Directory of Industrial Boilers and Combined Heat and Power Equipment This directory was published in partnership with: Section 1 03 Foreword 04 Introduction 06 Boilers and combustion 07 Combustion technology 10 Combined heat and power 12 Advanced conversion technologies Envirolink Northwest Section 2 14 At-a-glance manufacturer information Spencer House 16 Company summary table 91 Dewhurst Road Birchwood 18 Summary table Warrington Section 3 20 Detailed manufacturer information WA3 7PG 22 UK map T +44 (0) 1925 813 200 24 Directory F +44 (0) 1925 819 031 77 List of UK suppliers www.envirolinknorthwest.co.uk [email protected]

Combustion Association 1A Clarke Street Ely Bridge Cardiff CF5 5AL T +44 (0) 29 2040 0670 F +44 (0) 29 2055 5542 www.cea.org.uk [email protected]

CO2Sense Yorkshire Victoria House 2 Victoria Place Leeds LS11 5AE T +44 (0) 113 237 8400 www.co2sense.org.uk [email protected]

This directory was commissioned by Envirolink Northwest. North Energy Associates Limited compiled the bulk of the information as supplied by the listed manufacturers. Reproduction of content needs the written permission of manufacturers, Envirolink Northwest and/or North Energy Associates Limited. Using this directory Foreword The entries in the directory are listed in order of manufacturer. The European Union is committed to Other useful organisations such as UK agents, suppliers deployment and the UK is playing a major role. or installers are listed under that manufacturer’s entry as appropriate. Where appropriate, a UK example of an installation of that manufacturer’s equipment is given. Some manufacturers have many UK installations of their equipment, others have a number of examples in Europe and few in the UK, while others have many examples in Europe but none in the UK. The specifications and claims made in each listing are those of the manufacturer or agent. We have no way of validating these and they may be based on using a specific fuel. Validation In the Renewable Energy Strategy, non-domestic biomass has the third greatest contribution to make in the lead scenario technology mix to meeting the 2020 against the specific circumstances you are considering is vital. targets, after wind and transport fuels. In the lead scenario for heat alone, where 12% of heat should come from renewables, the largest contribution is from the The inclusion of a manufacturer in the directory does not imply industrial sector. that their equipment complies with relevant UK regulations. This is also the case for manufacturers that have installations This publication originated in Northern where a strong industrial sector in the UK. The specific regulatory requirements of any proposed continues to provide a vital contribution to our national economy. These industries consume a large amount of power and heat. Some have already switched to installation must be examined with the manufacturer of the sources helped by a particularly well developed wood and solid equipment. Many UK suppliers of European equipment can assist recovered fuel supply chain in the North West of England. with ensuring that any system designs achieve compliance with DECC is confident that energy generation from sustainable fuels will continue UK regulations. its rapid growth in the industrial sector, and that companies across the UK will reap the rewards. We welcome the initiative taken by Envirolink Northwest and the other Northern England agencies in producing this publication.

Andrew Perrins Department of Energy and Climate Change

2 3 Introduction

4 5 Boilers and combustion Combustion technology Solid combustible biomass material can be used directly as fuel Primary combustion air is usually introduced to the fuel bed, for boilers, giving a range of outputs. The boilers can be used to or in the case of pulverised fuel, it is mixed with the fuel. heat thermal oil or steam as required. The type of combustion This allows the processes of fuel drying, gasification and charcoal technology employed by these boilers is largely dependent on the combustion to take place. The addition of secondary air then form of the fuel used and the scale of the system. Different fuels enables the combustible gasses to be burned, usually in a separate have different physical properties, requiring a variety of equipment combustion zone. and technologies to handle them. For example, some biomass fuels flow easily and others need mechanical transfer to move them around.

Boiler output types: If only dry biomass fuel is to be used, combustion chambers with steel walls can be used. However, if wet biomass fuel is to be used, combustion chambers Thermal oil with insulating bricks should be used to act as thermal accumulators to buffer Higher temperatures can be achieved with thermal oil boilers than hot water variations in moisture content and combustion temperature. Biomass boiler systems, up to 300ºC. This makes thermal oil boilers suitable for process heat types are largely determined by which type of combustion system is required demands. Unlike steam, thermal oil boilers do not require a specially trained and for the fuel. licensed steam boiler operator. Steam Combustion systems can be divided in to three main types: Biomass boilers are available for raising steam. Saturated steam boilers are often Pulverised fuel combustion2 used for heat transfer applications, although there are generator prime movers1 Fixed bed that can make use of saturated steam. Fluidised bed Super heated steam boilers that utilise biomass fuel are available and may be used for electrical power generation. Pulverised fuel combustion Pulverised fuel such as sawdust and fine shavings can be used by injecting them pneumatically into the combustion system. The primary air is used as the transport air. This type of system usually requires an auxiliary burner to achieve the necessary temperature before the biomass fuel is introduced and the auxiliary burner shut down. It is necessary to maintain the moisture content and maximum James Proctor boiler particle size of the fuel to ensure optimum performance and minimum emissions. The explosion risk which exists with fine biomass particles requires careful control of the fuel feed. The fuel/air mixture is often injected tangentially into a cylindrical furnace muffle to give a rotational flow, which can be enhanced by recirculation of flue gas to the combustion chamber. Muffle furnaces are well suited to the use of dust and fine wood wastes such as those arising from the chipboard industry.

1 Primary movers generally refer to the engine or plant that provides the motive force to drive a generator. 2 Sjaak van Loo and Jaap Koppejan (2008) The Handbook of Biomass Combustion and Co-firing ISBN 9781844072491 6 7 Fixed bed combustion Fluidised bed combustion Fixed bed combustion systems can be further sub-divided into the various grate In fluidised bed combustion systems, fuels are burned in a suspension of hot bed furnace technologies which are available, as well as underfed stokers. The main types material consisting of sand, ash and additives or similar inert material. The hot are fixed grate, travelling grate, moving grate, rotating grate and vibrating grate. sand/inert material effectively dries and ignites even demanding fuels with low heating value and/or high ash content. Fixed grate systems are not well suited to modern, well-controlled biomass combustion systems. Fuel transport through the combustion zone is achieved by Fluidised bed combustion systems have been used widely for large-scale schemes the mechanism of feeding fuel to the boiler and moving the fuel through it. or combustion of municipal and industrial wastes. There are two main fluidised bed This makes it difficult to achieve high levels of control of the distribution of fuel technologies: bubbling fluidised bed and circulating fluidised bed. over the grate. It is usually only applied to small-scale equipment. It should be noted that fluidised bed combustion systems generally require long A travelling grate consists of grate bars that form a continuous band moving start times of a few hours. Good combustion efficiency can be achieved due to through the combustion chamber. The fuel bed does not move, but rather it is mixing, which minimises the requirement for excess air. The capital investment transported through the combustion chamber on the grate. The speed of travelling and the operating cost are high compared to fixed bed systems and fluidised bed grate systems can be varied to ensure complete burn out of the fuel. The grate is combustion plants are usually only found in large-scale developments. automatically cleaned of ash and dirt at the end of the combustion chamber, before With bubbling fluidised bed technology, the sand bed bubbles in the lower part of returning to the start. The grate bars may be cooled by primary air on the way back the furnace. The bed is fluidised by the primary air, which is supplied from below at to prevent overheating and to reduce wear. However, as there is no stoking of the around 1 to 2m/s. The secondary air is introduced through groups of nozzles higher embers, a longer burn out time is required than with other types of grate and it is up the sides of the furnace. The combustion zone retains all fuel heat, thus making not well suited to non-homogenous fuel as no mixing occurs. bubbling fluidised bed combustion well suited to biomass and recycled fuels. A moving grate consists of alternate fixed and movable rows of inclined grate bars. With circulating fluidised bed technology, the fluidising velocity is between The movable sections are moved forwards and backwards, usually by hydraulic 5 and 10m/s, and smaller sand particles are used. The bed material flows together actuators, transporting the fuel along the grate. This leads to good mixing of with the flue gas through the furnace, after which it is separated from the gas burned and un-burned fuel. The speed of different grate sections can be controlled by cyclones and returned to the lower part of the furnace. This technology is optimal independently as required by different stages of the combustion process. for higher heating value fuels, such as drier biomass, recycled fuels, fossil fuels Moving grate systems are suitable for a wide variety of fuel types. Primary air and co-combustion. The higher turbulence in circulating fluidised bed furnaces can be used to cool the grate when using wet fuel. Water cooled grates can be leads to better heat transfer and more even temperature distribution in the bed. used with dry fuels or fuels which have a low ash melting point. However, they are usually larger than bubbling fluidised bed systems, and therefore A rotating grate consists of contra-rotating conical grate sections. It is underfed by more expensive. screw conveyors and supplied with primary air from below. Ash makes its way to the outside edge of the circular grate and falls into a basin beneath the grate. This type of grate ensures good mixing of the un-burnt and burning fuel and is therefore well suited to the use of wet fuels. In a vibrating grate, primary air is supplied through the fuel from below in an MW power inclined finned tube wall. The vibrations cause the fuel and ash to progress down the inclined grate. This type of grate is used for fuels which have a tendency to form slag as the vibrations prevent the formation of large particles. However, the vibration increases the emission of fly-ash and the fuel and ash transport are difficult to control. Underfed stokers are also available whereby fuel is fed into the combustion chamber from below, usually by a screw auger. The fuel is usually moved up on to a grate and primary air is supplied through the grate. This technology is relatively low cost and quite reliable.

8 9 Combined heat and power Good quality CHP is defined by the quality index (QI) of a scheme as specified by Defra. The QI is a function of the electrical power generation efficiency and the heat It is often feasible to utilise biomass in direct combustion production efficiency. The criteria used when calculating the QI is dependent on the processes to provide heat only. This generally requires less technology employed, fuel used and capacity. capital investment than the cogeneration of heat and power Most examples of biomass CHP schemes are currently located in Europe (mainly but does not yield such high overall efficiencies. Austria, , Denmark and Italy). However, there is growing interest in the UK.

Gasification Steam turbines Gasification systems are included under Steam turbines are generally suitable the CHP category (see section for electricity or CHP plants using REF_Ref235375789\r\h0 for a description biomass fuel, with an electrical output of gasification). Gasification technology of greater than around 2MW up to can be used to produce synthetic gas large-scale generation schemes of that can subsequently be used in a gas many megawatts. Steam turbine CHP is the cogeneration of heat and electrical power. CHP can offer savings in CO2 engine to cogenerate heat and electrical manufacturers and suppliers are not emissions when compared to separate heat production and , power. Manufacturers of gas engines are included in the directory, rather the due to increased overall efficiency. Electricity is usually generated by thermal not listed in this directory but those of manufacturers and suppliers of the processes whereby combustion of a fuel provides the motive power to drive an gasification systems are. appropriate boilers have been identified. electrical generator. Such processes generate heat as a by-product. Where a demand for heat co-exists with electricity consumption, the usable waste heat from thermal Organic Rankine Cycle (ORC) turbines Biomass steam boilers are available electricity generation can be utilised. The Organic Rankine Cycle (ORC) is to suit this range of steam turbine similar to the thermodynamic cycle of capacities. CHP schemes have successfully been implemented in the hospitality industry, leisure a conventional steam turbine except Steam turbines industry, education sector and process industries. Many CHP schemes are fuelled by in the choice of fluid that drives the Steam engines (reciprocating and screw mains gas, although solid and liquid fuelled systems are also available. Equipment turbine. ORC turbines use an organic type engines) can be used with biomass- can be selected to utilise renewable forms of fuel, such as solid combustible biomass, fluid as the working medium (rather than fired steam raising boilers to generate although these are currently less common. water) to produce steam. The working heat and power. The technology employed for the prime mover (required to drive the generator) is medium can be silicon, hydrocarbon or generally dependent on the capacity required or fuel to be used. Smaller systems refrigerant-based fluids depending on Steam screw engines operating on can use stirling engines, steam engines or reciprocating internal combustion engines the temperature of the available heat a similar principle to a screw compressor, source. This allows operation at relatively except as an expansion machine and large capacity plant often use gas or steam turbines. Other types are available oC oC depending on the size and application. The ratio of power to heat varies with the low temperatures (70 to 300 ). rather than a compression device, are applicable to small-scale power technology used. ORC technology has been mainly generation. However, this technology utilised for heat recovery from waste Two of the factors which determine the viability of investment in CHP are the relative is not common and has not been heat streams associated with industrial price of fuel used and the financial value of the electricity generated. The larger included in the directory due to the processes and is also well known in the difference (higher electricity price and lower fuel price) the more favourable are small number of examples. the conditions for operating CHP. It is also important to ensure there is a use for geothermal applications. However, it as much of the heat generated as possible. This may depend upon the thermal is now being applied successfully with Reciprocating steam piston engines can output of the CHP system. Gas engines, for example, produce a mixture of low grade biomass boilers providing the heat source. be used for the cogeneration of heat and power. Steam engines can be and high grade heat, but a particular process site may have little or no need for low ORC generators are generally available in operated with low pressure saturated grade heat, but have a requirement for steam. capacities of around 0.3MW to 2MW e e steam and are more tolerant of wet and are well suited to part load operation, Additional benefits of CHP include: steam and other contaminants than giving increased flexibility. Efficiencies 3 steam turbines. Whilst no UK examples Exemption from the Climate Change Levy (CCL) on all fuel inputs to and electricity 3 CCL is a tax on energy of around 17% to 18% can be expected, have been found, this technology is outputs from “Good Quality CHP” (see below) use. The aim of the which is usually higher than that of levy is to encourage well developed in Europe and the main 4 consumers to improve Eligibility for Enhanced Capital Allowances (ECA) on Good Quality CHP systems energy efficiency, a steam turbine of comparable size. reduce energy use manufacturer of this equipment is Dedicated biomass fuelled CHP will earn 2 ROCs/MWh from 2009 and reduce emissions included in the directory. of greenhouse gases. 4 ECA is a scheme which allows organisations to write off the whole of the capital cost of their investment in qualifying technologies against their taxable profits of the period during which they make the investment. 10 11 Advanced conversion technologies Pyrolysis Pyrolysis is the thermal decomposition of biomass and occurs when the biomass This section includes systems which use gasification and pyrolysis. feedstock is heated in the absence of oxygen. This produces gas (syn-gas), solid These technologies can be deployed in the (char) and liquid oil (olefin). The gas and oil can be used to fuel an engine, turbine sector using municipal solid waste (MSW) and refuse-derived fuel or boiler. The char can be recovered and used as a fuel, or gasified. (RDF). Gasification and pyrolysis are also applicable to the use Gasification systems generally include a pyrolysis stage. However, systems which are based purely on pyrolysis are being developed. This technology is currently less well of woody biomass, food waste, agricultural residue and industrial developed than gasification although there are some examples of these systems waste material. being installed.

