SO 3 Emissions From a Tangentially- Fired Pilot Scale Boiler Operating Under Oxy-Combustion Conditions

Transcription

1 SO 3 Emissions From a Tangentially- Fired Pilot Scale Boiler Operating Under Oxy-Combustion Conditions 2011 IEAGHG Special Workshop on Oxyfuel Combustion J. R. Kenney, M. M. Clark, A. A. Levasseur, S. G. Kang London, UK, 26 Jan 2011

2 Agenda 1 Oxy T-Fired Boiler Development Project 2 Measurement Technique 3 Locations and setup at 15MWt Test Facility 4 Results from 15MWt Testing SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 2

3 15 MWth Oxyfuel Pilot Plant BSF Alstom Labs, Windsor, CT, USA Objective Develop Oxyfuel Tangential Boiler system producing high CO2 content gas for CCS Scope Design and develop an inovative oxyfuel firing system for T-fired boilers Evaluate the performance in pilot scale tests at 15 MWth BSF (combustion, heat transfer, pollutant emissions, deposition, corrosion, ) Evaluate and improve engineering and CFD tools for oxy-combustion by applying detailed test data obtained Reference Plant Study and Demo Design Status BSF Modified and Testing Started Sept Four Test Campaigns Completed Sub Bit., Low S Bit, High S Bit, Lignite Next Steps Two BSF Campaigns Schwarze Pumpe Lignite, 2nd Generation Concepts Tool Refinement and Validation, Demo Design SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 3

4 Oxy T-Fired Boiler Development Project Team: Alstom R&D Execution Alstom New & Retrofit Boiler Business DOE NETL ICCI Illinois Clean Coal Institute NDIC North Dakota Industrial Commission Utility Advisory Group Ten Utility Members: Ameren ATCO Dominion Energy Great River Energy Luminant (TXU) LCRA and Austin Energy MidWest Generation NB Power OG&E Vattenfall SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 4

5 Agenda 1 Oxy T-Fired Boiler Development Project 2 Measurement Technique 3 Locations and setup at 15MWt Test Facility 4 Results from 15MWt Testing SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 5

6 Overview Measurement Technique Standard SO 3 sampling techniques subject to biases Developed for sampling at sulfuric acid plants (low-dust) EPA Method 8A 80% isopropyl alcohol solution positive bias due to solubility of SO 2 in water Flue gas filtered negative bias due to SO 3 adsorption/reaction with ash worse in high-dust locations upstream of ESP or Baghouse Not ideal for coal-derived flue gases significant dust & SO 2 EPA Method 17 and ASTM T Controlled Condensation (CC) Flue gas filtered negative bias due to SO 3 adsorption/reaction with ash Reasons for ISP-Based Measurement Technique SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 6

7 Highlights of ISP Controlled Condensation Inertial Separation Probe (ISP) used to extract a dust-free flue gas sample ISP sample extraction induced by aspirator Aspirator sized to maintain axial gas velocities of 100 ft/s (30 m/s) through ISP Dust-laden sample flows axially through a tube made of sintered metal (sample frit) Low-volume sample flow ~2.5 Standard Liters Per Min. (SLPM) is drawn radially through the tube walls of the sample frit Dust remains entrained Minimizes negative bias due to SO 3 /ash interactions Probe and stinger are coated in a sulfur inert material Minimizes catalyzed SO 2 SO 3 Balance of sample train follows standard Controlled Condensation Exception: higher condenser temperature for oxy-combustion conditions (due to higher H 2 O dew point) SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 7

8 Diagram of Modified Controlled Condensation with ISP SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 8

9 Past Field Measurements Internal tests conducted Alstom ISP controlled condensation measurements executed at utility power plants Eastern-bituminous high-s coal: Unit A (AH inlet, AH outlet, & In-Furnace) Unit B (AH inlet & AH outlet) Compared 3 sampling techniques: Electrostatic Precipitator (ESP), Inertial Separation Probe (ISP), Glass Wool Plug (GWP) Unit C (AH inlet & AH outlet) Sub-bituminous low-s coal: Unit D (AH inlet) Unit A B C D AH In Measured SO3 O Acid dewpt (est.) F AH Out Measured SO3 O n/a Acid dewpt (est.) F Success and Experience in the Field SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 9

10 Unit B Air Heater Inlet Comparison ESP/ISP/GWP SO3, 3% O Electrostatic Precipitator Inertial Separation Probe Glass Wool Plug Test # 190 MW e divided wall Tangentially fired boiler firing 1.7% Sulfur Bituminous coal Negative Bias Observed in Industry Standard method (GWP) SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 10

11 Agenda 1 Oxy T-Fired Boiler Development Project 2 Measurement Technique 3 Locations and setup at 15MWt Test Facility 4 Results from 15MWt Testing SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 11

12 15MW th BSF Process Schematic! " %&'(! ) *+) # %, %&"(! )! " $ % # SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 12

13 Economizer Outlet Location SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 13

14 Windbox Inlet Location SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 14

15 15MW th BSF Oxy-Combustion Test Campaigns Test campaigns completed for four coals Sub-Bituminous Low-sulfur Bituminous High-sulfur Bituminous Dried Lignite SO 3 measurements executed during select conditions Air-fired Oxy-combustion with FGR Configurations: Hot and dirty no SO x control or fly ash removal from secondary FGR Post-baghouse, no SO x control Post-baghouse, with SO x control Oxy-combustion with spiking of SO 3 to secondary FGR SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 15

