RESEARCH ACIVITIES IN OXY-COMBUSTION

National Centre for Research and Development Strategic Programme Advanced Technologies for Energy Generation RESEARCH ACIVITIES IN OXY-COMBUSTION Professor Wojciech Nowak AGH University of Science and Technology, Krakow,Poland Meeting TOTem 41, Warsaw June 10-11, 2014

What are the possibilities? Pre-combustion developed under the Strategic Project: Research Tasks No. 3 Post-combustion: Strategic Project: Research Task No. 1 Strategic Project: Research Task No. 2 Source: Vattenfall Materials OXYFUEL COMBUSTION in PC and CFB Boilers 2

National Centre for Research and Development Strategic programme (started in May 2010) Advanced Technologies for Energy Generation 1. Development of high-efficiency, zero-emission technology for coal power plants integrated with CO 2 capture 2. Development of oxy-combustion technology for pulverised and fluidized bed boilers integrated with CO 2 capture Institute is the Leader 3. Development of coal gasification for effective power and fuel production 4. Development of integrated technologies for production of fuels and energy from biomass, agriculture and other wastes 3

Development of technologies for highly efficient zeroemission coal-fired power units integrated with CO 2 capture from combustion gas the development and verification of new concepts of the improvement in the cycle efficiency of condensing power stations the development and testing on a pilot scale the processes of CO2 capture from exhaust gas the finding of technological solutions to reduce efficiency losses related to the removal of CO2 from exhaust gas

Development of technologies for highly efficient zero-emission coalfired power units integrated with CO2 capture from combustion gas THEMATIC GROUP 1 Development of a set of algorithms and programmes for a full and plausible simulation of the operation of a power unit with a complex technological structure under various loads, with consideration given to the processes of CO 2 separation THEMATIC GROUP 2 Identification, examination and testing of the new concepts of improvement in efficiency of coal technologies of electricity and heat generation THEMATIC GROUP 3 Development of new methods and systems of operational supervision, methods of risk assessment, and planning the diagnostic-repair management for blocks THEMATIC GROUP 4 Optimization analyses, systemic and techno-economic studies laying foundation for the introduction of the 50+ unit (unit with efficiency exceeding 50%) into the Polish power industry THEMATIC GROUP 5 Pilot testing of the processes of CO 2 capture from exhaust gas for various classes of sorbents THEMATIC GROUP 6 Research and technological designs for the integration of CO 2 capture installations with coal-fired thermal power stations (electric power stations and thermal-electric power stations) THEMATIC GROUP 7 Determination of the technical and economic feasibility of the improvement in the efficiency of crude oil extraction with partial retention of CO 2 in geological structures with a considerable financial commitment of industrial partners 5

Introduction: Development of oxy-combustion technology for pulverised and fluidized bed boilers integrated with CO 2 capture What is the problem? What is the solution? What are the possibilities? Idea and technological options

Flue gases from oxy-fuel combustion boilers are almost pure CO 2, which allows its immediate sequestration Oxy-fuel combustion is suitable for modernization of old boilers, only by addition: ASU - Air Separation Unit, CPU - CO 2 Processing Unit and FGR - Flue Gas Recirculation 7

Technology options Pulverized coal boiler CFB boiler Pressurized CFB boiler All three options are being considered in Research Task No. 2 8

Aim of the project Technical readiness up to industry-scale demonstration of oxy-fuel combustion plant integrated with CO 2 purification and sequestration T h e s p e c i f i c o b j e c t i v e s Recommendation of one of three coal combustion technologies (PC, CFB, PCFB) Assessment of current power systems by adapting operated / depleted units to oxy-fuel combustion boilers Indicate the directions of clean coal technology development in Poland 9

Consortium 10

Project structure 11

flow reactor D r o p f u r n a c e 0xygen Combustion PROCESS ANALYSIS Air Combustion scanning electron microscope (SEM) Coal Fragmentation Structural Analysis - Advanced measurement methods behavior of individual fuel particles Atomic force microscope (AFM) TG-FTIR-MS Experimental studies, measurement systems 12

Oxy-combustion in PC and CFB boilers CFB, PC STEAM CYCLE ASU INTEGRATION CO 2 sequestration possible conceptions: chemical absorption physical absorption membrane techniques cryogenic separation 13

Probe material (SUMITOMO) Simullations Location of probes Experimental validation of models Corrosion tests in a 154 MWt CFB boiler ignition of coal dust propagation of coal dust 14

CO 2 and O 2 supply fuel supply control system 0.1 MW th CFB pilot plant 15

Slight increase in T below SG level Even profile of T above SG level Pressure loop remains in agreement with typical pressure balance around CFB loop (Basu P., Fraser S.A., 1991) Five zones along height of combustion chamber can be distinguish (Kunii D., Levenspiel O., 1991) Control room - PrtSc 16

Pilot-plant research 0.2 MW th PCFB pilot plant 30 kw bubbling fluidized bed 17

fuel preparation 0.5 MW th PC pilot plant gas supply system 18

Oxygen generator Pressure Swing Adsorption (PSA) on zeolite bed Separation of oxygen Membrane method using perovskite materials Oxygen purity of 95% - recommended for oxy combustion production of membranes Oxygen liquefaction and final purification membrane oxy-genation material structure 19

