Renewable

Waste-to-Energy Technologies

Clean, efficient and renewable energy from waste

Waste-to-Energy Technologies

Providing clean, efficient and renewable energy from waste

Our capabilities of turning waste into energy include the complete plant scope of combustion grates, state-of-the-art boilers, fuel and ash handling systems, and emissions control technologies. As a leading waste-to-energy company, B&W and our subsidiaries have more than 155 years of experience in designing, supplying and servicing some of the world’s cleanest, most efficient energy and environmental systems.

Complete Plant Scope

DynaGrate^® Combustion Grate

Advanced design features for high energy recovery, fuel flexibility and low maintenance costs.

Its unique design delivers a wave-like longitudinal movement which results in optimal turnover of the fuel bed.

Optimal fuel-bed agitation enables uniform and efficient combustion with a high burnout rate
Fuel flexibility along with biomass co-firing capability
No contact between moving parts limits wear and lowers spare part cost
Ability to process waste containing metals
Integrated air or water cooling ensures stable operation and high availability

Learn more>>

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Water cooled wear zones

Vølund^® Combustion Grate

Dependable and proven performance

For simplicity of design combined with robustness of operation, the air-cooled Vølund™ grate is one of the most dependable energy-from- waste grates available. It’s ideal for fuels with a wide calorific waste range. With auxiliary burner support, the grate can handle wet waste, common during rainy seasons. Learn more>>

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DynaFeeder^® Fuel Feeder

Provides a continual and even fuel layer across the entire combustion grate for steady energy output and maximum efficiency. It is tolerant and robust with design features that allow servicing during operations.

Changeable feeder rams lower maintenance cost
Air-cooled feeder rams minimize wear and tear of the rams
Feed scrapers inhibit waste buildup behind rams
Hydraulic cylinder location outside feeder mechanism avoids exposure to heat, allowing safe replacement without shutting down the plant

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DynaDischarger^® Ash Extractor

With mechanical design features for high availability, fewer unplanned stops and safe service access.

The DynaDischarger ash extractor is compatible with any grate, regardless of manufacturer. It can be retrofitted during a normal service shutdown period.

Accommodates larger objects and has fewer unplanned stops due to reduced blockage risk
Ash level sensors alert operators of an abnormal rise in ash levels to allow timely corrective action
Safe and quick removal of clogged items
Compatible with any combustion grate

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Project Summary

Amager Bakke, Copenhagen, Denmark

This iconic urban energy-from-waste plant is also a ski slope and center for recreation

Processes 400,000 tons/year unrecyclable waste
Generates 63 MW of electricity, and district heating for 120,000 homes
In the heart of Copenhagen for sustainable waste collection and optimal energy distribution
NOx emissions well below EU requirements

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Project Summary

Kelvin Plant, West Bromwich, UK

See how the DynaGrate, DynaFeeder and DynaDischarger were installed at this waste-to-energy plant

Will process 395,000 tons/year of unrecyclable waste
135 MWth waste boiler will generate 47 MW gross baseload electricity powering 95,000 homes

Energy-from-Waste Boiler Designs

Three major designs are used in waste to energy plants: 1) single-pass furnace, 2) multi-pass furnace with vertical convection pass, and 3) multi-pass furnace with a horizontal convection pass.

B&W has proven experience with designing and building all three variations, with the choice of design determined by the application. All three designs feature a furnace that is strategically arranged over the grate to control gas flow and maximize heat absorption, and thus, maximize efficiency. B&W designs the flue gas flow path to provide reasonably uniform cross-section flow and temperature distributions by using physical and/or numerical computational fluid dynamics (CFD) modeling, and empirical data.

WtE Amager Bakke Denmark Waste to Energy

Single Pass Furnace

B&W’s single-pass furnace is a top-supported design that features a single vertical shaft for the rising combustion gases from the grate, with enough residence time and temperature to burn the fuel completely and cool the flue gas to the required furnace exit gas temperature before entering the superheater. The flue gas then turns 90 degrees around a furnace arch to pass through the horizontal crossflow top-supported superheater before turning downward to flow through the longflow steam generating bank. The flue gas then passes vertically over the crossflow economizer and exits the boiler enclosure.

Multiple Pass Furnace with Vertical Convection Pass

B&W’s multipass furnace with vertical convection pass locates the steam generating bank and superheater in the vertical third pass, and the economizer in the fourth pass. In this design, furnace gases pass upwards through the radiative section then makes a 180-degree turn and flows downward through a second vertical radiation pass. The gas then makes another 180-degree turn and flows up through the third pass where the superheater and generating bank are located. Finally, the flue gas is directed downward through the fourth pass which contains the crossflow economizer. While this design minimizes the larger footprint of the three-pass furnace, accessing the superheater in the vertical gas path for maintenance is more difficult.

Multiple Pass Furnace – Horizontal Convection Pass with a Horizontal Economizer

The combustion gases of B&W’s multipass furnace with horizontal convection pass leave the grate and lower furnace and pass upward through the first open furnace pass and then downward through the second open pass. A portion of the first pass may be covered with specialized materials to reduce heat absorption and permit the flue gas to maintain a suitable temperature for complete combustion of the fuel in smaller boilers, and at lower loads in larger units. At the bottom of the second open pass, the flue gas turns 180 degrees to pass upward through the third pass to cool the flue gas to the required gas temperature before entering the horizontal convection pass with a horizontal economizer.

