Gas Turbine Combustion and Ammonia Removal Technology of Gasified Fuels
Abstract
:1. Introduction
Fuel | BFGa | COGb | LDGc | Gasified fuel | |||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Resource | Coald | Heavy residue | OrimulsionTM | ||||||||||
Coal type or mine | 1 | -g | 2 | 3 | 4 | 5 | 6 | 7 | |||||
Gasifier type | Fixed | Fluidized | Entrained | Entrained | Entrained | ||||||||
Coal supply | Dry | Dry | Dry | Slurry | |||||||||
Developer | BGL[4] | BC[5] | IGC[6] | Shell[7] | HYCOL[8] | Texaco[9] | Texaco | CRIEPI[11] | |||||
Oxidizer | O2 | Air | Air | O2 | O2 | O2 | O2 | O2 | |||||
Composition | |||||||||||||
CO [%] | 20 | 6 | 75 | 56.4 | 7.9–14.7 | 27.6 | 25.9 | 67.8 | 69.5 | 55.2–59.4 | 40.9 | 51.7 | 43.5 |
H2 [%] | 3 | 56 | - f | 25.6 | 13.2–15.0 | 9.4 | 10.9 | 28.8 | 31.0 | 31.1–33.7 | 29.9 | 43.1 | 42.2 |
CH4 [%] | - f | 30 | - g | 6.6 | 1.5–2.8 | 0.5 | 1.4 | 0.01 | 0.03 | 1.0–2.0 | 0.1 | 0.2 | 0.4 |
CO2 [%] | 20 | - f | 13 | 2.8 | 10.0–12.0 | 5.4 | 6.7 | 2.3 | 1.0 | 7.6–10.4 | 9.5 | 3.2 | 11.8 |
H2O [%] | - f | - f | - g | - g | 11.5–18.4 | - g | - g | - i | - i | - g | 12.3 | - i | - i |
NH3 [ppm] | - f | - f | - g | - g | 500–1000 | 1000 h | 100 | 600 | - g | - g | - g | - g | |
H2S+COS[ppm] | - f | - f | - g | 20 | - g | 714 | 404 | 1.1% | 0.14% | - g | - g | 1.6% | 1.35% |
Others[%] | N2 | C2H2 etc. | O2, N2 | 8.6 | 45.9– 47.3 | 56.1 | 54.2 | - g | - g | - g | 7.3 | 0.2 | 0.75 |
CO/H2 mole ratio | 7 | 0.1 | - f | 2.2 | - g | 2.9 | 2.4 | 2.1 | 2.4 | 1.6–1.9 h | 1.4 | 1.2 | 1.0 |
HHV[MJ/m3] | 2.9 | 21 h | 9.5 h | 13.0 | - g | 4.9 | 5.2 | 12.2 | 12.5 | 12.0 h | 9.0 | 12.1 i | 11.0 i |
LHV [MJ/m3] | 2.9 | 19 h | 9.5 h | 12.0 | 3.6–4.1 | 3.6 | 3.9 | 11.7 | 11.9 | 11.3 h | 7.4 | 11.3 i | 10.2 i |
Resource | Wood | Wastek | RDFm | Black Liquor | |||||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Feedstock type | Planer chip | Mill ends | Planer Bark briquette | Waste chip | Pellet | Round timber chip | Chip | ||||||||||
Moisture content[%] | 13.3 | 45 | 27 | 15 | 8 | 9 | -g | -g | -g | -g | 15 – 40 | -f | -f | -g | |||
Gasifier type | Kiln | Fixed-bed down-draft | Fluidized | Entrained | |||||||||||||
Developer | Chugairo Co., Ltd. | Kawasaki Heavy Ind | Indian Inst. Sci. | Lurgi | Guessing | CHOREN Ind. | Tampella [13] | Chemrec [14] | |||||||||
Oxidizer | Dry | Dry+O2 | Air | Air | Air | O2 | Air+steam | Air | O2 | Air+steam | Air | Air+O2 | O2 | ||||
distillation | |||||||||||||||||
Composition | |||||||||||||||||
CO [%] | 36.1 | 26.0 | 9.7 | 14.6 | 20.6 | 19.8 | 17.9 | 19 | 20 | 46 | 25 | 22 | 40 | 8.0–15.0 | 6 | 30 | 38.08 |
H2 [%] | 20.2 | 30.1 | 11.2 | 14.3 | 16.7 | 15.2 | 14.5 | 16 | 10 | 13 | 40 | 22 | 40 | 8.0–12.0 | 1.6 | 22 | 39.17 |
CH4 [%] | 16.6 | 2.5 | 1.2 | 1.4 | 1.3 | 1.9 | 1.3 | 12 | 5 | 10 | 10 | - g | - g | 4.0–8.0 | 0.9 | 0.4 | 1.34 |
CO2 [%] | 15.8 | 17.9 | - g | - g | - g | - g | - g | 2 | 14 | 23 | 22 | 11 | 20 | 13.0–18.0 | 12.4 | 4.1 | 19.05 |
H2O [%] | - g | - g | 1.3 | 0.7 | 2.8 | 0.9 | 1.8 | - g | - g | - g | - g | - g | - g | 7.0–15.0 | 23.4 | 5.9 | 0.18 |
N2 [%] | 5.6 | 17.9 | 56.9 | 53.5 | 50.2 | 49.9 | 52.1 | 51 | 51 | 8 | - g | 45 | - g | - g | - f | - f | 0.24 |
