RE LIABLE AND

E FFICIE NT POWE R
GE NE R ATION
POWER BOILERS
 FLUIDIZED BED TECHNOLOGY 4

ANDRITZ is a leading supplier of plants

based on Bubbling Fluidized Bed (BFB) and
Circulating Fluidized Bed (CFB) technolo-

E NGIN E E RE D
gies for boilers

SUCCESS
EcoFluid BUBBLING FLUIDIZED BED 6
(BFB) BOILER

Generating power from renewable fuel

sources – the fuel flexibility of an ANDRITZ
EcoFluid boiler is an inherent feature

SELECTED REFERENCES 10

References and current projects for

ANDRITZ boiler technologies

PowerFluid CIRCUL ATING 14

­F LUIDIZED BED (CFB) BOILER

Unmatched fuel flexibility – from biomass

to alternative fuels and waste products
AUGMENTED RE ALITY CONTENT
To present videos, illustrations and picture
galleries in a more direct and lively way, we have
added augmented reality to this article. View Metris BOA 14
video footage of this report in our augmented
reality app! Download our ANDRITZ AR app from A dashboard to advise operators and to
our website or in the AppStore/PlayStore! optimize and analyze complex plants
Scan the marked pages and experience
the enhanced content.

POWER PL ANT SERVICE 18

Full steam ahead – ANDRITZ expertise

for your plant’s entire lifetime

ANDRITZ EcoFluid BOILER

Montes del Plata , Uruguay Cover image: ANDRITZ EcoFluid boiler, Blackburn Meadows, United Kingdom

2 3
Fluidized bed technology – ADVANTAGES OF ANDRITZ FLUIDIZED
BED TECHNOLOGIES

Decades of experience • Fuel flexibility

• High burn-out and conversion rates
• Inherently low emissions
ANDRITZ is a leading supplier of plants based on Bubbling Fluidized Bed (BFB) and • Excellent availability with long, continuous operating periods
Circulating Fluidized Bed (CFB) technologies for boilers. The different technologies • Operational flexibility
• Minimal maintenance
are distinguished by capacity, fuel, and application.
• Proven design

Excellent mixing and heat transfer make fluidized bed technology ideal for a wide range of applications. A variety
of clean biomass fuels (bark, agricultural, forestry, and sawmill residuals) can be combusted, as well as many other
fuels (demolition wood, refuse-derived fuels, peat, various sludges, etc.) and various types of waste.

BFB TECHNOLOGY
In a BFB unit, the fuels are fed in above the hot fluid-
ized bed surface. BFB systems operate at a moderately
low fluidization velocity and under controlled tem-
perature conditions. Thanks to the large heat capac-
ity of the fluidized bed material, which is mostly sand,
the combustion conditions are ideal for biomass and
recycled fuels with varying moisture contents. In many
installations, various fuels are fired simultaneously.

CFB TECHNOLOGY
With CFB technology, the flue gas velocity in the furnace
is higher and the bed is expanded and entrained with
the flow. The bed material flows with the flue gas through
the furnace, after which the material is separated by
cyclones and returned to the lower furnace. CFB tech-
nology also allows an extremely wide range of fuels to be
fired in the same unit. The efficient mixing and relatively
low combustion temperatures contribute to low emissions
of carbon monoxide, hydrocarbons, and nitric oxides.

ANDRITZ open nozzle grid ANDRITZ PowerFluid waste boiler EcoFluid BUBBLING FLUIDIZED
BED (BFB) BOILER Vattenfall Uppsala,
Sweden

4 5
EcoFluid BFB boilers APPLICATIONS

EcoFluid Bio EcoFluid Waste

Generating power from renewable fuel sources – the fuel flexibility

of an ANDRITZ EcoFluid boiler is an inherent feature.

