Grate Firing

www.bertsch.at
Grate Firing
or
Bubbling Fluidized Bed Firing
An Economic and Technological Comparison
Philipp Kolbitsch
+43 676 7810006
philipp.kolbitsch@bertsch.at
4. CEBC Graz, 2014-01-16, Michael Netzer
2
Business segments of BERTSCHenergy
Solid Fuel Boiler Plants
Electricity and Heat from Biomass
Process Heat Recovery
Systems and Pressure
Equipment
Steam, Heat and Equipment for
Process Plants
Combined-Cycle /
Cogeneration HRSG
Service
Optimal Maintenance and Service
Electricity and Heat from Gas and Oil
Waste Heat Recovery Boilers
Steam from Waste Heat in Industrial
Processes
4. CEBC Graz, 2014-01-16, Michael Netzer
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Business segments of BERTSCHenergy
Solid Fuel Boiler Plants
Electricity and Heat from Biomass
•  design (from conception to detail)
•  Steam parameters: 15 – 80 t/h, 40 – 150 bar, 400 - 520° C
•  EPC solutions (lot wise or turnkey)
•  in house design
•  Air cooled grate
•  Bubbling fluidized bed
•  Water tube boiler
•  After sales services
• 24 references in 6 countries
4. CEBC Graz, 2014-01-16, Michael Netzer
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Fuel Spectrum
Wood chips
Waste wood
Wood from Landscape preservation
RDF
Short-rotation plantation
Municipal waste
4. CEBC Graz, 2014-01-16, Michael Netzer
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Criteria for choice of technology
Given fuel quality is the main
criteria for the choice of
combustion system
1.
Grate firing
Water content of
fuel
2.
Lower Heating
Value
3.
Ash content,
impurities,
Particle size
Bubbling fluidized bed
firing
4. CEBC Graz, 2014-01-16, Michael Netzer
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Criteria for choice of technology
Grate
BFB
Technology Technology
Reason
Economic
Effect
Fuel range
Max 15 MJ/kg
open
Wear on grate
-
Fuel grain size
< 350 mm
< 100 mm
Fuel feeding
Higher costs for fuel
treatment with BFB
Boiler efficiency
lower
higher
Lower excess air with
BFB
Savings in fuel costs with
BFB
very low
Lower combustion
temperature with
BFB
Savings in costs for DeNOx
additive
NOx Emissions
moderate
Boiler cleaning
cycles per day
1-3
0-1
Self cleaning effect,
low flue gas velocity
Saving of soot blowing
steam, less wear on
heating surfaces, less costs
for make up water
Electrical
consumption
2-2,5% of fuel
power
slightly higher
Bigger fans
Higher costs for electricity
with BFB
high
Fuel input directly
into combustion
Quick adaption of plant
performance to new
conditions
Load change
rate
low
4. CEBC Graz, 2014-01-16, Michael Netzer
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Criteria for choice of technology
Grate
BFB
Technology Technology
Reason
Economic
Effect
Pressurized air
depending
depending
for SNCR,
for bag filter
depending
Sand demand
no
yes
Sand for fluidized
bed
Costs for Sand
Start up burner
no
yes
Sand bed needs heat
Costs for start up fuel
Ash from firing
higher
lower
Higher ash output
with grate
Lower costs for disposal
with BFB
Ash from filter
lower
higher
Sand output with
BFB
Higher costs for disposal
with BFB
Wear
high,
depending on
fuel
low
No moving parts in
firing system with
BFB
Savings in wear part and
maintenance costs with
BFB
Investment
equal
equal
•  So far BFB technology is known as expensive and complex technology, but
•  Detailed analysis of economic effects driven by fuel type and plant application establish
the choice of firing technology
4. CEBC Graz, 2014-01-16, Michael Netzer
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Grate Firing
•  Air cooled reciprocating grate with optimized grate bar geometry for maximal
availability and life time
•  Fuel input with pusher and chute onto fuel feeder grate
•  Active control of fire position on grate for highest efficiency
•  Each grate zone with variable controlled primary air supply
•  Staged combustion due to primary and secondary air
•  Temperature control of burning chamber via recirculated flue gas
