the future of r&d requirements for oxyfuel combustion keynote... · the future of r&d...

The Future of R&D Requirements for qOxyfuel Combustion

-Activities in Japan-

Ken OKAZAKIDean School of Engineering

-Activities in Japan-

Dean, School of EngineeringProfessor, Dept. of Mechanical and Control Engineering

Tokyo Institute of Technology (Tokyo Tech), Japan

Takashi KIGATakashi KIGAPower Plant Division

IHI Corporation, Japan

C i R t Y A t li

Tokyo Institute of TechnologySchool of Engineering

Capricorn Resort Yeppoon, Australia 13th September, 2011

“Oxy-fuel combustion for power At the beginning

y pgeneration and carbon dioxide (CO2) capture”

Editted by Ligang Zheng

Part IIntroduction to oxy fuel combustion

Contents

Introduction to oxy-fuel combustionPart II

Oxy-fuel combustion fundamentalsPart IIIPart III

Advanced oxy-fuel combustion concepts and developments


Oxy-Coal CombustionAt the beginning

Presentations2004 No presentation2005 One presentation2005 One presentation2006 One session2007 Full sessions (full of audience)… …2011 Full sessions (full of audience)

Panel: Oxy-Fuel TechnologyOxy-Fuel Technology I : Overview & DemonstrationsO F l T h l II E i iOxy-Fuel Technology II : EmissionsOxy-Fuel Technology III: Experimental StudiesOxy-Fuel Technology IV: Understanding Oxy-Combustion Impacts


Oxy-Fuel Technology V : Burner Developments

US: FutureGen ProjectEU: Proposal under the NER300

2 Oxyfuel CCS projects were applied

At the beginning

"This investment in the world's

Announce of US DOE

US: FutureGen Project 2 Oxyfuel CCS projects were applied for a share of funding from NER300

This investment in the world s first, commercial-scale, oxy-combustion power plant will help to open up the over $300 billion

f J h ldmarket for coal unit repowering and position the country as a leader in an important part of the global clean energy economy."

Janshwalde Project(Germany)

global clean energy economy.

Dr. Steven ChuU.S. Secretary of EnergyA t 5 2010

Drax Project August 5, 2010

j(Yorkshire)(England)

Tokyo Institute of TechnologySchool of Engineering< Source by Homepage of US DOE > < Source by Homepage of NER300 >

Contents

Oxyfuel Development History in JapanOxyfuel Development History in JapanBasic Study ItemsStudy items for DemonstrationStudy items for DemonstrationFuture StudyConclusionConclusion


200 FutureGen/B&W

DemoDemo.

Bench/Pilot

Terry Wall, IEA 1st Oxyfuel Combustion Conference, 2009

Tokyo Institute of TechnologySchool of Engineering6

O2/CO2 (Oxy-firing) Coal CombustionConventional pulverized coal combustionConventional pulverized coal combustion

CO2 concentration in flue gas is about 13 %

Great energy consumption to separate CO22

O2/CO2 pulverized coal combustion

CO2 concentration in flue gas is enriched up

to 95 %Easy and efficient CO2 recoveryto 95 %

O2

Coal

O d tiAir Furnace

Practically realized by IshikawajimaharimaCo., Ltd. ASU

Small amount of exhausted gas (extremely low amount of

2O2 production Furnace

Oxy-firing of coal


( yNOx, SOx)Recycled gas<Okazaki, Ando, ENERGY, 1997>

Study Items for Commercialization

O d ti & l Oxyfuel Plant (Integrated operation)Oxygen production & supply Method & System oxygen purity

Oxyfuel Plant (Integrated operation)Performance (Boiler Efficiency, CO2 capture rate)Control (Oxyfuel, MFT)Operation(Mode change, Load range, Start-up, Shut-down)Durability and Safety

CoalBoiler

AH FFFGLPH

Durability and Safety

CO2 Capture ProcessSystem Optimization

GRF

AH

Stack

FGLPH

Mill

O2Air

N2

System OptimizationImpurities RemovalOutlet CO2 Properties

CO2 liquefaction

Non-condensable gas(CO2, H2O, SO2…)

