DGA Co Ltd

DGA Co Ltd

Specialist Combustion and BoilerDesigners

Presented by David Gardner

❖ Independent Energy Consultant based in Bangkok Thailand and operating in SE Asia, UK and Australia.

❖ Specialist in waste and biomass power and energy production.

❖ Combustion Engineering a speciality including Fluidised Bed Combustion, Grate firing and Suspension firing.

❖ 35+ years in EPC contracting in the waste and biomass power business.

❖ Full range of boiler and ancillary products including “in house” developed equipment.

❖ Primary Market has been outside Thailand, now focused in Thailand, Malaysia, Singapore, UK, Australia and the Asia Pacific area.

DGA Co Ltd

DGA are currently working on :-

❖ Second year of operation for the M30 Eco Biomass Plant for Sbang to produce 46 bara 490 C from mixed biomass in Central Thailand. Plant generate 6MWe for in house use and export to the grid.

❖ Completing the M45 Eco Biomass Plant for Sbang to produce 65 bara 515 C from mixed Parawood in South Thailand. Designed to generate 10 MWe for in house use and export to the grid.

❖ Second year of operation for the M20 Eco ORC Biomass Plant for Expel Oil to produce 2 MWe and heat for process with Syn2gen at Stratford UK. Power to be delivered to grid.

❖ Preparing fpr an M30 Eco Waste Plant for Sbang to to produce 30 tn/h of steam at 46 bara 430 C to produce 6 MWe from RDF produced from Municipal Waste in Laos.

DGA have live prospects (Next year) for :-

❖ UK

• 1 x M25 Eco Waste ORC plants to fire 18 MWth thermal oil heaters for Syn2gen to produce 5 MWe from firing RDF from Municipal Wastes in Midlands UK.

• 1 x Combined Heat and Power plant for client form a gas fired power plant, as Biomass on a very reduced availability in UK.

CURRENT PROJECTS

DGA Design & Manufactures :-

❖ Vee Grate stokers for palm waste and other solid fuels. These units are suitable for firing both thepackage and site erected solid fuel boilers. Currently developing the market to ERK licenseesworldwide. 30 + references for boiler sets around SE Asia.

❖ DGA have developed a push grate or ‘Bonfire Grate’ which is a water cooled design intended as analternative to the Vee grate for firing high LCV RDF. However, the technology can be used forburning larger sized raw waste. The Grate has not been sold yet.

❖ BFB (Bubbling Fluidised Bed) boilers to fire various solid fuels. The BFB is originally based ontechnology developed by the CRE (the Coal Research Establishment) of British Coal in the 1990skept current by working with EPI of the US, Ebara Corporation of Japan, Energy Equipment ofAustralia and finally with Double A Paper on the ‘Tampella’ plants. Many references in Europe onvarious fuels.

❖ Collaboration with ERK to develop the Eco plant range around the ERK boiler and the DGA VeeGrate.

❖ ERK Licensed Watertube Boilers sized up to 200 tn/h size. Can be fired by DGA grates, BFB orGasifiers for wastes and biomass fuels.

❖ A range of boiler ancillary products including Modular Bag Filters and Dry Scrubbers for pollution control behind boilers and gasifiers. These may only be supplied by Scheuch.

❖ A range of exhaust gas boilers designed specifically for the exhaust gas engines particularly the GE Jenbacher engine and HRSG (ERK license) for Gas Turbines

PRODUCTS

DGA became an ERK licensee in 2002. Since then, DGA have participated in the

design and development of many boilers of different styles, all taken from ERK’s library of 6000 built boiler designs. Some of these projects are illustrated on the following

slides

❖ 20 tn/h boiler for Energy Equipment Australia, BFB unit firing wood

❖ 65 & 100 tn/h power boilers for Stuck Biomass and Thai Alcohol on BIB traveling

grate

❖ 30 & 35 MW HMW water heaters for Gosfern (now Aalborg) for SBM

❖ 15 MW gas fired watertube boiler for HPP Australia, fired by Saacke burner

❖ Redesign and Rebuild 2 x 200 tn/h rice husk/bark fired BFB boilers for Double A

Paper

❖ Design of 100 tn/h marine superheat boilers for FPSO Polvo. Ship in commission with Prosafe. This is still the largest deck boiler with superheat in commission.

❖ Design of HRSG behind a Gas Turbine for Mackenzie. Ultimate client Petronas, Malaysia. Currently operating successfully.

❖ Development of the Eco Plant range for standardised waste fired plants for biomass and waste fuels in a fully EU WID compliant package.

ERK Eckrohrkessel GmbH License

This section describes the early projects of DGA.

