Developments in oxy-combustion technologies Toby Lockwood
Transcript of Developments in oxy-combustion technologies Toby Lockwood
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Developments in oxy-combustion technologies
Toby Lockwood
High temperature materials in pulverised coal technology
Kyle Nicol
24th
April 2014, 2pm AEST (Melbourne, Australia)
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Developments in oxyfuel
combustion of coal
Toby Lockwood
IEA Clean Coal Centre
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Oxyfuel concept
• Eliminate N2 from combustion for purer stream of CO
2
(>90% dry)
• Combustion air replaced with a mixture of pure oxygen
and recycle flue gases
Conventional plant + ASU
+ CPU + flue gas recycle
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Advantages
• Based on combining established technologies
• Straightforward retrofit
• Minimal interference with steam cycle
• High capture rates possible (98-99%)
• Low water use
• Reduced boiler size possible
• Potentially easier flue gas scrubbing
But:
• Energy penalty is significant (7-10 %pts) due to air
separation and CO2 purification/compression
• Capital cost
• Corrosion and air ingress issues
• Altered combustion properties
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Flue gas recycle
Possible recycle locations:
• Hot recycle before FGD: High SOx = corrosion risk
• Recycle post FGD: Thermal penalty
• Dry recycle post FGC: Even bigger penalty, but needed for
coal drying/transport
• Usually post FGD for 2˚ stream, post FGC for 1˚
• Dry deSOx is another solution for hot recycle
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Combustion
CO2 has very different properties to N
2:
• 1.7 x density: altered mass flows and heating rate
• 1.6 x specific heat: lower flame temperature, ignition
delay
• Active in IR spectrum: higher thermal radiation
• Reduced diffusivity of O2 and volatiles
• Gasification reactions
Oxyfuel flames are
less stable and can
detach from burner.
Flue gas RR is first
recourse to stabilise
combustion.
Air
Oxyfuel
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Combustion: Recycle ratio
• Reduce flue gas dilution to match air flame temperature
• ~27-29% oxygen needed for wet recycle
• Also reduces ignition delay and stabilises flame
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Combustion: Oxyfuel burners
Oxyfuel tailored burners needed for optimum
performance:
• Increase recirculation of hot exhaust with swirl or quarl
geometry
• Account for altered density/volumes on aerodynamics
• Pure oxygen injection
Alstom RWTH Aachen
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Combustion fundamentals
Gasification reactions:
CO2 + C → 2CO
H2O + C → CO + H
2
Clarifying effect on each combustion stage helps improve
CFD models:
• Coal drying: largely unaffected
• Devolatilisation: similar yield, slightly longer duration
• Ignition: Slightly delayed even at same flame temperature
• Char combustion: Gasification only significant at high
temperature and low oxygen. But highly endothermic, so
total char consumption is little affected.
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Pollutants
• Up to 75% less NOx due to NO reburning and lack of N2
• More SO2 retained in ash
• Species in recycled flue gas are concentrated up to 3-4
times (equivalent to combustion without nitrogen)
• No stack emissions: Mainly an issue for CO2 purification
and corrosion
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Low temperature corrosion
Dew point raised by around 30˚C due to high H2O and SO
3.
