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Development of High Efficiency CFB Technology to Provide Flexible Air/Oxy Operation for Power Plant with CCS
FLEXI BURN CFB
2nd International Workshop on Oxyfuel FBC Technology Antti Tourunen
VTT Technical Research Centre of Finland
2
Aim : to develop and demonstrate FLEXI BURN CFB concept enabling to reach the target of near zero emission power plantsThe FLEXI BURN CFB concept:High efficiency Circulating Fluidized Bed (CFB) power plant with CCS capable of air/oxyoperation with a wide range of fuels including biomass
Project objective
The FLEXI BURN CFB concept has a set of important advantages:
1. fuel flexibility in order to decrease dependency on imported coals and in order to improve power plant economics especially with CCS operation
2. operational flexibility in order to apply air-firing and oxygen-firing with CO2 capture
3. lower NOx production due to reduced and more uniform furnace temperature profiles, and lower SOx concentration in flue gases due to in-furnace capture, thus reducing the need for downstream flue gas cleaning
4. overall concept for phased transition into CCS technology with minimised risks through high efficiency air-oxy flexible CFB combustion
5. lower specific CO2 emissions from the reduced consumption of fuel due to the intrinsic high efficiency of the technology . In addition, by substituting e.g. 20% of coal input with renewable fuels, CO2 emissions can further be reduced by 15-20%.
6. Provides utilities an attractive alternative to take into use the new technology and decommission old capacity with lower efficiency and poorer emission performance
3
FLEXI BURN CFB diagram allowing operation under normal air-firing as well as oxygen-firing with CCS
Large scale high efficiency CFB boiler with
FLEXI BURN design
FuelBituminous coalLigniteBiomassPet coke etc.
Air Separation Unit (ASU) Mixing
AirSwitch
Fluegas (CO2-rich)
Flue gas recirculation
SwitchStack
95-97% O2
Flue gas cleaning
CO2 capture and storage (CCS)CondensationCompressionPurificationTransportStorage
The FLEXI BURN CFB concept: High efficiency Circulating Fluidized Bed (CFB) power plant with CCS capable of air/oxy operation with a wide range of fuels including biomass
Role of FLEXI BURN CFB Partners
Research institutes
Utilities
Dev
elop
men
t ste
ps
Industrial applicability
VTT, LUT, CzUT UNIZAR-LITEC, AICIA
Endesa, EDP, Tauron Generation
Laboratory and small pilot scale test(0.1-1MWth)
Concept
1st Commercial scale FLEXI BURN CFB Power Plant
FLEXI BURN CFB project2009 - 2012
ManufacturersFWEOY, FWESA, ADEX, Siemens, Praxair
UAP
DemonstrationPilot Plant
30 MWth, CIUDEN
Demonstration of FLEXI BURN CFBCIUDEN 30MW th- air-/ oxy-firing with fuel flexibility- CO2 separation
Field measurements at OTU CFBLagisza 460 MWe - scale-up information from the world first and largest OTU CFB- design model validation
Commercial scale FLEXI BURN CFB Technology
Scale up criteria
FLEXI BURN CFB - General project structure
R&D support Design tools Demonstration Boiler design Power plant concept
Commercial Scale
FLEXIBURN
WP1 WP2 WP3 WP4 WP5 WP6
nc Xkm
tmr O2c
c
dd
COefCO Ykt
Yd
d
)/1/(1 mCOef kk
nrefv ddTAb )/)(/exp(
Modelanalyses
CO combustionMixingChar combustion
Volatile, m
oisture release
k W /m 2
1D-MO DELflue gas
1
n n+ 1
to stack
Pr ima ry airSeco nda ry air
2
n-1
3
n-2
BENCH SCALE REACTOR (BFB/CFB)
Air
O2, C O2, CO, N 2, SO2, NO
S econdary a ir