Powietrze wtórne PRESSURIZED OXY BUBBLING FLUIDIZED BED REACTOR Analiza gazów Gas cooler Chłodnica gazowa T Water cooler Chłodnica wodna P T odpylacz Dust filter T P Odbiór ciekłych produktów z wychłodzenia gazu procesowego P T T M T P T Steam generator Wytwornica pary ze zbiornikiem wody DP F F Mikser/ zawirowywacz T O2, T T P P T T T F Podgrzewacz powietrza pierwotnego T N2 O2 CO2 F Podgrzewacz powietrza wtórnego Parameter Unit Reactor diameter mm 75 (50/120) Reactor height mm 1000 Fuel flow kg/h 0,5-3 Oxidizer (mixture) - O2/CO2/N2 Max. temperature C 1100 Max. pressure bar 15

General idea of population balance of CFB boilers 21

Numerical simulations CFB combustion chamber Solids hold-ip in CFB Numerical simulations of CFB 22

Numerical simulations of oxy PC Thickness of deposits Coal burners in PC combustors F o u l i n g m o d e l Air combustion Oxy combustion 23

Barracuda simulations of 0.1 MW th CFB oxy-fuel combustor - CPFD numerical method (computational particle fluid dynamics) is a hybrid of numerical methods for a fluid (continuum phase) and particulates (discrete phase); fluid phase is treated with Eulerian formulation (CFD), and particles with Lagrangian formulation (CPFD = CFD (for fluid) + solids) - Unlimited particle and gaseous species - Particle-wall deflections, particle stress tensor, particle-particle collisions - 3D simulations with particle size distribution (PSD) defined by user and chemical reactions 24

CO 2 capture and processing 25

Production of sorbents based on fluidized bed ash POWER PLANTS FLY ASH COMBUSTION BY-PRODUCTS CARBON DIOXIDE MERCURY SURFACE OF FLY ASH SURFACE OF ZEOLITES CO 2 CAPTURE Hg REMOVAL FLY ASH-BASED PRODUCTS ADSORPTION PSA TSA VSA PTSA MEMBRANES ADSORPTION utilization of petroleum-derivatives Removall of odor Clean water and air Soil decontamination develop an effective fly ash-based sorbent (mainly microporous zeolites) for the removal of gaseous pollutants (including CO 2 and Hg) and petroleum contaminants. 26

Na-A zeolite Na-P1 zeolite 27

CO 2 processing from CFB oxy combustor 4 kolumn VPSA installation for CO 2 processing from 0.1 MW oxy-fuel CFB combustor full laboratory scale capacity 5 m 3 /h adsorption pressure 180 kpa desorption 30 kpa temperature 40 o C SO2, NOx removal in carbon bed 28

Process integration Integration of oxy-fuel combustion CFB boiler with CO 2 sequestration 29

CO2 recovery [%] CO2 purity [%] Efficiency [%] CO2 Recovery 96.00 95.00 94.00 93.00 40 90 140 Flu gas temperature [ C] CO2 Purity 95.55 95.50 95.45 95.40 40 90 140 Flu gas temperature [ C] Efficiency 46.40 46.20 46.00 45.80 45.60 40 90 140 Flu gas temperature [ C] 30

Combustion chamber hight, m air Temp, 0 C Heat flux, CO2 O2 Heat flux, kw kw air 1224 189 19.41 4.63 Instytut Techniki Cieplnej www.itc.polsl.pl Konarskiego 22, 44-100 Gliwice OOXY1, 24% OXY2, 30% O2 1155 163 91.20 3.57 1228 183 89.98 3.71 31

Feasibility study CFB demo scale: CO2 purification Case study: Tauron Łagisza 460 MWe supercritical OTH CFB boiler Flue gas channel from CFB boiler Connection to PSA installation Control room PSA installation to capture CO2 32 Projekt Strategiczny - Zadanie badawcze nr 2 prof. dr hab. inż. Wojciech Nowak

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Feasibility study CFB demo scale: CCS Case study: PGE GiEK SA Turów 3 235 MWe CFB + 3 260 MWe Compact CFB + 460 MWe new PC CO2 pipelines to geological storage Pipelines routs Pipelines shortest rout Power plant Geological structure Nature 2000, 34

RealTime3D SOLUTION FOR DEMO OXY PROJECT 30 MW Tauron Lagisza Power Plant

Pre-feasibility study 30 MW e CFB and PC demo scale VR model integrates objects and datas from different applications 36

Understanding the population of German federal states Awareness of the Polish population N I M B Y S y n d r o m e L U L U S y n d r o m e N I M E Y S y n d r o m e Not In My Back Yard Locally Unacceptable Land Use Not In My Election Year 37

Pre-feasibililty study of high-efficient, multi-fuel and flexible oxy-fuel demo plant with a capacity of 30 MWe Three technological options (PC, CFB, PCFB) Pre-feasibility study of CFB technology with CCS for large-scale CFB power plants PGE GiEK SA Turów Power Plant: total 1485 MWe CFB Tauron Wytwarzanie SA Łagisza Power Plant 460 MWe supercritical CFB unit 38

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Contact: Prof. Wojciech Nowak AGH University of Science and Technology Centre of Energy, Director Krakow, Poland wnowak@agh.edu.pl 40