Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
Development in Oxy-coal Combustion Boiler: A View from Boiler Manufacturer
Timo Hyppänen, Arto HottaInaugural Workshop on OxyFuel Combustion
Cottbus, GermanyNovember 29.-30., 2005
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
Development in Oxy-coal Combustion Boiler: A View from Boiler Manufacturer
Outline of presentation• Oxycombustion in PC boilers
• Plant optimization• Burner design in oxycombustion• Boiler design in oxycombustion
• Oxycombustion in CFB boilers• R&D• Process performance in oxycombustion• Boiler design in oxycombustion• Commercialization pathway
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
Role of the boiler in oxycombustion plant
Partial CO2circulation
BoilerCondensation
DryingCompression
Flue gas cleaning
Air separation
O2
CoalCO2/H2O
N2AirH2O, …
TransportStorage
CO2
Main objectives for the development• Design: Develop and optimize boiler
design (heat balances, profiles, steam cycle, materials)
• Performance: Efficiency, combustion, emissions, availability
• Cost: Capital, operating and maintenance
Steam turbine G
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYPC STUDY
• System: Optimize plant design to maximize overall efficiency
• Burners: Optimize design to ensure stable ignition, safe operation, and minimize NOx
• Furnace and HRA: Optimize location of burners, ports, and internal radiant surfaces
• Economics: Compare cost of electricity generation to other CO2capture technologies
Reference: Subcritical 460MW HV Bituminous
Ref.: Selzer, Fan & Fout, 22nd Annual Pittsburgh Coal Conference Pittsburgh, PA, September 12-15, 2005
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYPCPlant Optimization
O2-Fired PC System Model (Aspen-Plus)Net Cycle Efficiency Vs. Flue Gas Recycle Flow
28.8
29
29.2
29.4
29.6
29.8
30
30.2
30.4
Effic
ienc
y (%
)
(Air-Fired PC Efficiency = 36.7%)
A6
G1
A5
A4
G3
47
G4
48
24
G5 G6
26
G7
G8
G9
G12
35
G13
41
G10
44
45
23
G11
81
G14
34
G15
PA
A2
G16
A1
A3
G17
NH3
G18
ASH
G19
G20
L2
L1
STK1
LIQ
SORB
SLV
SA
O2RY2
E1
G2
QB
Q
COAL
G21
C1
C2
C3
D1
C4
RY1
BYP
AIR
90
A0
AV
N2
C5
C6
C7
C9
C10
C8
D4
D2
D3
C11
D5
PIPE
VANT
49
67
3
1
27
5 6 8 28 29 30
40
WEW
22
21 18
56
25
5957
M AIN
2
10
9
14
MK
53
58
20
52
15
17
4
63
89
11
65
80
66 69
78
70
77
71
50
73
68
86
87
85
84
83
7
166174
32
E2
42
BLD
46
43
33
60
19
64
R STO IC
FLAME NOZ
FSH
FRH
SPG
UECO
PSH
RHB
DAM P
LECO
SC1
SC23
SC4
PW
PAFAN
AAHX
DENOX
ESPIDFAN
PREC
SLV
FGDPOND
SAFAN
SPA
SP1
HEATER
BOILER
M ILL
SPF
COL1
SEP1
RECY
GRH
COM P
DIST AC
COMP1COMP2
GBY
COMP3DEM
COL2 COL3COL-4
PCO2
DIS
EXPD
HP IP1 IP2 LP1 LP2 LP3 LP4 LP5
WM ULT
EG
EH
EI2
EL1 EL2 EL3 EL4
GV
COND
FSPLI T
SSR
VD
EI1
L2
V7 V6 V5 V3 V2 V1
CP
DEA
BFP1BFP2
FWH1FWH2FWH3FWH6FWH7FWH8
L1
M1
RGI BBS
EQ
DRUM
DIVW
ROOF
PRPB
FWV
SPQ
SPRAY
DPHRH
DPCRH
BYFWWETECO
FGD
ASU
50.0% 55.0% 60.0% 65.0% 70.0% 75.0%• Cryogenic ASU• Subcritical steam cycleFlue Gas Recycle Flow
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYPCBurner design
Burner design objectives• Low NOx • Stable ignition• Safe operation• Coal burnout
Optimization variables• Oxygen/recirc. gas ratios in primary
and secondary gas streams• Swirl and velocity in prim./sec. gases• Over fire gas
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYPCFurnace and HRA design
O2-Fired PCAir-Fired PC
Boiler DesignRecycle flow 56 %
Furnace Gas Temperature Furnace Wall Heat Flux
65% of Air PC Surface Area 45% of the volume
F Btu/hr-ft2F Btu/hr-ft2
• Significant heat flux increase due to higher T, H2O, CO2
• Waterwall material upgraded from C.S. to T91
Increased burnout, lower NOx
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYCFB
• The CFB advantages exist in CFB oxycombustion
• Multi-fuel capability (coal, petroleum coke, lignites etc.)
