Coal-fueled Pressurized Chemical Looping Combustion with a ...
Transcript of Coal-fueled Pressurized Chemical Looping Combustion with a ...
Coal-fueled Pressurized Chemical Looping
Combustion with a Spouting Fluidized Bed
Award Number
DE-FE0025098
University of Kentucky Research Foundation on Behalf of
Center for Applied Energy Research
University of Kentucky
2540 Research Park Drive
Lexington, KY 40511-8410
DOE Kickoff Meeting October 22, 2015
Outline
• Motivation and Development Pathway
• Project Objective
• Technical Approach
• Project Management Plan and Risk Management
• Schedule and Budget
• Progress
DOE Kickoff Meeting October 22, 2015
Chemical Looping Combustion (CLC)
Solid OC circulates between two reactors
Oxygen carrier (OC): oxygen, heat and
fuel energy
OC pick up O2 in the Air Reactor
(exothermic)
OC combust fuels in the Fuel
Reactor(endothermic)
Total heat release equal to normal fuel
combustion
OC materials: Fe, Ni, Mn, Cu, Ca, natural
materials, solid waste
Schematic Diagram of CLC Concept
DOE Kickoff Meeting October 22, 2015
Today’s CLC Facilities
Cyclone
C-1200
Test Section
C-1250
Loop Seal
R-1300
Upper
Riser
R-1150
Lower
Riser
R-1100
Air
Reactor
R-1000
Air Pre-heater and Tee
H-1800 & H-1850Air Pre-heater and Tee
H-1800 & H-1850
L-Valve
Housing
R-1450
Fuel
Reactor
R-1400
50 kWth at US-NETL
3 MWth at ALSTOM
140 kW (Vienna University
of Technology)
10 kWth at C.S.I.C.10 kWth at Chalmers
10 kWth at Chalmers
Gaseous Fuel
Solid Fuel
100 kWth at Chalmers25 kWth at OSU
Juan Adanez, Progress in Energy and Combustion Science 38 (2012) 215-282
CLC Development at UK-CAER
Cost-effective oxygen carrier
development:
- Fe-based: synthesized, ilmenite & solid
waste
System design & technical-economic
evaluation of PCL for power
generation/syngas production
Demonstration of PCLC/CLG (1-50
kWth fixed bed/fluidized bed/spouted
bed)
Fundamental: kinetics of coal char
gasification/OC reaction, pollutant
formation, interaction between OC and
coal ash
Bench-scale fluidized bed
50 KWth Spouted bed reactor
TGA-MS
Plant Efficiency and COE
System Design
DOE Kickoff Meeting October 22, 2015
Funded Projects on CLC/G at UK-CAER
Cost-effective and High Performance OC Development
• Supported by Carbon Management Research Group consortium at CAER
Novel Carbon Capture Technology Development for Power Generation
Using Wyoming Coal
• Investigation into the use of Wyoming coal as the feed for Solid-Fueled
CLC, State of Wyoming Clean Coal Technologies Research Program
Solid-fueled PCLC with Flue-gas Turbine Combined Cycle for Improved
Plant Efficiency and CO2 Capture
• Supported by DOE- Phase I , system design and economic analysis
Coal-fueled PCLC Combined Cycle for Power Generation and CO2
Capture
• Supported by Kentucky Energy and Environment Cabinet, FB
Application of Chemical Looping with Spouting Fluidized Bed for
Hydrogen-Rich Syngas Production from Catalytic Coal Gasification
• Supported by DOE, CL combined with catalytic gasification
DOE Kickoff Meeting October 22, 2015
Challenges for CF-CLC
• Oxygen Carrier
- Oxygen & heat carrier (Reactivity, oxygen transport capacity)
- Production cost
- Stability, agglomeration, sintering, attrition
• Slow Gasification
• Heat Balance
- Spontaneous process without the requirement
of any external heat sources
• Fuel Reactor
- Mixing between OC and fuel particles
- High solid fuel conversion
- Controlling OC reduction
- Heat transfer
H2+CO
Hot/Oxidized
OCs
H2O
H2O
Heat
CO2+H2O+H2+CO
