ENERGY-FROM-WASTE Peterborough, UK Turnkey Technology Solution The latest technology – from crane to stack – has been brought together in an exclusive, discrete building. This is the brief description of the turnkey energy-from-waste plant that is set to open in Pe- terborough, England, in 2015. The complete project will be supplied by Babcock & Wilcox Vølund, Göta- verken Miljö, and Interserve Construction Ltd., on behalf of Viridor. Starting in spring 2013, Babcock & Wilcox Vølund have officially opened the door to the British market with the latest turnkey energy-from-waste plant in Pe- terborough in East England. PLANT FACT SHEET The delivery includes cutting-edge technology, high steam data, a 27% electrical efficiency rate resulting in a R1 = 0.77. Götaverken Miljö, subsidiary to B&W Vølund, supply the latest in flue gas treatment (FGT). The plant will also be housed in a carefully considered construction to ensure that the city of Peterborough receives a high-performance plant wrapped in a rela- tively small and elegantly designed building. ”This is definitely a NextBAT ® plant. What’s more, we’ve managed to fit a plant that provides large waste capacity and a very high efficiency into a relatively small www.volund.dk
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ENERGY-FROM-WASTE
Peterborough, UKTurnkey Technology Solution
The latest technology – from crane to stack – has been brought together in an exclusive, discrete building. This is the brief description of the turnkey energy-from-waste plant that is set to open in Pe-terborough, England, in 2015. The complete project will be supplied by Babcock & Wilcox Vølund, Göta-verken Miljö, and Interserve Construction Ltd., on behalf of Viridor.
Starting in spring 2013, Babcock & Wilcox Vølund have officially opened the door to the British market with the latest turnkey energy-from-waste plant in Pe-terborough in East England.
PLANT FACT SHEET
The delivery includes cutting-edge technology, high steam data, a 27% electrical efficiency rate resulting in a R1 = 0.77. Götaverken Miljö, subsidiary to B&W Vølund, supply the latest in flue gas treatment (FGT).
The plant will also be housed in a carefully considered construction to ensure that the city of Peterborough receives a high-performance plant wrapped in a rela-tively small and elegantly designed building.
”This is definitely a NextBAT® plant. What’s more, we’ve managed to fit a plant that provides large waste capacity and a very high efficiency into a relatively small
www.volund.dk
building, which is extremely important for obtaining planning permits and local approval in England, and which is of cru-cial importance to the client”, explains Peter Laursen, the sales manager for the Engineering Procurement Construc-tion (EPC) Contract, in which Babcock & Wilcox Vølund and Götaverken Miljö, in consortium with Interserve Con-struction Ltd., entered into agreement with Viridor – one of UK’s leading waste management companies.
Viridor signed the overall contract with the Peterborough City Council on 1 February 2013, which entails the con-struction of the plant and its subsequent operation over a 30-year period.
A winner in safe technology and high electrical efficiency“Babcock & Wilcox Vølund gave us the best opportunity to win the project”, comments Euan Grimstone, Viridor’s project manager, on the decision to award the contract to Babcock & Wilcox Vølund.
”We went to the market with a set of criteria to fulfil the wishes of Peterborough City for the facility as part of their ambition to become the UK’s environmental capital”, re-counts Grimstone, who goes on to specify, “The criteria included obviously a facility that would work, a safe and proven low emission technology and a high level of ef-ficiency in terms of electricity output. Babcock & Wilcox Vølund gave us all that.”
Grimstone also stresses the fact that the plant’s man-ageable size can pave the way for similar local plants in England.
”Viridor is investing heavily in energy-from-waste facilities in order to deal with the issues facing the UK in terms of
the EU Landfill Directive and the necessary diversion of landfill. In that respect, the prospects for smaller scale fa-cilities in locally affordable solutions are good. Hence, local authorities elsewhere in the UK might well take an interest in the Peterborough project”, Grimstone points out.
A DynaGrate® at heartDynamics make all the differenceThe ever innovative technology of the DynaGrate® is unique in its fuel flexibility, optimised combustion, and minimal maintenance cost. All due to the mechanical de-sign and optimised combustion control.
