www.bertsch.

at
 Grate Firing
or
Bubbling Fluidized Bed Firing
An Economic and Technological Comparison

Philipp Kolbitsch
+43 676 7810006
philipp.kolbitsch@bertsch.at

4. CEBC Graz, 2014-01-16, Michael Netzer 2

 Business segments of BERTSCHenergy

Solid Fuel Boiler Plants Process Heat Recovery

Electricity and Heat from Biomass Systems and Pressure
Equipment
Steam, Heat and Equipment for
Process Plants

Combined-Cycle / Service
Cogeneration HRSG Optimal Maintenance and Service
Electricity and Heat from Gas and Oil

Waste Heat Recovery Boilers

Steam from Waste Heat in Industrial
Processes

4. CEBC Graz, 2014-01-16, Michael Netzer 3

 Business segments of BERTSCHenergy

Solid Fuel Boiler Plants

Electricity and Heat from Biomass

design (from conception to detail)

Steam parameters: 15 80 t/h, 40 150 bar, 400 - 520 C
EPC solutions (lot wise or turnkey)
in house design
Air cooled grate
Bubbling fluidized bed
Water tube boiler
After sales services
24 references in 6 countries

4. CEBC Graz, 2014-01-16, Michael Netzer 4

 Fuel Spectrum

Wood chips Wood from Landscape preservation Short-rotation plantation

Waste wood RDF Municipal waste

4. CEBC Graz, 2014-01-16, Michael Netzer 5

 Criteria for choice of technology

Given fuel quality is the main

criteria for the choice of
combustion system

1. 2. 3.
Water content of Lower Heating Ash content,
fuel Value impurities,
Particle size

Grate firing Bubbling fluidized bed

firing

4. CEBC Graz, 2014-01-16, Michael Netzer 6

 Criteria for choice of technology

Grate BFB Economic

Reason
Technology Technology Effect
Fuel range Max 15 MJ/kg open Wear on grate -
Higher costs for fuel
Fuel grain size < 350 mm < 100 mm Fuel feeding
treatment with BFB
Lower excess air with Savings in fuel costs with
Boiler efficiency lower higher
BFB BFB
Lower combustion
Savings in costs for DeNOx
NOx Emissions moderate very low temperature with
additive
BFB
Saving of soot blowing
Boiler cleaning Self cleaning effect, steam, less wear on
1-3 0-1
cycles per day low flue gas velocity heating surfaces, less costs
for make up water
Electrical 2-2,5% of fuel Higher costs for electricity
slightly higher Bigger fans
consumption power with BFB
Quick adaption of plant
Load change Fuel input directly
low high performance to new
rate into combustion
conditions

4. CEBC Graz, 2014-01-16, Michael Netzer 7

 Criteria for choice of technology

Grate BFB Economic

Reason
Technology Technology Effect
for SNCR,
Pressurized air depending depending
for bag filter
depending

Sand for fluidized

Sand demand no yes
bed
Costs for Sand

Start up burner no yes Sand bed needs heat Costs for start up fuel

Higher ash output Lower costs for disposal

Ash from firing higher lower
with grate with BFB
Sand output with Higher costs for disposal
Ash from filter lower higher
BFB with BFB
high, No moving parts in Savings in wear part and
Wear depending on low firing system with maintenance costs with
fuel BFB BFB
Investment equal equal

So far BFB technology is known as expensive and complex technology, but

Detailed analysis of economic effects driven by fuel type and plant application establish
the choice of firing technology
4. CEBC Graz, 2014-01-16, Michael Netzer 8
 Grate Firing

Air cooled reciprocating grate with optimized grate bar geometry for maximal
availability and life time

Fuel input with pusher and chute onto fuel feeder grate

Active control of fire position on grate for highest efficiency

Each grate zone with variable controlled primary air supply

Staged combustion due to primary and secondary air

Temperature control of burning chamber via recirculated flue gas

(beneath and above grate)