(beneath and above grate)
4. CEBC Graz, 2014-01-16, Michael Netzer
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Boiler with Grate Firing
•  Burning chamber integrated in boiler
•  Natural circulation boiler with membrane
walls
•  Secondary air and recirculation gas
above grate
•  SNCR to reduce NOx emissions (lances)
•  Empty path an convective path
•  Recirculation of fly ash
•  “Biomass super heaters”
•  Economizer in steel casing
•  Boiler cleaning with sootblowers
•  S.H. steam temperature control with
desuperheaters
4. CEBC Graz, 2014-01-16, Michael Netzer
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Bubbling Fluidized Bed Firing
•  Bubbling fluidized bed integrated in boiler
•  “open nozzle floor”
•  Fluidizing of bed via mixture of air and recirculation gas
•  Start up burners above freeboard
•  Staged combustion due to primary and secondary air
•  Deashing with ash grate
•  Sand classifier and sand recycling
4. CEBC Graz, 2014-01-16, Michael Netzer
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Boiler with Bubbling Fluidized Bed Firing
•  Natural circulation boiler with membrane walls
•  Fuel dosing with screws and chutes
•  3-path or 4-path design
•  SNCR to reduce NOx emissions (with
evaporation)
•  “Biomass super heaters”
•  Economizer in steel casing
•  Boiler cleaning with sootblowers
•  S.H. steam temperature control with
desuperheaters
4. CEBC Graz, 2014-01-16, Michael Netzer
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Engineering
•  CFD simulation with state of the art software tools
•  Design of boilers with KED BOILER DESIGNER
•  Design of water – steam cycle with EBSILON professional
•  Plant design with COMOS
•  3D Modelling with NAVIS Works
•  Highly educated specialists
•  Professional interface coordination
•  Well known sub suppliers
4. CEBC Graz, 2014-01-16, Michael Netzer
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Erection, Commissioning, Hand Over
•  Workshop mounting as far as possible
•  Erection through well known companies with Bertsch
supervision
•  Commissioning and training through our specialits
•  Performance tests and hand over
4. CEBC Graz, 2014-01-16, Michael Netzer
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References
Order-No.:
Customer:
Project name:
Technical data:
Electrical output
Thermal output (Heat appl.)
Thermal capacity
Steam output
Steam pressure
Steam temperature
Fuel
J130120S
Holzindustrie Schweighofer; Covasna, Romania
CHP-Plant for Natural Biomass and AI-AII Wood
15 MWe
38+10 MW
60 MW
68 t/h
80 bar
500 °C
Wood & bark; AI-AII
Scope of Supply:
- Turn key project excluding civil works
- Construction planning
- Fuel storage and transportation
- Grate firing
- Boiler
- Steam turbine with generator
- Water – steam cycle
- Flue gas treatment
- 10 MW backup boiler
- Boiler house
Clients responsibility:
Civil works
Date of Completion:
Q1 2015
Project Manager:
Dipl.-Ing. Andreas Neuper
4. CEBC Graz, 2014-01-16, Michael Netzer
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References
Order-No.:
Customer:
Project name:
Technical data:
Electrical output
Thermal capacity
Steam output
Steam pressure
Steam temperature
Fuel
J110178S
Barthel Pauls Söhne AG; Gouvy, Belgium
CHP-Plant for Natural Biomass
4,7 MWe
20 MW
22 t/h
66 bar
485 °C
Wood & bark
Scope of Supply:
-  Grate firing
-  Steam generator
-  Flue gas cleaning with chimney
Clients responsibility:
Building, Technical building services, Fuel
handling, Water / Steam circuit, Condenser,
Steam turbine
Date of Completion:
Mid 2013
Project Manager:
Dipl.-Ing. Andreas Neuper
4. CEBC Graz, 2014-01-16, Michael Netzer
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References
Order-No.:
Customer:
Project name:
J110003S
Siat Braun; F-67280 Urmatt, France
CHP-Plant for Natural Biomass
Technical data:
Electrical output
5 MWe
Thermal capacity
23 MW
Steam output
25 t/h
Steam pressure
65 bar
Steam temperature