<Oxyfuel boiler>

ASU

<Oxygen production & supply>

O f l B il (F )

CO2 tankFlue gas treatment & compressor Cold Box

Oxyfuel Boiler (Furnace)Combustion characteristicsFlame stabilityRadiation heat transfer Oxyfuel Boiler (Flue Gas)

C i E i t


< CO2 capture process > Corrosion Environment Trace Element

Oxyfuel system development history in JapanNow

201520102005200019951990Now

2020

Demonstration ReadyBasic Study(NEDO)(NEDO)

Feasibility Study(NEDO)

The first national Oxyfuel R&D project in Japan

Japan and Australia Joint Demonstration Project

( )

Callide Project(METI/NEDO)

Application Study

Demonstration

Future Study

Oxyfuel basic study was performed from 1990 Demonstration Ready by the end of 1990’s


Demonstration Ready by the end of 1990 s Demonstration Project was conducted from 2004, and operation will stat soon

Oxyfuel system development history in Japanal

e

Commercial

Sca

Pilot Plant (Horizontal)

Pilot Plant (Vertical)

Drop Tube Furnace Ignition apparatus Ignition apparatus

under Micro-gravity

Large Scale DemonstrationCallide-A


Time1990 1993 2011 2015~1998

Pilot plant and demo plant

Pilot Plant(Horizontal)

Pilot Plant(vertical)

Demo Plant(Callide)(Horizontal) (vertical) (Callide)

Capacity Max. 150kg/h(Coal)(1.2MW thermal)

30MWe(100MWth)

Furnace I D 1 3m x L 7 5m Steam GeneratorFurnace I.D. 1.3m x L 7.5m Steam GeneratorYear 1993 1998 2011

Photo


Basic Study Items

Coal jet ignition Chemistry Burner aerodynamics and heat transfery

Char burnout SOx

Ash partitioning Ash partitioning Deposition Trace elements

Combustion by-products Combustion by products NOx, SOx

Heat transfer Radiant zone Radiant zone Convective zone


NOx reduction in Oxyfuel

Pulverized Coal + Gas

Alumina tube

Heater To Exhanst

To Analysis

Combustion Efficiency and NOx Conversion Ratio

NOx Reduction Ratio(doped NOx in combustion gas)

Drop Tube Furnace

< Kiga, Thermal Energy Symposium,1992 >g , gy y p ,

Combustion Efficiency was not changed by substitution of CO2 for N2 NOx comversion ratio decrease with increase the CO2 substitution NOx is possible to be reduced by gas recycle into flame


NOx is possible to be reduced by gas recycle into flame

Mass balance of N-atoms

System CR*Exhausted-NExhausted N

Fuel-N=

local CR and local RR wereexperimentally identified.


<Okazaki, Ando, ENERGY, 1997>

d ffi i COEasy and efficient CO2d ffi i COEasy and efficient CO2

Further NOx Reduction by Heat Recirculation

CaCO3

Easy and efficient CO2

separation · recovery

High

Easy and efficient CO2separation · recovery

CaCO3

Easy and efficient CO2

separation · recovery

High

Easy and efficient CO2separation · recovery

<Liu & Okazaki FUEL 2003>3

Small amount of

CoalO2

High concen-tration CO2

Furnace

3

Small amount of

CoalO2

High concen-tration CO2

Furnace

<Liu & Okazaki, FUEL, 2003>

exhausted flue gas(Extremely low NOx,SOx)

CO2

Recycled heat SOx emissions)

exhausted flue gas(Extremely low NOx,SOx)

CO2

Recycled heat SOx emissions)SOx)

Recycled gas (Mainly CO2 including NOx, SOx)

Intensify coal combustionDecrease NO further

Additional merits

SOx emissions)SOx)

Recycled gas (Mainly CO2 including NOx, SOx)

Intensify coal combustionDecrease NO further

Additional meritsIntensify coal combustionDecrease NO further

Additional merits

SOx emissions)

