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KEPCO Research Institute, Plug-in Future
Co-combustion of Various Fuels in a Commercial CFB Boiler
CoCo--combustion of Various Fuels combustion of Various Fuels in a Commercial CFB Boilerin a Commercial CFB Boiler
KEPCO Research Institute, Green Energy LaboratoryKEPCO Research Institute, Green Energy LaboratoryJongMin LeeJongMin Lee([email protected])([email protected]), , D.W. Kim, J.S. Kim, K.I. Park, T.H. LeeD.W. Kim, J.S. Kim, K.I. Park, T.H. Lee
KEPCO Research Institute, Plug-in Future
Outlook for Fuel Utilization - World Outlook for Fuel Utilization Outlook for Fuel Utilization -- WorldWorld
Coal Consumption and OutlookCoal Consumption and Outlook•• Coal Reserves (929.3 billion short tons)Coal Reserves (929.3 billion short tons)
: about: about 50%50% -- low value coalslow value coals•• 42% of Coal Production 42% of Coal Production
EE--Power Gen.Power Gen.: increase low value coal utilization: increase low value coal utilization
•• Primary Energy Consumption Primary Energy Consumption [1965~2005][1965~2005]
•• Renewable EnergyRenewable Energy[2005][2005]
Coal
Gas
Oil
HydroNuclear
[ref. BP Statistical Review of World Energy ‘06]
[ref. IEA Report 2007 (a)]
•• EU Wood pellet IndustryEU Wood pellet Industry
Fuel DiversificationFuel Diversification•• CFB BoilerCFB Boiler (best way for fuel flexibility)(best way for fuel flexibility)
: : ’’09 market share09 market share
up to up to 10%10%: possible to use low value coals and : possible to use low value coals and various renewable fuels(biomass, waste)various renewable fuels(biomass, waste)
Renewable Energy Utilization StatusRenewable Energy Utilization Status•• 13%13% Share of Primary Energy ProductionShare of Primary Energy Production
: Combustible/Waste : Combustible/Waste –– about 10% about 10% •• EU :EU : ““Biomass Action Plan Biomass Action Plan ‘‘0505””•• Japan : Conversion of Waste into Energy Japan : Conversion of Waste into Energy
• Biomass, RPF/RDF, Sludge
[ref. IEA Report 2007 (a)]
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‘‘05~05~’’30 Renewable30 Renewable E: >20% of CoalE: >20% of Coal•• 21% of CO21% of CO22 Reduction Reduction
Renewable ERenewable E•• Considerable shares in Renewable Considerable shares in Renewable EnergyEnergy: combustible energy source: combustible energy source(biomass, waste)(biomass, waste)
Fuel Diversification (substantial and realistic measures of CO2 ) Fuel DiversificationFuel Diversification (substantial and realistic measures of CO(substantial and realistic measures of CO22 ))
KEPCO Research Institute, Plug-in Future
Vitalization of Using Renewable EVitalization of Using Renewable E--resources(Waste/Biomass/Waste) as Fuelresources(Waste/Biomass/Waste) as Fuel•• WastesWastes –– 3,400,0003,400,000 TOE /y (Waste PlasticTOE /y (Waste Plastic ((’’10)10) : about: about 2,000,000 t/y generation)2,000,000 t/y generation)•• Sewage Sludge : 3,027,829 mSewage Sludge : 3,027,829 m33/y/y (sea dumping(sea dumping 47%, landfill47%, landfill 15%, reuse15%, reuse 25%, incineration25%, incineration 13%)13%)•• BiomassBiomass : 2,000,000m: 2,000,000m22(potential) (potential) –– 5,000,000 t/y(5,000,000 t/y(‘‘20) supply plan (by Korea Forest Service 20) supply plan (by Korea Forest Service ’’10)10)
