Waste to Energy SolutionsBy V.B. Kabra- Divisional Manager (R&D) Thermax Babcock & Wilcox Limited - Pune India Fluid bed boilers Review Multi fuel firing capabilities - In combination of high/low ash coal or independent firing to give low cost solutions. BFB , IR CFBC AND PCFB BFB : Quite matured technology for regular applications of high/Low ash coals Second generation developments by B&W/TBW Open Bottom Multi-fuel firing options and addressing the environmental issues IR-CFB : Third generation B&W/TBW design - High Efficiency, compact, low maintenance, multi-fuel firing PCFB under development stage Fluid Bed Technology for Waste to Energy Historically the primary solid fuel combustion technology has always been stoker firing, before the BUBBLING FLUIDISED BED (BFB) technology emerged as most appropriate technology for handling wide range of industrial waste. In paper industry the paper sludge waste was normally dewaterred for handling & volume reduction & then it used to be sent for land filling. The other waste from paper mill like bark or wood waste used to be fired on stoker, with low efficiency.The BFB technology has now become popular for paper mills with it’s advantage to reduce both land fills & emissions from flue gases. The Open Bottom Design The unique open bottom design of B&W/TBW has distinct advantage over the bed plate type arrangement which allows the flexibility of uniform draining from entire bed area. For firing fuels like paper sludge, woody bio-mass, coffee waste, high fouling agricultural waste or high ash coals the BFB boiler must have system to drain tramped material which comes along with the fuel, agglomerated ash of high alkali fuels. The 100 % open bottom mounts the bubble caps on air pipes which are evenly spaced to allow draining from the entire bed. The design provides clear vertical path for the material to move freely to the drain area. The following presentation details out various distinct advantages of open hopper bottom design as well as the unique design of IR CFB. Fuel Analyses of Various Coals FUEL ANALYSES Indian coal Indonasian Coal 13.86 5.94 41.74 38.46 62.05 5.08 25.32 39.1 13.57 13.87 1.39 1.93 0.11 0.54 5835 South African Coal 3.56 18.7 23.5 54.24 62.5 2.95 10.94 52.8 4.8 33.8 0.48 0.94 0.2 1.15 5689 Washery Petcoke Reject Coal Fines 1.2 9.89 5.8 10 54.4 78.8 3.46 11.12 50 13.8 14.9 0.46 0.72 5.33 0.9 7940 21.3 24.84 43.97 52.9 4.35 10.21 53.96 14.73 23.65 0.53 0.23 0.3 1.05 5595 Char 2.3 63 1.26 33.44 34.2 0.25 0.04 57.48 9.3 25.78 0.8 0.4 0.08 0.13 1988 Lignite 24.25 5.15 38.93 31.67 55.23 4.76 21.61 16.3 10.38 11.42 0.48 11.17 4.72 0.64 5740 Moisture % Ash Content % Volatile Matter % Fixed Carbon % C% H% O% Silica % Iron % Alumina % Potassium % Sodium % S% N% GCV,kcal/kg 10.96 30.21 42.49 16.34 40.61 3.47 16.60 7.58 10.97 3.26 0.77 8.94 4.65 0.36 3765 Fuel Analyses of Bio-mass Fuels FUEL ANALYSES Julia Flora Bamboo Dust Eucaliptus Eucaliptus Dust Bark 8.92 2.1 73.79 15.19 34.23 3.85 27.18 0.00 0.34 0.43 0.00 0.08 0.35 3185.70 26.61 3.04 23.49 0.26 0.07 0.18 0.05 0.01 0.13 2467 