BtE Basic Training - Part Two - 14jun2022

Welcome to the AFRY
Biomass-to-Energy Training,
Part 2
The Event will start soon.

BEFORE WE START
Housekeeping rules
— Don’t use the camera, and keep your microphone muted.

— There will be a short Q&A session at the end of each topic
— Q&A sessions:
− Use ”Raise your hand” function on ”Chat”
− Switch on your microphone after you’ve raised your hand and you are asked to
do so
− Mute the mic and ”lower the hand” after stating your comment.
— The presenter will answer questions during the event. All questions that
will not be answered during the meeting will be collected and replied in
writing afterwards.
— The entire training session will be recorded.

— The recording of the session, slide deck and Q&A will be made available to
all attendees on the Thermal & Renewables Sharepoint site.
2 14 Jun-22 AFRY BTE TRAINING, PART 2

AFRY Biomass-to-Energy Training
AFRY Internal training, part 2 - Technology
STAFFAN NICKULL, 14 JUNE 2022

Content for today
― Introduction
― Fuel
― Fuel handling
― Boiler & gasification
─ Fluidized bed boilers
─ Grate boilers
─ Gasification
― Flue Gas Treatment

― SNCR
― Baghouse filter
― Flue gas condenser
― Operation
― Balance+

PERSONAL INTRODUCTION
Staffan Nickull
2020 - ongoing AFRY Solutions UK Ltd.
Principal Engineer
2019 – 2020 AFRY Finland
Head of Project Development
AFRY Energy Division’s Biomass Scrum Leader since 2020
2007 – 2019 Pöyry Finland & Pöyry Sweden
− Section Head
− Department Manager
− Project Manager
− Senior Engineer
2003 – 2007 WSP Environmental
Project Manager
2001 – 2003 AkerKvaerner (Today, Valmet Technologies)
Product Engineer, Recovery boilers
EDUCATION Åbo Akademi University, Finland
― Chemical Engineering; Master of Science (Eng.) (2001)

BTE HELP DESK
Where to get help and additional information

Ask your Scrum member:
Antti Toivonen / FINLAND

Staffan Nickull / UK Martti Teider / FINLAND
antti.toivonen@afry.com
staffan.nickull@afry.com martti.teider@afry.com
+358407574337
+447918600105 +358403485503
Ilkka Lassila, ASIA Jérémie Lalouette CH and MENA

ilkka.lassila@afry.com jeremie.lalouette@afry.com
+66614131566 +41763562369
INTRODUCTION
Biomass power plant, Main components

Content for today
― Introduction
― Fuel
― Fuel handling
─ Fluidized bed firing
─ Grate firing
─ Gasification

― SNCR
― Baghouse filter
― Operation
― Balance+

FUEL
Types of Biomass
Forestry residues (various types of trees depending on

the geographical area)
− thinning, harvesting waste, bark, stumps
Wood processing residues
− offcuts, bark, sawdust, demolition wood
Pulp and paper making residues
− black liquor, bark, sludge, dust, wood chips
Fast growing energy crops
− napier grass, rape seed, canary grass, bamboo
Agricultural residues
− straw, rice husk, bagasse, cane trash, palm kernel

shell, empty fruit bunch

FUEL – BIOMASS-TO-ENERGY
Plant size vs. biomass availability
10
10 14 June -22 AFRY BTE TRAINING, PART 2
FUEL
Biomass characteristics
Characteristics that have impact on the

boiler/power plant design and performance:
— Calorific/heating value
— Moisture content
— Chemical composition (ultimate/proximate)
— Ash content and characteristics:

— Ash fusion temperature (non-eutectic mixture)
— Alkali (Na+K) content
— Chlorine content
— Bulkiness / transportation
— Fuel handling requirements (drying, chipping,

removal of metals, mixing, etc...)
11 14 June -22 AFRY BTE TRAINING, PART 2

FUEL – BIOMASS CHARACTERISTICS
Harmful components / Elements in Biomass

− Agglomeration (sintering) of fluidised bed
Alkali metals (Na and K) − Slagging and fouling of heat surfaces
− High temperature corrosion
Chlorine − High temperature corrosion
Sulphur − Low temperature corrosion
Ash fusion temperature − Slagging and fouling

Harmful components in Biomass
BED AGGLOMERATION / SINTERING IN FLUIDISED BED BOILERS
— Alkali metals react on the surface of bed material (sand) particles forming silicates.
The surface of particles becomes sticky, particle size grows and causes disturbances in
fluidisation, local hotspots and accelerates agglomeration
— Efficient bottom ash removal is required in fluidised bed boilers when the fuel includes
harmful elements (impurities), large particles or contain metals with low melting point
— High alkali metal content ash may lead to bed agglomeration (sintering) in fluidised
bed boilers
— The most difficult alkali metals are sodium (Na) and potassium (K)
— If the biomass that is planned to be used contains a lot of alkali metals (e.g. straw) it
is recommended to use grate firing instead of fluidised bed firing.