Gasification The use of biomass gasification enables a useful gas to be produced from the biomass feedstock. The gas, when cleaned, can be used in a reciprocating engine to generate electricity. A further use for the gas can be in direct heating applications as a replacement for other fuels such as oil or . The production of gas from biomass, particularly wood, has a long history. The gasification technology was developed in the 1930s and was used extensively during the Second World War to produce a fuel which could be used in motor vehicles. There are three main types of gasifiers: down-draught gasifiers, up-draught gasifiers and fluidised bed gasifiers. The latter category can further be split into a number of sub-categories. Down-draught gasifiers are the most widespread type, and can be used up to sizes of about 2 to 3MW thermal. Various manufacturers use different methods, but overall the principle is as follows. Biomass fuel is introduced at the top of the gasifier, through Energos plant diagram a pressure lock feeding system. The biomass enters the first zone where it undergoes pyrolysis. It passes through a throat in the gasifier into the combustion (oxidation) zone and then into a reduction zone where the wood-derived gas is taken off. Some ash/char continues to the bottom of the gasifier where it passes through a pressure lock. The gas produced has a low calorific value and high tar content with some entrained ash. The tar and particulates must be removed by a gas cleaning system in order to be used in a gas engine. Some manufacturers have a variation on this system whereby two gas streams are produced; the first is a tar-rich stream which is burnt for heat and the second stream is much cleaner and can be used for power generation. It has been difficult to scale the down-draught gasifier to larger sizes, and so larger installations have a number of modules all producing gas in parallel. However, down-draught gasifiers are now used extensively in small biomass CHP plants. Up-draught gasifiers are not used much for power applications because of the high tar content of the gas. A typical example is the Bioneer gasifier used in Finland in small district heating schemes. Fluidised bed gasifiers can be further broken down by operational type. These are generally at a much larger scale. Low pressure circulating fluidised bed gasifiers can be scaled to sizes up to 100MW. Low pressure bubbling fluidised bed gasifiers are more suited to the 15 to 40MW scale. Pressurised fluidised bed gasifiers have promise in integrated combined cycle plants and have been developed in pilot plants. One interesting variation is the fixed and fluidised bed biomass gasification plant developed at the Gussing plant in Austria, which uses steam injection to produce a higher calorific value gas which can have further use as a synthetic natural gas.

12 13 At-a-glance manufacturer information

14 15 Company summary table Foster Wheeler Global Power Babcock & Wilcox Vølund Spilling Energie Systeme Vyncke Energietechniek KARA Energy Systems Biomass Engineering Ness Wärmetechnik Kablitz and Mitthof Hollensen Energy Graveson Energy Doosan Babcock LIN-KA ENERGY Inetec TherMec Puhdas Energia Byworth Boilers Keppel Seghers Waste2energy James Proctor Biomass CHP Bono Sistemi Ethos Energy Metso Power AE&E Group Weiss Kessel Polytechnik ICI Caldaie Schmid AG Uniconfort MW Power ITI Energy Danstoker ENERGOS MAWERA TK Energi Turboden Kohlbach Adoratec Bioflame Xylowatt Ranheat Entimos Repotec Aalborg Bioener Justsen Imtech Martin Refgas Wykes Binder Eratic TPS KIV

<3MW x xx xxxxx x x x x xxx xxx x xxxx x x xx x x 3–10MW xxxxxxxxx xxx xxxx xxx x x xxxx xxx xxx >10MW x xxxx xx xxx xxx x x xxxxxx xxx xx x x xxxx Thermal oil x xx xxxxx xx x xx x Steam xxxx xxxx x x x xxx xx xxxxxxxxxxx x x x xx xx Organic rankine cycle x x From gasification/pyrolysis x xxx xx xxx xxxxxxxx Steam turbine x xxx Steam engine x x Gasification x xxx xx x xxxxxxxxx Pyrolysis x Wood pellets/briquettes xxxxx x xx xxx xxxxxxxx x Wood chip xxxxxx xxx xx xx x x xx xxxx xxx xxxxxxxxxxxxxxx x x Clean wood processing waste xxx xxx xx xxxxx xx x x xx x x xx x xxx x x Clean sawdust and sanding dust xxx x x xxxxx xx x x xx xx x xx x xxx x x x Particle/fibreboard dust xxxx xxxxxxxxx Treated waste wood xxx xx x x xx Clean waste wood x xxxxx x x x xxxxx x xxx x x xx x x xxxx x x Clean timber, processing residues x xxxx xx x xxx x xx xxxxx xxxxx x x xxx x x x Food and drink, processing residues xxxxxx xxxx x Fibreboard & plywood residue xx xxx x x x x xxxxx Rice husk/olive stones, etc. xxxxx xxxx xxxxx Animal processed by-products x x x Chemical residues (e.g. liquor) x x xx Paper pulp residues and sludge xx x xxx xx x x Paper and cardboard xxxx xxx xxx Leather processing waste xx Refuse-derived fuel xx x x x xx xxx x x xxx Textiles waste and residues xxxxx xx x Plastic waste xx x xx xx x x Agrifibres and straw xxx xx x x xxxx x x xx Grains, seed waste, etc. xxx xx x x x x 16 17 Summary table This table shows which boilers within this directory are steam raising, the quantity of steam they can produce (tonnes per hour), the pressure (bar) and thermal capacity (megawatts), where known.

Steam raising boilers: Steam raising boilers: Part1 Part2

Companies Technical info Companies Technical info Tonnes per hour Pressure Megawatts Tonnes per hour Pressure Megawatts (t/h) (bar) (MW) (t/h) (bar) (MW) AE&E Group <500t/h 100bar <400MW KARA Energy Systems 20bar <15MW Babcock & Wilcox Vølund 3–25t/h 20MW Keppel Seghers <1.5–30t/h <70MW Binder KIV 60bar 0.8–25MW Bioener 20–80MW Kohlbach 0.5–36bar <15MW Bono Sistemi <150t/h <50bar <3.5–45MW LIN-KA Energy <7.8t/h 8–16bar <5MW Byworth <3t/h Martin <70MW Danstoker <0.3–35t/h <32bar Mawera <15MW Doosan Babcock <30–180t/h <110bar Metso Power 10–600MW Eratic <14MW MW Power 22–36t/h 17.8–29MW Foster Wheeler Global Power <270t/h Ness Warmëtechnik 2–28t/h <30bar <50MW Hollensen Energy <15MW Polytechnik 36bar <20MW ICI Caldaie 12.5–5.8MW Ranheat <5MW Imtech 5–20MW Schmid AG Wood-Firing Systems 5–32bar <1.2MW Inetech Thermec TPS <40MW James Proctor <20t/h <100bar <12MW Uniconfort 0.7–25bar <5.8MW Justsen <300kW–15MW Vyncke Energietechniek 2–100MW Kablitz and Mitthof <110bar <40MW Weiss Kessel <500t/h 100bar <15MW

18 19 Detailed manufacturer information

20 21 UK map The following map shows one example for each manufacturer in the UK, where installations exist or permission has been given.

25

1 Aalborg Energie Technik Page 24 2 AE&E Group Page 26 3 Binder Page 28 2 4 Bioener ApS Page 29 5 Bioflame Page 30 6 Biomass CHP Ltd Page 31 24 7 Biomass Engineering Ltd Page 32 8 Byworth Boilers Page 34 26 20 9 Danstoker Page 35 10 Energos Ltd Page 37 25 6 11 Ethos Energy Page 40 12 Foster Wheeler Global Power Page 41 12 13 Graveson Energy Management Ltd Page 42 14 ICI Caldaie Page 44 5 13 15 ITI Energy Ltd Page 47 16 Kablitz and Mitthof Page 50 17 KARA Energy Systems Page 51 21 9 18 Keppel Seghers (site under construction) Page 52 15 14 19 Martin GmbH Page 56 18 20 Metso Power Page 58 16 21 MW Power Page 59 22 Ranheat Engineering Page 63 23 Refgas UK Page 64 23 24 Turboden Srl Page 70 4 25 Vynke Energietechniek Page 72 27 26 Waste2energy Page 73 27 Wykes Engineering Page 75 7 1 19 17 11 8

10

22 23 Aalborg Energie Technik A/S Adoratec Aalborg Energie Technik A/S (AET) is an engineering company, Partnered with Maxxtec AG, Adoratec have developed the ORC based in Denmark, which designs, supplies and provides servicing combined heat and . Their services include the on complete biomass-fired boilers, CHP and power plants. development from the initial concept through to delivery of an economic solution for the client’s needs. Clarke Energy UK joined forces with Maxxtec in 2007, to provide an energy from biomass solution with the ORC module.

Category Biomass-fired CHP plants, power plants and boiler plants. Category CHP Organic Rankine Cycle (ORC)

Technical data Capacity 25MWth–150MWth Technical data Capacity 500kWe–2.5MWe Fuel Sustainable forestry wood is the typical fuel, but more or less any type Fuel Woody biomass of biomass can be used as a fuel source; this includes also recycled wood Output Electricity and hot water applications (dryers or heating systems) Output Electricity and heat Equipment & The ORC technology involves a steam-power system using an organic medium Equipment & AET boiler technology is based on a spreader stoker-fired boiler with travelling technology evaporated at low boiling conditions, instead of water. The steam is released technology grate. The boiler is a single drum natural circulation steam boiler. into the turbine to power the generator to produce electricity. However, the steam pressure is considerably lower, does not require high pressure technology Specially developed components include fuel dosing bin with dosing screws, fuel and simplifies the plant operation. Due to the thermodynamic characteristics of spreader, travelling grate and SNCR plant for injection of ammonia in the furnace. the used media, the partial loading capability of ORC plants is superior and the efficiency achieved is higher than comparable steam plants. Examples There are many examples in Europe and Scandinavia, but the only UK site is the Western Wood Energy Project. AET have worked with Burmeister & Wain Examples There are many examples of this plant in Europe, but there are no known sites Scandinavian Contractor A/S in a joint venture to provide the turnkey project for in the UK using biomass for this type of CHP plant. the biomass-fired power station in Wales. The plant in Wales has an AET — M1050 boiler that is fuelled by sustainable forestry wood and clean uncontaminated residues from wood processing (chips, logs and sawdust). The wood is received, stored, chipped and mixed before being fed to the combustion system. The 16.5MW turbine is from Mitsui Engineering & Shipbuilding. The plant was completed in 2008, and is the first biomass-fired power plant in Wales. Aalborg Energie Technik has also converted Glanford Power Station near Scunthorpe from burning 100% chicken litter to operating on 100% meat and bone meal (MBM) as the sole fuel source.

Contact UK contact Contact UK supplier Aalborg Energie Technik A/S Lars Broenden Adoratec Clarke Energy UK

T +45 96 32 80 0 T +45 26 30 07 32 T +49 (0) 4315 708 924 T 0151 546 4446 W www.aet-biomass.com E [email protected] W www.adoratec.com W www.clarke-energy.co.uk 24 25 AE&E Group Babcock & Wilcox Vølund AE&E Group is an international provider of systems for thermal Babcock & Wilcox Vølund is 100% owned by The Babcock & power generation and environmental technologies, and offers Wilcox Company in Barberton, Ohio, USA. The company is customised solutions for components, systems and turnkey. a leading supplier of equipment and technologies designed to convert household waste and bio-fuels into thermal energy.

Category Boilers Steam Category Boilers Hot water, steam CHP Gasification/pyrolysis, steam turbine ACT Gasification Technical data Capacity Up to 400MWth (150MWe) Fuel Bark and wood, sludge, RDF (refuse-derived fuel), plastic waste, and coal residues, biomass, sewage sludge, agricultural waste, pulp Technical data Capacity Up to 30MW and beyond depending on the client specification and paper industry residues, RDF, waste wood, various liquors and Fuel All types of waste, biomass, peat, RDF diverse other fuels Output Waste or biomass to energy systems — steam, hot water and Output Steam and electricity district heating and the possibility of biomass co-firing Output Gasification systems — electricity Equipment & — PowerFluid® Fluidised bed boiler: 50–500t/hr steam, up to 400MWth (150MWe) technology output fuelled by 6–40MJ/kg, bark and wood, sludge, RDF (refuse-derived fuel), Equipment & — W-grate (BS) water or air-cooled suitable for combusting all types of waste

plastic waste, coal and coal residues and diverse other fuels technology with efficient combustion ensuring very low CO2 emission and minimal unburnt — EcoFluid® bubbling fluidised bed boiler: 5–250t/hr steam, up to 200MWth organic compounds in combustion gases and up to 75MWe output, fuelled by 3–20MJ/kg, biomass, sewage sludge, — W-grate (BS) Mark 6 water-cooled suitable for combusting high calorific agricultural waste, pulp and paper industry residues, RDF, waste wood, other value refuse fossil fuels — W-grate (Vølund) air-cooled suitable for combusting all types of waste — W-grate (Vølund) water-cooled for combusting high calorific value refuse — Steam production; 3–35t/h Examples Bischofferode, Germany has a PowerFluid® system — a circulating fluidised bed — vibration grate (HVB) water-cooled for combustion of biomass, peat or boiler with reheat using natural woodchips and untreated wood waste. It has RDF with little or almost no ash content and a heat output of 2.5MW/m2 a steam output of 58.8–57.4t/hr at 535ºC and 130–25.4bar pressure. — gasification: up-draught gasification up to 1MWth Hallein, Austria has an EcoFluid® boiler — a bubbling fluidised bed boiler using wood waste, bark, sawdust and rejects. Examples 100t/h steam boiler (92 bar) at 520ºC at Wanze bioethanol plant, is The only example of this technology in use in the UK is Abengoa SA for Energy fired primarily with bran, which is a residue from the milling of wheat grain used Power Resources Ltd, Westfield, where AE&E were responsible for the engineering, for the production of ethanol. The steam from the boiler is expanded through supply, erection and commissioning of an EcoFluid® bubbling fluidised bed boiler a steam turbine to provide low pressure steam for the heating processes in the plant and condensation turbine fuelled by poultry litter. The plant provides 47t/hr ethanol factory. The power is sold to the grid. of steam at 60bar and 460ºC with an electric output of 11MWe. On the basis of an experimental 1MWth gasifier, built at Kynby in Denmark, a commercial 3.5MW plant was built in 1996, in Harboøre Municipality (Jutland, Denmark) with a full-scale gasifier for the combined heat and power plant.

