flexi burn cfb project tourunen

7/30/2019 FLEXI BURN CFB Project Tourunen

1/25

Development of High Efficiency CFB Technology to Provide Flexible

Air/Oxy Operation for Power Plant with CCS

FLEXI BURN CFB

CO2NET seminar and EU CCS conference, 24th 26th May

2011, London


2/25

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 rangeof 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 lowerSOx concentration in flue gases due to in-furnace capture, thus reducing the need for downstreamflue gas cleaning

4. overall concept for phased transition into CCS technology with minimised risks through highefficiency air-oxy flexible CFB combustion

5. lower specific CO2 emissions from the reduced consumption of fuel due to the intrinsic highefficiency 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 oldcapacity with lower efficiency and poorer emission performance


3/25

3

FLEXI BURN CFB diagram allowing operationunder normal air-firing as well as oxygen-firing

with CCS

Large scale

high efficiency

CFB boiler w ith

FLEXI BURN

design

Fuel

Bituminous coalLigniteBiomassPet coke etc.

Air SeparationUnit (ASU) Mixing

Air

Switch

Fluegas(CO2-rich)

Flue gas recirculation

Switch

Stack

95-97% O2

Flue gascleaning

CO2

capture and storage (CCS)

CondensationCompressionPurification

TransportStorage

The FLEXI BURN CFB concept:

High efficiency Circulating FluidizedBed (CFB) power plant with CCScapable of air/oxy operation with awide range of fuels includingbiomass


4/25

Role of FLEXI BURN CFB Partners

Research institutes

Utilities

Development

steps

Indust rial applicability

VTT, LUT, CzUT UNIZAR-LITEC, AICIA

Endesa, EDP, PKE

Laboratory and small

pilot scale test

(0.1-1MWth)Concept

1stCommercial scale

FLEXI BURN CFB Power Plant

FLEXI BURN CFB project

2009 - 2012

Manufacturers

FWEOY, FWESA, ADEX, Siemens, Praxair

UAP

DemonstrationPilot Plant

30 MWth, CIUDEN


5/25

FLEXI BURN CFB - General project approach

5

Comparison of air-

and oxy-fir ing

Development of

design tools

Boiler design

and performance

Power plant integration,

optimization

and economics

Feasibility and readiness for the utili zation of

the technology within different regions in EU

WP1

WP2

WP4 WP5

WP6

Technology demonstration andbackground for the commercialscale design process

Supporting R&D

work

Viable boi ler design Viable power p lant

WP7: Coordination and dissemination

Demonstration tests

at large pilot uni tand commercial

scale air fired unit

WP3


6/25

n

c Xkmt

mr O2c

c

d

d

COefCO Ykt

Y

d

d

)/1/(1 mCOef kk

nrefv ddTAb )/)(/exp(

Model

analyses

COcombustion

Mixing

Charcombustion

Volat

ile,mo

isturer

elease

k W / m2

1D-MODEL

f lue gas

1

n n+ 1

to stack

Primary airSecondary a ir

2

n-1

3

n-2

BENCH SCALE REACTOR (BFB/CFB)

