methanol as low cost alternative fuel for emission ... · methanol as low cost alternative fuel for...
TRANSCRIPT
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Methanol As Low Cost Alternative Fuel For Emission Reduction In Gas Turbines and Utilities Boilers
IEC and Dor Chemicals
Jan 13th , 2013 Weizman Institute of Science, Rehovot,
Israel
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C E OC E OC E O
The Israel Electric Corp. The Israel Electric Corp. –– Organization ChartOrganization Chart
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IECIEC’’ss Engineering Project Group OrganizationEngineering Project Group Organization
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Engineering Pr0jects GroupEngineering Pr0jects GroupEngineering Pr0jects Group
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The Israel Electric Corp. Power PlantsThe Israel Electric Corp. Power Plants
Orot Rabin
2X575
4X360Rutenberg
2X575
2X550
HaifaHaifa
22XX141141
ReadingReading
22XX214214EshkolEshkol
44XX228228 1+ X370
Alon Tavor
1X370
Gezer
2X370
Tzafit
1X370
Hagit
1X370+2X350
Ramat Hovav
1X340
Coal Fired Coal Fired
Oil/Gas FiredOil/Gas Fired
Oil FiredOil Fired
Combined CyclesCombined Cycles
Gas Turbine 2,540 MwGas Turbine 2,540 Mw
Total Installed power: Total Installed power:
~13000 Mw~13000 MwThe I
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2X370
2X630*
* Projects under execution
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. The Israel Electric Corp. The Israel Electric Corp. –– Fuel Burned Fuel Burned
••Bituminous coal Bituminous coal –– very wide range of properties very wide range of properties
••SubSub--bituminous coal bituminous coal –– Low SulfurLow Sulfur
••Heavy Fuel Oil#6Heavy Fuel Oil#6
••Light fuel Oil#2Light fuel Oil#2
••Natural GasNatural Gas
••MethanolMethanol
•• Preparation for Biomass (Preparation for Biomass (BiocoalBiocoal) and Coal co) and Coal co--firingfiring
••Preparation for Coal and Sewage coPreparation for Coal and Sewage co--firingfiring
••Oil ShaleOil Shale
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. The Israel Electric Corp. The Israel Electric Corp. –– Emission Reduction activity Emission Reduction activity
••Low Low NOxNOx Firing System Implementation Firing System Implementation
••Post Combustion Treatment:Post Combustion Treatment:
••SCR installation for SCR installation for NOxNOx ReductionReduction
••FGD installation for SOFGD installation for SO2 2 ReductionReduction
••ESP for ash reductionESP for ash reduction
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OutlineOutlineT
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Methanol Fuel properties
• Chemical Formula CH3OH
• Molecular weight 32.04
• Flash point 12 C (to 41 C)
• Auto ignition temperature 464 C
• Combustion (Adiabatic) temperature 2045 C
• Low heating value 4777 kcal/kg
• Density 793 kg/ M3 at 30 C
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OverviewOverviewT
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• Methanol is an attractive future fuel for utility boilers and gas turbine engines.
Methanol can achieve:1. Lower NOx emissions due to the lower flame
temperature and no FBN.
2. Since methanol has no sulfur there are no SO2 emissions.
3. The clean burning characteristics of methanol are expected to lead to clean heat surfaces and lower maintenance than with HFO or even with LFO.