Contact UK contact Contact AE&E Austria GmbH & Co KG Chris Coldwell Babcock & Wilcox Vølund

T +43 31 65 010 T 0191 252 6445 T +45 76 14 34 00 E [email protected] M 07850 736 352 E [email protected] W www.aee-austria.at W www.aee.co.at W www.volund.dk/home 26 27 Binder Bioener ApS Binder is based in Bärnbach, Austria. Binder has installed over Bioener ApS is a Danish registered company owned by the 3,000 boilers across the world over the last 25 years. They have Japanese companies Takuma Co Ltd and Itochu Ltd. The company thirteen sales and service centres in eleven countries. Binder boilers was established in 2002 when the straw-fired boiler technology have been applied to industrial process heat demands as well and patents were taken over from FLS Miljo a/s who, in turn, as space heating. had acquired the boiler company Burmeister & Wain in 1995. Bioener ApS has over 30 biomass power stations in Europe and Asia.

Category Boilers Steam Category Boilers Steam

Technical data Capacity 30kWth–20MWth Technical data Capacity In the range of 10MWe/20MWth–40MWe/80MWth Output Low pressure hot water, steam Fuel Straw (various), peat, wood, wood waste, wood chips and bark Fuel Up to 55% moisture content woodchip & up to 25% moisture content Output Steam pellets (wood, peat, atgro pellets) Can be supplied as containerised boiler plant: up to 1.5MW Equipment & Bioener ApS specialises in the design, manufacture, erection and commissioning technology of straw-firing and other biomass-fired energy power plants, including associated equipment. Equipment & Binder can produce a range of boiler types to suit the combustion of various fuels. technology They can supply boilers with injection burners to burn dusty fuels (<15% moisture content), solid retort burners with underfed stokers for granulated fuels, solid retort Examples Elean Power Station, Ely Business Park, Sutton, Cambridge, UK — client Energy burners for pelletised fuels, moving grate burners for high moisture content or high Power Resources (EPR) Ely Ltd. This was the world’s largest straw-fired power ash content fuels with ram or auger stokers. station (when completed in September 2000 by FLS Miljo) with a 38MWe output from 26.3tonnes/hour of wheat straw. Fuels that can be used by Binder boilers include sawdust, wood shavings, waste wood from furniture manufacture, forestry and arboricultural residues, bark, Lanesborough Power Station, Ireland — client Electricity Supply Board. This is reclaimed wood, energy crops, pomace and other food processing residues. a peat-fired plant burning 180 tonnes/hour and built in 1983.

Examples In 2006 Wood Energy Ltd installed a 1.65MW Binder boiler at Strabane Mills in County Tyrone. The boiler produces up to 2,000kg/hour of steam at 10 bar(g) for process heat demands at the animal feed mill. The system uses locally derived wood chip fuel (up to 55% moisture content) from a range of sources including sawmill residues and short rotation coppice. The boiler has a fully automatic cleaning system for the heat exchanger tubes and exhaust gas recirculation to allow the combustion temperature to be controlled. The Binder equipment also incorporates an exhaust gas cyclone to remove fly ash.

Contact UK supplier Contact Binder Wood Energy Ltd Bioener ApS

T +43 31 42 22 54 4 T 0845 070 7338 T +45 72 17 00 15 E [email protected] E [email protected] E [email protected] W www.binder-gmbh.at W www.woodenergyltd.co.uk W www.bioener.dk 28 29 Bioflame Biomass CHP Ltd Bioflame is an environmental engineering company, set up in Biomass CHP Ltd is a manufacturer of biomass gasification 2001 to develop a clean burn system for waste destruction. systems based in Northern Ireland. The technology was The initial burners were used in Central America and burnt coffee developed under the previous names B9 Energy Biomass Ltd husk waste to provide heat for drying coffee. In the UK, the and Exus Energy Ltd. system has been developed to be fully compliant with all relevant legislation. Three heat-only plants have been established burning food waste, agricultural production waste and railway sleeper waste respectively.

Category CHP Gasification/pyrolysis Category CHP Gasification/pyrolysis ACT Gasification ACT Gasification

Technical data Capacity 1–3MWe (0.5MWe demonstration plant), up to 7MWth Technical data Capacity 3,200 tonnes wet wood per year Fuel Wood waste (MDF, chipboard, plywood, painted wood, laminated Output 300kWe electricity and 300kWth hot water wood) and clean waste timber (old pallets and off-cuts from timber Fuel Fresh wet woodchip manufacture) Output Hot air, hot water or steam. Equipment & Biomass CHP has developed a process based on down-draught gasification of technology wood and power generation using a high performance gas engine. Biomass CHP's Equipment & The patented Bioflame ATTU (Advanced Thermal Treatment Unit) has high efficiency gasifier and gas cleaning system produces gas that is sufficiently technology a combustion temperature in excess of 1100ºC and uses the residence chamber to clean to facilitate continuous operation of a high efficiency gas engine driving allow for 3.9 seconds of residence time for the combustion process. The process is a generator. Typical units are sized in the 200kWe to 300kWe output range with fully WID compliant. the same level of heat production, although larger plants can be built in a modular form utilising multiple gasifiers and larger engine/generator sets. Variety of feedstock — currently projects are specified to use low grade wood waste in the UK as the current legislative climate makes wood waste the most Heat from the process is used to dry the wood and to pass out to other applications attractive and appropriate waste to turn into electricity, but the technology can be such as space heating. The process is environmentally friendly, efficient, is fully used for any agricultural, organic and process wastes. automated and can run unattended for extended periods. There is no liquid effluent and the exhaust gas meets UK Clean Air Act Examples Bioflame commissioned its 0.5MWe output demonstration plant, in Pickering, requirements. in January 2008. The plant burns locally sourced low grade wood waste that would otherwise go to landfill. The system burns under Waste Incineration Directive Examples Commercial plant is installed in Larne, Northern Ireland, with a capacity of 300kWe (WID) conditions and therefore the presence of these contaminants does not and 300kWth. It uses 3,200 tonnes per year fresh wet woodchip. It will produce affect the ultimate “clean” emission from the system. The heat generated from 1.8GWhe and 1.8MGhth per year. Higher outputs would be available if dryer fuel the combustion unit is fed into a boiler, which in turn generates steam to power were to be used, up to 600kWth output. The standard plant cost £700,000, and a steam turbine. At this particular site the boiler produces around 6.5 tonnes comes containerised, as five standard 40’ containers, three mounted on the ground of steam and the turbine and generator set will produce around 0.6MW of and two above. electrical power. Bioflame has built a £2.5m demonstration power station running on local wood waste at its base within the North Yorkshire National Park with the help of FEY and Yorkshire Forward. This site is fully commissioned and exporting electricity to the National Grid. The company looks for partners with access to a fuel supply of 28,000–30,000 tonnes/yr to form a joint venture company for power generation.

Contact Bioflame Ltd Contact Biomass CHP Ltd T 01751 472 831 E [email protected] W www.biomasschp.co.uk 30 W www.bioflame.com 31 Biomass Engineering Ltd Bono Sistemi Biomass Engineering Ltd is a volume producer of biomass Bono Sistemi designs and manufactures biomass-fired steam gasification systems with full design and manufacture in-house generators and thermal fluid heaters using a variety of waste fuels from a purpose-built 90,000 square feet facility in the north such as olive husks, rice husks and woodchip. The plant is most west of England. The system has been developed over 15 years, applicable to the food and the , where the production originally by Shawton Engineering, and is now fully commercialised. wastes, such as wood chips, sawdust, husks, etc. can provide fuel for both process heat and electric power. The boilers are also suitable for CHP application on district heating schemes.

Category CHP Gasification/pyrolysis Category Boilers Thermal oil, steam ACT Gasification CHP Steam turbine

Technical data Capacity Standard range is 250–275kWe, 450–600kWth, and multiple Technical data Capacity Steam boiler: 3.5MW–45MW modules thereof Thermal oil generator: 3MW–12MW Fuel Wide range of clean wood biomass feedstocks District heating: 0.6MWe and 2.8MWth to 2MWe and 8.7MWth Output Hot water and electricity Fuel Woodchip, sawdust, rice husks, olive husks, bark, grape residue and sorgum Steam Pressure: up to 50 bar Equipment & The technology is a down-draught gasifier combined heat and power system in Temperature: up to 450ºC technology a standard, modularised format. It is coupled with a gas engine. Clean biomass fuel Saturated steam: 5t/h to 60t/h at 10 to 20%mc is fed into the top of each gasifier at a rate of approx 250kg/hour. Temperature in/temperature out: 250ºC/300ºC The gasifier has pyrolysis, oxidation and reduction sections whereby the fuel is gasified. The resulting gas is cleaned using ceramic filters, which are purged using Equipment & A variety of fuel feed systems allow a range of fuels to be used. The reciprocating nitrogen. It is a low tar gas produced by careful pressure control. The cooled gas is technology gate is state of the art combustion technology suitable for any kind of biomass, fed to spark ignition gas engines with generators. The waste heat from these can ranging from high moisture content dump waste or virgin wood, dusty biomass and form the heat output into the heat mains. The resulting waste char and dust is low specific gravity feed stock (such as rice husk). collected in containers. The system is fully automatic and has a fully computerised control system. Examples We understand that there are no installations from this manufacturer in the United Kingdom. Examples Merthyr Industrial (Biomass) Services Ltd. A multi module 1MWe wood gasification plant in an industrial unit in South Wales. The plant exports renewable electricity to the grid and has the capacity to provide heat for use elsewhere on the industrial estate. The site comprises a fuel feed system, four gasifier and filter modules, gas cleaning and cooling skid, two wet electrostatic precipitators and 2 x500kWe Jenbacher engines. Other sites are in operation in the UK and Germany, and works are progressing at entering the markets in Italy, and Latvia. Visit this address to see a video of a working plant: www.youtube.com/user/BiomassEngineeringUK

Contact Biomass Engineering Limited Contact Bono Sistemi T 01925 295 959 E [email protected] T +39 02 55 30 28 48 W www.biomass.uk.com W www.bono.it 32 33 Byworth Boilers Danstoker Byworth Boilers are based in the UK and have been manufacturing This Danish firm have been making biomass boilers for 50 years boilers for over 35 years, and have a large fleet of trailer-mounted (they also produce fossil-fuelled boilers). The company has been hire boilers. The packaged boiler systems are traditional three in operation for 75 years and sells boilers around Europe. They do pass wetback shell boilers for industrial process applications and not manufacture combustion systems or feed systems and normally commercial heating. Their boilers can be supplied with burners from supply their boilers to other companies who provide a turnkey a range of manufacturers. Mobile truck-mounted boiler systems are design, supply and installation service. also available.

Category Boilers Steam Category Boilers Steam

Technical data Capacity Up to 12MW (hot water), 18t/hour (steam) Technical data Capacity Steam boilers: from 300kg steam/h to 35,000kg steam/h and a design Fuel Wood pellets, biogas, waste heat, fossil fuels pressure up to 32 bar Output Hot water, steam Fuel Forest residues, bark, sawmill/construction waste, sawdust, wood pellets, fruit stones, straw and agrifibres, textile waste (every boiler is adapted to suit the special characteristics of the fuel to be used) Equipment & The Byworth range includes oil and gas-fired hot water and steam boilers as well as technology waste heat boilers. There is a wood pellet boiler currently under development. Equipment & Danstoker has specialised in horizontal and vertical bio-fuel boilers. The range Byworth Boilers are the only boiler available in the UK to offer X-ID high efficiency technology includes hot water boilers, high pressure hot water and steam. The boilers vary boiler tube. Heat transfer from tubes to water is increased by over 80%, adding, for different sizes and purposes with triple pass fire tube boilers being used for usually, over 2% to overall boiler efficiency. hot water and, if required for steam raising, these are combined with water-tube sections for operating pressures up to 30 bar. Typically, the boilers are fitted with Examples Byworth have been working with the Regional Development Agency for the the Danstoker automatic pneumatic cleaning system. Yorkshire and Humber region, Yorkshire Forward, to develop a wood pellet-fuelled The Danstoker steam boiler, type DHF, is a 3-pass fire-tube boiler with open boiler. It is based on a proven design of coal boiler. The project includes the bottom and well-dimensioned furnace-tube with cylindrical upper part, intended for development of the stoker, ash removal equipment and flue gas grit arrester. combustion of solid fuel. The DHF boiler is designed to give complete combustion They are also engaged in projects to use organic waste such as food processing of the fuel and at the same time optimise the radiant heat in the furnace-tube, waste, whey, distillery “spent wash” and crop waste to produce biogas (from whereas the convection heat is maximised in the two subsequent fire-tube anaerobic digestion), which can be used to fuel their boilers. sections, all of which results in high efficiency and low fuel consumption. Danstoker boilers can operate with stokers, step grates or chain grates. Three boilers have recently been installed at Kings’ College Hospital in London, in a new energy centre. Two of these boilers produce 10,000kgs/hr of steam, utilising heat from the CHP engine exhaust gases. Examples The joinery manufacturer Premdor, in Barnsley, uses a 5MW Danstoker steam boiler producing 7.5t/hr steam at 8 bar.

Contact Contact UK contact Byworth Boilers Danstoker Danstoker UK Ltd

T 01535 665 225 T +45 99 28 71 00 T 07921 773 580 E [email protected] E [email protected] E [email protected] W www.byworth.co.uk W www.danstoker.dk W www.danstoker.dk 34 35 Doosan Babcock Energy Ltd ENERGOS Ltd Doosan Babcock is a multi-specialist energy services company ENERGOS Ltd is part of the ENER-G PLC group and is the ENER-G operating in the thermal power, nuclear, petrochemical, oil and gas Group’s specialist in gasification technology. It is a leading supplier and pharmaceutical industries. It is also a leading international of small scale, proven energy from waste plants. ENER-G services steam generation OEM (original equipment manufacturer) and include full system design, supply, installation and servicing, supplier of clean, efficient coal-powered technology. Doosan working with the food & beverage, pharmaceutical, paper and Babcock has a long history of licensing its technology, which automotive industries. includes large power plant co-firing technology with 20–25% biomass heat input co-fired with coal, and small scale fluidised bed technology combusting 100% biomass for process heat.

