Developments in Fluidized Bed Conversion in Canada 2010-2015

Robin Hughes Dec 6, 2016

Gas Analysis

Stack

FUEL HOPPER

LIMESTONE

HOPPER

WATER COOLED

FEED SCREW

WINDBOX

RECYCLE

BLOWER

BAGHOUSERETURN LEG

CFBC

CYCLONE

CONDENSER

Drain

Primary O2 /

Mixed Gases

Secondary O2

Air

WINDBOX

EDUCTOR

CALCINER /

COMBUSTOR

Air /

Recycle

Flue Gas

DIVERTER

VALVE

Air

KO VESSEL

CARBONATOR

ELECTRIC

BOILER

STEAM

SUPERHEATER

SOLIDS

TRANSFER

AUGER

Solids to CFBC

Solids from BFB

BFB

CYCLONE

Air

SOLIDS

TRANSFER

CYCLONE

CONDENSER

BAG FILTER

Flare / Stack

Gas Analysis

Manual Solids

Loading

Air / CO2 /

Simulated or Real

Flue Gas

Agenda

• Overview of R&D – Natural Resources Canada, CanmetENERGY

– Universities

• Oxy-pressurized fluidized bed combustion (Oxy-PFBC)

• Pressurized chemical looping combustion (PCLC)

3

Government A. Natural Resources

Canada – CanmetENERGY

University B. University of British

Columbia C. University of Western

Ontario D. University of Ottawa E. École Polytechnique

de Montréal Industry F. Catalyst Paper G. Athabasca Oil Sands

project H. Syncrude I. Emera Energy J. Nova Scotia Power

Organizations Discussed In Canada’s 2010 to 2015 IEA FBC Country Report

A

J

H

B D E

C

I

F G

CanmetENERGY

CanmetENERGY-Ottawa is one of the Canadian Federal government’s

R&D laboratories developing new clean energy technologies.

208 Total Staff

Scientific &

Professional Technical

Program &

Administrative

Executive

$27.2M FY2013/14

Select Complimentary R&D Date Initiated

CaO – CaCO3 fluid bed looping 2000

Entrained flow gasification 2002

Oxy – CFBC technology 2003

Oxy – PFBC technology 2005

Supercritical CO2 Brayton cycles 2008

CanmetENERGY Oxy-FBC Research 1990’s 2000-2010

Atmospheric Oxy - FBC

Bench to demo at 30 MW th

PERD, EcoETI and industry

funded

Air Fired FBC

Supported

development of

Point Aconi GS,

Nova Scotia

Sulphur capture

NOx reduction

PERD funded

CanmetENERGY Oxy-PFBC Development

2005 – First oxy-PFBC PFD at CanmetENERGY

2010 – Design of oxy-PFBC reactor initiated

2012 – Design of oxy-PFBC test facilities initiated

2013 to 2014 – Strategy developed with GTI to fill

technology gaps and demonstrate oxy-PFBC at 1

MWth

2015 to present – 1 MWth pilot with collaborators

CanmetENERGY PCLC Development

2000 – Calcium looping R&D initiated

2004 – Pilot demonstration of dual fluid bed calcium

looping

2013 – Design of PCLC applications initiated

2015 – Design of PCLC test facilities initiated

University of British Columbia

• Fluidization Research Centre (FRC) conducts fundamental and applied research on fluidized bed reactors, their modeling and/or applications.

– fluidization phenomena

– develop generic fluidized bed reactor models

– investigate new diagnostic methods and analysis techniques

– improve understanding of fluidization behaviour to enable more reliable design and operation of industrial-scale fluidized bed reactors

• Biomass conversion, hydrogen production, chemical looping, hydrodynamics, hydrotreating

6

Dual fluidized bed gasification pilot

plant at the Pulp and Paper Centre,

University of British Columbia.