Continuousfue l feed
Fuel batch feed
Cooler/heater
Cooler
Primary gas heatingPC control and data logg ing sys tem
Cyclone
FilterTo Stack
BENCH SCALE REACTOR (BFB/CFB)
Air
O2, C O2, CO, N 2, SO2, NO
S econdary a ir
Continuousfue l feed
Fuel batch feed
Cooler/heater
Cooler
Primary gas heatingPC control and data logg ing sys tem
Cyclone
FilterTo Stack
Air
O2, C O2, CO, N 2, SO2, NO
S econdary a ir
Continuousfue l feed
Fuel batch feed
Cooler/heater
Cooler
Primary gas heatingPC control and data logg ing sys tem
Cyclone
FilterTo Stack
AGISZA 460 MWe supercritical OTU CFB
kW/m2
Bench scale Pilot scale Boiler scale
EXPERIMENTAL SCALES
MODELS FOR PHENOMENA 1-D PROCESS MODELS 3-D PROCESS MODELS
MODELS AND DESIGN TOOLS
M
Secondarycyclone
Fuel containers 1 and 2 Zone 1
Zone 2
Primarycyclone
Observation port
Deposit probe port
Zone 3
Zone 4
To stack
Sampling port
Sampling port
Sampling port
Additivecontainer
Air
Secondary gas
Primary gas heating
O2, CO2, N2
PC control and data logging system
Sampling port
Sampling port
Gas analysator
FTIR sampling port
FTIR sampling port
Sampling port
Sampling port
Gas coolingBag filterFlue gasrecirculation
M
Secondarycyclone
Fuel containers 1 and 2 Zone 1
Zone 2
Primarycyclone
Observation port
Deposit probe port
Zone 3
Zone 4
To stack
Sampling port
Sampling port
Sampling port
Additivecontainer
Air
Secondary gas
Primary gas heating
O2, CO2, N2
PC control and data logging systemPC control and data logging system
Sampling port
Sampling port
Gas analysator
FTIR sampling port
FTIR sampling port
Sampling port
Sampling port
Gas coolingBag filterFlue gasrecirculation
PILOT SCALE CFB COMBUSTOR
M
Secondarycyclone
Fuel containers 1 and 2 Zone 1
Zone 2
Primarycyclone
Observation port
Deposit probe port
Zone 3
Zone 4
To stack
Sampling port
Sampling port
Sampling port
Additivecontainer
Air
Secondary gas
Primary gas heating
O2, CO2, N2
PC control and data logging system
Sampling port
Sampling port
Gas analysator
FTIR sampling port
FTIR sampling port
Sampling port
Sampling port
Gas coolingBag filterFlue gasrecirculation
M
Secondarycyclone
Fuel containers 1 and 2 Zone 1
Zone 2
Primarycyclone
Observation port
Deposit probe port
Zone 3
Zone 4
To stack
Sampling port
Sampling port
Sampling port
Additivecontainer
Air
Secondary gas
Primary gas heating
O2, CO2, N2
PC control and data logging systemPC control and data logging system
Sampling port
Sampling port
Gas analysator
FTIR sampling port
FTIR sampling port
Sampling port
Sampling port
Gas coolingBag filterFlue gasrecirculation
PILOT SCALE CFB COMBUSTOR
Development and demonstration in multiple scales
Process scale-up
• CFB technology is scaling up with the latest high-efficiency SC-OTU-references Lagisza (460 MWe). The Lagisza power plant (460 MWe), located in the southern Poland, is the world's largest CFB boiler, which is also the world's first supercritical CFB once-through unit (OTU)
CFB800 agisza Turow 4-6 JEA Turow 1-3 Furnace - Width m 40 27.6 22.0 26.0 21.2 - Depth m 12 10.6 10.1 6.7 9.9 - Height m 50.0 48.0 42.0 35.1 43.5
Unit Capacity (MWe)
0
100
200
300
400
500
600
1970 1975 1980 1985 1990 1995 2000 2005 2010Start-Up Year
Pilot Plant Oriental Chem
Lagisza
JEA
Turow 1
VaskiluodonNova ScotiaTri-State
General Motors
800 800 MWeUnit Capacity (MWe)
0
100
200
300
400
500
600
1970 1975 1980 1985 1990 1995 2000 2005 2010Start-Up Year
Pilot Plant Oriental Chem
Lagisza
JEA
Turow 1
VaskiluodonNova ScotiaTri-State
