Novel Oxy-steam Burner for Zero-emission Power Plants

Carlos Salvador, Milenka Mitrović & Kourosh Zanganeh

Zero Emission Technologies (ZET) GroupClean Electric Power Generation (CEPG)

SSeptember 10, 2009

Outline

Hydroxy-fuel combustion Motivation and Overall Objectives 3rd generation oxy-fuel systems

Novel burner concept and design Modes of operation Design and optimization Pilot-scale implementation

Experimental validation

2

Need for New Concepts and Technologies

Design for plant life Current and future needs (CO2 market, etc.)

Fl ibilit i d i t d t Flexibility in design to adapt Environmental regulations (near zero

emissions for fossil fuels) Low-value fuels and co-firing (bitumen,

petcoke, biomass, etc)petcoke, biomass, etc) Advancements in technology, e.g.,

Ion transport membrane for O2 production High temperature materials (boiler tubes,

etc)etc) Moving away from Rankin cycle (lower

efficiency) 3rd generation of oxy-fuel combustion

systemssystems Advanced turbines and power cycles Emerging technologies…

3

Hydroxy-Fuel Technology DevelopmentMotivation: Develop the technology base necessary for

the implementation of efficient zero-pemission fossil fuel systems

Overall Objectives: Investigate the feasibility of hydroxy-fuelInvestigate the feasibility of hydroxy fuel

combustion for the 3rd 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

Achieve high concentration of CO2 (> 90% on dry basis) in the exit flue gas stream

4

3rd Generation Oxy-fuel Systems

3rd Generation Oxy-fuel Combustion

Oxy steam Combustion O Combustion (no FGR)Oxy-steam Combustion O2 Combustion (no FGR) Low NOx & excess O2, Higher radiative & convective heat

transfer,

Minimize NOx & excess O2, High radiative & convective heat

transfer,, Process model, CFD, new system

and component design

Up to 40% scale reduction in unit size

, New materials, Process model, CFD, new system

and component designUp to 80% scale reduction in unit sizeUp to 40% scale reduction in unit size Up to 80% scale reduction in unit size

5

Novel Burner Design

Modes of Operation: Firing Rate 0.3 MWth (1.0 X 106 Btu/h) Fuels: Natural gas Oil Emulsion Fuels: Natural gas, Oil, Emulsion,

Pulverized coal, Petcoke, Coal Slurry, etc.Operational modes

►O2/steam►O2/steam►O2/RFG & O2/CO2►Air & oxygen enriched air►O2/steam/RFG2►O2/steam/CO2

Variable mass flow rates on secondary and tertiary streamsVariable oxygen concentration on

secondary and tertiary streams Independent swirl on secondary and

6

tertiary stream

Burner Operational Principles

O2Secondary

Pulverized CoalSwirl Stabilized Flame

O2SteamRFGCO2

SecondaryOxidizerStream

O2

SteamRFG

TertiaryOxidizerStream RFG

CO2Stream

Fuel RichZone

Tertiary

FlameStabilizationPoint

SecondaryFlow Zone

TertiaryFlow Zone

7

Design and Optimization

Determined system requirements via HYSYS simulations

Extended simulations to fix additional combustion parameters; i.e. O2-steam composition adiabatic flame temperature etcO2 steam composition, adiabatic flame temperature, etc.

Based on swirl burner theory, established the desired burner exit parameters

B d HYSYS Si l ti i l b i t d th Based on HYSYS Simulations, swirl burner requirements, and the possible effect of the combustor geometry, created a short list of possible burner geometries

8

Design Validation

Temperature CO Distribution O2 Distribution Equivalence Ratio

?

9

CFD Simulation done by CEPG CFD Group

Design Validation (cont’d)

Temperature Profile

Uniform temperaturedistribution

StagnationPointPoint

Vector Plot of Speed

10

CFD Simulation done by CEPG CFD Group

Burner Prototypes Development

1st Generation 2nd Generation 3rd Generation 4th Generation

Fixed Swirl Generator Testing

Variable Swirl Generator Testing

Modified Variable Swirl Generator Testing

2nd Variable Swirl Generator Testing

11

Pilot-Scale Implementation

Oxy-fuel Vertical CombustorResearch Facility (VCRF) Firing rate for tests: 0.2 MWth (0.7 X 106 Btu/h)

Combustion mode: O2/RFG or O2/SteamCombustion mode: O2/RFG or O2/Steam Fuel: Saskatchewan lignite coal Flow Paths:

