ADECOS II. Advanced Development of the Coal-Fired Oxyfuel Process with CO 2 Separation

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1 Fakultät Maschinenwesen Institut für Energietechnik, Professur für Verbrennung, Wärme- & Stoffübertragung ADECOS II Advanced Development of the Coal-Fired Oxyfuel Process with CO 2 S. Grahl, A. Hiller, J. Löser, S. Weigl, R. Wilhelm, M. Beckmann Dresden, 19th May 2009

2 Overview 1 Introduction 2 Objectives of the ADECOS II Project 3 Oxyfuel Process and Plant Layout 4 Research on Lignite 5 Flue Gas Treatment 6 Future Prospects Slide 2 of 22

3 Introduction What is the Oxyfuel Process? Three promising pathways for CO 2 separation: Pre Combustion IGCC (Integrated Gasification Combined Cycle) Process Gasification/partial oxidation of the fuel catalytic shift of the syngas from CO to CO 2 physical absorption of CO 2 Post Combustion Gas stream scrubbing with MEA (MonoEthanolAmine) in aqueous solution to remove CO 2 by acting as a weak base Oxyfuel Combustion Combustion with nearly pure oxygen and thus forming a CO 2 -rich flue gas stream with water as second most component and a minor part of residual gases Slide 3 of 22

4 Introduction The Collaborative Research Project ADECOS II includes: Experiments in laboratory and technical scale as well as theoretical investigation, modelling work and component design Comprehensive evaluation of CO 2 separation by using the Oxyfuel Technology for lignite and hard coal Slide 4 of 22

5 Objectives Objectives of the ADECOS II Project: The studies conducted including: Ignition and burn-out behaviour, fouling, slagging, NO reduction, start-up und shut-down behaviour, SO 2 removal, CO 2 separation by distillation, CFD modelling and validation at a 50 kw thermal combustion chamber Comparison and evaluation of different steam generator concepts (pulverised fuel combustion, circulating fluidised bed combustion, melting chamber combustion) Evaluation of the overall Oxyfuel Process and suggestions for optimisation, with special focus on intrinsic energy demand, residual gas separation, position of the desulphurisation facility as well as steam generator design and the compressor circuit for CO 2 compression Slide 5 of 22

6 The Oxyfuel Process Slide 6 of 22

7 The Oxyfuel Process Essential process steps: Air Combustion and Steam Generation Flue Gas Cleaning and Drying CO 2 Compression and of Residual Gases Slide 7 of 22

8 Pulverised Fuel Combustion Test Facility: Data sheet: Thermal input kw th d i =290 mm; L=2.5 m Fuel flow (lignite, 10 % moisture) kg/h Oxygen feed rate kg/h Flue gas recycle kg/h Air/recycle gas temperature C Flue gas exit temperatures C after flue gas cooler C Slide 8 of 22

9 Pulverised Fuel Combustion Test Facility: Slide 9 of 22

10 Recirculation Oxyfuel 17 Pre-dried Coal Oxygen Recirculation Combustion Chamber Flue Gas same global mass flow rate same flue gas concentration But: different local stoichiometry recirculation rate affects local stoichiometry Oxyfuel 33 Pre-dried Coal Oxygen Combustion Chamber Flue Gas Slide 10 of 22

11 Results for the combustion of lignite: Oxyfuel Point 25 means that 25 percent by volume of oxygen is present at the burner head Slide 11 of 22

12 Results for the combustion of lignite: Oxyfuel Point 25 means that 25 percent by volume of oxygen is present at the burner head Slide 12 of 22

13 Results for the combustion of lignite: Oxyfuel Point 25 means that 25 percent by volume of oxygen is present at the burner head (without in leakage air) (with in leakage air) Slide 13 of 22

14 Wet Flue Gas Desulphurisation Test Facility : Data sheet: Raw gas volume flow: 30 Nm³/h Operating temperature: up to 80 C Solvent feed rate: 800 l/h per absorption column Capacity of the absorber tank: 2 x 140 l (bottom tank) and 400 l (external oxidation tank) Dimensions: d i =125 mm; L 1 =2.0 m (spray absorber); L 2 =3.5 m (packed absorber) 1: Crude gas inlet 6: Inspection glass Material: PP-H 2: Clean gas outlet 7: Ventilator 3: Spray absorber 8: Agitator 4: Bulk or package absorber 9: Compressed air membrane pump 5: Absorber bottom tank 10: Electric control cabinet Slide 14 of 22

15 Results of the wet flue gas desulphurisation for combustion with air: Slide 15 of 22

16 Results of the wet flue gas desulphurisation for combustion with pure oxygen: Slide 16 of 22

17 Distillative Desulphurisation: Slide 17 of 22

18 CO 2 Liquefaction Test Rig: Data sheet: Flow rate: m³/h gas (inlet) Piston pre-compressor up to 140 l/min Additional filter road for dust removal Drying with a hollow fibre membrane module Piston compressor for bar Double pipe condenser with cocurrent or countercurrent principle Condensate pump for up to 20 kg/h Gas cylinder stock 2 x 50 l with balance (not in the picture) Material: stainless steel Slide 18 of 22

19 Distillation Column: Data sheet: Flow rate: l/h liquid CO 2 Operating parameters: max. 45 bar; Vapor outlet C; Condensate outlet C Heating capacity: max. 3 kw Cooling capacity: ca. 3.2 kw at 10 C Number of trays: 8 bubble trays Dimensions: d i =129.7 mm; L Col =1.62 m; L all =4.35 m Material: stainless steel (column) Purity: vol.-% CO 2 (head); vol.-% SO 2 (bottom) Slide 19 of 22

20 Research results of the distillation: Test conditions: Operating pressure: 30 bar Mixture composition of the feed: 93 mass-% CO 2, rest SO 2 Desulphurisation: From 7 mass-% SO 2 in the mixture to mass-% (250 ppmv) SO 2 in the CO 2 stream This equals a desulphurisation rate of % Purity of products: CO 2 : up to vol.-% (99.97 vol.-%) SO 2 : over 99 vol.-% (calculated; vol.-%) Slide 20 of 22

21 Future Prospects Summary: A stable oxyfuel combustion is possible. The dry flue gas stream reaches a CO 2 concentration of more than 90 vol.-%. Due to the recycle of flue gas the formation of some pollutants like nitrogen oxide can be reduced. The distillation of SO 2 as an alternative to the wet flue gas desulphurisation is possible and reduces the need of auxiliary substances and the disposal of gypsum. In the future: Further investigations of the circulating fluidised bed combustion as a promising technology for the Oxyfuel Process. Research in component design with the collected experiences. Slide 21 of 22

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