Potential of Fuel Diversification (Korea) Potential of Fuel Diversification Potential of Fuel Diversification (Korea)(Korea)
191,531
952,026
238,11277,575
161,127301,738
87,782
161,617
302,029
64,302
278,111
92,958
342,279380,197)
• RPF Generation (’09, t/y)
43,786
62,126)
25,910 16,350
30,402
12,945
7,620
15,755
31,320
4,519
38,931
10,869
15,500
10,60627,903
• Waste Generation (’09, 톤/일)
생활계(14%), 사업장
(35%), 건설폐기물(51%)
573,258
852,292
101,21267,674
98,336183,057
88,731
138,784
75,924
92,925
143,936
141,505
73,137176,172
• Sewage Sludge Generation (‘09)
200,304
• Biomass Potential
CompanyEWP
(Donghae- 200MW e)
KPSEP(YeoSu- 340MWe)
KOSPO(Smacheok-
500MWe)HHV
(kcal/kg) 4,500 4,900 4,200Anthracite,
Subbitu. Coal
Status UnderOperation
UnderOperation
UnderConstruction
Fuel Diversification
• CFB boiler for E-Power Gen. in Korea • Utilization of Renewable Energy Source구분 EWP (Donghae CFB)
Fuel RDF WoodPellet
WoodChip
Co-com. 5% 5% 10%
KEPCO Research Institute, Plug-in Future
ObjectiveObjectiveObjective
in Donghae CFB boiler
in in Donghae CFB boilerDonghae CFB boiler
RDF (Refuse Derived Fuel)RDF (Refuse Derived Fuel)
Biomass PelletBiomass Pellet
Biomass ChipBiomass Chip
with with
Main fuel : Anthracite/Bituminous coalMain fuel : Anthracite/Bituminous coal
Assessment of co-combustion of various fuelsin existing commercial CFB boiler
Assessment of coAssessment of co--combustion of various fuelscombustion of various fuelsin existing commercial CFB boilerin existing commercial CFB boiler
KEPCO Research Institute, Plug-in Future
Donghae CFB BoilerDonghae CFB BoilerDonghae CFB Boiler
mm TypeType-- CFB, IndoorCFB, Indoor-- Natural CirculationNatural Circulation-- Balanced Draft SystemBalanced Draft System
mm Leading SpecificationLeading Specification-- Steam Flow : 693 T/HSteam Flow : 693 T/H-- Max. Operating P @ T: Max. Operating P @ T: 169.6 kg/cm169.6 kg/cm22, 541, 541ooCC
mm Emission Control DesignedEmission Control Designed-- SOSO22 (O(O22 :6%) : :6%) : 150ppm150ppm-- NOx(ONOx(O22 : 6%) : 350ppm: 6%) : 350ppm
mm Ash DistributionAsh Distribution-- Fly Ash : 50%Fly Ash : 50%-- Bottom Ash : 50% Bottom Ash : 50%
mm Rectangular Furnace DesignRectangular Furnace Design-- More than 2:1 Aspect Ratio More than 2:1 Aspect Ratio
: to Allow for Good Fuel Mixing: to Allow for Good Fuel Mixing-- Size : 32m (H) x 19m (W) x 7m Size : 32m (H) x 19m (W) x 7m
(L)(L)-- StartStart--up Burner (Side Wall) : 4up Burner (Side Wall) : 4-- Lance Burner : SideLance Burner : Side--2, Rear2, Rear--33
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Fuel AnalysesFuel AnalysesFuel Analyses
RDF
Wood Pellet
Coal
Wood Chip
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RDF/wood pellet feeding siteRDF/wood pellet feeding site
RDF/wood feeding systemRDF/wood feeding system
Field Test Procedure Field Test Procedure Field Test Procedure
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Reaction PatternReaction PatternReaction Pattern
Temperature [ oC]
0 100 200 300 400 500 600 700 800 900
X [-
]
0.0
0.2
0.4
0.6
0.8
1.0
5oC/min10 oC/min20 oC/min30 oC/min
Korean Anthracite RDF Wood Pellet
Temperature [oC]
0 100 200 300 400 500 600 700 800 900
Wei
ght L
oss
(X) [
-]
0.0
0.2
0.4
0.6
0.8
1.0
Der
ivat
ive
Wei
ght
Loss
(dX/
dt) [
1/m
in]
0.00
0.01
0.02
0.03
0.04
0.05
Weight Loss (X)Derivative Weight Loss (dX/dt)
1st region
2nd region
3rd region