Decrease NO further through combustion with low O2 concentrationImprove fuel flexibilityB d l d h

Schematic of O2/CO2 Coal Combustion ith b th d h t i l ti






Broaden load change range of a boiler

with both mass and heat recirculation Broaden load change range of a boilerBroaden load change range of a boiler

with both mass and heat recirculationwith both mass and heat recirculation

Drastic Reduction of CR* (Fuel-N to NOx) by Oxy-firing

Base caseC ti l

Oxy-fuelO2 : 30% O f l

ConventionalO2 : 21%H.R.: 0%

O2 : 30%H.R.: 0%

Oxy-fuelO2 : 21%H.R.: 0%

Oxy-fuelO2 : 15%H.R.: 40%

<Liu & Okazaki, FUEL, 2003>


The first oxyfuel combustion trial in 1993Initial Combustion TestInitial Combustion Test

Difficult of holdingp. [d

egC

]

Air (Wind-box O2: 21%)

Difficult of holding the stable flame in case of wind-box O2 of 21% in Distance from burner exit [m]

Flam

e Te

m

oxyfuelm

e Te

mp.

[deg

C]

Oxyfuel (Wind-box O2: 21%)Need to increase the inlet-O2 in order to keep the stable flame and

Distance from burner exit [m]

Flam

egC

]

stable flame and radiation heat transfer

Flam

e Te

mp.

[de


Oxyfuel (Wind-box O2: 30%)

17

Distance from burner exit [m]

< NEDO Report, 1993 >

Flame Propagation Velocity in High CO2 Concentration30mm

Coal A(N2/O2)

Coal B(N2/O2)

Coal C(N2/O2)

Coal A(CO2/O2)

Coal A N2/O

2

1.5Ignition

5ms Coal A(CO2/O2)

Coal C(CO2/O2)1.0

5ms

10ms

Bright Low light

Coal C CO2/O

2

Coal C N2/O

2

Coal A CO2/O

2

0

0.5

15ms

20ms

light

Flame propagation behavior

0 1 2 3 4

Coal concentration　[kg/m3]

0

Result of gravity-free experiment

Coal A, N2/O2 Coal C, N2/O2 Coal C, CO2/O2

In CO2/O2, flame brightness reduces and flame becomes unstable.

< Suda, et al, IHI Engineering Review, 1999 >By using a microgravity condition, effect of natural convection and buoyancy can be neglected, and experiment data can be directly compared with numerical simulation.

Tokyo Institute of TechnologySchool of EngineeringCopyright © 2008 IHI Corporation All Rights Reserved.

2 2, g Flame propagation velocity in CO2/O2 largely decrease to 1/3–1/5 of that in N2/O2

One-Dimensional Flame Propagation Model

3

3.5

N2/O2CO2/O2

/ k Δl

x

Ignition source

Tw Radiation Tp(n)

Tg(n) Volatile releaseand combustion

1.5

2

2.5CO2/O2,k=0

In N2/O2

In CO2/O2

Absorption by gas or particle

Scattering by particle

Heat conduction betweengas and particle

x=L=N×Δln=N

Flame position Tp(n)>Tig

Element n=1

0

0.5

1

0 0 5 1 1 5 2 2 5 3 3 5One-Dimensional Model

0 0.5 1 1.5 2 2.5 3 3.5

Coal concentration [kg/m3]

Calculated Results of Flame Propagation Velocity

Large decrease of flame propagation velocity is mainly due to large heat capacity and small thermal diffusivity in CO2/O2

< Suda & Okazaki, FUEL, 2007 >


and small thermal diffusivity in CO2/O2

NOx Reduction in Pilot Plant Test


< Takano et al, IHI Engineering Review, 1995 > The effect of oxygen direct injection tothe burner on unburned carbon and NOx

Study items for Demonstration (Callide-A)