Type
FLEXIBLE SOLUTIONS Scalability and ease of construction are enhanced
In addition to typical biomass fuels such as wood because the main boiler components are designed as
(chips, bark, forest residues, and sawdust), more modules. Arrangement of all heating surfaces is tailored
recently short-rotation energy crops, sludges, rejects, to the customer’s requirements. The boilers are conserva-
agricultural wastes, and refuse-derived fuels (RDF) tively designed with regard to materials of construction,
Size range 35  –   4 50  t/h 15  –   1 40  t/h
have been introduced as fuel sources. Common char- location and spacing of heat surfaces. to ensure high
30 –  350 MW (fuel heat input) 10 –  1 00 MW (fuel heat input)
acteristics for these fuels are their high volatile matter plant availability and low maintenance requirements.
content and substantially varying moisture content. Main fuels Biomass fuels, peat RDF, rejects, sludge, wood waste, etc.
These alternative fuels require certain considerations An important feature of the boiler is the design of the flu-
in design as well as in the steam output parameters. idizing nozzle grid, which distributes the primary air and Secondary fuels: Secondary fuels:
Sludge, agricultural residues, RDF, rejects, coal Biomass fuels, wood, agricultural residues, coal
ANDRITZ has technical solutions for a broad range of drains inert, coarse material such as rocks and other impu-
fuels that can be burned in an EcoFluid boiler. rities. These materials can cause disturbances in bed flu- Steam parameters 150 bar(a) and 550 °C max. for clean biomass 65 bar(a) and 425 °C max.
idization if not removed from the furnace. The ANDRITZ
SCAL ABLE AND RELIABLE fluidizing grid can be designed with a unique water-
EcoFluid boilers can be either top- or bottom-supported, cooled or air-cooled structure, providing reliable and effi-
depending on the desired capacity and site conditions. cient removal of coarse material from the fluidized bed.
ADVANTAGES OF EcoFluid TECHNOLOGY

Wide fuel flexibility

EcoFluid technology, Fortum, Pärnu, Estonia

High combustion efficiency

Low emissions
FORTUM TERMEST A .S. PÄRNU, ESTONIA
Fuels Wood, peat, and natural gas Low maintenance costs

Technical data Steam output: 94 t/h (207 klb/hr)

High availability
Steam temperature: 525 °C (977 °F)
Steam pressure: 117 bar (1,700 psig)
Good turndown ratio
Features SNCR and bag filter combined with
sorbent injection
Fast load change rate

EFFICIENT AIR POLLUTION CONTROL Vattenfall) that reduces corrosive alkali chlorides as well as
Fluidization air (primary air) supplies part of the total com- NOx in flue gases, effectively reducing fouling and corrosion
bustion air and creates gasification conditions in the lower of the superheaters. These measures provide enhanced
furnace. The balance of the air (secondary and tertiary air) steam parameters and boiler reliability using more chal-
is injected higher up in the furnace to complete the lenging fuels, while keeping operating costs to a minimum.
combustion process. In combination with a suitable reac- Particulates are removed from the flue gases in an electro-
tion time, this reduces CO emissions to low levels, while the static precipitator or fabric filter, depending on customer
gradual addition of oxygen also ensures minimal formation ­preference and environmental requirements. Additional
of NOx. Further NOx reduction can be achieved by inject- emissions control can be achieved via sorbent injection to
ing ammonia into the furnace. This system can also be reduce gaseous emissions (SO2, HCl, Hg, and dioxin/
combined with ChlorOut, a patented process (license from furans). or other ANDRITZ flue gas cleaning technologies.

6 7
ASH HOPPER SCREWS
Radiation pass

8 9
We supply the power worldwide 2
4

5
6
1

STORA ENSO, MAXAU, GERMANY –

PowerFluid CFB BOILER
Steam conditions: 198 t/h (437 klb/hr),
520 °C (968 °F), 95 bar (1,378 psig)
Fuel: Coal, bark, rejects
Start-up year: 2010
9

9
2 8

MES, ICHIHARA , JAPAN –

HÄMEENKYRÖN VOIMA , PowerFluid CFB BOILER
FINL AND – EcoFluid BFB BOILER Steam conditions: 149/134 t/h
Steam conditions: 105/115 t/h (232/253 klb/hr), (329/259 klb/hr), 543 °C (1,009 °F),
510 °C (950 °F), 85 bar (1,230 psig) 140/37 bar (2,031/537 psig)
Fuel: Forest residues, bark, sawdust, peat, Fuel: Palm kernel shells,
natural gas for start-up wood pellets
Start-up year: 2012 7 Start-up year: 2020

3 8
4 5 6 7

STOCKHOLM EXERGI, VÄRTAVERKET, RIIKINVOIMA , FINL AND – IGGESUND WORKINGTON, E.ON, BLACKBURN MEADOWS, MONTES DEL PLATA, URUGUAY OTV SA , HONG KONG
SWEDEN – PowerFluid CFB BOILER PowerFluid CFB BOILER UK – EcoFluid BFB BOILER UK – EcoFluid BFB BOILER – EcoFluid BFB BOILER EcoFluid AC BFB BOILER, 4 UNITS
Steam conditions: 467 t/h (1,030 klb/hr), Steam conditions: 71 t/h Steam conditions: 195 t/h Steam conditions: 119 t/h Steam conditions: 75 t/h Steam conditions: 31.3 t/h
562 °C (1043 °F), 143 bar (2,074 psig) (156 klb/hr), 500 °C, (430 klb/hr), 540 °C (1,004 °F), (262 klb/hr), 490 °C, (914 °F), (165 klb/hr), 455 °C (851 °F), (69 klb/hr), 383 °C (721 °F),
Fuel: Forestry wood, bark, peat, wood (932 °F), 85 bar (1,233 psig) 102 bar (1,480 psig) 85 bar (1,233 psig) 95,8 bar (1,390 psig) 42 bar (906 psig)
pellets, wood dust, bituminous coal Fuel: RDF, light fuel oil Fuel: Forest residues, recycled saw- Fuel: Wood waste Fuel: Wood chips, bark, Fuel: Sewage sludge
Start-up year: 2016 Start-up year: 2016 mill chips, bark, sludge, sawdust Start-up year: 2013 wood rejects, sludge Start-up year: 2013
Start-up year: 2013 Start-up year: 2014

