5 Years of Operating Experience With The Biomass Plants of MVV Umwelt GMBH

5 Years of Operating Experience
with the Biomass Plants of

MVV Umwelt GmbH
Dr Eng. Johannes Gnther
VGB Experts Convention on Biomass
30 and 31 March 2009 at the Altbach Power Plant

structure of shareholders and other important investments
Stadtwerke Kiel AG
51.0%
Stadt Mannheim Energieversorgung

50.1% Offenbach AG
50.1%
Stadtwerke
RheinEnergie AG 49.9% Solingen GmbH
16.1%
Stadtwerke Ingolstadt
Free float Beteiligungen GmbH
48.2%
18.7%
MVV Energie AG
Mannheim MVV Umwelt
EnBW AG 100% GmbH
15.0%
MVV Energie CZ
100% Prag MVV Polska
Warschau
100%
MVV O&M GmbH
Products and Business Activities
f Power
f Environment
Growth Areas
f District
heating &
Steam
f Energy Services
f Gas
Core Business
f National Distribution
of Power
f Drinking
water
MVV O&M GmbH

Over the past 10 years, MVV has more than quadrupled its
incineration capacity
Thermal treatment capacity: 1.6 m t/a
WTEP Offenbach BMP Knigs
Generation of energy:
Wusterhausen
800,000 MWhel/a
600,000 MWhth/a
Schleswig-Holstein
Mecklenburg-Vorpommern
H amburg
Brandenburg
250,000 Mg/a
Bremen
Niedersachsen
120,000 Mg/a
B erlin
BMP Wicker
Saxony- Sachsen-Anhalt
Brandenburg
Anhalt
TREA Leuna
Nordrhein-Westfalen
Sachsen
Hesse Thringen
Sachsen
Hessen
Thuringia
110,000 Mg/a
Rheinland-Pfalz
WTEP and BMP Mannheim Saarland
390,000 Mg/a
Bayern
Baden-Wrttemberg
Baden-
Wuerttemberg
Biomass Plant
Waste: 550,000 Mg/a Waste Incineration Plant
Biomass: 130,000 Mg/a
MVV O&M GmbH
A decisive precondition for the profitable operation of BMPs is
their support by the REA (Renewable Energies Act)
.
Required electrical gross efficiency (e.g. 29 %, at 20 MWel)
Selection of the steam parameters according to the principle As high as necessary, as low
as possible; commonly used parameters: 65 bar, 450C
Determination of the amount of proceeds from power

Based on the waste-wood market price, this implies a certain minimum size of the plant.
.
REA power proceeds are not adjusted for
inflation, but fuel and operating costs keep
increasing!
As a rule, biomass plants are calculated assuming

8,000 hours of full-load operation per year
MVV O&M GmbH Dr.Ing. Johannes Gnther Page 5

The first-generation BMPPs were designed for operation with
waste wood
.
With the increasing number of competing BMPPs and the coming into force of the Waste
Disposal Regulation, the quality of waste wood used in the power plants became poorer and
poorer.
Is it waste wood?
Or is it rather waste
with traces of waste wood?
.
Suitable measures must be taken in the
power plant in the areas of conveying
equipment, furnaces, boilers and, if
applicable, flue gas cleaning.
Now let me come to our experience ..

BMP Mannheim
BMP Mannheim
MVV O&M GmbH

Key data of the Mannheim biomass plant
Boiler:
Startup: 2003
System: Travelling grate with spreader stoker, vertical flue boiler
Fuel: Wood 15.5 Mg/h, natural gas 4,000 Nm/h
Furnace thermal rate: 66 MW
Control range: 80 - 100 % with wood, 0 - 60 % with natural gas
Steam output: 80 Mg/h
Steam state: 65 bar, 450C
Ash removal: Wet ash extractor
Flue gas cleaning:
NOx removal: SNCR in the first boiler flue with urea

