The beginning

1.000.000 B.C.

Grate combustion technology

AUE 4. November 2013

Jørgen Hansen

Proprietary and Confidential

The developement The developement

15.000 B.C. 1500 A.D.
Year 0

1700 A.D

Controlled combustion
Proprietary and Confidential Proprietary and Confidential

The developement The fuels – very different properties

1870
B&W Water tube boilers

One fireman
max 1.5 tons coal pr. hour
Approx 12 MW

Proprietary and Confidential Proprietary and Confidential

1
 Extreme fuel - house hold waste Extreme fuel – Fresh Eucalyptus

Using this as a
fuel would make
any Koala bear
cry
Proprietary and Confidential Proprietary and Confidential

What is our task?
Solid fuels – relevant parameters

Hot flue gas

Heat Chemical properties Physical properties

Calorific value Density

Proximate analyses Size distribution
Ultimate analyses Particle shape
Ash analyses Humidity
Ash melting behavior Foreign matters
C-H-O + O2 → CO2 + H2O

Fuel Oxygen (air)

Proprietary and Confidential Proprietary and Confidential

Chemical properties
Combustion

1

Gas phase: CO + O2 → CO2
2

 − EA 
k p (T ) = A exp  

Reaction rate:  Ru T 

d [CO2 ]

Concentration CO and O2: = k p [CO ][O2 ]
dt

Proprietary and Confidential Proprietary and Confidential

2

The TTT rule – gas phase combustion
The fixed carbon combustion

Temperature

Time

Turbulens

Proprietary and Confidential Proprietary and Confidential

The combustion proces on the grate
The plant design challenges

The processes in a burning solid

fuel bed include:
 Drying
 Ignition
 Pyrolysis
 Gasification
 Solid-phase combustion
 Gas-phase combustion
The process is mainly controlled by
mass and heat transfer
Proprietary and Confidential Proprietary and Confidential

The Vølund Component Palette
The grate

Grates: Stokers and misc. firing equip.:

Air cooled waste grate type Vølund Hydraulic pusher

Water cooled waste grate type Vølund Feeding grate type Vølund

Air cooled waste grate type DynaGrate
Air cooled step grate type ASG
Water cooled vibration grate type HVB and
HVBD
Traveling grate type L
Hydraulic biomass feeder type HF
Pneumatic biomass spreader type ASA
Mechanical coal spreader type SF
Big bale burner type SBH

Traveling grate type WR Biomass rake type RBR

Spreader stoker grate type SL Biomass screw stoker

Chain grate type CR Charging chute for bulk material

Proprietary and Confidential Proprietary and Confidential

3

What does the grate do
Traditional step grate

Support the fuel – mechanical strength

Allow primary air access to the fuel - penetrated

Move the fuel with controllable velocity – proportional control

Tumble the fuel – if necessary – special surface movements

Move the ash against the slag chute

Withstand the high temperature – cooled or high alloy bars

Proprietary and Confidential Proprietary and Confidential

Traditional travelling
Waste combustion grates

Traditional waste grate type ”Vølund”

Modern waste grate

design type DynaGrate®

Travelling grate type L and SL

Originally developped for hard
coal. Today an excellent choise
for retrofit coal boilers with
combined firing coal/peat/bio.

Proprietary and Confidential Proprietary and Confidential © 2008 Babcock & Wilcox Vølund A/S. All rights reserved. .22

The unique DynaGrate® movements DynaGrate® – Air cooled and water cooled

Proprietary and Confidential © 2008 Babcock & Wilcox Vølund A/S. All rights reserved. .23 Proprietary and Confidential © 2008 Babcock & Wilcox Vølund A/S. All rights reserved. .24

4
 Some DynaGrate® data Water cooled vibration grate

West Palm Beach Hjørring

Grate area 133 m² Grate area 14,4 m²
37,8 t/h waste 3,8 t/h waste

Vibrationgrate type HVB

Erected and mechanical tested i
the workshop ready for shipment

Proprietary and Confidential Proprietary and Confidential

Vibration grate, standard surface and air sealing Water cooled vibration grate
Stoker Surface
Furnace
Customized hole pattern
Vibrating Wall
in
Grate panel Tubes
Furnace Membrane
Wall

