Novel Oxy-steam Burner for Zero-emission Power Plants
Carlos Salvador, Milenka Mitrović & Kourosh Zanganeh
Zero Emission Technologies (ZET) GroupClean Electric Power Generation (CEPG)
SSeptember 10, 2009
Outline
Hydroxy-fuel combustion Motivation and Overall Objectives 3rd generation oxy-fuel systems
Novel burner concept and design Modes of operation Design and optimization Pilot-scale implementation
Experimental validation
2
Need for New Concepts and Technologies
Design for plant life Current and future needs (CO2 market, etc.)
Fl ibilit i d i t d t Flexibility in design to adapt Environmental regulations (near zero
emissions for fossil fuels) Low-value fuels and co-firing (bitumen,
petcoke, biomass, etc)petcoke, biomass, etc) Advancements in technology, e.g.,
Ion transport membrane for O2 production High temperature materials (boiler tubes,
etc)etc) Moving away from Rankin cycle (lower
efficiency) 3rd generation of oxy-fuel combustion
systemssystems Advanced turbines and power cycles Emerging technologies…
3
Hydroxy-Fuel Technology DevelopmentMotivation: Develop the technology base necessary for
the implementation of efficient zero-pemission fossil fuel systems
Overall Objectives: Investigate the feasibility of hydroxy-fuelInvestigate the feasibility of hydroxy fuel
combustion for the 3rd generation of oxy-fuel systems
Investigate the reduction in size and capital cost of equipment
Use of water/steam, preferably with no FGR, to moderate the flame temperature
Achieve high concentration of CO2 (> 90% on dry basis) in the exit flue gas stream
4
3rd Generation Oxy-fuel Systems
3rd Generation Oxy-fuel Combustion
Oxy steam Combustion O Combustion (no FGR)Oxy-steam Combustion O2 Combustion (no FGR) Low NOx & excess O2, Higher radiative & convective heat
transfer,
Minimize NOx & excess O2, High radiative & convective heat
transfer,, Process model, CFD, new system
and component design
Up to 40% scale reduction in unit size
, New materials, Process model, CFD, new system
and component designUp to 80% scale reduction in unit sizeUp to 40% scale reduction in unit size Up to 80% scale reduction in unit size
5
Novel Burner Design
Modes of Operation: Firing Rate 0.3 MWth (1.0 X 106 Btu/h) Fuels: Natural gas Oil Emulsion Fuels: Natural gas, Oil, Emulsion,
Pulverized coal, Petcoke, Coal Slurry, etc.Operational modes
►O2/steam►O2/steam►O2/RFG & O2/CO2►Air & oxygen enriched air►O2/steam/RFG2►O2/steam/CO2
Variable mass flow rates on secondary and tertiary streamsVariable oxygen concentration on
secondary and tertiary streams Independent swirl on secondary and
6
tertiary stream
Burner Operational Principles
O2Secondary
Pulverized CoalSwirl Stabilized Flame
O2SteamRFGCO2
SecondaryOxidizerStream
O2
SteamRFG
TertiaryOxidizerStream RFG
CO2Stream
Fuel RichZone
Tertiary
FlameStabilizationPoint
SecondaryFlow Zone
TertiaryFlow Zone
7
Design and Optimization
Determined system requirements via HYSYS simulations
Extended simulations to fix additional combustion parameters; i.e. O2-steam composition adiabatic flame temperature etcO2 steam composition, adiabatic flame temperature, etc.
Based on swirl burner theory, established the desired burner exit parameters
B d HYSYS Si l ti i l b i t d th Based on HYSYS Simulations, swirl burner requirements, and the possible effect of the combustor geometry, created a short list of possible burner geometries
8
Design Validation
Temperature CO Distribution O2 Distribution Equivalence Ratio
?