Char
Heat
CO2+H2O+minor (H2+CO)
Ash
Heat
Reduced OCs
DOE Kickoff Meeting October 22, 2015
Coal-fueled Pressurized Chemical Looping
Combustion with a Spouting Fluidized Bed
DE-FE0025098
DOE Kickoff Meeting October 22, 2015
Project Objectives
Demonstrate an integrated coal-fueled PCLC facility at lab-scale:
design, fabrication, commissioning, hot testing, and performance
evaluation
Techno-economic assessment of the UK-CAER PCLC integrated
power generation at commercial scale
Technical gaps need to be narrow or addressed:
- Cost-effective materials for OCs ( Red mud)
- Overall fast reaction rates in the Fuel Reactor
- Simple & effective ash separation from binary mixtures of OCs & ash
- Suppression of OC agglomeration from the initial coal devolatilization step
- Pollutant mitigation to avoid emission of sulfur/NOx/alkaline metal into the hot
spent air stream
DOE Kickoff Meeting October 22, 2015
UK-CAER PCLC Facility
Demonstrate coal-fueled PCLC tech. at continuous model & data collection
Narrow the major near-term technical gaps impeding SF-PCLC & its scale up
TEA of UK-CAER PCLC at commercial scale
DOE Kickoff Meeting October 22, 2015
Fu
el R
eact
or
Air
Rea
ctor
Air Compressor
Loop
-sea
l
Ash cooler
Hot CO2/Steam
Hot Spend Air
Cyclone-1
Cycl
one-
2
Hopper-2
Char/coal
Ash
CO2
To Gas Analyzer-I
Vent to Air
To C
O2 R
ecycl
ing
/Com
pre
ssor
To G
as A
nal
yze
r-II
Cooler-I
Condenser
Vent to Flare
Screw Feeder
R P F
Pre-heater-1 Water Tank
Air
Tank
SG
Hopper-2
Pre-heater-2
Rai
ser
Hot Fluidization
Gas/N2
Hot
Fluidization
Gas/N2
H-Filter
L-Filter
Hea
ting E
lem
ents
To Fuel injectionFuel injection
1. AR & FR;
2. Fuel/OC feeding;
3. Gas supply: Steam; fluidizing gas; Air
4. Furnace
4. Gas clean- up;
5. Gas/solid sampling and measurement
6. P/T/Q measurement;
7. Data acquisition system;
8. Failsafe System
9. Supporting
Strategy to Achieve the Objectives
Cost-effective oxygen carrier from RM
Use of a spouted bed to avoid OC-coal agglomeration and to
improve fuel conversion and CO2 purity
Pulverized fuel injection
Improvement of solid fuel gasification under elevated pressure
CO2 recycling to save energy consumption
Elimination of external ash separation process
DOE Kickoff Meeting October 22, 2015
Task & Approach: PCLC facility & testing
DOE Kickoff Meeting October 22, 2015
OC
Performance
Experiments in
Fluidized Bed Reactor
(PCLC, kinetics)
Existing Spouted
Bed (cool model &
fluid-dynamics)
CFD/Aspen Simulation
(Heat-mass
balance/configuration)
Continuous PCLC facility
Design/ commissioning
Performance
Verification of
Major Components
Parametric
Testing
Long Term
Testing
Campaign
Fate of Sulfur &
Fuel Nitrogen
Transfer
Testing
Performance Evaluation
Task & Approach- Aspen Model
DOE Kickoff Meeting October 22, 2015
• PCLC = CC + PFBC + CLC (550 MWe PCLC Power Plant)– CC: 3-P combined cycle for high efficiency power generation
– PFBC: coal utilization
– CLC: low cost CO2 removal w/o ASU
• H&MB model on Aspen Plus platform to provide information– For plant performance evaluation, and for configuration, integration, and design
consideration
• Detailed reactor model– Reactor design and size with obtained kinetics
Task & Approach: T-E Analysis
DOE Kickoff Meeting October 22, 2015
Based on system simulation, key component sizing, and cost estimate of major
equipment:
1. A factored estimate of capital costs for power production and
CO2 capture
2. An estimate of operating costs (cooling water, steam, fuel,
oxygen carrier etc.)