University of Western Ontario

• The Particle Technology Research Centre (PTRC) at UWO is engaged in research programs in

– Fluidization – Ultra-fine powder processing – Particle production – Clean fuel technology and related topics – Fluidized bed coking

• Projects have involved

– Monitoring of industrial operations such as high- and low-pressure fluidized beds, pneumatic transport lines and solids dryers,

– Study of solids attrition in fluidized beds – Remediation of electrostatic effects – Optimization of solids mixers, cyclone

separators and filters

7

Syncrude Canada Ltd

Franco Berruti in the large fluid bed coker

in the T. E. Base Syncrude Pilot Plant Lab

at the University of Western Ontario

University of Ottawa

• Pressurized fluidized beds fundamentals – Entrainment rates of fine

particles passing through a coarse bed

– Electrostatics – Three phase gas / liquid / solid

• Applications

– Pyrolysis – Oxy-PFBC – Calcium looping – Heavy oil upgrading – Dense phase conveying of

biomass and fossil fuels

8

École Polytechnique de Montréal

• Combustion – Refuse derived fuel combustion – Early detection of defluidization due to

agglomeration

• Gasification – Biomass chemical looping

• Hydrodynamics – Gas - Solid

• Constructed a pilot-scale high pressure and temperature gas-solid fluidized bed reactor, 15 cm ID and 4.9 m in height

• Characterize the fluidization behavior of a wide spectrum of particles at elevated pressures and temperatures.

– Three phase fluidized beds / bubble columns

• Constructed a pilot-scale high pressure and temperature bubble column reactor, 15 cm ID and 5.3 m in height

• Characterize the fluidization behavior of different liquids and slurry phases at elevated pressures and temperatures

9

High pressure, high

temperature gas-liquid-solid

bubble column

High pressure, high

temperature gas-solid

fluidized bed

Oxy-PFBC

10

Air Separation Unit

Fuel & Sulphur Sorbent

Oxy-PFBC Boiler Flue Gas Processing

Power & Steam Generation

Nitrogen

Air

Oxygen

Fuel

Limestone(CaCO3)

Ash &CaSO4

HeatRecovery

WaterCO2

Sequestration

Steam or Supercritical CO2

Power

Boiler Feed

Steam to Process Applications

Oxy-PFBC Technology Overview

PRODUCT

• Oxy-fired, pressurized fluidized bed combustor, CO2 processing unit, with Rankine or supercritical CO2 Brayton cycle for power generation

BENEFITS

• Produces affordable electric power with near zero emissions or negative emissions

• Exceeds DOE coal goal for advanced combustion tech

• Utilization of biomass, coal and petroleum coke

MARKETS

• Electric power generation with CO2 capture

• Oil production (once-through steam, CO2 floods)

STATUS

• 1.2 MWth pilot plant construction at CanmetENERGY

• Mechanical & electrical completion January 2017

• Commissioning January through February

• Test campaigns firing bituiminous, sub-bituminous, and lignite coals February to September 2017

Gas Technology Institute Commercial Scale PFBC Concept

Similar to air blown PFBC, but issues that negatively affected reliability in the past have been addressed: • No hot gas filtration • No expansion turbine • Heat release rates managed via oxygen

partial pressure control

Oxy-PFBC – Key Design Points

Convective heat exchange tubes In bed heat exchange tubes • Steam (Rankine) • Supercritical CO2 (Brayton) Staged fuel / oxidant / sorbent injection • Pulverized fuel • Peak temperatures • Carbon conversion • Sulphur capture • Oxygen partial pressure

