Oxyfuel Pulverized Coal Steam Generator Development 30 MWth Pilot Steam Generator

Transcription

1 Oxyfuel Pulverized Coal Steam Generator Development 30 MWth Pilot Steam Generator Commissioning and Testing F. Kluger, P. Mönckert, B. Krohmer, G.-N. Stamatelopoulos Alstom J. Jacoby, U. Burchhardt Vattenfall 1st IEA GHG G International a Oxyfuel Combustion o Conference e Cottbus, Germany 8-11 September 2009

2 Agenda Alstom s Oxy PC Development Roadmap Oxyfuel Pilot Steam Generator Realisation & Description Oxyfuel Pilot Steam Generator Results from Operation Summary Next Steps

3 Roadmap Oxy PC Development Status and Next Steps Lab Scale 2004 Source: Vattenfall Source: Vattenfall Pilot Plants Demonstration Full-Scale < 2020 Up to 500 kw th Oxy PC Lignite & Bit Coal Testing Uni Stuttgart, Uni Cottbus, Uni Hamburg-Harburg, Uni Dresden ENCAP (EC Co-funded Project), ADECOS I & II (GER Cofunded Project), OxyBurner (EC Co-funded Project), OxyCorr (EC Co-funded Project), etc. 30 MW th Oxy PC MW el Lignite & Bit. Coal Oxy PC Lignite Schwarze Pumpe, (e.g. Vattenfall Germany (Vattenfall, Jänschwalde, Alstom) Feasibility Study Performed with 30 MW th Oxy Gas Alstom Natural Gas & Oil Contribution) Lacq, France (TOTAL, Alstom) MW el Oxy PC Bit. Coal 15 MW th Oxy PC Bitum. Coal & Lignite Windsor, CT, USA (DoE, Alstom) 400 1,100 MW el Oxy PC Lignite 600 1,100 MW el Oxy PC Bit. Coal

4 Agenda Alstom s Oxy PC Development Roadmap Oxyfuel Pilot Steam Generator Realisation & Description Oxyfuel Pilot Steam Generator Results from Operation Summary Next Steps

5 30 MWth Oxyfuel Pilot Plant - Realisation As planned... Milestones Contrac ct Award Permis ssion Lift of First Column Hydro Pressure Test First Co oal Fire First Ox xy-firing First To onne CO 2 Capture ed PAC Main Data 04/ 06 11/ 06 07/ 07 7 As realized 11/ 07 07/ 08 08/ / 08 12/ 08 Thermal Capacity: 30 MW th Steam Production: 40 t/h Steam Pressure: 25 bar Steam Temp.: 330 C Fuel: Lignite / Bit. Coal Fuel demand (Lig.): 5.2 t/h O 2 demand: 10 t/h CO 2 (liquid): 9 t/h CO 2 capture rate: >90 % Start operation: 2008 Source: Vattenfall

6 30 MWth Oxyfuel Pilot Plant - Realisation

7 30 MWth Oxyfuel Pilot Plant Process Scheme & Alstom Scope Coal Dust Primary Flue Gas Recycle Gas Burner Dry sorbent Ammonia Seal Gas <1,2 bar Steam- HEX Steam- HEX Air Seal Gas 6 bar Furnace 2 nd Path De-NOx Filter FGD ID Fan 1 ID Fan 2 FGC CO 2 - Process 3 rd Path Ash Secondary Flue Gas Recycle Steam- HEX Air Nitrogen Steam- HEX Oxygen ASU Air

8 30 MWth Oxy-Combustion Pilot Plant Key Information Key information generated for the next Oxycombustion development steps: Single burner & indirect firing system testing Combustion fundamentals (emissions, burnout, fouling & slagging, excess oxygen, flue gas recycle ratio etc.) Heat transfer (radiation, convection) Material selection (corrosion issues) Operational data for validation of oxyfuel CFD models Dynamic behaviour of entire oxy-combustion plant (Start-up t / shut down, switch air to oxy and vice versa) Interaction of ASU, Boiler, AQCS and GPU Control loops for oxy-combustion process and plant Integration Options Component Optimisation Achievable CO 2 capture rate and quality Flue-gas flow Intakeair damper Flue-gas recycledamper Oxidant flow Air flow O2 from ASU Recycled flue-gas flow 07:50 08:00 08:10 08:20 08:30 08:40 08:50 09:00 09:10 09:20

9 30 MWth Oxyfuel Pilot Plant - Boiler Boiler Design DeNOx-Option (optional) Ignition Burner Burner ECO 5 SH 1 HEX Gas ECO 4 Catalyst 1 Catalyst 2 SH 2 ECO 3 Catalyst 3 Burnout Oxydant Hydrated Lime ECO 2 ECO 1 ESP

10 30 MWth Oxyfuel Pilot Plant Burner / Firing System Operating Modes OxPP : 1 x 30 MW th Dried lignite / Transport air Core air core : Air Secondary air surround 1 : Air surround 2 : Air surround 3 : Air Air operation core : Oxygen+RFG* core : RFG* surround1 : Oxygen+RFG* surround1 : RFG* surround 2 : Oxygen+RFG* surround 2 : RFG* surround3 : Oxygen+RFG* surround3 : Oxygen Oxyfuel operation (premixed oxygen) Oxyfuel operation (direct oxygen injection) *RFG = Recirculated Flue Gas *RFG = Recirculated Flue Gas