16 As Fired Coal Analysis Sub-Bit Low-S E. Bit. High-S Bit. Lignite Proximate VM FC FC/VM VM, DAF FC, DAF Ultimate Moisture Hydrogen Carbon Sulfur Nitrogen Oxygen Ash Total HHV, BTU/lb 9,364 13,268 12, SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 16

17 Coal Ash Elemental Analysis Sub-Bit Low-S Bit. High-S Bit. Lignite Ash Elemental Composition % SiO % Al2O % Fe2O % CaO % MgO % Na2O % K2O % TiO % P2O % SO % Mn3O % BaO % SrO % Total Ash Chemistry Impacts SO 3 Emissions SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 17

18 Agenda 1 Oxy T-Fired Boiler Development Project 2 Measurement Technique 3 Locations and setup at 15MWt Test Facility 4 Results from 15MWt Testing SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 18

19 Sub-Bituminous: Economizer Outlet 5 4 Alstom 15MW th BSF Sub-Bituminous SO 3 Testing - Economizer Outlet Air Oxy w/o SOx control Oxy hot FGR SO3 ppmv % 0.2% 0.1% Conversion ,000 SO 2 ppmv SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 19

20 High-Sulfur Bituminous: Economizer Outlet Alstom 15MW th BSF High-Sulfur Bituminous SO 3 Testing - Economizer Outlet Air Oxy w/ SOx control Oxy w/o SOx control 175 SO3 ppmv % 2% % Conversion ,000 4,000 6,000 8,000 10,000 12,000 SO 2 ppmv SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 20

21 High-Sulfur Bituminous: Gas System Path SO ppm e Alstom 15MW th BSF High-Sulfur Bituminous SO 3 Testing Air Oxy w/ SOx control Oxy w/o SOx Control For windbox ppm e is the equivalent ppm the economizer outlet ppm e ppm n n SecondaryFGR FurnaceOut 50 0 Windbox Furnace Economizer Location SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 21

22 Lignite SO 3 Addition: Gas System Path SO Oxy w/o SOx Control Oxy w/ SOx addition Oxy hot FGR Alstom 15MWth BSF Lignite SO 3 Testing For windbox ppm e is the equivalent ppm the economizer outlet ppm e ppm n n SecondaryFGR FurnaceOut ppm e Windbox Furnace Economizer Location Recycled SO 3 does not impact outlet emissions SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 22

23 Lignite SO3 Addition: Economizer Outlet SO3 ppmv Alstom 15MW th BSF Lignite SO 3 Testing - Economizer Outlet Air Oxy w/o SOx control Oxy hot FGR Oxy w/so3 spike 3% 2% 1% Conversion ,000 1,500 2,000 2,500 3,000 3,500 SO 2 ppmv SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 23

24 Summarized Results Alstom 15MW th BSF Oxy Air SO3 ppmv 100 High-S Bit. 50 Lignite Low-S Bit. 0 Sub-Bit wt % sulfur Air Oxy w/o SOx control Sub-Bit Low-S Bit. High-S Bit. Lignite Measured SO 3 ppmv Acid dewpt (est.) F Measured SO 3 ppmv Acid dewpt (est.) F SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 24

25 Summary Higher concentration of SO 3 during oxy-combustion Due to nitrogen depleted flue gas No observed increase in SO 2 SO 3 conversion during oxy-combustion No observed impact of recycled SO 3 on outlet emissions Note: Although not demonstrated at these conditions and locations, higher levels of SO 2 /SO 3 control is possible SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 25

26 Acknowledgements This research was made possible with support, in part, by US Department of Energy Through the National Energy Technology Laboratories Illinois Department of Commerce and Economic Opportunity Through the Office of Coal Development and the Illinois Clean Coal Institute North Dakota Industrial Commission Utility Advisory Members Vattenfall, ATCO, Dominion Energy, Ameren, Luminant (TXU), LCRA, OG&E, MidWest Generation, Great River Energy, NB Power SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 26

27 Disclaimer Parts of this document were prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. This this document was also prepared with support, in part, by grants made possible by the Illinois Department of Commerce and Economic Opportunity through the Office of Coal Development and the Illinois Clean Coal Institute. Neither Alstom Power, nor any of its subcontractors, nor the Illinois Department of Commerce and Economic Opportunity, Office of Coal Development, the Illinois Clean Coal Institute, nor any person acting on behalf of either: (A) Makes any warranty of representation, express or implied, with respect to the accuracy, completeness, or usefulness of the information contained in this report, or that the use of any information, apparatus, method, or process disclosed in this report may not infringe privately-owned rights; or (B) Assumes any liabilities with respect to the use of, or for damages resulting from the use of, any information, apparatus, method or process disclosed in this report. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring; nor do the views and opinions of authors expressed herein necessarily state or reflect those of the Illinois Department of Commerce and Economic Opportunity, Office of Coal Development, or the Illinois Clean Coal Institute. Information disclosed herein is furnished to the recipient solely for the use thereof as has been agreed upon with ALSTOM and all rights to such information are reserved by ALSTOM. The recipient of the information disclosed herein agrees, as a condition of its receipt of such information, that ALSTOM shall have no liability for any direct or indirect damages including special, punitive, incidental, or consequential damages caused by, or arising from, the recipient s use or non-use of the information SO3 emissions from a tangentially-fired pilot scale boiler operating under oxy-combustion conditions - MMC,JRK,AAL,SGK - 26 JAN P 27

28