SLAGGING / FOULING OF SURFACES
— Slagging / fouling is accumulation of unwanted material on solid surfaces (deposit formation)
— Fouling of heat surfaces in a boiler reduces thermal efficiency, increases

corrosion and flue gas pressure loss,
— Alkali compounds are problematic regarding fouling of surfaces,
— In order to prevent fouling, flue gas temperature in the superheater area should be below ash melting
temperature, for wood and bark < 900°C, in some cases for more difficult biomasses < 750°C-650°C
(which may require an empty pass in the boiler, before the first heating surfaces),
— There should be free spacing between tube bundles (> 100 mm),
— Sufficient soot blowing should be used,
— Temperature measurements between superheaters detect fouling during operation (p measurement slow)
— Use of additives in fuel feeding to bind alkali compounds or use of fuel mixtures may be applied (e.g.
composition of alkali vapours changes when sulphur containing fuel such as peat or coal is cofired with
biomass.
HIGH TEMPERATURE CORROSION
— Serious problem occurs with biomass fuels when alkali metals and chlorine are present in biomass and
steam temperature is above 480°C
— Chlorine corrosion starts in the steam temperature range of 480 - 500°C,
— Corrosion mechanism is connected to enrichment of alkali chlorides (mainly KCl) on superheater surface,
— Growing (green) parts of biomass, such as grasses, leaves, treetops, etc. usually contain more chlorine
and are therefore more problematic,
— When high steam temperatures are used in superheaters, more corrosive resistant steel alloys can be
used. Heat transfer surfaces should be designed to avoid ash fouling,
— If alkali metals and chlorine are present in the fuel in large quantities, the risk of high temperature
corrosion should be mitigated by selecting low enough steam values. However, the use of lower steam
values also means lower power generating efficiency. In CFB boilers it is possible to locate the final
superheater in the loop seal bed that has a less corrosive environment.

FUEL
Fuel – Type, quality and supply
Fuel type and quality strongly influence:

− Fuel Handling System design
− Boiler type & design
− Flue Gas Treatment System
− Boiler availability, lifetime and efficiency
Fuel supply influences:

− Economic feasibility of the project
− Operation and availability
HSE
− Environmental impacts
− Health and safety
− Fire and explosion hazard

FUEL
Fuels – Example of biomass fuel range

- LHV (dry) 19,0 – 20,6 MJ/kg
- LHV (wet) 7,2 – 12,0 MJ/kg
- Moisture 34,6 – 55,0 wt-%
- Ash 1,6 – 10,0 wt-% (ds)
- Sulphur (S) < 0,30 wt-% (ds)

Summary of range and
- Nitrogen (N2) < 3,0 wt-% (ds) upper limits of the
- Chlorine 1 = 0,14 3 wt-% (ds) key fuel components for
a fuel mixture from one
- Aluminium (metal) < 0,04 wt-% (ds)
project.
- Alkali metals, weak acid soluble (Na + K) 2 < 0,25 wt-% (ds)
- Heavy metals (Cu + Pb + Zn) 2 < 0,3 wt-% (in fuel ash)
- Zinc (Zn) 2 < 150 mg/kg (ds)
- Lead (Pb) 2 < 20 mg/kg (ds)
- Fuel ash initial deformation temperature > 1050 °C
Non-fluidising inert material (e.g. stones, gravel, glass, < 0,5 wt-% (as fired fuel)
ceramics, ferric metals, non-ferrous metals)

Content for today
― Introduction
― Fuel
― Fuel handling
─ Grate firing
─ Gasification

― SNCR
― Baghouse filter
― Operation
― Balance+

FUEL HANDLING
Type and quality & impact on fuel handling
Fuel types directly affect:
− Equipment types that can or should be used

− Scale and types of loads applied to equipment
− Equipment dimensions > space needed
Fuel quality:
− Bulk density
− Impurities > equipment wear, pretreatment needs, blockages, breakages
− Moisture content
− Chemical composition
− Particle size distribution
Fire and
explosion
risks
Health risks

FUEL HANDLING
Overland transport
TRUCKS SUPER TRUCKS

- Normal max transportation range 50-100 km

FUEL HANDLING
Sea transport

FUEL HANDLING
Rail transport

Fuel handling system
Picture: BMH

FUEL HANDLING
Weight measuring
TRUCK WEIGHT RADIOMETRIC MEASUREMENTS ABOVE

BELT CONVEYOR

FUEL HANDLING
Fuel unloading – Small scale (1/3)
SMALL SCALE, UNLOADING HALL AS A FUEL STORAGE