Category Boilers Steam Category CHP Gasification ACT Gasification Technical data Capacity 5MWe to 50MWe Fuel A wide variety of fuels can be handled, if consistent in quality and size Technical data Developed for energy from waste requirements. Gasification on an Output 30–180t/hr of steam at up to 110bar pressure innovative duplex grate in modular form. steam generator for thermal customer or integral power generation use. Equipment & Doosan Babcock biomass technology uses bubbling bed fluidised boilers and is Output Standardised boilers can deliver saturated steam or for superheated technology suitable for the generation of steam for process or power generation. Steam outlet steam (21/39 bar, 380ºC). Boilers with other steam parameters conditions typically range from saturation up to 520ºC. can be provided. Capacity Type 41 (13.5MWth/3.1MEe) and type 51 (16.4MWth/4.1MWe) Existing examples of biomass fuels used include waste from the sugar industry Waste Each line can utilise 40,000 tonnes of waste or SRF, multiple line (cane and beet), woodchip and bark, agrowaste, sludge. Municipal waste cannot applications available to 160,000 tonnes. Very low emissions with be handled unless it is pelletised. flue gas cleaning system. Examples A current ongoing project is the supply of a fluidised bed boiler to produce 55te/hr of steam at 64bar pressure and 460ºC boiler for a whisky distillery in Scotland. Equipment & ENERGOS energy from waste plants has a patented two-stage thermal conversion The fuel is the spent grain from the distillery. The steam is used for process, technology process. Drying and gasification of the fuel is carried out in the primary chamber however if used for power generation would probably generate about 10MWe. under sub-stoichiometric conditions. The synthetic gas generated in the primary It is due to be commissioned in 2010. chamber is transferred to a separate secondary chamber where final high- temperature oxidation takes place. A proprietary software system monitors and controls the process. Recovered energy is converted into hot water or steam for delivery of district heating, process steam and/or electricity. ENERGOS plants are built as a modular approach with one or more processing lines in parallel to meet customer requirements regarding energy production and fuel processing capacity.

Examples ENERGOS have constructed a plant on the Isle of Wight to add to the seven already operational plants in Norway and Germany. The plant will generate electricity from the 30,000 tonnes of residual waste being processed at the Island Waste Services resource recovery facility.

Contact Doosan Babcock Energy Limited Contact ENERGOS Ltd T 01293 612 888 E [email protected] T 0845 683 7001 W www.doosanbabcock.com W www.energos.com 36 37 Entimos Eratic Entimos Ltd was founded in 1997 and produces wood gasifier- Eratic SA, and its sister engineering company, CIS Engineering, based combined heat and power plants. Wood gasification has have been trading for over 40 years. As well as manufacturing and a long history in Finland. The basic idea of the original two-stage maintaining biomass boilers, Eratic produce incinerators, gasifiers wood gasification system was developed by the late Kustaa Saares. and heat exchangers. The first prototype was developed in 1981, the second in 1996, in co-operation with VTT Energy and the University of Oulu, Finland.

Category CHP Gasification Category Boilers Thermal oil, steam ACT Gasification Technical data Capacity 116kW–14MW Technical data Capacity Approx 1,300kW fuel input Fuel Waste wood (bark, sawdust, MDF, etc.), waste paper, food waste, Output 300kWe/650kWth agricultural residues, animal wastes, industrial residues (contaminated Fuel Woodchip liquids, paint sludge, etc.) Output Electrical generation: 200kWe–6MWe Equipment & Uses a patented gasifier technology using combined up-draught and down- technology draught gasification and producing two gas streams. The tar-heavy stream forming Equipment & Eratic SA manufactures and installs a wide range of boilers and associated the “counter flow” is burnt directly to produce heat for the heat mains. The cleaner technology equipment, which are applicable in the following sectors: food, chemical, gas from the “forward flow” goes to a gas engine to produce electricity. pharmaceutical, paper, furniture, hotel, hospitals, laundry, textile, construction, The company’s own design feeding, grate and ash removal systems are in use. car, metal, petrochemical, residues management, agricultural and naval. Wood chips are gasified in an Entimos-gasifier and the produced gas is used in an engine/generator set, which produces 300kW (net) of electricity and 650kW Examples We understand that there are no installations in the United Kingdom. (net output) of heat. The electricity is directed to the national grid and the heat is used in district heating and for fuel drying.

Examples Lestijarvi CHP plant located in a small municipality in central Finland uses Entimos gasifier technology to produce gas for the combined heat and power scheme. It has been in operation since March 2008. Gross output is 400 kWe, net output is 300kWe and 650kW of heat is also exported to the district heat mains. The plant is operated by the local wood co-operative. Tervola CHP bio power plant in Finland was built in 2001 with a capacity of 470kWe and 1.13MWth to the district heating mains with an overall efficiency of 81.5%. Investment cost was €1.3m in 1999.

Contact Contact Entimos Eratic

T +358 (0) 40 54 76 62 0 T +34 96 15 48 516 W www.entimos.fi W www.eratic.es 38 39 Ethos Energy Foster Wheeler Global Power (Foster Wheeler Energia) Ethos Energy is a sister company to Ethos and is Foster Wheeler is a global company with two groups: Engineering a technology and energy business operating in the waste sector, and Construction Group and Global Power Group. Foster Wheeler producing energy from waste using the processes of pyrolysis and Global Power produces boilers for heat and electricity generation gasification. Ethos Energy's technology is a continuous process, based on bubbling fluidised bed (BFB), circulating fluidised bed utilising the advantages of pure pyrolysis, followed by gasification (CFB) technologies, with over 140 BFB boilers and 210 CFB units of the resulting char. in operation.

Category CHP Gasification/pyrolysis Category Boilers Steam ACT Gasification CHP Gasification ACT Gasification/pyrolysis Technical data Capacity From 1MWe/5MWth–7MWe/25MWth Fuel Broad waste streams can be used (MSW, clinical, industrial, sewerage, Technical data Capacity Gasifiers, fixed bed and fluidised bed up to 10MWth and up to etc.) Licensed for over 80% of the European Waste Catalogue 150MWe, industrial grate boilers — up to 270t/h steam Output Heat and electricity Fuel Gasifiers — biomass, industrial and municipal waste, plastics, waste paper and construction wood waste circulating fluidised bed boilers (CFB) — high moisture content waste with low emissions. Equipment & Ethos Energy's technology is a continuous process, utilising the advantages of pure Industrial grate boilers, bubbling fluidised bed boiler, high moisture technology pyrolysis, followed by gasification of the resulting char. The technology is available content fuels in the following sizes: Output Electricity, steam — ST150 – small-scale unit (1,000tpa) initially developed for use on Royal Navy ships, but ideally suited to on-site waste processing. Best suited to locations with Equipment & The (BFB) technology is ideal for firing with high moisture content and a heat load, up to 400 kW could be available for on-site processes. technology difficult ash characteristics, or fuels that are difficult to handle, such as sludges. — MT4 – suited to a small flow (up to 15,000tpa, but typically less) of high value It can be applied effectively as a boiler retrofit for older stoker boilers and recovery waste, such as clinical waste or on-site disposal of industrial wastes. It has the boilers. The (CFB) combustion process has the capability to fire a broad range of potential to generate up to 1 MWe and approximately 5MWth. fuel qualities from low-grade high-ash fuels, good quality bituminous and anthracite — MT8 – designed for larger waste flows typically found in the municipal waste to various biomass and waste fuels with low emissions. The CFBs can also market. It is designed for 30,000tpa (gate receipts may be 20% higher in capture sulphur as the fuel burns and use low-cost selective non-catalytic reduction volume if combined with Eco Drying system) and is capable of exporting 3MW (SNCR) to achieve ultra low NOx and SOx emissions in the furnace without the need of electricity and up to 11MWth of low grade heat. for additional flue gas cleaning equipment. Gasification technologies for use in lime — MT16 – designed to treat a sizeable proportion of larger settlement residual kilns include fixed bed, fluidised bed and entrained flow gasification. MSW arisings. It can accept 60,000tpa of waste (gate receipts may be 20% higher in volume if combined with Eco Drying system), and can export up to 7MWe and 25MWth of low-grade heat. The plant consists of two parallel Examples Sembcorp power station (30MWe), Wilton, Teeside — Foster Wheeler designed, MT8 lines. built and commissioned the complete boiler island including the fuel handling system, the biomass-fuelled (BFB) boiler (Foster Wheeler Global Power Group’s BFB biomass boiler), and the flue gas treatment system. The plant burns about 300,000 Examples Avonmouth — The original Avonmouth Plant (A1), designed and built by Compact tonnes of wood per year from various sources including green and recycled wood. Power (now Ethos Energy), has been successfully operating since 2001. Ethos Recycling Ltd has operated A1 since January 2008. No electricity is generated at A1 because Ethos can reclaim approximately five times more energy in the form of steam for sterilisation than it could by using the same steam in a turbine (to create electricity). The plant produces around 2MWth. Contact Contact UK supplier Ethos Energy Foster Wheeler Global Power Harry Lampenius

T 0844 844 1306 T +35 81 03 93 11 T +35 81 03 93 61 37 E [email protected] W www.fwc.com E [email protected] 40 W www.ethosenergy.co.uk 41 Graveson Energy Management (GEM) Hollensen Energy (Focus Energy) Graveson Energy Management Ltd (GEM) has developed an A Danish knowledge-based, project-oriented manufacturer advanced thermal conversion system that recovers energy from operating for 30 years, mainly supplying Scandinavian markets a wide selection of waste materials. They were chosen by DEFRA but now extending to rest of Europe. The company is not simply an to construct a demonstrator unit at Scarborough that will divert equipment supplier but rather a full turnkey/consultancy company. 18,000 tonnes of Municipal Solid Waste (MSW) from landfill Hollensen developed a demonstration 1MW pilot biomass down- and provide electricity and locally utilisable waste heat using draught gasification CHP plant in the 1990s. The CHP supplies pyrolysis technology. electricity to the grid and heat to the Hogild village heating company in Denmark.

Category CHP Gasification/pyrolysis Category Boilers Steam ACT Pyrolysis Technical data Capacity 400kW–15MW Technical data Fuel The process can accept a wide range of feedstock materials from Fuel Wood, timber residues and waste wood from processing domestic (MSW), industrial and agricultural sources such as sewage Output Steam sludge, rubber crumb, waste oils and other liquid waste, foodstuffs and rendered animal by-products, bio-crops, treated and clean wood. Equipment & Dry wood systems, useful for the wood working industries, in the performance The fuel specification is simply a small particle size (<2mm in one technology range of 400kW–3MW are based on the Biomaster P Boiler with horizontal piping plane), with a moisture content range of 5%–8% — a compact, efficient installation which is suitable for new or existing buildings Output Synthetic gas or transportable containers. Installations that generate 4MW or more are based on the Biomaster boiler, which uses vertical piping. Equipment & GEM’s advanced thermal conversion process is described as “flash pyrolysis”. Plant uses dry such as pellets, briquettes, dry woodchip, sawdust and technology It is the chemical decomposition of feedstock by intensive heat in the absence of shavings, or crop fuel in the form of cut straw, pellets, seed waste, grain and other oxygen, also known as “destructive distillation” or “cracking”. This has been widely granulated biomass product suitable for incineration. used in the petro-chemical industry for many years. The converter module has been designed to convert 1.5 tonnes per hour of suitable feed material into gas on There are also wet wood systems suitable for the timber processing industries. a continuous basis. Prepared fuel is continuously fed in via an auger mechanism Focus Energy supplies hot water, high pressure hot water and steam boilers that where heat instantly penetrates the particles, efficiently cracking them into cover an output range of 400kW to 15MW. The boilers are designed to match a synthetic gas. The gas is retained within the converter for up to 50 seconds to customer requirements and are adapted to suit specific demands. Woodchip fuel maintain the heat transfer and maximise efficiency. It is then cooled and cleaned with a moisture content of 25–60% can produce efficiency levels in excess of before use. 100%, through extracting heat from flue gases.

Examples Scarborough Power, Seamer Carr, Scarborough is GEM’s first full-scale plant in Examples No information is currently available. the UK. It was part of DEFRA’s New Technology Demonstrator Programme and can process 25,000 tonnes of unsorted Municipal Solid Waste per annum. It is a pyrolysis plant (including fuel store, dryer and thermal oxidiser) producing 2MW of electricity per hour and 2.5MW of heat per hour (1.8MW net heat output available for potential local utilisation). The GEM technology converts waste into a synthetic gas through pyrolysis, which is then used in a reciprocating engine to generate renewable power. The GEM process can be used on any carbon-based waste. Commissioning was completed in February 2009.

Contact Contact Graveson Energy Management Focus Energy

T 01639 864 611 T +45 97 14 20 22 W www.gem-ltd.co.uk W www.focusenergy.dk 42 43 ICI Caldaie Imtech ICI Caldaie was established in 1958 to manufacture steam boilers. Imtech is a large European technical services provider in the Since then, the company has been developing hot water and fields of electrical engineering, ICT and mechanical engineering. thermal oil boilers for the domestic, commercial and industrial Imtech has an annual turnover of more than €3.8 billion and over sectors. The company has offices in Italy, UK, Spain, , 22,500 employees. The biomass engineering is in two divisions, Romania, Kazakhstan and Ukraine. Their Verona facility houses one centred in the Netherlands (Imtech Industrial) and one in a training centre that provides courses on steam and hot Munich, Germany (Imtech Deutschland). The UK arm specialises water boilers. in advanced biogas from sewage systems.

