Modeling, Design, and Pilot-Scale Experiments of CANMET's Advanced Oxy-Fuel/Steam Burner

Transcription

1 2nd Workshop International Oxy-Combustion Research Network Hilton Garden Inn Windsor, CT, USA 25th and 26th January 2007 Hosted by: Alstom Power PRESENTATION - 09 Modeling, Design, and Pilot-Scale Experiments of CANMET's Advanced Oxy-Fuel/Steam Burner by: Carlos Salvador CANMET Energy Technology Centre, Canada

2 Modeling, Design, and Pilot-Scale Experiments of CANMET's Advanced Oxy-Fuel/Steam Burner K. Zanganeh, C. Salvador, and M. Mitrovic Zero-Emission Technologies Group, CEPG 2 nd IEA GHG Oxy-Combustion Workshop January 25-26, 2007 Technology Background Clean fossil fuel combustion with capture pathways Industrial Processes Raw Materials Process Carbon Release Process stream % Removal Value Added Products i.e. Ammonia, NG, Transport Fuels, Cement, Steel etc. Post-combustion Capture Air-Combustion Power & Heat Flue gas 5-10 % Removal Pre-combustion Capture Coal/Coke /NG/Fuel Oil/ Biomass Gasification/ Reforming Syngas % Carbon Removal H 2 Combustion Power & Heat Compression & Transport for Storage O 2 /Steam Oxy-fuel Combustion Oxy-Combustion Power & Heat Flue gas >80 % CO 2 Removal 2 2nd Int'l Oxy-Combustion Workshop Page 1

3 Technology Background (cont ) Oxy-fuel combustion pathways Energy Conversion Operation Technologies Combustion Atmospheric Scrubbing: Amine O 2 Fossil Fuel Gasification Reforming Pressurized Pressurized Pressurized removal CO + H 2 H 2 Oxy-Combustion: Retrofits New boilers Turbines/Fuel Cells Hydrogen Combined cycles Fuel cells 3 Oxy-fuel combustion systems Technology Background (cont ) 1 st generation oxy-fuel combustion systems - Flue gas is recycled to control the combustion temperature Other fuels, e.g., NG, bitumen Particulates, SO2 4 2nd Int'l Oxy-Combustion Workshop Page 2

4 Technology Background (cont ) No reduction in unit size/volume compared to air-fired combustion (up to flue gas branch point) No energy efficient integration and optimization of the process No efficient recovery of low temperature heat Need to design the whole plant as a gas-tight system and hot gas leakage out Operational safety considerations Plant has to operate at slightly negative pressure Air leakage in Need for flue gas recycle to transport coal from the mills Need for gas-tight mills Need for treatment of the primary recycle flow, etc 5 Technology Background (cont ) 2 nd generation oxy-fuel combustion systems - Energy efficient integration and optimization of the process, recovery of low temperature heat 6 2nd Int'l Oxy-Combustion Workshop Page 3

5 Technology Background (cont ) 3 rd generation oxy-fuel combustion systems Minimizing or eliminating the flue gas recycle (no FGR) Recycled Flue Gas 1/5 exit gas volume relative to air CO2 at 80-98% by volume Fossil fuel combustion O 2 Air Separation Unit Power or Heat N 2 Gas Purification Storage Compression Other pollutants and/or water For process heaters, furnaces and boilers 7 Technology Background (cont ) Low NOx & excess O 2, Higher radiative & convective heat transfer, process model, CFD, system and component design O 2 H 2 O Heat recovery Fuel Combustor (turbine) PR CHX to Compression Ash 8 2nd Int'l Oxy-Combustion Workshop Page 4

6 Hydroxy-Fuel Technology Development Motivation: Develop the technology base necessary for the implementation of efficient zero-emissions fossil fuel systems Overall Objectives: Investigate the feasibility of hydroxy-fuel combustion for the 3 rd 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 9 Hydroxy-Fuel Technology Development (cont ) Selected power cycles Advanced Steam Generators, Richards et. al, NETL A reheat cycle with steam or water as temperature moderator 10 2nd Int'l Oxy-Combustion Workshop Page 5

7 Development, Design and Integration Zero-Emission Oxy-Steam Combustion Process & System Design Oxy-Steam Burner VC Plant Steam Generation Delivery System Overall System Integration Optimization & Testing Scale-Up 11 Development, Design and Integration (cont ) CFD Simulation Gauged the suitability of a test burner for hydroxy-fuel combustion. Temperature Profile O 2 distribution Flame leans to one side. 12 2nd Int'l Oxy-Combustion Workshop Page 6

8 Development, Design and Integration (cont ) CFD Simulation Temperature Profile Uniform temperature distribution Stagnation Point Vector Plot of Speed 13 Development, Design and Integration (cont ) Burner prototype Firing rate: 0.3MWth (1MMBtu/hr) Fuels: Natural gas Oil, Emulsion Pulverized coal and coal slurry Operational modes O2/steam O2/RFG O2/CO2 Air Enriched air O2/steam/RFG O2/steam/CO2 Variable secondary & tertiary streams Independent secondary & tertiary swirl 14 2nd Int'l Oxy-Combustion Workshop Page 7

9 Development, Design and Integration (cont ) Integration with Vertical Combustor Steam generation system O 2 and steam piping design Instrumentation and control Graphical user/control interface 15 Concluding Remarks All aspects of hydroxy-fuel process design, technology development, and implementation were performed at CANMET i.e., design, manufacturing, system integration, and pilot-scale testing The preliminary pilot-scale test results are very encouraging Economic and scale up studies will be performed after completion of all pilot-scale tests The oxy-fuel/steam burner design is novel and we are in the process of applying for a patent 16 2nd Int'l Oxy-Combustion Workshop Page 8

10 Advance Flame Imaging System (AFIS) IMAGE PROCESSOR MONITOR COMBUSTOR SECTION (FLAME ZONE) Card BURNER ASSEMBLY VC CAMERA PROBE (AFIS) FIELD OF VIEW BURNER EXIT PLANE COMBUSTION FLUE GAS STREAM nd Int'l Oxy-Combustion Workshop Page 9

11 Thank You 19 2nd Int'l Oxy-Combustion Workshop Page 10