FUEL HANDLING
Fuel unloading (2/3)
SIDE UNLOADING REAR UNLOADING

FUEL HANDLING
Fuel unloading (3/3)
CRANE BUCKET LOADER

FUEL HANDLING
Multi-fuel handling systems
SCREENING, CRUSHING AND METAL REMOVAL

FUEL HANDLING
Fuel storages: Large scale storages, A-frame
A-FRAME STORAGE DISCHARGE SCREW AT THE BOTTOM OF SILO

> 10 000 m3

FUEL HANDLING
Large scale storages, A-frame
CONVEYORS IN A-FRAME STORAGE CONVEYORS AT THE TOP OF THE STORAGE

FUEL HANDLING
Large scale fuel silos
− Mainly concrete structures, roof metal cladding Rotating discharge screw at the bottom of silo
− Max volume appr. 10 000 m3
− Max. Height 20-25 m

FUEL HANDLING
Fuel conveyors (1/3)

BELT CONVEYOR, MAX ANGLE 13-14O BUCKET ELEVATOR

FUEL HANDLING
DRAG CHAIN CONVEYOR: MAX ANGLE 38O SCREW CONVEYOR

− Higher maintenance costs compared to belt
conveyors

FUEL HANDLING
PNEUMATIC CONVEYORS (i.e. for pellets) TUBULAR BELT CONVEYOR (avoid dusting)

FUEL HANDLING
Fuel analyses
— EN 18135 Solid biofuels sampling — Samples taken automatically from conveyors and stored
— Manual sampling in sample boxes
— Samples taken from fuel flow downwards

FUEL HANDLING
Fuel analysis: Automatic fuel sampling

AUTOMATIC FUEL SAMPLING (PROMOTEC)
− Takes 6-8 samples automatically
− Requires own sampling hall
X-RAY MEASUREMENT (Inray)

− Measures moisture content of whole truck
− Standard heat values agreed between the fuel supplier and client
− No need for sampling
− Detects foreign elements (e.g. stones) in fuel flow

Fuel handling system

Q&A
5 MIN BREAK

Content for today
― Introduction
― Fuel
― Fuel handling
─ Grate firing
─ Gasification

― SNCR
― Baghouse filter
― Operation
― Balance+

BOILER & GASIFICATION
Bio-to-energy plant
Superheaters
Drum
Stack
Hog Fuel
Feed Bin
Evaporator
Make Up
Sand Bin Fly Ash
Bin
Load
Burner Eco
AH
Electrostatic
Secondary Precipitator
Air Zone
Hog Fuel
Feed System SU
Burner
Fly Ash
Combustion Air Fans
Fly Ash Conditioner
Fluidizing
Bed Drain Air Conveyors ID Fan
Picture: Sumitomo SHI FW

Main flow diagram

Bubbling Fluidized Bed Boiler (BFB)
Picture: Valmet

Bubbling Fluidized Bed Boiler (BFB) video
https://www.youtube.com/watch?v=yE6UmW9HVUU&t=2s

Bubbling Fluidized Bed (BFB)

− Bed agglomeration avoided by bed temperature control and continuos
exchange and recirculation of bed sand.
− Flue gas recirculation for bed temperature control
− Long gas residence time to ensure dioxin, CO and fly ash carbon
decomposition
− NOX formation minimised by low temperature in furnace and multiple levels

of secondary air injection. Furnace flame temperature is 800 – 1100 °C
− Wide superheater, evaporator and economizer tube bank spacing combined

with soot blowing to maintain high efficiency and long tube lifetime
− Low flue gas velocity for minimum heat transfer surface erosion
− The water filled wall tubes receives heat from the combustion and generates
steam. -> Density difference of water in downcomers and wall tubes creates
a natural water circulation
− Fluidizing velocity is normally 0,8 - 1,2 m/s and medium size of the sand
particle is around 1 mm.
Picture: Valmet
BFB Furnace bottom
− Primary air is introduced into the furnace through

nozzles in the grate
− Coarse particles shift downwards between the

nozzles and are removed from the furnace
− Removed bottom ash, large particles and sand can

be sieved and good quality sand can be recycled
back to the furnace.
Picture: Valmet
Bubbling Fluidized Bed (BFB)

Data range
Fuel input: 4 – 15 MJ/kg (LHV)
Steam flow: 15 – 450 t/h
Steam parameters: 80 bar / 480 °C – 120 bar/520°C
Fuel heat input: 10 – 350 MWfuel
Electrical output: 5 – 100 Mwe
Boiler efficiency, EN 12952-15: 89–92%
FUELS
− Biomass (wood chips, forest residues, bark, saw dust, pellets, agro-
biomass)
− Wood waste
− Peat
− Sludges
− Refuse-Derived Fuels (RDF) / Solid Recovered Fuels (SRF)