NH3 [ppm] | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - f | - f | - g |
H2S+COS[ppm] | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - f | - f | 19,400 |
Others[%] | 5.7 | 5.6 | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | N2, C2H4 etc. N2 | - g | |
Tar [mg/m3] | 25,000 | 5 | 261 | 438 | 95 | 400 | 103 | 100 | - g | - g | - g | - n | - n | - g | - f | - f | 115 |
Dust [mg/m3] | 11,000 | <2 | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | <5 | - f | - f | - g |
CO/H2 mole ratio | 1.8 | 0.9 | 0.9 | 1.0 | 1.2 | 1.2 | 1.2 | 1.2 | 2 | 3.5 | 0.6 | 1.0 | 1.0 | - g | 3.8 | 1.4 | 1.0 |
HHV[MJ/m3] | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | - g | 1.8 | 6.8 | 10.3 |
LHV [MJ/m3] | 15.2 | 7.5 | 3.1 | 4.0 | 5.0 | 5.1 | 4.5 | 5.4 | 6.3 | 11.7 | 13.8 | 6.3 | 10.5 | 4 - 6 | 1.2 | 6.2 | 9.5 |
2. Background of IGCC Development in the World
2.1. Progress in IGCC developments worldwide
- (1)
- Air-blown gasifier + hot/dry type synthetic gas cleanup method.
- (2)
- Oxygen-blown gasifier + wet type synthetic gas cleanup method.
- (3)
- Oxygen-blown gasifier + hot/dry type synthetic gas cleanup method.
2.2. Subjects of gas turbine combustors for IGCCs
Synthetic gas cleanup | |||
---|---|---|---|
Wet type | Hot/Dry type | ||
Gasification agent | Air |
|
|
O2 |
|
|
2.3. De-NOx technologies of gas turbine combustors for IGCCs
2.3.1. Low-NOx combustion technology
2.3.2. Ammonia removal technology from gasified fuels
3. Basic Investigation of De-NOx Technologies for IGCCs
3.1. Low-NOx combustion technologies
3.1.1. Experimental device and methods of small diffusion burner
Experimental device
Supplied fuels and test conditions
Fuel properties/Conditions | Fuel standard conditions | ||||||
---|---|---|---|---|---|---|---|
Constituent | |||||||
CO [vol%] | 24.3~13.3 | 17.3 | 10.4 | 16~70 | 23.1 | 46.4 | 63.0 |
H2 [vol%] | 10.4~5.7 | 17.3 | 24.2 | 7~30 | 9.9 | 19.9 | 27.0 |
CH4 [vol%]*1 | 0~5.0 | 0, (2.6) | 0 | ||||
CO2 [vol%] | 0 | ||||||
H2O [vol%] | 0 | ||||||
NH3 [ppmv] | 0, 1000, (0~3000) | ||||||
N2 [vol%] | Balance*2 | ||||||
CO/H2molar ratio | 2.33 | 1.00 | 0.43 | 2.33 (1, 0.43*3) | 2.33 | 2.33 | 2.33 |
HHV[MJ/m3](at 273 K, 0.1 MPa) | 4.4 | 2.9~12.7 | 4.2 | 8.4 | 11.4 | ||
LHV[MJ/m3](at 273 K, 0.1 MPa) | 4.2~4.1 | 4.1 | 3.9 | 4.0~12.1 | 4.0 | 8.0 | 10.9 |
Tfuel [K] | 423, 298 | 633 | |||||
Tair [K] | 673 | 643 | |||||
Vfuel [m/s] | 92, 32 | 96 | |||||
Pressure | Atmospheric pressure condition |
3.1.2. NOx emission characteristics of low-Btu fuel
Effects of equivalence ratio
Effects of fuel constituents
(1) Effect of CO/H2 molar ratio in fuel
(2) Effect of NH3 concentration in fuel
3.1.3. Fuel-NOx emission characteristics in supplied-air staging combustion
Effects of fuel constituents
(1) Effects of CO/H2 molar ratio in fuel
(2) Effect of CH4 concentration in fuel
(3) Numerical analysis using an elementary reaction model for gauging the effects of a CH4 constituent on fuel-NOx formation
(4) Prediction methodology of fuel-NOx emissions
3.1.4. Combustion emission characteristics of medium-Btu fuel
Thermal-NOx emission characteristics
Fuel-NOx emission characteristics
