Activities of Poland in Oxy Combustion

National Centre for Research and Development

Strategic Programme
„Advanced Technologies for Energy
Generation”

ACIVITIES OF POLAND IN
CFB OXY-FUEL COMBUSTION
Wojciech Nowak
Piotr Grzybowski
Czestochowa University
of Technology, Poland
Jozef Pacyna, NILU Norway
POLEKO 2012

The European Commission is calling
for increased ambition in EU climate
legislation. Brussels to argue for
25% CO2 reduction target in 2020, at
least 80 percent in 2050 from 1990
level

World primary energy demand over
the 20 years will increase by approx.
30%. Poland plans to meet the 2020
EU emission targets by introducing
atomic energy in almost equal
measure with renewables as well as
Carbon Capture and Storage (CCS)
Poland relies on carbon-intensive coal
for more than 90 percent of its
electricity

Poland blocked an EU declaration on
climate policies and has repeatedly
said it would oppose any more
stringent climate policies than those
already agreed

2 Projekt Strategiczny - Zadanie badawcze nr 2 prof. dr hab. inż. Wojciech Nowak

CCS applied to a modern conventional power plant could
reduce CO 2 emissions to the atmosphere by approximately
80-90% compared to a plant without CCS


National Centre for Research and Development

Strategic programme (started in May 2010)
„Advanced Technologies for Energy Generation”

1. Development of high-efficiency, „zero-emission”
technology for coal power plants integrated with CO2
capture
2. Development of oxy-combustion technology for
pulverised and fluidized bed boilers integrated with
CO2 capture – Institute is the Leader
3. Development of coal gasification for effective power
and fuel production
4. Development of integrated technologies for production
of fuels and energy from biomass, agriculture and
other wastes

4

Development of oxy-combustion technology for
Introduction: pulverised and fluidized bed boilers integrated
with CO2 capture

What is the problem?

What is the solution?

What are the possibilities?
Idea and technological options

What are the possibilities?

Pre-combustion developed under
Post-combustion: Strategic Project:
the Strategic Project: Research
Research Task No. 1
Tasks No. 3

Strategic Project: Research Task
No. 2

Source: Vattenfall
Materials OXYFUEL COMBUSTION in PC and CFB Boilers


Flue gases from oxy-fuel
combustion boilers are
almost pure CO2, which
allows its immediate
sequestration

Oxy-fuel combustion is
suitable for modernization of
old boilers, only by addition:
ASU - Air Separation Unit,
CPU - CO2 Processing Unit
and
FGR - Flue Gas Recirculation


Technology options

Pulverized coal boiler CFB boiler Pressurized CFB boiler

All three options are being considered in Research Task No. 2


Aim of the project

Technical readiness up to industry-scale demonstration of oxy-fuel combustion plant
integrated with CO2 purification and sequestration

The specific objectives

Recommendation of one of three coal combustion technologies (PC, CFB, PCFB)

Assessment of current power systems by adapting operated / depleted units
to oxy-fuel combustion boilers

Indicate the directions of clean coal technology development in Poland


Consortium


Project structure


Structural Analysis - Advanced measurement methods behavior of individual fuel particles

scanning electron microscope (SEM)

Coal Fragmentation
Atomic force microscope (AFM)

TG-FTIR-MS

Air Combustion
Experimental studies, measurement systems

PROCESS ANALYSIS
Drop furnace
flow reactor

0xygen Combustion

Experimental validation of models Corrosion tests in a 154 MWt CFB boiler

Location of probes
• ignition of coal dust

Simullations
Probe material (SUMITOMO)
propagation of coal dust


0.1 MWth CFB pilot plant

control system
fuel supply
CO2 and O2 supply

Slight increase in T below SG level
Even profile of T above SG level

Pressure loop remains
Five zones along height
in agreement with
of combustion chamber
typical pressure balance
can be distinguish
around CFB loop
(Kunii D., Levenspiel O., 1991)
(Basu P., Fraser S.A., 1991) Control room - PrtSc


21%O2@CO2 35%O2@CO2
OXY-FUEL
O 2+ C O 2 C O N D I T I O N S

REFERENCE
AIR CONDITIONS

Progress in burn-out of combustible matter along height of
combustion chamber

Lower rate of combustion when N2 is substitued for CO2

Comparable to air and efficient combustion at oxygen
fraction >30%vol.