16.01 1.74 15.36 32.28 0.07 3.64 3.05 0.00 0.09 3634 14.95 1.77 8.49 0.00 0.22 0.10 0.07 0.49 1.43 1496.40 <1 0.28 0.74 0.06 0.07 2806 0.15 0.71 3865 0.02 1.10 5300 0.05 Paper Sludge Viscous Paper Sludge 22.18 28.95 43.7 5.17 21.86 3.54 23.34 Liquid Coffee Waste 82.2 1.68 12.55 3.57 8.92 1.33 0.71 Coffee Ground Press 68.4 0.3 27.1 4.2 20.50 3.20 6.48 Cotton Stalk 8.88 1.38 70.85 18.89 8.80 4.95 35.24 6.00 0.02 11.33 0.98 0.18 0.65 4239 Moisture % Ash Content % Volatile Matter % Fixed Carbon % C% H% O% Silica % Chlorides % Potassium % Sodium % S% N% GCV,kcal/kg 10.31 1.15 71.73 16.81 49.50 5.00 33.29 6.66 0.05 10.55 3.65 0.15 0.60 4393 HOPPER BOTTOM DESIGN # Unique design of B&W (Developed for effluent /MDF firing ) which can handle the difficult , agglomerating fuels. # Allowing uniform draining of agglomerate / clinkers through hopper bottom. # Ease on multiple fuel firing through over bed . # At JOCIL - 30 tph boiler in operation since# Performance on the rice husk and combination fi ring with various bio-mass fuels , observed to be quite satisfactory with very good reliability on operation. # Efficiency on rice husk achieved 84 % (against 82 % committed) # For firing rice husk , coal and other bio-mass such as cotton stalk, chilly stalk ,having high alkalis in fuel ash.( 15 to 40 %) HOPPER BOTTOM DESIGN BIOMASS POWER - JOCIL OPEN HOPPER BOTTOM AFBC BOILER • • • • Capacity - 30 tph, 66kg cm2g, 485 Deg C,r 6MW Design - Open Hopper Bottom Design Fuels- Rice Husk, Cotton & Chilly Stalk, Juliflora etc. Operational since February’2001. FEATURES • Open Hopper Bottom - Babcock & Wilcox Unique Design instead of conventional bed plate design. • India’s First Multifuel biomass fired AFBC boiler designed to handle high alkali fuels. • Easy control of bed chemistry ensures high availability and continues power generation • Easy removal of agglomerates,large amount of stones and mud ensure trouble free operation round the year • Separate bunkers & feeders for storing and feeding variety of fuels to meet any interruption in fuel availability. • High fuel flexibility ensures cost effectiveness in power generation. • Staggered air supply arrangement ensures complete combustion and high thermal efficiency. BIOMASS POWER - KHANNA PAPER ATMOSPHERIC FLUIDIZED BED BOILER • Capacity - 70 tph, 66kg cm2g, 485 Deg C for 15MW • Fuels Used : Rice Husk, Padthal, etc. FEATURES • India’s First large capacity ricehusk / biomass fired boiler designed to handle multiple biomass fuels with a provision for coal. Proper fluidization, less chances of clinker formation or local hot spots. Specially designed distributor plate - Babcock & Wilcox Design Adequately sized bed drain system - Controls bed inventory that ensures high availability and continues power generation Easy removal of large amount of stones and mud ensure trouble free operation round the year. Separate bunkers & feeders for storing and feeding variety of fuels to meet any interruption in fuel availability. Staggered air supply arrangement ensures complete combustion and high thermal