Development of innovative small(micro)-scale biomass-based CHP technologies

Report, 2017

To enhance the overall efficiency of the use of biomass in the energy sector in Europe, the large electricity production potential from small-scale biomass heating systems should be utilised. So far, no technologically sound (in terms of efficiency and reliability) and economically affordable micro- and small-scale biomass CHP technologies are, however, available. Therefore, the present ERA-NET project (MiniBioCHP) aimed at the further development and test of new CHP technologies based on small-scale biomass combustion in the electric capacity range between some W and 100 kW. Within the project, an international consortium consisting of 12 partners from 4 countries, including university institutions, institutes and industry (both engineering and manufacturing), collaborated closely to perform high level R&D on three promising micro/small-scale biomass based CHP technologies which are covering a broad range of applications in the residential heating sector. The Austrian engineering company BIOS, coordinated the international project. The project was based on earlier basic research and development work related to these promising new technologies and aimed at the achievement of a technological level which allows a first (commercial) demonstration after the end of the project. The three CHP concepts included in the MiniBioCHP project were; 1. Pellet stoves with a thermoelectric generator (TEG) 2. Small-scale biomass boilers (10-30 kWth) with a micro-ORC process 3. High temperature heat exchanger (HT-HE) for an externally fired gas turbine (EFGT) The Swedish part of the project was focused on the development of the concept of biomass based EFGT with dedicated R&D activities related to the development of the HT-HE system. The Swedish project consisted of the research partners Umeå University (project leader), Luleå University of Technology, Chalmers University of Technology and RISE Research Institutes of Sweden, together with the industrial partners Enertech AB/Osby Parca and Ecergy. The expertise of the Swedish partners regarding ash related problems, grate boiler combustion and modelling, deposit formation and high temperature corrosion, were combined with the know-how of a Polish partner regarding HT-HE design, construction, testing and optimisation. The HT-HE is the most crucial component in EFGT processes significantly influencing the investment costs, availabilities as well as the efficiencies that can be achieved. With a thermal capacity from several hundred kW up to 2-3 MWth) the CHP technology based on a biomass boiler and an EFGT is suitable for district heating systems, or process heat consumers. The electricity produced by the gas turbine (up to some 100 kWel) can be used to cover the own electricity consumption of a company and/or fed into the grid. Even though the concept of biomass based EFGT has been an interesting alternative for small-scale CHP production for some decades, and R&D activities have been undertaken, tackling both economic and technical aspects, only a few pilot-plants have been in operation and no initiative has so far reached the level of commercial implementation. Thus, the concept of EFGT fed with biomass is still considered to be in a rather early development stage and the main technical challenges are related to alkali deposit induced corrosion and thermal stress of the HT-HE material, turbine design/operation and system integration. Within the present project, a HT-HE prototype aimed for an EFGT system was therefore designed, constructed and successfully tested at flue gas temperatures up to 900°C. Thus, appropriate guidelines for a compact design of the HT-HE and recommendations have been worked out to minimize thermal stresses as well as ash related problems regarding ash deposit formation and high temperature corrosion in a biomass boiler system. Furthermore, different concepts for the overall biomass based EFGT system have been worked out and evaluated. The outcome of the project will hopefully be used in the further development work and form the basis for a first testing and demonstration plant within the coming years.