Category Boilers Thermal oil, steam Category Boilers Steam CHP Steam turbine Technical data Capacity 12.5kW–5.8MW Fuel Woodchip, wood pellet, logs, sawdust, nut shells, rice husk, coconut shell Technical data Capacity 1–5MWe and a thermal power of 5–20MWth Output Hot water, thermal oil, steam Output Electricity and hot water, steam Fuel Wood, biomass and municipal waste Plus Biomass steam-based CHP systems Equipment & The commercial biomass range includes wood pellet boilers and gasifying log Both moving grate and fluidised bed combustion systems technology boilers up to 110kW and woodchip boilers up to 1.2MW. High pressure water tube boilers The Biotherm range of boilers provides LTHW, MTHW and steam with a range Heat from steam condenser and flue gas condenser of duties from 348kW to 5.8MW or 500kg/hr to 8,333kg/hr. Biotherm US — Underfed stoker for fuel with moisture content <30% Equipment & Imtech Industrial (formerly Imtech Vonk) supplies biomass/wood-fired combined Biotherm SG — Screw fed for fuel with moisture content <55% technology heat/power installations with an electric power of 1–5MWe and a thermal power Biotherm LF — Hydraulic ram feed for fuel with moisture content <60% of 5–20MWth. Imtech in Germany supplies large combined heat and power systems including wood, biomass and waste-fuelled systems, mostly for district As well as hot water boilers, ICI Caldaie manufactures fossil fuel steam boilers up heating and utilities. to 20,000kg/hour and the associated equipment such as boiler blowdown vessels, calorifiers and feedwater treatment plant. Examples Vink Sion greenhouses, Netherlands, biomass steam CHP system producing ICI Caldaie has also supplied waste heat recovery boilers to water companies in 1.15MWe, 5.3MWth using a high pressure 55bar water tube boiler. the UK to produce steam from the exhaust gas of biogas engines. They can also provide boilers that use biogas and biodiesel. Heligenkreuz biomass CHP plant Austria, using a fluidised bed, output 10MWe, 12MWth, input 150,000 tonnes per year of wood chips. Examples There are two steam raising biomass boilers rated at 3.5t/hour currently The are no examples of biomass systems in the UK at present, although Imtech (November 2009) being commissioned at Wythenshawe Hospital, Manchester. UK have installed a fossil-fired district heating scheme for the Church End Estate, Brent, London.

Contact UK contact ICI Caldaie ICI Caldaie Ltd Contact UK contact Imtech Industry International Imtech UK Ltd T +39 04 58 73 85 11 T 0161 743 9595 E [email protected] E [email protected] T +31 (0) 52 45 99 22 2 T 01784 229 900 W www.icicaldaie.com W www.imtech.eu E [email protected] 44 45 Inetec TherMec ITI Energy Ltd Inetec is a specialised company with patented “abrasive drying” ITI Energy Ltd manufactures a compact and highly efficient technology for converting food waste and non-recyclable thermal conversion technology based on an advanced gasification packaging into heat energy. design. Combined with the most up to date, commercially available, gas clean-up systems, the technology generates a synthetic gas that is clean enough to fuel an internal combustion engine.

Category Boilers Steam Category CHP Gasification/pyrolysis ACT Gasification Technical data Capacity 2–8 tonnes per day of waste Fuel Food waste and non-recyclable packaging waste including a variety of Technical data Capacity 1.7MWe and 2.0MWth feedstock (food wastes, food sludge and slurry, sauces, out of date Fuel Difficult or negative value feedstock, e.g. leather waste items, non-recyclable card, paper and some plastics), reducing waste to Output Gas for CHP landfill by up to 80% Size 12m x 4m (approx 12m high) Output Either heat on site or fuel for off-site use Cost Low costs show return on investment within 3 to 4 years

Equipment & On-site method for converting food and non-recyclable packaging into energy Equipment & The synthetic gas would power an internal combustion engine to drive an technology and a mechanical process that can handle a wide variation of waste stream technology electricity generating plant and the heat available from the exhaust can be components. exported as hot water and used for district heating as part of a combined heat and power (CHP) scheme, for industrial processes or to enable further power generation Thermec 2000 — daily processing capacity, 2 tonnes (at 50% MC); biomass fuel from an Organic Rankine Cycle (ORC) process. produced, 1 tonne. Operating cycle 24 hours. Energy 0.6MWth. Cost without energy recovery, £250,000; cost with energy recovery, £600,000. The technology was developed at Newcastle University, over ten years, to produce a compact gasifier specifically designed to handle a wide range of “difficult” or Thermec 4000 — daily processing capacity, 4 tonnes (at 50% MC); biomass fuel negative-value feedstock and is particularly suited to the conversion of refuse- produced, 2 tonnes. Operating cycle 24 hours. Energy 1.7MWth. Cost without derived fuel (RDF) into energy. energy recovery, £400,000; cost with energy recovery, £800,000. Thermec 8000 — daily processing capacity, 8 tonnes (at 50% MC); biomass fuel Examples North Derbyshire project — two ITI gasifiers with internal combustion engines produced, 4 tonnes. Operating cycle 24 hours. Energy 3.0MWth. Cost without generating 3.2MW net output from locally sourced RDF feedstock, including 70% energy recovery, £700,000; cost with energy recovery, £1,200,000. biomass. There is a framework agreement with this client to develop a total of six sites using ITI technology.

Contact Contact Inetec ITI Energy

T 01656 746 439 T 01142 541 233 E [email protected] E [email protected] W www.inetec.co.uk W www.iti-energy.com 46 47 James Proctor Ltd Justsen Energiteknik A/S James Proctor Ltd is a fifth generation family business established Justsen is based in Denmark and has been providing whole in 1875. They began with coal-fired technology but extended into system solutions since 1960. They have supplied more than biomass-based technology approximately 11 years ago. 2,500 biomass heating plants to customers in Europe, North, South and Central America.

Category Boilers Steam Category Boilers Steam

Technical data Chain grate stokers and reciprocating grate stokers Technical data Capacity 300kW–15MW Output 500kW–6MW for process steam or CHP Fuel Woodchip, wood pellets and briquettes, clean wood waste, contaminated wood waste, bark, peat, grain, husk Reciprocating grate stokers and bubbling fluidised bed combustion Output Hot water, thermal oil, steam (low pressure and high pressure) Output <12MW, 20t/hr steam and 2MWe CHP Fuel Woodchip up to 70% moisture content, wood pellets Output Hot water, steam, CHP Equipment & Justsen boilers can burn a range of materials from clean wood pellets and high technology moisture content wood waste to contaminated wood waste and grain husks. They manufacture 3 pass and 5 pass boilers, underfed stokers, watercooled James Proctor has developed an efficient, cost effective boiler package which Equipment & moving grate systems, fuel handling equipment, automatic de-ashing systems enables high moisture content biomass to be utilised as a low cost, environmentally technology and filtration equipment. friendly fuel. Their burners incorporate advanced controls, firebreak units and variable speed drives to give unrivalled fuel savings and maximum efficiencies. Justsen systems have been applied to district heating systems, process steam requirements and waste combustion. A 1MW test boiler installed in their factory enables a customer to trial their fuel as a demonstration. The use of water cooled grate systems allows the boiler temperature to be controlled, allowing the use of a wide range of fuels of differing moisture contents. Examples No examples are available in the UK, but James Proctor has recently commissioned a wood pellet-fuelled system in Forssa, Finland producing 2MWth steam for Examples No examples are available in the UK, but Justsen commissioned a biomass- a textile facility. fuelled steam raising boiler at Atlantic Industries (part of the Coca-Cola Export Corporation) in Drogheda, Ireland in 2007. The boiler provides up to 6.3t/hour of process steam at 7bar. The 3 pass boiler has an open bottom and cylindrical steam drum and the moving grate is water cooled to ensure constant temperature. See case study at www.justsen.dk/00028/

Contact Contact Justsen Energiteknik A/S James Proctor Ltd T +45 86 26 05 00 T 01282 453 816 E [email protected] W www.jamesproctor.com W www.justsen.dk 48 49 Kablitz and Mitthof KARA Energy Systems (BIB Cochran) Kablitz and Mitthof designs and delivers mainly energy centres for KARA Energy Systems is a global supplier of biomass combustion the combustion of solid fuels "biomass" including fuel conveying systems, specialising in the conversion of solid fuels into energy and feeding systems, grates, combustion chambers, removal and and the manufacture of fuel handling, combustion and clean up cleaning systems and boilers. It was established in 1901, originally technology. BIB Cochran manufactures the boiler system. manufacturing heat exchangers. Heat exchangers are still used in the biomass plants, which allow fuels with low calorific values to be burnt efficiently. Kablitz plants are used in any industries burning waste wood to provide the production either with saturated or overheated steam or hot water.

Category Boilers Thermal oil, steam Category Boilers Thermal oil, steam

Technical data Capacity Up to 40MW and beyond, as specified by client Technical data Capacity 370 kW–15MW Outputs Steam pressure up to 110 bar/temperature up to 510ºC and thermal oil Fuel Dry fuel (flakes or sawdust from dried wood, fibre board, paper, card, Fuel Wood chips, bark, chipboard, medium density fibreboard, waste wood, etc.) — 8%–25% moisture content rice husks, olives stones, other solid biomass Output Thermal oil, steam (can be used with steam turbine for CHP) Feed water temperature 100OC to 190OC Dry underscrew furnace, wet underscrew furnace, fixed sloping grate, hydraulic flat grate, sloping hydraulic moving grate, cyclone burner Equipment & The biomass-fired steam boilers can be built vertically or horizontally, and can be Fuel Small wood particles with 25–40% moisture content, large wood technology as large as 30m tall/long. Steam is produced within a water tube boiler with natural particles with 20–60% moisture content, high ash content fuel, slow circulation. Kablitz delivers whole power plants including fuel feeding system, burning materials, with 30–70% moisture content thermal capacity up combustion and boiler system, ash removal system, flue gas cleaning, steam to 5MW, fine sawdust or dust with moisture content of up to 15% turbine and generator, piping for water and steam, steel construction, assembly and commissioning. Equipment & KARA Energy Systems B.V. supplies various types of incineration systems for all technology kinds of (biomass) wastes. Every installation is custom-made. Installations are Examples Kablitz and Mitthof have designed and delivered over 500 boiler grate systems and based on KARA Energy Systems B.V. designs. A variety of furnaces are available five power stations. A UK example is at Kronospan board mill at Chirk, Wrexham, depending on the fuel requirement. A range of boilers are available providing hot which is fired with virgin timber. water or steam, with pressures up to 20 bar and include a thermal oil boiler for high temperature (200–300ºC) applications. Other examples are given on the website.

Examples Slough Heat and Power — Slough’s energy centre has a multi-fuelled BIB Cochran vibrating grate boiler, fired by wood and fibre fuel (paper and cardboard based), drives a 12MW pass-out steam turbine and two woodchip-fuelled Foster Wheeler fluidised bed boilers that drive a 35MW steam pass-out turbine. The Energy Centre generates 270GWh/yr which is sold via a Non-Fossil Fuel Obligation contract.

Contact Richard Kablitz and Contact UK supplier Mitthof GmbH KARA Energy Systems BIB Cochran Ltd

T +49 (0) 93 43 79 01 24 1 T +31 54 68 76 580 T 01461 202 111 E [email protected] E [email protected] E [email protected] W www.kablitz.com W www.kara.nl W www.bibcochran.com 50 51 Keppel Seghers KIV Engineering Keppel Seghers is the environmental division of the Keppel A Slovenian company established in 1947, began designing, Corporation and is a provider of comprehensive environmental manufacturing and installing biomass boiler systems 30 years ago. solutions, ranging from consultancy, design and engineering, KIV also develops and produces bespoke WID-Compliant Energy technology and construction, to operations and maintenance of from Waste (EfW) systems. facilities. Their advanced technology solutions address a wide spectrum of environmental issues such as solid waste, biosolids and sludge treatment.

Category Boiler Steam Category Boilers Thermal oil, steam ACT Gasification Technical data Capacity Waste to energy plants up to 70MWth and 12MWe + high pressure steam for process applications, evaporator/combustor for sewage Technical data Capacity 1.3MWth–25MWth sludge up to 200 tonnes/day (at 22% dry solid content) Modul R-H-S Steam boiler up to 16 bar(g) pressure Fuel Mixed industrial waste, municipal solid waste and paper, oily, sewage Rating 1.3MWth–4MWth output (3 models) and chemical sludge, and RDF (refuse-derived fuel) Input Water tube superheated steam boilers up to 60 bar(g) Output Steam pressure (550oC), 12.5MWth to 25MWth input TPVb with firebox Equipment & The ZerofuelTM fluidised bed technology has been successfully applied to various — Steam boiler up to 20bar(g) pressure, 4–12MWth output (5 models) technology kinds of wastes such as municipal sludge, paper sludge, oily sludge, chemical — Steam production of 0.75t/h up to 15t/h sludge, RDF granules, wood residues, de-inking sludge, completely dried sludge, — Water tube superheated steam boilers up to 60 bar(g) pressure (550ºC), sewage sludge, etc. It can be used with or without energy recovery systems (steam, 12.5MWth to 25MWth heat, electricity). Fuel Wide variety from clean wood to sewage sludge Output Hot water, thermal oil, steam, Energy from Waste — gasification Examples Keppel Seghers will provide the technology and also build an Energy-from-Waste Combined Heat and Power Plant (EFW CHP plant) on behalf of Ineos Runcorn Equipment & KIV supplies fully automatic turnkey biomass and EfW WID-compliant systems. TPS Ltd (owned by Viridor Waste Management Limited, John Laing PLC and Ineos technology The EfW systems are based on a proven air-cooled step grate and use a patented Chlor). The plant, to be completed by 2012, will have a capacity to treat up to two-stage combustion furnace design with similar boilers to the biomass systems 420,000 tonnes per year of RDF, and will be able to supply at full capacity some up to 10 –12MWth input. Larger systems use specialist water-tube boilers. 270,000MWh of electricity and 500,000 tonnes of steam per year into the internal The output capacity of the EfW systems is 800kW–25MWth. Four-line plants can network of the Ineos Runcorn site. It features the company’s water-cooled grate, be designed to deal with 200,000t/yr of municipal solid waste/refuse-derived fuel the horizontal boiler design integrated with prism technology, for enhanced heat with a potential output of 26MWe net. KIV’s gasification technology uses the recovery, and double dry flue gas cleaning system. same step grate technology that is used in the biomass boilers.

