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Oxyfuel Fundamentals and Underpinning Technologies1ST International Oxyfuel Combustion Conference y7 – 11 September 2009, Cottbus, Germany
A Duncan, B F McGhee, C McGhie, D W Sturgeon and F D Fitzgerald*
10 September 200810 September 2008Research and Development Centre
Contents
• Doosan Babcock Energy Limited• Doosan Babcock R&D Centre• Doosan Babcock’s Oxyfuel Combustion Technology Roadmap (Past & Present)• OxyCoal-UK: Phase 1 – Fundamentals and Underpinning Technologies• Laboratory-Scale Corrosion Tests
D B b k’ O f l C b ti T h l R d (P t & F t )• Doosan Babcock’s Oxyfuel Combustion Technology Roadmap (Present & Future)• Concluding Remarks• Contact Details
Page 1
Doosan Babcock Energy Limited
D B b k E Li it d i l b l lti i li t
• Doosan Babcock Energy:
Doosan Babcock Energy Limited is a global, multi-specialist, energy services company.
– Designs, supplies and constructs some of the cleanest, most efficient coal-fired power plant in the world
– Provides complete aftermarket solutions for lif t i ffi i i t dlife extension, efficiency improvement and emissions reduction of coal fired power plant
– Is a leading engineering services provider operating in thermal power nuclear oil andoperating in thermal power, nuclear, oil and gas, and petrochemical industries
• Over 5,000 experts, engineers and technologists, in 20 offices around the worldworld.
• Through constant innovation, we aim to provide the highest standards in cutting-edge science, new technologies and ground breaking engineering solutions
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ground-breaking engineering solutions.
Doosan Babcock R&D Centre - Technology Disciplines
R & D C t f b il d l t d t h l i E l iti d i ti
Boilers
R & D Centre for boilers and related technologies. Exploiting new and innovative technologies and supporting existing products for Doosan Babcock and Doosan Heavy global power business.
Boilers Development of market
leading, high performance products
Advanced Supercritical
Environment Development of effective NOx
and heavy metal emission reduction technologiesDevelopment of carbon Advanced Supercritical
Boilers POSIFLOWTM vertical tube
Development of carbon capture technologies (PCC & OxycoalTM)
Materials & Fuels
CFD & Software and ToolsAsset Management
D l t f t
Development and validation of materials for boiler pressure part components
Analytical analysis of wide CFD & Software and Tools Use of commercial codes for
isothermal and combustion modeling
Continuous development of a
Development of component monitoring systems
Advanced fault prediction methods New inspection methods and tools
T h i d l f lif l
range of fuels, including coal and biomass
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wide range of in-house tools Techno-economic models for lifecycle optimisation
Doosan Babcock’s Oxyfuel Combustion Technology Roadmap
For over 15 years, we have been a leading player in the development of low carbon technology.
1992 to 1995 2005 to 2008 2005 to 2008 2007 to 2009 2008 to 2010
• Pulverised Coal • Oxy Combustion • CO2 Capture • OxyCoal 2• OxyCoal-UK:Pulverised Coal Combustion System for CO2Capture
Oxy Combustion Processes for CO2 Capture from Power Plant
• Development and
CO2 Capture Ready Power Plants
• Enhanced Capture of CO2
OxyCoal 2 Demonstration of an Oxyfuel Combustion System
OxyCoal UK: Phase 1 –Fundamentals and Underpinning T h l iExperimental
Validation of a Mathematical Modelling Methodology for
• Future CO2Capture Options for the Canadian MarketC l Fi d
Technologies
Methodology for Oxy-Fuel Combustion for CO2 Capture in Large Power Pl t
• Coal-Fired Advanced Supercritical Retrofit with CO2Capture
Page 4
Plantsp
OxyCoal-UK: Phase 1 – Fundamentals and Underpinning Technologies
• Lead Company
Project Partners
p y
• Industrial Participants
• University Participants
• Sponsors / Sponsor Participants
• Government Support
Page 5Page 5
OxyCoal-UK: Phase 1 – Fundamentals and Underpinning Technologies
The OxyCoal-UK: Phase 1 collaborative project addressed critical technology gaps and was led by Doosan Babcock and supported by the Technology Strategy Board.
