Jornada de Cogeneracion

Genera 2010. IFEMA

Madrid / Spain

Design & operation experience of

a biomass plant
C. Khne; Dr. F. Pfab; C. Vento

Group structure

An der alten B5
25813 Husum
Tel. ++49 4841 697-0
Fax ++49 4841 697-222
info-nord@wulff-deutschland.de
www.wulff-deutschland.de

Siemensstrae 10-12
25813 Husum
Tel. ++49 4841 9650-0
Fax ++49 4841 6950-60
headoffice@umag.com
www.umag.de

Gasstrae 18/Haus 5
22761 Hamburg
Tel. ++49 40 8517926-0
Fax ++49 40 8517926-29
info@wulff-hamburg.de
www.wulff-deutschland.de

Process & supply chain

Supply of customized plants for energy generation (steam, heat and

electricity) on the basis of most diverse primary energies (fossil fuels,
biomass and refuse-derived fuels).
Group competence covers the entire process chain: engineering,
design, fabrication, assembly, commissioning and after-sales service.
Focus: Thermal energy

Focus: Thermal & electrical energy

Standard solutions
from the catalogue

1 MW

Focus: Electricity
Ccustomized
for decentralized
ccombined heat & power plants

10 MW

Individual
large
power plants

100 MW

scale

Core Technologies

WULFF has its core competencies in the following technology areas:

Fuel technology (A)
Boiler technology (B) and
Exhaust gas technology (flue gas cleaning, C)

Engineering (G)
Service (H)
Fabrication of
- Grate and furnace systems
- Boilers (Waste heat; HRSGs; fresh air fired)
- Drying systems (disc dryer, rendering equipment)

CHP & CCP applications

UMAG HRSG system behind 30 MW gas turbine
Customer:

EUROPAC

Site:
Steam capacity:

Dueas / Spain
40 t/h at 63 bar, 432C HP steam
8,5 t/h 184C saturated LP steam
Rolls Royce RB211

Gas turbine:

Waste heat recovery boilers

UMAG waste heat boiler behind sewage sludge
combustion in a fluidized bed furnace
Customer:
Site:
Steam capacity:

BAMAG
Shell Green / UK
18 t/h, 42 bar/405C

Biomass Plants
Biomass Fuels
Most marketable fuels for WULFF
Biomass Plants are:

Wood and waste wood

AI

Natural wood or only mechanically machined

wood, which is only unsubstantially polluted, as
well as fresh wood from forestry.

A II

Waste wood being painted, coated, glued,

varnished or otherwise treated, free of
halogen-organic compounds or preservatives.

A III

Waste wood being coated with halogen-organic

compounds, but free of preservatives.

A IV

Waste wood being treated with preservatives,

such as wooden sleepers, telephone poles and
waste wood that can not be assigned to other
categories, except PCB-treated wood.

Sustainable fuels such as natural wood,

foresting residues, greens

Rape and rapeseed residues from biodiesel

refineries
Natural wood, such as bark, sawdust, pellets

Biomass Plants
Refuse-derived fuels (RDF)
for decentralized energy supply
Wulff development of waste-to-energy plants
As dumping or landfill of waste with significant organic content is prohibited by law, a high potential of
refuse derived fuel is available. RDF is made of commercial and industrial waste in mechanical and
biological waste treatment plants.
The energy recovery from RDF is clearly delimited from thermal waste treatment by law. Combustion
systems for highly contaminated waste wood have been the basis for the new developed RDF-toenergy plants.
The combustion chamber has been extended for low flue gas velocities and the grate has been
modified for 6 air sections.
Partial cladding of membrane walls protects against chlorine corrosion.

Due to the higher calorific value of these fuels the application of the WULFF water-cooled grate is
usually favorable.

Biomass plant Flohr / Neuwied

Fuel

Waste wood A1 A4 acc. German waste wood legislation AltholzVO

Heating value

12 18 MJ/kg, raw base

Water content

max. 31 weight %, raw base

Ash content

< 5 weight %, wf

Nitrogene content

< 4,3 weight %, wf

Firing capacity

30,2 MW

Fuel flow

6200 kg/h, wf

Steam quantity

32,3 t/h

Steam parameters

46 bar a / 455 C superheated HP steam

Control range

80 100 %

Electric capacity

6,2 MW by 7 MW heat displacement, max. 7,5 MW

Technology

Moving grate for coarse fuel / Single-drum water tube boiler

Flue gas scrubbing system

Dry flue gas scrubbing according to 17. BImSchV and SNCR

Particularities

Flue gas recirculation for combustion optimization and for grate cooling

Commissioning

End of 2004

Objectives
Economic / operational objectives
100 % reliability and guaranteed supply with process steam
Power generation using contaminated wood A1-A3 and simultaneous
generation of process steam via a regulated turbine bleed opening
Coverage of the process steam supply using natural gas-fired auxiliary
boilers

Environmental objectives
Improvement of the emission situation at site by lower emissions and shutoff of the outdated heavy-fuel fired boilers
Voluntary restriction of the operator only to generate 25% of the firing
capacity by using highly contaminated waste wood (A3)
Compliance with 17. BImSchV

Plant Concept

natural gas

auxiliary
boiler

natural gas

auxiliary
boiler

process
steam

turbine

electric
power

generator

waste
wood

combustion
(grate)

boiler

flue gas
cleaning

stack

Firing Capacity - Diagram

Biomass Boiler Operation

32,3 t/h

Main Boiler

t/h

exhaust steam
MP-header

process steam steel works

auxiliary
boiler 1

heating
t/h
LP-header

auxiliary
boiler 2

7 20 t/h

internal consumption

0 - 3 t/h

Peak Load Operation

32,3 t/h

Main boiler

up to 12 t/h

exhaust steam
MP-header

process steam steel works

auxiliary
boiler 1

internal consumption
heating
t/h
LP-header

auxiliary
boiler 2

20 28,5 t/h

3 - 5 t/h

Security Operation
0 t/h

Main boiler

3 12 t/h

exhaust steam
MP-header

process steam steel works

auxiliary
boiler 1

internal consumption
heating
3 12 t/h
LP-header

auxiliary
boiler 2

0 - 20 t/h

0 - 3 t/h

Boiler Concept & Design Criteria

Steam drum

ca. 300 C

shot-ball system

Eco 1

V2
850 C

sootblowers

Eco 2
1. pass

2. pass
1
ca. 6,5 m/s

ca. 4 - 5 m/s

Eco 3

2
< 650 C

Fuel

V1

Eco 4

ca. 700 C
ca. 1050 C

Eco 5

flue gas
to FCS
ca. 150 C

combustion
air
recirculated
flue gas
ash conveyor

Flue Gas Cleaning

Project Milestones

April 1999

Basic Engineering for approval

June 2000

Approval received

April 2003

Start of main order

March 2004

Start erection

June 2004

Boiler pressure test

October 2004

Operational readiness of the auxiliary boilers

December 2004

Operational readiness of the main boiler

Jan./ Febr. 2005

Test-runs

11.02.2005

Plant take-over and start of commercial operation

Emission Data
300

200

mg/m

200
150

100
50

50
18

10

1,7

0
Nox

CO

SO2

Emission limit

HCl

Full capacity reading

50

mg/m - g/m

40
30 g/m

30
20

20
10

10
2

0,5

0,1g/m

0
dust

total C
Emission limit

Full capacity reading

mercury

Plant Availability

10000
9500

hr/yr

9000
8500
8254

8000

8007

8336

8105

7500
7000
2004

2005

2006

2007

2008

2009

Grate after 4.000 Operation Hours

Superheater 2 after 4.000 operation hours

Thank you for your attention