Systems. Refrigeration. Air Treatment. Plant. Engineering. Lentjes GmbH.
Turnover ~ €350 m. 350 employees. Lurgi AG. Zimmer AG. Lurgi Bischoff GmbH
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Presentation of Waste incineration technologies from Lentjes GmbH
We are all making efforts to deal responsibly with our resources and with nature. Much has already been achieved in this respect.
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1. Company and Plant References 2. Technologies 3. Summary
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1. Company and Plant References
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Lentjes? A few words about the company …
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Lentjes GmbH Ø
Lentjes is a process lead international EPC turnkey contractor with a worldwide network in industrially active markets
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Lentjes is a pure engineering company with in-house proprietary technologies and processes for EfW plants (grate systems, steam generators, FGC systems)
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Over 80 contracts in the waste to energy sector since 1990
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Wide international experience
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Involvement in early stage regarding planning questions
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Local presence in key markets ensures deliverability 5
Turnkey EPC Expertise in
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Engineering (for all combustion systems, boilers, FGC processes, civils, water-steam-cycle, electrical, I&C, etc.)
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Procurement / International Sourcing
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Construction
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Project Management
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Quality Assurance / Health & Safety
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Construction Management
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Training, Commissioning, Performance Testing 6
GEA Group Aktiengesellschaft Turnover €4.5 billion
Employees 17,500
Customised Systems
Process Equipment
Process Engineering
Plant Engineering
Refrigeration
Mechanical Separation
Process Equipment
Lentjes GmbH
Dairy Farm Systems
Energy Technology
Air Treatment
Process Equipment
Turnover ~ €350 m 350 employees
Lurgi AG Zimmer AG Lurgi Bischoff GmbH
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Latest News …. Ø GEA has decided to concentrate on the component business, thus the Plant Engineering Division has been sold Ø Lentjes has recently found new owner in ATEC Industries Ø ATEC Industries will continue and strengthen all former Lentjes’ activities in the future Ø Lentjes will remain a strong and reliable partner in the ‘Energy from Waste’ business
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Headquarters Ratingen / Germany
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Lentjes Portfolio Energy Division
Environment Division
Ø Fossil Fired Power Plants
Ø Hazardous Waste Incineration
Ø Combined Cycle Power Plants
Ø Biomass to Energy
Ø Flue Gas Desulphurisation
Ø Sewage Sludge Incineration Ø Energy from Waste 10
Lentjes Product Portfolio
Fossil Fired Power Plants
Flue Gas Cleaning Power Plants
Treatment Plants for Industrial Waste/Residues Sewage Sludge
Energy from Waste Plants
Biomass to Energy Plants
Circulating Fluidised Bed
Desulphurisation Wet - FGD Seawater - FGD CFB - FGD Ammonia - FGD
Rotary Kiln
Grate Systems
Fluidised Bed
Circulating Fluidised Bed
Circulating Fluidised Bed
Grate Systems
ROWITEC®
Flue Gas Cleaning
Combined Cycle Power Plants Co-Generation and Industrial Power Plants
Denitrification SCR - Technology
Energy Division
Flue Gas Cleaning
Flue Gas Cleaning
Environment Division 11
Technologies of Energy and Environment Divisions Energy CCPP CFB Flue Gas Desulphurisation Environment Energy-from-Waste and Biomass Plants Sewage Sludge Incineration Hazardous Waste Incineration
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GAVI Wijster / NL, Water cooled grate 3 x 20 t/h
Taoyuan / ROC, Roller Grate 2 x 28 t/h 13
Madrid / E, ROWITEC 3 x 9 t/h
Sleco / B, ROWITEC 3 x 20,8 t/h
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Lenzing / D, CFB 110 MWth
Premnitz / D, CFB 60 MWth
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Ebenhausen / D 2 x 50.000 t/a
Bayer AG Dormagen / D 45.000 t/a
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Dordrecht / NL 3 x 12 t/h, 1 x 24 t/h
Crossness / UK 2 x 3,5 t/d, 5,2 MWel