4. CEBC Graz, 2014-01-16, Michael Netzer 9

 Boiler with Grate Firing

Burning chamber integrated in boiler

Natural circulation boiler with membrane
walls

Secondary air and recirculation gas

above grate

SNCR to reduce NOx emissions (lances)

Empty path an convective path

Recirculation of fly ash

Biomass super heaters

Economizer in steel casing

Boiler cleaning with sootblowers

S.H. steam temperature control with

desuperheaters

4. CEBC Graz, 2014-01-16, Michael Netzer 10

 Bubbling Fluidized Bed Firing

Bubbling fluidized bed integrated in boiler

open nozzle floor

Fluidizing of bed via mixture of air and recirculation gas

Start up burners above freeboard

Staged combustion due to primary and secondary air

Deashing with ash grate

Sand classifier and sand recycling

4. CEBC Graz, 2014-01-16, Michael Netzer 11

 Boiler with Bubbling Fluidized Bed Firing

Natural circulation boiler with membrane walls

Fuel dosing with screws and chutes

3-path or 4-path design

SNCR to reduce NOx emissions (with

evaporation)

Biomass super heaters

Economizer in steel casing

Boiler cleaning with sootblowers

S.H. steam temperature control with

desuperheaters

4. CEBC Graz, 2014-01-16, Michael Netzer 12

 Engineering

CFD simulation with state of the art software tools

Design of boilers with KED BOILER DESIGNER

Design of water steam cycle with EBSILON professional

Plant design with COMOS

3D Modelling with NAVIS Works

Highly educated specialists

Professional interface coordination

Well known sub suppliers

4. CEBC Graz, 2014-01-16, Michael Netzer 13

 Erection, Commissioning, Hand Over

Workshop mounting as far as possible

Erection through well known companies with Bertsch
supervision

Commissioning and training through our specialits

Performance tests and hand over

4. CEBC Graz, 2014-01-16, Michael Netzer 14

 References

Order-No.: J130120S
Customer: Holzindustrie Schweighofer; Covasna, Romania
Project name: CHP-Plant for Natural Biomass and AI-AII Wood

Technical data: Scope of Supply: Clients responsibility:

Electrical output 15 MWe -Turn key project excluding civil works Civil works
Thermal output (Heat appl.) 38+10 MW -Construction planning
Thermal capacity 60 MW -Fuel storage and transportation Date of Completion:
Steam output 68 t/h -Grate firing Q1 2015
Steam pressure 80 bar -Boiler
Steam temperature 500 C -Steam turbine with generator Project Manager:
Fuel Wood & bark; AI-AII -Water steam cycle Dipl.-Ing. Andreas Neuper
-Flue gas treatment
-10 MW backup boiler
-Boiler house

4. CEBC Graz, 2014-01-16, Michael Netzer 15

 References

Order-No.: J110178S
Customer: Barthel Pauls Shne AG; Gouvy, Belgium
Project name: CHP-Plant for Natural Biomass

Technical data: Scope of Supply: Clients responsibility:

Electrical output 4,7 MWe - Grate firing Building, Technical building services, Fuel
Thermal capacity 20 MW - Steam generator handling, Water / Steam circuit, Condenser,
Steam output 22 t/h - Flue gas cleaning with chimney Steam turbine
Steam pressure 66 bar
Steam temperature 485 C Date of Completion:
Fuel Wood & bark Mid 2013

Project Manager:
Dipl.-Ing. Andreas Neuper

4. CEBC Graz, 2014-01-16, Michael Netzer 16

 References

Order-No.: J110003S
Customer: Siat Braun; F-67280 Urmatt, France
Project name: CHP-Plant for Natural Biomass

Technical data: Scope of Supply: Clients responsibility:

Electrical output 5 MWe - Grate firing Building, Technical building services , Fuel
Thermal capacity 23 MW - Steam generator handling, Water / Steam circuit, Condenser,
Steam output 25 t/h - Flue gas cleaning plant with chimney Steam turbine
Steam pressure 65 bar - Water treatment plant
Steam temperature 485 C Date of Completion:
Fuel Wood & bark (W65) 4. Quarter 2012
Authorisation in acc. to french LRV
Project Manager:
Dipl.-Ing. Carl Christian Redl

