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Fuel Flexibility with Biomass for Coal Boilers at University of Iowa

Fuel Flexibility with Biomass for Coal Boilers at University of Iowa. Ben Anderson – University of Iowa Andy Ungerman – Stanley Consultants. Agenda. Introductions Overview & Biomass Initiatives Permitting Strategy Project Design & Biomass Considerations Project Construction

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Fuel Flexibility with Biomass for Coal Boilers at University of Iowa

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  1. Fuel Flexibility with Biomass for Coal Boilers at University of Iowa Ben Anderson – University of Iowa Andy Ungerman – Stanley Consultants

  2. Agenda • Introductions • Overview & Biomass Initiatives • Permitting Strategy • Project Design & Biomass Considerations • Project Construction • Startup & Lessons Learned • Future Plans • Conclusions & Questions

  3. Introductions • Ben Anderson – University of Iowa • Power Plant Maintenance & Engineering Manager • BSME from Iowa State University • Petro-chemical background • Andy Ungerman - Stanley Consultants • Mechanical Engineer – Energy Business Group • BS & MSME from Iowa State University • Power Plant Consulting Background

  4. Overview • University of Iowa – Main Power Plant • 4 Boilers: 600+ klb/hr, 3 Turbine Generators - 24.7 MW • 6 offsite natural gas and 1 biomass boilers 135,00 lbs/hr 140,00 lbs/hr

  5. Biomass Initiative • University of Iowa - Biomass Initiative • Achieve the goal of 40% renewable energy consumption on the campus by 2020 • More info at http://sustainability.uiowa.edu/biomass/

  6. Permitting Strategy • BLR 10 Biomass • IDNR to issue permit on 12/2011, failed PM 10 test, permit closed • New permit submitted several months ago • Wood chips, yard trimmings, paper sludge – Cedar Rapids Landfill & other local sources • Update with Fuel grasses – miscanthus • Expect approval in next month • Increased reporting • Track fuels usage • Frequent fuel sampling (ensure below PSD for NOx, SO2, and PM2.5) • BLR 11 Biomass • Current permit for oat hulls • Approved variance to burn wood chips • Collaboration with state park to dispose of 2500 tons of pine • Plan to have permanent change submitted in early February • Plant wide Applicability Permit (PAL) submitted to IDNR

  7. Project Design - Overview • Replace “dense” phase coal handling system with 30 TPH belt conveyor • Provide provisions for future biomass or PRB • Original plant – 1926 • 3D scan converted to 3D Model

  8. Project Design - Overview Compact, cartridge dust collectors ~16° incline, tubular gallery 75 ton bunker (8 hr supply) Equipment located for future biomass equipment Completely insulated enclosures and galleries Extensive reinforcement and modification to existing structures Gravimetric feeder w/ conical distributor

  9. Project Design: Co-firing with Biomass • UT Distributors for Biomass • Woodchip/Biomass issues – non uniform sizing1 • Volumetrically limited – Max 15% Biomass (soft number) – assuming sizing is similar1 • 15% vol blend = 6% by weight = 3% by BTU (assuming woodchip density of 20 lb/ft3, and a heating value of 4,500 Btu/ft3) • Closer the properties to coal, higher the percent1 – 100%? • Pelletized or torrifiedwood etc. • Non-Segregated Distributor • Woodchip/biomass issues – non uniform sizing • Different sizing may lead to segregation • Lack of data on biomass • Closer properties are to coal, the better • 1Per information received from Detroit Stoker Corp, used with permission.

  10. Project Design: Co-firing with Biomass with Stoker Boiler • Best Arrangements for Co-Firing Wood1 • Separate fuel trains • Different fuel sizing = separate trains • Goal is to get good ash bed on grate and uniform distribution • Symmetry is important! UTs 1 and 5 or 2 and 4 • Combo Feeders1 • 1000 lbs/in of feeder (Qty 2 feeders = 54 kpph) • Recommended fuel drop height = 10 ft • Distributes fuel lower in furnace (preferred) • Requires header to be moved • Air swept spouts1 • 50% of grate to be covered with spouts (20’ grate requires four 30” air spouts) • Location = higher in furnace • Tube bending vs. moving header • Must get around non-seg distributor • 1Per information received from Detroit Stoker Corp, used with permission. Air swept spouts Combo Feeders

  11. Future Biomass Flexibility at UOI • Unique design – grav. feeder w/ non-seg dist. • 75 ton (coal) bunker can be offset further compared to batch-type feeder. • Allows emergency unloading • Future biomass robbing screws and hoppers can be fed by a “surge bin” fed from a separate material handling system using a new silo • Detroit Stoker UT Distributor hoppers modified to allow for future Combo feeders. • Bunker could be modified to bottom reclaim (remove bottom cone) 75 Ton Bunker Drag chain Surge hoppers & robbing screws Future Feeder/Non Seg Offset UT hoppers allow for future Combo feeders.

  12. Comparison of Fuels and Mat’l Handling for Boiler 10 * Heat input and Heating value taken from Biomass Conversion Study Report (2010) for UOI by Riley Power. Used with Permission.

  13. Project Construction • Logistics • Equipment Fabrication • Crane - Gallery & Conveyor install • Boiler Shutdown and Dense Phase Demo • Start-up & Lessons Learned

  14. Project Construction – Logistics • Iowa River • Campus Location • Space Constraints • Equipment laydown • Contractors

  15. Project Construction – Equipment Fabrication • Schedules • Manufacturing visits • Delivery

  16. Project Construction - Crane • Logistics – 20+ semi tucks • Ground survey • Voids • Flat surface • Crane location & continued plant ops

  17. Project Construction - Installation

  18. Project Construction - Installation

  19. Project Construction - Boiler Shutdown & Dense Phase Demo • Major 3+ month outage • Boiler maintenance • Boiler lay-up • Planned start-up on 11/30/12 • Back-up boiler installed

  20. Start-up & Lessons Learned • Permitting & Construction Timing • Commissioning & Training • CHS operational - several nuisance trips • Alignment switches; belt tracking • CO monitors • VFD Fault on gravimetric feeder • Plugged conveyor • Alarm Rationalization (CO, Alignment switches) • Cleanliness

  21. Future Plans • Full inspection and baseline on boiler (complete) • Burn wood chips in near future (ASAP) • Begin developing test runs for other fuels (Ongoing) • Installing natural gas burner Spring 2013 • Internal inspection at regular intervals (Ongoing) • Modifications to fuel handling system for increased Biomass combustion

  22. Conclusions • Develop solid Biomass plan • Design projects to be flexible for future conversions • Work on permitting strategy early and plan for good discussions • Complete equipment scenario/what-if analysis and implement into planning/design

  23. Questions

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