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IGCC POWER

Biomass and Bioenergy Vol. 15, No. 3, pp. 205-211, 1998 1998 Published by Elsevier Science Ltd. All rights reserved Printed in Great Britain PII: S0961-9534(98)00025-7 0961-9534/98/$- see front matter

PLANT FOR VARNAMO,

BIOMASS SWEDEN

UTILISATION,

KRISTER STAHL*~ a n d MAGNUS NEERGAARDt *Sydkraft AB, S-205 09 Malmo, Sweden tSydkraft Konsult AB, Sweden Abstract--Sydkraft AB has built the world's first complete IGCC Power Plant which utilises wood as fuel. The plant is located in V/irnamo, Sweden, and the technology used in the power plant is based on gasification in a pressurised circulating fluidised bed gasifier. The gasification technology is developed in co-operation between Sydkraft AB and Foster Wheeler Energy International Inc., who also supplied the gasification plant. The plant at V~rnamo produces about 6 MWe electricity to the grid, as well as 9 MWth heat to the district heating system in the city of V/irnamo, from a total fuel input equivalent to 18 MW. The V/irnamo plant is an important step forward in developing highly efficient and environmentally acceptable technologies based on biomass fuels. Experiences gained in this co-generation plant will be utilised in the design of new and larger plants which will generate twice as much electricity as a conventional steam cycle plant with the same amount of heat demand. The start-up phase was completed during spring 1996 and the plant is now available for research and development work. A demonstration programme was launched in 1996, which will continue for some years, and during this period advantages and possible limitations of the new technology will be evaluated. Specific areas of interest include environmental issues, fuel flexibility and production costs in future facilities in addition to the technical development and improvements of the plant. As only part of the programme has yet performed, many of the tests still remain and accordingly must be reported at a later opportunity. However, operating experience with a fully integrated plant i.e. gas turbine on 100% gas, had by March 1997 exceeded 950 hours. 1998 Published by Elsevier Science Ltd. All rights reserved Keywords-----Biomass; gasification plant; combined cycles.

1. INTRODUCTION

Increasingly heavy demands are expected on future power plants in terms of efficiency, impact on the environment, fuel flexibility, power production costs etc. Biomass fuels are in most countries a domestic source of fuel and are often found as waste products in different kinds of industries e.g. agriculture, forestry, pulp and paper. Further, a lot of biomass garbage such as packaging is presently landfilled and in future there will probably be more stringent requirements to recycle garbage, thereby reducing landfilling. Carbon dioxide, methane and freons are examples of greenhouse gases that absorb infrared radiation from the earth and contribute to the net increase of radiation energy in the atmosphere, which results in a temperature increase. By utilising biomass fuels as feedstock there will be no net increase in carbon dioxide levels from power production, in contrast to a situation where fossil fuels are used.
SAuthor for correspondence. Tel: +0046-40-25-5881; Fax: + 0046-40-611-5184; E-mail: christina.wramborg@Sydkraft.se 205

Integrated gasification combined cycles (IGCC) have been developed and demonstrated for power generation using fossil fuels as feedstock. The main features are the possibility of cleaning the gas produced from impurities such as particulates, sulphur, etc. under pressure before the gas enters the combustor of the gas turbine, and also the relatively high electrical efficiency. Higher efficiencies also mean relatively lower emissions. On the basis of these considerations, Foster Wheeler Energy International, Inc. and Sydkraft AB have been developing the pressurised IGCC for biomass fuels since 1991. In June 1991, Sydkraft took the final decision to build a co-generation plant at V/irnamo, Sweden, to demonstrate the technology. The plant generates 6 MW of electricity and 9 MW of heat for district heating. The Vfirnamo Demonstration Plant is the first of its kind in the world. The plant is aimed at demonstrating the complete integration of a gasification plant and a combined cycle plant, fuelled by biomass. The basic idea is to demonstrate the technology rather than to run a fully optimised plant. Flexible and

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K. STAHLand M. NEERGAARD

Fig. 1. Aerial view of the V/irnamo Demonstration Plant.

conservative solutions were chosen for the plant layout and design, to ensure the success of the project and to make the plant suitable for R & D activities.

The plant is now undergoing a demonstration phase and has been successfully operated with full integration. An aerial view of the plant is shown in Fig. 1.
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Fig. 2. Plan of the V/irnamo Demonstration Plant.

