1Oyvind.Langorgen@sintef.no

1

Cold flow investigations of a Circulating Fluidized Bed Chemical Looping Combustion system as a basis for

up-scaling to an industrial application

Ø. Langørgen1, A. Bischi2, J. Bakken1, J.X. Morin3, M. Bysveen1

6th Trondheim CCS Conference, June 14 – 16, 2011

1 SINTEF Energy Research, Norway.2 The Norwegian University of Science and Technology, Norway.3 CO2-H2 Eurl, France.

2Contents

Chemical Looping Processes– Principle– Activities within the BIGCO2/BIGCCS project framework

Double Loop Circulating Fluidized Bed (DLCFB)

Scaling criteria– Overview– Adopted scaling strategy

Experimental set-up– Cold Flow Model

Experimental Campaign– Design case performance– Off-design tests

Conclusions & Outlook

3Chemical Looping principle

Chemical Looping Combustion (CLC):A divided combustion process with intrinsic CO2 separation. An oxy-fuel process without the need of an oxygen plant (potential lower costs and higher net power efficiency)

Fuel Reactor (FR)Reduction of the metallic oxygen carrier.Endothermic or slightly exothermic.

Air Reactor (AR)Oxidation of the metallic oxygen carrier.Exothermic.

Fossdal et al.,“Study of inexpensive oxygen carriers for chemical looping combustion”International Journal of Greenhouse Gas Control.

• $$$$•U•J•J

Reactor system:1. Cold Flow Model (CFM) construction,

commissioning and testing for validation of the 150kWth atmospheric rig design

2. 150kWth atmospheric rig construction, commissioning and test campaigns

3. Pressurized conditions

4

The BIGCLC projectA subproject within the larger BIGCO2/BIGCCS project framework

Oxygen carrier materials:1. Screening and preliminary investigation2. Selection and TGA testing (Mn-ore + Ca & Ti)3. Fabrication by industrial methods4. Testing in a small continuous FB process

Bischi et al.,“Design study of a 150kWth Double Loop Circulating Fluidized Bed reactor system for Chemical Looping Combustion with focus on industrial applicability and pressurization”International Journal of Greenhouse Gas Control.

5Double Loop Circulating Fluidized Bed (DLCFB)

Design criteria

High gas–solids contact

High solids exchange

Flexibility of configuration

Compactness

Choose industrial solutions wherever possible

Continuous operationBottom lifter

Steam

Steam

Steam

AR FR

Depleted Air CO2 and Steam

Air

Air

Fuel

Coo

ling

pane

ls

Steam

Steam

Bottom lifter

Steam

Steam

Steam

AR FR

Depleted Air CO2 and Steam

Air

Air

Fuel

Coo

ling

pane

ls

Steam

Steam

6Double Loop Circulating Fluidized Bed (DLCFB)

Bottom lifter

Steam

Steam

Steam

AR FR

Depleted Air CO2 and Steam

Air

Air

Fuel

Coo

ling

pane

ls

Steam

Steam

Bottom lifter

Steam

Steam

Steam

AR FR

Depleted Air CO2 and Steam

Air

Air

Fuel

Coo

ling

pane

ls

Steam

Steam

Design parameter AR 150kWth

FR 150kWth

uo [m/s] ~4 ~4

D [m] 0.25 0.15

L [m] 5 5

ρp [kg/m³] 2000 2000

ρf [kg/m³] 0.268 0.249

d50 [μm] 100 100

μ [Ns/m²] 4.84E-05 4.29E-05

T [°C] 1000 1000

P [Pa] 100000 100000

Design parameters

• Geldart Group A particles• Fast fluidization flow regime(CFB regime)

Glicksman scaling laws Simulating the hydrodynamics of a high temperature FB reactor with a smaller

cold flow model

Based on non-dimensional particles and fluid equations of motion

A set of scaling parameters to be matched between actual reactor and model

May impose different Geldart Group of particles and different flow regime

7Scaling criteria for fluidized bed hydrodynamics

Knowlton scale-up1. Select operating regime

2. Construct a pilot plant (typical diameter 150 – 300 mm for group A particles) Continuous operation for significant time Industrial concerns can be addressed Reduced wall effects

3. Construct a large cold-flow model (generally larger than the pilot)

4. Construct a demonstration plant

5. Construct a commercial plant

Flow regime and particle Geldart Group should be kept the same

8Scaling criteria for fluidized bed hydrodynamics

9Cold Flow Model (CFM) scaling strategy

Cold Flow Model

Hot Rig150 kW

Industrial Demo ~30MW

• Geometrical identity• Geldart A particles• Fluidization regime:

Ar & Rep

• Simplified Glicksman Criteria:

• Geldart A particles

• Fluidization regime:Ar & Rep

• Process parameters:T, P, gas composition

• Same Particles:Density, PSD, φ

• Fluidization regime:Ar & Rep

10Cold Flow Model (CFM) scaling strategy

Cold Flow Model

Hot Rig150 kW

Industrial Demo ~30MW

Lim, Zhu and Grace (1995)

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Cold Flow Model, full scale:Air Reactor (AR):

• 5m h, 0.23m id• Nominal air flow: ~5500Nl/min (2.4m/s at 20ºC)