General Motors
800 800 MWe
Reference plant for the project
OTU SC CFB Boiler layout at
Tauron GenerationLagisza Power
Plant
200 250 300 350 400 450 500
50
100
150
200
250
300
350
400
SO2 measuring data
Con
cent
ratio
n of
SO
2 [m
g/m
3 n](a
t O2 =
6%
in d
ry fl
ue g
ases
)
Unit load [MWe]200 250 300 350 400 450 500
50
100
150
200
250
300
350
400
NOx measuring data
Con
cent
ratio
n of
NO
x [mg/
m3 n]
(at O
2 = 6
% in
dry
flue
gas
es)
Unit load [MWe]
200 250 300 350 400 450 500
25
50
75
100
125
150
175
200
CO measuring data
Con
cent
ratio
n of
CO
[mg/
m3 n]
(at O
2 = 6
% in
dry
flue
gas
es)
Unit load [MWe]200 250 300 350 400 450 500 550
0
20
40
60
80
100
120
140
160
180
200
Dust measuring data
Con
cent
ratio
n of
dus
t [m
g/m
2 n](a
t O2 =
6%
in d
ry fl
ue g
ases
)
Unit load [MWe]
EMISSION ( at 6% O2, dry flue gas)(follows EU’s LCP directive), mg/Nm3
SO2 200
NOx (as NO2) 200
CO 200
Dust 30
Validation runs at a 460 MWe SC-OTU CFB boiler
750
775
800
825
850
875
900
925
950
0 5 10 15 20 25 30 35 40 45 50
Tem
pera
ture
[°C
]
Height [m]
Measured
calculated by model
Typical measurements during the test runs :Temperature profilesPressure profilesGas profilesProcess data (including emission data)Fuel and ash samples
BEN CH SCALE REACTOR (BFB/CFB)
Air
O2, C O2, CO, N2 , SO2, NO
Secon dary air
Con tin uou sfu el fee d
Fuel ba tch fee d
Co oler/hea ter
C ooler
Prima ry g as hea tin gPC con trol and d ata lo gging system
Cyclone
FilterTo Sta ck
BEN CH SCALE REACTOR (BFB/CFB)
Air
O2, C O2, CO, N2 , SO2, NO
Secon dary air
Con tin uou sfu el fee d
Fuel ba tch fee d
Co oler/hea ter
C ooler
Prima ry g as hea tin gPC con trol and d ata lo gging system
Cyclone
FilterTo Sta ck
A ir
O2, C O2, CO, N2 , SO2, NO
Secon dary air
Con tin uou sfu el fee d
Fuel ba tch fee d
Co oler/hea ter
C ooler
Prima ry g as hea tin gPC con trol and d ata lo gging system
Cyclone
FilterTo Sta ck
M
Secondarycyclone
Fuel containers 1 and 2 Zone 1
Zone 2
Pr imarycyclone
Observation port
Deposit probe port
Zone 3
Zone 4
To stack
Sampling port
Sampling port
Sampling port
Additivecontainer
Air
Secondarygas
Primary gas heating
O2, CO2, N2
PC control and data logging system
Sampling por t
Sampling port
Gas analysator
FTIR sampling port
FTIR sampling port
Sampling port
Sampling port
Gas coolingBag fil terFlue gasrecirculation
M
Secondarycyclone
Fuel containers 1 and 2 Zone 1
Zone 2
Pr imarycyclone
Observation port
Deposit probe port
Zone 3
Zone 4
To stack
Sampling port
Sampling port
Sampling port
Additivecontainer
Air
Secondarygas
Primary gas heating
O2, CO2, N2
PC control and data logging systemPC control and data logging system
Sampling por t
Sampling port
Gas analysator
FTIR sampling port
FTIR sampling port
Sampling port
Sampling port
Gas coolingBag fil terFlue gasrecirculation
PILOT SCALE CFB COMBUSTOR
M
Secondarycyclone
Fuel containers 1 and 2 Zone 1
Zone 2
Pr imarycyclone
Observation port
Deposit probe port
Zone 3
Zone 4
To stack
Sampling port
Sampling port
Sampling port
Additivecontainer
Air
Secondarygas
Primary gas heating
O2, CO2, N2
PC control and data logging system
Sampling por t
Sampling port
Gas analysator
FTIR sampling port
FTIR sampling port
Sampling port
Sampling port
Gas coolingBag fil terFlue gasrecirculation
M
Secondarycyclone
Fuel containers 1 and 2 Zone 1
Zone 2
Pr imarycyclone
Observation port
Deposit probe port
Zone 3
Zone 4
To stack
Sampling port
Sampling port
Sampling port
Additivecontainer
Air