9
CFD Simulation done by CEPG CFD Group
Design Validation (cont’d)
Temperature Profile
Uniform temperaturedistribution
StagnationPointPoint
Vector Plot of Speed
10
CFD Simulation done by CEPG CFD Group
Burner Prototypes Development
1st Generation 2nd Generation 3rd Generation 4th Generation
Fixed Swirl Generator Testing
Variable Swirl Generator Testing
Modified Variable Swirl Generator Testing
2nd Variable Swirl Generator Testing
11
Pilot-Scale Implementation
Oxy-fuel Vertical CombustorResearch Facility (VCRF) Firing rate for tests: 0.2 MWth (0.7 X 106 Btu/h)
Combustion mode: O2/RFG or O2/SteamCombustion mode: O2/RFG or O2/Steam Fuel: Saskatchewan lignite coal Flow Paths:
O2/Steam: ESP CHX1 StackO2/Steam: ESP CHX1 Stack O2/RFG: ESP CHX1 Recycle Stack
Measurements Gas composition (O2 CO2 CO SO2 NOx)Gas composition (O2, CO2, CO, SO2, NOx) Mercury (Ontario Hydro Method & CEM) Suction pyrometer Radiation heat fluxRadiation heat flux Ash Samples
12
VCRF Flow Diagram
3rd O2
X
2nd O22nd Steam3rd Steam
X – Sample PointsRack 44
AirCO2
Air/CO2
HeatExchangers
ID Recycle
VC
X
FansFD Fan
ID Fan
K-TronRecycledFlue Gas
ESP Bag Ho se
CHX 1 CHX 2XX
ESP Bag House
CO2 Capture and Compression Unit(CO2CCU)
Rack 63 Hg CEM
13
VC Furnace Measurement PortsBurnerO2 + RFG
orO2 + Steam
BurnerCombustorSection(Flame Zone)
BurnerExit Plane
Burner
FlameScanner
SuctionPyrometerPorts
RadiationMeasurementPorts
CombustorSection(Flame Zone)
CameraPort
CombustionFlue Gas
o t
* All dimensions in inchesCombustionFlue GasStream
Flue GasStream
14
Results – Oxy-fuel Temperature Profile
Oxy-fuel Combustion07.11.08TE 102
TE 103
TE 105TE 104
TE 99TE 98
07.11.08
Oxy-fuel Combustion07.11.08
1400TE 98
TE 97
TE 95800
1000
1200
ratu
re [º
C]
TE102TE103TE104TE105TE099TE098
TE 94
TE 93TE 91
0
200
400
600
Tem
per
TE097TE095TE094TE091
CombustionFlue GasStream
13:43
:0014
:13:00
14:43
:0015
:13:00
15:43
:0016
:13:00
16:43
:0017
:13:00
17:43
:0018
:13:00
18:43
:0019
:13:00
19:43
:0020
:13:00
20:43
:0021
:13:00
Time[hh:mm:ss]
15
Results - Oxy-fuel Combustor Exit
Oxy-fuel Combustion07.11.08
Camera cleaningO2/FGR
Shut-downSampling
Rack 44
70
80
90
100
ry
16
18
20
22(0.5, 0)
(0, 1.9)
g
(0, 0.8)(0, 0.6)(0, 0)
(0.5, 1.9)(0, 0.8)
P5
P4 P3
P2P1
P55
P44P33
P22P11
30
40
50
60
CO
2 %
Vol
. D
6
8
1012
14
O2
[% V
ol.] CO2
O2 (dry)O2(wet)K-Tron
Reload
K-TronReload
K-TronReload
K-TronReload
K-TronReload
K-TronReload
K-TronReload
0
10
20
43:00
13:00
43:00
13:00
43:00
13:00
43:00
13:00
43:00
13:00
43:00
13:00
43:00
13:00
43:00
13:00
0
2
4
6
13:43
14:13
14:43
15:13
15:43
16:13
16:43
17:13
17:43
18:13
18:43
19:13
19:43
20:13
20:43
21:13
Time [hh:mm:ss]
16
Results – Oxy-fuel Combustor Exit (cont’d)
Rack 44Oxy-fuel Combustion
0.7.11.082500 200
1500
2000
2500
ppm
] 150
200
Camera cleaningO2/FGR
Shut-down
Sampling
1000
1500
SOx
and
NO
x [
50
100
CO
[ppm
]
NOxSOxCO
K-TronK T
(0.5, 0) (0, 1.9)(0, 0.8)(0, 0.6)(0, 0) (0.5, 1.9)(0, 0.8)
P5
P4
P3
P2P1
P55P44
P33P22
P11
K-Tron K-Tron
0
500
43:00
13:00
43:00
13:00
43:00
13:00
43:00
13:00
43:00
13:00
43:00
13:00
43:00
13:00
43:00
13:00
0
K-TronReload
K TronReload
K-TronReload
K-TronReload
K TronReload ReloadK-Tron
Reload
13:43
14:13
14:43
15:13
15:43
16:13
16:43
17:13
17:43
18:13
18:43
19:13
19:43
20:13
20:43
21:13
Time [hh:mm:ss]
17
Results – Oxy-steam Temperature Profile
