presentation plant visit lucerne · hzi client event 2016: plant visit lucerne 2 key figures - 2...
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Presentation Plant Visit Lucerne Perlen, March 3rd 2016
LUZERN: Overview
2 HZI Client Event 2016: Plant Visit Lucerne
Key Figures
- 2 lines, 47MW thermal each
- Waste Hu = 9-16 MJ/kg
Objectives for HZI
- Build a highly efficient and highly automated waste to
energy plant
- Many new innovative systems and control logic
- A new benchmark plant for HZI
LUZERN: Overview
3 HZI Client Event 2016: Plant Visit Lucerne
LUZERN: Bunker
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Bunker with physically
separated
compartments
LUZERN: Bunker
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Bunker with physically
separated
compartments
LUZERN: Combustion and Boiler
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First plant with INOVA grate (10° forward acting grate)
Zones 1&2 with Aquaroll, Zones 3&4 aircooled
Maintenance friendly
INOVA Grate and
Ram Feeder
LUZERN: INOVA Grate
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INOVA Grate and
Ram Feeder
R-Grate Inova Grate
Zones 4-6 (standard 5) 4
Lenght 8-12 m 10.7 m
Angle 18° 10°
Functionality
Speed variable variable
Movement discontinuous
(optional continuous)
Continuous
(slow forward, fast backward)
Stroke length fixed (150 mm) Variable (max. 300 mm)
Advantages INOVA Grate
Maintenance: Better accessibility, faster maintenance
Building: Lower building height
Price: Less expensive grate surface
R-Grate Inova Grate
LUZERN: INOVA Grate / Ram Feeder
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INOVA Grate and
Ram Feeder
Ram feeder
Ram feeder drop
Aquaroll hoses
Grate block
Pneumatic grate riddling system
INOVA Grate: Teething Troubles
LUZERN: Combustion and Boiler
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Combustion chamber:
Open geometry
New design of combustion chamber
Open design → more radiation on waste → good burn-out quality
INOVA Grate and
Ram Feeder
INOVA Grate and
Ram Feeder
LUZERN: Combustion and Boiler
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Combustion chamber:
Open geometry
1st pass is fully cladded
Fast reaction of steam on combustion conditions
Little slagging observed
1st pass:
Fully cladded
Combustion chamber:
Open geometry INOVA Grate and
Ram Feeder
LUZERN: Combustion and Boiler
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Combustion chamber:
Open geometry
Injection of secondary air and recirculated flue gas
Two stages → improved flue gas mixing, lowered peak temperatures (NOx)
Volume flows to each injection fully controlled by automated dampers
1st pass:
Fully cladded
Combustion chamber:
Open geometry
1st pass:
Fully cladded
INOVA Grate and
Ram Feeder
SA/RFG Injection
on 2 stages
RFG extraction
directly after ESP
LUZERN: Combustion and Boiler
12 HZI Client Event 2016: Plant Visit Lucerne
Combustion chamber:
Open geometry
Efficient cleaning of all empty passes with shock wave pulse generators
1st pass:
Fully cladded
Combustion chamber:
Open geometry
1st pass:
Fully cladded
Shock wave generators
in pass 1 to 3
INOVA Grate and
Ram Feeder
SA/RFG Injection
on 2 stages
SA/RFG Injection
on 2 stages
RFG extraction
directly after ESP
RFG extraction
directly after ESP
LUZERN: Combustion and Boiler
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Combustion chamber:
Open geometry
Additional sensors for combustion control (CCS+), see later
Differentiation of full and empty grate
Fire end control
1st pass:
Fully cladded
Combustion chamber:
Open geometry
SA/RFG Injection
on 2 stages
RFG extraction
directly after ESP 1st pass:
Fully cladded
RFG extraction
directly after ESP
SA/RFG Injection
on 2 stages
Additional
sensors
INOVA Grate and
Ram Feeder
Shock wave generators
in pass 1 to 3
Shock wave generators
in pass 1 to 3
LUZERN: Combustion and Boiler
14 HZI Client Event 2016: Plant Visit Lucerne
Combustion chamber:
Open geometry
1st pass:
Fully cladded
SA/RFG Injection
on 2 stages
Additional
sensors
INOVA Grate and
Ram Feeder
Shock wave generators