Connecting
Rod
T-block
Gravity Seal Features:
•Hole diameter: 4-8mm
•Air velocity: 20 - 40 m/s
•Air temperature: 0 – 300ºC
•Part of evaporator
•Naturally circulating
•Can operate without ash cover Motor
2 x 3 Hopper Compartments
(e.g. oil or gas burner above)
•Inclined 6º

Proprietary and Confidential Proprietary and Confidential

Water cooled vibration grate Water cooled vibration grate

Furnace
Front
Wall
Stoker Springs
Grate Linkage Motor
and Vibrating
Mechanism Vibrating drive
Ash beams
Discharge
Hopper

Stoker Supports Connecting Rod

with cover

Undergrate Air Air Compartments

Plenum Siftings Hoppers

Proprietary and Confidential Proprietary and Confidential

5
 Water cooled vibration grate Water cooled vibration grate
Electric Motor

Vibrating
Mechanism
Electric Motor
Vibrating
Mechanism

Vibrating Drive Beam

(not shown)

Stoker Support Vibrating

Structure Mechanism
Support

Proprietary and Confidential Proprietary and Confidential

Water cooled vibration grate Water cooled vibration grate

Two panels for less than 6,4 m boiler width Four panels for more than 6,4 m boiler width

Proprietary and Confidential Proprietary and Confidential

Water cooled vibration grate Vibration grate, air sealing

HVBD for better char burn out
Uncooled for standing Cooled for hanging boilers
boilers

Proprietary and Confidential Proprietary and Confidential

6
 Vibration grate – hanging boiler Water cooled vibration grate
Equipped with cast blocks for difficult fuel

HVB 11259 for Händelö P11

Design data:
Thermal load 97 MW
Wall panels 115 Bar 320 Co
Proprietary and Confidential © 2008 Babcock & Wilcox Vølund A/S. All rights reserved. .37 Proprietary and Confidential © 2008 Babcock & Wilcox Vølund A/S. All rights reserved. .38

Vølund capacities B&W Vølund experience

Boiler size 20 – 200 MW th

Se
c.
ai
r
Se
c.
ai
r
Bi
o-
fu
el

Se
c.
ai
rSe
c.
ai
r
Se A1
e 43
dr 3-
w
g. 4-

Se
c.
ai
r
03
82
A
System

Se
c.
ai
r
Fuel\
0 – 70 MW el

Pu
ls
at
in
g
ai
r

Se
c.
ai
r
B
Se
c.
ai
r

LR
Steam data 16 Bar saturated

140 Bar 540 oC Hay and straw from wheat, Excellent Limited co-combustion No experience
rape, barley etc. Good
(330 Bar 580 oC)
Chips or pellets from Good Excellent Good
wood, bark, forest residue,
palm oil waste etc.
Fuels Biomass
Crushed fibrous biomass No experience Bad Excellent
like eucalyptus
Waste (Household and industry)

Hard coal and brown coal RDF, paper reject, RT wood Good Good Good
chips. If BVW size distribution
curve is observed
(Oil and Gas)

Proprietary and Confidential Proprietary and Confidential

Fuel feeding systems for grate firing Straw combustion

All baled fuel types, such as corn
stalks, thisels and switchgrass

Baled material combustion :
 Straw bales from wheat, barley, hey, rice, etc.
 Stalk bales from rape, thistles, etc.

Bulk material suspension combustion :

 Chipped wood, bark etc. acc. to BWV standard sieve analyses
 Crushed prunings, residue, peat, etc.
 Pilletised fuels.
 Particle shaped fuels like saw dust, baggase, husk etc.

Bulk material grate combustion :

 All above bio fuels not full filling the standard sieve analyses

Proprietary and Confidential Proprietary and Confidential

7
 Straw combustion Straw combustion
Bale logistic

Bale feeding system, bale rake, stoker

screw and grate layout

Proprietary and Confidential Proprietary and Confidential

Straw combustion Straw combustion

Test rig at workshop before String cutter

installing on test facility Bale stroke tipper

Test rig at work shop

Capacity 35 – 50 MW

Dosing drum Raking drum:

Engage each stroke and Higher tangential
One slice is loosened. Strings
drag it against the raking speed than the
get through the system without
drum dosing drum
creating problems.