Wood Pellet 5oC/min
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Wood Pellet Co-Combustion Ratio [%]
0 1 2 3 4 5 6
Tem
pera
ture
[o C
]
860
880
900
930
940
950
Furnace Lower PartFurnace Upper PartFurnace ExitCyclone Exit
RDF Co-Combustion Ratio [%]
0 1 2 3 4 5 6
Tem
pera
ture
[o C
]
860
880
900
930
940
950
Furnace Lower PartFurnace Upper PartFurnace ExitCyclone Exit
Co-Combustion Results (Temperature -1) CoCo--Combustion Results Combustion Results (Temperature (Temperature --1)1)
Backpass
Coal Silo
Boiler
Cyclone
FBAC
FBHE
Primary Air
Air
Air
Solid Flow
Air
Solid Flow
Gas FlowGas Flow
Windbox
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W ood C h ip co -com bustion ra tio [-]
0 .00 0 .01 0 .02 0 .03 0 .04 0 .05 0 .06 0 .07
Tem
pera
ture
[oC
]
8 60
870
880
890
900
910
920
U p per F u rnaceLow er F u rnaceF urna ce ex itC yc lone ex it
wood chip co-combustion ratio [-]
0.00 0.02 0.04 0.06 0.08 0.10
Tem
pera
ture
[oC
]
860
870
880
890
900
910
920
930
Upper FuranceLower Furnace Furnace exitCyclone exit
Co-Combustion Results (Temperature -2) CoCo--Combustion Results Combustion Results (Temperature (Temperature --2)2)
Wood chip co-combustion ratio
0.00 0.02 0.04 0.06 0.08 0.10
Tem
pera
ture
[o C]
840
860
880
900
920
940
960
Upper furnaceLower furnaceFurnace exitCyclone exit
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0 1 2 3 4 5 6
Tota
l Pre
ssur
e D
rop
[mm
H2O
]
1200
1300
1400
1500
1600
RDF Co-Combustion Ratio [%]
0 1 2 3 4 5 6Mid
dle
Par
t Pre
ssur
e D
rop
[mm
H2O
]
460
480
500
520
540
Upp
er P
art P
ress
ure
Dro
p [m
mH
2O]
120
150
180
210
240
270
Low
er P
art P
ress
ure
Dro
p [m
mH
2O]
960
990
1020
1050
1080
1110
Total Pressure DropLower Part Pressure Drop
Upper Part Pressure DropMiddle Part Pressure Drop
Backpass
Coal Silo
Boiler
Cyclone
FBAC
FBHE
Primary Air
Air
Air
Solid Flow
Air
Solid Flow
Gas FlowGas Flow
Windbox
Co-Combustion Results (Pressure) CoCo--Combustion Results Combustion Results (Pressure)(Pressure)
KEPCO Research Institute, Plug-in Future
Wood chip co-combustion ratio [-]
0.00 0.02 0.04 0.06 0.08 0.10
Unb
urnt
car
bon
fratio
n [%
]
0
4
8
12
16
Fly ashBottom ash
Wood chip co-combustion ratio [-]
0.00 0.01 0.02 0.03 0.04 0.05 0.06
Unb
urnt
car
bon
fract
ion
[%]
0
5
10
15
20
Fly ashBottom ash
Wood chip co-combustion ratio [-]
0.00 0.02 0.04 0.06 0.08 0.10
Unb
urnt
car
bon
fract
ion
[%]
0
5
10
15
20
25
Fly ashBottom ash
Co-Combustion Results (unburned carbon) CoCo--Combustion Results Combustion Results (unburned carbon)(unburned carbon)
KEPCO Research Institute, Plug-in Future
RDF Co-Combustion Ratio [%]
0 1 2 3 4 5 6
SO2 &
NO
x E
mis
sion
[pp
m, 6
% O
2]
0
50
100
150
200
250
Lim
esto
ne F
eedi
ng R
ate
[t/h
]
0
2
4
6
8
10
SO2NOx
Limestone
Wood Pellet Co-Combustion Ratio [%]
0 1 2 3 4 5 6
SO
2 & N
Ox
Em
issi
on [
ppm
, 6%
O2]
0
50
100
150
200
250
Lim
esto
ne F
eedi
ng R
ate
[t/h
]
0
2
4
6
8
10
SO2NOx
Limestone
Co-Combustion Results (Emission -1) CoCo--Combustion Results Combustion Results (Emission (Emission --1)1)
KEPCO Research Institute, Plug-in Future
Wood chip co-combustion ratio [-]
0.00 0.01 0.02 0.03 0.04 0.05 0.06
Con
cent
ratio
n [p
pm]
40
50
60
70
80
90
100
Lim
esto
ne c
onsu
mpt
ion
[ton/
h]
2.0
2.5
3.0
3.5
4.0
SOxNOxLImestone consumption
Wood chip co-combustion ratio [-]
0.00 0.02 0.04 0.06 0.08 0.10 0.12
Con
cent
ratio
n [p