Minimised maintenance costThe driving mechanism of the air-cooled DynaGrate® is situated outside the furnace thereby avoiding exposure of the mechanism to an aggressive environment and offer-ing easy access for maintenance. Finally, the mechanical set-up secures that movable grate parts are not in contact, thereby reducing wear and tear of the grate.
Fuel flexibilityThe mechanical design of the DynaGrate® is developed in response to the general energy-from-waste plant vulner-ability to e.g. metal contents in waste. Today, plant opera-tion is not interrupted by melting metals. Further, the me-chanical break-up of the waste layer on the grate results in thorough agitation and superior combustion conditions.
It is possible to upgrade the air-cooled DynaGrate® to a water-cooled one. The water-cooling system allows high heating values that are vital to fuel flexibility. The design results in high plant efficiency and excellent burnout of
Back row, from left: 1. Mogens Tyllesen, Sales Director, B&W Vølund, 2. Peter Laursen, Partner Manager, B&W Vølund, 3. Patrick Capper, Director of Business Transformation, Viridor, 4. Euan Grimstone, Development Manager, Viridor, 5. Paul Andrews, Associate Director, Interserve Construction, 6. Simon Ohlenschlager, Managing Director, Interserve Infrastructure, 7. Robert Ryan, Head of Contracts, Viridor Front row, from left: 1. John Veje Olesen, Managing Director, B&W Vølund, 2. Howard Ellard, Business Development Director, Viridor, 3. David Paterson, Managing Director, Interserve Construction.
The water-cooled wear zone consists of a number of heavy steel tubes covered with Inconel®. The cold surfaces prevent build-up of slag and thereby operation problems.
VoluMix™ seen from the furnace 7 Babcock & Wilcox Vølund
the waste evident for example in very low TOC values (around 0.2%) in the bottom ash.
Water-cooled wear zone prolongs the life of the boilerThe water-cooled wear zone has been developed to re-duce uncooled refractory lining in waste-to-energy boil-ers. A disadvantage of uncooled refractory lining is that large amounts of slag build up interrupting the operation of the system.
Especially on the lowest part of the furnace’s side walls, slag deposit build-up can hinder waste flow and thereby significantly influence the combustion process. At worst, this can result in operational stoppages.
• Awater-cooledwear zone absorbs approx. 80-100KW per m2.Atypicalsystemcanreceive1.5-2.8MWof extra energy; Energy which is absorbed as radiant heat.
• Heatabsorptioninthewearzonereducesthefurnacetemperature and therefore allows increased heating value and maintains waste capacity.
• Thewater-cooledwearzonereplacestherefractorylining in the system’s most heavily used area and ex-perience shows that a water-cooled wear zone has a longer life than refractory lining.
• Thewater-cooledwearzoneisconnectedinnaturalcirculation with the boiler drum and constitutes an in-tegral part of the boiler. This coupling increases the overall efficiency of the plant.
Innovation and design with CFDOur CFD designed overfire system VoluMix™ reduces CO and TOC to a minimum in addition to raw NOx emis-sion. VoluMix™ injects secondary air into the combustion zone – with a complete burnout in the gas phase.
When designing a new plant, CFD simulations are car-ried out to determine the geometry of the furnace and boiler, positions of air inlet nozzles and burners and the expected temperature distribution. Using CFD analysis ensures the very high quality in design, for which B&W Vølund is recognized.
In the design phase, we place great emphasis on achieving uniform flow through the boiler, as this gives the most effi-cient heat transfer, lowest wear and corrosion risk, and op-timum retention time in which combustion can take place.
Secondary air is added via nozzles in the furnace front and back ceiling and at one or more levels in the first boiler pass. The nozzles in the first boiler pass generate the VoluMix™ system.
The VoluMix™ system generates the micro and macro-scopic mixing which is required to ensure final burn-out of CO and particles.