• Combustion Fundamentals– Characterisation of coal ignition,
devolatilisation, char burnout and nitrogen partitioning behaviour under
f l fi i ditioxyfuel firing conditions.– Development of kinetic parameters
from test data and application in CFD models of OxyCoal™ burner and oxyfuel boileroxyfuel boiler.
• Furnace Design and Operation– Investigation of the performance of the
foxyfuel process and its key impacts on utility plant operation and performance. (Pilot-scale testing, fireside deposit characterisation and laboratory-scale corrosion testing )University of Nottingham
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laboratory-scale corrosion testing.)y gDrop Tube Furnace
OxyCoal-UK: Phase 1 – Fundamentals and Underpinning Technologies
The OxyCoal-UK: Phase 1 collaborative project addressed critical technology gaps and was led by Doosan Babcock and supported by the Technology Strategy Board.
• Flue Gas Clean-Up– Development and testing of novel flue gas
clean-up system for NOx and SO2 removal f f l d i d flfrom oxyfuel derived flue gas.
– Conversion of 160kWt Emissions Reduction Test Facility (ERTF) to oxyfuel firing configuration and parametric testing.
• Generic Process Issues– A desktop study to investigate the key
process issues associated with an oxyfuel i t ll ti l tilit l tinstallation on a large utility plant.
– Front End Engineering Design Study for oxyfuel conversion of 90MWt Clean Combustion Test Facility (CCTF).
Page 7Doosan BabcockEmissions Reduction Test Facility
Laboratory-Scale Corrosion Tests
Principal Concerns
• Under oxyfuel firing conditions the SO2/SO3 and HCl concentrations in the flue gases may
increase substantially.
• High temperature corrosion reactions in the final superheater and reheater sections of theHigh temperature corrosion reactions in the final superheater and reheater sections of the
boiler may increase.
• The suitability of current and candidate materials for application in these conditions has to
be assessed.
Page 8
Laboratory-Scale Corrosion Tests
Overview of Test Procedure
• Materials tested at temperatures between 550 and 810°C, controlled to ± 2°C, over a 1,000
hour exposure time.
• Materials exposed to synthetic ash chemical loading:Materials exposed to synthetic ash chemical loading:
Na2SO4 / K2SO4 / Fe2O3 (1.5 / 1.5 / 1 mole basis)
• Materials exposed in accurately controlled, synthetic gas atmospheres, i.e. normal flue
gas, high SO2, high CO2 and high SO2 and CO2.
• Corrosion rate measurements employing microscopic techniques.
• Full metal thickness loss-temperature curves plotted• Full metal thickness loss-temperature curves plotted.
Page 9
Laboratory-Scale Corrosion Tests
Test Materials
Type Name Cr,% Ni, %
FerriticT91 8.0 – 9.5 0.4 max
X20 10 0 12 5 0 3 0 8X20 10.0 – 12.5 0.3 – 0.8
Esshete 1250 14.0 – 16.0 9.0 – 11.0
Super 304H 17.0 – 19.0 7.5 – 10.5
Austenitic
Super 304H 17.0 19.0 7.5 10.5
TP347HFG 17.0 – 20.0 9.0 – 13.0
Sanicro 25 22.2 24.9
HR3C 24.0 – 26.0 17.0 – 23.0
Nickel Alloy IN740 25.0 ~ 49
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Laboratory-Scale Corrosion Tests
Test Apparatus – General Arrangement
ExhaustGas
ExhaustGas
Temperature Display
3
Temperature Display
3
Gas Cylinders for Controlled Atmosphere
3 - Zone Furnaces
1
x
x x
x
x
x
Hot
Zon
e 2
Hot
Zon
e
Gas Cylinders for Controlled Atmosphere
3 - Zone Furnaces
1
x
x x
x
x
x
Hot
Zon
e 2
Hot
Zon
e
Sample
Hot
Zon
e 1
x x
Sample
Hot
Zon
e 1
x x
Sample Levels
Mass Flow Controller
Water
Sample Levels
Mass Flow Controller
Water
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Laboratory-Scale Corrosion Tests
Test Apparatus – Sample Test Frame
Page 12
Laboratory-Scale Corrosion Tests
Typical Metal Thickness Loss – Temperature Curve
