprocessing agro fuels greatly reduces the operation risk

Preprocessing agro biomass may be more common in the future

since wood-based biomass is not available everywhere

Summary


Documents

Maximising the available fuel portfolio – improved ... … · Test run of one working week (100 hours non-stop) Share of EFB was increased gradually to 100% – Fouling tendency