4. CEBC Graz, 2014-01-16, Michael Netzer 17

 References

Order-No.: J090124S
Customer: Energie Wasser Bern / KVA Bern, Forsthaus, Switzerland
Project name: Wood CHP - KVA Bern

Technical data: Scope of Supply: Clients responsibility:

Electrical output 7 MWe - Fuel storage (Silos) and Fuel feed systems Concrete construction, Technical building
Thermal capacity 28,4 MW - Bubbling fluidized bed combustion services, Water / Steam circuit, Condenser,
Steam output 32,2 t/h - Steam generator Steam turbine, Chimney, I+C system, Water
Steam pressure 75 bar - Fabric filter treatment plant, Feed water supply
Steam temperature 485 C - SNCR
Fuel Wood / Recycled wood (W20-W50) - Combustion air / Flue gas fans Date of Completion:
Emissions at 11 vol. % O2 CO 50 mg/Nm - Boiler house steel / primary +secondary steel 4. Quarter 2012
NOX 100 mg/Nm - I+C support services
Project Manager:
Ing. Walter Jenny

4. CEBC Graz, 2014-01-16, Michael Netzer 18

 References

Order-No.: J090029S
Customer: HHKW Aubrugg, Switzerland
Project name: Biomass CHP-Plant at EKZ Power Station of Kanton Zrich

Technical data: Scope of Supply: Clients responsibility:

Thermal capacity 41,5 MW - Fuel feed Building, Technical building services, Fuel
Steam output 46,5 t/h - Bubbling fluidized bed handling, Expansion of water / steam circuit
Steam pressure 80 bara - Steam generator
Steam temperature 500 C - Fabric filter Date of Completion:
Fuel Wood chips (W35-W55) - I+C Siemens T3000 4. Quarter 2010

Authorisation in acc. to Swiss LRV Project Manager:

David Htzl

4. CEBC Graz, 2014-01-16, Michael Netzer 19

 References

Order-No.: J060152S
Customer: Holzkraftwerk Basel AG, Switzerland
Project name: Biomass Plant in der KVA der IWB Basel

Technical data: Scope of Supply: Clients responsibility:

Electrical output 8 MWe - Fuel feed Building, Technical building services, Fuel
Thermal capacity 33,5 MW - Bubbling fluidized bed handling, Expansion of water / steam circuit
Steam output 41,5 t/h - Steam generator
Steam pressure 40 bar - Fabric filter Date of Completion:
Steam temperature 400 C - Instrumentation & control system Mid 2008
Fuel Wood chips (W20-W50) - Steam distribution
Recycled wood AI - AII - Water / Steam circuit Project Manager:
Authorisation in acc. to Swiss LRV Dipl.-Ing. Otmar Bertsch

4. CEBC Graz, 2014-01-16, Michael Netzer 20

 References

Order-No.: J060114S
Customer: Industrie du Bois Vielsalm & CIE s.a., Belgium
Project name: Biomass CHP-Plant IBV

Technical data: Scope of Supply: Clients responsibility:

Electrical output 19 MWe - Fuel handling Building, Technical building services, Condenser
Thermal capacity 2 x 40 MW - Fuel feed circuit, Heating condenser, Steam turbine
Steam output 2 x 44 t/h - Grate firing (Reciprocating grate)
Steam pressure 65 bar - Steam generator Date of Completion:
Steam temperature 485 C - Electrostatic filter with chimney 2. Quarter 2008
Fuel Wood & Bark (W40-55) - Instrumentation & Control system
Authorisation in acc. to Belgium LRV - Steam distribution Project Manager:
- Water treatment plant Dipl.-Ing. Christian Gut
- Pressurised air supply

4. CEBC Graz, 2014-01-16, Michael Netzer 21

Your partner for solid fuel power plants

Thank you for your attention

4. CEBC Graz, 2014-01-16, Michael Netzer 22

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4. CEBC Graz, 2014-01-16, Michael Netzer 23