Design & operation experience of

a biomass plant

C. Khne; Dr. F. Pfab; C. Vento

Jornada de Cogeneracion

Genera 2010. IFEMA

Madrid / Spain

Group structure

An der alten B5

25813 Husum

Tel. ++49 4841 697-0

Fax ++49 4841 697-222

info-nord@wulff-deutschland.de

www.wulff-deutschland.de

Siemensstrae 10-12

25813 Husum

Tel. ++49 4841 9650-0

Fax ++49 4841 6950-60

headoffice@umag.com

www.umag.de

Gasstrae 18/Haus 5

22761 Hamburg

Tel. ++49 40 8517926-0

Fax ++49 40 8517926-29

info@wulff-hamburg.de

www.wulff-deutschland.de

Process & supply chain

Supply of customized plants for energy generation (steam, heat andelectricity) on the basis of most diverse primary energies (fossil fuels,

biomass and refuse-derived fuels).

Group competence covers the entire process chain: engineering, design, fabrication, assembly, commissioning and after-sales service.

Standard solutionsfrom the catalogue Ccustomized

for decentralized

ccombined heat & power plantsIndividual

largepower plants

Focus: Electricity

Focus: Thermal & electrical energy

Focus: Thermal energy

1 MW 10 MW 100 MW scale

WULFF has its core competencies in the following technology areas:

Fuel technology (A) Engineering (G) Boiler technology (B) and Service (H) Exhaust gas technology (flue gas cleaning, C) Fabrication of

- Grate and furnace systems

- Boilers (Waste heat; HRSGs; fresh air fired)

- Drying systems (disc dryer, rendering equipment)

Core Technologies

UMAG HRSG system behind 30 MW gas turbine

Customer: EUROPAC Site: Dueas / Spain

Steam capacity: 40 t/h at 63 bar, 432C HP steam

8,5 t/h 184C saturated LP steam

Gas turbine: Rolls Royce RB211

CHP & CCP applications

UMAG waste heat boiler behind sewage sludge

combustion in a fluidized bed furnace

Customer: BAMAG

Site: Shell Green / UK

Steam capacity: 18 t/h, 42 bar/405C

Waste heat recovery boilers

Wood and waste wood

A I Natural wood or only mechanically machined

wood, which is only unsubstantially polluted, as

well as fresh wood from forestry.

A II Waste wood being painted, coated, glued,

varnished or otherwise treated, free of

halogen-organic compounds or preservatives.

A III Waste wood being coated with halogen-organic

compounds, but free of preservatives.

A IV Waste wood being treated with preservatives,

such as wooden sleepers, telephone poles and

waste wood that can not be assigned to other

categories, except PCB-treated wood.

Biomass Fuels

Most marketable fuels for WULFF

Biomass Plants are:

Sustainable fuels such as natural wood,

foresting residues, greens

Rape and rapeseed residues from biodiesel

refineries

Natural wood, such as bark, sawdust, pellets

Biomass Plants

Refuse-derived fuels (RDF)

for decentralized energy supply

Wulff development of waste-to-energy plants

As dumping or landfill of waste with significant organic content is prohibited by law, a high potential of

refuse derived fuel is available. RDF is made of commercial and industrial waste in mechanical and

biological waste treatment plants.

The energy recovery from RDF is clearly delimited from thermal waste treatment by law. Combustion

systems for highly contaminated waste wood have been the basis for the new developed RDF-to-

energy plants.

The combustion chamber has been extended for low flue gas velocities and the grate has been

modified for 6 air sections.

Partial cladding of membrane walls protects against chlorine corrosion.

Due to the higher calorific value of these fuels the application of the WULFF water-cooled grate is

usually favorable.

Biomass Plants

Fuel Waste wood A1 A4 acc. German waste wood legislation AltholzVO

Heating value 12 18 MJ/kg, raw base

Water content max. 31 weight %, raw base

Ash content < 5 weight %, wf

Nitrogene content < 4,3 weight %, wf

Firing capacity 30,2 MW

Fuel flow 6200 kg/h, wf

Steam quantity 32,3 t/h

Steam parameters 46 bar a / 455 C superheated HP steam

Control range 80 100 %

Electric capacity 6,2 MW by 7 MW heat displacement, max. 7,5 MW

Technology Moving grate for coarse fuel / Single-drum water tube boiler

Flue gas scrubbing system Dry flue gas scrubbing according to 17. BImSchV and SNCR

Particularities Flue gas recirculation for combustion optimization and for grate cooling

Commissioning End of 2004

Biomass plant Flohr / Neuwied

Economic / operational objectives

100 % reliability and guaranteed supply with process steam Power generation using contaminated wood A1-A3 and simultaneous

generation of process steam via a regulated turbine bleed opening

Coverage of the process steam supply using natural gas-fired auxiliary boilers

Environmental objectives

Improvement of the emission situation at site by lower emissions and shut-off of the outdated heavy-fuel fired boilers

Voluntary restriction of the operator only to generate 25% of the firing capacity by using highly contaminated waste wood (A3)

Compliance with 17. BImSchV

Objectives

boilerflue gas

cleaningstack

electric

power

waste

wood

turbine

generator

combustion

(grate)

natural gasauxiliary

boiler

natural gasauxiliary

boiler

process

steam

Plant Concept

Firing Capacity - Diagram

Main Boiler G

auxiliary

boiler 2

auxiliary

boiler 1

MP-header

LP-header

exhaust steam

process steam steel works

internal consumption

7 20 t/h

t/h

t/h

32,3 t/h

heating0 - 3 t/h

Biomass Boiler Operation

Main boiler G

auxiliary

boiler 2

auxiliary

boiler 1

MP-header

LP-header

20 28,5 t/h

t/h

up to 12 t/h

32,3 t/h

3 - 5 t/h

exhaust steam

process steam steel works

internal consumption

heating

Peak Load Operation

Main boiler G

auxiliary

boiler 2

auxiliary

boiler 1

MP-header

LP-header

0 - 20 t/h

3 12 t/h

3 12 t/h

0 t/h

0 - 3 t/h

exhaust steam

process steam steel works

internal consumption

heating

Security Operation

V 1

2

1

V 2

Eco 4

Eco 3

Eco 2

Eco 1

ash conveyor

1. pass 2. pass

Steam drum

Fuel

flue gas

to FCS

combustion

air

recirculated

flue gas

Eco 5

850 C

ca. 1050 C

ca. 700 C

< 650 C

ca. 300 C

ca. 150 C

Boiler Concept & Design Criteria

ca. 4 - 5 m/s

ca. 6,5 m/s

sootblowers

shot-ball system

Flue Gas Cleaning

April 1999 Basic Engineering for approval

June 2000 Approval received

April 2003 Start of main order

March 2004 Start erection

June 2004 Boiler pressure test

October 2004 Operational readiness of the auxiliary boilers

December 2004 Operational readiness of the main boiler

Jan./ Febr. 2005 Test-runs

11.02.2005 Plant take-over and start of commercial operation

Project Milestones

200

50 50

10

150

182 1,7

0

100

200

300

Nox CO SO2 HCl

mg/m

Emission limit Full capacity reading

10

20

20,5

30 g/m

0,1 g/m

0

10

20

30

40

50

dust total C mercury

mg/

m -

g/

m

Emission limit Full capacity reading

Emission Data

80078105

8254 8336

7000

7500

8000

8500

9000

9500

10000

2004 2005 2006 2007 2008 2009

hr/y

r

Plant Availability

Grate after 4.000 Operation Hours

Superheater 2 after 4.000 operation hours

Thank you for your attention