O2/Steam: ESP CHX1 StackO2/Steam: ESP CHX1 Stack O2/RFG: ESP CHX1 Recycle Stack

Measurements Gas composition (O2 CO2 CO SO2 NOx)Gas composition (O2, CO2, CO, SO2, NOx) Mercury (Ontario Hydro Method & CEM) Suction pyrometer Radiation heat fluxRadiation heat flux Ash Samples

12

VCRF Flow Diagram

3rd O2

X

2nd O22nd Steam3rd Steam

X – Sample PointsRack 44

AirCO2

Air/CO2

HeatExchangers

ID Recycle

VC

X

FansFD Fan

ID Fan

K-TronRecycledFlue Gas

ESP Bag Ho se

CHX 1 CHX 2XX

ESP Bag House

CO2 Capture and Compression Unit(CO2CCU)

Rack 63 Hg CEM

13

VC Furnace Measurement PortsBurnerO2 + RFG

orO2 + Steam

BurnerCombustorSection(Flame Zone)

BurnerExit Plane

Burner

FlameScanner

SuctionPyrometerPorts

RadiationMeasurementPorts

CombustorSection(Flame Zone)

CameraPort

CombustionFlue Gas

o t

* All dimensions in inchesCombustionFlue GasStream

Flue GasStream

14

Results – Oxy-fuel Temperature Profile

Oxy-fuel Combustion07.11.08TE 102

TE 103

TE 105TE 104

TE 99TE 98

07.11.08

Oxy-fuel Combustion07.11.08

1400TE 98

TE 97

TE 95800

1000

1200

ratu

re [º

C]

TE102TE103TE104TE105TE099TE098

TE 94

TE 93TE 91

0

200

400

600

Tem

per

TE097TE095TE094TE091

CombustionFlue GasStream

13:43

:0014

:13:00

14:43

:0015

:13:00

15:43

:0016

:13:00

16:43

:0017

:13:00

17:43

:0018

:13:00

18:43

:0019

:13:00

19:43

:0020

:13:00

20:43

:0021

:13:00

Time[hh:mm:ss]

15

Results - Oxy-fuel Combustor Exit

Oxy-fuel Combustion07.11.08

Camera cleaningO2/FGR

Shut-downSampling

Rack 44

70

80

90

100

ry

16

18

20

22(0.5, 0)

(0, 1.9)

g

(0, 0.8)(0, 0.6)(0, 0)

(0.5, 1.9)(0, 0.8)

P5

P4 P3

P2P1

P55

P44P33

P22P11

30

40

50

60

CO

2 %

Vol

. D

6

8

1012

14

O2

[% V

ol.] CO2

O2 (dry)O2(wet)K-Tron

Reload

K-TronReload

K-TronReload

K-TronReload

K-TronReload

K-TronReload

K-TronReload

0

10

20

43:00

13:00

43:00

13:00

43:00

13:00

43:00

13:00

43:00

13:00

43:00

13:00

43:00

13:00

43:00

13:00

0

2

4

6

13:43

14:13

14:43

15:13

15:43

16:13

16:43

17:13

17:43

18:13

18:43

19:13

19:43

20:13

20:43

21:13

Time [hh:mm:ss]

16

Results – Oxy-fuel Combustor Exit (cont’d)

Rack 44Oxy-fuel Combustion

0.7.11.082500 200

1500

2000

2500

ppm

] 150

200

Camera cleaningO2/FGR

Shut-down

Sampling

1000

1500

SOx

and

NO

x [

50

100

CO

[ppm

]

NOxSOxCO

K-TronK T

(0.5, 0) (0, 1.9)(0, 0.8)(0, 0.6)(0, 0) (0.5, 1.9)(0, 0.8)

P5

P4

P3

P2P1

P55P44

P33P22

P11

K-Tron K-Tron

0

500

43:00

13:00

43:00

13:00

43:00

13:00

43:00

13:00

43:00

13:00

43:00

13:00

43:00

13:00

43:00

13:00

0

K-TronReload

K TronReload

K-TronReload

K-TronReload

K TronReload ReloadK-Tron

Reload

13:43

14:13

14:43

15:13

15:43

16:13

16:43

17:13

17:43

18:13

18:43

19:13

19:43

20:13

20:43

21:13

Time [hh:mm:ss]

17

Results – Oxy-steam Temperature Profile

TE 102TE 103

Oxy-Steam Combustion17.10.08

TE 103

TE 105TE 104

TE 99TE 98

Oxy-fuel Combustion07.11.08

1200

1400

TE 97

TE 95

TE 94600

800

1000

1200

pera

ture

[º C

]

