hydrogen –firing for a high capacity rotary kilnhydrogen –firing for a high capacity rotary kiln...
TRANSCRIPT
HYDROGEN HYDROGEN –– FIRING FOR A HIGH FIRING FOR A HIGH
CAPACITY ROTARY KILNCAPACITY ROTARY KILN
Ralph L. Coates, L. Douglas Smoot, Kent Hatfield
Combustion Resources, Inc.
Provo, Utah
29th Oil Shale Symposium
Colorado School of Mines Golden CO
20 October, 20091
PRESENTATION TOPICSPRESENTATION TOPICS
PROCESS Characteristics
KILN Characteristics
KILN FIRING – Hydrogen
PLANS – Full process
demonstration
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Combustion Resources, Inc. / Test Facility
20,000 sq ft
Provo, Utah 3
� First DOE/SBIR grant completed (March 2007)
� Second DOE/SBIR grant completed (June 2009)
� Utah Center of Excellence Grant (June 2009)
� Shale oil process patent application (2007)
� Preliminary designs of 5 tpd pilot, 300 tpd demo, 6000 bpd commercial plants
� Constructed pilot-scale rotary kiln
� Completed kiln firing and heating tests
� Rotary kiln patent application (2009)
� Process water reduction design (2009)
� Spent shale vegetation tests (2009)
� DOE/SBIR Phase II Grant (2009) 4
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�Efficient, flexible continuous plant operation
�Simple, advanced design horizontal kiln
�Minimal process water use
�Upgrading shale oil on-site - gasoline and diesel
�Near-complete elimination of CO2 - Option
�Low cost on-site hydrogen source -Option
�Compliant disposal of spent shale6
�Natural Gas – Kiln Firing with Oil/Gas Separation
�On – Site Shale Oil Upgrading
�Hydrogen Kiln Firing – CO2 Control
�On Site Hydrogen Production
- Kiln Firing with H2
- H2 for Oil Upgrading
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1. INDIRECT-FIRED ROTARY KILN
WITH H2/AIR COMBUSTION
2. CONTROLLED PEAK SHALE ORE KILN
TEMPERATURES – NO CARBONATE
DECOMPOSITION
3. NO RECOVERY OF SPENT SHALE
CARBON
4. RECYCLE OIL SHALE OFF GASES
5. CO2 CAPTURE
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• Simple, horizontal, low fabrication cost
• Advanced design technology
- High throughput rates
- Local control of shale and oil product temperature
- Elimination of shale carbonate – CO2 emissions
• H2 Firing Option
• Handles shale process fines
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Advantages
• No carbon dioxide emissions
• Complete, rapid combustion
• High energy content
• Wide temperature/composition range
Disadvantages
• Flame flash-back
• Cost
• Kiln start-up
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5726324. Spontaneous Ignition
Temperature (air), oC
HydrogenNatural Gas (CH4)Property/Units
2161. Molecular Weight , g/gmol
28.7122. Heat of Combustion, Kcal/g
4.0
75.0
5.0
15.0
7. Flammability Limits (air), vol%
Lean
Rich
29137.36. Max. Laminar Flame Speed,
cm/s
0.366.935. Min. Ignition Energy (10-5 cal)
240022103. Adiabatic (stoich) Flame
Temp. K
(Kanury, Glassman)
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Adiabatic Flame Temperature (K) vs Flammability Limits (vol%)
400.0
600.0
800.0
1000.0
1200.0
1400.0
1600.0
1800.0
2000.0
2200.0
2400.0
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
Flammability Limits (vol%)
Adiabatic Flame
Temperature (K)
0
500
1000
1500
2000
2500
3000
3500
4000
Ta, oF
H2 case
CH4 case
2394 K
2228 K
Adiabatic Flame Temperature (K)
CH4 stoich
H2 stoich
H2 case
CH4 case
Volume Percent of Fuel in Air
Adiabatic Flame Temperature, oF
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Maxon-natural gas, hydrogen
Wide Range Burner
Standard Commercial Units
Maximum firing rate –
150,000 BTU/hr
Pre-purge of gas manifold
Ignition with natural gas
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136Tests
HydrogenNatural Gas
91-15191Firing Rate (103 BTU/h)
OrangeTransparentFlame
1500 - 18001409 - 1695Probe Temperature
Range, oF
-86 +910-55 +41% Excess Air Range
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FR 147, H2 -17% xs air FR 90, H2 -52% xs air
FR 147, H2 +32% xs air FR 90, H2 -23% xs air
FR 157, H2 -5% xs air FR 90, H2 -2% xs air
FR 157, H2 +10% xs air FR 90, H2 +50% xs air
NATURAL GAS, +13% xs air
FR 90, H2 +97% xs air
FR = Firing rate,
1000’s BTU/hr
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Excess Air
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Temperature (K)
Temperature (F)
Excess Air
% Stoichiometric Air
Excess FuelLimit 910%
CH4 H2
Calculated (CH4)
Measured (NG)
Adiabatic-
Stoichiometric
� Commercial Burners Available - Hydrogen
� Ignition with NG increases reliability/safety
� Hydrogen – air clearly visible to monitor
� H2 – NG combustion temperatures similar
� Hydrogen-air flames stable over very wide
air/fuel range
- Minimize cost
- Control temperature
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• New DOE contract – 2009
• Demonstrate Full C-SOS Process
- Pilot plant, 5 tpd
- Kiln firing (NG, H2)
- Shale oil separation, recovery
• Demonstrate shale oil upgrading
- Hydrotreating
- Hydrocracking
• C-SOS Commercial Plant Design
- 1000 tpd
- to gasoline, diesel
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AcknowledgmentAcknowledgment
Coauthors Coates and HatfieldCoauthors Coates and Hatfield
U.S. Department of Energy/SBIR GrantU.S. Department of Energy/SBIR Grant
(Chandra Nautiyal, NETL)(Chandra Nautiyal, NETL)
State of Utah Center of Excellence GrantState of Utah Center of Excellence Grant
(Nicole Toomey Davis)(Nicole Toomey Davis)
2929thth Oil Shale SymposiumOil Shale Symposium
20 October 200920 October 2009
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