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SITA Kirklees, Huddersfield / UK 1 x 17 t/h
Shell Green, Manchester / UK 1 x 5,7 t/d Extension Target Price Contract Award 2005 18
WRG Allington, Kent / UK 3 x 21,4 t/h
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Madeira / P
Budapest / H Colleferro / I
Wuppertal / D
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Recent Plant References Energy-from-Waste Start-up
Plant
2001 2002 2002 2002 2002 2002 2002 2003 2003 2004 2005
Taoyuan South / ROC Kirklees / UK Madeira / P Terni / I San Vittore / I Colleferro I+II / I Premnitz / D Powergen / UK Strongoli / I Budapest / H Cantabria / E
2006
Sleco / B
2006 2006 2008 2008 2008 2008
Allington / UK Frankfurt / D Casteltermini / I Augusta / I Palermo / I Manchester / UK
Grate System Throughput LHV (kJ/kg) Roller Grate Recipr. Grate Roller Grate Reci. Grate w/c Reci. Grate w/c Reci. Grate w/c CFB FB CFB Roller Grate Roller Grate
2 x 675 t/d 1 x 410 t/d 2 x 192 t/d 1 x 300 t/d 1 x 300 t/d 2 x 300 t/d 1 x 60 MWth 1 x 530 t/d 2 x 20 MWel 4 x 360 t/d 1 x 288 t/d
ROWITEC
3 x 495 t/d
ROWITEC Recipr. Grate Reci. Grate w/c Reci. Grate w/c Reci. Grate w/c FB
3 x 513 t/d 4 x 480 t/d 2 x 413 t/d 3 x 413 t/d 3 x 552 t/d 1 x 140 t/d
Waste
FGC System
9,600 MSW Semi-dry 9,200 MSW Semi-dry 7,800 MSW Semi-dry 15,000 SRF Semi-dry 15,000 SRF Semi-dry 15,000 SRF Semi-dry 14,000 SRF Circoclean 5,200 Paper Sludge Fabric Filter 11,100 Biomass Dry (BiCar) 8,500 MSW Semi-dry 11,720 MSW Circoclean Circoclean + 50 % SRF 8,300 50 % Sludge Scrubber 9,200 MSW Circoclean 10,300 MSW Circoclean 12,560 SRF Dry (BiCar) 12,560 SRF Dry (BiCar) 11,550 SRF Dry (BiCar) 12,600 (DS) Sludge Wet multi-stage
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Plant References Energy-from-Waste
74 Lines in 43 Plants equivalent to
1.107 tph or ~8,85 mio tpy
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2. Technologies
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Lentjes’ Technologies Related to Waste Sector Furnace Types:
• • • • •
Heat Recovery Boilers:
• Horizontal / vertical multi pass systems • Standard WTE parameters preferred
Gas Cleaning:
• • • •
Reciprocating Grate (air/water-cooled) Roller Grate Circulating Fluid Bed ROWITEC® Fluid Bed Fluidized Bed
Conditioned Dry – CIRCOCLEAN® Semi Dry Wet Scrubbers SCR and SNCR
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Grate Systems Reciprocating Grate Counter Reciprocating Grate
Roller Grate
Application:
Application:
Incineration of MSW / SRF
Incineration of MSW 25
Fluidised Bed Systems ROWITEC®
Application: Incineration of MSW / SRF + Sludge
CFB
Application: Incineration of SRF
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Typical Application Ranges of Technologies
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Roller Grate
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Roller Grate Section I
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Roller Grate Section II
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Roller Grate Side Wall
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Grate Bar
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Roller Grate Drives
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Roller Grate Capability for High CV‘s EfW Plant Wuppertal / D Variation of Heating Values - Roller Grate 2002
2006
Average 2002 (11,8 MJ/kg)
Average 2006 (10,6 MJ/kg)
16.000
15.000
14.000
LHV MJ/kg
13.000
12.000
11.000
10.000
9.000
8.000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Week
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Combined Grate
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Function of Grate Type 410 (Reciprocating) Start Position
Middle Position
moving rows
Final Position
fixed rows
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Function of Grate Type 510 (Counter Reciprocating) Start Position
Middle Position
counter moving rows
Final Position
fixed rows
counter moving rows
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Center Flow Combustion Chamber
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Roller Grate / Reciprocating Grate Ø Both meet all guarantees (burnout incl. siftings) Ø Both have very good references Ø Both present modern state-of-the-art design Ø Roller Grate has lower energy use Ø Roller Grate has less maintenance requirements Ø Significant grate bar weight difference Ø Roller Grate has a higher CV limit in standard form Ø Geometry configuration is different (70 % difference in width has advantages for boiler design) Ø Roller Grate has lower exchange rates Ø Roller Grate applicable for both small and large units 39
ROWITEC® Fluidized Bed Firing Process Principle
