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Advanced Oxy- Fuel Boilers

&

CO2 Sequestration
BY

P A T HFIN D E R
GROUP-

2&3

Presentation Outline
Program goal and background Conceptual design of the Advanced Boiler for

Economic advantages
Present laboratory-scale tests Summary

Program Goal

Develop and commercialize a novel high efficiency boiler or process heater that can provide a CO2-rich product stream that can be inexpensively purified and compressed for Sequestration

A novel process for CO2 sequestration is proposed utilizing a supercritical oxygen-fired PC boiler, which, as part of a Rankine steam cycle, forms a high efficiency, zero emission, stack less power station. Coal is combusted in the furnace where the oxidizer consists of a mixture of O2 and recycled flue gas, which contains primarily CO2 gas.

The effluent of the plant is virtually pure

CO2, which is condensed, pressurized, and piped from the plant to the sequestration site.

Since the onset of the industrial age, CO2 concentrations in the Earths atmosphere have increased by about 1-2 ppm per year. This represents a 35% increase in the atmospheric CO2 concentration in less than 200 years. This increase may have a profound effect in causing global climate change. Increased atmospheric CO2 concentrations may not only cause solar energy to be trapped in the atmosphere but may also increase the acidity of the ocean due to increased CO2 dissolution .

CO2 capture technologies


CO2 capture technologies are based upon three general

concepts:

post-combustion capture, pre-combustion capture, and oxy fuel combustion.


Post-combustion refers to capturing CO2 from a flue gas after a fuel has been combusted in air. Pre-combustion refers to a process where a hydrocarbon fuel is gasified and water-gas shifted to form a mixture of hydrogen and CO2 and CO2 is captured from the synthesis gas before it is combusted. Oxy fuel (or O2-fired) combustion is an approach where a hydrocarbon fuel is combusted in a mixture of oxygen and carbon dioxide rather than air to produce an exhaust of a mixture of CO2 and water vapor.

Post-combustion capture is conceptually the simplest method of CO2 removal.

Advantages.
Oxy-fuel fired boiler

Improve thermal efficiency Increase fuel savings Simplify and reduce the cost of CO2 capture Ultra-low NOx emission Thermal integration of O2 separation for the boiler causes reduced operating and capital costs for oxy-fuel system

Oxygen source

Traditionally by external air separation unit high cost Oxygen Transport Membranes (OTM)

Conventional OTM Process

OTM-Dilute Oxygen Combustion Concept

OTM-Reactive Purge Combustion Concept

Conceptual OTM Boiler Process

Ash removal is accomplished in a dust removal device (such as an electrostatic precipitator), which is located between the recuperator and the wet-end economizer. The cold flue gas exits this wet-end economizer and contains primarily CO2 (over 90% by mass) and small amounts of O2 and H2O. The cold flue gas is split into two streams: 1) recycled to the furnace through the recuperator (55 70% flue gas flow) and 2) compressed and condensed to produce a liquid effluent (30 45% flue gas flow). The preheated recycled flue gas is split into primary and secondary streams. The primary stream, without O2 addition, is sent to the coal pulverizers, where it is used for drying and transport of the pulverized coal, and exits the mill at a temperature 250 350F.

Economics Case Study


Conventional Boiler Capital Cost (INR) Boiler 276000000 414000000 Advanced OTM boiler

Annualized capital cost Operating Costs(INR)


Annual Fuel @Rs230/MMBTU Annual Power @ Rs2.07/kWh Annual Cost of Oxygen(INR) Total Operating Costs Combined annual Cost

47196000

70794000

1347800000 2438000

1209800000 69000000

1350238000 1397434000

1278800000 1349594000

Oxy-fuel fired boiler Improve thermal efficiency 2 year payback

Economics Case Study


Conventional Boiler Capital Cost (INR) Advanced OTM boiler

CO2 Capture System Annualized capital cost Operating Costs (INR)

1,403,000,000 239,890,000

276,000,000 47,196,000

Annual Steam @230/MMBTU Annual Power @ 2.07/kWh Annual Chemicals Total Operating Costs Combined annual Cost Net Supercritical CO2 Cost

269,422,000 96,600,000 69,000,000 435,022,000 674,912,000 1886/ton 35,650,000 82,846,000 230/ton 35,650,000