At this stage DGA worked mainly as a consultancy advising and participating with

Double A paper on their arbitration with Kvaerner on the performance of the 2 Kvarner

(Tampella) supplied boilers.

DGA assisted BIB and Gosfern (Australia) to become ERK licensees and assisted in

training their engineers

Also involved in a number of other projects for Double A as an expert in Fluid Bed Firing

Technology and steam boilers.

Early Products

Energy Equipment BFB Boiler

Supplied to Queensland Australia

The boiler was built by Bangkok Industrial Boilers, their first ERK boiler. The design was by DGA.

The plant was installed in Queensland Australia in 2002

65 tn/h Power Boiler for Stuck Biomass

supplied to Buriram, Thailand, 2003

30MW HMB Boiler for FPSO vessel

supplied to Gosfern for Vessel in Singapore, 2004

HMB watertube heater fired by Natural Gas on an FPSO vessel. DGA designed and supervised the

manufacture of this and 4 more units for the offshoremarket.

15 MW Gas Fired Process Steam Boiler

supplied to Sun for Highland Pine Products, Australia

This boiler was DGA’s first package gas fired boiler to ERK basic design.

The boiler is a 23 tn/h boiler to meet limited attendance operation. It is firing successfully in Australia.

Grate

Biogas

burner

Economisers

Multicyclones

Fuel

Hopper

100 tn/h Power Boiler for ThaiAlcohol.

supplied to Thai Alcohol, now operating. 2006

Drum

This plant was built by BIB with support from DGA.

DGA were the consultants anddetail designers for a major redesign of the

Thai Power Supply (Part of AA, Double A

Paper) PP4 power boiler.

Boiler is a 200 tn/h 80 barg 480 C BFB

boiler by Tampella firing rice husk and wet

eucalyptus bark and at times

supplementary coal fuel

Scope included approximately 550 tn of

boiler pressure parts, including

economisers, air heaters and a revised and

redesigned combustion system.

Work was completed successfully in May

2005 and the plant is now able to generate

38 MWe.

DGA followed this project by redesigning

the sister boiler PP5 to fire a different fuel

range to PP4. the plant was completed in

2016

Double A Paper

Development of FPSO Deck Boilers

This section describes the early development of the Deck Boiler with

Gosfern. Gosfern became a licensee of ERK on DGA’s recommendation. This allowed ERK to become involved in the design

of marine boilers primarily for the FPSO market.

The initial concepts were provided by DGA and following 3 years of

marketing, a project was won. The Polvo FPSO has 3 x 100 tn/h steam

boilers which run Steam Turbines.

This sketch shows the design by DGA of an oil & gas fired 100 tn/h power boiler, skid mounted for use

offshore in the oil and gas industry (for Gosfern Pty Ltd).

3 x 100 tn/h 40 bar 400 C ERK Steam Boilers

Designed for Gosfern Australia, 2006

FPSO Polvo

3 x 100 tn/h 40 barg 400 C oil and gas fired boilers of to Singapore for installation on

the Polvo FPSO. The vessel is now located off the coast of Brazil. The boilers were

designed by DGA under ERK License.

Safely installed on the FPSO Polvo at the Dockyard in Singapore

EGB and HRSG Development

DGA were approached by Navigat for a compact steam boiler to operate behind the

GE Jenbacher engine burning gas.

The result was the development of the EGB or ‘baby boiler’. 8 boilers were sold until Navigat realised that absorption chillers were more popular.

The design has been adapted to operate with multiple engine installations

Approximately 5 years ago Navigate cease to be the agent for Jenbacher and the

contact passed away and DGA stopped supply of the small HRSG.

DGA with ERK is capable of completing the basic designs provided by ERK into the

fully designed, stressed, design to suit the manufacturers capability precisely as

achieved for Mackenzie for the boiler supplied to Petronas.

Exhaust

Gas Inlet

Exhaust Gas

Discharge

DGA EGB (exhaust gas boiler)

Load Control Damper

Economise

r

Container

profile

Steam

drum

Location for :-

Circ pump

Control box

Damper actuator

External controls

Insulated Housing

For bank tubes

Exit duct

withdrawa

l

Explosion

door

In 2002 Navigat, the Indonesian Agent for GE Jenbacher enquired for a compact steam

boiler To suit the Jenbacher engine. This sketch design was submitted by DGA.

Forced circulation

bank

These boilers were ordered by Navigat in 2006 and supplied to Argo Pantes. After

initial problems with poor water, all 5 boilers have operated consistently since. This

was DGAs 3RD order for EGB.

