project awirs 4 - energie facteur 4

Conférence Innovation et Technologie de la

Transformation des Déchets en Energie

24 mai 2007 - Liège

EF4 – AILg

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11ELECTRABEL BELUX GENERATIONELECTRABEL BELUX GENERATION LABORELEC

PROJECT AWIRS 4

WOOD PELLETSLiège


NEW WAY : IMPORT OF (WOOD) PELLETSNEW WAY : IMPORT OF (WOOD) PELLETS

��Wood «Wood « pelletspellets »»

��Already testedAlready tested

��Peanuts huskPeanuts husk

��SunflowerSunflower

��Later onLater onother «other « pelletspellets »»

��cerealscereals

��coffee huskcoffee husk

��……

• controlled energy balance(energy consumption for production and transportation)

• controlled sustainability( « FSC » certification of woods)

• great excess of wood residues in the world = large potential on the long run




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Wood pellets production

• compress up from 200 kg/m 3 up to 650 kg/m 3

Grinding

• grind with hammer mills

� Produced in pellet mills

• dry up to moisture content < 17%


�� Swedish norm ASAE 269.4 (Dec96) or European TCSwedish norm ASAE 269.4 (Dec96) or European TC--335335

DURABILITYDURABILITY

Already test other possibilitiesAlready test other possibilities•• Expansion under water (CRAGx, Gembloux)Expansion under water (CRAGx, Gembloux)

EXPANSIONEXPANSION•• DensityDensity

BULKBULK = 650 kg/m= 650 kg/m33, INTRINSIC = 1280 kg/m, INTRINSIC = 1280 kg/m33

Test performed Test performed by Electrabelby Electrabel




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10 – 40 mm4 – 10 mm

Quality norms pellets sept-04

Parameters Units ElectrabelDiameter mm 4-10Length 10-40 mmVolatile matterWater content % DM < 10 %Bulk (apparent) density kg/m3 > 600Low heating value GJ/ton ar > 17Ash content % DM < 1%Bark content < 5%Initial melting temperature (red cond) °C > 1200°CCl % DM < 0,03 %S % DM < 0,2%F ppm < 30Additives (past, vegetal oil) % FORBIDDENWaste wood Qualitative FORBIDDENHeavy metalsAs mg/kg DM < 2Cd mg/kg DM < 1Cr mg/kg DM < 15Cu mg/kg DM < 20Hg mg/kg DM < 1Pb mg/kg DM < 20Zn mg/kg DMBenzo-a-pyrene mg/kg DM < 0,5Pentachlorphenol mg/kg DM < 3Particle size distribution minimum% < 3.0 mm (Durability) 100,0%% < 2.0 mm 95,0%% < 1.5 mm 75,0%% < 1.0 mm 50,0%

Wood pellets spec’s


�� Boiler manufactured Boiler manufactured by Cockerill Metallurgical Industries :by Cockerill Metallurgical Industries :-- natural circulationnatural circulation-- license license Combustion EngineeringCombustion Engineering

�� OilOil––gas unit commissioned in 1967 gas unit commissioned in 1967

�� Converted in 1982 to coal Converted in 1982 to coal –– gasgas

�� Power level :125 MWPower level :125 MW

�� Steam : 390 ton/h, 145 bar, 545Steam : 390 ton/h, 145 bar, 545°°CC

Awirs Unit 4 power plantAwirs Unit 4 power plant




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Project diagramProject diagram

wood pellets hammer mills boiler electricity

pellet silo’s

natural gas fan

wood dust silo

unloading

boiler

electricitygenerator

steam

flue gas

network


Facts and figuresFacts and figures

plant 34% efficiency80,3 MWe

wood pellets 17 GJ/ton4,7 MWhp/ton1,6 MWhe/ton

350.097 tons/year50 tons/h

generation 7000 hours562.100 MWh

green certificates 0,70 tau(CO2) min.393.470 certificates/y




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�� ExistingExisting old power plant old power plant

�� Short delayShort delay : 7 months for realisation: 7 months for realisation

�� CommissioningCommissioning : August 2005: August 2005

�� Full substitutionFull substitution of coal : «of coal : « World PremiereWorld Premiere »»

�� Must be Must be fully reversiblefully reversible to coal in 3 weeks timeto coal in 3 weeks time

�� Safety issueSafety issue: fire and explosion with wood dust: fire and explosion with wood dust

�� Delivery wood pellet : Delivery wood pellet : justjust--inin--timetime 1200 tons/day1200 tons/day

�� SteamSteam : 510: 510°°C instead of 545C instead of 545°°CC

�� Power levelPower level : 80 MW instead of 120 MW with coal: 80 MW instead of 120 MW with coal

Major Project ConstraintsMajor Project Constraints


UnloadingUnloading

unloading with unloading with mobile cranemobile crane

flatboat flatboat

500500--2000 ton2000 ton

screening, filtering screening, filtering

Just-in-time deliveryWith unloading 200 t/h




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HOPPER

TDB0TDB1

new

TDB2

new

TDB3old coal conveyor (350 m)

TR5

CENTREX 2

CENTREX 1

Conveying belts

FILTER 3

FILTER 2

FILTER 1

all conveyors fully covered


Handling Handling

weight balance

metal detector

hopper, sieve 5 cm and filter

Over band




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•• safetysafety : : -- sparkling detection sparkling detection -- water µwater µ--pulverisation pulverisation -- water deluge water deluge -- Fike explosion extinguish deviseFike explosion extinguish devise