3.2. Non-catalytic reduction of NH3 from gasified fuel
3.2.1 Experimental device and numerical analysis model
Experimental device and method
Temperature distribution in reactor
Analysis model and validity of numerical analysis
3.2.2. Influence of various factors on ammonia removal characteristics
Effects of reaction temperature
Effects of adding O2 and NO
Effects of combustible components
(1) Effects of CO constituent
(2) Effects of H2 constituent
(3) Effects of CH4 constituent
3.2.3. Scope of application
4. Test Facility and Method for Demonstration and Combustion Characteristic-Evaluation of Gasified Fueled Combustors
4.1. Test facilities
4.2. Measurement system
5. Combustor for Air-Blown Gasification System with Hot/Dry Type Synthetic Gas Cleanup
5.1. Design concept of combustor
- (1)
- Combustion stability. It is necessary to stabilize the flame of low-calorific fuel.
- (2)
- Low NOx emission technology to restrain the production of fuel-NOx from NH3 in the fuel.
- (3)
- Cooling structure to cool the combustor wall efficiently with less amount of air.
5.1.1. Assurance of flame stabilization
5.1.2. Fuel-NOx reduction
(1) Air to fuel ratio in primary combustion zone
(2) Introduction method of secondary air
5.1.3. Cooling of combustor liner wall
Tair | 700 K |
Tfuel | 633 K |
Tex | 1773 K |
Ur | 16 m/s |
P | 1.4 MPa |
φex | 0.62 |
Combustion Intensity | 2.0 × 102 W/(m3 ·Pa) |
5.2. Test results
5.2.1. Combustion emission characteristics
Emission characteristics in gas turbine operations
Effect of fuel calorific value on CO emission characteristics
Thermal-NOx emission characteristics
Fuel-NOx emission characteristics
(1) Effect of CH4 constituent
(2) Effect of fuel calorific value
(3) Effect of fuel-bound nitrogen
(4) Effect of pressure
- CO = 18.3vol%, H2 = 6.9vol%, CH4 = 2.5vol%,
- CO2 = 15.9vol%, N2 = 56.3vol%, NH3 = 1000 ppmv
- HHV = 4.2 MJ/m3, LHV = 4.0 MJ/m3
- Mass
- Momentum
- Species
- Energy
5.2.2. Thermal characteristics of combustor liner wall
Effect of fuel calorific value
Effect of exhaust gas temperature
Effect of combustion pressure
6. Combustor for Oxygen-Blown Gasification System with Wet Type Synthetic Gas Cleanup
6.1. Subjects of combustor
6.2. Design concept of combustor
6.3. Test conditions
Composition | CO | 30.4 vol% |
H2 | 27.5 vol% | |
CH4 | 6.8 vol% | |
CO2 | 35.3 vol% | |
HHV (at 273 K, 0.1 MPa) | 10.1 MJ/m3 |
Tair | 603 K |
Tfuel | 583 K |
TN2 | 333 K |
Tex | 1700 K |
N2 / fuel ratio | 0.3 kg/kg |
P | 1.4 MPa |
Combustion Intensity | 2.2 × 102 W/(m3 ·Pa) |
6.4. Test results
7. Combustor for Oxygen-Blown Gasification System with Hot/Dry Type Synthetic Gas Cleanup
7.1. Subjects of combustor
- (1)
- Low NOx-emission technology: Thermal-NOx emissions produced by thermochemical reactions, mainly of the Zel’dovich NO mechanism using nitrogen injection, and fuel-NOx emissions originating from NH3 using a two-stage combustion, must be simultaneously restrained.
- (2)
- Higher thermal efficiency: Nitrogen injection must be tailored so as to decrease the power to compress nitrogen, which is returned into the gas turbine in order to recover a part of the power used for the air-separation unit.