• SOx and NOx reduction without scrubbers
Dual-firing Capability: Design CFB boiler for air-firing and oxy-firing.
Balancing of temperature levels by fluidized bed mixing -> Potential for high O2 contents -> Opportunities to make significant size reductions and high boiler efficiencies.
FW CFB heat surface options available for high O2 contents.
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYCFB testing and developmentCombustion process
ENERGYENERGY
CIRCULATING FLUIDIZED BED REACTOR
S e c o n d a r yc y c lo n e
F u e l c o n ta in e r 1 a n d 2 Z o n e 1
Z o n e 2
G a s c o o lin g
P r im a ryc y c lo n e
O b s e r v a t io n p o r tS a m p lin g p o r t/D e p o s it p ro b e
Z o n e 3
Z o n e 4T o s ta c k
S a m p l in g p o r t
S a m p lin g p o r t
O b s e rv a tio n a n d s a m p lin g p o r t /D e p o s i t p ro b e
A d d it iv ec o n ta in e r
O 2
S e c o n d a ry g a s(p re h e a te d )
P r im a ry g a s h e a t in g
C O 2 / N 2
P C c o n tro l a n d d a ta lo g g in g s y s te mP C c o n tro l a n d d a ta lo g g in g s y s te m
S a m p l in g p o r t
S a m p lin g p o r t
A ir
nc Xkm
tm
r O2cc
dd
==
COefCO Ykt
Y=−
dd
)/1/(1 mCOef kk τ+=
nrefv ddTAb )/)(/exp(=τ
Modelanalyses
CO combustionMixingChar combustion
Volatile, m
oisture r
elease
k W /m 2
1D -M O D E Lflue g a s
1
n n+ 1
to s ta ck
Pr im ary a irS econ da ry a ir
2
n-1
3
n-2
B E N C H S C A LE R E A C TO R (B F B /C F B )
A ir
O 2, C O 2, C O , N 2 , S O 2 , N O
S econdary a ir
C ontinuousfue l fee d
Fue l ba tch feed
C oo ler/hea ter
C oo ler
P rim a ry gas heatin gPC con tro l and da ta logg ing sys tem
C yc lone
F ilte rTo S tack
B E N C H S C A LE R E A C TO R (B F B /C F B )
A ir
O 2, C O 2, C O , N 2 , S O 2 , N O
S econdary a ir
C ontinuousfue l fee d
Fue l ba tch feed
C oo ler/hea ter
C oo ler
P rim a ry gas heatin gPC con tro l and da ta logg ing sys tem
C yc lone
F ilte rTo S tack
A ir
O 2, C O 2, C O , N 2 , S O 2 , N O
S econdary a ir
C ontinuousfue l fee d
Fue l ba tch feed
C oo ler/hea ter
C oo ler
P rim a ry gas heatin gPC con tro l and da ta logg ing sys tem
C yc lone
F ilte rTo S tack
ŁAGISZA 460 MW e supercritical OTU CFB
kW /m 2
Bench scale Pilot scale Boiler scaleEXPERIMENTAL SCALES
Models for phenomena
1-D Processmodels
3-D Processmodels
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYCFB boiler performanceCombustion process – bench scale tests
Bench scale testing• VTT, Technical Research Centre of Finland
850
870
890
910
930
950
970
0 60 120 180 240 300 360
Time [s]
Tem
pera
ture
[ºC
]
10% O2 in CO2
20% O2 in CO2
30% O2 in CO2
60% O2 in CO2
990
BENCH SCALE REACTOR (BFB/CFB)
Gas
Nitrogen
Secondary air
Continuousfuel feed
Fuel batch feed
Cooler/heater
Cooler
Primary gas heatingPC control and data logging system
Cyclone
FilterTo Stack
Nitrogen
Secondary air
Continuousfuel feed
Fuel batch feed
Cooler/heater
Cooler
Primary gas heatingPC control and data logging system
Cyclone
FilterTo Stack
Effect of O2/CO2 atmosphere on• Emissions
• NOx• CO• SO2/Sorbent
• Combustion• Materials
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYCFB boiler performanceCombustion process – pilot testing
Pilot scale testing• VTT, Technical Research
Centre of Finland
•Emissions•Combustion profiles•Temperature/heat duty profiles•Materials
ENERGYENERGY
CIRCULATING FLUIDIZED BED REACTOR
S econdarycyc lone
F ue l con ta iner 1 an d 2 Zo ne 1
Zo ne 2
G as coo lin g
P rim a rycyc lone
O bserva tio n portS am pling p ort/D epos it p robe
Z one 3
Zone 4T o s tack
S am pling po rt
S am plin g po rt
O b servation a nd sam pling po rt/D epos it p robe
A dd itiveco nta iner
O 2
S econda ry gas(p rehe ated )
P rim ary ga s hea ting
C O 2 / N 2
P C co n tro l an d da ta logg in g sys temP C co n tro l an d da ta logg in g sys tem
S am p ling po rt
S am p ling port
A ir
0
0.2
0.4
0.6
0.8
1
1.2
1000 1100 1200 1300 1400 1500Time (s)
Rel
ativ
e ox
ygen
con
cent
ratio
n
Model, 10% O2 (bench)Measurement, 10% O2 (bench)Model, 20% O2 (bench)Measurement, 20% O2 (bench)Model, 45% O2 (pilot)Measurement, 45% O2 (pilot)
Oxygen responses for a coal fuel batch
Effect of Oxycombustion
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYCFBBoiler design
Effect of O2 concentration on boiler heat balance.
