center of research on energy resources & consumption test facility for the hydrodynamic...
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Center of research on energy resources & consumption
Test Facility for the Hydrodynamic Characterization of two CFB for Ca Looping Systems
Luis M Romeo ([email protected])
Pilar Lisbona, Ana Martínez, Yolanda Lara
CIRCE - Center of research on energy
resources & consumption
4th International Workshop on In-Situ CO2 Removal,
Imperial College (London), July 2008
Center of research on energy resources & consumption
INDEXCIRCE description
Ca looping cycles
Introduction
Objectives
Test facility description
Test plan
Energy integration of Ca looping systems
Objectives
Results
Center of research on energy resources & consumption
CIRCE description
• non-profit private organisation, sponsored by
R&D in energy and thermal and electrical engineering
experience in coal & biomass combustion, plant tests & monitoring, laboratory work, simulation, CFD, conventional (PF) and advanced (FBC, IGCC, co-firing) concepts, CO2 capture
Utility Mining Educational Government
Center of research on energy resources & consumption
Experience in EC projects:CFB800: Utility Scale CFB for Competitive Coal Power (RFCS 2004, project RFCR-CT-2005-00009)
VISCON: Visual sensing for optimised control of tube bank performance and enhanced lifetime (5th FP, project NNE5-1999-00463)
INTCON: Intelligent process control system for biomass fuelled industrial power plants (5th FP, project ENK6-2001-00542)
BIOMAX: Maximum biomass use and efficiency in large-scale cofiring (5th FP, project NNE5-2001-00291)
CARNO: Development of a carbon-in-ash notification system. (ECSC 2001, project 7220-PR-130)
BIOCARD: Global process to improve Cynara cardunculus exploitation for energy applications (6th FP STREP, project SUSTDEV 1.2.5 019829)
CLEAN SELECTIVE: Intelligent monitoring and selective cleaning control of deposits in pulverised coal boilers (RFCS 2005, project RFCR-CT-2006-000098)
Experience in CO2 projects (National programs):
Efficiency improvement and reduction of greenhouse gases in existing power stations (2004)
Technical, economical and legal feasibility of technologies for reduction of CO2 emissions from coal (2004-07)
Biomass oxy-co-firing in fluidized bed (2005-08)
CENIT CO2- Spanish national council for RTD in CO2 capture and storage (2006-09)
Center of research on energy resources & consumption
CIRCE description. Experience in CO2 issues:
Laboratories:
Biomass/coal combustion
Oxyfuel combustion
CFB looping
European Technology Platform for Zero Emission Fossil Fuel Power Plants.
CO2 Spanish Platform. Secretariat (2007)
Center of research on energy resources & consumption
INDEXCIRCE description
Ca looping cycles
Introduction
Objectives
Test facility description
Test plan
Energy integration of Ca looping systems
Objectives
Results
Center of research on energy resources & consumption
Ca looping systems. Introduction
Carbonate looping requires the movement of solids between two different reactors:
CFB for sorbent carbonation and CO2 reaction
CFB for sorbent regeneration and CO2
releasing
Key factor: sorbent stability after high number of cycles
To overcome the loss of sorbent activity two strategies are proposed
operating at high purge,
operating at high solid internal circulations.
Carbonator Calciner
CaO + CaCO3 + CaSO4 + ash
CaO + CaSO4 + ash
CO2
O2
CaCO3
Combustor
Air
Fuel
Fgas + FCO2(1-ηcapt)
Purge (I)
ycomb
1-ycomb
Fgas + FCO2
Purge (II)
Carbonator Calciner
CaO + CaCO3 + CaSO4 + ash
CaO + CaSO4 + ash
CO2
O2
CaCO3
Combustor
Air
Fuel
Fgas + FCO2(1-ηcapt)
Purge (I)
ycomb
1-ycomb
Fgas + FCO2
Purge (II)
Center of research on energy resources & consumption
Ca looping systems. Introduction
Operation conditions will be defined by a compromise among:
purge percentage
Increment of cost of fresh sorbent
Increment of capture cost
high solid circulation
relevance of understanding hydrodynamics behavior in the CFB’s loop
knowledge of pressure drop along the CFB and seals
control/variation of Gs as function of independent variables
carbonator “internal” circulation effect
Influence on heat transfer in the system
Heat transfer coefficient within each reactor: dense bed and freeboard
Heat transfer between reactors: Sensible heat in the solids is transferred from calciner to carbonator.
Center of research on energy resources & consumption
Ca looping systems. Objectives
Objectives:
Test Facility for the Hydrodynamic Characterization of two CFB for Ca Looping Systems
Cold flow and made of Plexiglas for flow visualization
Analyze the pressure drop along the two CFB and loop-seals
Knowledge of the design/controllability of the system
Study the influence of different variables in solid circulation rates
Increase carbonator circulation rates to increase capture efficiency
Analyze the system performance with design modifications
Center of research on energy resources & consumption
CFB looping. Description
Two Plexiglas risers
4 m height and 160-170 mm i.d.