Air

O2, CO2, CO, N2,SO2, NO

Secondaryair

Continuousfuelfeed

Fuelbatchfeed

Cooler/heater

Cooler

PrimarygasheatingPC control anddata logging system

Cyclone

FilterTo Stac k


Air

O2, CO2, CO, N2

,SO2, NO

Secondaryair

Continuousfuelfeed

Fuelbatchfeed

Cooler/heater

Cooler


Cyclone

FilterTo Stac k

Air

O2, CO2, CO, N2

,SO2, NO

Secondaryair

Continuousfuelfeed

Fuelbatchfeed

Cooler/heater

Cooler


Cyclone

FilterTo Stac k

AGIS ZA 460 MWe supercritical OTU CFB

kW/m 2

Bench scale Pilot scale Boiler scale

EXPERIMENTAL

SCALES

MODELS FOR PHENOMENA 1-D PROCESS MODELS 3-D PROCESS MODELS

MODELS AND

DESIGN TOOLS

M

Secondary

cyclone

Fuelcontainers 1and 2 Zone1

Zone2

Primary

cyclone

Observation port

Deposit probepor t

Zone 3

Zone4

Tostack

Samplingport

Samplingport

Samplingport

Additivecontainer

Air

Secondary gas

Primary gas heating

O2,CO2,N2

PCcontrolanddatalogging system

Samplingport

Samplingport

Gasanalysator

FTIRsamplingp ort

FTIRsampling port

Samplingport

Samplingport

Gascooling

Bag filterFluegasrecirculation

M

Secondary

cyclone


Zone2

Primary

cyclone

Observation port

Deposit probepor t

Zone 3

Zone4

Tostack

Samplingport

Samplingport

Samplingport

Additivecontainer

Air

Secondary gas

Primary gas heating

O2,CO2,N2

PCcontrolanddatalogging systemPCcontrolanddatalogging system

Samplingport

Samplingport

Gasanalysator

FTIRsamplingp ort

FTIRsampling port

Samplingport

Samplingport

GascoolingBag filterFluegasrecirculation

PILOT SCALE CFB COMBUSTOR

M

Secondary

cyclone


Zone2

Primary

cyclone

Observation port

Deposit probepor t

Zone 3

Zone4

Tostack

Samplingport

Samplingport

Samplingport

Additivecontainer

Air

Secondary gas

Primary gas heating

O2,CO2,N2

PCcontrolanddatalogging system

Samplingport

Samplingport

Gasanalysator

FTIRsamplingp ort

FTIRsampling port

Samplingport

Samplingport


M

Secondary

cyclone


Zone2

Primary

cyclone

Observation port

Deposit probepor t

Zone 3

Zone4

Tostack

Samplingport

Samplingport

Samplingport

Additivecontainer

Air

Secondary gas

Primary gas heating

O2,CO2,N2

PCcontrolanddatalogging systemPCcontrolanddatalogging system

Samplingport

Samplingport

Gasanalysator

FTIRsamplingp ort

FTIRsampling port

Samplingport

Samplingport



Development and demonstration in multiple scales

(1/2)


7/25

Demonstration of FLEXI BURN CFBCIUDEN 30MWth- 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

Commercialscale FLEXI

BURN CFBTechnology

Scale upcriteria

Development and demonstration in multiple scales

(2/2)

R&D support Design tools Demonstration Boiler designPower plant

concept

CommercialScale

FLEXIBURN

WP1 WP2 WP3 WP4 WP5 WP6


8/25

Process scale-up

CFB technology is scaling up with the latest high-efficiency SC-OTU-referencesLagisza (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 2010

Start-Up Year

Pilot PlantOriental Chem

Lagisza

JEA

Turow 1

Vaskiluodon

Nova ScotiaTri-State

General Motors

800800 MWeUnit Capacity (MWe)

0

100

200

300

400

500

600

1970 1975 1980 1985 1990 1995 2000 2005 2010

Start-Up Year

Pilot PlantOriental Chem

Lagisza

JEA

Turow 1

Vaskiluodon

Nova ScotiaTri-State

General Motors

800800 MWe

Reference plant for the project


9/25

Balance test runs at Lagisza CFB boiler

Unit loads (100%MCR, 80%MCR, 60%MCR and 40%MCR) High/low level of bed pressure within combustion chamber

Measurement parameters during test runs :

Temperature within the combustion chamber (rear wall)

Vertical pressure profile within furnace (front wall)

Gas profiles (at level 13.00m)

Process data (including emission data)

Solid samples

coal, limestone, bottom ash, fly ash , in-furnace sample and circulating

material

Location of measurement ports

at OTU-SC 460MWe Lagisza boiler

Load unit : 100% MCR, 80% MCR

Solids Sampling frequency

Bituminous coal 4 (everytwo hours)

Bottomash 4 (everytwo hours)

Flyash 4 (everytwo hours)

In-furnacesample 4 (everytwo hours)

Circulatingmaterial 4 (everytwo hours)

Limestone 1 (in half of test balance)

Load unit : 60% MCR, 40% MCR

Solids Sampling frequency

Bituminous coal 3 (in half of test balance)

Bottomash 3 (in half of test balance)

Flyash 3 (in half of test balance)

In-furnacesample 3 (in half of test balance)

Circulatingmaterial 3 (in half of test balance)

Limestone 1 (in half of test balance)

Validation runs at a 460 MWe SC-OTU CFB boiler


10/25

OTU SC CFB Boiler layout at

PKE S.A. Lagisza Power Plant

Low Emissions

200 250 300 350 400 450 500

50

100

150

200

250

300

350

400

SO2

measuring data

ConcentrationofSO

2

[mg/m3 n]

(atO

2=6%

indryflue

gases)

Unit load [MWe]

200 250 300 350 400 450 500

50

100

150

200

250

300

350

400

NOx

measuring data

ConcentrationofNO

x

[mg/m3 n]

(atO

2=6%

indryflue

gases)

Unit load [MWe]

200 250 300 350 400 450 500

25

50

75

100

125

150

175

200

CO measuring data

ConcentrationofCO[

mg/m

3 n]

(atO

2=6%

indryfluegase

s)

Unit load [MWe]

200 250 300 350 400 450 500 5500

20

40

60

80

100

120140

160

180

200

Dust measuring data

Concentrationofdust[mg/

m2 n]

(atO

2=6%

indryfluegase

s)

Unit load [MWe]

EMISSION ( at 6% O2, dry flue gas)

(follows EUs LCP directive), mg/Nm3

SO2 200NOx (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

Temperature[C]