Secondarygas
Primary gas heating
O2, CO2, N2
PC control and data logging systemPC control and data logging system
Sampling por t
Sampling port
Gas analysator
FTIR sampling port
FTIR sampling port
Sampling port
Sampling port
Gas coolingBag fil terFlue gasrecirculation
PILOT SCALE CFB COMBUSTORVTT0.3kW
VTT0.1MW
CANMET1MW
CIUDEN30MW
Dem
onst
ratio
n sc
ales
Time
Concept for 300 MWe
2009 2012
FLEXI BURN CFB – Demonstration steps
Completed
In progress
Aim : to develop and demonstrate FLEXI BURN CFB concept enabling to reach the target of near zero emission power plants
Laboratory scale combustion tests have been carried out with pilot scale and bench scale test rigs at VTT
Tests provide a base for development and validation of the design tools needed in the concept development
Totally seven different fuels were selected for the combustion tests
The selected project fuels cover the whole range of coals from anthracite to lignite
Straw pellet represents a typical agrobiomass which is easily available whereas wood represents a typical good quality forest-based biomass which is also available in many locations of the Europe
Small pilot scale CFB experiments (0.1MW) under air- and oxygen-firing conditions
Fuels Mixture ratio on energy basis (LHV wet)
Mixture ratio on mass basis (wet)
Anthracite + Pet-coke 55/45 70/30Anthracite 100 100Bituminous coal (Polish) 100 100Lignite (Spanish) + South African coal 55/45 70/30Anthracite + wood 90/10 85/15Bituminous coal (Polish) + straw pellet 80/20 75/25
Small pilot scale CFB experiments (0.1MW) under air- and oxygen-firing conditions
Air-firing Oxygen-firing
Air-firingOxygen-firing
Fuel reactivity
Transition between air- and oxygen-firing
Combustion process dynamics
Ash characteristics: air/oxy
Air-firng (Test 19)
CaCO3 [%]CaO [%]CaSO4 [%]
Oxygen-firing (Test 20)
CaCO3 [%]CaO [%]CaSO4 [%]
Bottom ash
Bottom ash
Oxygen-firing test with high temperature
Air-firing testMeasured calcium compounds in bottom ash
Model based analysis of the CANMET test data
• Detailed analysis of solids mass balance
• Furnace vertical temperature profile
• Combustion and energy release profile
• Solids density profile
• Heat flux profile
Furnace heat transfer
500
550
600
650
700
750
800
850
900
950
1000
0 2 4 6
Tem
pera
ture
Furnace height
High load OXYHigh load AIR
– 15 test weeks
– Runs: 88 of which
– 35 in air combustion
– 53 in oxy combustion
Test program at CanmetENERGY, Ottawa
FLY ASHSILO
FLY ASHFEEDING SYSTEM
LIMESTONESILO
LIMESTONE,DeSOx
LIMESTONEFEEDING SYSTEM
SAND SILO
SAND FEEDINGSYSTEM
FUEL SILO
FUEL FEEDING SYSTEM
NATURALGAS
START-UP BURNER
SKID
BOILER FEED WATER
FLUE GAS
BOTTOM ASH
FLY ASHSYSTEM
PRIMARYOXIDANTFAN
SECUNDARYOXIDANTFAN
MIXER
FLY
ASH
REC
IRC
ULA
TIO
N
LIM
ESTO
NE
SAN
DFU
EL F
EED
AMMONIA,DeNOx
MIXER
MIXER
CB1
CB2
OXYGEN
CIRCULATING FLUIDIZED BED BOILER – FLOW DIAGRAM
Demonstration runs at a 30 MWth CFB pilot plant
Presentation on Thursday 28th June:Oxyfuel testing at 30MWth CIUDEN Oxy-CFB boiler
Plant size:
Specifications for a FLEXI BURN CFB demonstration plant
• Two cases considered:
Flexi Burn CFB demonstration plant: – 300-350 MWe gross. (Detailed technical scope, main focus)
Full Commercial plant - post-2020: – 800 MWe gross (techno-economical feasibility study)
Operating parameters: Dynamic requirements for the power plant
Operational Mode Base Load
Load change rate Max ramping 4%/min
Minimum load 40%
Start-up time (cold) <24h
