oxyfuel pulverized coal steam gtdl tgenerator … 1/alstom_oxpp_iea... · 30 mwth pilot steam...

Oxyfuel Pulverized Coal Steam G t D l tGenerator Development

30 MWth Pilot Steam Generator Commissioning and TestingCommissioning and Testing

F. Kluger, P. Mönckert, B. Krohmer, G.-N. StamatelopoulosAlstom

J. Jacoby, U. BurchhardtVattenfall

1st IEA GHG International Oxyfuel Combustion Conference1st IEA GHG International Oxyfuel Combustion Conferencest G G te at o a O y ue Co bust o Co e e ceCottbus, Germany

8 - 11 September 2009

st G G te at o a O y ue Co bust o Co e e ceCottbus, Germany

8 - 11 September 2009

Agenda

Alstom’s Oxy PC Development Roadmap

Oxyfuel Pilot Steam Generator – Realisation & DescriptionOxyfuel Pilot Steam Generator – Realisation & Description

Oxyfuel Pilot Steam Generator – Results from OperationOxyfuel Pilot Steam Generator – Results from Operation

SummarySummary

Next StepsNext Steps

Roadmap Oxy PC DevelopmentStatus and Next Steps

Pilot Plants Demonstration Full-ScaleLab ScaleSource: VattenfallSource: Vattenfall

2008 2014-15 < 2020

30 MWth Oxy PC Lignite & Bit. Coal

200 – 300 MWelOxy PC Lignite

Up to 500 kWth Oxy PC Lignite & Bit Coal Testing

2004

gSchwarze Pumpe, Germany (Vattenfall, Alstom)

Oxy PC Lignite (e.g. Vattenfall Jänschwalde, Feasibility Study Performed with

400 – 1,100 MWelOxy PC Lignite

Lignite & Bit Coal Testing

Uni Stuttgart, Uni Cottbus, Uni Hamburg-Harburg, Uni Dresden

30 MW Oxy Gas Alstom Contribution)

ENCAP (EC Co-funded Project),ADECOS I & II (GER Co-funded Project), OxyBurner (EC Co-funded Project),

30 MWth Oxy Gas Natural Gas & Oil Lacq, France (TOTAL, Alstom) 200 – 300 MWel

Oxy PC Bit. Coal600 – 1,100 MWelOxy PC Bit. Coal(EC Co funded Project),

OxyCorr (EC Co-funded Project), etc.

15 MWth Oxy PC Bitum. Coal & Lignite Windsor, CT, USA (DoE, Alstom)

y

Agenda

Alstom’s Oxy PC Development Roadmap Alstom’s Oxy PC Development Roadmap

Oxyfuel Pilot Steam Generator – Realisation & Description


SummarySummary


30 MWth Oxyfuel Pilot Plant - Realisation

As planned... Milestones

ct

ssio

n

Pre

ssur

e

Firs

t n oa

l Fire

xy-F

iring

onne

CO

2ed

Con

trac

Awar

dP

erm

is

Hyd

ro P

Test

PAC

Lift

of F

Col

umn

Firs

t Co

Firs

t Ox

Firs

t To

Cap

ture

6 7 7 8 8 886As realizedMain Data

11/’0

6

07/’0

7

11/’0

7

07/’0

8

08/’0

8

12/’0

8

09/’0

8

04/’0

6Thermal Capacity: 30 MWthSteam Production: 40 t/hSteam Pressure: 25 barSteam Temp : 330 °CSteam Temp.: 330 CFuel: Lignite / Bit. CoalFuel demand (Lig.): 5.2 t/hO2 demand: 10 t/h

Source: Vattenfall

2CO2 (liquid): 9 t/hCO2 capture rate: >90 %Start operation: 2008

30 MWth Oxyfuel Pilot Plant – Process Scheme & Alstom Scope

Primary Flue Gas Recycle

Coal Dust

Burner

y y

Steam

GasSteam-

HEXSeal Gas <1,2 bar

Seal Gas 6 bar

Dry sorbent

Furnace

Steam-HEX Air

Ammonia

Filter FGC CO2-ProcessFGD

2nd Path

De-NOx ID Fan 1 ID Fan 2S d Fl

Steam-

3rd Path

Air

Nitrogen

Secondary Flue Gas Recycle

Ash

HEX

AirASUSteam-HEX

Air

Oxygen

30 MWth Oxy-Combustion Pilot Plant –Key Information

• Single burner & indirect firing system testing

Key information generated for the next Oxy-combustion development steps:

• Combustion fundamentals (emissions, burnout, fouling & slagging, excess oxygen, flue gas recycle ratio etc.)• Heat transfer (radiation, convection)• Material selection (corrosion issues)

• Operational data for validation of oxyfuel CFD models

• Dynamic behaviour of entire oxy-combustion l t (St t / h t d it h i tplant (Start-up / shut down, switch air to oxy

and vice versa)

• Interaction of ASU, Boiler, AQCS and GPUFlue-gas flow Intakeair damper Flue-gas recycledamperFlue-gas flow Intakeair damper Flue-gas recycledamper

• Control loops for oxy-combustion process and plant

• Integration Options

Flue gas flow

Oxidant flow

Air flow Recycled flue-gas flow

Intakeair damper Flue gas recycle damperFlue gas flow

Oxidant flow

Air flow Recycled flue-gas flow

Intakeair damper Flue gas recycle damper

• Component Optimisation

• Achievable CO2 capture rate and quality07:50 08:00 08:10 08:20 08:30 08:40 08:50 09:00 09:10 09:20

O2 from ASU

07:50 08:00 08:10 08:20 08:30 08:40 08:50 09:00 09:10 09:20

O2 from ASU

30 MWth Oxyfuel Pilot Plant - Boiler

BurnerIgnitionB

DeNOx-OptionBoiler Design DeNOx (optional)

ECO 5

HEX Gas Catalyst 1

Burner

SH 1ECO 4

y

Catalyst 2

SH 2 ECO 3

ECO 2B t

Catalyst 3

ECO 1

ESPHydratedLime

BurnoutOxydant

30 MWth Oxyfuel Pilot Plant – Burner / Firing System Operating Modes

OxPP : 1 x 30 MW30 MWthth

Dried lignite / Transport air

Core air core : Air

Seco

ndar

y air surround1 : Air

surround2 : Air

surround3 : Air

Air operation

core : Oxygen+RFG* core : RFG*

surround1 : Oxygen+RFG*



surround1 : RFG*

surround2 : RFG*

surround3 : Oxygen

Oxyfuel operation(premixed oxygen)

*RFG = Recirculated Flue Gas

Oxyfuel operation(direct oxygen injection)

*RFG = Recirculated Flue Gas

30 MWth Oxyfuel Pilot Plant – Oxy-Firing Operation Modes

Burner

Burner

Burner

Combustion chamber

2. Pass

Combustion chamber

2. Pass

Combustion chamber

2. Pass

(DeNOx)

3. Pass

(DeNOx)

3. Pass

(DeNOx)

3. Pass

Oxygen

Recycle

Oxygen

Recycle

Oxygen

Recycle

– Oxyfuel –Pre-mixed Mode

– Oxyfuel –Expert Mode A

– Oxyfuel –Expert Mode B

Agenda



Oxyfuel Pilot Steam Generator – Results from Operation

SummarySummary


Results from OperationSwitch From Air-Firing to Oxy-Firing

Mass flows (Air, Oxidant, Flue gas)

Flue-gas flow Intakeair damper Flue-gas recycle damperFlue-gas flow Intakeair damper Flue-gas recycle damper

~ 20 – 30 min

Oxidant flowOxidant flow

Air flow Recycled flue-gas flowAir flow Recycled flue-gas flow

O2 from ASUO2 from ASU

07:50 08:00 08:10 08:20 08:30 08:40 08:50 09:00 09:10 09:2007:50 08:00 08:10 08:20 08:30 08:40 08:50 09:00 09:10 09:20Time

Results from OperationSwitch From Air-Firing to Oxy-Firing

~ 45 – 60 minFlue Gas Species

CO2 >85 vol.-% (dry) after ESP

Thermal performance

~ 20 – 30 min

SO2

H2O ca. 28 vol.-% after ESP

O2NO

xCO

07:50 08:00 08:10 08:20 08:30 08:40 08:50 09:00 09:10 09:20Time

Results from Operation - Burner / Firing System (Air-Firing)

• Burner operates in a stable and reliable way

• Limits for emissions kept easily for airLimits for emissions kept easily for air mode of operation

• Primary measures for NOx reduction appliedapplied

• Typical emission values are:Dust << 20 mg/Nm³ (dry)CO < 100 mg/m³ (dry)

