3rd Oxyfuel Combustion Conference

(September 10,2013)

Advanced Oxy-Fuel Combustion Technology

Toshihiko Mine1), , Kenji Kiyama1), Yuji Fukuda1),
Noriyuki Imada1), Pauli Dernjatin2)
1) Kure Research Laboratory, Babcock-Hitachi K.K.
2) Power Division, Fortum Power and Heat

Contents
1. Background and Objective
2. Advanced oxy-fuel combustion system
(Gas cooler system)
3. Development of new burner for oxy-fuel combustion
4. Erosion and fouling risk
5. Summary

© Babcock Hitachi k.K.. 2009. All rights reserved.

1.1 CCS Technology Development Trend and Hitachi Vision
- Coal firing is currently the leading source of power generation
- Hitachi has been developing two key technologies of CO2 capture from coal fired power
plants; “CO2 Scrubbing”, “Oxy-fuel Combustion” and high efficiency technologies of
“700C A-USC”, “ IGCC”
2010 2015 2020 2025 2030
Regulation Capture Ready Partial
Reduction
Full
Reduction
Pilot Testing Demonstration
Road of Plant Plant
Commercial
Plant
Ultimately-
Clean Plant
Development
700℃ A-USC
Efficiency of 46%(HHV)
CO2 Scrubbing 700℃ A-USC
Hitachi Vision + CO2 Capture
of Oxy-fuel Combustion -High Efficiency
-Zero Emission
Technology
Development Chemical Looping
IGCC + CO2 Capture
1
1.2 Development Subjects in Oxy-fuel Combustion

Burner
-stable operation Boiler
-low p'ry O2 concentrations High radiation intensity: CO2, H2O
-same boiler for air and oxy
-risk of erosion and fouling
Boiler
AQCS
-keep SCR,ESP,FGD performance
ASU SCR
-installation of gas cooler
AQCS: Air Quality Control System
AH
Mill Cooler ESP FGD CPU
O2 stack
Liq.CO2
Fan
Gas Cooler System CPU
ASU -decreasing flue gas -reduce corrosion potential
-reduce initial cost temperatures at the ESP inlet (SO3, Hg, Cl etc)
-reduce power consumption
-reduce corrosive substances -reduce power consumption
compact & low power
: SO3,Hg compact & low power
ASU: Air Separation Unit CPU: CO2 Compression and Purification Unit 2
Advanced Oxy-Fuel Combustion Technology

2. Advanced oxy-fuel combustion system

(Gas cooler system)

3
2.1 Subjects of Gas Re-Circulation in Oxy-fuel Combustion

Boiler exit corrosive substances are concentrated

by recirculation under condition of Oxy-fuel combustion
Condition SO2 [ppm] SO3 [ppm] Hg [µg/m3N]
Air Combustion 2,000 30 10
Oxy-fuel Combustion 10,000 180 40
Percentage of gas re-circulation:75％
Boiler
SCR

ESP FGD
CPU

ASU Gas Re-circulation line

Hg absorbing tower
4
2.2 Mechanism of SO3 Removal
- Below acid dew point, SO3 in flue gas change to mist
- Mist sticks to ash and is neutralized by alkali contained in ash and caught by ESP
Boiler SCR
ASU
Cooler ESP FGD
CPU

Gas re-circulation
Location of cooler
1.0 without Cooler(160 deg-C)
Ash
SO3 Concentration [-]
SO3 (Gas) with Cooler(90 deg-C)
160 deg-C
Finned tube

Adsorbed
90 deg-C SO3 mist
(< acid dew point) 0
SCR ESP ESP FGD
Outlet Inlet Outlet Outlet
5
2.3 1.5MWth Test Facility (Verification of Flue Gas Treatment)

Furnace
Flue gas treatment
total system

O2 Tank

Gas cooler
(Finned tubes)

This study was partly carried out under contract with New Energy and Industrial Technology Development Organization(NEDO) of Japan. 6
 2.4 Result of 1.5MWth Test

SO3 can be reduced under 1ppm with 90 deg-C cooler system

Hg removal through the overall system is about 85%
Boiler SCR Measurement point
ASU (C)
Cooler ESP (A)
CPU

FGD
(B) Gas re-circulation
Test condition Test condition
- Coal : High sulfur coal (S=2.7%) - Coal : Bituminous coal (Hg=198µg/kg)
- Moisture content in flue gas :30-40% - Moisture content in flue gas :30-40%
40 40 100
Corrosion Rate [mg/cm2]

Hg removal efficiency [%]

SO3 at ESP outlet [ppm]

carbon steel
(A) (B) (C)
sulfuric acid
30 80
30 resistance steel
20 20 60

10 10 40
<1 mg/cm2
0.2ppm
0 0 20
Without Cooler With Cooler Without Cooler With Cooler Without Cooler With Cooler
(160 deg-C) (90 deg-C) (160 deg-C) (90 deg-C) (160 deg-C) (90 deg-C) 7
2.5 Features of Hitachi Oxy-fuel Combustion System
(500MWe Class Power Plant)