pm]
30
40
50
60
70
80
90
limes
tone
con
sum
ptio
n [to
n/h]
2.0
2.5
3.0
3.5
4.0
SOxNOxlimestone consumption
Co-Combustion Results (Emission -2) CoCo--Combustion Results Combustion Results (Emission (Emission --2)2)
KEPCO Research Institute, Plug-in Future
Co-Combustion Ratio [%]
0 2 4 6 8 10
Dio
xins
[ng
-TE
Q/S
m3 ]
0.00
0.02
0.04
0.06
0.08
0.10
Wood pelletRDF
Wood pellet
Regulation limit
RDF Co-Combustion Ratio [%]
0 1 2 3 4 5 6
HC
l Em
issi
on [
ppm
]
0
1
2
3
4
5
Amou
nt o
f Chl
orin
e [k
g/da
y]
0
100
200
300
400
500
600
700
Chlorine in RDFChlorine in AshHCl in Flue Gas
Co-Combustion Results (Emission -3) CoCo--Combustion Results Combustion Results (Emission (Emission --3)3)
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Conditions(RDF)
0 % 1 % 3 % 5 %RegulationF/A B/A F/A B/A F/A B/A F/A B/A
Pb (mg/l) ND ND 0.01 0.02 0.01 ND 0.02 ND 3.0Cu (mg/l) ND ND 0.028 0.036 0.022 0.023 0.021 0.021 1.0As (mg/l) ND ND 0.017 0.004 0.008 0.005 0.01 0.012 1.5Hg (mg/l) ND ND ND ND ND ND ND ND 0.005Cd (mg/l) ND ND ND ND ND ND ND ND 0.3Cr6+ (mg/l) ND ND 0.09 ND 0.11 ND 0.16 ND 1.5CN- (mg/l) ND ND ND ND ND ND ND ND 1.5
Conditions(Wood pellet)
0 % 1 % 3 % 5 %RegulationF/A B/A F/A B/A F/A B/A F/A B/A
Pb (mg/l) ND ND ND ND ND ND ND ND 3.0Cu (mg/l) ND ND 0.021 0.030 0.074 0.022 0.037 ND 1.0As (mg/l) ND ND 0.010 0.015 0.034 0.018 0.013 0.023 1.5Hg (mg/l) ND ND ND ND ND ND ND ND 0.005Cd (mg/l) ND ND 0.004 ND ND ND ND ND 0.3Cr6+ (mg/l) ND ND ND ND ND ND 0.16 ND 1.5CN- (mg/l) ND ND 0.010 ND ND ND ND ND 1.5
Conditions(Wood chip)
0 % 3 % 10 % (1차) 10 %(2차) RegulationF/A B/A F/A B/A F/A B/A F/A B/APb (mg/l) ND ND ND ND ND ND ND ND 3.0Cu (mg/l) ND ND 0.074 0.101 0.095 0.022 0.044 0.035 1.0As (mg/l) ND ND ND 0.014 ND ND ND ND 1.5Hg (mg/l) ND ND ND ND ND ND ND ND 0.005Cd (mg/l) ND ND ND ND ND ND ND ND 0.3Cr6+ (mg/l) ND ND ND ND ND ND ND ND 1.5CN- (mg/l) ND ND 0.01 ND ND ND ND ND 1.5
Co-Combustion Results (Emission -4) CoCo--Combustion Results Combustion Results (Emission (Emission --4)4)
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SISI--TR output (RDF)TR output (RDF)
SISI--TR output (Biomass)TR output (Biomass)
Co-Combustion Results (Emission -5) CoCo--Combustion Results Combustion Results (Emission (Emission --5)5)
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Co-combustion ratio 0% 1% 3% 5%
Power Generation(MW) 200.9 201.6 201.3 200.9
Coal consumption(t/h) 107.09 104.27 103.98 102.87
Heating value of fuel (kcal/kg) 4,842 4,968 4,966 4,844
Supplying heating value (Gcal/h) 518.5 518.0 516.4 498.3
Power Generation/Supplying heating value(MWh/Mcal) 387.5 389.2 389.8 403.2
Bituminous Coal Ratio [%]
0 5 10 15 20 25 30 35Pow
er G
en./C
oal F
low
[MW
/ t/h
]
1.9
2.0
2.1
2.2
2.3
Actual Power Gen./Coal FlowPower Gen./Coal Flow based on Heating Value
Bituminous coalBituminous coal
Wood PelletWood Pellet
Co-Combustion Results (Performance) CoCo--Combustion Results Combustion Results (Performance)(Performance)
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ConclusionConclusionConclusion
Solution is ... Fuel Diversification
Pouring money into power plant, and emission of CO2 !
Problems are ...
Economical & Environmental EfficiencyEconomical & Environmental EfficiencyFuel supply and demand Fuel supply and demand
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Thank You.Thank You.