Height [m]

Measured

calculated by model


11/25


Air

O2, CO2, CO, N2,

SO2, NO

Secondaryair

Continuousfuelfeed

Fuelbatchfeed

Cooler/heater

Cooler

Primarygas heatingPC controlanddataloggingsystem

Cyclone

FilterTo Stack


Air

O2, CO2, CO, N2,

SO2, NO

Secondaryair

Continuousfuelfeed

Fuelbatchfeed

Cooler/heater

Cooler


Cyclone

FilterTo Stack

Air

O2, CO2, CO, N2,

SO2, NO

Secondaryair

Continuousfuelfeed

Fuelbatchfeed

Cooler/heater

Cooler


Cyclone

FilterTo Stack

M

Secondary

cyclone

Fuelcontainers1 and2 Zone1

Zone 2

Primarycyclone

Observation port

Depositprobeport

Zone 3

Zone 4

Tostack

Sampling port

Sampling port

Sampling port

Additivecontainer

Air

Secondarygas

Primarygas heating

O2,CO2,N2

PCcontroland datalogging system

Samplingport

Sampling port

Gasanalysator

FTIRsampling port

FTIRsampling port

Sampling port

Sampling port

GascoolingBagfilterFlue gasrecirculation

M

Secondary

cyclone


Zone 2

Primarycyclone

Observation port

Depositprobeport

Zone 3

Zone 4

Tostack

Sampling port

Sampling port

Sampling port

Additivecontainer

Air

Secondarygas

Primarygas heating

O2,CO2,N2

PCcontroland datalogging systemPCcontroland datalogging system

Samplingport

Sampling port

Gasanalysator

FTIRsampling port

FTIRsampling port

Sampling port

Sampling port



M

Secondary

cyclone


Zone 2

Primarycyclone

Observation port

Depositprobeport

Zone 3

Zone 4

Tostack

Sampling port

Sampling port

Sampling port

Additivecontainer

Air

Secondarygas

Primarygas heating

O2,CO2,N2

PCcontroland datalogging system

Samplingport

Sampling port

Gasanalysator

FTIRsampling port

FTIRsampling port

Sampling port

Sampling port


M

Secondary

cyclone


Zone 2

Primarycyclone

Observation port

Depositprobeport

Zone 3

Zone 4

Tostack

Sampling port

Sampling port

Sampling port

Additivecontainer

Air

Secondarygas

Primarygas heating

O2,CO2,N2

PCcontroland datalogging systemPCcontroland datalogging system

Samplingport

Sampling port

Gasanalysator

FTIRsampling port

FTIRsampling port

Sampling port

Sampling port



VTT

0.3kW

VTT

0.1MW

CANMET

1MW

CIUDEN

30MW

Demonstrationscales

Time

Concept for 300 MWe

2009 2012

FLEXI BURN CFB Demonstration steps

Completed

In progress

Aim : to develop anddemonstrate FLEXIBURN CFB conceptenabling to reach thetarget of near zeroemission power plants


12/25

Operational point of views:

Combustion process dynamics

Transition between air- and oxygenfiring

Small pilot scale CFB experiments (0.1MW) under air- and

oxygen-firing conditions

Air-firing Oxygen-firing Air-firingOxygen-firing


13/25


oxygen-firing conditions have been completed withtotally 33 experiments

Transition between air- and oxygen firing conditions

could be carried out smoothly and safely with the

renovated automation system which included an

automated transition mode between air- and oxygen-firing

Combustion process could be operated in the both modes

without any major drawbacks

Based on the dynamic tests the reliable control of oxidant

oxygen concentration is very important from the safety

operation and process controllability point of view

If the inlet gas (oxidant) oxygen concentration is controlled

effectively the combustion process stability seems to be

comparable to corresponding air-firing conditions

If flue gas emissions are expressed in milligrams per

megajoules the emission levels between air- and oxygen-

firing have not remarkable differences


oxygen-firing conditions

Air-firng (Test 19)

CaCO3 [%]

CaO [%]

CaSO4 [%]

Oxygen-firing (Test 2 0)

CaCO3 [%]

CaO [%]

CaSO4 [%]

