High efficient multi-fuel
CYMIC concept for
biomass, rejects and coal
for Hamburger Hungaria
28.4.2016
Katriina Jalkanen
Valmet Technologies Oy
CYMIC – Multi-Fuel Design Concept:
general and case example Hamburger Hungaria
Presentation outline:
• Fuel based challenges
• Solutions to selected challenges
• Fuel based CFB concepts
• Bio / Multifuel concept
• Design features
• Case example: Hamburger Hungaria
Power project
• Design data
• Design features
• Main components
• Conclucions
2 28-04-2016
Fuel based challenges
FUEL
Challenge field Recycled
Fossil Wood Agro SRF
wood
High temp corrosion 0 0...1 1 1 2
Mid temp corrosion 0 0 0 2 2
Cold end corrosion 0 0...1 1 2 2
Superheater fouling 0...2 0...1 2 1 2
Cold end cleaning 0 0 1 1 1
Bed agglomeration 0...2 0...1 2 1 1
Loop agglomeration 0...2 0...1 2 0 1
High bottom ash/debris flow 0...2 0...1 1 1...2 2
High fly ash flow 0...2 0 0 1 1
Back pass erosion 1 0 0 1 2
Emissions 1 1 1 1 1
3 28-04-2016
Challenge: High temp corrosion
Solution: Fluidized bed heat exchanger
Ÿ Final superheater is located in loop seal,
effective gas flow isolation from both furnace
and cyclone side
Ÿ Gas atmosphere is much less corrosive
compared to furnace or back pass location
Ÿ Layered tube design for SRF applications to
avoid alkali chlorine condensation
Outside surface T ~ 700 ˚C
Inside T = 450..520 ˚C
4 28-04-2016
Challenge: Mid temp corrosion
Solution: Easily replaceable superheaters
• To minimize the downtime of the boiler when Pb induced
corrosion cannot be fully prevented
• 5 days replacing time per bundle
5 28-04-2016
Challenge: High debris flow / bed agglomeration
Solution: Grid design and bed ash recirculation
6 28-04-2016
Challenge: Erosion / Emissions
Solution: Cyclone with high collection efficiency
Benefits of high collection efficiency:
Ÿ Fine particles stay in hot loop circulation:
– Even temperature profile
– High combustion efficiency
– Low NOx
– High inherent SO2 capture by fuel alkalis
– Low erosion in furnace and back pass (critical for
PbCl induced corrosion/erosion)
Ÿ High bottom ash/fly ash flow ratio
– Reduced dumping cost
Ÿ Minimized make-up sand consumption
7 28-04-2016
Fuel based CYMIC CFB concepts
Fossil Bio/Multi Recycled Wood SRF
•Low solids •Agro •Multifuel
•High solids •Wood
•Portion of SRF
•100 - 1200 MWth •75 - 900 MWth •75 - MWth •75 - 200 MWth
•Max 565 C, 175 bar •Max 545…565 C, •520...540 C / 90 bar •480 C / 70 bar…
175 bar 520 / 90 bar
8 28-04-2016
CYMIC for Bio / Multifuel
Special design features
Possibility for
Extended additive injection
refractory in the
furnace
for WID
compliance on 2 s Appropriate
in 850°C arrangement and
in waste co- spacing of the
combustion superheater
surfaces
against fouling
and corrosion
Two wall fuel
feeding
for high reliability Final superheater in
the loop seal bed
9 28-04-2016
CYMIC boiler
Circulating Fluidized Bed (CFB) technology
Hamburger Hungaria Power
Dunaujvaros
Hungary
Steam 158 MW th
62 kg/s
113 bar
520°C
Fuels Biomass, coal,
reject, sludge,
biogas, RDF
Start-up 2015
28-04-2016 10
Hamburger Hungária Power, Dunaújváros, Hungary
Design fuels
CYMIC boiler - Circulating Fluidized Bed (CFB) technology
Type Moisture LHV Ash Nitrogen Sulphur Chlorine % of
% MJ/kg % of DS % of DS % of DS % of DS fuel heat
input
Biomass 39 10 1,3 0 – 65
Coal 10 24 10 0 – 97
Rejects 42 13 9 0 – 18
Sludge 55 5 18 0–7
RDF 14 17 20 0 – 12
Biogas 3-8
Design 44,2...5,0 9,6...28 ...25 ...1,5 ...2,5 ...0,3
ranges
Natural gas Start-up
11 28-04-2016
Hamburger Hungária Power, Dunaújváros, Hungary
Emission guarantees
CYMIC boiler - Circulating Fluidized Bed (CFB) technology
mg/Nm3
NOx 200
SO2 180
Dust 10
CO 50
HCl 50
HF 14
Cd+Tl 0,05
Hg 0,05
Sb+As+Pb+Cr+Co+Cu+Mn+Ni+V 0,5
Dioxins and furans, I-TEQ, ng/Nm3 0,1