Low density straw: ~20 kg/m3

Large visible surface

Proprietary and Confidential Proprietary and Confidential

Straw combustion Straw combustion

Rotary biomass rake type RBR 1300
opens and loosen any baled biomass
type.

Can be adopted to any big bale size

on the marked.

Proprietary and Confidential Proprietary and Confidential

8
 Straw combustion Straw combustion

Proprietary and Confidential Proprietary and Confidential

AVV2 Straw combustion Bulk fuel combustion

 Advanced Steam Data
583C, 310 bara
End superheater
 Loosened straw for grate firing
 Slag tap super heater

Slag tap superheater

Straw rotary rake

Stoker screw

Water cooled vibration grate

Proprietary and Confidential Proprietary and Confidential

Suspension firing bulk fuels Suspension firing bulk fuels

Small particles are carried over Large particles fall
and burnout in 1st pass. onto grate
100
%

General size limits for

suspension firing with
air spouts on an water
cooled vibrating grate
10

1
0,1 1 10 100 1000
Particle size: D = 0,25 mm Particle size: D = 10 mm
mm

Proprietary and Confidential Proprietary and Confidential

9
 Furnace and grate layout Furnace and grate layout

Air spouts

Grate heat release: Tertiary air

1.4 – 2.5 MW/m2

Sec.air front

Air spouts
Sec.back

Proprietary and Confidential Proprietary and Confidential

Spout feeding system design Day silo and fuel feeding

Two different “day” silos

Coarse and wet particles with Small, dry particles or fuels with a
limited content of fines high content of fines and dust

Proprietary and Confidential Proprietary and Confidential

Day silo and fuel feeding Day silo and fuel feeding

Vibrating
Sizing Screen
100
%

10

1
0,1 1 10 100 1000
mm

Proprietary and Confidential Proprietary and Confidential

10
 Day silo and fuel feeding Day silo and fuel feeding

System set up for best

Day Silo boiler control

S
e
c
.
a
ir
S
e
c
.
a
ir
B
io
-
fu
e
l

S
e
c
.
a
irS
e
c
.
a
ir
SA
e1
e4
d3
r3
w-
g4
.-

S
e
c
.
a
ir
0
3
8
2
A

S
e
c
.
a
ir
P
u
ls
a
t
in
g
a
ir

S
e
c
.
a
ir
B
S
e
c
.
a
ir

R
L
Proprietary and Confidential Proprietary and Confidential

Day silo and fuel feeding Day silo and fuel feeding

Proprietary and Confidential Proprietary and Confidential

Day silo and fuel feeding Day silo and fuel feeding

Cold feeding test to observe distribution on grate Perfect distribution and even heat release

Proprietary and Confidential Proprietary and Confidential

11
 Grate firing very coarse bulk fuels Grate firing very coarse bulk fuels

Strängnäs:
Crane feeding and hydraulic
pusher to fire coarse wood and
waste fuels

Proprietary and Confidential Proprietary and Confidential

Grate firing very coarse bulk fuels Landskrona Multifuel Fired plant, 2012

Damper
SA-front Volumix
Burners

SA back

Feed arch

Pusher

Proprietary and Confidential Proprietary and Confidential

Grate firing very fine bulk fuels Biowanze bran firing

Biowanze: Biowanze:

100 m3 ”day” silo and water 100 m3 ”day” silo and 6 water
cooled screw stokers for cooled screw stokers for
maximum capacity control maximum capacity control

Proprietary and Confidential Proprietary and Confidential

12
 Biowanze bran firing Alternative combustion system - BFB
850-900C
Front wall penetrations

Alkali and phosphor content in

fuel calls for a furnace with no or
litle use of refractory.

Stoker screw penetrations

designed in accordance with this.

