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INFUB ‐ 11th European Conference on Industrial Furnaces and Boilers, INFUB‐11
Francisco Carrasco‐Maldonadoa , Jørn Bakkenb, Mario Ditarantob, Nils E. L. Haugenb, Øyvind Langørgenb, Simon Grathwohla, Jörg Maiera
aIFK, University of Stuttgart, Pfaffenwaldring 23, 70569 Stuttgart, GermanybSINTEF Energy Research, Trondheim, Norway
Oxy‐fuel burner investigations for CO2 capture in cement plants
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Raw meal
Cyclonepreheater
Flue gas
Calciner
Tertiary air duct
Cooler exhasut gas
Fuel/air
Fuel
Cooler
Cooling air
Rotary kiln 2000 °C
300 ‐ 350 °C
700 ‐ 1000 °C
200 °C ‐ 350 °C
850 °C
700 ‐ 1000 °C
Clinker
60 % Material CO2
40 % Fuel CO2CaCO3, SiO2, Al2O3, Fe2O3
Cement emissionsrepresent 5% of
total anthropogenicCO2 emissions
CO2 emissions in the cement industry
Source: ECRA
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The need for CCS in Cement productionWithout reduction measures: 2.4 Gt/a in 2050BLUE MAP scenario (with CCS): max 1.6 Gt/a in 2050
Increase of energy efficiencyAlternative fuels useReduction of clinker share
Reduction by:
CCS
2.5
2.0
1.5
Global CO2em
issions ofthe
cemen
tind
ustryin Gt/a
0.0
2010 2030 2050
44 %
56 %
Source: IEA Cement Roadmap
• IEA target for 2050: 50 % of all cement plants in Europe, Northern America, Australia and East Asia apply CCS
• Cement plants typically have a long lifetime (30‐50 years or more) and very few (if any) are likely to be built in Europe→ Retrofit
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Technologies to be tested ‐ oxyfuelCalciner test rigExisting <50 kWth entrained flow calciner (USTUTT) to be used for oxyfuel calcination tests
Clinker cooler To be designed and built for on‐site testing at HeidelbergCement in Hannover
Partners: USTUTT, VDZ, IKN, CTG
Partners: IKN, HeidelC, VDZ
Partners: USTUTT, TKIS, SINTEF‐ER
Oxyfuel burner Existing 500 kWth oxyfuelburner at USTUTT to be modified for CEMCAP
Source: ECRA
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1. Validation of CFD models for oxy‐fuel combustion.
2. Adaptation of test facility for cement kiln burner investigations.
3. Preliminary results of oxy‐fuel investigations.
Outline
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Simulation of USTUTT Combustion facility:
1. Validation of CFD models for oxy‐fuel combustion.
Bottomash
ID fanESPSCR
StoragetanksFD/ RG fan
O2
CO2
Stack
AirO2 CO2
Gasdistribution
APH
Coal feeding
Burnerwindbox
Air
By-passes
Bottomash
ID fanESPSCR
StoragetanksFD/ RG fan
O2
CO2
Stack
AirO2 CO2
Gasdistribution
APH
Coal feeding
Burnerwindbox
Air
By-passes
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Simulation of oxy‐fuel test at USTUTT Combustion facility with IFK burner:
1. Validation of CFD models for oxy‐fuel combustion.
Test case O2 in oxidizer[vol‐% wet]
Stoichiometricratio
O2 in stack[vol‐% dry]
Fuel input[kW]
Air 21 1,15 2,8 305
OF29 29,5 1,15 4,5 305
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South African coal:
1. Validation of CFD models for oxy‐fuel combustion.
0.002.004.006.008.0010.0012.0014.0016.0018.0020.0022.0024.0026.0028.0030.00
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
1.00 10.00 100.00 1000.00
Vol
ume-
%
Particle size [um]
CD
D[v,0.5](um)
BD
Water
[%]
Ash[%]
Volatiles
[%]
Cfix[%]
C[%]
Htot
[%]
H[%]
N[%]
S[%]
O[%]
an 1,65 14,36 27,22 56,77 67,83 4,77 4,59 1,77 0,44 9,35raw 8,94 13,30 25,20 52,56 62,80 5,25 4,25 1,64 0,41 8,66wf - 14,61 27,67 57,72 68,97 4,67 4,67 1,80 0,45 9,51
Ho,v[J/g]
Hu,p[J/g]
an 27.383 26.355raw 25.444 24.316wf 27.942 26.943waf 32.721 31.551Ho,v = HHV and Hu,p = LHV
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1. Validation of CFD models for oxy‐fuel combustion.