Serious issue for oxyfuel pilots:
• Preheater, economiser, FGD, FGC and CPU at risk
• Avoid stagnation and leaks: Use purges and welded joints
• Stainless steels or coatings employed
• FGC can be Ni alloy
• Parts of CPU are plastic
Ciuden Schwarze Pumpe
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High temperature corrosion
Several mechanisms for worse superheater corrosion:
• High CO2: carburisation (brittle metal carbides)
• High SOx: sulphidation
• High H2O: volatises Cr, aids diffusion through scale
• Hot corrosion: SOx forms molten salts with Na/K
• Many studies show higher corrosion rates
but no consensus
• Fundamental chemistry is unchanged
• Peak hot corrosion at higher temperature
• Water vapour has a significant influence
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Oxygen production: Cryogenic ASU
Cryogenic air separation is an established technology
for >4000 tpd O2:
• Air is compressed and cooled to dew point
• 500 MW plant needs ~1000 tpd = 2 x largest units built
• Low purity O2 is optimum (~97%)
• Energy intensive: 10-15% of gross output, but potential
for further optimisation
• Flexibility limitations
Air Pre-
cooling
TSA
Drying
Cooled
<-170˚C ~5 bar Distillation
O2 N2
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Cryogenic ASU: Optimisation
• Significant efficiency gains
made for oxyfuel ASU
• More complex process
cycles such as triple column
distillation
• Further optimisation forecast
for next few years
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Liquid oxygen storage
Storing oxygen can allow operating cost saving:
• Off-peak: Use cheaper power to produce O2
• Peak: Use stored O2 and turn down ASU
• Capital intensive so need volatile market
• Can also improve ASU ramping/turndown
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Ion transport membranes
Possibility for lower energy oxygen production, pre-
commercialisation:
• Based on perovskite ceramic membranes
• Air feed is 800-900˚C and >13 bar
• 5 tpd pilot from Air Products, 100 tpd pilot this year
• Modular design: Stacks of flat wafers
• Requires integration with gas turbines to realise
efficiency potential (1-2% pts)
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Flue gas purification: CPU
No standard for CO2 purity. Pilot CPU have aimed for very
high purity CO2 (>99%):
• High level of dehydration (ppm levels) required to prevent
pipeline corrosion: Temperature swing adsorption used
• Very low O2 required for EOR
• O2, N
2, Ar add to compression energy
• Hg damages Al heat exchangers: Sorbent guard bed
• SOx/NOx, pipeline and compressor corrosion: Several
polishing technologies demonstrated
FG compression,
cooling + flash or
distillation
FGC Drying Cold Box:
Liquefaction,
distillation
CO2 Flue gas ~30 bar
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Flue gas purification: CPU
Callide CPU
2NO + O2 → 2NO
2
2NO2 + H
2O → HNO
2 + HNO
3
‘Autorefrigeration’ by
product CO2
NaOH
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SOx/NOx removal
Low volume/high pressure FG aids SOx/NOx removal. PPM
levels of SOx and NOx achieved by various means:
• Air Products: Sour compression. Exploits the catalysis of
SO2 oxidation by NO at high pressure:
NO2 + SO
2 → NO + SO
3
• Air Liquide: low pressure scrubs with NaOH or Na2CO
3
and distillation of NO2
• Linde: Cold scrub with ammonia water or NaOH at 15 bar
(LICONOX). Conversion of NOx to fertilisers or nitrogen
gas possible.
• Praxair: Activated carbon
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Vent gas purification
Waste gases from distillation contain some CO2 and O
2
• Use polymer membranes or pressure swing adsorption
• Recover O2 for boiler and reduce ASU power
• Increase CO2 capture rate from 90 to 98%, reduce
capture cost per ton
Air Liquide: Membrane
Praxair: VPSA
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Thermal integration of plant
Energy savings possible from thermal integration of boiler,
steam cycle, ASU, and CPU.
• ASU compressor heat for feedwater heating: 7 to 9% of
ASU energy recovered, ~0.4%pts in plant efficiency
• Lesser gains from CPU compressor heat
• Steam used for ASU/CPU sorbent regeneration
Coil wound HX for
ASU heat recovery
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Oxyfuel pilot projects
ANL/BHP
ANL/EERC IFRF
IHI
Canmet
B&W/AL
IVD-Stuttgart
PowerGen
Jupiter
B&W
Enel
RWE-npower
Oxyxoal UK
Alstom
VattenfallCiuden CFB
Ciuden PC
Callide
0.1
1
10
100
1980 1985 1990 1995 2000 2005 2010 2015
Gro
ss o
utp
ut
(MW
e o
r M
Wt/
3)
Combustion pilot
Pilot with CPU
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Schwarze Pumpe (2008)
Vattenfall 30 MWt plant in Germany was first full-chain pilot.