Pre-dedusting: 2 x cyclone dust separators
Separation of SO2 , HCL, HF,
Heavy metals, dioxins and furans: Dry sorption with mixing tank, mixing section and bag filter
Absorbtion/ Adsorption: Hydrated lime and activated carbon
Turbine:
Condensing turbine
Terminal power: 20 MW (effective power)
Bleeding: 4 bar, 148C (deaerator steam)
Extraction: 1.2 bar, 105C (feed-water heater)
Condenser: Air-cooled, pressure: 0.12 bar, 20C

Mannheim biomass plant: Fuel pre-treatment
Silo (5,000 m3)
50 t/h
Fine crusher
10 h/d
18 m
Magnetic separator
Separator of ferrous and

non-ferrous metals
Magnetic separator
Coarse crusher 15.5 t/h

8,000 h/a

Mannheim biomass plant: Plant structure
The power plant consists of the following components:
Furnace
Travelling grate with spreader stroker
Steam generator
Flue-gas cleaning
SNCR (selective non-catalytic red.)
Cyclones Bild Martin-Anlage
Reactor with Ca(OH)2, activ. carbon
Bag filter

Mannheim biomass plant: Structure of the steam generator
The steam generator is subdivided as follows:
Radial passes
1st and 2nd flue: Evaporator
Convection passes
3rd flue: Superheater
4th flue: Eco (feed water heating)
The steam generated is turned into power

in a condensing turbine

BMP Wicker
MVV O&M GmbH

Key data of the Wicker biomass plant
Boiler:
Startup: 2003
System: Travelling grate with spreader stoker, vertical flue boiler
Fuel: Wood 11.25 Mg/h, gasoil = 1,750 kg/h
Furnace thermal rate: 48 MW
Control range: 80 - 100 % with wood, 0 - 40 % with gasoil
Steam output: 54.27 Mg/h
Steam state: 65 bar, 450C
Ash removal: Wet ash extractor
Flue gas cleaning:
NOx removal: SNCR in the first boiler flue with urea

Pre-dedusting: 2 x cyclone dust separators
heavy metals, dioxins and furans: Dry sorption with mixing tank, mixing section and bag filter
Absorption/ Adsorption: Hydrated lime and activated carbon
Turbine:
Condensing turbine
Terminal power: 14.012 MW (effective power)
Extraction: 2.8 bar, 131C (deaerator steam and heating of building)
Condenser: Air-cooled, pressure: 0.1 bar, 15C

BMP Knigs Wusterhausen
MVV O&M GmbH

Key data of the Knigs Wusterhausen biomass plant
Boiler:
Startup: 2003
System: Circulating fluidized bed combustion
Fuel: Wood 15.84 Mg/h, gasoil light 3 Mg/h
Furnace thermal rate: 54.6 MW
Control range: 60 - 100 % with wood, 0 60 % with gasoil
Steam output: 63.75 Mg/h
Steam state HP: 87 bar, 477C
Steam state LP: 16 bar, 477C
Ash removal: Dry ash removal
Flue gas cleaning:

Pre-dedusting: Cyclone dust separator
heavy metals, dioxins and furans: Dry sorption, mixing section and bag filter
Absorption/ Adsorption: Hydrated lime and activated carbon
Turbine:
Condensing turbine (HP-, LP-part)
Terminal power: 20 MW (effective power)
Tapping: 8.44 bar, 389.6C (deaerator steam), 2.9 bar, 263C (LPD 2)
0.45 bar, 95C (LPD 1)
Condenser: Water-cooled, pressure: 0.059 bar
Hybrid cooling tower:

Water throughput: 2.950 Mg/h / cooling down from 31 to 22C, at 20C ambient tem
perature
BMP Knigs Wusterhausen:
Schematic Structure
waste
wood
MVV O&M GmbH

Operating experience at the Mannheim biomass plant
Startup in September 2003
2nd year of operation: 7,990 hours of full-load operation
Since the 3rd year of operation > 8,000 hours of full-load operation

