Technology cooperation

The Fraunhofer IFF approach on decentralized energy utilization of waste and biomass using fluidized bed combustion technology
Opportunities for cooperation
Background Fluidized bed technology Energetic utilization – pilot plants Concept for technology and know-how transfer Annex

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation

Main Fraunhofer IFF Magdeburg building

Virtual Development and Training Centre The Fraunhofer IFF is an autonomous research organization within the Fraunhofer-Gesellschaft.
Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation From know how transfer to long term cooperation - Fluidized bed technology

Selected other areas

Partnership

a. b. b. c.

Renewable energies and smart grids ICT supported Sustainability Management in industries Logistic und automation, VR for planning processes Technical Vocational Education & Training …

Fluidized bed applications
Capacity & Institution Building

d. e.

R&D

Industry Applications

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Selected Project References Asia I
• Green Productivity Project (GPP I / II) (Indonesia, Thailand, Philippines, Vietnam / 1999 – 2005)
www.epa-for-industry.de

• Training on Cleaner Production Technology (CPT I / II / III / IV) (Indonesia, Thailand, Philippines, Vietnam / 2000 - 2003) • • Web Based Training: Life Cycle Oriented Plant Management (LCPM) (Vietnam, Indonesia, Thailand / 2001 - 2005) Information Technology and Communication in the Field of Sustainable Environmental Protection for Resource Intensive Enterprises (ASIA IT&C FORCE, Thailand / 2002 – 2004)
www.asia-itc-force.de)

Technology Transfer – Fluidized Bed Gasification Plant (Biomass / Hanoi, Vietnam / 2006)

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Selected Project References Asia II
• Technology Partnership and Training Cooperation in European Management Information Systems to Enhance the Competitiveness of Thai SMEs
(SPF TEAMS SME; Thailand / 2006 – 2007, www.teams-sme.de)

European-Malaysian Alliance and Capacity Building of Malaysian Intermediary Institutions in European MIS to Enhance Corporate Social Responsibility in Export Oriented Malaysian SMEs (EMIT CSR (Malaysia / 2007 – 2008, www.emit-csr.de)

Empowering Asian Business Intermediaries through Knowledge-based Networking focused on Sustainability Management (EMP-ASIA; Thailand, Vietnam / 2007 – 2009, www.empasia.org)

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation IFF Process and Plant Engineering – Areas
Biomass / Residues Bioethanol Production

Combustion

Gasification Syngas

Fermentation Biogas

Heat

Gas Cleaning and Gas Conditioning

Membrane Reactor
Fuel Cell
• ProBio • COST 543 • WISA • Intell-FC IFF R&D Activities
Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Organic Rankine Cycle
• Templin • Wolmirstedt

Gas Engine or Turbine
• Stackelitz

IFF Engineering Activities

Technology cooperation Fluidized bed technology - principle
Flue gas (high temp.)

Fluidized bed technology systems consist of a vertical pipe with an air distribution plate. The air distribution plate is covered by a bed material, usually quartz sand (yellow), mixed with the fuel (green). As air (gray) flows through the nozzles, it entrains the bed material with the combustible material into a fluidized state where the fuel is converted (flue gas - white ). New fuel is gradually fed into the fluidized bed from the side.
Fuel

Air distribution plate Air

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Application and advantages of the fluidized bed technology
Applications: Energetic utilization of solid matters (fossil fuel, biomass, residues, silage, sewage sluge, etc.) Waste processing e.g. incineration plant Product drying and coating Product treatment e.g. coffee roasting (food industry) Product design e.g. medical pills production (pharmaceutical-industry)

Advantages for energy conversion processes, i.e. combustion and gasification:
Use of a broad range of fuels with regard to lumpiness (broad grain size), type of fuel / heterogeneity, moisture content and content of contaminants (S, Cl) High combustion/gasifier performance with low space requirements Excellent mass and heat transfer conditions associated with process Excellent possibilities to intervene for process optimization at high dynamics.

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Decentralized energy utilization plants based on fluidized bed technology
Advantages for small and medium applications (1-20 MW) Low capacity Close to place of consumption CHP (combined heat and power) • • • • • • • High degree of fuel utilization Reduced resource consumption and greenhouse gas emissions Small fuel source radius Low transport costs Low grid costs and losses High investment certainty Regional value added

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Process and plant engineering know how
thermal energy biomass residues and waste materials energy transformation electricity
(self-sustaining energy supply of production processes and/or network supply)

(heating/cooling of industrial, commercial and municipal processes)

process development

plant engineering

plant control

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Energetic utilization of biomass – plant Wolmirstedt
Technology: Fluidized bed combustion Combined heat and power with ORC-process 4,3 MW firing thermal capacity Fuel: wood residues from forest and industry Fuel input: 1 t/h Power: 500 kWel / 2.400 kWtherm. (ORC) Heat: heating network Bodelschwingh-Haus E-power: sale to the public grid (EEG) Start of operation: 2007

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Energetic utilization of municipal waste – plant Neumünster
Technology: Fluidized bed combustion Steam cycle process 110 MW firing thermal capacity Fuel: community waste Fuel input: 20 t/h; 150.000 t/a Power: Max. 20 MWel - max. 90 MWtherm. Heat: district heating network E-power: sale to the public grid 2005

Start of operation:

source: www.stadtwerke-neumuenster.de
Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Consequences for technology application
Localization of technology to applications Market conditions (materials, demands on products, production process, prices, financial conditions) Local conditions (climate, culture …) Interdisciplinary qualified experts and specialist Institutionalized capacities and R&D (further development, ToT …) Adaptation by local businesses

Example The Fraunhofer IFF approach on decentralized energy utilization of waste and biomass using fluidized bed combustion technology
Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Scope and potential results of the IFF technology cooperation model

1.