• Lignite-fired, 9 t/hr of CO2 produced
• Multiple burner tests, corrosion tests, plant control…
• Brief storage trial (road transport)
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Es.CO2, Ciuden (2011)
30 MWt oxyCFB (Foster Wheeler) and 20 MWt oxyPC units.
• Air Liquide CPU: Full flue gas dehydration, 6% to pure CO2
• Up to 40% oxygen used in CFB
• Testing anth/petcoke blends, CFB deSOx, CPU/boiler
integration…
Air Oxy
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Callide (2012)
100 MWt full-chain oxyfuel PC retrofit (IHI) from consortium
of utilities, manufacturers, and mining company.
• CPU takes ~15% of flue gas: 75 tpd liquid CO2
• Local Callide bituminous coal, no FGD
• Generates electricity to grid
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Demonstration projects: Futuregen 2.0
• 167 MWe gross retrofit from consortium of energy and
mining companies (plant design: B&W and Air Liquide).
• FEED completed Dec 2013, start construction this year?
• $1 bn of CAPEX from DOE. Illinois meeting O&M deficit
• 98% capture yields 1.1 Mt CO2/yr
• 21.5% (HHV) design efficiency
• FGD by circulating dry scrubber
• 50 km CO2 pipeline to onshore saline aquifer
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Other demonstrations
• Compostilla, Spain: 300 MW gross SC oxyCFB project,
FEED completed, seeking funding
• Young Dong, Korea: 100 MW retrofit, FEED completed,
government funding withdrawn
• WhiteRose, UK: 450 MW gross USC plant. FEED contract
awarded Oct 2013, finalist for £1 bn UK government
funding
• ENEL, Italy: feasibility study for 320 MW net pressurised
plant
China:
• 35 MWt HUST pilot, 200 MW FEED underway
• Several other large demos in early stages of planning
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Pressurised oxyfuel
At high pressures:
• Latent heat of water vapour is recovered at temperature
usable for feedwater preheating
• Reduced air ingress
• Reduced fan power
• Reduces wet compression in CPU (shifted upstream)
ENEL operate a 5 MWt pilot, 50 MWt pilot and demo planned:
• Coal slurry
• Flameless combustion
• Low emissions
• Ash runs off as slag
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Costs
• ASU is largest additional plant cost (14-20% of total
capex)
• Estimates of postcombustion and oxyfuel costs are
similar (~80% increase in COE)
• Oxyfuel potentially lower cost retrofit
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Summary
• Oxyfuel ready for demonstration
• Main boiler issue is corrosion: May restrict fuel use or
recycle path
• Cryo ASU has potential for further optimisation and
integration with steam cycle
• CPU offers less potential for energy gains but lower
cost flue gas cleaning possible
• Minimum energy penalty of 6-7%pts through plant
integration and other optimisation
• Capital cost estimates equivalent to post-combustion
• Next generation systems could include pressurised
combustion and O2 production by membranes
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High temperature steels and nickel
alloys in pulverised coal technology
Kyle Nicol
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Introduction
Most of coal-fired power plant are pulverised type
▲ Electrical efficiency = ▼ coal use & ▼ environmental
impact & can favour plant economics
▲ steam temperature = ▲ electrical efficiency
Steam temperature limited by materials
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Commercial Steels
1880s - Ferritic steels: Proven and peaked at <565ºC
1960s - Martensitic steels:
9% chromium in <600ºC superheat
11-12% chromium in <620ºC reheat
1990s - Austenitic steels: Excellent up to 665ºC, but
limited to thin-section
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Cyclic Operation
Cyclic operation results in cracks
Methods can accurately predict component lifetime