10 11
PowerFluid CFB boilers CFB APPLICATIONS

PowerFluid Bio PowerFluid Waste

Unmatched fuel flexibility – from biomass to alternative fuels and

waste products. CFB technology is the state-of-the art technology
for multi-fuel combustion.

FREEDOM OF CHOICE: MULTI-FUEL DESIGN Type

This enables the PowerFluid boiler to use fuels of differing quality from different sources – giving
plant operators the freedom to take advantage of changing market conditions and fuel supplies.

The modular CFB design of an ANDRITZ PowerFluid boiler enables the boiler to utilize conven-
Cooled furnace Adiabatic furnace
tional and alternative fuels. The core components are standardized to deliver efficient, reliable
performance. Size range 100  –   750  t/h 50  –   200  t/h
80  –   550  MW (fuel heat) 40  –   1 50  MW (fuel heat)
In addition, many features can be custom-tailored for optimal performance in each installation.
In addition to firing conventional fuels (coal, lignite, and biomass), P
­ owerFluid boilers have proven Main fuels Biomass, coal, RDF (refuse-derived fuel), SRF Pre-treated municipal and industrial waste, RDF,
(solid recovered fuel), RPF (refuse plastic fuel) SRF, RPF, rejects, sludge (co-firing), wood waste, etc.
reliable in firing such fuels as biogenic residues, sludge, and rejects or waste fractions with high
calorific value (RDF). These can be fired as the primary fuel or in combination with others. Secondary fuels: Secondary fuels:
Sludge, peat, coke, TDF (tire-derived fuel) Biomass fuels, wood, agricultural residues, coal

Steam parameters 170 bar(a) and 570 °C max. for clean biomass 85 bar(a) and 500 °C max.
PowerFluid technology, Stora Enso, Maxau, ­Germany

The large heating capacity and turbulent intermixing of the fluidized bed compensate for fluctua-
tions in fuel variations and maintain full combustion, even using low-grade fuels with high moisture
and ash contents.

STORA ENSO, MAXAU, GERMANY

SUPERIOR ENVIRONMENTAL PERFORMANCE
Fuels Coal, bark, rejects The removal of nitric oxides (NOx) and sulfur oxides (SOx) is easily accomplished with CFB com-
bustion. PowerFluid boilers can meet strict emission requirements without adding post-combustion
Technical data Steam output: 198 t/h (437 klb/hr) cleaning equipment, such as flue gas desulfurization and selective catalytic reduction systems. The
Steam temperature: 520 °C (968 °F)
low temperatures and staged combustion in the furnace prevent thermal NOx formation and sup-
Steam pressure: 95 bar (1,378 psig)
press the oxidation of fuel nitrogen – resulting in low NOx formation and high fuel burn-out rates.
Features Multi-fuel concept for the Low cost limestone used as a sorbent in the furnace captures the fuel’s sulfur components in a sim-
­t reatment of fuels with higher ple and efficient way during the combustion process.
chlorine content

ADVANTAGES OF PowerFluid TECHNOLOGY

Exceptionally broad fuel flexibility

High combustion efficiency

Low emissions

Low maintenance costs

High availability

12 13
Metris BOA (Big Data,
Optimization, and Analyses)
Discover the world of digital transformation.
Operator dashboard to analyze, optimize, and advise.

Today there is a constant need to improve and

optimize boiler performance and decrease the
operating and maintenance costs.

Metris BOA effectively helps to achieve these

goals by supporting the operator with active
status gauges, traffic lights, and trends and rec-
ommendations for the whole boiler as well as Fuel Emission
data data
separate equipment. Metris BOA uses the DCS
Boiler data
data to analyze and optimize the process, which

001
011
is completed with additional smart sensors –
so-called sentinels.
Smart Digital
sensor adviser

001011101
01101010011101
1100100110
11010011001
Pattern diag.,
Additional apps enable the operator to operate Machine learn.