Proprietary and Confidential © 2008 Babcock & Wilcox Vølund A/S. All rights reserved. .73 Proprietary and Confidential

Product gas

Alternative combustion system - CFB Gasification

Up-draft technology originally

acquired from Dr. Gatzke
Drying • A B&W Vølund research area
since 1988
Pyrolysis Fuel
• Licensed to:
Reduction
• JFE Engineering Corp. -
Oxidation Japan

Ash Steam/Air
Proprietary and Confidential Proprietary and Confidential

Gasification Gasification
Full developed
Harboøre Plant

Combined cycle plant

Developed and ready for sale

Combined Cycle Gasifier - Process

Proprietary and Confidential Proprietary and Confidential

13
 Capacity diagram Heat and Mass balance
Lambda versus T-prim og brændselsfugt

1,60

1,55

1,50
0C
1,45 100 C
1,40 200 C

Lambda
300 C
1,35

1,30

1,25

1,20

1,15

1,10
0 5 10 15 20 25 30 35 40 45 50 55 60
Fugtighed %

Proprietary and Confidential Proprietary and Confidential

Basic combustion design Boiler design

Strängnäs 40 MW th Landskrona 33 MW th

Furnace volume load 252 kW/m3 190 kW/m3

Proprietary and Confidential Proprietary and Confidential

CFD Secondary air system design CFD Secondary air system design
TA nozzles
TA-principle

Secondary Air Refractory for high radiation

intensity to increase particle

In the furnace: OFA 3.1 temperature and increase
OFA 3.2 particle combustion rate
Front
OFA 2.1
Back OFA 2.2
OFA 1.1 Uniform flow increase real

In the boiler first pass: OFA 1.2 particle residence time

Over Fire Air (OFA) Front Tangential flow increase

particle separation due to
wall collision
Back

Proprietary and Confidential Proprietary and Confidential

14
 CFD Secondary air system design Process & Instrumentation diagrams
Volumix® OFA 1.2 OFA 1.1

OFA 1.1

OFA 1.2

OFA 1.1

OFA 1.2 OFA 1.1

Plane 4,5m above OFA1 Air injection from OFA nozzles

A100
Proprietary and Confidential Proprietary and Confidential

CFD Flus gas distribution CFD Particle tracks

Char combustion

Pyrolysis

Boiling

Drying

Heating/cooling
A100 C100 A100 C100

Symmetry plane Symmetry plane

Proprietary and Confidential Proprietary and Confidential

CFD Temperature distribution CFD Temperature distribution - SNCR

1.pass 2.pass A 100

1600
Average Temperature 1.pass °C
Minimum Temperature 1.pass °C
1400 Max imum Temperature 1.pass °C
Average Temperature 2.pass °C
Minimum Temperature 2.pass °C
1200
+8 m Max imum Temperature 2.pass °C

1000
Temperature [°C]

800

+6 m
600

400
+4m
200

+2 m 0 1 2 3 4 5 6
Vertical position above furnace outlet [m]
7 8 9 10

Furnace
T2s>850°C
C 35

T2s>850°C outlet 1600

Average Temperature 1.pass °C
Minimum Temperature 1.pass °C

1400 Max imum Temperature 1.pass °C

Average Temperature 2.pass °C
Minimum Temperature 2.pass °C
1200 Max imum Temperature 2.pass °C

1000
Temperature [°C]

800

600

400

A100 C100 200

0
0 1 2 3 4 5 6 7 8 9 10

Symmetry plane Vertical position above furnace outlet [m]

Proprietary and Confidential Proprietary and Confidential

15
 CFD CO distribution Flue gas emission

Necessary conditions for obtaining low

emission values

Continous fuel feed

Even fuel distribution
Stabil fuel quality
Calorific value according to boiler design
Even and adequate air distribution
Sufficient turbulence and recidence time
Stabil control circuites (feed water etc.)

A100 C100

Symmetry plane
Proprietary and Confidential Proprietary and Confidential

Flue gas emission Flue gas emission

Typical wood firing
Typical wood firing Typical straw firing

Typical straw firing

Proprietary and Confidential Proprietary and Confidential

Flue gas emission

NOx emission

500
N O x m g /N m 3 @ 6 % d ry O 2

400

300
0,5
200 1
1,5
100
2
0 2,5
Thank’s for listening
3,5 4,5 5,5 6,5 7,5 Dry O2 8,5

Proprietary and Confidential Proprietary and Confidential

16