4. Relative to NG and FO , methanol can achieve higher power output due to higher mass flow in GT engines.
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Mechanism of Mechanism of NOxNOx Emission FormationEmission Formation
There are three known mechanism of NOx formation
- Thermal NOx
- Fuel NOx
- Prompt NOx
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NOxNOx formation mechanismformation mechanism
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Combustion temperature of blend of Combustion temperature of blend of
methanol and HFOmethanol and HFOT
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Combustion temperature of blend of methanol and HFO
vs metanol heat fraction
2020
2040
2060
2080
2100
2120
2140
2160
2180
2200
2220
2240
0 10 20 30 40 50 60 70 80 90 100
Methanol heat fraction, %
Ble
nd
co
mb
usti
on
tem
pera
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,C
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Methanol and HFO Co-Firing At Large Utility Boiler of 140 Mw
Unit
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Haifa Power Plant SiteHaifa Power Plant SiteT
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Steam Generator of Haifa C Steam Generator of Haifa C –– General viewGeneral view
140 Mw unit140 Mw unit
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Primary measures implementationPrimary measures implementation
Furnace Furnace crossectioncrossection
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Primary measures implementationPrimary measures implementation
Burner Burner –– General viewGeneral view
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Primary measures implementationPrimary measures implementation
Burner Burner –– DesignDesign
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Primary measures implementationPrimary measures implementation
HFO Atomizer HFO Atomizer –– General viewGeneral view
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Primary measures implementationPrimary measures implementation
HFO Atomizer HFO Atomizer –– General viewGeneral view
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Upgrading for Methanol Firing Upgrading for Methanol Firing
Methanol Atomizer Methanol Atomizer –– General viewGeneral view
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Upgrading for Methanol Firing Upgrading for Methanol Firing
Key DiagramKey Diagram
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. Methanol Storage TankMethanol Storage Tank
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. Methanol supply displayMethanol supply display
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NOxNOx reduction tests resultsreduction tests results
Unit#3 Haifa PS BoilerUnit#3 Haifa PS Boiler
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NOxNOx reduction tests resultsreduction tests results
DOR Chemicals boiler (Capacity 10 DOR Chemicals boiler (Capacity 10 t/ht/h))
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. Particulates reduction tests resultsParticulates reduction tests results
Unit#3 Haifa PS BoilerUnit#3 Haifa PS Boiler
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. SO2 reduction tests resultsSO2 reduction tests results
Unit#3 Haifa PS BoilerUnit#3 Haifa PS Boiler
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. Other emission reduction tests resultsOther emission reduction tests results
Unit#3 Haifa PS BoilerUnit#3 Haifa PS Boiler
CO emission CO emission -- ““00””
FormaldehydeFormaldehyde -- ““00””
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. Comparison of furnace heat absorption for HFO Comparison of furnace heat absorption for HFO
and HFOand HFO--metanolmetanol coco--firingfiring
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(90MW)(90MW)
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. ReheaterReheater metal temperature (90MW)metal temperature (90MW)
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. Primary Primary superheatersuperheater metal temperature (90MW)metal temperature (90MW)
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. HFOHFO--Methanol CoMethanol Co--Firing TestFiring Test
ResultsResults
4606903870NegligibleNegligible33038090
4106903760NegligibleNegligible30037070
3506902547NegligibleNegligible27034550
HFO-Met
Co-FiringHFO
HFO-Met
Co-FiringHFO
HFO-Met
Co-FiringHFO
HFO-Met
Co-FiringHFO
SO2, mg/dNm3@15%Particulates
mg/dNm3@15%
CO,
mg/dNm3@15%
NOx, mg/dNm3@15%
Unit Load,
Mw
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Methanol Firing at FT4C TWIN PAC 50 MWe GT Unit
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Tested unit
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. TP TP --1 Base Plate Assembly1 Base Plate Assembly
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FT4 FT4 –– Engine & Power TurbineEngine & Power Turbine
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LinerLiner–– General viewGeneral view
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LinerLiner–– General viewGeneral view
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LinerLiner–– General viewGeneral view
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NozzleNozzle–– General viewGeneral view
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FO Atomizer AssemblyFO Atomizer Assembly–– General viewGeneral view
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FO Atomizer FO Atomizer –– General viewGeneral view
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FO Supply SchemeFO Supply Scheme
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Flame temperture distribution through liner length
1400
1450
1500
1550
1600
1650
1700
1750
1800
1850
1900
1950
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Calculation zone number
Tem
pera
ture
, C
Fuel oil#2
Methanol
Calculated Flame Temperature DistributionCalculated Flame Temperature Distribution
100% Load100% Load