HRSG Behind 2 Gas Turbines at Petronas, manufactured by Mackenzie design by

DGA to ERK License.

Vibrating Combustion Grate

DGA were approached by Mackenzie to develop a combustion grate for their palm

oil boilers. As Vickers they had some technical success with the Detroit Stoker Grate

which was priced out of the market.

DGA has since supplied 30+ grates for boilers sized between 20 and 70 tn/h steam.

The grate has proven successful at handling Palm EFB which is a notoriously

difficult fuel.

The most notable success was one of the very early Vee grates which was supplied

to MNI boiler which, despite a number of errors on the driving mechanism, still

produced an Availability of 90% over a 4 year period on a Palm EFB mix.

When DGA started to work with the Fraser Group, Mackenzie acquired the right tomanufacture and market the Vibrating Grate for their own boilers .DGA continue to market the Vee Grate to other boilermakers notably other ERKboiler licensees.

An original 3D drawing of the vibrating grate. After the initial grates were built, animprovements programme led to detail redesign of the concept. Now the grates run

successfully on Palm EFB (Empty Fruit Bunch).

W/C Vibrating Grate Stoker ForPalm Waste being installed

in a Mackenzie Boiler at MiniMalaysia. Operating on EFB.

(~48 Months)

MNI Malaysian Newspaper Industriesis powered by a Mackenzie Biomass Boiler with DGA Vee Grate on Palm EFB.

Rubber Wood, EFB and Waste in Thailand

Following a visit to MNI by SBANG in 2011, DGA received an increasing number of enquires from

SBANG, considered by many, to be the premier EPC contractor for small to medium sized power projects

in Thailand. A relationship was formed leading to the formation of a JV between Sbang and DGA under

the SBANG Corporation. The JV combined Sbang expertise in construction with DGA’s combustion and boiler experience. This JV has since lapsed and Sbang are just a customer. Four projects have since been

commissioned successfully.

• APK Hat Yai is successfully producing 60 tn/h steam from Rubber Wood root stock and slab.

• NEPS project is successfully producing power from prepared EFB fired as a single fuel.

• Clover Project (CVP) is successfully producing power from a wide variety of biomass fuels.

• Clean Energy Community (CBE) is successfully producing power from a wide variety of biomass fuels 1 project is under commissioning.

• RTB Project, Songkla is under testing and commissioning on December 2020. New orders are in or

expected from 3 Biomass power projects sized c 10 MWe via our partners in UK.

All projects use the DGA Vee Grate and the ERK licensed boiler.

Project APK Hat Yai, Thailand with SBANG

60 tn/h ERK Boiler burning Parawood slab and roots (c 2013)


60 tn/h ERK Boiler burning Parawood slab, roots and EFB)

Mixed of parawood slab and roots Empty Fruit Brunch (EFB)


60 tn/h ERK Boiler burning Parawood slab, roots and EFB)

Performance Test

Project Natural Palm, Surat Thani, Thailand with SBANG 50 tn/h ERK Boiler firing Palm EFB (c 2013)


DGA – Vibrating grate Fuel - EFB


Performance Test

Project Clover, Phrae (CVP) , Thailand with SBANG 45 tn/h ERK Boiler firing agriculture waste (C 2016)

Project Clover, Phrae (CVP) , Thailand with SBANG

45 tn/h ERK Boiler firing multi-agriculture waste (C 2016)

DGA - Vibrating grate Fuel – Woodchip, rice husk, corncob and other agriculture waste

Project Clover, Phrae (CVP) , Thailand with SBANG 45 tn/h ERK Boiler firing multi-agriculture waste (C 2016)

Project Clover, Phrae (CVP) , Thailand with SBANG 45 tn/h ERK Boiler firing multi-agriculture waste (C 2016)

Performance Test

Project Clean Energy Community,

Phitsanulok, (CBE) ,

Thailand with SBANG 30 tn/h ERK Boiler firing agriculture waste (C 2018)

Project Clean Energy Community, Phitsanulok, (CBE) , Thailand with SBANG 30 tn/h ERK Boiler firing agriculture waste (C 2018)

Vibrating grate

DGA - Vibrating grate Fuel – Woodchip, rice husk, corncob and other agriculture waste

Performance Test

Project Clean Energy Community, Phitsanulok, (CBE) , Thailand with SBANG

30 tn/h ERK Boiler firing agriculture waste (C 2018)

Under commissioning - Project RTB, Songkla , Thailand with SBANG46 tn/h ERK Boiler firing parawood chip, root and EFB

Woodchip

ROOT

EFB

Under commissioningProject RTB, Songkla , Thailand with SBANG

46 tn/h ERK Boiler firing parawood chip, root

and EFB

Vibrating grate

Under commissioning - Project RTB, Songkla , Thailand with SBANG46 tn/h ERK Boiler firing parawood chip, root and EFB

40 tn/h DGA Ekrohr Boiler with Removable Vee Grate.

