overview of burner tests in vattenfall’s oxyfuel pilot plant
TRANSCRIPT
Overview of Burner testsin Vattenfall’s Oxyfuel Pilot Plant
Uwe Burchhardt, Rainer Giering,Gerd WeißVattenfall, BU R&D Projects
2013-09-10
2 | OCC3 – Burner tests in OxPP I U. Burchhardt
Agenda
The electrical ignition burner4
Summary5
Tests and results of different burner types3
Requirements on burners for Air and Oxyfuel2
Overview concept of Oxyfuel Pilot Plant1
3 | OCC3 – Burner tests in OxPP I U. Burchhardt
Base data and Technology partners
• Start up test operation Sept. 2008
• Until 17.000 operating hours in total,from it 13.200 in Oxyfuel mode,captured CO2 approx. 10.660 t
• CO2 removal rate > 90 %
• High plant availability
• Good CO2 quality for transport, storage and CCU Thermal capacity: 30 MWth
Coal demand: 5.2 t/hInvestment 80 Mio. €Total costs 150 Mio. € Technology partner :
4 | OCC3 – Burner tests in OxPP I U. Burchhardt
Boiler and Measurement points
Eco 5
SH 1
SH 2
A ir pre-heater
Eco 4
Eco 3
Eco 2
Eco 1
M easurem ent level 1 , +17500
L 8,+11500
L 9,+15500
L 10,+18500
L 11,+21000
Level 12
Level 13
Level 14
SCR 1
SCR 3
SCR 2
Burner
Steam drum
Ash transport
OFA 1 & 2
SCR optional
13m high4x4m cross area
Floor level, +0
M easurem ent level 2 , +16500
M easurem ent level 3 , +14500
M easurem ent level 4 , +13000
M easurem ent level 5 , +12000
M easurem ent level 6 , +10000L 7,
+9000
Eco 5
SH 1
SH 2
A ir pre-heater
Eco 4
Eco 3
Eco 2
Eco 1
M easurem ent level 1 , +17500
L 8,+11500
L 9,+15500
L 10,+18500
L 11,+21000
Level 12
Level 13
Level 14
SCR 1
SCR 3
SCR 2
Burner
Steam drum
Ash transport
OFA 1 & 2
SCR optional
13m high4x4m cross area
Floor level, +0
M easurem ent level 2 , +16500
M easurem ent level 3 , +14500
M easurem ent level 4 , +13000
M easurem ent level 5 , +12000
M easurem ent level 6 , +10000L 7,
+9000
Fron
t wal
l
Left side wall
Right side wall
~100
0~10
50~1
050~
1000
~1000 ~1050 ~1050~1000~1000 ~1050 ~1050~1000
3 2 14
5
67 8 9
FurnaceSoot blower before each super-heater and eco 5
3
2 1
4
2nd draft30 MW burnertop mounted
5 | OCC3 – Burner tests in OxPP I U. Burchhardt
Direct coal dosage to burner
Combustion behaviour can only be judged in connection with coal dosage
6 | OCC3 – Burner tests in OxPP I U. Burchhardt
Agenda
Outlook : The electrical ignition burner4
Summary5
Tests and results of different burner types3
Requirements on burners for Air and Oxyfuel2
Overview of concept for Oxyfuel Pilot Plant1
7 | OCC3 – Burner tests in OxPP I U. Burchhardt
Requirements on burners
- high range of particle size distribution- Variation to LHV
Flexibility for fuel quality
- Combustion gas: air or O2-mixed flue gas (21%-39%)- Fuel transport gas: air or CO2-rich flue gas- Fuel loading up to 5 kg / kg transport gas
Transport and combustion gas
- Optimal intermixing of coal stream by swirl of secondary airs
- Influence on flame characteristics regarding heat transfer behaviour
Possibility to swirl of secondary airs