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. Calculated Liner Wall Temperature DistributionCalculated Liner Wall Temperature Distribution
100% Load100% Load
Relative liner wall metal temperature reduction during
methanol burning
0.5
0.6
0.7
0.8
0.9
1
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Calculation zone number
Meta
no
l to
FO
#2 w
all
meta
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tem
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rati
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Comparison of Comparison of NOxNOx Formation Through Liner Formation Through Liner
Length for FO#2 and Methanol FiringLength for FO#2 and Methanol Firing
100% Load100% Load
NOx emission formation through liner length
0
50
100
150
200
250
300
350
400
450
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Calculation zone number
NO
x,m
g/d
Nm
3 @
15%
O2
,
Fuel oil#2, calculated
Methanol, calculated
Fuel oil#2, measured
Log. (Fuel oil#2, calculated)
Log. (Methanol, calculated)
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Upgrading for Methanol Firing Upgrading for Methanol Firing
Key DiagramKey Diagram
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. Methanol TestMethanol Test
Methanol tankMethanol tank
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piping connectionpiping connection
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Control Room DisplayControl Room Display
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Emission measurements Emission measurements
instruments general viewinstruments general view
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Average TT7 as function of GT load
Tamb=22-24C
800825850875900925950975
100010251050107511001125115011751200
0 5 10 15 20 25 30
GT load, Mw
TT
7, F
Oil#2 Methanol Power (Oil#2) Linear (Methanol)
Methanol TestMethanol Test
ResultsResults
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ResultsResults
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ResultsResults
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ResultsResults
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ResultsResults
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. Methanol TestMethanol Test
ResultsResults
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. Methanol TestMethanol Test
ResultsResults
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ResultsResults
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ResultsResults
Formaldehyde as function of GT load
0
5
10
15
20
25
0 5 10 15 20 25 30
GT load, Mw
Fo
rma
lde
hy
de
,
mg
/dN
m3
@1
5%
O2
Methanol
Formaldehyde Limit
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. Methanol TestMethanol Test
ResultsResults
5036.37132.0224.09.0
01.56306.756.510.0
0501.3613.78164.463.464.5269.013.6
0501.2813.28107.443.971.2296.916.0
5012.5923.0372.722.5
MetLFO#2MetLFO#2MetLFO#2MetLFO#2
SO2,
mg/dNm3@15%
Particulates
mg/dNm3@15%
CO,
mg/dNm3@15%
NOx,
mg/dNm3@15%GT Load,
Mw
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NEXT PHASE
• RESTORE CAPACITY• We need to double the fuel flow• We need to open the bottle necks:
– High Pressure Pumps (replaced by external pumps)
– Modulating valve (replaced by VSD)
– Pressure & Dump valves (internal strainer replaced)
– Spraying nozzles (replaced from Excello nozzles to Delevan)
• Two phase Test (In Eilat)– Run a short term test to check feasibility of such a system and validate
perfomance & low emissions
(2-3 weeks)
– Run a long term test to gain operational experience and confidence in the system
(2-3 years, 1500-2000 hrs each year)
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Fuel oil
Methanol
Filters
By others
ps
i
ps
i
Fuel SOVs
(shut-off valves)
gpm
gpm
75 HP
VSD
Engine
80 gpm
pump
40 gpm
pump
Control House
Mixing Block
30 HP
VSD
PEPCO Fuel Control Proposal for
dual Methanol system (one skid)
1.5” SS pipe
1.25” SS pipeInlet piping
both fuels 3”
400V 50Hz
~75KVA
Control Air 250-
110 psi
Motor power
wire from VSDControl wires:
2 digital outputs
2 analog inputs
2 analog outputs
PEPCO
Fuel Control
Control wires:2 digital outputs
6 digital inputs
5 analog inputs
Restoring Capcity – fuel control & external pumps
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Eilat test – restoring capicity
•Replacing nozzles to Delevan high flow
66
Adding external
high perssure pumps
67
Adapting fuel unloading and
storage sytem
• New unloading piping
• Tank adaptation – floating roof
68
Adapting fire fighting system
69
Fuel unlouding platform
70
Danger zone analysis
71
Time Schedule
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Engin
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Long Term Methanol Firing Long Term Methanol Firing
Modification in Modification in EilatEilat
The IEC in cooperation with Dor Chemicals are in advanced stage of the project converting FT4C TWIN PAC 50 MWe GT Unit in Eilat to mehanol firing.
The target is to collect long term data of operating the GT on methanol, which is scheduled to start later this year.
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Summary Summary
The results presented here clearly show that with minor lowThe results presented here clearly show that with minor low
cost fuel system retrofit methanol firing leads to significantcost fuel system retrofit methanol firing leads to significant
NOxNOx, , SO2SO2 and and particulatesparticulates emission reduction while similaremission reduction while similar
facilities performance characteristics are preserved. facilities performance characteristics are preserved.
We believe that the conclusions of the present work are general We believe that the conclusions of the present work are general and canand can
be applied to other boilers and gas turbines as well. be applied to other boilers and gas turbines as well.
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