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The EU-Project RECOFUEL Part 1: Production of SBS ® Part 2: Use of SBS ® in PC and CFB-plants. Part 1: Production of SBS ®. Two quality groups, two trade marks since 1995/1998. SBS ®. BPG ®. B rennstoff aus p roduktionsspezifischen G ewerbeabfällen. S ubstitut b renn s toff.

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The EU-Project RECOFUEL Part 1: Production of SBS ® Part 2: Use of SBS ® in PC and CFB-plants


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slide1

The EU-Project RECOFUEL

Part 1: Production of SBS®

Part 2: Use of SBS® in PC and CFB-plants

part 1 production of sbs
Part 1:

Production of SBS®

two quality groups two trade marks since 1995 1998
Two quality groups, two trade markssince 1995/1998

SBS®

BPG®

Brennstoff ausproduktionsspezifischenGewerbeabfällen

Substitutbrennstoff

High calorific fractions

(HCF)

sorted out from

poste-use waste

Source seperated

wastes /

production residues

5 different qualities for different customers
5 different qualitiesfor different customers

SBS 1power plants

lignite

BPG 1

power plants

BPG 2cement kilns

BPG 3lime kilns

SBS 2cement kilns

hard coal

different high-calorific fractions

from

-MSW

-demolition wastes

residues from

paper

productionrejects,punchings,photography

paper,blocks,wet-strength

paper,cellulose

cloths etc.

paper wastesas BPG 1,plastics- resins- polyacrylic- polyester- polyolefine- PUR

- etc.fibre fabrics

carpets etc.

low ash

plastics- resins- polyacrylic- polyester- polyolefine- PUR

- etc.

see SBS 1

input materials for sbs

mechanical-biological treatment plant

high calorific fraction (HCF1)

high calorific fraction (HCF2)

LFP-sorting

construction and demolition wastes

high calorific fraction (HCF3)

SBS®

high calorific fraction (HCF4)

bulky wastes

high calorific fraction (HCF5)

commercial wastes

high calorific fraction (HCF6)

composting

Input materialsfor SBS®

SBS®-production

QA ofSBS®

Quality Assurance of HCF`s

slide6

Specifications

for BPG® and SBS®

slide7

Bulky/Commer-

cial waste

feeding

biomass

water

MSW

feeding

biol. drying

residues/ MSWI

screening

Fe-/ NF-

seperation

Fe-/ NF-

metals

Fe-/ NF-

seperation

NIR-

seperation

New plant (ABA)

SRF-plant (AKEA)

fine grinding

storage/

loading

SRF`s:

BPG® and SBS®

HCF

NF-seperation

size reduction

Fe-seperation

Fe-/ NF-

metals

Production

wastes

feeding

Prior size

reduction-

windshifting

disturbent

materials

LFP-residues, production w.

feeding

NIR-seperation

residues

Waste treatment center VZEK, ErftstadtFlow-sheet (12/2005)

slide8

Near Infrared-System

Computer

(NIR)

Camera

Feeding

Nozzle Pipes Control System

Positive fraction

Acceleration conveyor

Nozzles

Sorting residues

Positive fraction  SBS®

Sorting residues  MSWI

HCF-Sorting with NIR-systemspositive separation

slide9

Development of input materials

for SBS®1E [weight %]

slide10

Extended QMS

for the production of SBS®

Process-chain

QA-chain

Acceptance area

Input control

Positive sorting of HCF

Process control

SBS®-Production

Process control

Product control:

Internal and external

SBS®-Storage

ISO 9001 

EFB 

RAL-GZ 724 

CEN TC 343 

quality product control

Regular sampling

during production

Analysis of H2O in the plant

Single samples are combined to

500-Mg-mixed-samples,....

Sampling behind last step

of size reduction

... and are analysed by

an external laboratory :

Every 1.500 Mg additional

parameters are analysed:

Delivery to the customer

Analysis report – Number ...

1.500-Mg-analysis

for BPG and SBS

Parameter:

ds, H2O, Cl, Ash, NCV, F, ...

HM Group I-III:

As, Be, Cd, Co, Cu, Hg, Mn, Mo,

Ni, Pb, Sb, Se, Sn, Te, Tl, V, Zn

Ash:

Al2O3, CaO, Fe2O3, K2O, MgO,

Na2O, P2O5, SiO2, SO3, TiO2, ZnO

Analysis report – Number ...

500-Mg-analysis

for BPG and SBS 

Parameter:

ds, H2O, Cl, Ash, NCV

+ 2 HM (changing monthly)

Quality/product control
development of cl values of sbs since 1997 n 919 10 2007
Development of Cl-values of SBS®since 1997 (n = 919, 10/2007)

First trials with NIR

Effect of German landfill-directive

development of parameters with slagging fouling or corrosion potential for sbs 1 08 2007
Development of parameterswith slagging, fouling- or corrosion-potential for SBS®1 (08/2007)
slide16

realistic

fossil

share

realistic

fossil

share

120

110

100

90

80

70

60

50

40

30

SBS1

BPG2

Hard coal

Natural gas

Light fuel oil

Lignite

Heavy fuel oil

Energy specific CO2-emissionsof different fuels

t CO2/TJ

CO2-reduction:0,75(HC) - 1(BC) t CO2 /SBS(with 50% biomass content)