- O2 excess in flue gas (downstream boiler) < 4% - compliance emission limits (CO, NOx, dust) - unburned in ash < 2%
High combustion quality: - low excess O2- emissions - unburned
- Ignition within 5 seconds- Hot-, warm- and cold start ability
Fast start ability, stable ignition, stable flame
RequirementsBurner characteristic
8 | OCC3 – Burner tests in OxPP I U. Burchhardt
Overview of tested burner
2009
2008
Burner 1: comb. Jet-/swirl burner
Burner 3:pure swirl burner
Burner 5: swirl burnerwith pre-mix possibility
Burner 2: pure swirl burner
Burner 4: swirl burneras pre-mixed burner
2010
2011
2012
9 | OCC3 – Burner tests in OxPP I U. Burchhardt
Overview of constructions
- concentric formation of one core pipe for oxidant supply, one fuel/transport gas and three secondary oxidant cross-sections
- swirl generator located in secondary and tertiary oxidant supply. Option to modify the angle of swirl generator
- Injection of fuel directly into third oxidant supply cross section
Pre-mixed swirl burner
- concentric formation of one core pipe for oxidant supply, one fuel/transport gas and two oxidant cross-sections
- Conduct of flame with a high swirl rate - Flame is short and shows characteristic bell shape
Pure swirl burner
- concentric formation of one core pipe for oxidant supply, one fuel/transport gas and three secondary oxidant cross-sections
- length of flame nearly up to exit of firth path of the boiler
Combined Jet-/swirl burner
CharacteristicsBurner type
10 | OCC3 – Burner tests in OxPP I U. Burchhardt
Agenda
Outlook : The electrical ignition burner4
Summary5
Tests and results of different burner types3
Requirements on burners for Air and Oxyfuel2
Overview of concept for Oxyfuel Pilot Plant1
11 | OCC3 – Burner tests in OxPP I U. Burchhardt
Overview of burner tests
- Flame characteristics and heat transfer- Switch from Air to Oxyfuel operation and back- O2 concentration in combustion air (burner lambda, boiler lambda)- Reduction O2 excess at compliance emission values- Swirl variation- In-flame measurements- Optimization firing behaviour with variation OFA- part load behaviour- different lignite qualities (sulfur, particle size distribution)
12 | OCC3 – Burner tests in OxPP I U. Burchhardt
Comparison of operational points in Oxyfuel
characteristic diagram for different burner test
20
25
30
35
40
45
2,0 3,0 4,0 5,0 6,0 7,0 8,0
O2 in fluegas (Vol %,f)
O2
in o
xida
nt (i
n %
)
TC 3
TC 4
TC 5
TC 6
TC 7
TC = Test Campagne of burners
13 | OCC3 – Burner tests in OxPP I U. Burchhardt
Emissions in Oxyfuel: NOx, CO vs. excess O2 (TC 5)
0
100
200
300
400
500
600
700
800
900
1000
0 1 2 3 4 5 6 7 8
Excess O2, vol-% (wet)
CO
& N
Ox,
mg/
Nm
3 (6
% O
2, d
ry)
Oxy24 CO Oxy24 NOx Oxy28 CO Oxy28 NOx
Oxy32 CO Oxy32 NOx Oxy36 CO Oxy36 NOx
14 | OCC3 – Burner tests in OxPP I U. Burchhardt
O2-Mix: Pre-mixed mode, Expert mode und Hybrid mode
Furnace
BurnerStart burner
2. path
(DeNOx)
3. path
Oxygen
FG-Rec.
Furnace
Burner
2. path
(DeNOx)
3. path
Oxygen
FG-Rec.
Furnace
Burner
2. path
(DeNOx)
3. path
Oxygen
FG-Rec.