Values are at dry gas
TOC 10 corrected to 6% O2 (dry)
12 28-04-2016
Hamburger Hungária Power, Dunaújváros, Hungary
Description of Basic Components
Component Dunaujvaros
Furnace Extended lining
Grid Directional nozzle
PSH Back pass
SSH Back pass
TSH FBHE
AH Tubular
Emission control Limestone, SNCR, BHF, HL, AC
Corrosion management Steam Data, FBHE (opt. Additive injection)
13 28-04-2016
Hamburger Hungária Power, Dunaújváros, Hungary
Overview of the Plant Systems
Aqueous NH3
Rear wall:
Sand
Front wall:Biomass,
Reject, sludge
Front & RDF
rear wall:,
Coal Hydrated lime
Activated Ca(OH)2
carbon
Limestone
CaCO3
Biogas
Natural gas
Stack
Bottom ash Fly ash
Feedwater
Trisodium-
Ph control Oxygen
phosphate
chemical scavenger
14
28-04-2016
Main systems in boiler plant (1/2)
By Valmet’s system definition
1. Feed water system 17. Boiler plant safety systems
2. Boiler water and steam system 18. Compressed air and instrument air system
3. Sootblowing system 19. Civil construction
4. Blow down system 20. Auxiliary steam systems
5. Combustion air system 21. Sampling and analyzing system
22. Chemical dosing system
6. Flue gas system
23. Ventilation system
7. Flue gas treatment
8. Aqueous ammonia system
9. Limestone feeding system
10. N/A (Sulphur feeding system: not applicable)
11. Solid fuel feeding system
12. Sand feeding system
13. Bottom ash system
14. Fly ash system
15. Auxiliary fuel systems
16. Cooling and service water systems
15 28-04-2016
2. Boiler water and steam system
Ÿ Economizers (5 pcs), bare tube
Ÿ Steam drum
Ÿ Steam generator:
– furnace walls (inc. refractory)
– loop seal + cyclone walls (incl. refractory)
– 2nd pass walls
Ÿ Primary (2 pcs), Secondary (2 pcs)
and Tertiary superheaters (1 pc)
Ÿ Steam attemperators (3 pcs in 2
stages)
16 28-04-2016
5. Combustion air system
Primary air
Ÿ Primary air fan (1 pc)
– Combustion (fluidizing) air
– Fuel feeding air (cooling, purging,
sealing)
Ÿ Steam coil primary air preheater
Ÿ Flue gas air preheaters (2 pcs)
Secondary air
Ÿ Secondary air fan (1 pc)
– Combustion (staging) air
– Combustion air to start-up burners
– Combustion air to gas lances
– Sand feeding air (purging and cooling)
Ÿ Steam coil primary air preheater
Ÿ Flue gas air preheaters (2 pcs)
17 28-04-2016
6. Flue gas system
Ÿ Furnace
Ÿ Cyclone and Loopseal
Ÿ Manifold duct
Ÿ 2nd pass
Ÿ 3rd pass
Ÿ Flue gas ducting and dampers
Ÿ Bag House Filter (BHF)
• Flue gas (induced draft) fan (1 pc)
Ÿ Flue gas recirculation fan (1 pc)
Ÿ Recirculation gas ducting and
nozzles
Ÿ Stack and CEMS (not by Valmet)
18 28-04-2016
11. Solid fuel feeding system
Front and rear wall
Reject + RDF (yellow):
Ÿ Feeding to front wall
Biomass + sludge (brown):
Ÿ Feeding to rear wall
Ÿ Reject silo can also be utilized to
bio/sludge feeding
Coal to front and rear wall (red)
Ÿ Dedicated feeding in front wall, common
feeding system in rear wall with bio
19 28-04-2016
13. Bottom ash system
Bottom ash:
Ÿ Bottom ash hoppers
Ÿ Water cooled screws
Ÿ Drag chain conveyor
Bottom + loopseal ash handling,
recycling and discharging:
Ÿ Magnet with a drop pipe
for separated metal particles
Ÿ Sieve
Ÿ Pneumatic transmitter for sieved
returnable bed material (fines)
Ÿ Discharge conveyor to containers
20 28-04-2016
Conclusions
Ÿ Fuel based CYMIC CFB concepts have been created to
– Fossil fuels
– Bio / Multi Fuel
– Recycled Wood
– SRF
Ÿ CYMIC for Bio/Multifuel in Hamburger Hungária Power, Dunaújváros,
Hungary plant has proven it’s performance
– Taking over of the boiler 22.3.2016
Ÿ Key design features in multifuel concept are:
– High efficiency cyclone for good emissions and low erosion rate
– Robust fuel feeding and bottom ash equipment
– Sophisticated final superheater design
21 28-04-2016