TE 102TE 103
Oxy-Steam Combustion17.10.08
TE 103
TE 105TE 104
TE 99TE 98
Oxy-fuel Combustion07.11.08
1200
1400
TE 97
TE 95
TE 94600
800
1000
1200
pera
ture
[º C
]
TE102TE103TE104TE105TE099TE098TE097TE 94
TE 93TE 91
0
200
400
00 00 00 00 00 00 00 00 00 00 00 00 00 00
Tem
p
TE095TE094TE091
CombustionFlue GasStream
11:00
:011
:30:0
12:00
:012
:30:0
13:00
:013
:30:0
14:00
:014
:30:0
15:00
:015
:30:0
16:00
:016
:30:0
17:00
:017
:30:0
Time[hh:mm:ss]
18
Results – Oxy-steam Combustor Exit
Rack 44Oxy-steam Combustion17.10.08
(0, 1.1)O2/Steam
S li
70
80
90
100
Dry 12
14
16
18
]
CO2
P44
P55
P33
P22
P11
Coal Sample
OX-043Blow dow n
Sampling
20
30
40
50
60
CO
2 %
Vol
. D
4
6
8
10
O2
[% V
ol. CO2
O2 (dry)O2 (wet)
K-TronReload
K-TronReload
K-TronReload
K-TronReload
K-TronReload
K-TronReload
67 min 68 min 65 min 64 min 62 min
Ports
0
10
20
1:00:00
1:30:00
2:00:00
2:30:00
3:00:00
3:30:00
4:00:00
4:30:00
5:00:00
5:30:00
6:00:00
6:30:00
7:00:00
7:30:00
0
2
4
Racksoff-line
Portsopen
11 11 12 12 13 13 14 14 15 15 16 16 17 17
Time [hh:mm:ss]
19
Results – Oxy-steam Combustor Exit (cont’d)
Oxy-steam Combustion17.10.08
(0, 1.1)
Rack 44
2000
2500
ppm
]
400
500
P44
P55P22
P11
( , )O2/Steam
Coal Sample
OX-043
Sampling
1000
1500
Ox
and
NO
x %
[p
200
300
CO
[ppm
] SOxNOxCO
K-TronReload
K-TronReload
K-TronReload
K-TronReload
K-TronReload
P33P11
K-TronReload
Blow dow n
67 min 68 min 65 min 64 min 62 min
Radiationmeasurement
0
500
11:00:00
11:30:0
012:0
0:0012:3
0:0013
:00:0013:3
0:0014:0
0:00
14:30:00
15:00:00
15:30:0
016:0
0:0016:3
0:0017
:00:0017:3
0:00
SO
0
100Racksoff-line
measurement
Portsopen
11 11 12 12 13 13 14 14 15 15 16 16 17 17
Time [hh:mm:ss]
20
Results (cont’d)
Suction Pyrometer Measurements on Centre Line
1500
Oct. 7, 2008 (O2/RFG)Oct. 28, 2008 (O2/RFG)Oct. 17, 2008 (O2/Steam)Oct 9 2008 (O2/Steam)
1300
1400
]
Oct. 9, 2008 (O2/Steam)Aig. 1, 2008 (O2/Steam)Poly. (Oct. 9, 2008 (O2/Steam))Poly. (Oct. 17, 2008 (O2/Steam))Poly. (Oct. 7, 2008 (O2/RFG))
1200
1300
empe
ratu
re [o
C] y ( , ( ))
Poly. (Oct. 28, 2008 (O2/RFG))Poly. (Aig. 1, 2008 (O2/Steam))
1000
1100Te
P11P22
P33P44
P55 P1 P2 P3 P4 P5900
0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50
Distance from Burner Exit Plane [m]
P11 P33 P55 P1 P2 P3 P4 P5
21
Results – High Swirl Oxy-Steam Flame
Quarl
Burner FlameScanner
FlameScannerCombustion
Flue GasStream
CombustorSection(Flame Zone)
CameraPort
FlameEnvelop
CL
22
CL
Conclusions
Best results, for oxy-steam, was achieved when all of theyO2 was sent via the outer annulus and moderate to highswirl numbers where used; best results, for oxy-fuel, wasachieved when all of the O2 was sent via the inner annulusachieved when all of the O2 was sent via the inner annulus. Oxy-steam combustion resulted in high CO2 concentrations
(~ 90%), low CO, moderate NOx and typical SOx levels.Eli i ti f l t i t d d d Elimination of recycle stream, in oxy-steam mode, reducedair infiltration issues boosting CO2 concentrations by 5-10%. Combustor outlet moisture content approximately was 60%
23
Acknowledgement
This work was supported by the PERD (Program ofEnergy Research and Development) and theCanmetENERGY CO2 R&D Consortium. The authorsgratefully acknowledge the support provided by theseprograms.p og a s
24
Oxy-steam Flame
L S i l Hi h S i lLow Swirl High Swirl
25