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Company

Presentation
Waste to Energy
& Figures

...
subsidiaries +80
in 15 countries
certificates
+1.900 & licenses
mployees
24
+100 operating
years subsidiaries
+3.500
active in
reference projects
of combined in more than 60 countries
competences +11 sectors 2
om
3 state of the art
patented
technologies

public private
partnership with
nership with
2 ministries
universities
partnership with
4 research
om
institutions 3
porate structure

Christof Industries GmbH


AT, Graz
Christof Project GmbH
AT,Gratkorn
FMT - Ferro Technik GmbH
Christof Project Financing GmbH AT,Wels, Werndorf, Wien
AT, Graz

SFA GmbH FMT - Instandhaltung GmbH für Industrieanlagen


CH, Rothrist DE, Meerbusch

JCR - Christof Consulting S.R.L. FERROMONT UK Ltd.


RO, Prahova UK, Camberley

J. Christof E & P Services S.R.L. FERROMONT Bulgaria Ltd .


RO, Prahova BG, Branipole Plovdiv
Dinafit S.R.L.
FERROMONT Russia Ltd .
RO, Prahova
RU, Moskau
Ferrostaal Christof Romania S.R.L.
RO, Prahova FERRO-Montage-Technik-SE d.o.o.
RS, Kragujevac
REP Renewable Energy Products GmbH
AT, Graz Ferromont - KR d.o.o .
CRO, Cakovec
CMB Maschinenbau- und Handels GmbH
AT, Gratkorn
International Industry Servis d.o.o.
Greentech Energiesysteme GmbH SI,Maribor
AT, Graz
FERROMONT South Africa Ltd.
VLAY Kunststoff GmbH ZA, Johannesburg
AT, Radkersburg
FMT US Inc.
Christof Technology Holding US, SC, Greenville
CHN, Hongkong

Christof Industries Iran


IRN, Teheran

Doubrava Industrieanlagenbau GmbH


AT,Wels
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tof Industries locations and
ence projects across the globe

ndustries locations

rojects
dustries

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developing our
Responsibility experience in preventive
maintenance
king ahead
Flexibility

Our Values placing great value


on treating natural
resources
sustainably
Proactivity acting ahead
Quality
eaking new ground in field of
newable energies
Innovation 6
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r services: 360°

stof Industries is a partner in the development, construction and upkeep of


strial plants for industry and energy providers across the globe. Thanks to our
rse portfolio of services, we take care of every stage of the life cycle of your
strial plant – from project development through to upgrades.

offer:
360° portfolio for international industry and energy producers
hroughout the life cycle of your industrial plant
plant construction and in industrial services
ith bespoke services and products up to and including EPC(M)

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ervices throughout • Advisory
• Concept studies
fe cycle of your • Feasibility studies
• Project development
trial plant • Process development
• Planning Application Support

• Revamps • Basic engineering


• Redesign • Detail engineering
• Renovation • Design & development of components
• Relocation • Pre-Engineering & permitting

General plant services • Mechanical & electrical installation


Oilfield services • Electrical engineering & automation
Complete plant checks • Logistic systems & Material handling
Repairs • Manufactoring of components
Monitoring • Start-up
Operation • Pipline construction
Spare parts management and replacement • Project & Construction site management
Material testing • Staff training

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Scope of Work

G as Systems and Components Provider and as General Contractor


Combustion Boiler Turn-key
Gasification Plants Plants
Systems For energy generation Waste to Energy plants
ed on grate technology - all types of industrial boilers - tailor-made solutions
SFA grate firing systems - resource protection by using organic fuels, - economic & environmentally friendly
R2P flight phase Incineration residues, RDF/SRF - conversion of waste into energy
Advanced 2-stage gasification - incineration of waste

G as Service Provider
Refurbishment Operation & Service &
Maintenance Aftersales

lacement of grates, Plant management and operation, Aftersales services,


-bars, fuel-intake line and operation-supervision during spare- and wear-parts
plete firing systems warranty period supply and management

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Advantages of Technology

solutions are based on efficient and environmentally sound technologies and can be flexibly 
pted to client’s requirements:
n line with European Emission Standards (WID / IED) 

High flexibility with regard to the calorific value and particle size of the fuel (up to untreated waste)

ossibility of sub‐stoichiometric operation (gasification) of the boiler

ong‐term high availability with low maintenance‐time and costs

roven technologies for all main components

ntegrated SNCR and advanced air‐management for good burn‐out and low emissions (NOx, CO)

ailor‐made flue‐gas cleaning system with continuous emission monitoring system (CEMS)

imum price / performance ratio  low OPEX and CAPEX

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Main Fuels / Performance Range