Bottom ash

Bottom ash


14/25

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

perature

Furnace height

High loadOXY

High load AIR

15 test weeks

Runs: 88 of which

35 in air combustion

53 in oxy combustion

Test program at CanmetENERGY, Ottawa


15/25

Demonstration runs at a 30 MWth CFB pilot plant

TECHNICAL &

INDUSTRIAL

BUILDINGS

DCS

PC BOILER

GASES RECIRCULATION

AND MIXTURE

CFB BOILER

CO2 COMPRESSION

& PURIFICATION

FLUE GAS CLEANING

FUEL

PREPARATION


16/25

FLY ASH

SILO

FLY ASH

FEEDING SYSTEM

LIMESTONE

SILOLIMESTONE,

DeSOx

LIMESTONE

FEEDING SYSTEM

SAND SILO

SAND FEEDING

SYSTEM

FUEL SILO

FUEL FEEDING

SYSTEM

NATURAL

GAS

START-UPBURNER

SKID

BOILER FEED

WATER

FLUE GAS

BOTTOM ASH

FLY ASH

SYSTEM

PRIMARY

OXIDANTFAN

SECUNDARY

OXIDANTFAN

MIXER

FLYASH

RECIRCULATION

LIMESTONE

SAND

FUELFEED

AMMONIA,

DeNOx

MIXER

MIXER

CB1

CB2

OXYGEN

CIRCULATING FLUIDIZED BED BOILER FLOW DIAGRAM



17/25

17

01 03 04 05 0602 07 09 10 11 1208

20122011

FLEXI BURN

TEST PERIOD

01 03 04 05 0602 07 09 10 11 1208

PLANNING OF

TEST MATRIX

CFB FUNCTIONALITY

TEST

FLEXI BURN

PROJECT DEADLINE

COMPILATION OF

RESULTS


NEXT STEPS

CFB CONSTRUCTION

& COMMISSIONING


18/25

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)


19/25

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)


20/25

Other oxycombustion criteria:

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 bar

Temperature 20 C

Specifications for a FLEXI BURN CFB

demonstration plant


21/25

Current status (1/2)

During the first half of the project a lot of experimental work has been carried out inorder 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 scalehigh efficiencyCFB boiler with

FLEXI BURNdesign

Fuel

Bituminous coalLigniteBiomassPet coke etc.

Air SeparationUnit (ASU) Mixing

AirSwitch

Fluegas(CO2-rich)

Flue gas recirculation

Switch

Stack

95-97% O2

Flue gascleaning

CO 2 capture and storage (CCS)CondensationCompressionPurificationTransport

Storage

Demonstration tests at different scales:

VTT 0.1MW, CANMET 1MW has beencompleted (totally over 100 test balances)

with encouraging results

If flue gas emissions are expressed inmilligrams per megajoules the emission levels

between air- and oxygen-firing have not

remarkable differences

Emission limits based on the concentrationsand volumetric units are not applicable for

the CCS processes. Emission limits in CCS

applications should be expressed in energy

basis.


22/25

Current status (2/2)

The basic design parameters for a FLEXI BURN CFB plant, from a

technical and functional 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 initial conceptual design of the FLEXI BURN CFB boiler has been

developed

The first 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

Steam

Cycle

Oxidant Flue gas

IntegrationIntegration

Power Utilities Power Utilities


23/25

Next steps

The second test campaign at Lagisza Power Plant is carried out during thefirst half of 2011

Demonstration tests at CIUDEN in the beginning of 2012

Concept optimisation for the boiler island and the integrated power plantunit 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 acommercial scale range

Identification of the key success factors of the FLEXI BURN CFB technologycovering 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

Co-operation with Utilit y Advisory Panel (UAP)


24/25

FLEXI BURN CFB - Summary

1) What has been achieved, what do we now know and what can we now do, technically and commercially? Flexible operation under air- and oxygen-firing modes have been successful demonstrated in the small

scales (0.1MW-1MW)

The first validation test campaign with the world first and the largest (460 MWe) OTSC-CFB has beensuccessfully completed

2) What is NOT yet achieved?

Final concept and demonstration in the large scale (30MW-300MWe)

3) What are the next logical steps, i.e.: what do we still need to do within the subject of the presentation

towards the implementation and commercialisation of CCS?

Next logical steps: demonstration tests at CIUDEN (30MW) and development of final concept for 300MWe Development of 2nd generation oxyfuel concept with significantly higher overall plant efficiency Transportation and storage part is not in the scope of the project but it will be the key issue in the

implementation and commercialisation of CCS

Emission limits for CCS plants must be reconsider (concentration based limits are not valid)

4) Who do you think is best placed to take these next steps forward?

Demonstration of FLEXI BURN CFB concept: FLEXI BURN CFB consortium and OXYCFB300 consortium Development of 2ndgeneration oxyfuel concept: Organizations who have been involved in the

development of the 1st generation oxyfuel concepts

Transportation and storage: all together, public acceptance and political decisions are very important Emission limits for CCS: European Commission is working on the issue


25/25

FLEXI BURN CFB Workshops

1st Flexi Burn CFB Workshop was held in Brussels 24th March 2011

More information:

http://www.vtt.fi/sites/flexiburncfb/

2nd FLEXI BURN CFB Workshop will be held in summer 2012

highlighting the final results of the project

Welcome!

Thank You !
http://www.vtt.fi/sites/flexiburncfb/http://www.vtt.fi/sites/flexiburncfb/

flexi burn cfb project tourunen

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