1. Waste Feeder 2. Revolving Fluidised Bed 3. Fluidising Air 4. Flue Gas 5. Deflector Plate 6. Non-combustibles Discharge Chute 7. Inclined Nozzle Plate
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ROWITEC® Fluidized Bed Flue gases to boiler Freeboard burner
Secondary air inlet nozzles
2. Screen
Sand valve Waste Feeder
Bed Material (sand) storage silo
Primary air supply
Bed preheat burner
Non combustibles discharge screw conveyor
1. Screen
Magnetic separator
Bucket elevator
Non combustibles discharge conveyor
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Flue gases to boiler Freeboard burner Secondary air inlet nozzles 2. Screen Sand valve Waste Feeder Bed Material (sand storage silo) Bed preheat burner Primary air supply Non combustibles discharge screw conveyor 1. Screen Magnetic separator Bucklet elevator Non combustibles discharge conveyor 41
ROWITEC® Fluidized Bed Madrid Integrated Waste Processing Facility
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ROWITEC® Fluidized Bed Madrid Integrated Waste Processing Facility
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ROWITEC® Fluidized Bed Bed Nozzles and Deflector Plates
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ROWITEC® Fluidized Bed Bootom Ash after Ferrous Metals Separation
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ROWITEC® Fluidized Bed Ferrous Metals separated from Bottom Ash
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ROWITEC® Fluidized Bed Residues in Botton Ash
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ROWITEC® Fluidized Bed Firing Ø Improved heat transfer through the use of a sand bed. Ø Rapid, complete combustion in the fluidized bed with a short retention time. Ø High flexibility with regard to variations in the composition of the refuse. Ø Ease of control due to staged, targeted combustion air feeding. Ø Reducing atmosphere in the bed zone, therefore substantially lower NOx levels in the combustor. Ø Complete combustion: the residual carbon content of the bed ash and fly ash is usually less than 0,1 wt. %. Ø No moving parts in the hot combustor area. 48
Combustion System / Steam Generator I
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Combustion System / Steam Generator II
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Combustion System / Steam Generator III
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Combustion System / Steam Generator IV
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Horizontal / Vertical Boilers Ø Both meet all guarantees Ø Both have very good references Ø Both present modern state-of-the-art design Ø Horizontal boiler has less steam consumption Ø Vertical boiler results in lower invest cost Ø Vertical boiler requires higher buildings Ø Horizontal boiler requires more space Ø General tendency: Horizontal boilers for small units Vertical boilers for large units
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Flue Gas Treatment Processes Process Types Flue Gas Treatment downstream Waste Incineration Plants
Dry Processes
Wet Scrubbing
Catalytic/Non-Catalytic Processes
• NEUTREC • Ca(OH)2 based processes
• Spray scrubbers • Packed columes scrubbers • Multi stage scrubbers • Wet electrostatic precipitators
• Activated carbon processes • SCR-DeNOx and DeDiox • SNCR-denitrification
Semi-Dry Processes • CIRCOCLEAN • Spray absorbtion • Dry conditioned processes
Combined Processes • Effluent free processes by means of evaporation and/or recovery of valuables
Process Recovering • Gypsum recovery • HCl-recovery • Recovery of NaCl/CaCl2
Adsorption Processes • Transport reactor • Fixed bed adsorber • CFB
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Comparison of Flue Gas Treatment Systems Dry / Dry Conditioned Processes
Wet Processes
+ Low Investment Costs
+ High Removal Efficiency
+ Low Maintenance and Operational Costs
+ Minimised (Stoichiometric) Sorbent Consumption
+ Effluent Free
+ Minimised Residue Production + Minimised Residue Disposal Costs
- Limited Removal Efficiency
- High Investment Costs
- High Sorbent Consumption
- High Maintenance and Operational Costs
- High Residue Production
- Possibly Waste Water Treatment required
- High Residue Disposal Costs 55
Circoclean® Flue Gas Cleaning System Water
Stack
Fabric Filter
TIC p
Activated Carbon
Lime Pressure combustion chamber
A
LC FIC
Control
Control
Flue Gas
ID - Fan Residues
CFB Reactor
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MHKW Frankfurt (Old Plant)
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MHKW Frankfurt Comparison of Design Data Old Plant
New Plant
Annual Capacity t/a
447.000
525.000
Number of Lines
4
4
Capacity per Line t/h
15
20
LHV @ MCR MJ/kg
9,2
10,3 (8,0 – 14,0)
Steam Parameter °C/bar
500/60
500/60
Boiler Design
3-Pass + Horiz.