TE102TE103TE104TE105TE099TE098TE097TE 94

TE 93TE 91

0

200

400

00 00 00 00 00 00 00 00 00 00 00 00 00 00

Tem

p

TE095TE094TE091

CombustionFlue GasStream

11:00

:011

:30:0

12:00

:012

:30:0

13:00

:013

:30:0

14:00

:014

:30:0

15:00

:015

:30:0

16:00

:016

:30:0

17:00

:017

:30:0

Time[hh:mm:ss]

18

Results – Oxy-steam Combustor Exit

Rack 44Oxy-steam Combustion17.10.08

(0, 1.1)O2/Steam

S li

70

80

90

100

Dry 12

14

16

18

]

CO2

P44

P55

P33

P22

P11

Coal Sample

OX-043Blow dow n

Sampling

20

30

40

50

60

CO

2 %

Vol

. D

4

6

8

10

O2

[% V

ol. CO2

O2 (dry)O2 (wet)

K-TronReload

K-TronReload

K-TronReload

K-TronReload

K-TronReload

K-TronReload

67 min 68 min 65 min 64 min 62 min

Ports

0

10

20

1:00:00

1:30:00

2:00:00

2:30:00

3:00:00

3:30:00

4:00:00

4:30:00

5:00:00

5:30:00

6:00:00

6:30:00

7:00:00

7:30:00

0

2

4

Racksoff-line

Portsopen

11 11 12 12 13 13 14 14 15 15 16 16 17 17

Time [hh:mm:ss]

19

Results – Oxy-steam Combustor Exit (cont’d)

Oxy-steam Combustion17.10.08

(0, 1.1)

Rack 44

2000

2500

ppm

]

400

500

P44

P55P22

P11

( , )O2/Steam

Coal Sample

OX-043

Sampling

1000

1500

Ox

and

NO

x %

[p

200

300

CO

[ppm

] SOxNOxCO

K-TronReload

K-TronReload

K-TronReload

K-TronReload

K-TronReload

P33P11

K-TronReload

Blow dow n

67 min 68 min 65 min 64 min 62 min

Radiationmeasurement

0

500

11:00:00

11:30:0

012:0

0:0012:3

0:0013

:00:0013:3

0:0014:0

0:00

14:30:00

15:00:00

15:30:0

016:0

0:0016:3

0:0017

:00:0017:3

0:00

SO

0

100Racksoff-line

measurement

Portsopen

11 11 12 12 13 13 14 14 15 15 16 16 17 17

Time [hh:mm:ss]

20

Results (cont’d)

Suction Pyrometer Measurements on Centre Line

1500

Oct. 7, 2008 (O2/RFG)Oct. 28, 2008 (O2/RFG)Oct. 17, 2008 (O2/Steam)Oct 9 2008 (O2/Steam)

1300

1400

]

Oct. 9, 2008 (O2/Steam)Aig. 1, 2008 (O2/Steam)Poly. (Oct. 9, 2008 (O2/Steam))Poly. (Oct. 17, 2008 (O2/Steam))Poly. (Oct. 7, 2008 (O2/RFG))

1200

1300

empe

ratu

re [o

C] y ( , ( ))

Poly. (Oct. 28, 2008 (O2/RFG))Poly. (Aig. 1, 2008 (O2/Steam))

1000

1100Te

P11P22

P33P44

P55 P1 P2 P3 P4 P5900

0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50

Distance from Burner Exit Plane [m]

P11 P33 P55 P1 P2 P3 P4 P5

21

Results – High Swirl Oxy-Steam Flame

Quarl

Burner FlameScanner

FlameScannerCombustion

Flue GasStream

CombustorSection(Flame Zone)

CameraPort

FlameEnvelop

CL

22

CL

Conclusions

Best results, for oxy-steam, was achieved when all of theyO2 was sent via the outer annulus and moderate to highswirl numbers where used; best results, for oxy-fuel, wasachieved when all of the O2 was sent via the inner annulusachieved when all of the O2 was sent via the inner annulus. Oxy-steam combustion resulted in high CO2 concentrations

(~ 90%), low CO, moderate NOx and typical SOx levels.Eli i ti f l t i t d d d Elimination of recycle stream, in oxy-steam mode, reducedair infiltration issues boosting CO2 concentrations by 5-10%. Combustor outlet moisture content approximately was 60%

23

Acknowledgement

This work was supported by the PERD (Program ofEnergy Research and Development) and theCanmetENERGY CO2 R&D Consortium. The authorsgratefully acknowledge the support provided by theseprograms.p og a s

24

Oxy-steam Flame

L S i l Hi h S i lLow Swirl High Swirl

25