16

slide17
Part 2:

Use of SBS®

in Pulverized Coal-

and Circulating Fluidized Bed-plants

within the

RECOFUEL-project

slide18

EU-Project RECOFUELProduction of SRF (SBS®) and use in lignite boilers

  • term
    • duration 36/48 month
    • start June 2004
  • partner
    • consortium 12 partner of 6 EU-states
    • coordinator REMONDIS
  • issues
    • sustainable production of SRF`s suitable for power plants
    • environmental acceptability and technological feasibility
    • accompanying research
    • european technology transfer
slide19

Project RECOFUELmain issues of the partners

  • REMONDIS SRF-production + coordination
  • RWE Power large-scale demonstration co-combustion
  • University Stuttgart lab tests + simulation
  • INFA balances of SRF-production
  • KEMA ash properties + corrosion
  • TAUW quality control in the power plant
  • CESI corrosion
  • Åbo Akademi Process SFR properties + ash
  • University of Athens combustion model
  • VINCA mill measurements
  • ESSENT technology transfer
  • PPC technology transfer
slide21

PC-plant of RWE Power in WeisweilerFeeding device for paper sludge (incl. 3 hoppers)

Source:

RWE Power

slide22

Co-combustion of SBS® with lignitein Weisweiler

SRFdelivery

cooling tower

Fluff

SBS-delivery: average 20-25 Mg/h maximum 50 Mg/h

boilers with primary DENOX:

2 x 600 MWel

hopper

REAdesulphorisation

lignite supply

1200 Mg/h

Source:

RWE Power

electrostatic filter

8 coal mills

trials at weisweiler pp in 2005
Trials at WeisweilerPP in 2005

SBS®1: 4200 Mg, 12,5 Mg/h (up to 4% thermal share)

Paper sludge during SBS®1: ca. 13000 Mg

Lignite during SBS®1: ca. 345 000 Mg

Steam data: 530°Cel., 169 bar

  • Test and measurement plan:
  • Input and output analysis of SBS®1 production
  • Fuel input analysis at the power plant
  • Analysis of the biogenic content
  • Investigation of fuel preparation and mill behaviour
  • Emission measurement in flue gas
    • Flue gas composition
    • HCl-measurement in the raw gas
  • Furnace measurements
  • O2- and temperature meas. before/after mill
  • Analysis combustion residues
  • First investigations of the corrosion potential

Source: IVD, University Stuttgart

slide24

Direct co-combustion

of SBS®1 in Weisweiler

Source:

RWE Power

slide25

Evaluation of SBS®-co-incinerationin Weisweiler

  • quality of SRF (SBS®)
  • delivery and transfer
  • feeding and dosing
  • combustion behaviour (ignition and burnout)
  • fixing of heavy metals etc. in ash and gypsum
  • flue gas cleaning system
  • emissions according 17. BImSchV (WID)
  • landfilling characteristics of combustion residues

Co-incineration of SBS® in lignite power plants is technically and environmentally feasible

Source:

RWE Power

extension of the project to a new power plant and a duration of 48 months
Motivation:

Missing longterm permission in PC-plant of Weisweiler

Existing feeding technology in CFB/CHP-plant Berrenrath

Existing longterm permission for SBS®-use in Berrenrath

Consequences:

Additional administrative work (Consortium and EC)

Increased knowledge about corrosion risk with respect to two technologies

Use of the potential of lignite burning PC-power plants in West-Germany postphoned

Use of the potential of CFB-plants stabilized

Extension of the projectto a new power plant and a duration of 48 months
berrenrath power plant
Berrenrath Power Plant

Source:

RWE Power

co combustion installations of the berrenrath power plant
Co-combustion installationsof the Berrenrath Power Plant

sewage sludge

pulverized lignite coke (activated carbon)

run-of-mine-lignite

SBS®1

Source:

RWE Power

cfb boiler chp in berrenrath

SUPERHEATER 4

SUPERHEATER 3

SUPERHEATER 2

ECONOMIZER

AIR PREHEATER

CFB boiler (CHP)in Berrenrath
  • BERRENRATH CFB (ca. 300 MWtherm)
  • Steam data :
    • 77.8 kg/s
    • 510 ºC
    • 90 bar
  • Fuels :
    • Lignite
    • Sewage sludge
    • Lignite sludge
    • Demolition wood
    • SRF (up to 25% thermal share)

Source:

RWE Power

summary part 1 2
NIR-technology is the key to select suitable high calorific fractions from MSW, bulky waste and mixed commercial wastes

NIR-technology in development (improvements of selectivity)

Modern treatment-technology is the basis for good chemical und physical fuels properties

QMS according RAL-GZ 724/CEN TC 343 can improve the reliability of fuel properties

Improved SBS®1-qualities even after effectiveness of landfill directive

Very low Cl-values (mean of 3 assays < 0,5% of d.s., max < 0,7% of d.s.) requested by RWE Power

New location for longterm-tests: CHP-plant in Berrenrath (CFB-techn.)

Interesting CO2-reduction potential: 1t CO2/t SBS®1

Summarypart 1-2
slide31
Acknowledgment

The RECOFUEL-project is funded by the European Commission under the Sixth Framework Programme

European Commission Directorate-General for Energy and Transport

and

Intelligent Energy Europe

Thank you!