Recycle systems include:
two HE cyclones
80 mm i.d. 1447 mm height Plexiglas standpipe
177 mm i.d. 300 mm height cylindrical Plexiglas loop-seal
return pipe made of translucent flexible plastic.
Fluidizing air is supplied by blower
nominal flow volume 360 Nm3/h
nominal pressure of 1365 mm w.c
Center of research on energy resources & consumption
CFB looping. Description
An electric resistance for heating purposes
increase calciner fluidizing air temperature and maintain dimensional similarity
1,5m-long electrical resistance of 3x2200W controlled by a PID temperature controller
Control valves for fluidizing air (risers and loop-seals)
Dynamic pressure measuring and recording system, measurement devices and ancillaries
Center of research on energy resources & consumption
Ca looping systems. Description
Instrumentation
10 inductive differential pressure transducers (Testo 6340)
connected by means of 4mm i.d. silicone tubes
at different points of the CFB loop,
Pressure transducers are protected by a wire net to inhibit entry of powder from the risers
2 temperature measurements at the entrance of fluidizing gas
Temperature is measured by a PT100 prior entering the calciner riser
2 hot-wire anemometers to monitor gas velocities.
The transmitters output to a multi-channel data-logger Agilent® 34670A (34901A 20-channel general purpose multiplexer) processed by means of the Agilent® software package
Solid circulation rate is measured by flow diversion in the return pipe which connects the loop-seals and the bottom bed of the CFB
Center of research on energy resources & consumption
CFB looping. Description
Center of research on energy resources & consumption
Center of research on energy resources & consumption
Center of research on energy resources & consumption
Center of research on energy resources & consumption
CFB looping. Description
Test plan
CFB´s characterization (carbonator and calciner at different Tin)
P= f(h, ur, uls, Gs, solid inventory, Tin, …)
Gs= f(ur, uls, solid inventory, Tin, …)
CFB loop analysis
P= f(h, ur, uls, Gs, solid inventory, Tin, …)
Gs= f(ur, uls, solid inventory, Tin, …)
CFB with internal recirculation
P= f(h, ur, uls, Gs, solid inventory, Tin, …)
Gs= f(ur, uls, solid inventory, Tin, …)
Cyclone P= f(Gs, …)
Center of research on energy resources & consumption
INDEX
CIRCE description
Ca looping cycles
Introduction
Objectives
Test facility description
Test plan
Energy integration of Ca looping systems
Objectives
Results
Center of research on energy resources & consumption
Energy integration of Ca looping systems. Objective
Objective
design a highly integrated process to capture CO2 from an existing power plant based on carbonation/calcination cycle
retrofit scheme that integrates the energy released by carbonation–calcination capture cycle in a supercritical steam cycle
Carbonator (Q1)
Flue gases from carbonator (Q2)
Flue gases (CO2) from calciner (Q3)
Purge (Q4)
Center of research on energy resources & consumption
Energy integration of Ca looping systems. Results
Existing supercritical coal power plant without desulphurization unit of 427.5 MW net output (450.0 MW gross output).
Energy integration from:
carbonator (Q1= 292MWth)
flue gases from 650ºC to 150ºC (Q2= 232MWth)
CO2 stream from the calciner at 875–950ºC (Q3= 163MWt h).
solid purge heat exchanger (Q4= 33 MWth).
Calciner energy requirements 728.6MWth
coal mass flow rate of 28.8 kg/s
oxygen flow rate of 58.9 kg/s
172.5 kg/s of near-pure CO2
Purge of 48.9 kg/s of deactivated CaO, CaSO4 and ashes
Center of research on energy resources & consumption
Energy integration of Ca looping systems. ResultsCarbonator (Q1)
Flue gases from carbonator (Q2)
Flue gases from calciner (Q3)
Purge (Q4)
Center of research on energy resources & consumption
Energy integration of Ca looping systems. ResultsLive steam is 186.5 kg/s and avoid the need of an extra boiler
Gross power output, 308.5MW. Gross efficiency of 42.51%
Three additional heat exchangers have been placed to:
Preheat coal, CaCO3 and oxygen using heat from the hot CO2 stream, flue gases and CaO purge.
Solids are heated up to 130ºC and oxygen up to 80ºC and gases reduce temperature to 130ºC and ashes to 120ºC.
Auxiliary consumption:
Air separation unit 46.6 MWe
52.8 MWe for new fans, solid and gases circulation, CO2 compression
usual power plant auxiliaries 15.4 MW.