21%O2@CO2 35%O2@CO2
OXY-FUEL

REFERENCE
AIR CONDITIONS

High value of total sulfur conversion ratio

Considerable amount od H2S and residual impurity of SO3

Phenomenon of selfdesulfurization


21%O2@CO2 35%O2@CO2
OXY-FUEL

REFERENCE
AIR CONDITIONS

Fuel-N behavior under oxy-fuel conditions
will be presended

Tuesday, 5PM, Session A

Czakiert T., Nowak W., …, The Effect of Oxygen
Concentration on Nitrogen Conversion in Oxy-Fuel
CFB Environment


Pilot-plant research

0.2 MWth PCFB pilot plant 30 kW bubbling fluidized bed


fuel preparation

0.5 MWth PC pilot plant gas supply system


Oxygen generator Separation of oxygen
Pressure Swing Adsorption (PSA) on zeolite bed Membrane method using perovskite materials

Oxygen purity of 95% - recommended for oxy combustion production of membranes

Oxygen liquefaction and final purification membrane oxy-genation material structure


PRESSURIZED OXY BUBBLING FLUIDIZED BED REACTOR

Analiza gazów

Chłodnica
Gas cooler
Chłodnica T Water
wodna
cooler
gazowa

Odbiór ciekłych
P T T P produktów z P T
odpylacz wychłodzenia
Dust filter gazu procesowego
T

M

T

P

T
Wytwornica pary
Steam generator
ze zbiornikiem wody
DP

T
T T
O2,

Powietrze
P

wtórne
T T P
Mikser/ T
F F
zawirowywacz

F
Podgrzewacz
powietrza pierwotnego T

N2 O2 CO2
F Podgrzewacz
powietrza wtórnego

Parameter Unit
Reactor diameter mm 75 (50/120)
Reactor height mm 1000
Fuel flow kg/h 0,5-3
Oxidizer (mixture) - O2/CO2/N2
Max. temperature °C 1100
Max. pressure bar 15

Emission of NO and N2O at flexible change of the combustion
Influence of the temperature on NO and conversion under conditions (under atmospheric pressure) from air-fired to oxyfuel.
oxy-fuel (20:80 vol % O2/CO2) conditions and atmospheric pressure. Conditions: air-fired [fuel feed, 0.29 kg/h; flow rate, 5.35 m3/h
The concentration values are based on 6% O2 as a reference level. (STP); and O2(out), 10.6 vol %] and oxy-fuel [fuel feed, 0.27 kg/h;
O2/CO2, 20:80; flow rate, 4.98 m3/h (STP); and O2(out), 10 vol %].

Energy&Fuels. Pressurized Oxy-fuel Combustion: A Study of Selected Parameters
Janusz A. Lasek,* Krzysztof Głód, Marcin Janusz, Krzysztof Kazalski, and Jarosław Zuwała. 2012
Institute for Chemical Processing of Coal, ul. Zamkowa 1, 41-803 Zabrze, Poland


NO NO

N2 O N2 O

Oxy combustion (20/80 % vol. O2/CO2) Air combustion


atm

4.4 bar

Air combustion Oxy combustion (20/80)

NO conversion N2O conversion


General idea of population balance of CFB boilers


Results
Time of chair combustion over particle dimension –
Simulation results versus experimental data

Results

Elutration constant vs. particle dimension

Combustion constant vs. particle dimension

Numerical simulations of CFB

Solids hold-ip in CFB

CFB combustion chamber
Numerical simulations


Numerical simulations of oxy PC

Thickness of
deposits

Coal burners in PC combustors

Air combustion Oxy
Fouling model combustion


Barracuda simulations of 0.1 MWth
CFB oxy-fuel combustor

- CPFD® numerical method
(computational particle fluid dynamics)
is a „hybrid” of numerical methods for a
fluid (continuum phase) and particulates
(discrete phase); fluid phase is treated
with Eulerian formulation (CFD), and
particles – with Lagrangian formulation
(CPFD® = CFD (for fluid) + solids)

- Unlimited particle and gaseous species

- Particle-wall deflections, particle stress
tensor, particle-particle collisions

- 3D simulations with particle size
distribution (PSD) defined by user and
chemical reactions


Average particle volume fraction cv and average gas velocity

0,40
cv [-]