Hammer millsHammer mills

•• silo’s of silo’s of 20 m20 m33 per mill per mill (density of wood dust about 0,4)(density of wood dust about 0,4)

•• two millstwo mills

•• supplier : supplier : Brabant van OpstalBrabant van Opstal

•• capacity each : capacity each : 25 ton/h25 ton/h


2 BVO hammer mills2 BVO hammer mills

25 ton/h25 ton/houtlet coal hopperoutlet coal hopper

inlet millinlet mill

stones sieve and stones sieve and magnetic metal separatormagnetic metal separator

sieve grid sieve grid 2,5mm2,5mm

hammershammers

selector at inletselector at inlet

Mill selection criteriaMill selection criteria–– Electricity consumptionElectricity consumption–– Required particle sizeRequired particle size

distribution : distribution : 90% < 1 mm, 90% < 1 mm, 100% < 1,5mm100% < 1,5mm

–– Cost : Cost : investment + investment + maintenancemaintenance




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2 BVO hammer mills 25 ton/h2 BVO hammer mills 25 ton/h

stones sieve and stones sieve and magnetic metal separatormagnetic metal separator

sieve grid sieve grid 2,5mm2,5mm

hammershammers

Mill sieve gridMill sieve grid–– Opening holes Opening holes –– Required particle sizeRequired particle size

distribution : distribution : 90% < 1 mm, 90% < 1 mm, 100% < 1,5mm100% < 1,5mm

–– permeability : permeability : 30 to 50%30 to 50%

Mill hammersMill hammers–– Number of hammersNumber of hammers–– Size and length of the Size and length of the

hammershammers–– Material to withstand Material to withstand

wearing (Crosabro, Nihard)wearing (Crosabro, Nihard)–– Cost : Cost :

unavaibility+ maintenanceunavaibility+ maintenance

Mill powder level Mill powder level indicatorindicator

–– Ultrasonic LTUltrasonic LT–– Capacitive LTCapacitive LT–– Capacitive LT withCapacitive LT with

–– 2 of 3 function2 of 3 function–– Cleaning systemCleaning system


BurnersBurners

Primary air

woodPre mixing

room

Turbulence devise




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Safety measuresSafety measures

�� Fire & explosionFire & explosion (Atex 137)(Atex 137)−− Inside the bins : explosive mixtures Inside the bins : explosive mixtures −− Training of personnel about dust explosion safety, Training of personnel about dust explosion safety,

�� Prevention equipmentsPrevention equipments−− Electrical installation (zone 20) Electrical installation (zone 20) −− static electricity linksstatic electricity links−− Spark detectionSpark detection−− Water µWater µ--pulverisationpulverisation−− Water delugeWater deluge−− metal detection metal detection −− CO detection in the buildingCO detection in the building−− Special safety design of fuel binsSpecial safety design of fuel bins


Overview safety systemsOverview safety systems

infra-red spark detector

FIKE bottle

sprinkler systemWater deluge




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�� ActiveActive systemsystem

�� Explosion Explosion detectiondetection via pressure sensorsvia pressure sensors

�� InjectionInjection of extinction agent (sodium bicarbonate) of extinction agent (sodium bicarbonate)

�� NN22 is is propulsionpropulsion agentagent

Fire explosion suppression system

extinctionextinction bottlebottleexplosionexplosion sensorssensors

resistance limitresistance limit

pressure (bar)pressure (bar)

time (msec)time (msec)Operation of the explosion Operation of the explosion

insulation insulation

Container of Container of explosionexplosion

Control panelControl panel

Explosion Explosion DetectorDetector


•• Temperature detection and water deluge systemTemperature detection and water deluge system

••FikeFike bumbbumb

Fuel bins

Arrival of Arrival of the TDB3the TDB3

CENTREX CENTREX 11

CENTREX CENTREX 22

Extractor Extractor TR5TR5

R2R2

••Limited residence timeLimited residence time : 10 hours: 10 hours

••ReRe--usedused �� avoid 6 months delay for permittingavoid 6 months delay for permitting

�� Two existing coal binsTwo existing coal bins••VolumeVolume of 600 m3of 600 m3




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Gaseous emissionsGaseous emissions

Awirs4Awirs4 DustDust SOxSOx NOxNOx

mg/Nmmg/Nm33 @6%O@6%O22

resultsresults 55 00 140140

limits before limits before 1/1/20081/1/2008

350350 17001700 11001100

limits after limits after 1/1/20081/1/2008

100100 12001200 600600


Growth of pellet market in the EUGrowth of pellet market in the EUSource Peter W. Heller 09/04, PerEnergy gmbh




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Wood pellets Electrabel in 2006Wood pellets Electrabel in 2006Requirements : 350.000 (Awirs4)

Pellets Feedstock Electrabel Pellets Feedstock Electrabel

British ColumbiaBritish Columbia Main supplierMain supplier

GermanyGermany

RussiaRussia

LethonieLethonie

FinlandFinland

SwedenSweden


ELECTRABEL BELUXELECTRABEL BELUXAwirs 4 Wood PelletsAwirs 4 Wood Pellets




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project awirs 4 - energie facteur 4

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