Biomass Performance range


 Waste wood (contaminated)
 Agro-residues  5 – 100 MWth
 Sawmill dust, wood dust  10 – 120 t/h steam
 3 – 35 Mwel
Sludge  5 – 30 MWth R2P
 Municipal sewage sludge
 Paper + de-inking sludge

RDF, SRF , C&I Calorific value


 Rejects  6 – 24 MJ/kg
 Foils and plastics  6 – 18 MJ/kg R2P
 Fibre and particle board waste
Particle size of fuel
Waste  max 500 / 800 mm (untreated)
 Municipal waste  max 180 mm (R2P)
 Commercial & Industrial waste

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Main Areas of Activity - 1

From Engineering to Commissioning
Design, Supply, Erection, Commissioning, Training, Service & Maintenance

ombustion / Gasification Boilers Power Plants

SFA SFA & R2P


ard acting pusher grates  In line with EU-requirements (WID)  Overall engineering competence for all major
r‐cooled grate  Integrated boiler design, components
p to size 50 MWth self-supported or top-supported  Fuel preparation and transport
uel with low CV (6‐12 MJ)
 Vertical boiler  Water-steam cycle
 cost-effective, space saving solution  Steam turbine
Water‐cooled grate
p to size 100 MWth  Horizontal boiler  Electric, C&I
„Tail-end“ boiler with effective
uel with high CV (7‐24 MJ)  Gas cleaning technology
cleaning device (rappers)
dvanced two‐stage gasification
ub‐stoichiometric combustion R2P
 Adiabatic combustion chamber secures 2 sec ret-
t to Power – R2P time > 850degC
ight phase incineration regarding emissions
p to size 30 MWth  Recovery boiler
ir‐cooled grate
uel injection via spinning wheels

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Main Areas of Activity - 2

mprehensive competence for perfect solutions.

solutions are based on efficient and environmentally sound technologies and can be flexibly adapted to 
client’s requirements

e‐of‐the‐art design from both, technically and economically 

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Technical Solutions for WtE - 1

take care of your WASTE – we convert it into ENERGY


tilisation of waste and residues instead of disposal

he incineration of organic residues and waste is a tried and tested method for economic and environment‐friendly energy 
eneration.

he substitution of fossil fuels by residues and waste


an important and environmentally-sound step in this direction.

 The dumping of organic residues and


wastes on landfills constitutes a considerable
burden on the atmosphere.

 The thermal utilisation of such materials


counteracts these effects.

 Your WASTE is ENERGY


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Technical Solutions for WtE - 2

Our solutions for converting WASTE into ENERGY:
1. Waste separation before incineration 
 incineration of pre‐treated fuel
 ”SMART ENERGY FROM WASTE” Reject to Power
Thermal incineration of pre‐sorted, prepared and volume‐reduced energy fractions such as plastics, packing 
material and plastic foils 

2. Waste separation after incineration
 incineration of un‐treated  fuel
 mass‐burning ‐ waste incineration with SFA Grate Technology
 recycling of ash and slag
Thermal incineration of un‐treated waste fractions such as larger items and furniture with grate technology 
and recycling of slag with separation of valuable materials such as copper, aluminum, gold after the 
incineration.
State‐of‐the‐art incineration plants generate electricity and also feed heat into district heating 
systems.

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Technical Solutions for WtE - 3

nicipal waste incineration plant
m the waste acceptance area via the waste 
eration boiler, with a water‐cooled grate to the 
o‐generator unit for heat and energy 
uction

aste‐acceptance area

Boiler plant Turbo‐generator
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Technical Solutions for WtE - 4

SMART ENERGY FROM WASTE” - a Reject to Power plant solution

Smart Energy from Waste” is a Reject to Power plant solution designed for recycling and the thermal 
eatment of municipal mixed waste to produce electric energy and process heat from the biomass fraction 
f municipal waste.
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Technical Solutions for WtE – 5
pical Energy Balance

Only Power generation Power generation with heat recovery

ombustion and boiler Combustion and


adiation losses, 40 bar radiation losses,
ue gas losses 400 °C flue gas losses
0% 20 %
ondenser,
turbo-generator Generator and
enerator and
radiation losses
adiation losses
2%
6%
uxiliary power, Auxiliary power,
nergy loss energy loss
ansformer district-heating transformer
% 3%

