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Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018
Pressurized Steam Fluidized Bed
Drying (PSFBD) of Lignite - State of
the Development and selected
Results of 15 Years R&D
9th International Freiberg Conference on IGCC & XtL Technologies
Berlin, 05.06.2018
Matthias Merzsch, Dr. Matthias Klatt, Prof. Hans Joachim Krautz
Chair of Power Plant Technology, BTU Cottbus – Senftenberg
Dr. Olaf Höhne
LEAG - Lausitz Energie Kraftwerke AG
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018 2
Brief introduction
PSFBD Facilities
Development activities
Outlook
Table of Contents
Cottbus
Berlin
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018
57%
3%
23%
17%
Lusatian processing coal (raw)
3
Why to Dry Lignite?
raw
w=19%
9.2
19
0
5
10
15
20
raw w=19%
9.2
19
05
101520
raw w=19%
Net calorific Value [MJ/kg]
Proximate analysis of Lusatian processing coal
2 Lusatian lignite briquettes
(w=19%, 1.15 kg)
evaporated water from
raw lignite (0.967 kg)
water remaining in
briquettes (0.219 kg)
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018
Why to Pre-Dry Lignite in a (Pressurized) Steam Fluidized Bed?
4
Schematic diagram of the PSFBD process
Increasing the efficiency by up to 5 percentage
points in lignite fired power plants (44% 49%)
Drying with heating steam at low temperature in
place of hot flue gases
use of vaporized lignite water energy
more intensive heat & material transmission in
contrast to conventional tube dryers
(upgrading/processing facilities)
Up to 80% less energy consumption
Precondition for CCS technologies in power plants
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018 5
Industrial Park Schwarze Pumpe – Lausitz Energie Kraftwerke AG
Raw lignite throughput < 550 kg/h
commissioning 2003
BTU Cottbus-Senftenberg – Chair of Power Plant Technology
PSFBD Facilities
Raw lignite throughput 8…10 t/h
commissioning 2008
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018 6
PSFBD Facilities - development activities
rotary feeder
•Test of different Manufacturers and different sealing
methods (conical rotor, sealing faces, minimum gap)
Reduction of leakage steam by 75% compared
with commissioning
5-10% losses of vapor by leakage
• High moister of raw lignite in combination with the small particle size
• Minimize the leakage steam of the pressurized vessel (efficiency,
particle moisture)
20
30
40
50
60
70
80
0 10 20 30 40 50 60
rep
os
e a
ng
les
φ[
]
water content [% total mass]
Lusatian processing coal 0-2 mm
Central german processing coal 0-2 mm
Challange:
φ
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018 7
PSFBD Facilities - development activities
1. Change over to a finer grained lignite
(0-6 mm 0-2 mm)
2. Installation of a dust recirculation
(average particle diameter ↓, average moisture ↓)
0
100
200
300
400
500
600
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80
he
at tr
an
sfe
r c
oe
ffic
ien
t h
[W
/(m
²K)]
fluidization velocity [m/s]
0-2 mm 0-3 mm
0-4 mm 0-6 mm
0
100
200
300
400
500
600
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
he
at tr
an
sfe
r c
oe
ffic
ien
t h
[W
/(m
²K)]
fluidization velocity [m/s]
0-2 mm
0.02-2 mm
0.04-2 mm
performance improvement (fluidized bed heat transfer /
0
100
200
300
400
500
600
0 10 20 30 40 50 60
ma
xim
um
he
at tr
an
sfe
r c
oe
ffic
ien
t h
ma
x[W
/(m
² K
)]
water content [% total mass]
0-2 mm
0-3 mm
0-6 mm
process stability)
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018 8
PSFBD Facilities - development activities
design improvement (fluidized bed heat transfer / tube bundle)
0
100
200
300
400
500
600
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
he
at tr
an
sfe
r c
oe
ffic
ien
t h
[W
/(m
²K)]
fluidization velocity u [m/s]
tube diameter = 14 mm
tube diameter = 21.3 mm
tube diameter = 33.7 mm
0
10
20
30
40
50
0 20 40 60 80 100
vo
lum
e-r
ela
ted
he
at tr
an
sfe
r [k
W/m
³K]
packing density [m²/m³]
tube diameter = 12 mm
tube diameter = 22 mm
tube diameter = 35 mm
3. Detailed investigation of different
heat tube bundle geometries
(tube diameter,
tube arrangement & pitch)
zy
x
sh
sv
c)
sh
sv
b)
sh
sv
a)
But: stability criteria for higher moisture contents??