Heat AbsorptionCombustibilityCarbon-in-ash

EmissionNOxNOx

Corrosion EnvironmentSOxHgDynamic Characteristics

AuxiliaryAuxiliaryMixing O2 with Recycle flue gas Flame Detector


Ignition of Fly ash

70 Air case Need to be the same furnace heat absorption in

Simulation of heat absorption

Air Oxy1 Oxy2 Oxy3Total gas flow 142t/h 117t/h 140t/h 170t/h

50

60

70

bsor

ptio

n (M

W)

Air caseOxy case

WB O2: 40wet%

WB O2: 50wet%

pcase of retrofit from air combustion boiler

Total gas flow 142t/h 117t/h 140t/h 170t/h

Total O2 conc. 21% 30.2% 26.5% 21.7%

FEGT Base Lower Nearly equal Higher

Heat absorption Base Lower Nearly equal Higher30

40

20 25 30 35Furn

ace

heat

ab

O2 content of total gas (wetvol%)

WB O2: 30wet%

Air Oxy 1 Oxy 2 Oxy 3Left Front Right Rear Left Front Right Rear Left Front Right Rear Left Front Right Rear

Si l i l h b 2 % f l O i< NEDO Report, 2005 >


Simulation results suggests that about 27% of total O2 concentration seems to be the same heat absorption in furnace as air combustion

Heat flux and Flame temperature (Pilot plant)

Flame temperatureHeat flux

1800Coal B/Oxy

100 OxyAi

1400

1500

1600

1700

(deg

ree

C.)

Coal B/OxyCoal B/Air

50Flux

Air

1100

1200

1300

Flam

e te

mp.

(50

Hea

t

900

1000

0 1 2 3 4 5 6

Distance from burner throat (m)

T t l O C 27%( t)

00:00 0:10 0:20 0:30 0:40 0:50 1:00

Time

Same level with heat flux at air in case of 27% total O2 Concentration

Total O2 Conc. : 27%(wet)< CCSD Report, 2006 >


Flame temperature was 50 degree C lower than that of air

Combustion Characteristics (Pilot plant)

10

e(%

) Coal ACoal B

400

500

MJ)

Coal ACoal B

5

sh O

xy m

ode

Coal C

300

400

mod

e (m

g/M

Coal C

Car

bon-

in-a

s

100

200

NO

x, O

xy

00 5 10

CCarbon-in-ash Air mode(%)

00 100 200 300 400 500

NOx, Air mode(mg/MJ)

NO C b i hNOx Carbon-in-ash

NOx emission is reduced in compared with air combustion

*Negative Pressure in Furnace < CCSD Report, 2006 >


p Carbon-in-ash is also reduced in oxyfuel

Combustion Characteristics (Pilot plant)

20

pm)

Coal ACoal B

2000

m)

Coal ACoal B

10

15

xy m

ode

(pp Coal C

1000

1500

y m

ode

(ppm Coal C

5SO3,

Ox

500

SO2,

Oxy

00 5 10 15 20

SO3 , Air mode(ppm)

00 500 1000 1500 2000

SO2 , Air mode(ppm)

SO SOSO2 SO3

SOx concentration is higher than in air combustion due to recycle

*Negative Pressure in Furnace< CCSD Report, 2006 >


g y

1000 Coal A-Air

SO3 behavior (Pilot plant)

100

1000

ativ

e nu

mbe

r)

Coal A-AirCoal A-OxyCoal B-AirCoal B-Oxy

: Value is low er limit, in caseof less than detection level

SO3 concentration is rapidly decreased at outlet of air heaterSO3 emission is not detected at the

1

10

SO

3 (-

, rel

a 3stack inlet

air heaterinlet

air heateroutlet

bag filterinlet

bag filteroutlet

SO3 is captured in ash deposit on the heat transfer surface of air heater and the filter of the bag filter

Electrical heater M i P i

This behavior is the same as flue gas in condition of air combustionC i i t ft b

PAF

Stack

IDF

Furnace

Pulverized coal

heater

Bag filter

Gas cooler

Gas cooler

Air heater

Measuring Point

Corrosive environment after bag filter outlet is the same as air combustion

Ai

Pre-mixingBurner Mixing


AirFDF/GRFElectrical

heaterO2

< Yamada et al, GHGT-10, 2010 >

‐Oxyfuel Hg‐Behavior of Trace Elements (Mercury)