0
0
0
the boiler process in an optimum way. Clear rec- 10
ommendations are given for the main operating
1
01
improvement issues. The operator can also ana-
0
01

lyze time series and correlations between multi-

1
1
ple measurements within the simple dashboard Big Data
11

analyses
0

environment. Advanced analysis tools based on

10

machine learning algorithms for PID controller

0
01

optimization and AI technology for pattern diag-

1
1

nostics enhance the understanding and optimi-

01

zation of the complex boiler process.

1101

The software architecture is based on micro-ser-

vices with standardized communication channels.
This makes it possible to tailor Metris BOA to the
user’s needs.
WITH THE Metris BOA SMART SOLUTIONS,
Integration of Metris BOA according to user needs. ANDRITZ PROVIDES A SOLUTION TO OPTIMIZE
Different installation set-ups are possible: THE FOLLOWING KEY FACTORS:

• full scale on-site Metris BOA ­including hard- Optimizing performance

ware, dashboard user interface and back-end
­calculations down to Increasing reliability
• calculation services linked to an existing
­customer dashboard. Reducing operating costs

Optimizing the use of resources

14 15
Power Plant Service Retrofits and upgrades by
Full steam ahead – ANDRITZ expertise
for your plant’s entire lifetime
ANDRITZ Power Plant Service
Put our in-depth knowledge of fluidized bed technologies and years of experience
Turnkey installation of a plant is one thing – lifelong to work at your plant to get the maximum return out of your investment.
operation in a highly competitive industry with strin-
gent and changing legal requirements is another.
Your assets may require a technological
With ANDRITZ, you can ensure that your plant is still up upgrade if your business model changes or
and running at full power even decades after its initial more stringent regulations are introduced. This
start-up. is where our process specialists come into their
own again. They are skilled in helping you to
With its expert teams and holistic solutions, ANDRITZ upgrade and renew the essential components
knows how to apply state-of-the art technology – of your boilers.
not only to build your plant, but also to maintain your
assets’ economic efficiency over their entire lifetime. With a wide range of value-added services,
enhancements and upgrades, ANDRITZ can
improve your plant’s performance and reliability
so that it measures up to the constantly chang-
ing requirements and general conditions:

Extend asset •  Capacity increase planned

•  More flexible part-load behavior required
YOUR BENEFITS

life and reduce costs •  Fuel change imminent

•  Further reduction of emissions prescribed
Increased availability

Reduced total cost of ownership

Whether during or after your warranty period, we’ll have maintenance, personal consulting, and field service.
Shorter and more effective shutdowns
your customized spare parts package ready for use. This Whether you need maintenance and repairs, equip-
reduces your plant downtimes and increases its efficiency. ment and process knowledge, or spare parts, we can
tackle your challenges together and keep your plant Longer service intervals
Rely on ANDRITZ’s tailor-made services, all-inclu- up and running over its entire lifecycle with minimum
sive if you like. We can support you with preventive downtimes. Increased energy efficiency

Minimized emissions

SPARE PART CONDITION

INVENTORY MONITORING

OPERATOR TROUBLE-
TRAINING SHOOTING WE CAN BE WITH YOU IN AN INSTANT, EITHER PHYSICALLY OR THROUGH REMOTE DIAGNOSTICS.
ASSET LIFE
ANDRITZ
SPARE PART
E-SHOP CYCLE SYNERGY™
PLAN
Services ADVISE HOW
SPARE FIELD ASSESS INSTALL
PARTS SERVICE ANALYSE TO IMPROVE
CONDITION OF EQUIPMENT
SERVICE OPERATIONS EFFICIENCY/
DATA
REPORT EQUIPMENT (IF NEEDED)
ANALYTICS
FILING
PERFORMANCE
SAFETY With ANDRITZ SYNERGY™, you are on the safe side:
INSPECTION Select the combination of different products and service
modules that best serve your business requirements.
We are passionate about engineering success for our customers: Let us help you engineer it, too!

16 17
 Excellence
in every detail

18 19
ANDRITZ POWER BOILERS ALL AROUND THE WORLD
From biomass handling to boiler tech­n ologies and flue gas cleaning sys­tems –
a worldwide network of ANDRITZ engineers and service experts will guide you
through your entire project.

AUSTRIA FINL AND

ANDRITZ AG ANDRITZ OY
p: +43 316 501 0 p: +358 204 50 5555
[email protected] [email protected]

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1 Austria  2 Finland  3 Brazil  4 USA  5 China  6 Japan  7 India  8 Sweden

ANDRITZ.COM/THERMAL-POWER

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