− Animal litter
− Fuel particle size P65 – P100 (En 14961-1)

− Fuel moisture range 20-65 weight-% in dry material
Picture: Andritz

Circulating Fluidized Bed Boiler (CFB)
Picture: Valmet

Circulating Fluidized Bed Boiler (CFB)
Picture: Valmet

CFB – Overview of plant (Porin Prosessivoima)
Picture: Valmet

Circulating Fluidized Bed Boiler (CFB) video
https://www.youtube.com/watch?v=klOVbs0TZ6c&t=1s

Circulating Fluidized Bed (CFB)
− Excellent solids mixing ensure uniform temperature for

complete combustion and low flue gas emissions
− Low CO emission and unburned carbon loss
− Cyclones allow longer burn out time and efficient reduction of

NOX with SNCR
− Low NOx emission due to low primary NOx and optimal temperature
for SNCR
− Final superheater located in loop seal with less corrosive

environment. Higher steam temperatures can be reached with
this design
− Limestone (CaCO3) can be used for sulfur capture in the

furnace
− Fluidizing velocity is between 2 and 5 m/s and the size of the

circulating material less than 0,6 mm.
Picture: Sumitomo SHI FW

CFB Boiler – Loop Seal
− Sand is returned from the cyclone to the furnace

through the loop seal
− Prevents flue gas flow from the furnace bottom

directly to the cyclone
− Final superheater is located in loop seal, effective

gas flow isolation from both furnace and cyclone
side
− Gas atmosphere is much less corrosive compared to

furnace or back pass location
− -> Higher steam parameters with low corrosion is
possible!
Picture: Valmet

Circulating Fluidized Bed (CFB)

Data range
Steam flow: 100 – 750 t/h
Steam parameters: 120 bar/520°C - 175 bar/565°C
Fuel heat input: 80 – 800 MWf
Electrical output: 20 – 300 Mwe
Boiler efficiency, EN 12952-15: 89–92.5%
FUELS
− Biomass (wood chips, pellets, agro-biomass, palm kernel shells)
− Wood waste
− Industrial waste (rejects)
− Sludge (co-firing)
− Municipal waste, Refuse-Derived Fuels (RDF), Solid Recovered Fuels
(SRF)
− Coal
− The same boiler can be designed for 100% biomass and 100% coal
– Difference in flue gas amount per MW can be 30%
– It is compensated by flue gas recirculation
Picture: Andritz

CFB boiler – Firing diagram (OULU)
CFB boiler
Lower heating value: 7.2 – 12 MJ/kg
Maximum load, fuel: 210 MW, fuel
(17.5 kg/s *12 MJ/kg)
Maximum load, Thermal: 194 MWth
Minimum load with typical 70%

full superheating:
Minimum load, with 40%
emission compliance:
NOTE:
Maximum load drops somewhat at low LHV fuels, upper right
corner.
− Reason is that wet fuels have higher flue gas flow for
same heat input and dimensioning for high flue gas flow
is expensive.

Oulu – Power plant and drum

Oulu – Solid fuel feeding & boiler grate

Oulu – Cyclone

Oulu Superheater and header

Grate Boiler
Data range
Steam parameters: 120 bar/525 °C
Fuel heat input: 200 MWf
FUELS
− Wood based (Wood chips, forest trimmings, bark, brash)
− Agro residues (Straw, Maize, Miscanthus, Sorghum)
− Industrial by-product ( Sawmill residue, olive grains & stones,
composted wood, rape seed extraction, bio and sunflower- pellets,
saw dust)
− Contaminated fuels (waste wood, demolition wood, chipboard waste,
sander dust, railway sleepers, RDF)
− Other fuels (Poultry litter, Meat and bone meal, paper sludge)
Picture: Aalborg Energie Technik a/s

Comparison of combustion technologies

Fluidized bed boiler Grate boiler
Advantages Advantages
+ Complete ash burn-out and steady combustion + Can combust larger fuel particles
+ Lower NOx and CO emissions + Better suited for combustion of straw and other fuels with
+ Higher efficiency thanks to lower O2 content in flue gases high potassium (K) and chlorine (Cl) content
+ Suitable for co-incineration with other fuels, e.g. sludge,
peat, and coal in case of CFB Disadvantages
+ Maximum boiler size larger than grate boilers - Difficulty to combust other fuels (sludge, peat etc.)
- Slow load change
CFB:
+higher steam parameters than BFB and grate boilers
 Electricity production increases
Disadvantages
- Requires smaller fuel particles
- Higher N20 emissions
- CFB has higher Capex than BFB and grate boilers