3. An estimate of the energy performance and parasitic energy
load of the technology
4. An estimate of the cost of CO2 capture
Project Management Plan & Schedule
DOE Kickoff Meeting October 22, 2015
Task Name Start Finish Task Cost
1.0 Project Management & Planning 9/1/2015 8/31/2017 $192,437
2.0 Detailed Engineering Design 9/1/2015 2/29/2016 $77,290
3.0 Large Quantity OC Production 11/16/2015 3/21/2016 $59,060
4.0 Fabrication, Installation, & Commissioning of PCLC facilities 3/1/2016 8/31/2016 $195,237
4.1 Modification, fabrication, and installation 3/1/2016 6/30/2016
4.2 Commissioning 7/1/2016 8/31/2016
5.0 Performance Verification of Major Components 9/1/2016 12/2/2016 $69,876
6.0 Parametric Testing 12/2/2016 4/3/2017 $61,907
7.0 Long Term Testing Campaign 4/4/2017 6/5/2017 $46,901
8.0 Fate of Sulfur & Fuel Nitrogen Transfer 12/1/2016 5/31/2017 $46,454
9.0 Process Simulation of 550 MWe PCLC Power Plant 12/1/2016 5/31/2017 $43,843
10.0 Technoeconomic Assessment 6/1/2017 8/31/2017 $82,775
Budget
Period 1
Budget
Period 2
Deliverables
Task 1 Project Management Plan 10/30/2015
Task 2 The engineering design (including P&ID, general
layout, blueprint for Reducer, material and instrument
selection, et.al)
02/29/2016
Task 3 Installation & commissioning 08/31/2016
Task 5 & 6 Effectiveness of major components & optimized
operation conditions04/3/2017
Task 7 – 9 Database of pollutants & stream table from simulation 05/31/2017
Task 10 TEA 08/31/2017
DOE Kickoff Meeting October 22, 2015
Team Structure
DOE NETL
Center for Applied Energy Research, UKy Trimeric Corporation
Engineering Design
OC Production
Reactor
Fabrication/Installation/
Commissioning
Techno-Eco
Analysis
Process Simulation of
550 MWe PCLC
Budgeting/ Coordinating /Reporting
Test
DOE Kickoff Meeting October 22, 2015
Risk Management
Description of Risk Probability (Low, Moderate, High)
Impact (Low, Moderate, High)
Risk Management (Mitigation and Response Strategies)
Technical Risks: Performance of OC Low High Addition of supports/additives
Change preparation methods
Catalyst-OC contamination Moderate Moderate Desulfurization sorbent Agglomeration in draft tube Moderate Moderate Re-configuration
Gas leakage between reactors Moderate Moderate Re-configuration of loop-seal Solid circulation & flux estimation
Moderate High Developing model for accurate prediction
Resource Risks: Air permit Low High EH&S Team early involvement
Project cost overrun Low High UKRF Project team assistance Management Risks:
Contract agreement delay Low High Dedicated UKRF staff
DOE Kickoff Meeting October 22, 2015
Available Instruments & Equipment
TGA/DSC/DTA/MS with WV
FurnaceHitachi S-4800 Philips X’pert
DOE Kickoff Meeting October 22, 2015
Available Facilities