efficiency. Multiple fuel feeding arrangement (Overbed / Under bed options) ensures operation round the year. • • • • • • • BIOMASS POWER-NESTLE NANGANGUD ATMOSPHERIC FLUIDIZED BED BOILER Capacity Fuel - 15 tph, 24 kgf/cm2, 223 deg.cel. - High moisture fuels such as Spent Coffee Ground, Spent Tea Ground, Coconut shell , Coal - Over bed - No inbed surfaces - 140 deg C - 320 deg C - 62 %( 64%Moisture - M. loss alone -25%) - NOx- 300 ppm, CO- <100 ppm Fuel feed Pressure parts Back End temperature Air preheat temp Efficiency Emissions DESIGN FOR FIRING IN VARIOUS COMBINATIONS SCG-85%M SCG-60%M STG70%M Coal Coconut shell. B&W/ TBW IR-CFB technology B&W/ TBW IR-CFB technology # # # # # # # # High combustion efficiency Compact, economical design Higher reliability & availability Lower maintenance costs Reduced erosion Fuel flexibility Low emissions Lower plan area EFB FEEDING AND FIRING ON OVERTHRUST GRATE FLUID BED - EXPERIENCE of THERMAX 1. 2. 3. LOW CAPACITY PROCESS BOILERS - UP 10 TPH - BY PROCESS HEAT DIVISION. MEDIUM CAPACITY BOILERS - 10 TPH TO 30 TPH BY ENERGY SYSTEM DIVISIONDIVISION. LARGE CAPACITY BOILERS- 30 TPH AND ABOVE BY THERMAX BABCOCK & WILCOX LTD EXECUTED MORE THAN 900 FLUID BED BOILERS TBW TRAVAGRATE SPREADER STOKER Catenary Design Provides automatic take-up or tensioning of grate chains. External shaft adjustments not required. SIDE SEAL CASTINGS GRATE CASTINGS FRONT BOTTOM SEALS SUPPORT FRAME Grate surface Grate surface is made in short sections- low maintenance cost Small sections castings (230 and 300 mm). JGC A/c Riotuba Nickel Project (Palwan Phillipines) 1 X 105 TPH, INDONESIAN COAL FIRED TRAVELLING GRATE BOILER FLUID BED - EXPERIENCE 1. 2. 3. LOW CAPACITY PROCESS BOILERS - UP 10 TPH - BY PROCESS HEAT DIVISION. MEDIUM CAPACITY BOILERS - 10 TPH TO 30 TPH BY ENERGY SYSTEM DIVISIONDIVISION. LARGE CAPACITY BOILERS- 30 TPH AND ABOVE BY THERMAX BABCOCK & WILCOX LTD EXECUTED MORE THAN 900 FLUID BED BOILERS EXPERIENCE ON MULTIFUELS Talcher Coal High Alfa Quartz Content - Very Erosive Ash 1 x 60 TPH Boiler in operation since 1996 at J K Corporation Raigada Orissa. 2 X 110 TPH Boilers in operation at Paradeep Orissa for Oswal Chemicals & Fertilizers. ( 55 MW CPP) 2 x 65 TPH, 93 ata under Commissioning for 1 x 30 MW CPP at Nava Bharat Ferro Alloys Ltd. Washery middlings Very High ash Content ( >60%) 2 x 95 TPH Boilers are in operation since 1998 at L&T Awarpur Cement Plant ( 2 x 23 MW CPP) at Chandrapur Grade C to F coal Wide range of Calorific value and Ash content 1 x 110 TPH Boiler in operation since 2000 at Usha Martin through L&T (25 MW CPP) - at Jamashedpur 1 x 100 TPH, 105 ata at Karnool AP for Sri Rayalseema Allied & Chemicals Ltd. (25 MW) under execution EXPERIENCE ON LIGNITE Kutch / Rajasthan Lignite Slagging & Fouling nature of Ash • 1 x 90 TPH, 105 ata Pressure Boiler is in operation since 1998 at GHCL Veraval Gujarat • • • • 1 x 47 TPH, 47 Ksca, Boiler under commissioning at Nova Petro Chemicals Limited, Ahmedabad. 1 x 70 TPH, 66 kg/cm2(g), Boiler in operation since 2002 at M/S Khanna Paper Mills, Amritsar, Punjab. 