in pass 1 to 3
RFG extraction
directly after ESP
New control logic
Air systems run energy optimized (fan and damper control)
New HZI combustion control system (HZI-CCS)
Advanced combustion control (CCS+)
Combustion Control System
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Steam flow setpoint
Preset NCV
Adj. fire position
3 manual inputs required
Performance Examples CCS
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Narrow O2 band
Rapid load changes
Very stable steam flow After load change
no over/undershoots
Additional sensors – CCS+
Additional sensors for prediction and detection of situation on grate
Differentiate between empty and full grate
Analyse waste properties (density, LHV)
Burn-out control
Benefit
Further improve live steam stability
Proper reaction on changing waste properties
More stable combustion conditions
Less manual interactions
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Sensor Package A: Example Laser Scanner Logic
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Scans the surface of
waste on feedhopper
Waste density,
volume- and
mass-flow
Early information
about waste type
Visualisation of real data
HZI Client Event 2016: Plant Visit Lucerne
Fire End Line: Burnout control
Example: fire gets too long
► primary air flow increased
► grate speed reduced
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Visualisation of real data
Blue pyramids indicate where and how much primary air is added
HZI Client Event 2016: Plant Visit Lucerne
LUZERN: Combustion and Boiler
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Achievements
O2 Down to 3 vol% wet possible
NOx (uncontrolled) < 200 mg/Nm3 at 11% O2
TOC in bottom ash Around 0.5 wt%
Live steam stability Excellent (standard deviation: 1.5%)
Manual corrections Little (highly automated)
LUZERN: Combustion and Boiler
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LUZERN: Flue Gas Treatment
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Electrostatic Precipitator to collect fly ash; ESP ash used for Zinc recovery
Flue gas flow after ESP measured with a raw gas venturi
Raw gas
Venturi Raw gas
Venturi
ESP
LUZERN: Flue Gas Treatment
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1st stage: NaHCO3 for acid removal (HCl, SO2)
stoichiometry close to 1; Residues recycled by RESOLEST
“Xerosorb” fabric filter with integrated residue recirculation
Raw gas
Venturi
Raw gas
Venturi
Reactor 1
Bicar ESP ESP
LUZERN: Flue Gas Treatment
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Catalyst modules mounted from top
Raw gas
Venturi
Reactor 1
Bicar
Reactor 1
Bicar
SCR
Catalyst
ESP
LUZERN: Flue Gas Treatment
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Energy recovery with economizer
Used for feedwater preheating
Raw gas
Venturi
Reactor 1
Bicar
SCR
Catalyst
SCR
Catalyst economizer
ESP
LUZERN: Flue Gas Treatment
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Hydrated lime and lignite coke – “polishing” and Mercury absorption
Modular “Xerosorb” fabric filter
Raw gas
Venturi
Reactor 1
Bicar
SCR
Catalyst economizer
Reactor 2
Hydrated lime
economizer
ESP
LUZERN: Flue Gas Treatment
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Recovery of energy before stack
Energy used for condensate heating
Raw gas
Venturi
Reactor 1
Bicar
SCR
Catalyst economizer
Heat
exchanger
ESP
Reactor 2
Hydrated lime
Reactor 2
Hydrated lime
LUZERN: Flue Gas Treatment
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240 °C
135 °C
130 °C
235 °C
235 °C
80 °C
Gradual temperature
decrease
Energy recovery.
No energy losses due to
reheating of flue gases
130 °C
Emission values
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Summary
New HZI standard for new projects
Open combustion chamber &
staged secondary air injection for operation at low O2
Inova grate (partly)
New HZI CCS and CCS+ with additional sensors (also as retrofit)
Dry flue gas cleaning (Xerosorb)
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Thank you very much for your attention
HZI Client Event 2016: Plant Visit Lucerne