Bench Scale Fluidized Bed Facility Spouted Bed Reactor
DOE Kickoff Meeting October 22, 2015
Why Red Mud – The Properties
Physical Characteristics
• Fe2O3:30%-60%
• Al2O3:10%-20%
• SiO2: 3%-50%
• TiO2: 2%-25%
• Na2O: 2%-10%
• CaO: 2%-8%
Chemical Composition(Dry)
Active composition
Support
Bonding
Particle size: 80% particles <10μm
Concentration: 50-65%
pH: 12-13.5(need neutralization)Direct Granulation
(spray dry method)
Cost-effective OC
Calcination
No mechanical grinding
& slurry preparation needed
No additive needed
DOE Kickoff Meeting October 22, 2015
Red Mud OCs
• SEM images
Chemical composition of raw red mud and OC samples
Composite Red mud OCs (after
calcination)
Raw 1100 oC/6h 1150
oC/6h
Fe2O3 51.14 50.96 51.56
SiO2 9.85 10.51 9.98
Al2O3 17.92 18.54 18.18
TiO2 6.44 6.39 6.47
CaO 8.14 7.96 7.77
MgO 0.49 0.52 0.51
Na2O 1.81 1.91 1.85
K2O 0.2 0.19 0.18
Balance 4.01 3.02 3.5
(a) Fresh particle (b) Fresh (c) used after 20 redox cycle
20 25 30 35 40 45 50 55 60 65 70
Used after 20 cycles
1150 oC/6h
1100 oC/6h
Raw red mud
8 7
11
91
18 7 19 1 11
52
1
1 111
6 133 54 41
11
8
Inte
nsity (
a.u
.)2
1-Fe2O3; 2-AlO(OH); 3-TiO2;
4-SiO2; 5-CaCO3; 6-NaOH;
7-CaTiO3; 8-NaAlSiO4; 9-CaAl2Si2O8
XRD patterns
DOE Kickoff Meeting October 22, 2015
Chemical Stability
Composite Red mud OCs (after calcination)
Original 1150 ºC/6h 500h 1000h 1500h 2000h 2500h 3000h
Fe2O3 51.14 51.56 50.94 51.01 51.43 50.28 51.27 50.83 SiO2 9.85 9.98 10.44 10.03 10.23 10.33 9.81 10.32 Al2O3 17.92 18.18 18.1 18.24 17.95 18.27 18.45 18.35 T iO2 6.44 6.47 6.39 6.34 6.39 6.35 6.37 6.39 CaO 8.14 7.77 7.79 8.38 7.83 8.35 8.44 8.37 MgO 0.49 0.51 0.44 0.43 0.65 0.66 0.68 0.68 Na2O 1.81 1.85 1.67 1.58 1.88 1.79 1.60 1.68 K2O 0.2 0.18 0.18 0.16 0.17 0.15 0.12 0.13
Balance 4.01 3.5 4.05 3.83 3.47 3.82 3.26 3.25
FG-RM-1150/6h(125-300) Baking under 1100 for 500 h Baking under 1100 for 1000 h
Baking under 1100 for 1500 h Baking under 1100 for 2000 h Baking under 1100 for 2500 h
Experiments in Fluidized Bed Reactor
Oxygen carriers:
Ilmenite
S Red mud OC (FG1150 C/6h)
A Red mud OC (FG1150 C/6h)
Particle size: 125-350 um
Fuels:
EKy coal char (pretreated at 700 C)
WKy coal char (pretreated at 700 C)
PBR coal char (pretreated at 800 C)
Particle size: 180-350 um
Operation condition:
Gasification agent: 50% steam balanced
by N2
OC/Fuel ratio: 150: 1
F F
AirN2
MFC MFC
Pre-pump
Pre
ssu
re T
ran
smit
ter
Fil
ter
Co
ole
rC
on
den
sate
Co
llec
tor
Gas
An
aly
zer
N2
Cycl
one
Sam
ple
Po
rt
Deionized Water Thermocouple-1
Th
erm
oco
up
le-2
Fu
el B
in
Th
erm
oco
up
le-3
Moisture
Trap
Lock
Hooper
Fu
rnac
eD
istr
ibu
tor
Flo
w M
eter
Steam Generator
DOE Kickoff Meeting October 22, 2015
OC Reduction with Simulated Syngas
Red mud OC
Ilmenite OC
0 200 400 600 800 10000
2
4
6
8
10
Test Condition:
Temperature: 950 oC