Laboratory-scale Tests
OTM material development

thermal and mechanical stability long-term operation reliability high oxygen transport flux cost effective OTM tube manufacturing

Thermal integration of OTMs with fuel combustion

Multi-tube OTM reactor

temperature control and heat transfer

complete and efficient combustion


very low NOx more detailed capital cost estimate to meet requirements for cost effective CO2 capture

OTM Material Development


Ceramic membrane is key to program success Membrane performance tests occur at severe operating

conditions

Membrane material optimization in progress Robust

porous support

no tube failures when exposing to fuel

no tube failures during thermal cycles


no tube failures despite events with rapid cool down

Multi-tube OTM Reactor

Flow Diagram of Multi-tube OTM Reactor

Technology Roadmap

Overall power plant system and component designs are presented for a 475 MW (gross) supercritical coal-fired plant. The power plant system cycle was optimized to minimize the overall power plant heat rate and facilitate CO2 sequestration.

Models of Air-Fired and O2-Fired Furnaces (with right side wall removed)

Gas Temperature

Wall Heat Flux

Oxygen fired Burner

Summary
Advantages of thermally integrated OTM boiler

Utilize OTMs to supply oxygen for combustion, eliminating the need of an external air separation unit. Produce high purity CO2 exhaust, significantly reducing the cost of CO2 capture. Improved efficiency provides economic incentive for commercialization.

Current laboratory-scale tests

OTM material development to demonstrate material stability and sufficient oxygen flux Multi-tube OTM reactor experiments to understand the thermal integration of OTMs with fuel combustion

Thanks
PRESENTED BY COORDINATOR: MR. P.K.SAHA SPEAKER SANDEEP SAHU BANAMANLI MOHANTA PRANAY NAYAN

Oxy-fuel refers to technology that burns oxygen with

gaseous fuel. As compared to air, which contains 20.95% oxygen, higher temperatures can be reached using pure oxygen. Approximately the same total energy is produced when burning a fuel with oxygen as compared to with air; the difference is the lack of temperature diluting inert gases. The most common fuel burned in a torch with oxygen is acetylene; even though it presents special handling problems, it has the greatest heat output. The process has also been proposed as a method of capturing carbon dioxide from coal-fired electric power plants because the output flue gases from combustion in oxygen as opposed to air have a higher carbon dioxide content fraction.

1= air inlet 2= mechanical energy is supplied 3= nitrogen outlet 4= oxygen outlet 5= recycled exhaust gas inlet 6= fuel inlet (ie coal, ...) 7= cold water pipe 8= steam inlet pipe 9= steam turbine 10= steam outlet pipe 11= steam condensor 12= cooling pipe of steam condensor 13= bottom ash 14= fly-ash removal 15= sulpher + gypsum removal 16= cooler 17= water condensor (water removal) 18= mechanical energy is supplied (CO-compressor) 19= CO outlet

oxy-fuel welding, a welding torch is used to weld

metals. Welding metal results when two pieces are heated to a temperature that produces a shared pool of molten metal oxy-fuel cutting, a cutting torch is used to heat metal to kindling temperature.

http://news.bbc.co.uk/2/hi/science/nature/7586569.stm

AIR SEPARATION
In this first stage, the Air Separator removes

nitrogen, which makes up 78% of air. Once the nitrogen has been removed, the remaining product is an almost pure stream of oxygen. However, there is a downside; the air separation process demands a lot of energy and reduces the overall efficiency of the power plant.

FUEL INJECTION
At this point, a mixture of coal and oxygen is blasted

into the boiler and ignited. Many power stations "wash" and pulverise the coal before it is fed into the boiler. "Washing" actually refers to a process that involves passing coal through a series of liquids with varying densities. This removes many of the impurities found in coal (the impurities sink in the liquid, allowing them to be removed easily).

BOILER
The combustion of the coal and oxygen generates the

heat that generates the steam to power the generator. Because the coal/oxygen mix burns at a higher temperature than a coal/air mix, it is necessary to recycle some of the flue gas, primarily consisting of CO2 and water vapour, back into the boiler to reduce the overall temperature.

STEAM TURBINE
The steam generated as a result of heating water

passed through the boiler in pipes is then used to power steam turbines that generate electricity. However, the pilot plant at Schwarze Pumpe will not use the steam to power electricity generators. Instead, the steam will be piped to a nearby industrial plant.