Special properties of a biomass boiler
— Steam parameters 480–540 °C, 40–120 bar (typical)
— Circulating fluidized bed boiler CFB boilers can reach higher steam parameters than BFB or
grate boiler by locating final superheater in the less corrosive
environment of the loop seal
— Flue gas end temperature 140 °C (typical)
— Flue gas condenser A flue gas condenser will give large amount of additional district
heat production due to wet fuel. The water in the flue gases can be
condensated and the latent heat can be recovered. Additional heat
recovery is between 10 – 25% calculated from fuel heat input. Heat
recovery can be further increased by combustion air humidification
and heat pump.

GASIFIER TECHNOLOGY
Gasification of biomass
Fuel gas Flue gas

Different technologies provide gas with different gas
properties : Hot
bed material
— Partial oxidation with air at ~750°C gives a gas

with low heat value. Relatively simple process Biomass
that today dominates biogas supply for lime kilns. Gasification Combustion
in fluidized bed of char
— Partial oxidation with oxygen or with indirect heat
transfer gives a higher heat value gas. Examples
of technologies with indirect heating are the
Cortus two-stage process and the Repotec hot
Bed material +
sand fluid bed. A partial oxidation process char
example is Chemrec black liquor gasification Steam
— Gas that contains almost only hydrogen and

carbon monoxide is called syngas and gives a Principle of gasification with indirect heating in fluid bed
potentially very high lime kiln capacity. (Repotec)

GASIFIER TECHNOLOGY
Air-blown biomass CFB gasifier
— Biomass , wood and bark, is shredded and dried

to high dryness (moisture content 5 – 10%).
— Heated in a CFB gasifier to a gasification

temperature of ~750°C by partial oxidation with
air. The gas is led hot without cooling to the lime
kiln
— Separates major part of the ash from the gas,

allowing use of ash-rich feedstock like bark
— Recent references include Metsä Joutseno and

Metsä Äänekoski, Finland, APP OKI in Indonesia
etc, etc
— Typically gives 15-20% lower lime kiln capacity

than with fuel oil.

LIME KILN EXAMPLE
Fuel properties influence lime kiln capacity

KEY FUEL PROPERTIES INFLUENCING KILN CAPACITY
Adiabatic flame temperature

A hotter flame can in the hot end of the kiln transfer more heat by radiation to the lime and also
provide a larger portion of the heat above the calcination temperature of lime.
Relative flue gas volume

Fuels that produce a lower flue gas volume for a given heat input allows higher total heat input
without exceeding volume or velocity restrictions.
Flame luminosity
A fuel with high flame luminosity can transfer more radiation heat at a given flame temperature.
Flame length
A fuel that is difficult to ignite gives a longer flame with a lower peak temperature potentially
lowering kiln capacity.

Q&A
65
Content for today
― Introduction
― Fuel
― Fuel handling
─ Grate firing
─ Gasification

― SNCR
― Baghouse filter
― Operation
― Balance+

Flue Gas Treatment (FGT)
Boiler
− Primary methods, e.g. air staging
& volume, avoidance of high
Secondary methods, Dry
temperature
− Electrostatic precipitator
− Selective non-catalytic reduction
− Bag house filter
(SNCR) Secondary methods, Wet
− Additive injection e.g. (AC,
− Selective catalytic reduction − Flue gas scrubber
Ca(OH)2
(SCR) − Acid scrubber
− Limestone injection − NOX scrubber

− Heat recovery
− Water recovery

FLUE GAS TREATMENT
FGT at a glance
The FGT system shall assure compliance with the emission requirements at all times:
1. NOx reduction
- Selective non-catalytic reduction, SNCR: SNCR is an ammonia/urea injection system which reduces NOx emissions
- SNCR + slip catalyst: SNCR+ small catalyst
- Selective catalytic reduction, SCR: Lowering of nitrogen oxide emissions in power plants with the use of a catalyst
2. Removing particulate matter :

- Fabric filter or electrostatic precipitators for removal of particles
3. Reduction of acid gases (SO2, SO3, HF, HCl):

− Feeding of powdered limestone (CaCO3) into a fluidized bed
− Reagent to a fabric filter (Ca(OH)2 or NaHCO₃)
− Reagents to a flue gas scrubber (Ca(OH)2 or NaOH)
4. Adsorption of activated carbon or coke

− Absorption of heavy metals, dioxides & furanes from the flue gases in a bag house filter (scrubber)
5. Continuous Emission Monitoring (CEM)
FGT also includes the following:

− Storage silos, conveying and dosing of chemicals;
− Storage tank, pumps and piping for ammonia water or urea;
− Fly ash/spent absorbent collection and transfer up to fly ash silo(s).