Fuel Reactor (FR): • 5m h, 0.14m id• Nominal air flow: ~2400Nl/min (2.6m/s at 20ºC)

Air Reactor Loop-seal:• Nominal air flow: ~165Nl/min

Fuel Reactor Loop-seal:• Nominal air flow: ~95Nl/min

Fe-Si Powder:Geldart group A

• Starting d50: 34micrometers• Density: 7000kg/m3

• Total Solids Inventory (TSI): ~ 120kg

Experimental set-up

P 1

P 4P 3

P 2

P 5

P 6

P 8

P 7

P 9

P 10

P 12P 25

P 14P 15

P 16P 17

P 18

P 19

P 20

P 21

P 22

P 23P29

P11 P24 P32

P31

P26P13

P28

E-1

P 27 P 30

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Frequency controlled fan and filter box mounted on scale

Bottom lifter

AR FR

FRLSARLS

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Experimental campaign overview

Design condition performance• Operational performance and stability• Validate design solutions

“Off-design” tests• FR increased flux/concentration• Part-load (50%)• Simulate reforming conditions

14Design conditions

Bottom lifter

AR FR

AR: 5500Nl/min (2.4m/s)Primary Secondary 1 Secondary 255% 22.5% 22.5%

FR: 2400Nl/min (2.6m/s)Primary Secondary 1 Secondary 250% 42% 8%

Lift: 700Nl/min (1.5m/s) Primary Secondary~70% ~30%

ARLS

FRLS

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-0.5

0.5

1.5

2.5

3.5

4.5

5.5

-10 290

Pressure relative to ambient pressure [mbar]

Rea

ctor

hei

ght [

m]

AR reactor body ~1.9kg/s (~46kg/m2s)

FR reactor body ~0.75kg/s (~46kg/m2s)

AR primary nozzle

FR primary nozzle

AR cyclone & loop-seal

FR cyclone & loop-seal

50 100 150 200 250 300 0

0

1

2

3

4

5

0 0.1 0.2 0.3 0.4

Solids concentration [m3sol/m

3tot]

Rea

ctor

hei

ght [

m]

AR, ~1.9kg/s

FR, ~0.75kg/s

Pressure loop

Design conditions

Solids concentration

Rea

ctor

hei

ght [

m]

Rea

ctor

hei

ght [

m]

Solids concentration [m³sol/m³tot]Pressure relative to ambient pressure [mbar]

AR Solids flow (flux)~ 2kg/s ( 48kg/m2s)

FR Solids flow (flux) ~ 0.8kg/s ( 46kg/m2s)

Active mass ~25kg

Active mass ~16kg

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AR loop-seal

0

50

100

150

200

250

0 120 240 360 480 600 720 840Time [s]

Pre

ssur

e re

lativ

e to

am

bien

t [m

bar]

P28(P1+P2)/2P15

FR loop-seal

0

50

100

150

200

250

0 120 240 360 480 600 720 840Time [s]

Pres

sure

rela

tive

to a

mbi

ent [

mba

r]

P31(P1+P2)/2P14

Pressure balance between loop-seals & return points

Design conditions ARLS

AR FR(P1+P2)/2 P15

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0

1

2

3

4

5

-10 15 40 65 90 115 140 165

Pressure relative to ambient pressure [mbar]

Rea

ctor

hei

ght [

m]

FR Superficial gas velocity: 2.4m/s~0.62kg/s (~38.1kg/m2s)FR Superficial gas velocity: 2.6m/s~0.74kg/s (~45.7kg/m2s)FR Superficial gas velocity: 2.8m/s~0.79kg/s (~48.7kg/m2s)

0 25 500

1

2

3

4

5

0 0.1 0.2 0.3 0.4Solids concentration [m3

sol/m3tot]

Rea

ctor

hei

ght [

m]

1.8

2.8

3.8

4.8

0.000 0.005 0.010 0.015 0.020

ZOOM

Zoom

Design conditions

Fuel Reactor (FR) sensitivity

18Conclusions & Outlook

1. Achievement of stable operation at design conditions of the DLCFB cold flow model:• Solids flow above 2 kg/s → Solids flux (AR) 48 kg/m2s

2. Stable operation achieved at some defined off-design conditions:• Increased FR solids concentration/entrainment• Part load conditions• Simulated reforming conditions

3. Integrate lessons learnt in the final design of the 150kWth hot rig• Return leg height• Increase in FR solids concentration/entrainment

4. Scaling strategy incorporating elements from both Glicksman and Knowlton; the 150 kWth hot rig (i.e. the next step of the BIGCLC project) and the existing large CFM will together give valuable guidelines and process and design validation for further up-scaling

AcknowledgementThis publication forms a part of the BIGCO2 project, performed under the strategicNorwegian research program Climit. The authors acknowledge the partners: Statoil, GEGlobal Research, Statkraft, Aker Clean Carbon, Shell, TOTAL, ConocoPhillips, ALSTOM,the Research Council of Norway (178004/I30 and 176059/I30) and Gassnova (182070) fortheir support. In addition the valuable help of Masoud Ghorbaniyan (NTNU) and ValentinaBisio (Università degli studi di Genova) during the cold flow model experimental campaignis acknowledged.

Thank you

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