Start-up time (ASU cold) <8h
Annual equivalent operating hours
Oxy mode 6500 h
Air mode 500 h
TOTAL 7000 h
600 ºCReheated steam temperature
57 barReheated steam pressure
270 barMain steam pressure
598 ºCMain steam temperature
600 ºCReheated steam temperature
57 barReheated steam pressure
270 barMain steam pressure
598 ºCMain steam temperature
Steam parameters:
CONCENTRATIONH2O < 500 ppmCO < 2000 ppm
O2 + N2 + Ar < 4 vol%SOx < 100 ppmNOx < 100 ppmCO2 >95.5 %
Specifications for a FLEXI BURN CFB demonstration plant
• Air inleakage: Base case 1% (sensitivity analysis up to 3%)
• O2/CO2 ratio: close to air concentration (24% O2 wet)
• Oxygen purity:
Oxygen purity 96,6 % volPressure 1,2 barTemperature 20 ºC
Other oxycombustion criteria:
CO2 compressed to transport by pipeline
Current status (1/2)A lot of experimental work has been carried out in order to support the development of FLEXI BURN CFB concept
Combustion tests in different scales and field measurements in a commercial scale power plant provide a base for development and validation of the design tools needed in the concept development
Large scale high efficiency CFB boiler with
FLEXI BURN design
FuelBituminous coalLigniteBiomassPet coke etc.
Air Separation Unit (ASU) Mixing
AirSwitch
Fluegas (CO2-rich)
Flue gas recirculation
SwitchStack
95-97% O2
Flue gas cleaning
CO2 capture and storage (CCS)CondensationCompressionPurificationTransportStorage
Demonstration tests at different scales:
– VTT 0.1MW, CANMET 1MW has been completed (totally over 100 oxyfuel test balances) with encouraging results
– Flexible operation under air- and oxygen-firing modes have been successful demonstrated in the small scales 0.1MW-1MW
– Validation test campaigns with the world first and the largest (460 MWe) OTSC-CFB has been successfully completed
Current status (2/2)
The design parameters for a FLEXI BURN CFB plant, from a technical and operational point of view, have been determined
Two cases considered: 1) Flexi Burn CFB demonstration plant: 300-350 MWe gross 2) Full Commercial plant - post-2020: 800 MWe gross
The conceptual design of the FLEXI BURN CFB boiler has been developed
The conceptual design for the FLEXI BURN has been implemented including a preliminary integration with the Air Separation Unit (ASU) and the Compression and Purification Unit (CPU)
Boiler
CPUASU
SteamCycle
Oxidant Flue gas
IntegrationIntegration
Power Utilities Power Utilities
Next steps• Demonstration tests at CIUDEN are ongoing
• Final verification of the concept based on the test results form CIUDEN
• Concept optimisation for the boiler island and the integrated power plant unit including dynamic simulation of the plant
• Health and safety assessment related to oxygen-firing conditions
• Estimate economics for the new concept and evaluate their feasibility on a commercial scale range
• Identification of the key success factors of the FLEXI BURN CFB technology covering the process efficiency, operability, maintainability, environmental impact and responsiveness to the market requirements, all leading to the economic performance of this new approach for power generation
• Project completed by February 2013
FLEXI BURN CFB
• More information on the project http://www.vtt.fi/sites/flexiburncfb/
Acknowledgements:The research leading to these results has received funding from the European
Community’s Seventh Framework Programme (FP7/2007-2013) under grant agreement n° 239188.