Pre-treatment of fuels (PTF) and storage
Fuels must be treated according to their method of incineration
Fuel processing in grate firing (low expenditure)
Fuel processing in CFB (high expenditure)
Important when planning a PTF facility
Ensure it has sufficient capacity
Provide redundant facilities for treatment, conveyance and feed

Problems in fuel pre-treatment
Dust develops in many places
Pollution
Health hazards
Risk of explosion
high cleaning expenditure and/or primary measures
Difficult-to-handle material
High wear due to impurities (preventive

maintenance!)
Tends to entangling and bridge formation
Self-ignition due to heat generated by decay

Encapsulation of dust sources (e.g. conveying equipment),
doubling of exhaustion capacity

Large-area installation of water sprinklers
for dust abatement

Installation of new, state-of-the-art spraying equipment

Erection of 6 m 8 m high dust collection walls
Before
After

Extension of the dust collection wall and extension of the
spraying system
Water curtain
MVV O&M GmbH

Purchase and operation of a suction sweeper

Risk of fire during storage:
Small fire great impact (in the public)
Self-ignition of uncrushed wood is rather improbable.
When crushed wood is stored, temperatures in the

heaps of broken material may rise up to 90 C.
When screen overflow of MBT materials or bulky

refuse is stored, there is a high risk of fire.
Counter-measures
Minimise dwell times of critical materials in the storage area
Installation of fire detection and extinction devices
Infrared cameras

Particularities and highlights at the Mannheim BMP
.
Slagging of the combustion chamber while commissioning.
The combustion chamber was too hot due to its masonry lining.
.
Removal of the masonry lining

Removal of the
refractory system

Particularities and highlights at the Mannheim biomass plant
.
Break of evaporator pipe due to corrosion after the removal of the masonry lining
(after 3,000 hours of operation).
.
Installation of cladding

Corrosion protection concept
Inconel 625

.
Slagging of the front and rear walls of the 1st pass; lumps of slag came off the walls
and damaged the grate.
.
Installation of a water-jet blower
Clyde Bergemann

.
Pipe break in the stay pipes of the 3rd pass caused by the soot blowers
.
Complete replacement of the stay
pipes, installation and extension of
the cladding around the soot blowers

Some facts from the
BMP Mannheim
.
Damage of the turbine gear, broken cog at the pinion
.
Replacement of complete gearbox
MVV O&M GmbH

Operation experience at the Wicker biomass plant
Startup in October 2003
1st year of operation: Over 100 plant failures (about 4,660 hours of full-load
operation)
2nd year of operation: About 10 failures (about 6,900 hours of full-load

operation)
Since the 3rd year of operation: > 8,000 hours of full-load operation per year

Particularities and highlights at the Wicker BMP: Boilers
.
In the combustion chamber and in the upper area of the first pass,
parts of the refractory lining were removed. At the same time, the
protective evaporator arranged upstream of the superheaters was
removed to ensure the desired live steam temperature would be
reached.
After the removal of the refractory system, the respective surfaces were
cladded.
Gradually, the surfaces cladded in the first pass had to be enlarged to

meet increasing requirements. By cladding the diaphragm walls in the
first pass, corrosion can be controlled here.

Particularities and highlights at the Wicker BMP: Boilers
The second and third pass are uncritical.
The corrosion in the superheater area does not give rise to

any concerns.
Due to the deterioration of the fuel quality, the dirt

accumulation in the boiler, particularly in the convection
area, has greatly increased. Remedial actions are adequate
cleaning concepts including blast cleaning.
Due to the operation of the soot blowers, the material of

the superheaters along the soot blower tracks, in
particular at the rear reversal point, was heavily worn.
Solution: thicker cladding.

Particularities and highlights at the Wicker BMP: Grate
.
With the grate (travelling grate made by Detroit Stoker) there were
problems similar to those we experienced in Mannheim (same grate
manufacturer). However, problems were not as dramatic as we were
able to react more adequately during startup based on our past
experience with the Mannheim BMP.
Along with the deterioration of the waste wood quality, wear of the
grate has increased dramatically.
Wear and tear is caused by the friction between the grate rails made of
cast materials and the grate bars.
Additionally, slag components such as sand, glass and metal coming

from the use of MBT screen overflow and waste wood cause increasing
wear (abrasion). As the inert substances cannot be kept away from the
abrading components, the surfaces exposed to wear must be protected
and harder materials must be chosen for protection against these
abrading components.