12

1 MWth Oxy-PFBC at CanmetENERGY

Combustor spools

PFBC pressure

vessel

Fly ash

filter

CHX2

pressure

vessel

Coal &

limestone

hoppers

DCC & Liconox

columns

Convective HX 2

0.05 MWth Atmospheric Oxy-FBC Facility

Gas Analysis

Stack

FUEL HOPPER

LIMESTONE

HOPPER

WATER

COOLED FEED

SCREW

WINDBOX

RECYCLE

BLOWER

BAGHOUSE

RETURN LEG

CYCLONE

CONDENSER

Drain

PRIMARY

FLOW

SECONDARY

FLOW

SOLIDS

DISCHARGE

AIR

Air /

Recycle

Flue Gas

DIVERTER

VALVE

VIEW PORT

VIEW PORT

VIEW PORT

Visualization

and Particle

Image

Velocimetry

(PIV) – 3 Bed

Heights

Primary O2 /

Mixed Gases

Secondary O2

PRESSURIZED

HOPPER DRY

FEED SYSTEM

CO2 / N2

CO2 / N2

Contains an

internal sintered

filter for fines

collection

Priorities in Multiphase Flow Science For Oxy-PFBC

Validate reactant jet models at high pressure under various fluidizing regimes

Improve modeling of complex geometries within fluid beds • Heat exchangers • Distributors / injectors

Improve ability to implement complex reaction mechanisms • Oxidation of metals and metal oxides at high temperature • Conversion of calcium hydroxide to CaSO4 in high CO2 partial

pressure

Implement design optimization algorithms into transient performance models – RNM and/or process simulation

Improve heat transfer models which consider changing properties of solids as the solids react

15

Early CFD Results Available

16

Oxy-PFBC - dense

bed region with a

subset of HX tubes

PCLC – riser reactor,

solids conversion with

reaction a) 0.7, b) 1.0

PTGA for reaction kinetics

to 1600 C; 100 bar

Reactant Jet Characteristics

Development Need

• Predict radial and axial dispersion / mixing of reactants

• Influence large scale flow patterns

• Establish number and size of injectors

• Avoid erosion / corrosion

Tools needed

• Prototype system

• Sensors to understand local void fraction, gas and solid flux

• Models to predict jet length, angle, entrainment, interaction between jets and other features

17

Pressurized Column for Jet Characteristics

Dimensions • 6” diameter • 12 x ½” port • 3 x 1” port

Parameters of Interest • Injector diameter • Injected gas velocity / density • Solid loading • Nozzle position • Particle size [in fluidized bed] • Particle density

X-Ray Tomography

Optical Fibre Probes

Transient Modeling

Development Need • Start-up / shutdown • Load following • Heterogeneity of

reactants • Optimal controls

development • Risk analysis

Tools needed • Prototype system • Sensors to understand

system dynamics and validate models

• CFD to establish flow fields – Complex geometries – Appropriate reaction

mechanisms – Useful scale

• Reactor network model

19

Reactor Network Models For Transient Analysis

Oxy

gen

Fuel

Stea

m

Ste

am

Oxy

gen

ERZ 1 ERZ 1

JEZ 2

DSZ

JEZ 1

Reactor network model for

CanmetENERGY gasifier

Commercial gasifier simulation

PCLC Technology Overview PRODUCT

• Pressurized chemical looping fluidized bed combustor system for heat, steam and/or syngas generation

BENEFITS

• Produces affordable product with near zero emissions

• Minimal or no requirement for air separation unit

• Utilization of biomass, coal and gaseous fuels

MARKETS

• Heavy oil extraction and upgrading

• Syngas generation for clean liquid fuels production

• Power generation

STATUS

• 0.6 MWth pilot plant construction at CanmetENERGY

• Requisitions for compressors issued

• Most pressure vessels on-site

• Commission 2018

Why Pressurized CLC?

