RDF-LIGNITE CO-COMBUSTION IN A CFB BOILER
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1 WIEN 48 th IEA-FBC MEETING RDF-LIGNITE CO-COMBUSTION IN A CFB BOILER Kari Peltola, Foster Wheeler Energia Oy, Finland Pekka Lehtonen, Foster Wheeler Energia Oy, Finland Bernhard Röper, RWE Power AG, Germany
2 CO-COMBUSTION OF LIGNITE AND RDF IN A CFB BOILER
3 CO-COMBUSTION OF LIGNITE AND RDF IN A CFB BOILER CONTENT OF THE PRESENTATION Description of the test equipment Analyses of the feedstock Course of the test runs Basic process parameters Probe tests - Fouling rate (corrosion) Comparison of the results to other plants Summary
4 TEST ARRANGEMENT - POWER PLANT LIGNITE FIRING CFB Steam data : 77.8 kg/s 510 ºC 90 bar Fuels : Lignite Sewage sludge Lignite sludge (Demolition wood) RDF PROBE LOCATION SUPERHEATER 4 SUPERHEATER 3 SUPERHEATER 2 ECONOMIZER AIR PREHEATER
5 TEST ARRANGEMENT - DEPOSIT PROBE
6 TEST ARRANGEMENT - ELECTROCHEMICAL PROBE Galvanic pair different materials deposit works as electrolyte
7 FUEL ANALYSIS LIGNITE SLUDGE RDF Moisture % Ash % (in d.s.) Heat value MJ/kg (a.r.) Carbon (C) % (in d.s.) Hydrogen (H) % (in d.s.) Nitrogen (N) % (in d.s.) Sulfur (S) % (in d.s.) Chlorine (Cl) mg/kg (in d.s.) < Sodium (Na) mg/kg (in d.s.) Potassium (K) mg/kg (in d.s.) Lead (Pb) mg/kg (in d.s.) Cadmium (Cd) mg/kg (in d.s.) <1 4 3 Chrome (Cr) mg/kg (in d.s.) Copper (Cu) mg/kg (in d.s.) Mercury (Hg) mg/kg (in d.s.)
8 TEST PROGRAM Test Fuel mix Duration Load RDF RDF Sludge Coal Hours % % (heat) %(mass) %(mass) %(mass) #1 lignite+sludge #2 lignite+sludge #3 lignite+sludge+rdf #4 lignite+sludge+ RDF #5 lignite+sludge+ RDF #6 lignite #7 lignite+sludge+ RDF
9 OPERATION DURING THE TESTS 300 Steam ton/h HCl mg/nm3 ZRA #1 #2 #3 RDF #1 #4 RDF #2 #5 RDF #3 #6 #7 RDF # : : : : :00 -
10 MAIN PROCESS PARAMETERS Test run #1 #5 #6 Additional fuels Sludge Sludge RDF - Load % T bed C T cyclone C O2 %, dry SO2 mg/nm 3 ( SO2 retention % Ca/S tot mol/mol CO mg/nm 3 ( NOx mg/nm 3 ( Hg µg/nm 3 ( HCl mg/nm 3 ( RDF share (2 % (1 Emissions expressed in 7% O 2 ; (2 Based on heat input
11 SOLIDS BALANCE OF FUELS S Cl Ca Na K Mg Al Si Fe Mn Ti P ash 250 Share of fly ash >95 % Elements g/s lignite + sludge lignite ash kg/s coal+sludge (#1) coal+sludge+rdf (#5) 100% lignite (#6)
12 Particle size of fly ash d(10) d(50) d(90) 1000 particle diameter µm lignite + sludge lignite + sludge + RDF 100 %lignite
13 Composition of fly ash and deposit 80 lignite + sludge lignite + sludge +RDF 100 %lignite Cl S 60 Na K Ca % 40 Fe Mg 20 P Si Al 0 #1 #1 #5 #5 #6 #6 fly ash dep.in fly ash dep.in fly ash dep.in Ti
14 FOULING RATES MEASURED BY DEPOSIT PROBES #2 g/m2/h % LIGNITE #6 #7 #1 #5 #3 2.0 # Temperature (Cyclone) C
15 COMPARISON OF PROBE TEST RESULTS FROM BOILERS WITH DIFFERENT FUEL COMBINATIONS FOULING RATE [g/m2h] T_FG C Challenging fouling behavior to be expected Fouling controllable with conventional sootblowing T_FG 700 C T_FG 820 C Probe fouling rate Qualitative probe corrosion rating T_FG 810 C T_FG 650 C T_FG 650 C 206 T_FG C T_FG 795 C T_FG 820 C T_FG 810 C CORROSION RATING 0 0 Mixed wood Mixed wood Peat 38% + mixed wood Peat 8% + mixed wood Recycled wood PDF RDF Lignite Lignite, sludge Lignite, sludge, RDF 120 MWth 120 MWth 157 MWth 157 MWth 63 MWth 91 MWth 59 MWth 235 MWth 235 MWth 235 MWth
16 CO-COMBUSTION OF LIGNITE AND RDF IN A CFB BOILER SUMMARY MAIN CONTRIBUTING FACTORS TO SUCCESSFUL TEST RESULTS the proportion of RDF was low tolerable content of Cl, Zn, Pb in RDF ash originating from wastewater sludge dominated the solids characteristics absorption or dilution of the fouling elements particle size of fly ash with sludge was coarser than ash from lignite alone chlorine corrosion was not detected
17 CO-COMBUSTION OF LIGNITE AND RDF IN A CFB BOILER SUMMARY CO-COMBUSTION OFFERS AN ENERGY EFFICIENT WAY OF THERMAL RECYCLING. HOWEVER, PROCESS CONDITIONS AND BOILER CONSTRUCTION NEED TO BE EVALUATED INDIVIDUALLY AND FOLLOWED UP DURING OPERATION
18 DEPOSIT PROBE AFTER 100% LIGNITE COMBUSTION A Flue gas flow B C #2 #1 deposit oxide metal #3 #2 #1 A) windward (dox. 105µm) B) side wall (dox. 90µm) C) leeward (dox. 30µm)
19 DEPOSIT PROBE AFTER LIGNITE AND SLUDGE CO-COMBUSTION A Flue gas flow B #2 #1 A) Windward (dox. 50µm) B) Leeward (dox. 50µm)
20 DEPOSIT PROBE AFTER LIGNITE, SLUDGE AND RDF CO-COMBUSTION A Flue gas flow B C #3 #2 #1 #2 #1 A) windward (dox. 135µm) B) side wall (dox. 40µm) C) leeward (dox. 30µm)
21 FOR COMPARISON : PROBE IN 100% RDF FIRED BOILER element % O 10.4 Si 0.8 S - Cl 7.0 K 0.6 Ca 0.8 V 0.7 Cr 29.2 Fe 48.8 Ni 2.1 Sum 100.4
22 FOR COMPARISON : PROBE IN RDF /SLUDGE PILOT TEST O/Fe molar ratio <1 interface oxide oxide O Si Al S * Cl K Ca Na Fe Cr Cu SUM
23 INSTALLATION OF PROBES
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