Output district- Output electrical


heating 69 % Power 6%
Electrical power 21 % Total energy output 75 %
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Combustion / Gasification Systems

Technologies for the thermal utilisation of residues and waste


Combustion 2 Gasification

Grate Technology
air-cooled grate Advanced SFA Gasification
water-cooled grate syngas generation
air/water cooled grate sub‐stochiometric operation
Reject to Power water‐cooled grate
flight-phase incineration
with air-cooled grate
and spinning wheels
Fluidised Bed
with partners, for projects with
special fuel‐requirements

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Combustion Systems - 1

ularised design concept of the boilers and grates enables tailor‐made solutions and assures 
igh efficiency and quality of our plants
rade of standardisation and modularisation:
‐ natural circulation
‐ fulfilment of WID‐Directive for the combustion of waste 
‐ membrane wall evaporator of  3 path design 
‐ economiser / air pre‐heater in steel sheet casing 
‐ air‐ or water‐cooled grate
‐ fuel feed with “pusher”
‐ start‐up and auxiliary burners
GRATE TYP TYPE S TYPE M TYPE L
ularised
widths*) 3,0 m  6,0 m  9,0 m
odular concept, expandable to 30cm each, depending on
ype of fuel and steam capacity
ardised
9,3 m 12,3 m*) 12,3 m*)
depth
th burn-out grate

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Combustion Systems - 2

water‐cooled combustion grate SFA air‐cooled combustion grate

ights Highlights
Tailor‐made solutions up to 100 MWth  Tailor‐made solutions up to 50 MWth
For all fuels with high CV (7‐24 MJ/kg)  For all fuels with low CV (6‐12 MJ/kg)
 all types of biomass  all types of biomass
 household / municipal waste  waste‐wood, contaminated
 RDF, chemical and industrial waste  waste with low calorific value
 low OPEX costs due to high durability of grate bars –  durability of grate bars – max. 12.000hrs 
32.000hrs (replacement <10%) (replacement < 10%)

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Combustion Systems - 3

ct to Power key element is the innovative combustion chamber

Combustion tower
2 sec. Retention Time
> 850°C

Post combustion
Fuel supply by
wheels
Combustion
Burnout zone
Gasification zone
pinning wheel technology is a combination of:
 Flight phase incineration 
(Similar to fluidized bed technology)
 Grate incineration with air‐cooled grate
 Fuel feeding with spinning wheels
Individually controlled air supply

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Gasification Systems

fication – in general
Process of converting combustible solids into gases under 
sub‐stoichiometric conditions into methane (CH4), carbon 
(CO) and hydrogen (H2)

Process takes place at increased temp. (900 ‐ 1.300 degC) 
but with limited oxygen supply (Lambda 0,2 – 0,4 ) to 
ensure gasification

Gas produced is called SYNGAS and can be further used as 
fuel

For plant sizes up to 25 MWth

Requirements on Fuel:
Fuel sizing < 120mm (10% < 180mm)

For all fuels with high CV >14 MJ/kg
 all kinds of biomass, waste wood
 RDF, SRF, pre‐treated waste

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. Steam Boilers - 1

Vertical Boiler Design


 cost-effective, space-saving alternative
 height about 30 m necessary
 stop for boiler-cleaning after 6-8 months after
4.000 – 6.000 hrs
Horizontal Boiler Design
 „Tail-end“ with top-supported horizontal pass
 cleaning of the horizontal pass with rappers
 only 1 yearly maintenance stop for cleaning after 8.000
- 8.400 hrs

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. Steam Boilers - 2

recovery boiler downstream combustion chamber
onally required systems
Fuel: treatment, transport and storage
Ash: transport and storage Recovery boiler Flue gas treatment

sec. Retention Time Recovery Boiler


> 850 °C
Economiser
~ 950°C
Cyclone
~ 300°C

el Metering
and
nning Wheel
ring Bed
~ 630°C

~
2P Core unit 160°C

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. Gas Cleaning Technologies - 1

fferent legal regulations and various components of the fuels 
quire the use of different gas cleaning technologies. 
DRY SYSTEM WET SYTEM
Dry flue gas cleaning / scrubbing systems: Requirements More stringent 
CR stage for reduction of NOx levels (200mg) according to WID requirements