Examples No examples currently installed in the UK but the technology is installed in various European countries. An EfW WID-compliant plant (18MWth input) has recently been installed in Celje, Slovenia using gasification technology. The plant combusts 37,500 tonnes of municipal solid waste (MSW), mixed with 7,500 tonnes of sewage sludge cake annually. Power output will be 2.4MWe net, plus hot water for approximately 500 dwellings. Contact Contact UK supplier Keppel Seghers UK Ltd KIV Engineering Energia Ltd

T 01902 733 798 T +38 63 70 34 111 T 01684 585 238 E [email protected] E [email protected] E [email protected] W www.keppelseghers.com/home W www.kiv.si W www.kiv-uk.com 52 53 Kohlbach LIN-KA ENERGY Kohlbach is a family owned company based in Austria. Over the LIN-KA ENERGY A/S based in Denmark is one of the world leaders last forty years they have installed over 1,000 biomass boiler within the field of biomass heating and steam-raising plants. plants throughout Europe. Kohlbach is represented in the UK The company has over thirty years of experience and know-how and Ireland by Buccleuch BioEnergy Ltd. Applications include hot on the combustion of biomass and also has particular expertise water, thermal oil and steam boilers for use in individual space with the utilisation of straw. heating, district heating, combined heat and power and process heat applications.

Category Boilers Thermal oil, steam Category Boilers Steam

Technical data Capacity 300kWth to 10MWth Technical data Capacity Steam 200kW–5MW Oil 150ºC–300ºC (up to 9MW) Capacity District heating 1.5MW –5MW, 1.5MW–10MW Steam 0.5 bar–40 bar (saturated and super heated) Fuel Woodchip, pellet and straw Fuel 10–60% moisture content. Woody biomass (such as woodchip, Output Hot water, steam bark and sawdust) Containerised 400kW–3MW Containerised 400kW–1.6MW Equipment & Applications for LIN-KA boilers include hot water, steam, district heating and Equipment & Kohlbach boilers utilise moving grate technology. Their scope of supply also technology containerised systems. Hot water plants are primarily used for space heating. technology includes flue gas treatment using flue gas condensation, cyclone filters, Steam plants are intended for process industry where higher temperatures or electrostatic filters or fabric filters as appropriate. Thermal oil boilers with exit pressures are required, e.g. within the food and beverages sector, laundries, etc. temperatures in excess of 200ºC can be supplied with economisers. Steam boilers are available that can provide saturated or super heated steam. Kohlbach can also The heating plant is for use in towns or communities for establishing or expanding supply the balance of plant required for the operation of their steam boilers (e.g. a district heating system. feed-water pumps, tanks). Kohlbach CHP systems use either Organic Rankine Cycle technology (up to 1.6MWe) or steam technology (steam turbine or steam engine) Examples There are no examples of LIN-KA steam boilers in the UK. However, there are up to 32 bar. a number of operational systems in Scandinavia.

Examples Buccleuch BioEnergy Ltd has installed a number of Kohlbach boiler systems in the UK providing space heating and domestic hot water. One example is the 1.5MW boiler at Queen Margaret University campus in Musselburgh near Edinburgh (35- acre campus with biomass district heating scheme using wood fuel with a moisture content of 60%). Examples of process heat, steam and combined heat and power are located in mainland Europe and there are over 40 examples of Kohlbach plants using thermal oil boilers and ORC units.

Contact UK supplier Contact UK supplier Kohlbach Buccleuch BioEnergy Ltd LIN-KA ENERGY A/S Manco Energy Ltd

T +43 (0) 43 52 21 57 0 T 0131 561 5000 T +45 97 34 16 55 T 01430 828 660 E [email protected] E [email protected] E [email protected] E [email protected] W www.kohlbach.at W www.buccleuch-bioenergy.com W www.linka.dk W www.mancoenergy.com 54 55 Martin GmbH Mawera Martin GmbH is based in Munich, Germany and has been actively Mawera is now part of the Viessman group and has been supplying involved in the construction of energy from waste plants for 80 biomass boiler systems since 1975, with over 4,000 systems years. The company also works with all associated components installed throughout Europe. There are around 40 installations and systems, including heat recovery boilers and flue gas cleaning in the UK with a total installed capacity of around 80MW. systems. There are over 670 installations worldwide for the Their services include full system design, supply, installation combustion of waste. and servicing. Applications include CHP, district heating and industrial process heat. Mawera has a test facility to carry out product research and development and testing and evaluation of clients’ fuel.

Category Boiler Thermal oil, steam Category Boilers Thermal oil, steam CHP Steam turbine Technical data Capacity 100kWth–15MWth Technical data Capacity <70MW Fuel Various from 5%–60% (forest and sawmill residue, bark, wood Output Electricity and heat processing residue, sander dust, shavings, panel board residue, Fuel Municipal solid waste, commercial solid waste, can use wood or straw pellets and briquettes) if mixed with solid waste Output Hot water, thermal oil, steam

Equipment & Martin boilers use air cooled grate combustion technology. The three combustion Equipment & Mawera boilers are available to generate hot water, thermal oil (180ºC–350ºC) technology systems differ in the composition of the combustion air provided: technology and steam and can use wood pellets, sawdust and fines, residue from forestry, sawmill and landscaping activities, bark (hogged and unhogged), wood processing — In the conventional combustion system, underfire and overfire air is fed to the and furniture manufacture residue and reclaimed waste wood (from demolition combustion process and construction). — With flue gas recirculation, most of the overfire air is replaced with recirculated flue gas, after particulate removal They are 3-pass horizontal flame tube boilers with automatic tube cleaning. — The SYNCOM process which features oxygen enrichment of underfire air, Firing systems include air injection (850kW–15MW), underfed stoker (110kW– flue gas recirculation to overfire air, combustion control supported by 5MW) and moving grate (110kW–5MW) depending on fuel to be used. Combined infrared cameras heat and power systems have been based on the Stirling cogeneration system and ORC technology. Examples CNIM offer turnkey project development services and incorporate Martin boilers into energy from waste schemes in the UK. CNIM have built eight energy from Examples Mawera had two steam boilers in the UK. One is no longer in use and the other waste plants in the UK using Martin boilers, including the South East London (4.5t/hr) has been relocated to Italy. Combined Heat and Power Facility (SELCHP). This is capable of handling In 2008 Mawera UK installed a 4.2MW hot water boiler at the main manufacturing 420,000 tonnes of waste from households and businesses per annum and facility of the furniture manufacturer The Symphony Group plc. The boiler, which produces electricity to power around 48,000 homes. Steam leaves the boilers at is fed from a 1000m3 fuel silo, uses up to 5,000kg per hour of waste wood from a temperature of 395ºC and pressure of 46 bar, and is fed directly into a single the on-site operations per hour. The boiler features fully automatic de-ashing and 35MW steam turbine generator. The turbine rotates the generator to produce emissions to atmosphere are controlled by a multi-cyclone grit arrestor. electricity. Steam from the turbine is also used to pre-heat the combustion air for the waste burning process.

Contact UK supplier Contact UK contact Martin GmbH CNIM Mawera Mawera Uk

T +49 89 35 61 70 T +33 49 41 03 00 0 T +43 (0) 55 74 74 30 10 T 01543 258 844 E [email protected] W www.cnim.com/hi/index.htm E [email protected] E [email protected] W www.martingmbh.de W www.mawera.com W www.mawera.co.uk 56 57 Metso Power MW Power Metso is a global supplier of sustainable technology and services MW Power Oy is a joint venture by the globally operating Metso for mining, construction, energy, metal recycling and the pulp (60%) and Wärtsilä (40%). MW Power provides medium and and paper industries. Metso Power manufactures equipment for small-scale power and heating plant solutions for sustainable fluidised bed combustion for the pulp and paper industry and power energy generation and focuses on flexible utilisation of local producers using the combustion of biomass and other fuels, as well renewable fuels, innovative technologies and service capabilities. as co-combustion.

Category Boilers Steam Category Boiler Steam CHP Gasification/pyrolysis, CHP Steam turbine ACT Gasification Technical data Capacity 3.2MWe, 5.6MWe–9.4MWe, heat up to 25MWth Technical data Capacity Steam capacity 10–600MW, CFB Gasifier limekiln use — 26.8MW Steam 17.8MW, (22t/hr)–29MW (36t/hr) Output 340t burntlime/day Fuel Spent grain, bark, sawdust, wood chips, wood residues, peat, Fuel 100% biomass, 100% coal or any combination of the two, bark, wood sawmill residue chips, sawdust, forest residue, peat, rice husk, dry solids, recovered fuel, Output Steam, hot water, CHP de-inking and water treatment sludge, and many other recycled products MW Biopower technology is based on a BioGrate or bubbling fluidised bed (BFB) Output Steam, synthetic gas Equipment & technology combustion, which are modular and based on standardised components. A typical plant includes fuel feeding, boiler island, flue gas cleaning, steam turbine, generator Equipment & Circulating fluidised bed boiler (CYMICTM), bubbling fluidised bed boiler (HYBEXTM), and all auxiliary systems and can utilise local renewable fuels effectively. technology recovery boilers (RECOXTM) power generation. CYMICTM boiler uses circulating fluidised bed technology and is optimal for higher Examples In 2009, MW Power delivered two identical power plants for the Manchester and heating value fuels, such as drier biomass, recycled fuels, fossil fuels and Tadcaster breweries in the UK Each plant includes a condensing-extraction turbine co-combustion. HYBEXTM boiler uses bubbling fluidised bed technology and is and a steam boiler. The plants burn a mixture of spent grain and wood chips from suitable for power generation from biofuels and recycled fuel. RECOXTM boilers local sources. They generate steam and electricity for brewery processes and export range from small units to the largest in the world, operating up to 7,000 tons of dry electricity to the local grid. The steam capacity of the plant is 4.7MWe/0MWth solids per day. or 3.1MWe/7.4MWth, steam pressure: 62bar and steam temperature: 480ºC. The Manchester plant cost £11M and burns tonnes of brewer’s spent grains from the The CFB Gasifier is a circulating fluidised bed (CFB) reactor developed by Metso. site and 33,000 tonnes of clean waste wood plus some wood prunings and spent It uses a wide range of fuels from peat and biofuels to different waste fractions. grain from other Scottish & Newcastle sites. It can be applied to substitute oil, natural gas or other fossil fuels in industrial furnaces like limekilns, or to substitute coal, peat or other fossil fuels in power boilers.

Examples Steven’s Croft Power Station, Lockerbie — Metso supplied the power plant boiler (HYBEX), fuel supply system and flue gas cleaning system for E.ON UK’s Steven’s Croft Power Station, which has a capacity of 44MWe, generating electricity only from wood chips and other wood-based fuels as well as recycled fuels.

Contact UK supplier Contact UK supplier Metso Power Joule Power Ltd MW Power Joule Power Ltd

T +35 82 01 41 21 T 01892 823 485 T +35 82 01 41 36 00 T 01892 823 485 E [email protected] E [email protected] E [email protected] E [email protected] W www.metso.com W www.mwpower.fi 58 59 NESS Wärmetechnik GmbH Polytechnik Ness is a key player in the German boiler industry and has been Polytechnik has installed more than 2,200 plants worldwide operating around the world since 1964. They can supply equipment and has 35 years’ experience in the science of combustion of for the complete management of energy on industrial sites: thermal biomass fuels. They have experience of supplying equipment oil, steam, process heating, space heating, and heat recovery for large industrial applications and district heating schemes. from solids, liquids or gases produced during processes, for re-use The Polytechnik range includes water, steam and CHP plants elsewhere on site. from 300kW to 20MW.

Category Boilers Thermal oil, Steam Category Boilers Thermal oil, Steam

Technical data Capacity Up to 50 MW Technical data Capacity Up to 20MWth/4MWe Fuels Wood, particle boards, off-cuts, sawdust, sanding dust, other solid Oil Up to 300ºC process wastes, gaseous and liquid wastes from chemical process Steam Up to 36 bar, up to 450ºC Output Hot water, thermal oil, steam, superheated steam, saturated steam Fuel Waste wood Output Hot water, thermal oil, steam Equipment & Ness Wärmetechnik boiler equipment utilises combustion systems with air- technology entrained sawdust firing, underfed stokers and grate firing systems, combined Equipment & Polytechnik boilers are available with underfed stokers and reciprocating grate blown and underfed stoker. technology stokers. The main application for their equipment is the timber and forestry industry, process industries and municipal and community district heating. Plant up to 50MW is also available with output temperatures up to 320ºC utilising many solid, liquid or gaseous fuels including process wastes. They can provide heat only or combined heat and power systems. Electricity generation is carried out using steam turbines or steam engines or alternatively by All the following can be supplied to burn conventional fossil fuels or residual using thermo oil in an Organic Rankine Cycle (ORC) plant. The scope of Polytechnik gaseous, liquid or solid material: supply can include flue gas dedusting equipment such as fly ash cyclone units and The NESS thermal oil heater — the 95kW to 20MW fuelled by conventional fuels or electrostatic filters. production waste (gaseous, fluid or solid) producing supply line temperature: up to 300ºC/400ºC with suitable heat transfer medium. Examples There is currently one example of a Polytechnik boiler in the UK. Rural Energy Ltd Steam generators for saturated and superheated steam — power range: 200kg/h designed, supplied and installed the biomass heating system, which uses a 2MW to 28,000 kg/h, pressure: up to 30 bar. moving grate Polytechnik hot water boiler, at Bell Brothers Nurseries, Boston in 2007. The boiler, which can utilise fuel with 20–50% moisture content, uses G100 grade woodchip, which is sourced from local tree surgeons, low value woodland Examples There are examples of Ness plant in use in the building materials and concrete residues and timber off-cuts from local wood working factories. industry, chipboard and wood industries, paper industry, chemical and plastic There are no examples of Polytechnik steam boilers in the UK. industries and the mineral oil industry. However, there are currently no details available of any UK examples.

Contact UK supplier Contact UK supplier Ness Wärmetechnik GmbH Global Heat Transfer Ltd Polytechnik Rural Energy Ltd

T +49 71 81 96 75 1 T 0800 298 0488 T +43 26 72 89 00 T 01664 454 989 E [email protected] W www.ness.de E [email protected] W www.ruralenergy.co.uk/technical/ W www.ness.de W www.polytechnik.com 60 61 Puhdas Energia Ranheat Engineering Ltd Puhdas Energia Oy has been developing its gasifiers since 1999. Ranheat Engineering are a long established company manufacturing boilers (under 600kW) and combustion equipment in Northampton to a Danish design. Their larger boilers (up to 2.5MW) are imported from Danstoker in Denmark with the combustion part of these boliers made by Ranheat. Their main market is the wood working industry, with their equipment generally used to produce space heating for disposal of waste wood, off-cuts and dust.