(1) SO3 and Hg removal with 90 deg-C cooler

(2) LP turbine power increases because cooler preheats feed water.
(Improvement of plant net efficiency : 1.5 points)

+18MW
TB GE CPU CO2
+3MW (2) (1)
-60MW 90deg-C
Cooler Stack GGH

SCR ESP FGD

Boiler IDF
Burner Gas
SCAH
Heater
PAF FDF
Hot Air
1282MW
Oxygen
Coal ASU
Mills

This study was partly carried out under co-research with FORTUM OYJ. 8
Advanced Oxy-Fuel Combustion Technology

3. Development of new burner for oxy-fuel combustion

9
3.1 Subjects of Oxy-fuel Combustion Burner

Burner flame becomes unstable by change of gas composition (N2⇒CO2)

Item Air Combustion Oxy-Combustion

N2 CO2
Flue gas
composition O2 O2
CO2 H2 O H2 O

Direction of flame spread

Air Combustion (Pry O2=21%)

Coal particle
Radiation
Flame spread speed in Oxy-fuel combustion is
lower than that of air combustion because of gas
heat capacity is increased. Oxy-fuel Combustion (Pry O2=21%）
Photographs of burner flame
Mechanism of Flame Spread (4MWth test facility) 10
3.2 Results of Numerical Analysis

NR-LE burner can realize stable combustion under low Pry O2 concentration
O2 rich gas
(O2>30%) Secondary gas

Coal and
Primary gas
(Low O2=10%)

PC Concentrator

O2 rich gas Supply nozzle

Flame is stable at low primary O2

Gas temp. NR-LE Burner
High Primary
O2=10%

O2=21%

Low NR-3 Burner

11
3.3 4MWth Test Facility
(Verification of Flame Stability of Burner)

Typical test conditions

- Coal type : Bituminous
Cyclone

AH
・FEGT

Burner
Furnace GC

Water Sprayer

・Gas Monitor
（O2，CO2，CO，NOx，SO2）
・UBC Sampling

IDF
O2
Stuck

Coal Coal feeder

400kg/h GRF

PAF
FDF

This study was partly carried out under co-research with FORTUM OYJ. 12
 3.4 Result of 4MWth Test(1) ; Operation Stability

Switching time from air to oxy-fuel combustion ; 30min

Flame is stable during switching from air to oxy-fuel combustion
Coal in Air comb. Air to Oxy Oxy-fuel comb. Oxy to Air
50
Secondary O2
O2 (vol%,dry)

40
30 Primary O2
20
10 Exit O2
0
600
O2 Flow Rate(m3N/h)

Secondary O2
500
400
300
Primary O2
200
100
0
1200
Coal Flow Rate(kg/h)

1000
FEGT(deg-C)

800
FEGT (Furnace Exit Gas Temperature)
600 Coal Flow
400
200
0
12:00 12:30 13:00 13:30 14:00 14:30 15:00 15:30 16:00 16:30 17:00 17:30 18:00 18:30 19:00 19:30
Time[-] 13
3.5 Result of 4MWth Test(2) ; Flame Stability

Primary O2 content can be reduced to 10% with a new burner (NR-LE)

even under unexpected O2 control conditions
Stable Stable Unstable

a. Pry O2=21%(wet) b. Pry O2=10%(wet) c. Pry O2=5%(wet)

NR-LE Burner
Stable Stable Unstable

a. Pry O2=28%(wet) b. Pry O2=24%(wet) c. Pry O2=21%(wet)

NR-3 burner 14
Advanced Oxy-Fuel Combustion Technology

4. Erosion and fouling risk

15
4.1 Erosion and Fouling Risk ; Erosion

-Recirculation gas is taken from the outlet of ESP in Hitachi’s system.

-Ash content of the gas stream is the same for air combustion and oxyfuel
combustion.
-Erosion rate will not change between air combustion and oxyfuel
combustion.

Erosion rate, E (um/h)

6.0
5.0
4.0
3.0
2.0
1.0
0.0 0 200 400 600 800
ash concentration (g/m3)

Ash erosion test equipment Effect of ash concentration on erosion rate

16
4.2 Erosion and Fouling Risk ; Fouling

Ash deposition rate is the same for both cases of air and oxyfuel
combustion.
Typical test conditions
- Coal type : Bituminous

Ash deposition Tube 17

4. Summary

Hitachi has developed a new system for oxy-fuel combustion.

Features of this system include:
(1) SO3 and Hg removal by decreasing flue gas temperatures at the ESP inlet with a cooler
system.
(2) There is a large increase power of LP turbine output because the gas cooler preheats
boiler feed water and reduces steam extraction from LP turbine.
(3) Stable combustion under low O2 concentration of primary gas with NR-LE Burners is
achieved.
(4) Erosion and fouling potential must be same to air combustion because ash concentration
of oxy-fuel combustion is same to that of air combustion.

We are ready to apply highly efficient and reliable technologies for oxy-
fuel combustion to actual projects.

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