Enable Indonesian engineers / organizations to utilize the full technological potential of fluidized bed technology for the benefit of their country (training of specialists and training of trainers) Apply the technology for market driven and environmentally friendly applications in Indonesia (design, construct and operate power plants) Support sustainable and decentralized energy supply Advance science and technology development through international and local research (R&D activities on fuel utilization and technology applications) Long term partnership and international R&D cooperation

2.

3. 4.

5.

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation
Components
Know-how transfer

Description
Training of 6 – 10 engineers in theory and practice on: 1. Solid fuel combustion, fluidized bed technology 2. Distributed low and medium capacity power plants 3. Operation of national train the trainer program Set up of infrastructure for engineering research and education purposes: 1.Engineering, construction and operation of semi-industrial scale BFBC (bubbling fluidized bed combustor) including measurement and analysis systems 2.Laboratory set up for fuel analysis (e.g. calorimeter, dry chamber, proximate and ash analyzer), and fuel conditioning (e.g. grinder, sieve apparatus) as well as work shop facilities. Realization of the first combustion plant with CHP and ORC-process: 1.Planning, engineering and construction of fluidized bed combustion plant, e.g. 4 - 6 MW firing thermal capacity (approx. 1 t/h fuel input), fuel possibilities: municipal waste, biomass or residues from forestry or industry 2.Qualification of plant operators and technicians Duration: 3 to 5 years depending on specification Project team: Fraunhofer IFF Magdeburg, Germany, Hamburg University of Technology (TUHH), Indonesian partners (private or public), private or public investors (Indonesian, international) Budget: Depending on specification – range 10 - 13 Mio EUR - turn key
Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Set up of knowledge infrastructure

Fluidized bed combustion application

Program organization

Technology cooperation Potential next steps / outlook
Initiation of cooperation and specification to set-up transfer program

Study Tour Germany / Indonesia Technology road show - practical tour on best practice examples Duration: approx. 14 days, costs: depending on number of participants

Feasibility study Analysis, evaluation of specific conditions, constraints and requirements Design of a tailored transfer and cooperation program respectively business plan for private investors, Duration: max. 12 months, approx. total costs: 120.000 EUR

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation

Annex

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Energetic utilization of biomass, waste and residues
Combustion - CHP plant principle
Fluidized bed Combustion module Boiler module Flue gas cleaning module Flue gas Additives Thermo Oil Biomass, waste or residues feed Sorbens

Air

Ash

Fly ash

ORC-Module
Heat (80/60°C)

Power
Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Energetic utilization of biomass, waste and residues
Gasification - CHP plant principle
heat extraction flue gas (district heating network) fluidized bed gasifier
fuel gas treatment fuel gas cooler

flue gas

ash ash

air air fuel gas

residual wood preheated air

gas engine

generator

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Potential project infrastructure for a national scale program
Supervision / Steering Financier / Ministries

Coordination Management Controlling Coordination / /Management / /Controlling IFF in cooperation with local partner IFF in cooperation with local partner Technology and Technology and Know-how Partner Know-how Partner (Germany) (Germany) Fraunhofer IFF Fraunhofer IFF Technical University Technical University of Hamburg of Hamburg … …

R&D and technology partner R&D and technology partner Universities, R&D centres Universities, R&D centres Commercialisation Partners Commercialisation Partners Biomass and residues suppliers, Biomass and residues suppliers, Energy consumer provider, Energy consumer / /provider, Local communities, Local communities, Engineering companies Engineering companies
Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Energetic utilization of biomass – plant Güssing, Austria

Technology: Fast Internal Circulating Fluidized Bed Steam Gasification Fuel: wood chips Fuel input: 2.3 t/h 2 MWel / 4.5 MWtherm Heat: district heating system 2002

Power:

Start of operation:

source: http://www.renet.at

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Energetic utilization of municiple solid waste – plant TwinRec, Japan
Technology: Fluidized Bed Gasification and Ash Melting Fuel: municiple solid waste Fuel input: 8.3 t/h, in 3 process lines 4 MWel / 3x9.5 MWtherm Heat:Ube City 2003

Power:

Start of Operation:

source: http://www.ebara.ch

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Energetic utilization of biomass – plant Northampton , USA
Technology: Circulating Fluidized Bed Combustion Steam Generation Fuel: culm Fuel input: 545,000 t/a Power: 110 MWel / 277 MWtherm primarily supplying steam to an adjacent pulp and paper mill Start of Operation: 1995

source: http://www.power-technology.com/projects/northampton/

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Energetic utilization of biomass and waste – plant Handelo , Sweden
Technology: Circulating Fluidized Bed Combustion Fuel: miniciple solid waste,industrial waste,sewage sludge,rubber and demolition wood Fuel input: 4000,000 t/a Power: 11 MWel / 75 MWtherm district heat and process steam Start of Operation: 2002

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

Technology cooperation Example for competences on related topics - wood logistics
ICT supported wood logistic chains “from the forest to the factory” focusing on its environmental orientation
Improvement of the supply chain from forest to factory Economic feasibility and cost cutting Transparency, information and communication Environmental compatibility and prevention Primary target groups Forestry and wood processing industries Forest and logistics service providers Forest owners Selected services and technologies Order management and condition monitoring Resource and inventory management Route planning, navigation, routing, driver‘s log Mobile terminals for on site recording and information

Frank Mueller, FMC, Magdeburg, Germany mueller@epi-fmc.com Ralf Opierzynski, Fraunhofer IFF, Germany ralf.opierzynski@iff.fraunhofer.de

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