Category CHP Gasification/pyrolysis Category Boilers Steam ACT Gasification Technical data Capacity All sizes up to 2.5MW Technical data Capacity 1MWth Fuel All types of wood including MDF, MFC soft and hard woods, plywood, Fuel Softwood woodchip, consumes 300kg/hour at 15%MC hardboard and wood-derived products Output Synthetic gas, CHP with 350kWe available Output Steam Uses Driers, heat treatment, bakeries, etc. Equipment & Ranheat make up turnkey solutions using a wide range of equipment from Equipment & The pressurised gasifier has a patented refractory reactor with no nozzles; this technology a variety of manufacturers. technology enables high gas flow rates. Reactor diameter is 500mm with 250mm throat and All their equipment is fully compliant with the appropriate British air quality 450mm reduction layer. Gas exists at 600–750ºC. Char loss is 5–8% of energy legislation as it applies to each size of plant. input. The company has also developed a special ceramic burner for the wood producer gas, complete with residual oxygen control, enabling direct retrofit for Handling and storage systems for sawdust, sanding dust and shavings are boilers and process heating. This enables use of wood-derived producer gas in also available. industrial applications. A semi-wet electrostatic precipitator has been developed for gas cleaning to a high level of purity. Examples They have 500 installations in the UK and they are selling to Europe and the USA. Retrofit unit — Gasifier with automatic infeed and ash removal, multicyclone and Ranheat have supplied one steam raising system in the UK for a timber merchant a gas burner with integrated automation system, installed in a single container. in Essex which uses steam for the kilns. The system, which generates 1.6t/hr of CHP system of 350kWe is also available. Puhdas supply the gasifier part of steam at 8bar, is based on a Danstoker boiler with a Ranheat retort. the system.

Examples Greenhouse heating and CO2 production using a 1MW wood pellet gasifier, Vaanela, Finland.

Contact Contact Puhdas Energia Ranheat Engineering Ltd

T +35 82 63 35 25 T 01604 750 005 E [email protected] W www.ranheat.com 62 63 Refgas UK Repotec Refgas UK design and build a gasifier which is market leader in size Repotec are engineering consultants advising on the technology to power output, operating from a factory in Sandycroft, Flintshire, behind the very successful Güssing biomass gasifier combined Wales. The technology has been developed by being awarded heat and power plant. They are based in Güssing and Vienna. a SMART Cymru grant. The company received more than £220,000 worth of funding from the Welsh Assembly.

Category CHP Gasification/pyrolysis Category CHP Gasification/pyrolysis ACT Gasification ACT Gasification

Technical data Initial system based on refuse-derived fuel. Wood biomass system also Technical data Fast internally circulating fluidised bed gasifier. Combined fluidised bed developed, wide variety of feedstock with higher moisture content than gasification and circulating fluidised bed combustion zones. Steam injection conventional gasifier. System eliminates driers and pelletisers. A single 2.5MWe to gasification bed gives high calorific value producer gas. gasifier plant will require 2 tonnes per hour of wood feedstock. Output 2MW electrical, 4.5MW thermal Efficiency Total efficiency 80% Equipment & It uses the down-draught gasifier principle. The reactor works under a vacuum, Users Heat for district heating scheme technology therefore there is no danger of gas leakage as the vessel is not under pressure. System has been further developed to create liquid bio-fuels and synthetic The process is a thermo-chemical process in which the biomass is heated in an natural gas. oxygen deficient atmosphere, the high temperatures (1000oC+) and reduced oxygen limit emissions. It utilises gas clean-up technology to ensure the gas produced is suitable to be efficiently burnt in engines with a very favourable Equipment & Repotec are engineering consultants advising on the technology behind the very emissions profile. technology successful Güssing gasifier combined heat and power plant. This technology, originally developed at Vienna Technical University, was developed into a 2MWe A 500kW (electrical output) plant is housed in 2 x 20’ containers. and 4.5MWth output plant. It is well proven with over 45,000 hours of successful operation since 2001. A high value producer gas is generated. It is converted in an Examples The biomass gasifier CHP plant at the University of East Anglia cost £8.5 million, associated gas engine to heat and electricity. Compared to steam turbines, a much with the gasifier costing approximately £2m. It is a 1.4MWe plant producing higher efficiency can be reached. 2MW of heat for the campus heat mains. 10% of the electrical power produced is required by the system to run the internal compressors. Examples Güssing has about 4,000 inhabitants, and is situated close to the Hungarian Short video of installation: border. The region around the town is heavily wooded. The combined heat and http://news.bbc.co.uk/1/hi/england/norfolk/8016402.stm power (CHP) plant has a capacity of 8MWth/2MWe. The plant is fuelled by wood chips (20 to 30%mc). The plant consists of a dual fluidised bed steam gasifier, a two-stage gas cleaning system, a gas engine with an electricity generator, and a heat utilisation system. The inhabitants of the town benefit from low and stable heat and electricity prices.

Contact Contact Repotec Refgas UK T +43 (0) 12 16 18 95 T 01244 529 589 E [email protected] W www.refgas-uk.com W www.repotec.at 64 65 Schmid AG Wood Firing Systems Spilling Energie Systeme Schmid AG is headquartered in Switzerland with other sites in Spilling is based in Germany and designs, constructs and delivers Germany and . Employing over 200 people, the company complete systems for generating electricity from biomass. is a family owned business which has been developing wood The sectors that use their technology include timber industry, pellet energy for more than 70 years. They manufacture biomass boilers plants, biomass cogeneration and district heating plants, chemical, and supply all associated plant such as fuel storage and transfer paper, textile and food processing industries. equipment and flue gas cleaning systems.

Category Boilers Thermal oil, steam Category CHP Steam turbine, steam engine

Technical data Capacity 2.4MWth–25MW Technical data Fuel Woodchip/pellets Outputs Thermal oil, steam Capacity 100kWe–5MWe Fuel Wood pellets <10%MC, woodchip, shavings, sawdust and wood Output Electricity and hot water processing residue up to 50%MC Containerised boilers 180kW–1.2MW Equipment & Spilling have proven themselves as prime movers for small to medium size biomass Operating pressure 5–32 bar technology power generation plants in the industry and district heating sectors. They are most Max steam temperature 425ºC often operated as combined heat and power systems. The steam engines are usually deployed in connection with boilers in moderate Equipment & Schmid AG CHP systems are based on either steam cycle turbines or the ORC “live steam conditions” and/or saturated steam boilers, particularly where steam technology technology. There are examples of both systems installed in Europe. They have also mass flow or energy acceptance is subject to clear fluctuations. developed systems to use spent brewers grains with one such system installed in a Heineken brewery in Nigeria (4.3MW of hot water at 170ºC from 5 tonnes/hour There are examples of this plant installed throughout Europe, but there are spent wet grains). Examples currently no installations in the UK.

Examples There are no examples of Schmid AG steam boilers in the UK. Imperative Energy has installed a Schmid UTSK 1.2MW boiler at the new Pembury Hospital in Kent. The boiler, which uses woodchip fuel delivered to site in hook bins, provides low temperature hot water to meet the hospital’s space heating base load.

Contact UK supplier Schmid AG Wood Firing Systems Imperative Energy Ltd Contact Spilling Energie Systeme T +41 (0) 71 97 37 37 3 T 01270 758 790 W www.holzfeuerung.ch E [email protected] T +49 (0) 40 78 91 75 0 W www.imperativeenergy.com W www.spilling.de/english 66 67 TK Energi TPS Termiska Processer AB TK Energi was founded in 1990 by Mr. Thomas Koch and became TPS provides technical solutions for combustion of renewable a limited company in 1996. The company employs 15 people. It is biofuels and for retro-fitting multi-burner installations to existing a technology developer and turnkey supplier. It produces primarily oil and coal-fired boilers and burners, enabling them to run on prototypes with all other production outsourced. biofuels. TPS is part of Tall Oil, which is an integrated group of bio-energy companies.

Category CHP Gasification/pyrolysis Category Boilers Steam ACT Gasification Technical data Capacity Specialists in large plant 100kW to 100MW Technical data Capacity 2.3MWth Outputs Hot water and steam Fuel Wood chips Fuels Pellets, any type of wood, and wastes such as paper, card and plastic Output Synthetic gas Equipment & TPS produce a wide range of equipment and can design and install complete Equipment & TK Energi, based in Denmark, has developed a three-stage, down-draught gasifier technology specialist systems for waste disposal/energy generation. technology that includes pyrolysis and partial oxidation zones, and a reformer-based char BioSwirl™ cyclone burner — Capacity: 2MWth to 15MWth, fuelled by crushed wood gasification zone. The internally heated pyrolysis reactor has no mechanical parts pellets (10%mc) and wood chips (<25%mc). The burner requires gas and/or oil that could be exposed to the high temperatures. The tars in the pyrolysis gas are all ignition and wood fuel is introduced when the required temperature is reached. thermally cracked when passing through the combustion zone (up to 1250ºC) and Used in steam raising for process or electricity generation, or for hot water, and for the fixed char bed, leaving a clean gas. incineration systems. The thermal efficiency is 60%, while the electrical efficiency is estimated to be up Multi-fuel burner — 5–50MW. The burner is a free burning type. Fuel pellets or to 32%. The gasifiers are designed for 7000 hours of continuous operation before wood chips need to be less than 10% mc. The burner is of particular interest for shutting down for maintenance. There is about 3–10% of energy remaining in large plants replacing oil and gas burners. the char. Stepfire — fire tube high efficiency boilers. Range from 500kW–3MW and are A plug feeder system has also been developed to feed biomass (up to 400 tonnes suited to combustion of pellets, briquettes and dry wood chips (less than 30%mc). per hour) into pressurised systems (up to 75 bar). The Stepfire boiler is a complete heating solution based on continuous combustion The company is also developing a slagging gasifier for producing 3rd generation on a stationary grate. As the fuel burns it is transported over the grate by scrapers liquid biofuels from waste. until it reaches the end, at which point the fuel is burnt out completely and only ash remains. Examples There are no examples in the UK at present, but there is a district heating system Purpose designed waste burning systems — TPS can deliver complete plants at Gjøl, Denmark — a 2.3MWth (dry wood input) gasifier where the gas is used in or rebuild existing units to meet the demands of the EU's Waste Combustion an existing natural gas-fired Jenbacher engine, to generate electricity. The plant Directive, providing grate-fired plants for unsorted wastes as well as grate-fired and was commissioned in January 2006. There is also a slagging entrained flow sludge fluidised bed plants for sorted wastes (paper, wood, plastics) and co-fired plants. gasifier in Køge. Examples We understand that there are no examples of TPS boilers in the United Kingdom, although there are many in Europe.

Contact Contact TK Energi TPS Termiska Processer AB

T +45 46 18 90 00 T +46 (0) 85 35 24 60 0 W www.tke.dk W www.tps.se 68 69 Turboden Srl Uniconfort Turboden Srl is an Italian company with nearly 30 years’ experience Uniconfort is based in Italy. The company manufactures and of designing, manufacturing, installing and maintaining turbo installs biomass-fired boilers to produce hot water, high-pressure generators based on the Organic Rankine Cycle (ORC) for hot water, hot air, steam and thermal oil. Uniconfort has recently the cogeneration of heat and electrical power. There are currently installed a new boiler at the Comune di Apiro (Apiro City Hall) in 129 systems installed in Europe as at January 2009 (93 in Italy, which burns 30% straw and 70% woodchips. operation, 36 under construction).

Category CHP Organic Rankine Cycle (ORC) Category Boilers Thermal oil, steam

Technical data Capacity 400 kWe–2.2 MWe Technical data Capacity 93kWth–5.8MWth, containerised up to 348kWth Fuel Woody biomass (woodchip, bark, sawdust, treated wood), agricultural Fuels Wood pellets, woodchip, straw, waste wood and residues (straw, rice husk), arboricultural residues, waste material agricultural (sewage sludge, marc) (1000kg/hr–5250kg/hr) Output Thermal oil 280ºC Output Electricity and hot water Steam 0.7 bar to 25 bar saturated Efficiency 20% e(gross) 78%th Fuel Untreated wood up to 30–55% moisture content, pellets Efficiency Up to 24% e non-cogeneration or chips

Equipment & The equipment is packaged CHP plant and is well suited to the use of industrial Equipment & Biotech range Outputs 348kW–5.8MW providing hot or superheated water. technology waste wood. Existing applications in Europe include timber drying in sawmills, technology CMT range Outputs 92.8kW–3,480kW providing hot or superheated water sawdust drying in wood pellet plants, air pre-heating in the MDF industry and also and steam. district heating schemes in Europe. DUAL range Outputs 92.8kW–3.48MW providing hot or superheated water and steam. GLOBAL range Outputs 348kW–5,800kW providing hot or superheated water, There is one unit currently under construction (mid-2009) for LandEnergy Ltd. Examples saturated steam and thermal oil. The application is for a wood pellet mill in Scotland. The turbine is used for on-site power production and the excess heat is used to dry the wood fibre. Heat input: 14MW biomass-fuelled thermal oil boiler, output: 2.2MWe gross, 10MWth (water Examples We understand that there is a Uniconfort boiler installed in Hereford but no details 60ºC/90ºC). of the installation are currently available. Schuberts Biomass is now supplying Uniconfort boilers to the UK market but has not completed any UK installations yet (summer 2009).

Contact Contact UK contact Turboden Srl Uniconfort Schuberts Biomass

T +39 03 03 55 20 01 T +39 04 95 95 20 5 T 01226 360 900 W www.turboden.it W www.uniconfort.com W www.schuberts-biomass.co.uk 70 71 Vyncke Energietechniek Waste2energy Vyncke is based in Belgium and has been operating since 1912, Waste2energy is a US company that acquired, in 2007, a 95% delivering tailor-made solutions to customers all over the world. share in Enerwaste, an environmental engineering, manufacturing They offer complete industrial waste to clean energy solutions and technology company specialising in innovative processes for all under one roof, from design, engineering, manufacturing, the disposal of a wide variety of waste. The waste is converted into installation and commissioning to training and after-sales service. a synthetic gas that can be used to produce steam and electricity. There are over 40 projects installed worldwide by Enerwaste, with another 60 projects developed on the Enerwaste principle.