1 1

0.5

Hg

(-)

Hg2+ 0.5

Hg

(-)

Hg2+

0AH inlet AH outlet BF inlet BF outlet

Hg0Dust

0AH inlet AH outlet BF inlet BF outlet

Hg0Dust

AH inlet(450degC)

AH outlet(200degC)

BF inlet(170degC)

BF outlet(120degC)

Gas sampling point (Gas Temp.)

AH inlet(450degC)

AH outlet(200degC)

BF inlet(170degC)

BF outlet(120degC)

Gas sampling point (Gas Temp.)

Gas(Air) Gas(Oxy)

Hg behavior in Oxyfuel was almost the same as Air combustion


< Gotou et al., ICOPE-11 , 2011>

Ai b ti O f l b ti

Performance of Flame DetectorAir combustion

(PFT : 1400degree C)Oxyfuel combustion

(PFT : 1330degree C)

4

6

ut (V

)

Gain adjustment*PFT：Peak Flame Temperature

-2

0

2

etec

tor s

igna

l out

p

Ai b iO f l b i O f l b i Ai b i

Flame signal On

-6

-4

2

13:00 14:00 15:00 16:00 17:00

Flam

e de Air combustionOxyfuel combustion Oxyfuel combustion Air combustion

Mode change Mode changeMode change

*Self check of detector every 2minutes

Detector signal was generally stable under both air and oxyfuel combustion

Detection signal of the flame at both air and oxyfuel combustion

< Yamada et al , ICOPE-09, 2009 >


Detector signal was generally stable under both air and oxyfuel combustion. Impact of combustion mode change was very small

O & t th d t ll

O2 mixing with Recycled flue gas

Operation load 100% 100% 80%

O2 conc. & temp. on the duct wall O2 distribution at the inlet of burner wind-box (Optimization of O2 nozzle)

O2BurnerWind-Box Air Heater

Burner load

Nozzle type Type1(Initial)

Type2(Optimum)

Type2(Optimum)

O2 conc. on th d t ll

Burner

the duct wall[%](Max.)

(98%) (34%) (34%)

O2 Injection Nozzle

Wind-BoxInlet

Duct

RFG

Plate

*

O2 conc. at the wind-box inlet [%](Max.-Min.)

(3 3%) (1 3%) (0 7%)

*

Tokyo Institute of TechnologySchool of Engineering*Type of injection nozzle is optimized.

(3.3%) (1.3%) (0.7%)

Future Study on oxyfuel process

ASU (Air Separation Unit)

BTG (Boiler, Turbine, Generator)

CPU (CO2 Compression and Purification Unit)( 2 p )

Upgrading basic model for simulation

SSystem integration


Improvenent of Net efficiency

Improvement with Higher plant efficiency

Improvement with Scale up and application of membrane separation

Air Separation CO2 Capture assumption

200

250

300

350

oal

onsu

mpt

ion

(t/h)

p 2 p assumptionCapital Power Capital Power

Case1 -30% -30% - - Scale up (7500 ton/d)

Case2 -30% -30% -20% -20% Case 1 + Scale up of CO2 Capture

C 3 40% 60% Application of

3,500CO2 capture (Power)Air separation (Power)Operation & MaintenanceO

2) 30405060

Effi

cien

cy (%

)

Air combustion

200

Co

CoCase3 -40% -60% - - pp

Membrane separation

Case4 -40% -60% -20% -20% Case 3 + Scale up of CO2 Capture

1 500

2,000

2,500

3,000Operation & MaintenanceRetrofit of Boiler (Capital)CO2 capture (Capital)Air separation (Capital)

cost

(JPY

/ton-

CO

900

1000

1100

put (

MW

)