Rice Husk Fired Boiler

DGA have been working on a Rice Husk boiler to produce amorphous silica ash for

approximately 7 years. The technology was provided by Torftech but it proved to be incapable

of delivering amorphous ash. DGA ensured that the client was left with an operable boiler, but

with crystalline ash.

DGA have suggested that the temperature control should be improved by changing the

design to Fluidised bed combustion, but the owner has run out of funds and now wishes to

sell the plant.

The owner is currently talking to a potential purchaser who requires DGA to be part of the

sale. DGA are willing but will require payment which must come from the new owner. This

project is currently on hold.

The target for this unit is to produce amorphous silica ash with low carbon in ash which was

the target for the original boiler. The existing design may be suitable for modification but using

the suggested BFB technology.

Cyclone Boiler

This view shows how the cyclone firing

technology has been integrated into a

modern BFB watertube Boiler.

The design of the boiler is by DGA based

on a license from ERK Eckrohrkessel of

Germany.Close coupling of the furnace and boiler allows standard boiler materials to be used for the Furnace

The design uses strict temperature

controls and FGR to control the

combustion conditions required for an

effective husk fired plant.

The development of the BFB Cyclone

boiler has been Fully supported by ERK

Eckrohrkessel.

The Boiler is designed in accordance with

ASME 1 but not stamped

The gas velocities through the boiler are

generally low to preserve the boiler from

wear, as rice husk is extremely abrasive.20 tn/h steam boiler shown

Dated 5th August 09 this picture shows a DGA boiler being assembled adjacent the

turbine house. All major equipment was on site and completed in February 2012.

DGA Plant at ABC in Cambodia – Picture taken ~August 2011

Waste & Biomass Gasifiers

DGA understands gasification technology as it is used in BFB firing systems and have

developed gasifier designs for use with Dry Biomass fuels on steam cycle plants.

However DGA believe that gasification of waste is a not a mature technology,

particularly if used with ‘syngas’ fired engines due to the high contaminants loading. Removing contaminants from hot syngas to the required level is very expensive.

If syngas is fired in a steam boiler to use the thermal energy released, then DGA can

offer suitable steam boilers to receive and combust the syngas and use dry scrubbing

systems and filters in compliance with EU WID regulations. See diagram following for a

low profile boiler to suit UK planning regs.

DGA recommend a direct combustion system for wastes as this is better controlled and

less dangerous than gasification systems. Direct combustion uses an identical

mechanism to gasification but merely completes the process safely in one reaction in a

single furnace.

12 MWe Combustor and Boiler for SYNGAS from Gasifier Firing RDF(With full WID compliance)

The plant was commissioned March 2017. It

has recently passed the emission tests

which allow it to be operated in UK.

The ERK Thermal Oil heater employs a

unique system of oil flow temperature

monitoring on a membrane tube wall which

is thought to be the first time this system

has been employed on a fired heater. This

safety system allows many of the properties

of a watertube boiler to be incorporated into

fired heater designs, including low fouling of

walls and heater bundles, very low refractory

usage, and therefore fast light up periods. It

also allows space to use firing devices

normally used on watertube boilers such as

the DGA Vee grate.

This technology opens opportunities for low

pressure equipment to be used on small

power generation plants in many areas

currently filled by steam plants, which

requires operators trained to high standard

to operate.

Thermal Oil Heater partially erected showing method of

erection by shipping reassembled modules to site.

Responding to an Enquiry from Syn2gen in UK DGA designed a thermal oil

heater to drive a Turboden ORC plant in UK.

Heater was built complete in Press Part workshop, then dismantled

for Shipment by container and flatrack.

Heater Sections

arrive on site UK,

Are checked and

prepared for lifting

straight from

transport to final

location.

Main section

prepares for Lift.

1. Heater

carried in

Lifting frame,

changes

from

horizontal to

vertical.

2. Set down in

vertical position

3. Change to vertical liftingframe

4. Ready for lifting into position.

The fired heater for compact ORC style power plant.

1

2

34

The compact building was

prepared with a section of roof

removable to accommodate

the heater and ancillary

equipment which included Bag

Filters,Cyclones ,and DGA combustion package (not shown here).

5. Main section lifted throughroof hole

6. Lowered onto tube framebelow

7. The heater is 9m tall andscale is provided from thisphoto showing erectors

The heater installation is a very

compact Installation and will

make a good reference Plant

for this technology.