485 °C
Fuel
Wood & bark (W65)
Authorisation in acc. to french LRV
Scope of Supply:
-  Grate firing
-  Steam generator
-  Flue gas cleaning plant with chimney
-  Water treatment plant
Clients responsibility:
Building, Technical building services , Fuel
handling, Water / Steam circuit, Condenser,
Steam turbine
Date of Completion:
4. Quarter 2012
Project Manager:
Dipl.-Ing. Carl Christian Redl
4. CEBC Graz, 2014-01-16, Michael Netzer
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References
Order-No.:
Customer:
Project name:
Technical data:
Electrical output
Thermal capacity
Steam output
Steam pressure
Steam temperature
Fuel Wood / Recycled wood
Emissions at 11 vol. % O2
J090124S
Energie Wasser Bern / KVA Bern, Forsthaus, Switzerland
Wood CHP - KVA Bern
7 MWe
28,4 MW
32,2 t/h
75 bar
485 °C
(W20-W50)
CO 50 mg/Nm³
NOX 100 mg/Nm³
Scope of Supply:
-  Fuel storage (Silos) and Fuel feed systems
-  Bubbling fluidized bed combustion
-  Steam generator
-  Fabric filter
-  SNCR
-  Combustion air / Flue gas fans
-  Boiler house steel / primary +secondary steel
-  I+C support services
Clients responsibility:
Concrete construction, Technical building
services, Water / Steam circuit, Condenser,
Steam turbine, Chimney, I+C system, Water
treatment plant, Feed water supply
Date of Completion:
4. Quarter 2012
Project Manager:
Ing. Walter Jenny
4. CEBC Graz, 2014-01-16, Michael Netzer
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References
Order-No.:
Customer:
Project name:
Technical data:
Thermal capacity
Steam output
Steam pressure
Steam temperature
Fuel
J090029S
HHKW Aubrugg, Switzerland
Biomass CHP-Plant at EKZ Power Station of Kanton Zürich
41,5 MW
46,5 t/h
80 bara
500 °C
Wood chips (W35-W55)
Authorisation in acc. to Swiss LRV
Scope of Supply:
-  Fuel feed
-  Bubbling fluidized bed
-  Steam generator
-  Fabric filter
-  I+C – Siemens T3000
Clients responsibility:
Building, Technical building services, Fuel
handling, Expansion of water / steam circuit
Date of Completion:
4. Quarter 2010
Project Manager:
David Hötzl
4. CEBC Graz, 2014-01-16, Michael Netzer
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References
Order-No.:
Customer:
Project name:
Technical data:
Electrical output
Thermal capacity
Steam output
Steam pressure
Steam temperature
Fuel
J060152S
Holzkraftwerk Basel AG, Switzerland
Biomass Plant in der KVA der IWB Basel
8 MWe
33,5 MW
41,5 t/h
40 bar
400 °C
Wood chips (W20-W50)
Recycled wood AI - AII
Authorisation in acc. to Swiss LRV
Scope of Supply:
-  Fuel feed
-  Bubbling fluidized bed
-  Steam generator
-  Fabric filter
-  Instrumentation & control system
-  Steam distribution
-  Water / Steam circuit
Clients responsibility:
Building, Technical building services, Fuel
handling, Expansion of water / steam circuit
Date of Completion:
Mid 2008
Project Manager:
Dipl.-Ing. Otmar Bertsch
4. CEBC Graz, 2014-01-16, Michael Netzer
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References
Order-No.:
Customer:
Project name:
J060114S
Industrie du Bois Vielsalm & CIE s.a., Belgium
Biomass CHP-Plant IBV
Technical data:
Electrical output
19 MWe
Thermal capacity
2 x 40 MW
Steam output
2 x 44 t/h
Steam pressure
65 bar
Steam temperature
485 °C
Fuel
Wood & Bark (W40-55)
Authorisation in acc. to Belgium LRV
Scope of Supply:
-  Fuel handling
-  Fuel feed
-  Grate firing (Reciprocating grate)
-  Steam generator
-  Electrostatic filter with chimney
-  Instrumentation & Control system
-  Steam distribution
-  Water treatment plant
-  Pressurised air supply
Clients responsibility:
Building, Technical building services, Condenser
circuit, Heating condenser, Steam turbine
Date of Completion:
2. Quarter 2008
Project Manager:
Dipl.-Ing. Christian Gut
4. CEBC Graz, 2014-01-16, Michael Netzer
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Thank you for your attention
4. CEBC Graz, 2014-01-16, Michael Netzer
22
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