Net power output 193.6MWe. Net efficiency 26.68%
Original situation: 333.8 tonCO2/h to produce 427.5MWe (0.781 kgCO2/net kWh)
Integrated system:79.5 tonCO2/h to produce 621.1MWe (0.122 kgCO2/net kWh)
Center of research on energy resources & consumption
Test Facility for the Hydrodynamic Characterization of two CFB for Ca Looping Systems
Luis M Romeo ([email protected])Pilar Lisbona, Ana Martínez, Yolanda LaraCIRCE - Center of research on energy
resources & consumption
4th International Workshop on In-Situ CO2 Removal, Imperial College (London), July, 2008
Center of research on energy resources & consumption
Biomass oxy-co-firing in fluidized bed (2005-09)
100 kWt O2/CO2 bubbling fluidized bed
Center of research on energy resources & consumption
Biomass oxy-co-firing in fluidized bed (2005-09)
100 kWt O2/CO2 bubbling fluidized bed
Center of research on energy resources & consumption
Biomass oxy-co-firing in fluidized bed (2005-09)
100 kWt O2/CO2 bubbling fluidized bed
2.7 m height, 23 cm i.d. FB water cooling
2 x 200 litres for fuel feeding (coal, sorbent, biomass)
CO2/O2 mixer and flue gas recirculation
Preheating of fluidising gas
Gas cleaning: cyclone and fabric filter
Recycling ratio: from 0% to 80%
O2 in the mixture: from 20% to 40%CoalCoal
++BiomassBiomass
AirAir
Electric Electric PowerPower
Flue gasesFlue gasesCO2, H2O,...
COCO22
CompressionCompressionand dehydrationand dehydration
COCO22 transport transport and storageand storage
Air Air Separation Separation Unit (ASU)Unit (ASU)
OO22
COCO22 recirculationrecirculation
CoalCoal++
BiomassBiomass
AirAir
Electric Electric PowerPower
Flue gasesFlue gasesCO2, H2O,...
COCO22
CompressionCompressionand dehydrationand dehydration
COCO22 transport transport and storageand storage
Air Air Separation Separation Unit (ASU)Unit (ASU)
OO22
COCO22 recirculationrecirculation
Center of research on energy resources & consumption
selected, recent papers:
Romeo, L.M., Lara, Y., Lisbona, P., Escosa, J.M. 2008. Optimizing make-up flow in a CO2 capture system using CaO. Chemical Engineering Journal, Accepted for publication (2008)
Lisbona, P. Romeo, L.M. Enhanced Coal Gasification Heated by Unmixed Combustion integrated with an Hybrid System of SOFC/GT. International Journal of Hydrogen Energy, Accepted for publication (2008)
Romeo, L.M., Abanades, C., Escosa, J.M., Pano, J., Giménez, A., Sanchez-Biezma, A., Ballesteros, J.C. Oxyfuel carbonation/calcination cycle for low cost CO2 capture in existing power plants. Energy Conversion and Management, doi:10.1016/j.enconman.2008.03.022 (2008)
Romeo, L.M., Espatolero, S., Bolea, I. Designing a supercritical steam cycle to integrate the energy requirements of CO2 amine scrubbing. International Journal of Greenhouse Gas Control, doi:10.1016/j.ijggc.2008.03.002(2008)
Romeo, L.M., Bolea, I., y Escosa, J.M. Integration of power plant and amine scrubbing to reduce CO2 capture costs. Applied Thermal Engineering, 28, 1039–1046 (2008)
Abanades, J.C., Grasa, G., Alonso, M., Rodriguez, N, Anthony, E.J., Romeo, L.M. Cost Structure of a Postcombustion CO2 Capture System Using CaO. Environmental Science and Technology, 41, 15, 5523-5527 (2007)
Center of research on energy resources & consumption
selected, recent papers:
Romeo, L.M. y Gareta, R. Fouling Control in Biomass Boiler. Engineering Applications of Artificial Intelligence, 19, 8, 915-925 (2006)
L. M. Romeo, R. Gareta. Neural Network for Evaluating Boiler Behaviour. Applied Thermal Engineering, 26, 14-15, 1530-1536 (2006)
R. Gareta, L.M. Romeo, A. Gil. Forecasting of Electricity prices with Neural Networks. Energy Conversion and Management Journal 47, 1770 (2006)
J. Pallarés, I Arauzo, L. I. Díez. Numerical prediction of unburned carbon levels in large pulverized coal utility boilers. Fuel 84, 2364 (2005).
E. Teruel, C. Cortés, L.I. Díez, I. Arauzo. Monitoring and Prediction of Fouling in Coal-Fired Utility Boilers Using Neural Networks. Chemical Engineering Science 60, 535 (2005)
L. I. Díez, C. Cortés, A. Campo. Modelling of pulverized coal boilers: review and validation of on-line simulation techniques. Applied Thermal Engineering 25, 1516 (2005)
R. Gareta, L. M. Romeo, A. Gil. Methodology for the economic evaluation of gas turbine air-cooling systems in combined cycle applications. Energy 29, 1805 (2004)