11 30 MWth Oxyfuel Pilot Plant Oxy-Firing Operation Modes Burner Burner Burner Combustion chamber 2. Pass (DeNOx) 3. Pass Combustion chamber 2. Pass (DeNOx) 3. Pass Combustion chamber 2. Pass (DeNOx) 3. Pass Recycle Recycle Recycle Oxygen Oxygen Oxygen Oxyfuel Pre-mixed Mode Oxyfuel Expert Mode A Oxyfuel Expert Mode B

12 Agenda Alstom s Oxy PC Development Roadmap Oxyfuel Pilot Steam Generator Realisation & Description Oxyfuel Pilot Steam Generator Results from Operation Summary Next Steps

13 Results from Operation Switch From Air-Firing to Oxy-Firing Mass flows (Air, Oxidant, Flue gas) ~ min Flue-gas flow Intake air damper Flue-gas recycle damper Oxidant flow Air flow Recycled flue-gas flow O2 from ASU 07:50 08:00 08:10 08:20 08:30 08:40 08:50 09:00 09:10 09:20 Time

14 Results from Operation Switch From Air-Firing to Oxy-Firing Flue Gas Species ~ min Thermal performance ~ min CO2 >85 vol.-% (dry) after ESP SO 2 H2O ca. 28 vol.-% after ESP NO x CO O 2 07:50 08:00 08:10 08:20 08:30 08:40 08:50 09:00 09:10 09:20 Time

15 Results from Operation - Burner / Firing System (Air-Firing) Burner operates in a stable and reliable way Limits for emissions kept easily for air mode of operation Primary measures for NO x reduction applied Typical emission values are: Dust << 20 mg/nm³ (dry) CO < 100 mg/m³ (dry) NO x < 300 mg/m³(dry) SO 2 < 1,000 mg/m³(dry) O 2 < 4 vol.-% (wet) Good burnout with low unburnt carbon in fly ash and slag Hydrated lime injection for SO 2 control Hydrated lime injection for SO 2 control causes fouling in the economizer heating surfaces Air-Firing

16 Results from Operation - Burner / Firing System (Oxy-Firing Pre-mixed Mode) Burner operates in pre-mixed mode in a stable and reliable way with an oxygen concentration in the oxydant of 28 Vol.-%. Limits for emissions kept easily for oxyfuel mode of operation Primary measures for NO x reduction applicable but not required Typical emission values are: Dust << 20 mg/nm³ (dry) CO < 300 mg/m³ (dry) NO x < 700 mg/m³(dry) O 2 < 4.5 vol.-% (wet) Good burnout with low unburnt carbon in fly ash and slag In oxyfuel mode operation longer response In oxyfuel mode operation longer response time due to the flue gas recirculation Oxy-Firing (premixed mode)

17 Results from Operation CO-Concentration Comparison of different operation modes CO Em missions s Expert Mode A Expert Mode B Pre-mixed Mode O 2 Concentration in Flue Gas

18 Results from Operation NO x -Concentration Comparison of different operation modes NOx Em missions s Expert Mode A Pre-mixed Mode Expert Mode B O 2 Concentration in Flue Gas

19 30 MWth Oxyfuel Pilot Plant Status of Operation as End of August O 2 Con ncentration n in Oxidan nt (vol.-%) Oxyfuel - Expert Mode - Air Oxyfuel - Pre-mixed Mode O 2 Concentration in Flue Gas (vol.-%)

20 30 MWth Oxyfuel Pilot Plant Status of Operation as End of August 2009 Total Operation Air Operation Oxyfuel Operation Burner Pre-mixed Mode Burner Expert Mode 3,100 h 1,500 h 1,600 h 1,000 h 600 h

21 Agenda Alstom s Oxy PC Development Roadmap Oxyfuel Pilot Steam Generator Realisation & Description Oxyfuel Pilot Steam Generator Results from Operation Summary of Oxy-Steam Generator Pilot Experience to Date Next Steps

22 Summary of Oxy-Steam Generator Pilot Experience to Date Design approach for thermal design and firing system design confirmed in practical operation Mode switch from air mode to oxy mode and vice versa works easier than originally anticipated All contractually fixed parameters are met for air and oxy combustion CO 2 concentrations in the flue gas downstream of the boiler >85 Vol-% dry Oxy-Firing Expert Mode results in lower flue gas oxygen concentration compared to the Pre-Mixed Mode, O 2 values below 3 Vol.-% can be achieved Burner and firing system has demonstrated its high flexibility with good performance Test program under execution Data for CFD model development and Test program under execution. Data for CFD model development and validation, dynamic behaviour, heat transfer etc. already generated. Extensive material testing under execution.

23 Agenda Alstom s Oxy PC Development Roadmap Oxyfuel Pilot Steam Generator Realisation & Description Oxyfuel Pilot Steam Generator Results from Operation Summary Next Steps

24 Next Steps Testing of Alternative Alstom Burner Design OxPP : 1 x 30 MW th Dried lignite / Transport air Core air Design A Design B Secondary air Main features Each burner compartment can be individually enriched with oxygen up to 39 Vol.-% One swirl device Ring of lances for 100% oxygen injection Separate ignition burner for start-up Main features Each burner compartment can be individually enriched with oxygen up to 39 Vol.-% Two swirl devices Annular clearance for 100% oxygen injection Integrated gas lance for start-up

25 Next Steps Testing of Alternative Alstom Burner Design Testing of firing system and burner Air Mode Oxy Mode - Pre-mixed Mode - Expert Mode A - Expert Mode B Measurements Gaseous Emissions, Ashes, Deposits Corrosion Heat Transfers Detailed in-flame measurements for CFD modeling

26 Thank You For Your Attention!

27 30 MWth Oxyfuel Pilot Plant - Realisation PLAY!