Expert modePre-mixed mode Hybrid mode
15 | OCC3 – Burner tests in OxPP I U. Burchhardt
Comparison of burner operational area on varied operation mode and in respect to emission limits
16
18
20
22
24
26
28
30
32
34
36
1 1,5 2 2,5 3 3,5 4 4,5 5
O2 in flue gas (Vol.-%,w)
O2
in O
xida
nt (
Vol.-
%,w
)pre-mixed Mode Expert-Mode Air operation Hybrid-Mode
16 | OCC3 – Burner tests in OxPP I U. Burchhardt
Influence of swirl change on flame shape and temperature
Before adjustmentswirl SA1/SA2
After adjustmentswirl SA1/SA2
Furnace camera Thermovisions camera (DURAG) CombTec-Measurement
17 | OCC3 – Burner tests in OxPP I U. Burchhardt
Overview of burner tests
Variation O2 content 21% to 39%in different burner registerStable operation < 3% O2 excess possible
O2 concentration in combustion air(burner lambda, boiler lambda)Reduction O2 excess at compliance emission values
Swirl of secondary air flows necessary Swirl variation
Optimisation OFA has influence of combustion behaviour (reduce NOx/CO)
Combustion behaviour with variation OFA (staged combustion)
Validation for CFD burner model possibleIn-flame measurements
In general in 20 minutes realizedSwitch from air to Oxyfuel operation and back
Stable flame without pulsation,- Flame shape (volume and length)
Flame characteristics and heat transfer
ResultsBurner tests
18 | OCC3 – Burner tests in OxPP I U. Burchhardt
Agenda
Outlook : The electrical ignition burner4
Summary5
Tests and results of different burner types3
Requirements on burners for Air and Oxyfuel2
Overview of concept for Oxyfuel Pilot Plant1
19 | OCC3 – Burner tests in OxPP I U. Burchhardt
Features of OxyAir Burner 5
Page 19
Low-NOX-Technology
Load Range 100 % down to 30%
Fuel Load up to 4 kg/kg
Applicable for Oxyfuel and Air Operation Mode
Flame Stabilizer and Swirler for reliable Ignition and stable Flame
20 | OCC3 – Burner tests in OxPP I U. Burchhardt
Test of ignition by Microwave-Plasmatron
Concept:• Direct Ignition of dried lignite by Microwave Plasmatron• Usage of up to 3 plasma lances for ignition during tests operation• Control of ignition by control box on-site• Supply of external media e.g. power, compressed air and cooling water
Microwave- Plasmatron:• No electrodes that could wear, low afford
of maintenance• Easy construction• Low power consumption for ignition• Technology is in development, currently
no commercial solution available• Limited in size• Due to high temperature of plasma
flame an external cooling is required
Generator
Ignition lance
Ignition flame
Fasteningat burner
© Copyright by Hegwein (Patent pending)
©
21 | OCC3 – Burner tests in OxPP I U. Burchhardt
Ignition of 30 MW dry lignite burner with plasma lances
22 | OCC3 – Burner tests in OxPP I U. Burchhardt
Test results electrical Ignition
Successful ignition without preheating of combustion air30 °CWithout
pre-heatingTemperature of combustion air
Optimal position is dependent on burner designPosition of plasma lance
Get more information about ignitionbehaviour after long term depositionin boiler
> 100 StartLong term experience
Successful Ignition with 2 kW el. Load2 kW3 kWel. load for ignition
of plasma lance
Successful Ignition over a wide Range, lowering of start
performance on 10% (3 MW )3 - 15 MW15 MWStart up load of burner
Successful ignition in cold boiler43°CCold boilerBoiler temperature
All major issues of optimization arecarried out with one plasma lance13 - 1Number of plasma lances
CommentsActualTargetCriteria
23 | OCC3 – Burner tests in OxPP I U. Burchhardt
Agenda
Outlook : The electrical ignition burner4
Summary5
Tests and results of different burner types3
Requirements on burners for Air and Oxyfuel2
Overview of concept for Oxyfuel Pilot Plant1
24 | OCC3 – Burner tests in OxPP I U. Burchhardt
Summary and outlook
• Vattenfall cooperated with many technology partners for the burner development for Oxyfuel (5 burners from 4 different manufactures)
• Varified stable ignition and burnout behaviour
• Stable operation with high O2 concentration in oxydant and low O2excess. All emission limits are reached.
• Pre-mixed mode for commercial CCS plant sufficient
• Burner design depends on firing concept
• Electrical ignition burner is an economical alternative
Vattenfall is ready to scale up for a demo plant