Air-FiringCO < 100 mg/m (dry)NOx < 300 mg/m³(dry)SO2 < 1,000 mg/m³(dry)O2 < 4 vol.-% (wet)2 ( )

• Good burnout with low unburnt carbon in fly ash and slag

• Hydrated lime injection for SO2 controlHydrated lime injection for SO2 control causes fouling in the economizer heating surfaces

Results from Operation - Burner / Firing System (Oxy-Firing – Pre-mixed Mode)

• Burner operates in pre-mixed mode in a stable and reliable way with an oxygen concentration in the oxydant of 28 Vol.-%.y

• Limits for emissions kept easily for oxyfuel mode of operation

• Primary measures for NO reductionPrimary measures for NOx reduction applicable but not required

• Typical emission values are:Dust << 20 mg/Nm³ (dry)Dust << 20 mg/Nm (dry)CO < 300 mg/m³ (dry)NOx < 700 mg/m³(dry)O2 < 4.5 vol.-% (wet)

Oxy-Firing (pre-mixed mode)

2 ( )• Good burnout with low unburnt carbon in

fly ash and slag• In oxyfuel mode operation longer responseIn oxyfuel mode operation longer response

time due to the flue gas recirculation

Results from OperationCO-Concentration

Comparison of different operation modess

Expert Mode A

mis

sion

s

Pre-mixed Mode

Expert Mode B

CO

Em

O2 Concentration in Flue Gas

Results from OperationNOx-Concentration

Comparison of different operation modess Expert Mode

mis

sion

s Expert Mode A

NO

x Em Pre-mixed

Mode

Expert Mode B

O2 Concentration in Flue Gas

30 MWth Oxyfuel Pilot Plant – Status of Operation as End of August 2009

35

30nt (v

ol.-%

)

30

n in

Oxi

dan

Oxyfuel - Pre-mixed Mode -

25

ncen

trat

ion

Oxyfuel - Expert Mode -

20

O2 C

on

Air20

2 3 4 5 6 7O2 Concentration in Flue Gas (vol.-%)

30 MWth Oxyfuel Pilot Plant – Status of Operation as End of August 2009

Total Operation 3,100 h

Air Operation 1,500 h

Oxyfuel Operation 1,600 h

• Burner Pre-mixed Mode 1,000 h

• Burner Expert Mode 600 h

Agenda




Summary of Oxy-Steam Generator Pilot Experience to Date


Summary of Oxy-Steam Generator Pilot Experience to Date

Design approach for thermal design and firing system design confirmed in practical operation

M d it h f i d t d d i k i Mode switch from air mode to oxy mode and vice versa works easier than originally anticipated

All contractually fixed parameters are met for air and oxy combustiony p y

CO2 concentrations in the flue gas downstream of the boiler >85 Vol-% dry

Oxy-Firing “Expert Mode” results in lower flue gas oxygen concentration compared to the “Pre-Mixed Mode”, O2 values below 3 Vol.-% can be achieved

Burner and firing system has demonstrated its high flexibility with good performance

Test program under execution Data for CFD model development and Test program under execution. Data for CFD model development and validation, dynamic behaviour, heat transfer etc. already generated. Extensive material testing under execution.

Agenda




SummarySummary

Next Steps

Next Steps – Testing of Alternative Alstom Burner Design

OxPP : 1 x 30 MW30 MWthth

Dried lignite / Transport air

Core airDesign A Design B

Seco

ndar

y air

Main features

• Each burner compartment can be individually enriched with oxygen up to

Main features

• Each burner compartment can be individually enriched with oxygen up toindividually enriched with oxygen up to

39 Vol.-%

• One swirl device

individually enriched with oxygen up to 39 Vol.-%

• Two swirl devices

• Ring of lances for 100% oxygen injection

• Separate ignition burner for start-up

• Annular clearance for 100% oxygen injection

• Integrated gas lance for start-up

Next Steps – Testing of Alternative Alstom Burner Design

• Testing of firing system and burner Air Mode

Oxy Mode- Pre-mixed Mode- Expert Mode A- Expert Mode B

• Measurements Gaseous Emissions Gaseous Emissions,

Ashes, Deposits

Corrosion

Heat Transfers Detailed in-flame measurements for

CFD modeling g

Thank You For Your Attention !

www.alstom.com


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oxyfuel pulverized coal steam gtdl tgenerator … 1/alstom_oxpp_iea... · 30 mwth pilot steam...

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