Preventative action can be economically favourable
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Commercial boiler steels
Boiler component and steam
temperature
Materials Fireside
corrosion
resistance
Steamside
oxidation
resistance
Creep
resistance
Fatigue
resistance
PWHT Comments
Tube: Waterwall <480°C Ferritic: T11, T12 Low Very Low Very Low Very Low No None
Tube: Waterwall <565°C Ferritic: T22, T23, T24 Moderate Low Low Low No SCC of T24
Tube: Superheater and
reheater 550-575°C
Ferritic: T22, T23, T24
Moderate Moderate Low -
Moderate
Low -
Moderate
No SCC of T24
Martensitic: T91 Yes Type IV
Tube: Superheater and
reheater <600°C
Martensitic: T92, E911,
T122, NF12, SAVE12
High High Very High
(superheat
) High
(reheat)
Very High
(superheat)
High
(reheat)
Yes Type IV
Austenitic: 347HFG, 310 Yes DMW
Tube: Reheater <620°C Austenitic: Super 304H,
Esshete 1250, 17-14
CuMo, Sanicro 28,
NF709, HR3C, SAVE 25
Very High Very High Moderate Moderate Yes DMW
Pipe: Headers <580°C and <22
MPa
Martensitic: P91 Moderate Moderate High Moderate Yes Type IV
Pipe: Header <600°C and 22-25
MPa
Martensitic: P92, E911,
P122
High High Very High High Yes Type IV
Pipe: Headers <620°C and <10
MPa
Martensitic: NF12,
SAVE12
Very High Very High High Moderate Yes Type IV
Pipe: Superheat <600°C and
22-25 MPa
Martensitic: P92, E911,
P122
None High Very High Very High Yes Type IV
Pipe: Reheat <620°C and <10
MPa
Martensitic: NF12,
SAVE12
None Very High Moderate Moderate Yes Type IV
Furnace floors, upper furnace
walls, convection pass
enclosures and economisers
Ferritic: High carbon
grades, chromoly steels
Moderate None Low Low Yes None
Baffles, supports, hanger
fittings, oil burner impellers,
soot-blower clamps and
hangers
Austenitic: 25Cr-20Ni,
25Cr-12Ni
High None Moderate Moderate Yes None
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Commercial turbine steels
Steam turbine component Materials
Steamside
oxidation
resistance
Creep
resistance
Fatigue
resistance Comments
HP/IP Rotor <620°C Martensitic: 9-12CrMoVNbN, 9-12CrWCo,
E, FB2, TR1150, TOS110 High High High
Single material to
avoid DMW.
HP/IP Rotor <593°C Martensitic: TR1100, TOS107 Moderate Moderate Moderate
HP/IP Rotor <566°C
Ferritic: 1CrMoV
Martensitic:, 11CrMoVTaN (TOS101),
12CrMoVW, 12CrMoVNbN,
26NiCrMoV11.5
Low Low Low
LP Rotor <600°C Martensitic: 3.5NiCrMoV Moderate Moderate Moderate
LP Rotor <566°C Martensitic: NiCrMoV Low Low Low
Blades <620°C Martensitic: 9-12CrWCo High High High Coatings may be
applied to protect
against erosion, but
not corrosion.
Blades <593°C Martensitic: 9CrWCo, R26 Moderate Moderate Moderate
Blades <566°C Ferritic: 1.25CR-0.5Mo (cast)
Martensitic: Alloy 422, 10CrMoVNb Low Low Low
Inner casing and vale body <620°C
Martensitic: 9CrMo(W)VNbN, CB2,
12CrMoVCbN (cast or forged), 9-12CrW,
12CrWCo (cast)
Austenitic: 19Cr12.5NiNbMoC (CF8C-
Plus)
High High High
Thermal coefficient of
casings must be
similar. Inner casing and vale body <593°C Martensitic: 9Cr1MoVNb, 10CrMoVNb Moderate Moderate Moderate
Inner casing and vale body <566°C
Ferritic: 2.25CR-1Mo (cast), 1.25CR-
0.5MoV (cast), 1.25CR-0.5Mo (cast)
Martensitic: 10CrMoVNb, 9CrMoVNb
Low Low Low
Outer casing <600°C Ferritic: 2.25Cr-1Mo (cast) Negligible Moderate Moderate None
Outer casing <566°C Ferritic: 1.25Cr-0.5Mo (cast) Negligible Low Low
Valve internals and turbine nozzles
<620°C Martensitic: 9-10CrW, 12CrWCo High High High
None
Valve internals and turbine nozzles
<593°C
Martensitic: 9Cr1MoVNb cast,
10CrMoVNb, 12Cr1MoVNbN Moderate Moderate Moderate
Valve internals and turbine nozzles
<566°C
Ferritic: 2.25CR-1Mo (cast), CrMoV
Martensitic: 10CrMoVNb (cast) Low Low Low
Bolts <620°C Martensitic: 9-12CrMoV,
Nickel alloy: IN718, A286 Negligible High High
Thermal coefficient
must be similar to that
of casings.