FLUE GAS TREATMENT
Selective Non Catalytic Reduction (SNCR)
Selective Non-Catalytic Reduction (SNCR) system

for lowering of gaseous emissions of NOx
The process involves injecting either ammonia or urea into the

boiler at a location where the flue gas is between 850 and
1,050 °C to react with the nitrogen oxides formed in the
combustion process.
4 NO + 4 NH3 + O2 → 4 N2 + 6 H2O
At lower temperatures or bad mixing the NO and the ammonia

do not react. Ammonia that has not reacted is called ammonia
slip.
At too high temperatures ammonia oxidizes and form NO:
4 NH3 + 5 O2 -> 4 NO + 6 H2O
NOx reduction is typically 30 - 60 %
Requires: Time, Temperature & Mixing Typically, 25% ammonia solution

FLUE GAS TREATMENT
FGT Flow
Chemical silos
Bag house filter
ID fan and Flue Gas re-

circulation
Air pre-heater
Fly ash Silo
Stack and Continuous

Emission Monitoring
(CEM)

FLUE GAS TREATMENT
Fabric Filter
The function of the fabric filter is:
− to remove solid particulate matter (fly ash) by

filtration through fabric media.
− Particles are collected at the surface of the bag

filter & the gas goes through the filter and out
− Bag filters are periodically cleaned by pressured

air and the collected fly ash is removed from the
bottom of the filter and transported to fly ash
silo with pneumatic conveyors
The fabric filter can be combined with reagents:
Lime or sodium hydroxide

- React with acid pollutants, SO2, SO3, HCl, HF
− Activated carbon
- Absorption of heavy metals and dioxin/furan

FLUE GAS TREATMENT
Flue Gas Condenser
Picture: Valmet

FLUE GAS TREATMENT
Flue Gas Condenser, Heat recovery
— A Flue Gas Condenser recovers heat from the

flue gases by condensing the water in the flue
gases and by recovering the latent heat.
— A Flue Gas Condenser can typically increase

the production of district heat by 15-20%.
— The heat recovery can be enhanced by

combustion air humidification and heat pumps
— Low CAPEX and very low OPEX
— Heat recovery sensitive to:

─ Flue gas moisture content
─ Temperature of heat sink (District heat)
Picture: Valmet

FLUE GAS TREATMENT
Flue Gas Condenser
— Scrubber can efficiently wash

─ SO2, near 100 % reduction
─ HCl, near 100 % reduction
─ NH3, near 100 % reduction
— Dust, reduction is dependent on

particulate size distribution,
concentration and fuel, with biofuel
typically 50..90%
Picture: Valmet

FLUE GAS TREATMENT
Flue gas condenser & condensate water

treatment
Flue gas condenser This FGC increased

District heat
Condensate production
treatment building by 60MW
+
Lower emissions
Packing material &

and Spray nozzles
inside the flue gas
condenser for
incresed surface
area and better
reaction.

FLUE GAS TREATMENT
Emission limits to air from BtE

Emission levels for emissions from biomass – 2020, Project in Finland
Parameter Unit Limit Averaging period
NOx (As NO2) mg/Nm3 ≤ 100 Continuous measurement, Daily average
SO2 mg/Nm3 ≤ 50 Continuous measurement, Daily average
CO mg/Nm3 ≤ 75 Continuous measurement, Daily average
Particulate matter mg/Nm3 ≤5 Continuous measurement, Daily average

NH3 mg/Nm3 ≤ 10 Continuous measurement, Daily average
HCl mg/Nm3 ≤5 Continuous measurement, Daily average
HF mg/Nm3 ≤1 Continuous measurement, Daily average
TOC mg/Nm3 ≤5 Continuous measurement, Daily average
Cd + Tl mg/Nm3 ≤ 0.005 Measurement 4 times/year

Sb + As + Pb + Cr +Co + Cu + Mn + Ni
mg/Nm3 ≤ 0.3 Measurement 4 times/year
+ V +Sn
Hg mg/Nm3 ≤ 0.005 Measurement 4 times/year
Dioxines and Furanes (PCDD/F) ng/Nm3 ≤ 0.03 Measurement 4 times/year
Note: Reference condition are 0°C, 1013 hPa, 6% O2, dry flue gases.
Q&A
77
Content for today
― Introduction
― Fuel
― Fuel handling
─ Grate firing
─ Gasification

― SNCR
― Baghouse filter
― Operation
― Balance+

BALANCE+ TECHNOLOGY FOR THE BIOFUEL FIRED POWER PLANTS
Comprehensive consultation
and solutions to
Plant Energy and performance
improvements