Particularities and Highlights at the Wicker BMP: Turbine
.
Problems
The control valve could not be operated
properly.
The control valve could not be closed
completely.
The cross-joint of the casing leaked
Despite the deficiencies, the first power was

supplied in 2003 (manual operation).
Various time-consuming repair activities

followed.
Repair work completed in summer 2004,

then the machine was taken over.

Operation Experience at the Knigs Wusterhausen BMP
Hot startup in June 2003, turbine in October 2003
The initial availability of 6,100 full-load operation hours per year could be
increased towards the planned availability of 8,000 full-load operation hours
per year by various optimisation and reconstruction measures.
In the last business year, we will noticeably exceed the magic threshold of
8,000 full-load operating hours.

Particularities and highlights at the Knigs Wusterhausen BMP:
Boilers
.
Already during hot commissioning, some areas of
the fuel and residue conveyance system had to be
rehabilitated due to heavy wear and clogging.
Wear of the refractory lining in the boiler

cyclones was so heavy at the beginning that after
its failure in June 2003, the evaporator was
damaged.
The inspection intervals for the refractory lining
considerably influenced the availability of the
plant.
Later on, SiC material was used for the refractory

lining, which has better thermal conductivity and
higher resistance to wear.

Boilers
.
In summer 2005 the unprotected area of the combustion chamber rear wall had to be
replaced. This area was then completely cladded.
During this standstill, Superheaters II and I and Reheater I had to be replaced after only 9,800
hours of operation.
Causes of the extreme corrosion:
Boiler design -> too high flue gas temperatures before entry into the superheaters
But also the high HCl concentrations in the flue gas
In summer 2006 the unprotected areas of the side and front walls of the combustion chamber
were provided with a sprayed coating (Sulzer metco).
The areas of the rear wall cladded in the previous year showed considerable wear due to
erosion.
In this summer, too, superheaters II and I were replaced again. To increase their lifetime,
corrosion and temperature resistant austenitic stainless steel (TP 347 HFG) was used this time.
Additionally, parts of the refractory lining were removed in the combustion chamber and the
deflection chamber arranged downstream of the cyclones, which resulted in a considerable
reduction of the flue gas temperature upstream of the superheaters.

Boilers
.
Fortunately, the corrosion caused by molten

salt we had feared to happen in the fluidized
bed cooler fortunately did not occur.
The current findings show that thanks to the

sprayed coating, the combustion chamber
walls did not have to be replaced and that
the useful life of the superheaters could be
tripled due to temperature reduction and the
use of high-alloy steel.

5 Years of BMP: Summary and conclusions for MVV Umwelt
The startups of the biomass plants vary a lot.

Already in its second year of operation, the Mannheim plant reached its intended operation
level.
The troublesome startup of the Wicker plant was mainly due to the deficiencies of the
turbine.
In the Knigs Wusterhausen plant, availability during the first years of operation was
influenced by corrosion in the combustion chamber and the superheaters and erosion in the
boiler cyclones.
The waste wood used in the BMPs is a difficult-to-handle fuel which may cause various problems
both in terms of pre-treatment and combustion.
The combustion problems greatly depend on the firing method; the grate makes much lower
demands on the fuel than the fluidized bed.
Mechanical wear in both the waste wood pre-treatment facility and the boiler can
generally be controlled by specific protection of the surfaces subject to wear.
Resurface welding, flame-spraying of cladding and plating