IGCC power plant for biomass utilisation, Varnamo, Sweden 2. T H E P R O C E S S

207

Figures 2 and 3 show the plant, which works as follows. The fuel is dried in a separate fuel preparation plant, using a flue gas dryer, to a moisture content of 5-20%. The dried and crushed wood fuel is pressurised in a lock-hopper system to a value which basically is determined by the pressure ratio of the gas turbine, and is fed by screw feeders into the gasifier a few meters above the

bottom. The operating temperature of the gasifier is 950-1000C and the pressure is approximately 20 bar(a). The gasifier is of a circulating fluidized bed type and consists of the gasifier itself, cyclone and cyclone return leg. The three parts are totally refractory lined. The fuel is pyrolized immediately on entering the gasifier. The gas transports the bed material and the remaining char towards the cyclone. In the cyclone, most of the solids are separated from the gas and are returned to the bottom of

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Fig. 3. The Vgrnamo Gasification plant.

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K. STAHL and M. NEERGAARD

the gasifier through the return leg. The recirculated solids contain some char which is burned in the bottom zone where air is introduced into the gasifier. The combustion maintains the required temperature in the gasifier. After the cyclone, the gas produced flows to a gas cooler and a hot gas filter. The gas cooler is of a fire tube design and cools the gas to a temperature of 350-400C before it enters the ceramic filter vessel where the particulate clean-up occurs. Ash is discharged from the ceramic filter and from the bottom of the gasifier, and is cooled before entering the de-pressurization system. The gasifier is of an air-blown type. Thus about 10% of the air is extracted from the gas turbine compressor, further compressed in a booster compressor, and finally injected into the bottom of the gasifier. The gas generated is burned in the combustion chambers and expands through the gas turbine, generating 4 MW of electricity. The gas turbine is a single-shaft industrial gas turbine. The fuel supply system, fuel injectors and the combustors have been redesigned to suit the low calorific value gas (5 MJ/nm3). The hot flue gas from the gas turbine is ducted to the heat recovery steam generator (HRSG) where the steam generated, along with steam from the gas cooler, is superheated and is then supplied to a steam turbine (40 bar, 455C). The plant is equipped with a flare on the roof of the gasification building, which is used during start-up procedure and when testing

less well known conditions, in order to protect the gas turbine. The technical data is summarised in Table 1.
3. PLANT COMMISSIONING

Commissioning of the plant started late in 1992 by start-up of the fuel preparation plant. Commissioning of the combined cycle was completed on liquid fuel during March 1993. The first gasifcation test on wood chips at low pressure was performed in June 1993, and combustible gas was produced and burned in the flare. The plant had been in gasification mode for about 4000 hours by the end of February 1997. Commissioning of the combined cycle part of the plant was carried out according to plan, which was expected since the design is ahnost conventional. However, commissioning of the gasification plant as well as the total integration of the two parts has been slightly more time-consuming than planned. For cost reasons, very few redundant components and systems are installed and, considering the high degree of integration and the complexity, the risk of delay in commissioning always exists. However, we have to admit that what could be considered reasonably conventional technology has caused, in some instances, unexpected delays. This in particular applies to the handling of solid materials. Furthermore, different bed materials have been tested to find out how they affect the process. During tests with different materials,

Table 1. Technical data of the V/irnamo Plant Power generation Heat for district heating Fuel input Fuel Net electrical efficiency (LCV) Total net efficiency (LCV) Gasification pressure Gasification temperature Lower calorific value of Product Gas Steam pressure Steam temperature Plant owner Suppliers: Engineering Gasifier Gas cooler Ceramic filter Gas turbine Booster compressor Heat recovery steam generator Steam turbine Plant control system 6 MWe 9 MWth 18 MWfuel (85%ds) Wood chips 32%

83% 20 bar(a)
950-1000C 5 MJ/m3n 40 bar a 455C Sydkraft AB Sydkraft Konsult/Foster Wheeler Foster Wheeler Foster Wheeler Schumaeher GmbH European Qas Turbines Ltd. Ingersoll-Rand Foster Wheeler Turbinenfabrik Nadrowski GmbH Honeywell

IGCC power plant for biomass utilisation, Varnamo, Sweden

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temperatures and pressure levels, deposits sometimes occurred. Deposits and fouling have verified the importance of controlling the process and ensuring suitable design of components. It is of great importance to operate the whole process under suitable conditions to achieve the best results, i.e. minimum deposits and best possible gas quality. What we have achieved is to run the process quite satisfactorily, but we are confident that we can optimise it further. However, before performing this optimisation work on the gasification process, it was decided to demonstrate the possibility of running the gas turbine with product gas and full plant integration. Accordingly, in late spring 1995, the product gas fuel supply system, fuel injectors and combustors were installed in the gas turbine. In September, after the summer shut-down, the modified gas turbine commissioning on liquid fuel was completed, and the first test runs on product gas were performed in October. In order to minimise the risks, the first test runs were very short and product gas was introduced gradually with a corresponding reduction in liquid fuel, which eventually resulted in operation solely on product gas. Observations during the fuel changeover phase and during operation on 100% product gas showed no adverse effect on either combustion performance or turbine behaviour. Unfortunately, leakage of liquid fuel caused a fire inside the gas turbine enclosure in late October, and the plant had to be shut down for a couple of months, as the gas turbine had to be shipped to the UK for repairs. During spring 1996, the gas turbine went back into operation and the commissioning was concluded.
4. EXPERIENCE GAINED DURING FIRST YEARS OF TEST OPERATION