2 x 80 TPH, 64 kg/cm2(g), Boilers in operation since 2002 at M/S Shree cements limited, Beawar, Rajasthan. 1 x 48 TPH, 66 Ksca, Boiler under commissioning at M/S Sangam Spinners, Rajasthan. EXPERIENCE ON PET COKE Petcoke Very high Sulfur >6% & very low ash <1%, High carbon content 1. 2 x 80 TPH Petcoke & coal fired Boilers already commissioned Shree Cement at Beawar, Rajashthan 2. 1 x 70 TPH, Pet coke, Lignite fired boiler in operation since 2002 at Khanna paper mills, Amritsar, Punjab. 3. 1 X 47 TPH lignite, coal and Petcoke fired under operation at Nova Petro Chemicals Ahmedabad. 4. 1 x 48 TPH coal and Petcoke fired boiler under commissioing at Sangam Spinners, Bhilwara,Rajasthan 5. 1 x 50 TPH rice husk, coal and Petcoke fired Boiler under execution for Chaddha Paper, Rampur UP 6. 2 x 45 TPH, Imported coal, Rice husk and Petcoke fired under execution for Gujarat Ambuja Cement (Ropar unit) 7. 1 x 100 TPH, Pet coke, Lignite, Paper sludge and plastic waste fired boiler is under execution at Khanna paper mills, Amritsar, Punjab. EXPERIENCE ON AGRO WASTE Rice Husk Agro waste fuel 1 x 70 TPH Rice Husk fired Boiler at Khanna Paper Amritsar 1 x 35 TPH Rice Husk and coal fired boiler at JCT Ltd. Phagwara 1 x 30 TPH Boiler in operation since 2001at Dokiparru AP for Jocil Ltd 1 x 35 TPH Boiler in operation since 2003 at Saro Power Ltd. AP EXPERIENCE ON BIOMASS Biomass Juli Flora, Cotton stalk, Coconut Shell, Mustered Husk, etc 1 x 30 TPH Boiler in operation since 2001at Dokiparru AP for Jocil Ltd 1 x 35 TPH Boiler in operation since 2003 at Saro Power Ltd. AP Coffee Ground Very high moisture- > 85% 1 x 18 TPH Boiler in operation for > 5 years at Nestle Ltd, Nanjangud, Karnataka 1 x 15 TPH Boiler under execution for Nestle (Quality Coffee Thailand) 1 x 17 TPH Boiler under execution for Nestle - Russia EXPERIENCE ON HOPPER BOTTOM FLUID BED Biomass Julia Flora, Cotton stalk, Coconut Shell, Mustered Husk, etc 1 x 30 TPH Boiler in operation since 2001at Dokiparru AP for Jocil Ltd 1 x 35 TPH Boiler in operation since 2003 at Saro Power Ltd. AP 1 x 85 TPH, 87 ata, coal and Char Fired AFBC boiler for Bhushan Steels Orissa 1 x 100 TPH, Pet coke, Lignite, Paper sludge and plastic waste fired boiler is under execution at Khanna paper mills, Amritsar, Punjab. Coffee Ground Very high moisture- > 85% 1 x 17 TPH Boiler under execution for Nestle - Russia EXPERIENCE IN STEEL INDUSTRY Steel Industry 1 X 110 TPH, 66 kg/cm2(g) Boiler in operation at M/S Usha Martin Industries Limited, Jamshedpur. ( 25 MW CPP) 2 X 110 TPH, 66 kg/cm2(g) Boilers in operation at Paradeep Orissa for Oswal Chemicals & Fertilizers. ( 55 MW CPP) 2 x 65 TPH, 93 ata boilers in operation at Nava Bharat Ferro Alloys Ltd. (30 MW CPP) 1 x 85 TPH, 87 ata Hopper bottom design, coal and Char Fired AFBC boiler for Bhushan Steels Orissa TBW’s Experience -CFBC Boiler Technology in India. B&W Design Internal Re-circulation CFB Boiler with SS U beams as primary solids separator. 1 x 105 TPH, 67 ata 480°C high ash coal fired CFB boiler at Kanoria Chemicals Renukoot UP. In operation since 1997.