praying reductive substance (urea/ammonia) into the boiler BIOMASS BAGHOUSE‐FILTER

y flue gas scrubbing system using additives
dditive (lime / sodium bicarbonate) is injected  WASTE WOOD
DRY FLUE‐GAS Single‐Stage or
RESIDUES, REJECTS
 neutralise SO2, HCl and HF acids.  SCRUBBING SYSTEM Two‐Stage Wet 
RDF, SRF
so injection of active carbon to reduce heavy metals  SNCR Scrubbing System
MUN. + IND. 
nd dioxins / furans.  SCR
WASTE

g house filter for reduction of particles in flue gases NOX SNCR SCR


h particles with spent / unspent additive are filtered out.
Wet flue gas cleaning systems:
ingle‐stage or two‐stage wet scrubbing system in combination with an SCR. Is used in case of stricter environmental limits and enables to fall up to 50‐
100% below the limits of WID, depending on fuel characteristics.
Continuous emission monitoring system (CEMS) ‐ required by WID / IED ‐ will be installed in the stack and monitors all main parameters to the 
ontrol room.

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Gas Cleaning Technologies - 2

ntinuous emission monitoring system (CEMS)

MS is required by WID, the following parameters are monitored: 

bon monoxide content (CO)
rogen oxides content (NO)
ygen content (O2)
phur dioxide content (SO2)
drochloric acid content (HCl)
drofluoric acid content (HF)
ganic carbon content TOC
oisture in flue gas content
st content
mperature of the flue gas
solute pressure of the flue gas
ume flow of dry flue gas

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. Patents

Patented water‐cooled grate plate and Innovative combustion chamber with


nted motion compensator for the
patented connection system for the air‐cooled grate system
ng water circuit
water‐cooled grate plates

supply by spinning wheels 3‐D Demonstration of the water flow Patented air‐cooled grate plate with
vative combustion tower inside of the grate plate air outlet opening with integrated 
cleaning scrappers
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Main References - 1

SAICA Partington / UK - 2012


22 MWth heat (20 bar/215°C)
rejects, paper fibres, sludge

Vattenfall Rostock / D - 2010


87 MWth (42/65 bar, 405°C) grate
RDF, municipal- + industrial waste

RWE Berlin Neuköln / D - 2006


2 x 53 MWth (60/80 bar, 450°C)
waste wood, RDF

RBB Böblingen / D - 2005


6 MWth (40 bar, 390°C)
biomass, wood residues

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Main References - 2

MM Karton Hirschwang / A - 2005


4,8 MWth (80 bar, sat. steam)
rejects, bio-sludge, wood

Mainova Fechenheim / D - 2006


44 MWth (66 bar, 450°C)
waste wood, RDF

Meidensha / Thailand - 2007


50 MWth (45/66 bar, 420°C)
biomass (palm stalk)
ASME test-procedure

Dresden / Germany - 2003


27 MWth (66/80 bar, 425°C)
biomass, waste wood, RDF

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Main References - 3
y additional References in various Industries
Engineering
Chemical Industry (14), Disposal Industry (5), Wood Industry (2), Synthetics (1),
Metal Industry (4), Paper Industry (1), Textile Industry (2), Shipbuilding Industry (2)
General Contractor
Chemical industry (10), Garbage/Sewage Sludge Biomass (20), Other Industries (10)
Engineering / General Contractor
Military Enterprises (5)

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Main References - 4 –
Waste to Energy - Plant

tenfall Europe, Rostock:


MWth, 65/42 bar, 405 degC

nt Output: Power 20 MWe + Heat 25 MWth

l amount: 180.000t/a (max.230.000t/a)


orific value (LHV): 11 – 18 MJ/kg
l size: 90% < 500 mm, 10% < 800 mm
ilability: > 8.000h
te Dimension: 9 m x 12,6 m

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Main References - 5 - Saica Site Picture

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. Contact

Christof Industries
CONTACT DETAILS

Christof Industries GmbH


Plabutscherstrasse 115
8051 Graz, Austria
P +43 502080
welcome@christof.com
www.christof.com

Christof Project GmbH – Office Vienna


Esslinggasse 17/2
1010 Vienna, Austria
P +43 502080 8406
office.cpg@christof.com

SFA Handels GmbH


Bernstrasse 24
CH – 4852 Rothrist, Switzerland
P +41 62 785 11 85
info@sfa-anlagenbau.com
www.sfa-anlagenbau.com

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