Primary/ coal
Secondary
Natural Gas
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CFD input
1. Validation of CFD models for oxy‐fuel combustion.
Ansys Fluent models
Code Fluent 17.02D‐Axisymmetric swirl
Mesh, number of cells 113757 (structured mesh)
Turbulence k‐epsilon, realizable, standard wall functionsk‐omega SST
Chemistry Species transport, Finite rate/Eddy Dissipation, 2‐step reaction
Radiation P1 with particle‐radiation interaction
Furnace wall temperature Profile calculated from IFK experiments. Implemented by an UDF
Inlets Velocity inlet (constant velocity)
Outlet Pressure outlet
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Temperature profile – Oxy‐fuel Case
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Source: ThyssenKrupp
a) Design of a prototype oxy‐fuel burner for cement kilns.
Source: ThyssenKrupp‐ POLFLAME
2. Adaptation of test facility for cement kiln burner investigations.
• Scaling factor of 100 between industrial and pilot burner.
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• Primary Gas (nozzles)o Velocity ca. 250 m/so 8 nozzleso Angle: 0‐40°
• Carrier gas (outer coal channel)o Transport air velocity ca. 15 m/s
2. Adaptation of test facility for cement kiln burner investigations.
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b) Adapt test facility for oxy‐cement processing
2. Adaptation of test facility for cement kiln burner investigations.
Clinker cooler
Cement kiln
Secondary Gas 700‐100°C
Primary and carrier gas
• Preheating of secondary gas• Dry secondary gas
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level no.
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Continue gas measurements
Bottomash
ID fanESPSCR
StoragetanksFD/ RG fan
O2
CO2
Stack
AirO2 CO2
Gasdistribution
APH
Coal feeding
Burnerwindbox
Air
By-passes
Bottomash
ID fanESPSCR
StoragetanksFD/ RG fan
O2
CO2
Stack
AirO2 CO2
Gasdistribution
APH
Coal feeding
Burnerwindbox
Air
By-passes
In-flameMeasurements:• Gas emissions• Gas temperature• Heat flux• Radiation, etc.
Air/Flue gas
Test facility: 500 kWth KSVA (Pulverized Coal Combustion Plant)
Burn out
2. Adaptation of test facility for cement kiln burner investigations.
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19Bottom Ash
ID fanESPSCR
Storage Tanks
Carrier gasCO2
Stack
O2 CO2
Coal feeding
Air
By-passes
CO2, O2
Air
Air
CO2, O2
Primary gas
Secondary gas
Preheaters
• Secondary gas flow lines• Gas storage tanks• Quenching system• Head of combustion chamber• Preheater system• Radiation probes
2. Adaptation of test facility for cement kiln burner investigations.
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Source: ECRA CCS Project
3. Preliminary results of oxy‐fuel investigations.
Longer flame. Altered temperature
profile. Altered heat flux
profile to material bed.
Previous results published by ECRA:
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3. Preliminary results of oxy‐fuel investigations.
Ho,v[J/g]
Hu,p[J/g]
an 33.077 32.237wf 34.657 33.894Ho,v = HHV and Hu,p = LHV
Water[%]
Ash[%]
Volatiles[%]
Cfix[%]
C[%]
Htot
[%]
H[%]
N[%]
S[%]
Cl[%]
an 4,56 2,12 11,3 82,0 77,0 3,91 3,40 1,47 3,03 0,074wf ‐ 2,22 11,9 85,9 80,7 3,56 3,56 1,57 3,17 0,078
Fuel characterization: Petcoke
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Primary gas (nozzles)
Coal + Carrier gas
482 kW
Secondary gas
T = 740 °C
v = 4,5 m/s
O2 = 21%
N2 = 79%
λ = 1,12
O2 = 2,2% vol,dry
CO2= 16,5% vol,dry
NOx = 536 ppm, dry
Flue gas
CC Shell radiation
PG = 21%
Primary gas (nozzles)
Coal + Carrier gas
482 kW
O2 = 53%
CO2 = 47%CO2 =100%
Secondary gas
Flue gas
CC Shell radiation
AIR CASE OXY‐27
T = 712 °C
v = 3 m/s
O2 = 21%
CO2 = 79%
λ = 1,13
O2 = 3,4% vol,dry
CO2= 84,6% vol,dry
NOx = 770 ppm, dry
Swirling 40°
PG = 24%
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3. Preliminary results of oxy‐fuel investigations.
Air Case Oxy-fuel
Fuel burnout 98,0 98,3
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Summary
• First simulation of test rig. Validation vs Experimental data was successful.• Two turbulence models were tested, K‐Omega produced better results.• Test facility was adapted for relevant oxy‐cement tests.• Burner prototype was designed and tested.• Demonstration tests evinced suitability to obtain similar radiation profiles
under oxy‐fuel conditions.
Further Steps• Additional testing with a higher volatile fuel.• Simulation of additional oxy‐fuel cases not investigated in facility.
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AcknowledgementsThis project has received funding from the European Union's Horizon 2020
research and innovation programme under grant agreement no 641185
This work was supported by the Swiss State Secretariat for Education, Research and Innovation (SERI) under contract number 15.0160
www.sintef.no/cemcapTwitter: @CEMCAP_CO2