1-Pass + Horizontal
Flue Gas Cleaning System
Semidry, ESP,
Cond. dry Circoclean
Fabric Filter
with PAC
17. BImSchV
17. BImSchV
Emission Values
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MHKW Frankfurt Typical Operation Data (mg/mn³)
HCl SO2
Raw gas
Clean gas Ø
600 – 750 160 – 270
7,5 8,4
CO Cges NOx
8,6 0,5 180
Hg
0,002
Dust
0,5 59
MHKW Frankfurt Impressions during the Erection
I
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MHKW Frankfurt Impressions during the Erection II
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MHKW Frankfurt Impressions during the Erection III
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MHKW Frankfurt (New Plant)
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Taoyuan South Plant Location
Taoyuan South Plant Location
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Technical Data
Service Area
25 km Radius, Southern Taoyuan County (near International Airport), 950.000 Inhabitants Municipal / Commercial Waste 420.000 t/a Waste Bunker Volume 12.000m³ Waste Pre-treatment System none Incineration 2 x 28,125 t/h Grate Type Roller Grate Heating Value Waste 5,9 – 13,4 MJ/kg (9,6) Incineration Temperature 1100°C Steam Generation per Boiler 85 t/h, 40 bar, 400°C Power Generation 40 MWe, 4 MWth District Heat Flue Gas Cleaning System 2 x 160.000 m³/h, Spray Dryer (Semi-dry) with Baghouse, Provisions for SNCR Emission Limits Acc. to Taiwan EPA Land Required 200 m x 175 m 65
Taoyuan South Flow Diagram 1. 2. 3. 4. 5. 6. 7. 8. 9.
Waste Tipping Incinerator with Steam Generator Deslagging Spray Absorber Bag Filter Residue Silos Cement Silo Solidification Turbo Generator Set and Water / Steam Cycle
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Taoyuan South Sectional View 1
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3
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5
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A
A
Taoyuan Southern Region BOO Municipal Solid Waste Incineration Plant
STACK
B
B
C
C
FLUE GAS CLEANING
4
BOILER HOUSE
BUNKER
TIPPING HALL
D
D
2 E
E
8
5 1
F
6
F
G
G
H
H
J
J
K
K
7
L
3
M
10
AIR COOLED CONDENSER
L
1 2 3 4 5 6 7 8 9 10
TURBINE HOUSE
N
9 P
Refuse Bunker Refuse Crane Incinerator Waste Heat Recovery Boiler Semi Dry Scrubber Bag Filter I.D. Fan Stack Steam Turbine Generator Set Air Cooled Condenser
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N
P
Q
Q
R R
1
2
3
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5
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8
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10
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Plant Model
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Plant Impressions
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Plant Impressions
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Plant Impressions
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Plant Impressions
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Taoyuan South Operation Data
Year / Month 200201 200202 200203 200204 200205 200206 200207 200208 200209 200210 200211 200212 Total Year / Month 200301 200302 200303 Total
#1 Incinerator Operation hour Treatment tonnage 744 672 744 456 744 699 744 744 720 299 720 744 8030
21147,07 18720,49 21048,29 12275,28 19431,81 19021,61 21378,9 20061,29 18514,16 7916,25 16812,76 18965,85 215293,76
#1 Incinerator Operation hour Treatment tonnage 744 672 680 2096
20211,92 19461,47 39673,39
#2 Incinerator Operation hour Treatment tonnage 744 672 643 482 744 720 744 744 720 456 556 774 7999
21143,37 18491,61 17748,42 12558,53 19472,69 20261,06 20941,95 19419,1 18639,41 11646,48 12154,78 18450,36 210927,76
#2 Incinerator Operation hour Treatment tonnage 743 672 744 2159
19615,74 18820,72 38436,46
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3. Summary
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Lithuania Projects Ø
Lithuania EfW facilities will require ü
l
Large Contractor with Parent Company Backing
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Long Term Commitment to European EfW ü Market
l
Robust Guarantees
ü
l
Bankability
ü 75
Lithuania Projects Ø
Lentjes provides … l
Type and range of technologies
ü
l
Ability to meet capacity range
ü
l
Experience and references in PL
ü
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Summary High level technologies for the incineration of waste are available and allow economic and efficient disposal concepts. All technologies fulfil the requirements for ü large units ü high efficiency A decision for a system must be taken on a project specific basis! The aim must remain: Environmentally safe and reliable incineration of waste. 77
Lentjes GmbH Forward Market Philosophy Ø
Build on sustained presence in key WTE markets
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Select target projects technically and commercially
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Maintain turnkey capability
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Longterm WTE experience with multiple references
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Continue to offer proven technology
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Maintain Lentjes’ reputation for quality process plants
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Increase market share in Waste to Energy markets
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Lithuania Requires waste management solutions incorporating steam/power experts
Win-Win-Position Turnkey Contractor
Strong Market Presence
In House Chute to Stack Technologies
Bankability
Lentjes GmbH
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Lentjes GmbH
… is the worldwide experienced EPC General Contractor with proprietary technical solutions for solid and liquid, hazardous and non-hazardous waste incineration plants.
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Thank you for your attention! Gunnar Lischke Sales Director Lentjes
We have Technologies We have Know-how We have References 81