WHY HOW
At AFRY, we drive continuously We improve your existing assets

to improve our own and our with advanced control solutions.
client’s operations making the
world better place in the It is not a plug-and-play but
chancing market conditions. comprehensive customized
solution package using AFRY’s
– Reduced emissions
unique technology, expertise and
– Plant and fuel flexibility
experience from the processes
– Energy efficiency
and business.
– Reliability & availability
– Digital ambition
Providing leading solutions for

generations to come.
WHAT BALANCE +
STRONG TRACK RECORD
We improve the processes – WITH PROVEN RESULTS
boilers and industrial processes Balance+ has provided
— Headline - making them more efficient, significant benefit to numerous
flexible, reliable and reduce plants, e.g:
emissions. – 2% higher plant efficiency
– 10% higher production with
Balance+ is best available WtE unit
technology for the power plants! – 3% higher sustained production
with biofuel fired units
At the same time it happens to – 40% lower NOx formation
make significant savings… – 50% lower minimum load
– 10% reduction in house load
– Improved plant flexibility (4%
ramp rates)
ENERGY OPTIMISATION (BALANCE+)
Balance+: Bringing additional profit
Key Characteristics
- Advanced control solution for boilers and industrial processes
- Optimized production and performance, increased boiler life cycle, less
emissions
- More accurate and more stable control, robustness to controls
- We improve the processes – boilers and industrial processes - making them
more efficient, flexible, reliable and reduce emissions.
- Distinctly different from traditional controls and from other APC (advanced
process control) solutions
- Balance+ is not tuning the existing software, instead reprogramming the software
- Other products are built on top of the old solutions when same root causes exists
- Process based concept, self-learning features and history data use
- Main variables based on adaptive calculation models, thermodynamic modelling etc.
- Strong track record with proven results: Solutions are in more than 80
boilers worldwide with significant improvements
Proven and patented technology
A vendor independent approach
for any owner plant, with total plant control philosophy

Balance+: Solutions for biofuel fired boilers

Solutions
 Steam & Electrical load allocation
 Intelligent usage of PID controllers concept
 Most of the control response is depending on • Physical calculation based concept
the process based calculations
• Accurate HP, MP & LP header control
 Fuel and air controls
• Priority of steam producers
• Load control by using sophisticated
thermodynamic model based concept • Production optimization inside of the
control concept
• During loading and unloading boiler inner
energy compensated • Sophisticated operation with multiple
turbines and boilers
• Intelligent heat value correction
 Patented drum level concept
• Intelligent fuel distribution and combustion
optimization for optimal bed behaviour • Disturbance handling and feedwater
cycle optimization
• Combustion optimization with grate, BFB and
CFB boilers • Reduced power consumption
• Fuel pocket level control  Patented model based steam
temperature control
• Accurate and right fire/air balance control
and air distribution primary, secondary and • Advanced thermodynamic model base
tertiary control concept with self-learning
functions
• Adaptive air factor to learn the fuel moisture
content change • Sootblow actions learning function
• CO and NOx optimization

Balance+: references and results

Balance+ has provided significant benefit to Primary outcomes from Enery
numerous plants, e.g: Strong track record with Efficiency (Balance+ projects/
• 2% higher plant efficiency proven results solutions)
• 10% higher sustained production in Increased Energy Efficiency

maximum load Worlds biggest Worlds biggest
biofuel boiler CFB boilers Higher sustained maximum capacity -
• 3% higher sustained production with possibility to provide load control
biofuel fired units
Controls and optimizes the process as
• 40% lower NOx formation whole - not individual regulator or system
Complex co-
• 50% lower minimum load Combined cycle
generation More accurate control and Lower house
units
plants load
• 10% reduction in house load
• Improved plant flexibility (4% ramp rates) Stabiles the process, and enables lower
minimum and higher maximum loads
• Steam venting and condensing losses with 700 – 1100
Waste to MWe ultra-
the steam network reduced significantly energy units supercritical
Improved availability and extended life
cycle
• Reduced oil consumption units
• Reduced consumption of ammonia/urea Enables frequency control and Faster and

smoother load changes
with optimized combustion and NOx control
Steam &
District heat Possibility to use variety of different fuels
• 30 – 40 % reductions in consumption electrical load
networks
allocation
• Possibility to provide primary and Increases the degree of automation
secondary frequency support with accurate
Improved plant efficiency and reduced
control and minimized plant stresses
emission levels (e.g. NOx)