28
40
60
80
100
0
10
20
30
40
50
60
70
80
90
100
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000T adiabatic [°C]
hot l
oop
shar
e of
tota
l hea
t dut
y of
bo
iler [
%]
0
10
20
30
40
50
60
70
80
90
100O
2 share if input gas [%]
Existing CFB units / designsO2 CFB designsO2 share of input gas (O2/CO2)
normal air combustion
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYCFBBoiler design options
Boiler design• Heat balances for
varying loads/fuel qualities
• Optimisation of oxygen/recirc. gases
• Development of heat surface configurations
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYCFBEffect of oxygen enrichment, a preliminary study
600 MWth
60 % oxygen in input gas
INTREX
2 CASES, 600 MWth:
•O2 21 %: Normal combustion with air.
• O2 60 %: 60 % of gas fed to the CFB is O2. The flue gas flow rate is 40 % from normal air combustion. Total volume reduced to 38 %.
21 % oxygen in input gas
40.8 m x 20.3 m x 9.4 m 45.0 m x 12.5 m x 5.3 m
H x D x W
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYCFBOxygen enrichment
Heat duties in the two cases
171
8733
0
117
0
408
11785
39
152 10540
0
192
28
517
40 53750
100150200250300350
Hea
t dut
y [M
W]
Air design (21% O2 of input gas)
O2 design (60% O2 of input gas
0
400450500550600
Furnac
e wEva
p wing Rleg
+ INT
Evap IN
T
EX superh
eat
allsu
perhea
ting
Total in
hot
ackp
ass su
perwate
r prAir /
O2 p
re
alls
wall
Separa
tor +
wall REX
INTR
ing
WingW
loopB
heat
Feed
ehea
t
heat
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYCFBOxygen enrichment
Vertical temperature profiles in the furnace in the two cases
800810820830840850860870880890900910920930940950960970980990
1000
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44
Tem
pera
ture
[°C
]
Air design (21% O2 of input gasO2 design (60% O2 of input gas)
Height [m]
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYCFBEffect of oxygen enrichment, a preliminary 3-D study
2 CASES, 600 MWth:
•O2 21 %: Air combustion, O2 = 21 %.
• O2 60 %: 60 % of gas fed to the CFB is O2. The fluegas flow is 40 % from normal air combustion. Total volume reduced to 38 %.
21 % O2 60 % O2
40.8 m x 20.3 m x 9.4 m 45.0 m x 12.5 m x 5.3 m
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OxyCFB boiler performanceCombustion process, 3-D study
Oxygen concentration TemperatureAir Design 60 % O2 DesignAir Design 60 % O2 Design
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
Oxycombustion CFB – Commercialization Pathway(if development schedule would be limited only by oxycombustion boiler)
• Partnerships for R&D and commercial demonstrations
• R&D (2003 -> )
• Small scale pilot testing (2005 -> )
• Large scale (1 - 10 MWt) oxycombustion CFB pilot plant (2006 – 2008)
• Small scale (25 MWe) demonstration plant in US / Europe (2008 – 2010)
• Large scale (250 MWe) demonstration plant in US / Europe (2010 – 2015)
• First commercial sale (100 – 400 MWe) (2013 – 2016)
Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005
OXYCOMBUSTIONSUMMARY
• Both PC and CFB technology are feasible solutions for oxycombustion
• Further development and optimisation will provide more comprehensive picture of the role of oxycombustion in reducing CO2.• fuels, capacities, steam cycles, overall plant options, new designs/concepts
• Experimental research and demonstration of oxycombustion needed• reduce risks• refine the prediction and design methods and tools for boiler designs and
performance predictions
• Demonstration of oxycombustion• small risk in combustion process especially for lower oxygen concentrations
in retrofits