High stress relaxation
resistance
Bolts <593°C Martensitic: Refractory 26
Nickel alloy: Nimonic 85A Negligible Moderate Moderate
Bolts <565°C Martensitic: Alloy 422, 9-12CrMoV,
Nickel alloy: Nimonic 80A, IN718 Negligible Low Low
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Raising the steel barrier to 650ºC
580
590
600
610
620
630
640
650
660
670
Thin-section superheater
and reheater (all pressures)
Thick-section, superheater
header, pipe and valves
(high pressure)
Thick-section, reheater
header, pipe and valves
(low pressure)
Steam turbine
Ste
am
te
mpera
ture
(°C
)
State-of-the-art materials 650°C Steels
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Advanced Ultrasupercritical (700ºC)
Advanced ultrasupercritical (AUSC) steam at 700ºC permit
>50% η, achieved with high cost nickel based alloys
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Advanced Ultrasupercritical (700ºC)
199
8
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200
0
200
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200
2
200
3
200
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200
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China: Stage 3b (operate FSDP)
China: Stage 3a (build FSDP)
China: Stage 2 (CTF)
China: Stage 1 (inc long-term creep)
China: Stage 1 (exc long-term creep)
India: Stage 3b (operate FSDP)
India: Stage 1, 2 and 3a (build FSDP)
Japan: Stage 3b (operate FSDP)
Japan: Stage 3a (build FSDP)
Japan: Stage 2 (CTF)
Japan: Stage 1 (inc long-term creep)
Japan: Stage 1 (exc long-term creep)
USA: Stage 3b (operate FSDP)
USA: Stage 3a (build FSDP)
USA: Stage 2 (CTF)
USA: Stage 1 (inc long-term creep)
EU: Stage 3b (operate FSDP)
EU: Stage 3a (build FSDP)
EU: Stage 2 (CTF)
EU: Stage 1 (inc long-term creep)
EU: Stage 1 (exc long-term creep)
![Page 44: Developments in oxy-combustion technologies Toby Lockwood](https://reader031.fdocuments.in/reader031/viewer/2022012516/6190b7e312cbc97dd25476eb/html5/thumbnails/44.jpg)
Conclusions
If cycling older plant then re-assess material
lifetimes to avoid catastrophic failure
1880-2010s: 600ºC steels = <47% ŋ (net, LHV)
2020s: 650ºC steels = 48-50% ŋ (net, LHV)
2030s: 700ºC nickel alloys = 50-53% ŋ (net, LHV)
Materials development give tangible benefits
![Page 45: Developments in oxy-combustion technologies Toby Lockwood](https://reader031.fdocuments.in/reader031/viewer/2022012516/6190b7e312cbc97dd25476eb/html5/thumbnails/45.jpg)
Next Webinar
Upgrading the efficiency of worlds coal fleet to reduce
carbon dioxide emissions
Wednesday 14th
May 2014 Midday UK time
Ian Barnes
![Page 46: Developments in oxy-combustion technologies Toby Lockwood](https://reader031.fdocuments.in/reader031/viewer/2022012516/6190b7e312cbc97dd25476eb/html5/thumbnails/46.jpg)
Thank you for listening
Questions?
Toby Lockwood
Kyle Nicol
46