0,30 21%O2/79%CO2

0,20
0,40
0,10
0,35
0,00 21%O2/79%CO2 x/R:(-1;1)
0,30
0,0 1,0 2,0 3,0 4,0 5,0
0,25 x/R:(-1;0)
h [m]
0,20 x/R = 0(axis)

cv [-]
0,15 x/R:(0;1)
0,10
0,05 exit
0,00 zone
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0
h [m]
8,0
x/R:(-1;1)
7,0
x/R:(-1;0)
6,0
x/R=0(axis)
5,0
x/R:(0;1)
4,0
ug [m s-1]

3,0
2,0
1,0
0,0
0 1 2 3 4 5
h [m]


CO2 capture and processing


Production of sorbents based on fluidized bed ash

POWER PLANTS

FLY ASH
COMBUSTION BY-PRODUCTS

CARBON DIOXIDE MERCURY SURFACE OF FLY ASH SURFACE OF ZEOLITES

CO2 CAPTURE Hg REMOVAL

FLY ASH-BASED
PRODUCTS

Removall of odor
ADSORPTION
PSA ADSORPTION utilization of
TSA MEMBRANES petroleum-derivatives
Clean water and air
VSA
PTSA

Soil decontamination

develop an effective fly ash-based sorbent (mainly microporous zeolites) for the removal of gaseous
pollutants (including CO2 and Hg) and petroleum contaminants.


Na-A zeolite

Na-P1 zeolite


CO2 processing from CFB oxy combustor

4 kolumn VPSA installation
for CO2 processing from 0.1
MW oxy-fuel CFB combustor

full laboratory scale
capacity 5 m3/h
adsorption pressure 180 kPa
desorption 30 kPa
temperature 40 oC
SO2, NOx removal in carbon
bed


Three-phase fluidized bed photobioreactor for CO2 capture by algae

Parameter
Temperature 250 C
Light intensity 80 µmol m-2 s-1
Photoperiod 12:12
Algae species Chlorella v.

CO2

The experiments were conducted in the climatic
chamber


The influence of intermittent CO2 and continuous air supply on growth
of Chlorella vulgaris

stationary
exponential phase

declining
x105 ml-1

adaptation phase

decline
Cell ,

Time, days

• CW: intermittent supply of CO2
• PW: continuous air supply 38

Process integration
Integration of oxy-fuel combustion CFB boiler
with CO2 sequestration


CO2 Recovery CO2 Purity Efficiency
96,00 95,55 46,40

Efficiency [%]
CO2 recovery [%]

CO2 purity [%]
46,20
95,00 95,50
46,00
94,00 95,45
45,80
93,00 95,40 45,60
40 90 140 40 90 140 40 90 140
Flu gas temperature [C] Flu gas temperature [C] Flu gas temperature [C]


air
Combustion chamber hight, m

Temp, 0C Heat flux, CO2 O2
Heat flux, kW
kW

air 1224 189 19.41 4.63
OOXY1, 24%
1155 163 91.20 3.57
Instytut Techniki Cieplnej www.itc.polsl.pl Konarskiego 22, 44- OXY2, 30% O2
100 Gliwice 1228 183 89.98 3.71


Feasibility study
CFB demo scale: CO2 purification
Case study: Tauron Łagisza 460 MWe supercritical OTH CFB boiler

Flue gas channel
from CFB boiler
Connection to PSA
installation

Control room

PSA installation to capture CO2


Feasibility study
CFB d e m o s c a l e : C C S
Case study: PGE GiEK SA Turów 3 × 235 MWe CFB + 3 × 260 MWe Compact CFB + 460 MWe new PC

CO2 pipelines to geological
storage
Pipelines routs
Pipelines shortest rout
Power plant
Geological structure
Nature 2000,


Pre-feasibility study
30 MWe CFB and PC demo scale

VR model integrates objects and
datas from different applications


Understanding the population of German federal
Awareness of the Polish population
states

NIMBY Syndrome Not In My Back Yard

LULU Syndrome Locally Unacceptable Land Use

NIMEY Syndrome Not In My Election Year


Pre-feasibililty study of high-efficient, multi-fuel and flexible oxy-fuel demo plant with a
capacity of 30 MWe
Three technological options (PC, CFB, PCFB)

Pre-feasibility study of CFB technology with CCS for large-scale CFB power plants

PGE GiEK SA Tauron Wytwarzanie SA
Turów Power Plant: Łagisza Power Plant 460 MWe
total 1485 MWe CFB supercritical CFB unit


Activities of Poland in Oxy Combustion

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