541-856Svanemærket tryksag
www.volund.dk
Babcock & Wilcox Vølund A/S
Falkevej 2 • DK-6705 Esbjerg Ø • Denmark • Tel: +45 76 14 34 00 • Fax: +45 76 14 36 00We have a branch office in Glostrup/Copenhagen, Denmark.
The information contained herein is provided for general information purposes only and is not intended or to be construed as a warranty, an offer, or any representation of contractual or other legal liability. Babcock & Wilcox Vølund A/S is 100% owned by Babcock & Wilcox Power Generation Group, Inc. in Barberton, Ohio, USA. © 2013 Babcock & Wilcox Vølund A/S. All rights reserved.
Plant design data (per line)
Process parameters GuaranteedValues* Units
Waste capacity (MCR) 11.1 t/h
Heat value, lower 9.0 MJ/kg
Steam output 33.5 t/h
Steam temperature 440 °C
Steam pressure 65 barA
Gross Electric Output 7.0 MW
District Heating Output Prepared MJ/s
Boiler outlet flue gas temp. 155 °C
Feed water temperature 125 °C
Flue gas values:Out of boiler
Guaranteed Values* Units
NOx** 150 mg/Nm3@11%O2, dg
CO** 25 mg/Nm3@11% O2, dg
NH3** 10 mg/Nm3@11% O2, dg
TOC 5 ng/Nm3@11% O2, dg
Values Guaranteed Values* Units
HCl ≤ 10 mg/Nm3@11%O2, dg
SOx ≤ 50 mg/Nm3@11% O2, dg
Dust ≤ 10 mg/Nm3@11% O2, dg
Dioxin 0.1 ng/Nm3@11% O2, dg
* All values refer to 11% O2 dry gas** 24-hour average
Facts: NextBAT® from Babcock & Wilcox Vølund and Götaverken MiljöBabcock & Wilcox Vølund and Götaverken Miljö have a long tradition for focusing on high efficiency and low emis-sions, and together we have a solution for future energy-from-waste plants.
NextBAT® is the Scandinavian solution to the next genera-tion of Best Available Technology, from crane to stack.
The next generation of BAT standards will be presented in the coming waste combustion BREF due in 2015. The re-vised BREF will set new standards for energy-from-waste plants in terms of higher efficiency and lower emissions.
An energy-from-waste plant’s level of efficiency is meas-ured by the R1 formula. High overall energy efficiency ensures maximum substitution of fossil fuels and thereby reduces the impact of greenhouse gases (GHG).
NextBAT® ensures that plant owners achieve a high R1 rate because of our unique technologies, for example Dy-naGrate®, water-cooled wear zone, Inconel®, ACC (Ad-vanced Combustion Control) and CFD simulation.
Project timeline • 1 February 2013: Signing of contract between the
Peterborough City Council and Viridor, with Babcock & Wilcox Vølund and Interserve Construction Ltd. serving as consortium partners and joint suppliers of the plant and associated buildings.
• June2013:Projectedstartofconstruction.
• 2015:Expectedcompletiondateoftheplant.
Scope • ThetotalprojectinvestmentisaroundGBP75million.
• Babcock &WilcoxVølundwill supply the completewaste treatment system in cooperation with our sub-sidiary Götaverken Miljö who will supply the flue gas cleaning system.
• InterserveConstructionwillconstructalloftheplant’sbuildings.
• Viridorwilloperatetheplantfor30years,beginningin 2015.
The plant will process waste from Peterborough City for the next 30 years and has an annual capacity of up to 85,000tonnesofwaste.Peterboroughcurrentlyproducesaround 90,000 tonnes of waste each year. The city’s an-nual volume of waste is expected to increase to 140,000 tonnes by 2040.
Today, 43% of the city’s waste is recycled, while the re-maining 50,000 tonnes or so are deposited in landfills. The new energy-from-waste plant means that 94% of the city’s landfill waste will instead be used to generate elec-tricity. The plant’s electrical power generation capacity will be 7.25 MW. Its annual electrical production will be around 53,000 MWh, which corresponds to 15% of the total annual household electrical consumption in Peter-borough.
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