5 Years of BMP: Summary and conclusions for MVV Umwelt
Corrosion of the steam generators during the combustion of waste wood (with reasonable steam
parameters) can be controlled by
cladding
Thermal spraying
Use of higher-grade materials for the superheaters
The waste wood market is extremely tight, which forces operators to add alternative biomass for
combustion to be able to gain additional contribution margins.
But even minor changes in the fuel composition may result in major disturbances.
These disturbances are often so serious and/or time-consuming that the resulting economic
damage is much higher than the benefit.
Finally we can say that:

MVV Umwelts biomass plants make the desired contribution to MVV Umwelts result.
The Groups decision to enter into the generation of power from biomass was right.
However, profits realized from biomass plants are lower than was expected in the initial euphoria.
The air is becoming increasingly thinner as costs keep rising while earnings from the sale of
power stay the same.

Thank you very much
for your attention!
Dr Eng. Johannes Gnther

Managing Director of MVV O&M GmbH
Authorised representative of MVV Umwelt
Managing Director of MVV BMP Mannheim GmbH
Managing Director of Biomasse Rhein-Main GmbH
Phone: 0621-290-4633
www.mvv-oum.de
j.guenther@mvv.de

5 Years of Operating Experience With The Biomass Plants of MVV Umwelt GMBH

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5 Years of Operating Experience

with the Biomass Plants of

Dr Eng. Johannes Gnther

VGB Experts Convention on Biomass

30 and 31 March 2009 at the Altbach Power Plant

Stadt Mannheim Energieversorgung

MVV O&M GmbH

WTEP and BMP Mannheim Saarland

Determination of the amount of proceeds from power

As a rule, biomass plants are calculated assuming

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 5

Now let me come to our experience ..

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 6

MVV O&M GmbH

Flue gas cleaning:

NOx removal: SNCR in the first boiler flue with urea

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 8

Silo (5,000 m3)

Separator of ferrous and

Coarse crusher 15.5 t/h

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 9

The power plant consists of the following components:

SNCR (selective non-catalytic red.)

Cyclones Bild Martin-Anlage

Reactor with Ca(OH)2, activ. carbon

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 10

The steam generator is subdivided as follows:

3rd flue: Superheater

4th flue: Eco (feed water heating)

The steam generated is turned into power

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 11

MVV O&M GmbH

Flue gas cleaning:

NOx removal: SNCR in the first boiler flue with urea

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 13

MVV O&M GmbH

Flue gas cleaning:

Hybrid cooling tower:

MVV O&M GmbH

Startup in September 2003

2nd year of operation: 7,990 hours of full-load operation

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 17

Fuels must be treated according to their method of incineration

Fuel processing in grate firing (low expenditure)

Fuel processing in CFB (high expenditure)

Important when planning a PTF facility

Ensure it has sufficient capacity

Provide redundant facilities for treatment, conveyance and feed

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 18

Dust develops in many places

high cleaning expenditure and/or primary measures

High wear due to impurities (preventive

Tends to entangling and bridge formation

Self-ignition due to heat generated by decay

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 19

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 20

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 21

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 22

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 23

MVV O&M GmbH

MVV O&M GmbH Dr.Ing. Johannes Gnther Page 25

 Self-ignition of uncrushed wood is rather improbable.

 When crushed wood is stored, temperatures in the

Determination of the amount of proceeds from power

Self-ignition of uncrushed wood is rather improbable.

When crushed wood is stored, temperatures in the

When screen overflow of MBT materials or bulky

Minimise dwell times of critical materials in the storage area

Installation of fire detection and extinction devices

Gradually, the surfaces cladded in the first pass had to be enlarged to

The second and third pass are uncritical.

The corrosion in the superheater area does not give rise to

Due to the deterioration of the fuel quality, the dirt

Due to the operation of the soot blowers, the material of

Solution: thicker cladding.

Additionally, slag components such as sand, glass and metal coming

Despite the deficiencies, the first power was

Various time-consuming repair activities

Repair work completed in summer 2004,

Wear of the refractory lining in the boiler

Later on, SiC material was used for the refractory

Fortunately, the corrosion caused by molten

The current findings show that thanks to the

The startups of the biomass plants vary a lot.

Finally we can say that: