Foster Wheeler Atmospheric Gasification Technology Presentation)

Foster Wheeler Atmospheric Gasification Technology: Development and Latest Experiences Brief Summary Matti Hiltunen Foster Wheeler Energia Oy Finland

Topics Rome, Palazzo dei Congressi, May 10, 2004

• Update of recent projects – Lahti plant, Finland – Corenso plant, Finland – Ruien plant, Belgium

• Gasification of recycled fuels – Clean gas production – Lahti Slip Stream Tests

Lahti Gasification Plant Rome, Palazzo dei Congressi, May 10, 2004

Lahti Fuels Rome, Palazzo dei Congressi, May 10, 2004

Lahti Operating Experiences 1998-2003 Rome, Palazzo dei Congressi, May 10, 2004

• Operation of the gasifier and the gas burners has been stable • Stability of the steam cycle and coal burners good • No deposit formation or high temperature corrosion observed on the heat transfer surfaces • Operating data 1998 - 2002 – Operating time 27 000 hours – Energy produced 1700 GWh – Fuels gasified 498 000 ton – Availability of the gasifier 97.5 %

Gasifier Effect to Main Boiler Emissions Rome, Palazzo dei Congressi, May 10, 2004

NOx SOx CO HCl Particulates Heavy metals Dioxins, etc.

Decrease by 10 mg/MJ (= 5 to 10 %) Decrease by 20 - 25 mg/MJ No change Increase by 5 mg/MJ , base level low Decrease by 15 mg/m3n Increase in some elements, base level low No change

Corenso Design Rome, Palazzo dei Congressi, May 10, 2004

Original design Gasifier 40 MW

Boiler 40 MW product gas 68 MW HFO

Reject consumption 18 000 ton/a Energy produced 165 GWh/a Substituting 16 500 ton HFO/a Aluminium recovered 2 100 ton/a Increased effect The effect of the gasifier was increased to 50MW.

Rome, Palazzo dei Congressi, May 10, 2004

Corenso Fuel Rome, Palazzo dei Congressi, May 10, 2004

Corenso Operating Experience Rome, Palazzo dei Congressi, May 10, 2004

• • • • • • •

Commercial operation since autumn 2001 Operating hours appr. 12 500 h Feeding of light reject into dense fluidized bed Aluminium handling: operating windows are ensured FW spring hammers as a solution to keep the furnace clean Cl emissions in control Availability equal to normal power plant availabilities

Ruien Design Rome, Palazzo dei Congressi, May 10, 2004

• Biomass gasifier producing “green electricity” in co-combustion with coal in an existing PC boiler • Using of renewable fuels to cut CO2 emissions • Design 50 MWth with 50 % fuel moisture (86 MWth with 20 % fuel moisture) • Electric efficiency 34 % (Boiler 36 %, gasifier 98 %) • Produced “green” electricity 17 MWe • Annual production 120 GWh

Ruien Gasifier Rome, Palazzo dei Congressi, May 10, 2004

BRYSSEL

RUIEN

Ruien Fuels Rome, Palazzo dei Congressi, May 10, 2004

• Bark • Demolition wood • Crushed wood based boards, chip boards, etc. • Moisture 25-30 %

Ruien Process Performance Rome, Palazzo dei Congressi, May 10, 2004

The gasifier in operation since May 2003 Environmental benefits – NOx & SOx reduced – CO & dust emission about the same or slightly reduced – Trace metals & dioxins no change – CO2 reduction 120.000 t/a, substituting of coal 50.000 t/a

Clean Gas Concept Rome, Palazzo dei Congressi, May 10, 2004 Main boiler feed water

Recycled fuels Bed materials

Flare Fuel feed system

Gas cooler boiler

Pulsing gas

CFB Gasifier Filters Main boiler furnace

LP Steam

Cooling water

Fly ash

Lahti Slip Stream Tests Rome, Palazzo dei Congressi, May 10, 2004

• To demonstrate the performance of the Clean Gas Concept, a long term product gas cooling and filtration tests including product gas combustion tests for different fuel mixtures was arranged • Connected to the commercial 70 MWth CFB gasifier in Lahti firing a blend of wood and wastes • In the slip stream plant 5% of the syngas produced in the CFB gasifier was cooled and filtered • The long term testing was stopped in April 2004, after more than 3300 hours of operation.

Lahti Slip Stream Tests Rome, Palazzo dei Congressi, May 10, 2004

LLV Slip stream unit

Filter by-pass line Sorbent feeder

Syngas duct from gasifier

Pulsing N2

Filter

Ash discharge systems Syngas cooler

Combustion air

Syngas combustor

Lahti Slip Stream Tests Rome, Palazzo dei Congressi, May 10, 2004

In the Lahti slip stream tests it was demonstrated that • By cleaning the waste derived product gas before the boiler, the amount of harmful components in the gas (heavy metals, alkalies, chlorine, dust, etc.) can be reduced significantly. • The cleaned product gas can be safely burned in a high efficiency boiler with high steam temperatures • The combustion of the cleaned gas was also environmentally safe: e.g.the emissions of heavy metals and dioxines were clearly below the WID limits