CO Flow Rate: 1.0 L/min
Mass L
oss o
f O
xygen F
rom
OC
(g/1
00g F
e2O
3)
Time/s
SRM OC reduced by 20% CO+50% Steam+Balance N2
Fe3O4
0 200 400 600 800 1000 1200 14000
2
4
6
8
10
Test Condition:
Temperature: 950 oC
CO Flow Rate: 1.0 L/min
Mass L
oss o
f O
xygen F
rom
OC
(g/1
00g F
e2O
3)
Time/s
Ilmenite reduced by 20% CO+50% Steam+Balance N2
Fe3O4
0.00 0.01 0.02 0.03 0.04 0.050.75
0.80
0.85
0.90
0.95
1.00
Fe2TiO5
Com
bustion E
ffic
iency
LOxygen
/ moxygen
Ilmenite OC
S Red mud OC
Fe2O3 Fe3O4
FeTiO3
Combustion efficiency
Fixed bed reactor:
(1) Bed material: 600 g ilmenite OC
(2) Fuel: 1.5 L/min CO +1.1 g/min water
+1.5 L/min N2
(3) Temperature: 950 oC
DOE Kickoff Meeting October 22, 2015
The Effectiveness of Red Mud with
Solid Fuel-2
0.0 0.2 0.4 0.6 0.8 1.00.000
0.001
0.002
0.003
0.004
0.005
0.006
Conditions :
(1) bed material: SRM OC (300g);
(2) Solid fuel: 2g EKY(700)
(3)Temperature: 950 oC
(4) Fluidizing agent: 50 vol% Water Vapor
1 cycle
5 cycles
10 cycles
Insta
nta
neous r
ate
of
convers
ion (
g/g
/s)
Degree of Carbon conversion(Xc)0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
0.5
0.6
0.7
0.8
0.9
1.0
Conditions :
(1) bed material: SRM OC (300g);
(2) Solid fuel: 2g EKY(700)
(3)Temperature: 950 oC
(4) Fluidizing agent: 50 vol% Water Vapor
1 cycles
5 cycles
10 cycles
Co
nve
rsio
n
Conversion of OC from Fe2O3 to Fe3O4
High Stability in Fuel Conversion
DOE Kickoff Meeting October 22, 2015
Combustion efficiency of PCLC process
• Combustion efficiencies are independent of operation pressure
and the type of fuels
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.80.50
0.55
0.60
0.65
0.70
0.75
0.80
0.85
0.90
0.95
1.00
Test conditions:
1. Temperature: 950 oC
2. Steam concentration: 50vol%
3. Fuel: PRB 800 1.0 g
4. OC: ilmenite 150 g
Ga
s C
on
ve
rsio
n
Conversion of OC from Fe2O3 to Fe3O4
1 bar
2 bar
4 bar
6 bar
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.80.50
0.55
0.60
0.65
0.70
0.75
0.80
0.85
0.90
0.95
1.00
Test conditions:
1. Temperature: 950 oC
2. Steam concentration: 50vol%
3. Fuel: PRB800 1.0 g
4. OC: ARM 150 g
Ga
s C
on
ve
rsio
n
Conversion of OC from Fe2O3 to Fe3O4
1 bar
2 bar
4 bar
6 bar
A Red mud OCIlmenite OC
DOE Kickoff Meeting October 22, 2015
Hydrodynamics in Spouted Bed
0
50
100
150
200
250
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
Inte
rnal
Cir
cula
tion R
ate
(kg/
h)
Fluidizing Gas Flow Rate (m3/h)
Bed Height=20 inch
Bed Height=15 inch
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16
16
18
20
22
24
26
28
2.5" tube height 300
unstable area
stable area
Sp
ou
tin
g g
as v
elo
city (
m/s
)
Fluidizing gas velocity (m/s)
H=350 mm
H=400 mm
H=500 mm
Question/clarification
Path forward
Task modification
Expected deliverables
Discussion
DOE Kickoff Meeting October 22, 2015