timo hyppänen, arto hotta inaugural workshop on oxyfuel … · outline of presentation ... fspl it...

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


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


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


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


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


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


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


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.


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


Fue l ba tch feed

C oo ler/hea ter

C oo ler


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


Fue l ba tch feed

C oo ler/hea ter

C oo ler


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


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


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


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


OXYCFBBoiler design options

Boiler design• Heat balances for

varying loads/fuel qualities

• Optimisation of oxygen/recirc. gases

• Development of heat surface configurations


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


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


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]


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


OxyCFB boiler performanceCombustion process, 3-D study

Oxygen concentration TemperatureAir Design 60 % O2 DesignAir Design 60 % O2 Design


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)


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

timo hyppänen, arto hotta inaugural workshop on oxyfuel … · outline of presentation ... fspl it...

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