2000
2500
Normal f lue gas
Normal CO2 w ith high SO2
1500
n ra
te n
m/h
Normal CO2 w ith high SO2
High CO2 w ith normal SO2
High CO2 and High SO2
500
1000
Cor
rosi
on
0500 600 700 800 900
T t (ºC)
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Temperature (ºC)
Laboratory-Scale Corrosion Tests
Typical Metal Thickness Loss – Temperature Curve
700
800
Normal f lue gas
Normal CO2 and high SO2
400
500
600
rate
(nm
/h)
g
High CO2 and Normal SO2
High CO2 and high SO2
200
300
Cor
rosi
on
0
100
500 600 700 800 900
Temperature (ºC)
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Temperature ( C)
Laboratory-Scale Corrosion Tests
Typical Metal Thickness Loss – Temperature Curve
600
700
800
Normal f lue gas
Normal CO2 and high SO2
400
500
600
on ra
te (n
m/h
)
High CO2 and normal SO2
High CO2 and high SO2
100
200
300
Cor
rosi
o
0
100
500 600 700 800 900
Temperature (ºC)
Page 15
Laboratory-Scale Corrosion Tests
• In all cases, the measured corrosion rates increase from relatively low values at around 550-600°C to peak values at temperatures in the range 700-750°C, and then decrease to
Summary of Results
p p g ,lower values at around 800°C.
• The measured corrosion rates decrease markedly, as expected, with increasing chromium and nickel contents.
• In general terms, the impact of the increased SO2 and CO2 concentrations was lower for the higher grade materials.
• On average, the ratios of the measured corrosion rates to those measured under a normal coal flue gas atmosphere, were
• Normal CO2 and high SO2 1.6• High CO2 and normal SO2 1 4High CO2 and normal SO2 1.4• High CO2 and high SO2 2.2
• Increasing both the SO2 and the CO2 concentrations by a factor of five had a significant impact on the corrosion rates and that the impact was greater for the lower alloy materials
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impact on the corrosion rates, and that the impact was greater for the lower alloy materials.
Doosan Babcock’s Oxyfuel Combustion Technology Roadmap
Through our investment in R&D we continually look for innovative ways to create a low carbon future.
• OxyCoal 2 – • Optimisation of • 1000MW Oxyfuel• Front End
2008 to 2010 2008 to 2010 2009 to 2011 2009 to 2015 2020
• Impact of HighOxyCoal 2 Demonstration of an Oxyfuel Combustion System
Optimisation of Oxyfuel PF Power Plant for Transient Behaviour
1000MWe Oxyfuel Power Plant
• Commercialisation
Front End Engineering Design Studies
• 100 to 250MWeOxyfuel
Impact of High Concentrations of SO2 and SO3 in Carbon Capture Applications and Miti ti• Optimised
OxyCoal Combustion
DemonstrationPower Plants
Mitigation
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Concluding Remarks
Doosan Babcock is developing the capability to provide competitive oxyfuel firing technology suitable for full plant application post-2010.
• Doosan Babcock has established a dedicated Carbon Capture Business Group to commercialise Carbon Capture technologies.
• We are undertaking front end engineering design (FEED) studies for utility clients’ Oxyfuel power plants.Oxyfuel power plants.
• We aim to design, supply and construct an oxyfuel power plant of similar scale that will be operational by 2015 and awill be operational by 2015, and a 1000MWe oxyfuel power plant by 2020.
Page 18
Contact Details
Doosan Babcock is committed to delivering unique and advanced carbon capture solutions.
Dr David FitzgeraldSenior Engineer R&DE [email protected]
Mark BryantDi t C b C t
Doosan Babcock Energy,Porterfield Road,RENFREW.
Director Carbon CaptureE [email protected]
Peter Holland-Lloyd
PA4 8DJ
T + 44 (0) 141 886 4141Peter Holland LloydBusiness Development ManagerE [email protected]
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