The Filters and cyclone and other bulky equipment were installed through the roof and the heater followed as shown…

5

6

7


One of the advantages of this style of energy conversion is the lack of deposition from difficult waste and biomass fuels due

to the comparatively low metal temperatures used on the heat transfer with fluid temperatures being close to 300-315 C.

Higher fluid temperatures typically at the superheater on a steam plant of 450 C and higher are common and require very

careful design to produce a reliable high Availability plant without HT corrosion.


This is the condenser of the Organic Rankine Cycle unit. Turboden are a leading exponent of ORC

machines and this technology is available worldwide

This system is similar to steam cycle arrangement but is considered more safe than steam cycle as

much lower pressures and temperatures are used, which allows more monitoring by computer than an

equivalent steam unit.

This is the alternator which is driven by the ORC on this plant which generates up to 1.8 MWe of power

for use on the plant.

The secret of the ORC system is that it allows combined and heat power to be extracted which makes

a very efficient plant and saves the owners significant costs.


18 CHP Conditions at heater inlet

& outlet termination points

Flow

rate

kg/s

Supply

temp

0c

return

temp

0c

Normal operation –ORC ~1400

kWe with steam

37.7 310 190

Steam production only 37.7 ~240 210

Restricted power production

~1400kWe only (no steam)

37.7 310 236

Maximum power only

~1800kWe (no steam)

60 310 130

TYPICAL SCHEMATIC WHOLE SYSTEM

This diagram shows the basic simplicity of the organic Rankine cycle. It shows how the thermal oil circuit are split into

two circuits which allows the reduction of the exhaust gas temperature to provide higher plant efficiency and also keeps

the gas temperature low enough to be suitable for cleaning by a compact Baghouse Filter

The plant load is Varied by controlling the oil outlet temperature so high temperature Peaks at Plant MCR and low load

is provided by l ow temperature. The HP circuit oil flow to the ORC Is maintained constant as this receives the radiant

heat in the furnace. Some variation in the LP circuit is allowed.

TYPICAL FIRING CONDITIONS



Located in a delightful agricultural location nr Stratford the RCMA plant powered by Syn2gen with a CHP plant

using a Turboden ORC system and a compact Thermal Oil Heater from DGA promises great things for

Renewable Energy in Britain in future.

Hand Over - Following a performance trial RCMA accepted the plant on in June 2018 and it is now the heat and

power source for the RCMA production plant producing rape seed oil for human consumption.

Eco Plants

DGA set about the development of the Eco Plant range after realising that:

• The market in Asia is for small size power plants, 1 to 12 Mwe.

• There is an abundance of biomass and waste fuels in the region.

• Power plants must meet tightening emission regulations.

• Cost must be low to meet power purchase prices.

• Plant availability must be high.

Two distinct styles of plant are required, but where possible the same equipment can be used on both

The Eco Biomass Plant:

• Must cover a wide range of biomass fuels.

• Have reliable particulate removal equipment.

• Simple and robust design Eco Waste Plant.

• Plant design must comply with EU WID standards as minimum.

• Must have competent combustion system.

• Boiler design must be proven on waste fuels.

• The gas cleaning equipment must comply with EU WID.

A typical Eco waste plant is shown in next few slides.

Eco Waste Plant Rated for up to 10 MWe showing gas Cleaning Equipment (DGA Design)

Side Elevation

Typical Eco Waste Plant Rated for up to 10 MWePlant View

Typical Eco Waste Plant Rated for up to 10 Mwe.Front Elevation

This presentation shows the development of DGA from a small consultancy based on the combustion

expertise of David Gardner to a specialist designer and supplier of purpose designed power plants to

meet a growing market worldwide. By working with established proven entities in each market area the

technology is spreading.

DGA acknowledge the expertise and relationship with their licensor for boilers ERK Eckrohrkessel GmbH

ERK produce the very best boiler designs for many applications only some of which are shown in this

Presentation.

DGA also acknowledge the expertise in Gas Cleaning systems of Scheuch GmbH, in particular the

branch just starting in Thailand and we hope we can fold their equipment into our Eco waste and

biomass plants.

DGA also acknowledge the support provided by their various partners with whom we have worked or are

working with now, these include:

• Mackenzie for their tolerance during the development of the Vee grate,

• Sbang Corporation for their previous support in Thailand

• Fraser Thermtech in Malaysia for working to enter the Malaysian WTE market

• Syn2gen in UK for opening the market in UK for fired heaters, and the Eco Plant range

• Global in Australia for continuing the effort of selling WTE in Australia

DGA Co Ltd

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