Higher gas-solid reaction rates

Low cost, non-toxic oxygen carriers

Increased heat transfer rate

Effective use of latent heat

Compact, modular design

Reactor

arrangements

are based on

fluid catalytic

cracker designs

PCLC – Key Design Points Solids separators required to meet solids loading spec of expansion turbine

Convective heat exchange tubes

Staged air injection

• Oxidation rate

• Circulation rate

In bed heat exchange tubes

• Steam

• Supercritical CO2

• Heavy oil (visbreaking)

Solids separators

Convective heat exchange tubes

Fuel injection

Fuel Rx Air Rx

Kinetics of Various Oxygen Carriers

23

Fully synthetic vs porous Al2O3-casting Isothermal test at 950°C

750 oC

950 oC

850 oC

Fully synthetic Fe2O3/Al2O3

Progress on Outputs for 2016-2017

Instantaneous at 71s Average over 71s

Average in riser: 2.8%

Y=2.5m

Y=7.5m

Y=15m

Y=20m

Y=2.5m

Y=7.5m

Y=15m

Y=20m

Solid volume fraction

Average in riser: 3.9m/s

Y=2.5m

Y=7.5m

Y=15m

Y=20m

Gas upwards velocity X-ray diffraction system

R-402-001

REV. DESCRIPTION DATE BYNotes:

K-203-001

E-204-002

E-204-001

E-501-001

E-501-002

F-601-001

E-504-001

F-602-001

E-602-001

PurgePurge

P-204-001 A/B

E-502-001

Nat. Gas

Water

O2 Carrier

LP Air

LP Air

1

E-503-001

R-401-001

V-203-001

V-102-001

V-202-001

K-201-001

K-201-002

V-201-001

K-602-001

V-601-001

VLV-601-001

To Truck

To Vent

To Flare

To Wastewater

Treatment

To Vent

VLV-602-001

2 3

4

5

6 7

9

8

11

12

13

14

15 16

10

18

19

20

21 22

24

23

25

26

29

30

31

32 33 34 35

36

37

38

39

40

4142

46

44

45

43

17

28 27

1-08-G35PSV-1306

(2000 psig relief)1"-NG-120.02-G316

T-103-020 1/2"-NG-124-G316

DISCHARGE

STANTION

1-03-01-C35 2"-NG-102-A106 2"-NG-102-A106

HV-1321

PIP

E R

AC

KP

IPE

RA

CK

1/2"-N2-103-C316

1/2"-N2-104-C316

CV-1802 HV-1819

(lockout)

K-103-020

(Details not shown)

MO-103-020

1320

1/2"-NG-120-G316

1"-NG-120.01-G316

HV-1322 CV-1301

V-1

03-0

20

PSV-1307

(2000 psig relief)

1/2"-NG-121-G316

CV-13021/2"-NG-121.01-G316

HV-1323

HV-1324

(lockout)

1/2"-NG-122-G316

HV-1325

1/2"-NG-121.02-G316

HV-1330

1/2"-NG-124.01-G316

PSV-1305

1/2"-NG-124.02-G316

HV-1326

CV-1803 HV-1820

(lockout)

1/2"-NG-125-G316

CV-1304

CV-1303

HV-1328

HV-1327

Other Users – HiP System

F-103-020(>50 psi collapse

pressure)

Description

Design Pressure

Design Temperature

Design Capacity

Motor Size

IT

1320

XC

1320

XF

1320

XO

1320

MAWP 2000 psig

Equipment Tag

Description

Design Pressure

Design Temperature

Design Capacity

HV-1329

PT

1301

1"-NG-102.06-A106

HV-1320

1/2"-N2-103-C316

1/2"-N2-103.02-C316

HV-1818

HV-1817

DPI

1301

PID – NG supply Process flow diagram

Basic Design and Procurement of a 0.6 MWth Pressurized Chemical Looping Facility at CanmetENERGY

25

Air Rx

Spools

Riser

Spools

Air &

Natural Gas

Compressor

Specs

Oxygen

Carrier

Handling

Vessels

Fuel Rx

Spools

Therminol & Glycol

System Specs

Flue Gas

Scrubber

Reactor Sizing is On-going

26

Case study results Process simulation flow diagram

For more information contact: Robin Hughes Research Scientist Group Leader, Fluidized Bed Conversion & Gasification Robin.Hughes@Canada.ca 1-613-867-3865 CanmetENERGY, Natural Resources Canada