1st International Oxyfuel Combustion Conference 3/2_Demonstration of t… · Full-scale testing of...
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Demonstration of the Doosan Babcock 40MWt OxyCoal TM 1 st International Oxyfuel Combustion Conference Combustion System 7 – 11 September 2009, Cottbus, Germany E D Cameron*, D W Sturgeon, C McGhie and F D Fitzgerald 10 September 2009 Research and Development Centre
Transcript of 1st International Oxyfuel Combustion Conference 3/2_Demonstration of t… · Full-scale testing of...
Demonstration of the Doosan Babcock 40MWt OxyCoalTM
1st International Oxyfuel Combustion Conference
Combustion System
y7 – 11 September 2009, Cottbus, Germany
E D Cameron*, D W Sturgeon, C McGhie and F D Fitzgerald, g , g10 September 2009Research and Development Centre
Contents
• Doosan Babcock Energy Limited• Doosan Babcock R&D Centre• Doosan Babcock R&D Centre• Doosan Babcock’s Oxyfuel Combustion Technology Roadmap (Past & Present)• OxyCoal 2 Demonstration of an Oxyfuel Combustion System• OxyCoalTM Combustion Modellingy g• OxyCoalTM Burner Test Results• Doosan Babcock’s Oxyfuel Combustion Technology Roadmap (Present & Future)
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Doosan Babcock Energy Limited
D B b k E Li it d i l b l lti i li t
• Doosan Babcock Energy:
Doosan Babcock Energy Limited is a global, multi-specialist, energy services company.
– Designs, supplies and constructs some of the cleanest, most efficient coal-fired power plant in the world
– Provides complete aftermarket solutions for lif t i ffi i i t dlife extension, efficiency improvement and emissions reduction of coal fired power plant
– Is a leading engineering services provider operating in thermal power nuclear oil andoperating in thermal power, nuclear, oil and gas, and petrochemical industries
• Over 5,000 experts, engineers and technologists, in 20 offices around the worldworld.
• Through constant innovation, we aim to provide the highest standards in cutting-edge science, new technologies and ground breaking engineering solutions
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ground-breaking engineering solutions.
Doosan Babcock R&D Centre - Technology Disciplines
R & D C t f b il d l t d t h l i E l iti d i ti
Boilers
R & D Centre for boilers and related technologies. Exploiting new and innovative technologies and supporting existing products for Doosan Babcock and Doosan Heavy global power business.
Boilers Development of market
leading, high performance products
Advanced Supercritical
Environment Development of effective NOx
and heavy metal emission reduction technologiesDevelopment of carbon Advanced Supercritical
Boilers POSIFLOWTM vertical tube
Development of carbon capture technologies (PCC & OxycoalTM)
Materials & Fuels
CFD & Software and ToolsAsset Management
D l t f t
Development and validation of materials for boiler pressure part components
Analytical analysis of wide CFD & Software and Tools Use of commercial codes for
isothermal and combustion modeling
Continuous development of a
Development of component monitoring systems
Advanced fault prediction methods New inspection methods and tools
T h i d l f lif l
range of fuels, including coal and biomass
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wide range of in-house tools Techno-economic models for lifecycle optimisation
Doosan Babcock’s Oxyfuel Combustion Technology Roadmap
For over 15 years, we have been a leading player in the development of low carbon technology.
1992 to 1995 2005 to 2008 2005 to 2008 2007 to 2009 2008 to 2010
• Pulverised Coal • Oxy Combustion • CO2 Capture • OxyCoal 2• OxyCoal-UK:Pulverised Coal Combustion System for CO2Capture
Oxy Combustion Processes for CO2 Capture from Power Plant
• Development and
CO2 Capture Ready Power Plants
• Enhanced Capture of CO2
OxyCoal 2 Demonstration of an Oxyfuel Combustion System
OxyCoal UK: Phase 1 –Fundamentals and Underpinning T h l iExperimental
Validation of a Mathematical Modelling Methodology for
• Future CO2Capture Options for the Canadian MarketC l Fi d
Technologies
Methodology for Oxy-Fuel Combustion for CO2 Capture in Large Power Pl t
• Coal-Fired Advanced Supercritical Retrofit with CO2Capture
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Plantsp
OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
The OxyCoal 2 collaborative project is led by Doosan Babcock and supported by the Department of Energy and Climate Change.
Prime SponsorLead Company
University Participants
SponsorsUK Government Support
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SponsorsUK Government Support
OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
During Summer 2009, Doosan Babcock Energy has commenced its 40MWt OxyCoal™ demonstration, the world’s largest demonstration of an oxyfuel combustion system.
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OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
Testing a burner of the type and size applicable to new build and retrofit coal-fired boilers.
• Demonstrate operational envelope and performance of the OxyCoal™ burner
– Flame stability– Flame Shape– Turndown– Start-up– Shutdown– Transition between air and oxyfuel firing– Furnace heat transfer characteristics– CO22
– NOX
– Carbon in ash
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OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
Full-scale testing of the oxyfuel combustion process on Doosan Babcock’s 90MWt Clean Combustion Test Facility (CCTF).