Multiple Pass Furnace – Horizontal Convection Pass with a Vertical Economizer

The combustion gases of B&W’s multipass furnace with horizontal convection pass leave the grate and lower furnace and pass upward through the first open furnace pass and then downward through the second open pass. A portion of the first pass may be covered with specialized materials to reduce heat absorption and permit the flue gas to maintain a suitable temperature for complete combustion of the fuel in smaller boilers, and at lower loads in larger units. At the bottom of the second open pass, the flue gas turns 180 degrees to pass upward through the third pass to cool the flue gas to the required gas temperature before entering the horizontal convection pass with a vertical economizer.

Water-Cooled Wear Zones

Water-cooled wear zones are an innovative, efficient and economical way to improve operational accessibility and productivity for waste-to-energy plants. The water-cooled zones reduce the area of uncooled refractory in the furnace of our waste-to-energy boilers.

Reduces maintenance costs by reducing refractory volume
Constructed to ensure stability and withstand pressure
More heat absorption in the water-cooled wear zone provides additional plant output
Can be installed during a standard maintenance outage

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Water cooled wear zones

Adaptive SNCR for Optimized Boiler NOx Reduction

The selective non-catalytic reduction (SNCR) system from B&W provides optimized nitrogen oxides (NOx) control while maintaining proper boiler operation. By knowing the detailed design criteria of the SNCR system and integrating this into our computational fluid dynamics (CFD)-based boiler design process, we optimize boiler operation and NOx emissions. Read this project summary to learn how our adaptive SNCR was integrated into the plant upgrade at Filborna, Sweden.

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filborna-Sweden_image_Fagerhult

VoluMix Systems

Proper, turbulent mixing of the flue gases in the boiler furnace provides a better combustion process and burn-out in the gas phase.

With the VoluMix™ system, all primary air passes through the narrow gap between the grate bars, creating a strong, turbulent combustion zone. The system is installed at the inlet of the first pass.

VoluMix ensures very low carbon monoxide (CO) and total organic carbon (TOC) content in the flue gas.

Advantages of VoluMix include:

Good mixing and combustion conditions in the furnace – gas-phase burnout
Staged combustion makes it possible to reduce the formation of fuel NOx
Avoidance of hot spots in the furnace and boiler which would speed up corrosion
Obtaining turbulent conditions for optimum burnout–low CO levels
Uniform temperature and velocity distribution in the convection passes to maximize heat transfer and residence time
Basis for low excess air resulting in high overall thermal efficiency
Eliminates the need for flue gas recirculation, saving fan investment cost, as well as operation and maintenance costs

VoluMix™ System Waste-to-Energy Company

Inconel^® Cladding for furnace corrosion protection

Since the combustion products from municipal solid waste fuels are very corrosive, some form of corrosion protection is needed. Typically, the protection area will encompass all four furnace walls up to a certain elevation.

A proven method of corrosion protection is utilizing Inconel® weld overlay on lower furnace wall sections of municipal solid waste boilers. In fact, B&W pioneered the use of this method for lower furnace protection as well as other corrosion-susceptible areas.

B&W has in-house capability to apply Inconel cladding in a continuous welding process at our production facility in Esbjerg, Denmark. The spiral welding machine can process up to 8 tubes at the same time at lengths up to 12 meters. Watch the video to see how we do it.

Safety and Service Solutions

Proper maintenance is essential for achieving the full potential, performance and safe operation of your plant. B&W offers a wide range of technology and service solutions that can improve safety and simplify maintenance while helping to reduce downtime and save money.

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B&W Diamond Power® Sootblowers

Diamond Power^® sootblowers remove deposits and maintain waste-to-energy boiler efficiency with our specialized designs. Available in steam/air, high pressure water, and dual-media air heater cleaning configurations to meet specific customer needs for boiler cleaning precision, reliability and efficiency.

Flue Gas Cleaning and Condensation

B&W provides our GMAB™ flue gas cleaning and flue gas condensation technologies for waste-to-energy plants. Our capabilities include complete process engineering, project execution, equipment supply, installation and commissioning on a turnkey basis. Unique, integrated technologies provide an efficient removal of toxic emissions.

B&W’s ADIOX^® technology has applications wherever dioxin removal is required and is especially suitable for wet scrubbers for gas cleaning systems at energy-from-waste and incineration plants.

SPIG™ air-cooled condensers

Dry cooling technology provides many environmental benefits. SPIG dry cooling systems are well-suited for use in several applications such as waste-to-energy, biomass and solar power plants. Using only ambient air, our air-cooled condensers provide effective cooling without the need for water. We are committed to the preservation of our environment and promote the use of this high-efficiency technology in a growing variety of applications.

Integrated carbon capture

B&W has been at the forefront of research and development for effective decarbonization technologies for several decades. Two technologies can be integrated into a waste-to-energy plant. Our SolveBright™ solvent-based carbon capture technology can be designed to accommodate a customer’s choice of solvents. And our OxyBright™ oxy-combustion technology has been demonstrated at a large scale and is commercially ready.

Health, Safety and Sustainability

B&W Renewable's waste-to-energy operations are ISO 45001 certified. Our goal is to continually improve our work environment by managing and controlling the risks that exist at the workplace, at our own production facility in Esbjerg, at our offices, and when working on-site at clients’ plants. Also, health and safety are engrained in B&W work culture via the Target Zero program. It reflects our commitment to the overall safety of each employee.

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Waste-to-Energy Technologies