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018 9
PSFBD Facilities - development activities
Fluidizing stability
Reduction Fluidization blower power of 50%
Minimizing of dust discharge
10 0.1 0.4 0.5 0.4 0.5 0.7 0.5 0.3
9 0.4 0.8 1.8 1.4 1.2 1.8 0.7 0.4
8 1.3 1.6 3.7 2.7 2.1 2.9 1.7 0.8
7 2.3 1.2 2.7 2.9 1.7 2.6 1.7 2.1
6 1.3 0.6 0.7 1.1 1.1 0.8 0.6 1.2
5 2.0 1.1 1.5 1.4 0.7 0.6 0.6 1.3
4 2.9 2.8 3.4 1.3 1.4 2.6 1.6 1.9
3 1.0 1.6 2.4 1.5 1.5 3.2 1.9 0.6
2 0.1 0.3 0.8 0.9 1.0 1.4 0.3 0.1
1 0.0 0.1 0.3 0.3 0.2 0.2 0.1 0.0
A B C D E F G H
10 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
9 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
8 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
7 0.0 0.0 0.0 1.3 0.8 0.0 0.0 0.0
6 0.0 0.0 6.4 20 22 2.1 0.0 0.0
5 0.0 0.1 5.8 18 22 1.3 0.0 0.0
4 0.0 0.0 0.1 0.3 0.3 0.1 0.0 0.0
3 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
2 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
1 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
A B C D E F G H
4. Raw lignite distribution
from laboratory investigation
to industrial application
wit
ho
ut
dis
tru
bu
tor
wit
h o
pti
miz
ed
dis
tru
bu
tor
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018 10
PSFBD Facilities - development activities
Pressurizing and technology extension
5. Increasing heat transfer rates and efficiency
through pressurizing
400
420
440
460
480
500
520
540
560
1 1.5 2 2.5 3 3.5 4 4.5
ove
rall h
ea
t tr
an
sfe
r c
oe
ffic
ien
t [W
/m²K
]
system pressure [bar abs.]
PSFBD - Schwarze Pumpe
successful installation and testing of a
steam converter and a steam recompression plant
LEAG – Schwarze Pumpe
LEAG – Schwarze Pumpe
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018 11
PSFBD Facilities - development activities
Pressurizing and technology extension
LEAG – Schwarze Pumpe
LEAG – Schwarze Pumpe
Re-use of 90% of the vaporized lignite water
Reduction of 65…80% thermal energy demand
Reduction of 40…50% primary energy demand (Electrical energy demand compressor)
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018 12
PSFBD Facilities - development activities
further R&D activities
155
156
157
158
159
160
161
162
163
164
165
0
1
2
3
4
5
6
7
8
9
10
16:20 16:30 16:40 16:50 17:00 17:10 17:20 17:30 17:40
Kü
hlw
asse
rte
mp
erat
ur
[°C
]
Tem
pe
ratu
rdif
fere
nz
Sat
tdam
pf -
Ro
hrw
and
[K
]
Temperaturdifferenzen in Messstrecke Dampf - Rohrwand
T_39 (-30°) T_36 (+60°) T_37 (-120°) T_38 (+150°) T_KW
-120
-30
150
60
-30
-120 150
60
-30
-120 150
60
-30
-120 150
60
5,6
0 m
0
200
400
600
800
1.000
1.200
1.400
1.600
1.800
5 6 7 8 9 10 11 12 13 14 15 16
dif
fere
nti
elle
Bin
du
ng
sw
ärm
e
[kJ
/kg
W]
Wassergehalt [Ma.-%]
1,0 bar
1,5 bar
2,0 bar
3,0 bar
4,0 bar
6,0 bar
Fundamental research – heat of binding at preassures up to 6 bar
numerical modeling of hydrodynamics
and heat/mass transfer
Process integration – thermal schematic calculations
Experimental investigation of condensation in horizontal pipes
at pressures up to 10 bar (heat transfer & pressure drop)
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018 13
Outlook
PSFBD as prestage for further lignite refinement
(e.g. activated carbon production for mercury
capture from stack gas of power plants)
Further optimization of the dryer design
(performance increase by innovative pipe structures)
PSFBD as Retrofit for existing power plants
(depends on political circumstances)
Brandenburg University of Technology Cottbus - Senftenberg, Chair of Power Plant Technology
www.b-tu.de/fg-kraftwerkstechnik Berlin | 9th Freiberg Conference | 05.06.2018 14
Many thanks for your attention!
Dipl.- Ing. (FH) Matthias Merzsch
Chair of Power Plant Technology
Brandenburg University of Technology Cottbus – Senftenberg
Telefon: +49 (0) 355 69 4007
E-Mail: [email protected]