• Start-Up / Light-Up• Air Heavy Fuel Oil Firing• Air Coal Firing• Transition• OxyCoal Firing• Shutdown
• Heavy Fuel Oil– 3000 litres
• Kellingley Coal• Kellingley Coal– up to 50 tonnes
• Liquid Oxygen– up to 100 tonnes
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OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
Halifax Fans: Primary FGR Fan
• VSD Control• Power: 160 kW
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OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
Halifax Fans: Secondary FGR Fan
• VSD Control• Power: 400 kW
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OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
Air Products: Oxygen Storage Plant
• Design: 40MWt for 8 hrs/day• 3 off Liquid O2 Storage Tanks• Capacity: 50,000 litres each• 8 off Ambient Vaporisers
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• Design Pressure: 25 Barg
OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
Air Products: Oxygen Flow Control Skid
• Design: 70MWt• Primary FGR Injection
– Design O2 Conc. 21% v/v• Secondary FGR Injection
Max O Conc 45% v/v
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– Max O2 Conc. 45% v/v
OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
Davidson Clark: FGR Cooling System
• Dry Primary / Transport FGR• Dry Primary / Transport FGR• Closed Loop system• 2 off Cooling Columns (Primary / Transport)• 1 off Dual Cell Watermiser GRP Cooling Towers
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g• 1 off 12,800 litres Condensate Tank
OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
Fawcett Christie Hydraulics: Primary FGR Heater
S S• Heating medium: Superheated Steam• 2 off banks of finned tubes• Design Pressure: 15 Barg• Target PFGR Temperature: 110ºC
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Target PFGR Temperature: 110 C
OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
Heat Flux Probes
10 ff IFRF T t l H t Fl D i• 10 off IFRF Total Heat Flux Design• Water Cooled• Investigate difference between Air and Oxyfuel firing
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OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
Gas Measurement Instruments: Carbon Dioxide Detection System
• Active 80 multi channel gas monitoring system• 6 off CO sensors 0 5m off the ground• 6 off CO2 sensors, 0.5m off the ground• Visual and Audible alarm• Alarm level 1: 0.5% v/v (LTEL for CO2)• Alarm level 1: 1.5% v/v (STEL for CO2)( 2)
X4
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OxyCoal 2 – Demonstration of an Oxyfuel Combustion System
• Based on current low NOx air-fired burner technology
OxyCoalTM Burner Design
technology– Compatible with existing plant for retrofit
purposes– Exploits range of potential operating
conditions for both Oxyfuel and air firingy g
• Uniform “simulated air” flue gas composition and design recycle rate based on the consideration of heat transfer
taspects
• For Oxyfuel operation the volumetric flow rate and oxygen content of the primary gas i i t i d i fi i
Close-up of Burneris maintained as per air firing
• The overall stoichiometry is 1.2, and the flue gas recycle rate chosen to give an di b ti i l t t i ti
p
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adiabatic equivalent to air operation
OxyCoalTM Combustion Modelling: Temperature
• Modelling of a full scale OxyCoal™ burner in air staged and single stage oxyfuel firing modes showed acceptable flame characteristics and emissions performance
• A narrower hotter flame with increased burnout was predicted for oxyfuel at 66% recycle;• A narrower, hotter flame with increased burnout was predicted for oxyfuel at 66% recycle; flame cools as recycle rate increases
Temp (oC)Temp. (oC)
Air Firing Oxyfuel Firing: 75% FGR
Oxyfuel Firing: 66% FGR Oxyfuel Firing: 80% FGR
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OxyCoalTM Combustion Modelling: Carbon Monoxide
• Local CO concentrations in the flame can be much higher under oxyfuel firing conditions, especially at lower recycle rates (lower volume of gas in furnace)
• Exit concentrations are broadly comparable with air firing
CO (vppm)
Air Firing Oxyfuel Firing: 75% FGR
Oxyfuel Firing: 66% FGR Oxyfuel Firing: 80% FGR
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OxyCoalTM Burner Testing
Preliminary results
Air Firing Oxyfuel Firing
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OxyCoalTM Burner Testing
Preliminary results – wall heat flux
Oxyfuel Air
eat F
lux
H
Si il FEGT d h t fl
Oxyfuel has lower heat flux & less peaky distribution due to FGR dilution effect in flame
Axial Distance From Burner Inlet
Similar FEGT and heat flux towards furnace exit
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Doosan Babcock’s Oxyfuel Combustion Roadmap
Through our investment in R&D we continually look for innovative ways to create a low carbon future.
• OxyCoal 2 – • Optimisation of • 1000MW Oxyfuel• Front End
2008 to 2010 2008 to 2010 2009 to 2011 2009 to 2015 2020
• Impact of HighOxyCoal 2 Demonstration of an Oxyfuel Combustion System
Optimisation of Oxyfuel PF Power Plant for Transient Behaviour
1000MWe Oxyfuel Power Plant
• Commercialisation
Front End Engineering Design Studies
• 100 to 250MWeOxyfuel
Impact of High Concentrations of SO2 and SO3 in Carbon Capture Applications and Miti ti• Optimised
OxyCoal Combustion
DemonstrationPower Plants
Mitigation
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Concluding Remarks
Doosan Babcock is developing the capability to provide competitive oxyfuel firing technology suitable for full plant application post-2010.
• Doosan Babcock has established a dedicated Carbon Capture Business Group to commercialise Carbon Capture technologies.
• We are undertaking front end engineering design (FEED) studies for utility clients’ Oxyfuel power plants.Oxyfuel power plants.
• We aim to design, supply and construct an oxyfuel power plant of similar scale that will be operational by 2015 and awill be operational by 2015, and a 1000MWe oxyfuel power plant by 2020.
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Contact Details
Doosan Babcock is committed to delivering unique and advanced carbon capture solutions.
Euan CameronSenior Engineer R&DE [email protected]
Dr David FitzgeraldSenior Engineer R&DE [email protected]
Doosan Babcock Energy,Porterfield Road,RENFREW.
Mark BryantDirector Carbon CaptureE [email protected]
PA4 8DJ
T +44 (0)141 886 4141y @
Peter Holland-LloydBusiness Development ManagerE pholland-lloyd@doosanbabcock com
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