In particular three areas were of great concern already during the early design stage, namely: --how to prevent formation of deposits in the cooler - - h o t gas filter operation --gas quality Tests have so far been performed with different bed materials such as limestone, dolomite and MgO. The gas produced with these have been within the requirements of the gas

turbine, but the recarbonisation of limestone/ dolomite have of course caused deposits in the gas cooler system. Insufficient cracking of the tars have also caused fouling of cooler tubes. The fouling and deposits in the gas cooler have always been a threat to long term operation as with the installed type of coolers cleaning during running is not possible. However, increased knowledge of the "useable operating window" of the process (i.e. temperature, circulation, cracking etc.), and for this type of cooler use of non recarbonising bed material, now allow us to run for prolonged periods. Concerning the hot gas filtration, one of the ideas behind this is of course to allow gaseous tars to pass through the filter and other tars to stick to the filter cake and not pass into the fine pore structure of the filter itself. As the amount of benzene and tars is not insignificant from a gas heating value point of view this is very important to achieve. Figure 4 shows a typical operating curve for the hot gas filters and clearly indicates that no continuous increase in pressure drop is taking place. However after more than 1200 hours of trouble-free operation suddenly two candles broke. No serious damage was caused and the reason for the breakage has not yet been established. During the commissioning as well as the demonstration programme the gas quality has been checked regularly. The gas quality, regarding hydrogen content has turned out to be slightly lower than predicted, but the heating value has been maintained by an increase in methane. A typical range of dry gas composition is specified in Table 2. Percentage is by volume and gas heating value in the range of 5.3-6.3 MJ/m3n have been recorded. We see great possibilities of improving the gas, as tests so far have not been aimed at optimising the quality. For example the amount of nitrogen may be reduced. Of course tar and ammonia measurements have been performed and indicate levels are below 5 g/m3n respectively below or well below 700 ppm vol. Recorded

Table 2. Typical range of dry gas composition used in the plant CO 16-19% H2 9.5-12% CH4 CO2 N2

5.8-7.5% 14.4-17.5% 48-52%

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K. STAHL and M. NEERGAARD

IGCC V a m a m o

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Fig. 4. Operating curve for hot gas filters

levels of alkalines have been below 0.1 ppm

wt.

Furthermore we can state that the general results so far from the demonstration programme are very promising, and the gas turbine has, by March 1997, been operated entirely on gasifier-produced gas for almost 1000 hours, and during one single test for more than 250 hours continuously. During these test different loads were tested up to 100% as well as full plant integration. Recently tests with high bark content (> 50%) in the fuel have been run, and even if some influence on gas quality has been recorded no adverse effects have been observed to the gasifier or the gas turbine.
5, DEMONSTRATION AND DEVELOPMENT PROGRAMME

requirements by low emission levels in future plants. The demonstration/development programme has been organised in four blocks: 5.1. Technology Some components/systems do not allow long term operation (months) between overhauls. Accordingly we intend to improve and develop these further. In general the improved design will then be tried and tested in the plant. The technology development is however not confined to areas of developing existing components but will also look into possibilities of increasing the efficiency by, for example, reducing the amount of inert gas required. 5.2. Economics With the information available from our computer system regarding actual maintenance and operating cost in V/irnamo we should have the possibility to assess these costs not only for the V/irnamo plant but also for larger and improved plants. Furthermore, we intend to evaluate reliability and availability for this type of plant. 5.3. Environment An emission measurement programme including NOx, CO, UHC, etc. as well as

An extensive demonstration/development programme will be carried out between 1996 and 1999. The objectives are to confirm the technical and economic viability of the technology and to provide engineering data for the design of commercially rated power plants. Plant performance and process characteristics will be evaluated in order to achieve high cycle efficiencies, high ratios of electric power to heat, and compliance with environmental

IGCC power plant for biomass utilisation, Varnamo, Sweden

211

heavy metals and dust has been laid down. The results from this programme may generate the need for a further development of components/systems. 5.4. Fuel flexibility During the commissioning and first part of the demonstration programme normal wood waste from pine trees has been used. It is our intention to study the plant's ability to operate

on different kinds of fuels based on biomass from short rotation forestry such as salix, to wastes such as packaging materials.
REFERENCES 1. Sffthl, K., Neergaard, M., Stratton, P. and Nieminen, J., IGCC power plant for biomass utilisation Vdrnamo. Sweden, presented at Developments in Thermochemical Biomass Conversion, Banff, Canada, 1996.