Air combustion

2030

Net

E Oxyfuel

0

500

1,000

1,500

CO

2ca

ptur

e c

700

800

900

Sub-critical(35%)

Supercritical(40%)

A-USC(45%)

Future(50%)

Nel

Out

pOxyfuel


Case1 Case2 Case3 Case4Base

Feasiblity Study

1000MW t fit t d i JPlant Specification

1000MWe retrofit study in Japan

Study Result

ASU 2 x 500,000 m3N/hBTG 600/620 degC USCCPU 770 t/h

p

Items Cost [billion JPY]

AuxiliaryPower [MW]

Additional Area [m2]

Boiler retrofit 110 30 -

Study Result CPU 770 t/h

BTG (Blue)ASU 295 115 21,000CO2 capture 205 140 17,000

Efficiency Base Oxyfuel [air case] retrofit case

Gross efficiency [%] 44.2 46.0Net efficiency [%] 42.0 33.4

CO2 capture unit

ASU (Pink) Improvement the power consumption for

ASU & CO2 capture unit Compactification or downsizing of ASU &


(Green)CO2 capture unit< NEDO Report, 2011 >

Dynamic plant simulation

Stack

Pre-cooler &pre-treatmentequipments

O2

Oxygen Pre-heater

Air separation unit

Air

Primarywith P.C.

PGF Inter-cooler

AirGRF/FDFGAH/GGH

EP CO2Compressors

Mill

Feed water heater

Post-treatmentequipments

Boiler

Plant conditionA : Start up（Light off）B : Turbine rollC : Synchronization 300MW

600MW1,000MWRequired time for

ASU hot start-up is approx. 17 hours.

CO2

yD : Turbine master autoE : Combustion changeF : Fuel changeG : Furnace draft control

Combustion mode

300MWCO2capture

Air

A B C E F GD

Oxyfuel

Main fuel

Furnace draft control

Flue gas O2 control

O

Coal

Non-control(Forced draft)

Compressors(Balanced draft)

Air flow（GRF outlet） O2 flow

Recirculation gas flow

Light oil


Burner WB O2 control Non-control（Air）Recirculation gas flow

（GRF outlet）

Future Study on ASU (Air Separation Unit)

Scale-upSystem optimizationSystem optimizationReducing power consumption Innovative air separation method Innovative air separation method Membrane PSA etc PSA etc.


Future Study on BTG (Boiler, Turbine, Generator)

Higher plant efficiency Higher Steam Condition (A-USC)g ( ) High temperature material corrosion

Countermeasure against air ingressg gDirect oxy-fuel combustion with minimum or no flue

gas recycleHigh pressure oxyfuel combustion systemChemical-looping combustion for power generation


Needed Sub-Models for Oxy-PC Furnace

Heat transfer sub-model Radiant zone Convective zone

Ccal jet ignition sub-model Chemistry Burner aerodynamics and heat transfery

Char burnout sub-model SOx

Ash partitioning sub-model Ash partitioning sub model Deposition Trace elements

Combustion by-products Combustion by products NOx, SOx, Hg

Integrated furnace model


< J.O.L. Wendt, 2007 AIChE Meeting >

Future Study on CPU (CO2 Compression and Purification Unit)

Scale-upProcess optimizationProcess optimizationReducing power consumptionOptimized Pollutant Removal processOptimized Pollutant Removal process NOx SOx Hg, etc.


Conclusion

The oxyfuel R&D and feasibility study were performed from the beginning of 1990’s for national program infrom the beginning of 1990 s for national program in Japan, and fundamental data was obtained.

Oxyfuel demonstration project is in progress andti ill t toperation will start soon.

Future activities are in study, and we progress toward commercialization and future oxyfuel combustion systemcommercialization and future oxyfuel combustion system


Thank you for your attention !e-mail: [email protected]

[Acknowledgements]These studies for the demonstration project were greatly supported by METI NEDOThese studies for the demonstration project were greatly supported by METI, NEDO, JCOAL, J-Power and IHI.


the future of r&d requirements for oxyfuel combustion keynote... · the future of r&d...

Documents