ACHEIVING IN ENERGY EFFICIENCY
Approach to enhance overall Energy efficiency and improve

performance
Solution Concept
and Validation
(3-4 weeks/ overall) Note:
− Timeline indicative.
− Site visits, when needed and if possible

during the assessment phase.
Due-diligence Implementation
and Diagnosis and Project execution − Projects can be taken on a turnkey
(3-4 weeks) (5-6 months/ solution) basis after initial assessment.
− Gaining model can be based partly of

achieved performance for mutually
selected KPI’s.
– Identify processes and scope for – Summary of findings and – Solution development
evaluation and initial recommendations – Customized design and engineering
assessment – Initial concept validation and testing
– Identification of improvement
– Acquire relevant details on opportunities – Solution implementation (at site) and
current process and operations interface with existing systems (as
– Overall concept & solution
performance (historical, as- needed)
approach for improvement
running, operating procedures and
other relevant data) – Baseline and benchmarking – Performance evaluation
– Plant controls, instrumentation, metrics and target KPI’s, and – Site support and consultancy
mechanical side investigation improvement potential. – Fine tuning/improvement, if needed
based on data, operation and – Overall analysis and – Operator and plant personnel training.
design documentation. assessment.

ENERGY OPTIMIZATION (BALANCE+)
(indicative)
Customer References
Project Name Year Location Project Name Year Location

Q&A
— The links to the slide deck and
recording will be e-mailed to all attendees
as soon as they are available.
— The material will be stored in the Thermal &

Renewable Teamsite, under the “Training
and Development” tab.

Thank you!

BtE Basic Training - Part Two - 14jun2022

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BtE Basic Training - Part Two - 14jun2022

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Welcome to the AFRY

The Event will start soon.

— Don’t use the camera, and keep your microphone muted.

— The entire training session will be recorded.

2 14 Jun-22 AFRY BTE TRAINING, PART 2

STAFFAN NICKULL, 14 JUNE 2022

3 14 Jun-22 AFRY BTE TRAINING, PART 2

― Flue Gas Treatment

4 14 Jun-22 AFRY BTE TRAINING, PART 2

EDUCATION Åbo Akademi University, Finland

― Chemical Engineering; Master of Science (Eng.) (2001)

Where to get help and additional information

Antti Toivonen / FINLAND

Ilkka Lassila, ASIA Jérémie Lalouette CH and MENA

Biomass power plant, Main components

7 14 Jun-22 AFRY BTE TRAINING, PART 2

― Flue Gas Treatment

8 14 Jun-22 AFRY BTE TRAINING, PART 2

Forestry residues (various types of trees depending on

− thinning, harvesting waste, bark, stumps

Wood processing residues

− offcuts, bark, sawdust, demolition wood

Pulp and paper making residues

− black liquor, bark, sludge, dust, wood chips

Fast growing energy crops

− napier grass, rape seed, canary grass, bamboo

− straw, rice husk, bagasse, cane trash, palm kernel

9 14 Jun-22 AFRY BTE TRAINING, PART 2

Plant size vs. biomass availability

Characteristics that have impact on the

— Chemical composition (ultimate/proximate)

— Ash content and characteristics:

— Fuel handling requirements (drying, chipping,

11 14 June -22 AFRY BTE TRAINING, PART 2

Harmful components / Elements in Biomass

Chlorine − High temperature corrosion

Sulphur − Low temperature corrosion

Ash fusion temperature − Slagging and fouling

12 14 Jun-22 AFRY BTE TRAINING, PART 2

Harmful components in Biomass

BED AGGLOMERATION / SINTERING IN FLUIDISED BED BOILERS

13 14 Jun-22 AFRY BTE TRAINING, PART 2

Harmful components in Biomass

SLAGGING / FOULING OF SURFACES

— Slagging / fouling is accumulation of unwanted material on solid surfaces (deposit formation)

— Fouling of heat surfaces in a boiler reduces thermal efficiency, increases

— Alkali compounds are problematic regarding fouling of surfaces,

— Sufficient soot blowing should be used,

Harmful components in Biomass

HIGH TEMPERATURE CORROSION

— Chlorine corrosion starts in the steam temperature range of 480 - 500°C,

15 14 Jun-22 AFRY BTE TRAINING, PART 2

Fuel – Type, quality and supply

Fuel type and quality strongly influence:

Fuel supply influences:

16 14 Jun-22 AFRY BTE TRAINING, PART 2

Fuels – Example of biomass fuel range

- LHV (wet) 7,2 – 12,0 MJ/kg

- Moisture 34,6 – 55,0 wt-%

- Ash 1,6 – 10,0 wt-% (ds)

- Sulphur (S) < 0,30 wt-% (ds)

- Zinc (Zn) 2 < 150 mg/kg (ds)

- Lead (Pb) 2 < 20 mg/kg (ds)