Bmkw Mannheim e Nq

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Project information

Construction of a biomass power plant

in Mannheim


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3Kraftanlagen Mnchen GmbH | Construction of a biomass power plant in Mannheim

General contractor for engineering, erection and commissioning ofthe entire civil construction, mechanical, electrical, instrumentationand control systems.

Project description.

Customer

MVV BMKW Mannheim GmbH

Brief descriptionThe plant supplied by Kraftanlagen Mnchen comprises the

steam generation system with a feeding system and travelling

grate, flue gas cleaning as stipulated in the 17th federal German

ordinance on emissions control (17. BlmSchV), the steam turbine,

the air-cooled condenser, the water/steam cycle, and the elec-

trical, instrumentation and control systems for operation and

monitoring of the over-all plant.Scope of services

Overall plant layout

Construction services

Detail engineering of the entire process

technology and power engineering optimization

Supply of the entire power plant systems

Electrical, instrumentation and control

technology and safety engineering

Utility services and auxiliary systems

Installation and site management

Commissioning and trial operation

Documentation and training

Technial data

Thermal furnace output biomass boiler: 66.9 MW

Main steam capacity: 78.8 t/h

Main steam temperature: 450 C

Efficiency (> 29 % in acc. with biomass ordinance): 30.26 %

Electrical output steam turbine: 20 MW

Fuel requirement: 124,000 t/a

Calorific value of fuel: 10 - 17 MJ/kg

Operating hours at full load: 8,000 h/a

Picture below: Turbine rotor.

Picture above: Air-cooled condenser.

Project milestones

Placement of order December 2001Approval engineering January June 2002

Construction period July 2002 July 2003

Commissioning / Trial operation August December 2003

Partial view of the

biomass power plant.


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Plant description.

Water/steam cycle

The steam from the steam generator is

converted into electricity in a turbine. 25

bar steam for the supply of process loadscan also be extracted by means of redu-

cing stations. The service steam required

for feedwater degasifaction is extracted

from the turbine via a 3 bar tap. Another

tap is used for preheating the conden-

sate before it enters the feedwater tank.

From there, the feedwater is pumped into

the steam generator where it evaporates

again.

Fuel supply

Around 124,000 t of Class A I - A IV bio-

mass is converted into electricity in the

biomass power plant in Mannheim each

year. The raw materials are stored in an

open space warehouse. Following the

processing and seperation of unwanted

materials and usable materials, the cut-

up fuel is stored in a silo.

Power generationA condensation turbine feeds 20 MW in-

to the power grid. The exhaust steam is

condensed in an air-cooled condenser

and fed back into the water/steam cycle.

Around 160 GWh of electricity is genera-

ted this way each year.

Functionality of the biomass power plantin Mannheim.

Demin water

Feedwater tank

Feedwater pumpsCentral control building

Biomass boilerBottom ash container

Fuel silo

Process steam25 bar

Condensate preheater

65 bar

450 C

Steam pressurereducing station

Steam bypassstation

Main steam

CyclonesEmergency ashdischarger

Electrical energy20 MW

20 kV

Transformer

10 kV

Steam turbine

Condensate tank Air cooledcondensor

Induced draught ventilatorFabric filterReactorFly ash silo andreaction product silo

Chimney

Boiler

The core of the plant is the 4-pass boiler

with its combined spreader-suspension

firing system. 78.8 t/h of high-pressuresteam at 450 C and 65 bar is generated

through the incineration of 15.5 t/h of

biomass. The fuel is incinerated on a trav-

elling grate in a natural circulation-type

water tube boiler. The furnace passes (pass

1 to 3) are configured as evaporator.

The superheater bundles are installed in

the third pass and the economizer bun-

dles in the fourth pass, both in a horizon-tal position. The wood burns partly on

the grate and partly in the air before hit-

ting the grate. The grate ash is removed

by means of a wet slag removal system.

Coarse ash particles separated in the

boiler passes are crushed and recircula-

ted into the firing system.

Flue gas cleaning

The flue gas cleaning system fulfils the

limits stipulated by the 17th federal Ger-

man ordinance on emissions control (17.

BlmSchV) and is designed in four stages:

1. The flue gases are denitrogenated in

accordance with the principle of selec-

tive, non-catalytic reduction with the

addition of carbamine.

2. The flue gas flows through two cy-

clones connected in parallel where ini-

tial dust separation takes place.3. Calcium hydrate and hearth furnace

coke are introduced into the flue gas

in an entrained flow reactor. The acids

in the flue gas bind with the reactive

calcium hydrate. The hearth furnace

coke functions as a pick-up agent for

volatile heavy metals and toxic organic

components.

4. Fly ash, reaction salts and hearth fur-

nace coke are separated in the fabric

filter.


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Electrical, instrumentation and control technology.

Operating and safety concept.

The power plant is automated to a great

extent. All the essential instrumentation

and control functions are implemented

in a redundant configuration. This per-mits operation with minimum personnel

requirements and an annual availability

of over 8,000 hours. The plant is equipped

for 24-hour unsupervised operation. The

plant can also be monitored and remote-

ly controlled via an operating station in-

stalled in the neighbouring heating power

plant. A comprehensive fire alarm system

provides reliable fire protection. A battery-

backed UPS system ensures controlled

shutdown of the plant in the event of a

power failure.

Environmental protection.

Amendment of the CO2-balance.

Flue gas cleaning

Ultramodern firing methods reduce the generation and release

of pollutant emissions. The unavoidable emissions resulting from

incineration are minimized by flue gas cleaning. The addition ofcalcium hydrate and hearth furnace coke binds the pollutants

in the flue gas and separates both, them and the dust, in two

cyclones and a downcircuit fabric filter. The plant operates be-

low the limits permitted by the 17th federal German ordinance

on emissions control (17. BlmSchV).Fuel

The incineration of old wood and waste wood constitutes a par-

ticularly environmentally conscious type of power generation.

The incineration of biomass in power plants does not generate

any additional greenhouse gases which contribute to climate

changes. CO2is released, but only in the same quantities as were

drawn from the atmosphere when the

plants were growing. The high degree of

efficiency of the plant also ensures effi-

cient fuel utilization.

Engin eer ing station O pe rator st at ion 1 Operator station 2 Contr ol room heatin g power plan t

Wood processing

Terminal bus

Process bus

Back up

ASFlue gascleaning

ASBiomass boiler

SPS-F

ASWSC & BOP

ACC

HVAC Turbine

Picture above:

Low-voltage distribution.

Picture on the left:

Instrumentation and

control configuration.

Picture above:

Fabric filter with

chimney.

Picture on the left:

Wood processing

and storage.


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Divisions of the Kraftanlagen Mnchen Group

Power plant technology

Energy technology

Renewable energies

Underground piping construction

Utility services

Chemical and petrochemical plantsFabrication

Engineering services

Kraftanlagen Mnchen GmbH

Ridlerstrasse 31 c | 80339 Munich

Germany

T: +49 89 6237-0 | F: +49 89 6237-223

[email protected]

www.ka-muenchen.de

1011.07.1 20.5.940

Documents

Bmkw Mannheim e Nq