Category Boilers Thermal oil, steam Category CHP Gasification/pyrolysis ACT Gasification Technical data Capacity 2–100MWth and up to 10MWe Fuel Thermal systems — biomass, agricultural waste and wood processing Technical data Capacity <50MW from 1,500 metric tonnes per day (MTPD) of waste waste from coarse to fine and from wet to dry. Electrical systems can Fuel Multiple types of waste take in addition — paper and packing waste, demolition wood, RDF Output Synthetic gas for CHP Output Thermal oil, steam Equipment & The Batch Oxidisation System (BOS) was designed as a low emission and low Equipment & Dynamic Watercooled Stepgrate DWS® forms the basis of the energy plants, which technology labour approach to small and medium-scale solid waste disposal. The BOS™ utilises technology range from 2MWth to 100MWth and can be supplied either as steam, hot water, a gasification process that thermally converts waste products into a combustible thermal oil, hot gas, electricity (up to 10MWe) or in any assorted combination. gas. This two-stage process provides the lowest possible emissions and is the most environmentally sound method for waste disposal for 1–150 tonnes per day. Vyncke provide combustion and boiler systems for decentralised power stations (1–10MWe ) and turnkey energy plants (1–65MWth) using various homogenous The Mass conversion system is a low-cost gasification and oxidation system in secondary biomass fuels, such as demolition wood, refuse-derived fuels (RDF), which both processes are carried out within the same vertical chamber. Like the packing materials, paper waste, etc. Different agricultural waste streams (e.g. rice BOS™ system, it oxidises at high temperature giving extremely clean emissions. husks, coffee husks, coconut shells, etc.) can be burnt in one installation, either It features a mechanical feed system that is ideally suited to large quantities of separately or mixed. Wood processing industry production waste, which varies in biomass or other consistent waste feedstock from 50–1,000 tonnes per day. granular size, fuel humidity and chemical composition, is mainly converted into thermal energy such as steam, hot water and/or thermal oil. Examples Six new plants are to be established in the UK, including the power station at Dumfries Dargavel, Scotland, UK for Scotgen (construction started 2008), for Examples The Balcas wood pellet production facility in Invergordon, Scotland has a 40MWth a plant with 120 MTPD mixed waste and 5MW Power Recovery BOS system. Vyncke boiler that uses woodchip (up to 55% moisture content). The fluidised bed The power station at Bristol has planning permission to commence construction boiler is due to be commissioned in the summer of 2009 followed by the 8MWe on a plant using 100,000 tonnes/year waste. steam turbine generator. The plant generates the process heat required by the wood pellet processing operations and 3MWe of electricity for the site’s own requirements, with the remaining 5MWe being exported to the grid.

Contact Contact UK contact Vyncke Energietechniek Waste2energy Planet Advantage Ltd

T +32 56 73 06 30 T +864 (0) 67 91 62 5 T 0161 724 2222 E [email protected] E [email protected] E [email protected] W www.vyncke.be/english/energ.php W www.waste2energy.com 72 73 Weiss Kessel Wykes Engineering Weiss Kessel, Anlagen und Maschinenbau GmbH is based in Wykes Engineering is part of the Wykes Group. Its core design Germany and has been producing boilers for the wood working business focuses on heavy mechanical handling and process plant industry for over 30 years, with boilers sold in 60 countries including layouts, and associated equipment from screw conveyors, and the UK and around Europe. pressure vessels through to power stations. Ancillary components was formed to specialise in developing new solutions to existing and emerging needs for creative waste management across a range of industries.

Category Boilers Thermal oil, steam Category Boilers Steam

Technical data Capacity 650kW–50MW Technical data Capacity Specialists in large plant up to 50MWth Fuels Wood, sawdust, briquettes, shavings, off-cuts, MDF and particle boards Outputs High or low pressure steam Outputs Thermal oil, steam Fuels Any

Equipment & The CHP plants range from 500kW to 10MW electrical output with steam turbine Equipment & Wykes Engineering provides bespoke large-scale systems based on bubbling technology and steam engine. Organic Rankine Cycle turbo-generators for power supply range technology fluidised bed technology. from 300kW up to 1,200kW electrical output. The cyclone furnace (underfeed stoker furnace) generates warm water at 90ºC and Examples Goosey Lodge Power Plant is based on bubbling fluidised bed (BFB) technology hot water up to 230ºC, low pressure steam at 1 bar, high pressure steam up to 36 and combusts a wide variety of materials — solids, liquids and sludges. The plant bar and superheated steam up to 80 bar and 480ºC. Screw gate furnaces, cyclone exceeds the current and planned future environmental standards prescribed by UK burner furnaces (muffle furnaces), jet blower furnaces and push grate furnaces are and EU law. A similar plant was designed and built by Wykes Engineering for PDM also used. Group at Widnes BFB Power Plant. — multicrat boiler 800 – 2.2MW — turbocrat boiler 1,000 – 8MW — three pass boiler 1,000 – 10MW — watertube boiler 4,000 – 35MW — thermal oil heaters up to 10MW — hot gas generators up to 35MW

Examples There are currently no examples of Weiss Kessel steam boilers in the UK. There are, however, a 1.4MW boiler at Gresham Office Furniture, Bolton, which uses MDF dust as fuel and a 5MW pusher grate hot water boiler at Howden Joinery in Runcorn using process waste wood and wood products as fuel.

Contact UK supplier Contact Weiss Kessel Modern Energy Systems Wykes Engineering

T +49 27 71 39 30 T 0844 561 7469 T 01933 315 818 E [email protected] E [email protected] E [email protected] W www.weiss-kessel.de W www.modernenergysystems.co.uk W www.wykesengineering.co.uk 74 75 Xylowatt Xylowatt specialises in the design, construction and management List of UK suppliers of fully automated modular biomass gasification units, converting biomass into heat and electricity. With over 20 years of experience in biomass resources, gasification systems, electrical generating sets and cleaning systems, Xylowatt designs, builds and monitors bio-energy systems from 300kWe to several MWe. The Xylowatt CHP power plant allows on-site electricity production at high efficiency for production at these power levels.

Category CHP Gasification/pyrolysis ACT Gasification

Technical data Capacity 300kWe–1.5MWe/600kWth (biomass 270kg/hour)–3MWth (biomass 1,350kg/hour). Larger outputs can be accommodated using modular units with several gasifiers Fuels Wood chips, wood processing waste, municipal thinnings, short rotation coppice Output Synthetic gas for electricity generation via a gas engine, with CHP Throughput 1,500 to 25,000 tonnes of wood per year Efficiency Electrical 25%, thermal 50%, total 75%

Equipment & The Xylowatt biomass combined heat and power system is based on a down- technology draught fixed bed gasifier, the NOTAR® reactor developed at the University of Louvain. The output fuel gas has a calorific value between 4.5 and 5.8 MJ/nm3, which suits standard gas engines, and less than 50mg/nm3 tar is produced at the gasifier outlet. The wood gas obtained still contains some fines, particles and tars so it is cleaned before being fed to a standard gas engine linked to a generator. In a typical system about 1% ash is produced.

Examples Three plants are currently running, and five plants are under construction. The operational plants are as follows: — one sawmill, where the electricity and heat generated are used in the process. CHP district heating scheme was installed at the village of Gedinne in spring 2007 — an xW300 unit was sold to Tournai city and supplies electricity and hot water for the local swimming pool using municipal trimmings — end of 2009, an xW300 unit is due to be installed in the United Kingdom

Contact Xylowatt

T +32 (0) 71 60 68 00 E [email protected] W www.xylowatt.com 76 77 List of UK suppliers

BIB Cochran Ltd Byworth Boilers ENERGOS Ltd Inetec Manco Energy Ltd Rural Energy Ltd Newbie Works, Annan, Parkwood Boiler Works, 11b Olympic Park, Woolston Grange Unit 17, Village Farm Road, Market Weighton Road, Manor Farm, Main Street, Owston, Dumfries & Galloway, DG12 5QU Parkwood St, Keighley, Avenue, Birchwood, Village Farm Industrial Estate, North Newbald, Oakham, Leicestershire, LE15 8DH T 01461 202 111 West Yorkshire, BD21 4NW Warrington, WA2 0YL Pyle, Bridgend, CF33 6BL East Yorkshire, YO43 4SP T 01664 454 989 E [email protected] T 01535 665 225 T 0845 683 7001 T 01656 746 439 T 01430 828 660 W www.ruralenergy.co.uk W www.bibcochran.com E [email protected] W www.energos.com E [email protected] E [email protected] Supplies: Polytechnik Supplies: KARA Energy Systems W www.byworth.co.uk Supplies: ENERGOS W www.inetec.co.uk W www.mancoenergy.com Supplies: Byworth Boilers Supplies: Inetec Thermec Supplies: LIN-KA Schuberts Biomass Bioenergy Technology Energia Ltd Clarke Energy UK ICI Caldaie Mawera UK Ltd Athersley House, Pound Lane, Framfield, Uckfield, Malvern Hills Science Park, Geraldine Pilley Hills, Tankersley, East Sussex, TN22 5RU Power House, Senator Point, South Road, Malvern, Worcestershire, Unit 6 West Link Business Park, PO Box 5581, Lichfield, South Yorkshire, S75 3AT T 01825 890 140 Boundary Road, Knowsley Industrial WR14 3SZ Guide Street, Salford, Staffordshire, WS14 4FS T 01226 360 900 W www.bioenergy.org Park, Liverpool, L33 7RR T 01684 585 238 Manchester, M50 1EW T 01543 258 844 W www.schuberts-biomass.co.uk Supplies: range of boilers T 0151 546 4446 E [email protected] T 0161 743 9595 E [email protected] Supplies: Uniconfort E [email protected] W www.kiv-uk.com E [email protected] W www.mawera.co.uk W www.clarke-energy.co.uk W www.icicaldaie.com Bioflame Ltd Supplies: KIV Supplies: Mawera UK Biomass Ltd Supplies: Adoratec Supplies: ICI Caldaie South View Yatts, Pickering, Ethos Energy Modern Energy Systems 13 Quay Level, St Peters Basin, North Yorkshire, YO18 8JN CJM Coldwell Ltd ITI Energy Newcastle-upon-Tyne, NE6 1TZ T 01751 472 831 Kestrel Court, Harbour Road, PO Box 154, Bexhill-on-Sea, T 0191 265 4400 E [email protected] 26 Claremont Gardens, Whitley Bay, Portishead, Bristol, BS20 7AN Advanced Manufacturing Park, East Sussex, TN39 4WQ E [email protected] W www.bioflame.com Tyne and Wear, NE26 3SB T 0844 844 1306 Technology Centre, Brunel Way, T 08445 617 469 Rotherham, South Yorkshire, S60 5WG Supplies: Binder Supplies: Bioflame T 0191 252 6445 E [email protected] E [email protected] M 07850 736 352 W www.ethosenergy.co.uk T 01142 541 233 W www.modernenergysystems.co.uk E [email protected] Wood Energy Ltd Biomass CHP Ltd Supplies: AE&E Supplies: Ethos Energy Supplies: Weiss Kessel W www.iti-energy.com Pinkworthy Barn, Oakford, Tiverton, 19 Point Street, Larne, Supplies: ITI Energy Devon, EX16 9EU Danstoker UK Ltd Imperative Energy Ltd Planet Advantage Ltd Co. Antrim, BT40 1HY T 0845 0707 338 E [email protected] PO Box 82, Malton, YO17 1AG Suite 2, Chancellor Forms, Dragons James Proctor Ascot House, Water Street, E [email protected] Wharf, Dragons Lane, Sandbach, Radcliffe, Manchester, M26 3DE W www.biomasschp.co.uk T 07921 773 580 W www.woodenergyltd.co.uk Cheshire, CW11 3PA PO Box 19, Cow Lane, Burnley, T 0161 724 2222 Supplies: Biomass CHP E [email protected] Lancashire, BB11 1NN Supplies: Binder W www.danstoker.dk T 01270 758 790 E [email protected] W www.imperativeenergy.ie T 01282 453 816 Biomass Engineering Ltd Supplies: Danstoker Supplies: Waste2energy, design and Wykes Engineering Supplies: Schmid AG Wood Firing W www.jamesproctor.com project management services Junction Lane, Sankey Valley Industrial Systems Supplies: James Proctor Plant & Equipment, Goosey Lodge, Doosan Babcock Energy Ltd Estate, Newton-le-Willows, WA12 8DN Joule Power Ltd Ranheat Engineering Ltd Wymington, Rushden, T 01925 295 959 11 The Boulevard, Crawley, Imtech Northants, NN10 9LU E [email protected] West Sussex, RH10 1UX 1H Woodhill Park, Pembury, 62 St James Mill Rd, T 01933 315 818 W www.biomass.uk.com Imtech House, 33–35 Woodthorpe Tunbridge Wells, Kent, TN2 4NN Northampton, NN5 5JP E [email protected] T 01293 612 888 Road, Ashford, Middlesex, TW15 2RP Supplies: Biomass Engineering E [email protected] T 01892 823 485 T 01604 750 005 W www.wykesengineering.co.uk W www.volund.dk/home T 01784 229 900 E [email protected] E [email protected] Supplies: Wykes Engineering UK E [email protected] Supplies: MWPower Supplies: Danstoker Buccleuch BioEnergy Ltd Supplies: Doosan Babcock W www.imtech.eu/uk Computer House, Dalkeith Country Supplies: Imtech Refgas Ltd Park, Dalkeith, Edinburgh, EH22 2NA T 0131 561 5000 Whittle Close, Engineer Park, W www.buccleuch-bioenergy.com Sandycroft, Deeside, Flintshire, CH5 2QE Supplies: Kohlbach, Turboden T 01244 529 589 E [email protected] Supplies: Refgas 78 79 80 81 Printed with vegetable inks using 100% recycled (minimum 75% post-consumer waste) paper. © Envirolink Northwest, May 2010. Envirolink Northwest is a company limited by guarantee. Company Reg Number 3914702. Design: www.moderndesigners.co.uk

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