Combustion processdevelopment

VTT Bioruukki, Espoo, Finland26th February, 2016Toni Pikkarainen

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Our main targets in development offluidized bed combustion

Lower emissions§ higher efficiency → contribution for once-through

supercritical CFB development§ oxyfuel CFB development for Carbon Capture and

Storage (CCS)Higher fuel flexibility§ solutions to utilise challenging biomass and waste

derived fuels§ understanding of ash chemistry during combustion

related to bed agglomeration, deposition andcorrosion

New process concepts to decrease CO2 emissions§ solar-hybrids§ advanced multifuel concepts

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COMBUSTION PROCESS DEVELOPMENT

NEW APPLICATIONS• Advanced flexibility for utility plants• Dynamic simulation of energy processes• Bio-solar hybrid development• Solar applications – dynamic modelling of

CSP (Concentrated Solar Power)

• Apros Renewables development• PtG GtP and PtX concepts

2003 2006 2009 2012 2015 20172000 2019 2021Control for ash chemistry:

CorroStop® and CINDY CFBC® development

Development of high efficiency CFBtechnology (OTSC CFB design) to increase

Efficiency (HIPE, CLEFCO, CFB800)

Oxyfuel combustion developmentfor reduction of CO2 emissions(FlexiBurn, O2GEN projects)

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Pilot and bench scale combustion facilities(CFB, BFB, grate)

Fuel combustion tests at pilot and bench scales are used to§ Understanding in-furnace phenomena under fully controlled conditions

§ Combustion profiles§ Gas, solids, temperature

§ Heat transfer phenomena during combustion§ Emission formation§ Material behavior during combustion§ Ash behavior characteristics

§ Aerosol sampling inside furnace§ Formation and analysis of deposition

§ Combustion control studies

All critical parameters forboiler design!

http://www.vtt.fi/statichtml/combustionresearchandservices/vtt.html

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Fuel characterization tests in pilot scale

Combustion

Combustion profile(heat release), fuel

reactivity

Unburned carbon(UBC)

Emissions

Main componentssuch as CO2, O2,

CO, H2O, SOx andNOx

Trace elementse.g. HCl, HF, N2O,

NH3, CxHy, Hg

Ash

Ash compositionand split: bottomash vs. fly ash

Agglomeration,fouling and

corrosion tendency

Limestone

Reactivitycompared to

reference one

Estimate limestonedosage to reach

the emission limits

• optimal combustion conditions(temperature, air staging)

• furnace dimensioning• type and location of heat transfersurfaces

• material selections• emission control system• ash removal systems and utilization

Data to design andoptimize high

performance boilerwith low emissions

and highavailability in terms

of

6AnthraciteBituminous

coal Brown coal/lignitePet coke/Coal

waste PeatOil

shaleBiomass

(wood, bark etc)Agro biomass

(straw, rapeseed etc)Waste

(SRF etc) Limestone

Worldwide references of the fuels tested at VTTsite

Companies§ FWe, Foster Wheeler Energia Oy§ Metso Power Oy (Valmet)§ N.N., Canada§ ETI – ETI Aluminyum S.A., Turkey§ SAMCA - SAMCA Group, Spain§ ÅF – ÅF-Consult Ltd.§ Metso – Metso Power Oy§ Fortum – Fortum Oyj§ Promark – Promark Services Ltd. (Rio Tinto)§ Lahmeyer – Lahmeyer International GmbH§ Neste Jakobs Oy§ Finnish Power Companies

Several combustion tests forTurkish lignite has also been done

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Development steps in fluidisedbed combustion

0

50

100

150

200

250

300

350

400

1976

PilotPlant0,05

Pihlava5

Kauttua20

Leykam40

Tri-State2 x 55

Kajaani85

Vaski-luoto125

NovaScotia180

Turow235

MWe

1979 1981 1987 1987 1989

Year

1990 1993 1998

Alholmen240

2001

Natural circulation

First OTSCCFB

Lagisza460

2009 2010 2011

CIUDEN30

VTT coordinated R&Dprojects marked as agreen star

550

Build up of VTT’s first FB pilot

Four 550 MWe blockSamcheok GreenPower Project in Koreaunder construction

Demonstration ofoxyfuel combustionCIUDEN project inSpain

CFB800 Design

20xx

*

*

*

*

*

Once through boilers

World’s first successfuloxyfuel-CFB demonstrationby VTT (2006)

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Requirements for future power plant concepts

§ These trends call for new features also for the fluidized bed boilers

• Target 420-550 gCO2/kWh without CCS (~33% reduction)→ wider fuel flexibility including gas, biomass and thermal solar

• Improved load following capability→ design modifications, enhanced role of gaseous fuels etc.

• Gas/methane economy, shale gas boom, power to gas → gascombustion (superheating) could be an important option to improveplant dynamics and emission performance

• Size optimization: lower load factor, higher share of biomass and solar inthe design, load following capability → smaller unit size?

multifuel CFB solar-boostedCFB

solar-gas-boosted CFB

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Drivers towards solar hybrids - EmissionPerformance Standard

§ Emission PerformanceStandards 420-550gCO2/kWh proposed

§ Combination of thermalsolar and biomass with coal

§ Other option is to increaseshare of gas (emissionfactor ~60% of coal) inaddition to biomass andsolar

§ Could be a cost effectiveroute to reduce CO2 andmeet the new emissionlimits

Target level

Reduction needed~250 gCO2/kWh~33%

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New concepts under development to meetthe requirements of future power business

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Highly Flexible and Efficient Fossil Fuel Base Load Power Plants to ProvideFluctuating Back-up Power with High Share of Intermittent Renewable Energy –

“EFFLEX Concept”

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Integration of solar energy intoconventional power plant

§ Solar energy will have globally apredominant role in energysystem – VTT is developingconcept to integrate solar into“conventional” biomass boiler

§ Solar energy intermitted energysource (as well as wind power) inour concept biomass has a roleas a energy storage

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