PARTICLE REMOVAL
This is the first of several "cleaning" processes that

the flue gas will pass through. At this point, small particles called "fly ash" are removed from the gas.

SULPHUR REMOVAL
This stage, which usually involves a process called

flue gas desulphurisation (FGD), removes sulphur dioxide (SO2), which causes acid rain if it is released into the atmosphere. A mixture of limestone and water is sprayed over the flue gas, which reacts with the SO2 to form gypsum (a calcium sulphate), a material that can be used in the construction industry.

COOLER AND CONDENSER


At this final filtering stage, the flue gas is cooled to

condense the water vapour. Because nitrogen was removed during the air separation process, nitrogen oxides were prevented from forming during the combustion process. As a result, the remaining gas is an almost pure stream of CO2 (formed when oxygen and carbon atoms bonded together during combustion).

Combustion in an O2/CO2 mixture (oxyfuel combustion)

has been recognized as a prom-ising technology for CO2 capture as it produces a high CO2 concentration flue gas.
The Zero Emission Technology (ZET) term is mainly

used to describe CO2 emission abatement; greenhouse gas emissions in general can be decreased through increased power plant energy efficiency, use of lower carbon-intensive fuels and greater use of re-newable energy, and through CO2 capture technologies.

Oxy-fuel combustion systems


The oxy-fuel combustion process eliminates nitrogen from the flue

gas by combusting a hydrocarbon fuel in either pure oxygen or a mixture of pure oxygen and a CO2 - rich re-cycled flue gas (carbonaceous fuels include biomass). Combustion of fuels with pure oxygen reaches adiabatic combustion temperatures around 3500C which is far too high for typical power plant materials. The combustion temperature is controlled by the pro-portion of flue gas and gaseous or liquid-water recycled back to the combustion chamber. The combustion products consist mainly of carbon dioxide and water vapour to-gether with excess oxygen required to ensure complete combustion of the fuel. combustion cap-ture systems.

The CO2 capture efficiency is very close to 100% in oxy-fuel

characteristics of oxy-fuel combustion with recycled flue gas differ with air combus-tion in several aspects including the following

To attain a similar adiabatic flame temperature the O2 proportion of the gases flowing through the burner is typically 30%, while in air combustion it is ~ 21%, and about 60% of the flue gas is recycled. The volume of gas flowing through the furnace is reduced somewhat, and the volume of flue gas (after recycling) is reduced by about 80%. The density of the flue gas is increased, as the molecular weight of CO2 is 44, com-pared to 28 for N2. Without gas cleaning in the recycle stream, emissions including corrosive sulphur gases show higher concentrations than in air firing. As oxy-fuel combustion combined with sequestration must provide power to several significant unit operations, such as flue gas compression, that are not required in a conventional plant without sequestration, oxy-fuel combustion / sequestration is less efficient per unit of energy produced. However, it is more efficient than a conventional plant with sequestration due to the significant energy required scrubbing a dilute gas stream prior to compression. NOx emissions (mass per unit of energy released from the coal) decreases compared to that in air combustion. The reduction was shown to depend on the oxygen concen-tration due to the change in the flame temperature. However, the difference de-creases significantly even if as little as 3% N2 presented. SO2 emission (mass per unit of energy released from the coal) was not affected sig-nificantly by the variations of O2 or CO2 concentration. The decrease in SO2 during oxy-fuel combustion is due to SO3 formation and subsequent sulphur retention. CO concentration is not a considerable problem. Increasing the oxygen concentration decreased the CO emission. The decrease of CO concentration along the flame is slower compared to air combustion because of high CO2 gas concentration in oxyfuel combustion.

Pre-combustioncapture: Also

termedfueldecarbonisation.The processistypicallysuggestedtobeusedinconnectionwit hInte- gratedGasification CombinedCycle(IGCC)powerplantswhereitis termedIGCCeCCS. Coalgasification isappliedtoobtainagas (syngas) containingCO,CO2, andH2. TheCOistransformedintoCO2 by thewatergasshiftreactionandcanthenbeseparatedfromthe remaininghydrogencontaininggasbeforethisiscombu stedinagas turbine.

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