7.2. Design concept of combustor
(1) Assurance of flame stabilization
(2) Nitrogen injection
(3) Fuel-NOx / Thermal-NOx reduction
7.3. Test results
Supplied fuel in test | Commercial gasified fuel | |
---|---|---|
Constituent | ||
CO | 31.4 % | 40.9 % |
H2 | 28.6 % | 29.9 % |
CH4 | 0~3.0 %*1 | 0.1 % |
CO2 | 32.0 % | 9.5 % |
H2O | 0.0 % | 12.3 % |
N2 | 5.0 % | 7.3 % |
NH3 | 0~3000 ppm*2 | 500 ppm |
HHV (at 273 K, 0.1 MPa) | 8.8 MJ/m3 | 9.0 MJ/m3 |
LHV (at 273 K, 0.1 MPa) | 8.1 MJ/m3 | 8.2 MJ/m3 |
Tair | 603 K |
Tfuel | 583K |
TN2 | 333 K |
N2/fuel | 0.70 kg/kg |
Tex | 1773 K |
φex | 0.66 |
P | 1.2 MPa |
Ic | 4.0 × 102 W/(m3·Pa) |
Ur | 5.6 m/s (at 273 K basis) |
ΔP/q | 1.64 × 102 |
7.3.1. Combustion emission characteristics
Effect of exhaust gas temperature
Effect of sectional flow velocity
Effect of N2 bypassing way
Effect of N2 flow rate
Effect of NH3 constituent
Effect of combustion pressure
Prediction of combustor’s performance
Emission characteristics in gas turbine operations
7.3.2. Thermal characteristics of combustor exhaust
8. Conclusions
- Air-blown gasifier + Hot/Dry type synthetic gas cleanup method
- Oxygen-blown gasifier + Wet type synthetic gas cleanup method
- Oxygen-blown gasifier + Hot/Dry type synthetic gas cleanup method
(1) Non-catalytic reduction of NH3
Gasification type | Air-blown | Oxygen-blown | ||||
---|---|---|---|---|---|---|
Carrier type of feedstock | Dry feed | Dry or Slurry | Dry feed | |||
Gas cleanup method | Wet type | Hot/Dry type | Wet type | Hot/Dry type | ||
Plant system
| Oxygen production unit not required | In operation now | Simpler system | |||
+2.5 points | +4.5 points | +1.5 points*3 | +2.5 points*3 | |||
Features of gasified fuel |
|
| ||||
Fuel contains NH3 and a lot of fuel-NOx emissions are discharged. | Fuel contains NH3 and a lot of fuel-NOx emissions are discharged. | |||||
Subjects of combustors’ development | Combustion stability of low calorific fuel | Reduction of thermal-NOx emissions | Reduction of thermal-NOx and fuel-NOx emissions simultaneously | |||
Reduction of fuel-NOx emissions | ||||||
Developed technologies | 40%~70%
| - |
| |||
Non-catalytic reduction of NH3 in fuel
| - | |||||
Low NOx combustion methods and advantageous effect (1) Auxiliary combustor + Two stage combustion NH3/HHV*6 [ppm/(kcal/m3)] [ppm/( MJ/m3)]
| - | 1.00
2.4 × 102 60%≦ ≦7 ppm | - | - | ||
(2) N2 direct injection
| - | - | 80%*7≦ | - | ||
(3) N2 direct injection + quick quench by combustion air
| - | - | 80%*8≦ | - | ||
(4) Auxiliary combustor + Two stage combustion + N2 direct injection
| - | - | - | ≦0.25 / 1.00≦
≦0.6 × 102 / 2.4 × 102≦ ≦40% / 60%≦ 80%≦ | ||
Features of developed low-NOx combustor |
|
|
| |||
Combustors’ performance | ||||||
Evaluation items | Target | |||||
Rated exhaust temperature | 1773 K (1500 °C) | 1673 K (1400 °C) | 1773 K | 1873 K (1600 °C) | ||
Combustion efficiency | ≧99.5% | ≧99.99% (CO ≦ 20 ppm) | ≧99.99% (CO ≦ 20 ppm) | ≧99.99% (CO ≦ 20 ppm) | ||
NOx emissions*1 Total NOx*5 | ≦60 ppm | - | ≦60 ppm*2 | - | ≦34ppm*4 | ≦40 ppm*4 |
Thermal-NOx | ≦10 ppm | ≦7 ppm | ≦8 ppm~11 ppm | ≦7 ppm | ≦8 ppm | |
Pattern factor (P.F.*10) at rated load condition | ≦15% | ≦7% | ≦13% | ≦7% | ≦7% | |
Maximum temperature of Liner wall | ≦850 °C | ≦1123 K (850 °C) | ≦1123 K | ≦1123 K | ≦1123 K | |
Remarks
HHV: corrected at 273 K, 0.1 MPa. |
|
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| |||
|
(2) The advantage of low NOx combustion
- Two-stage combustion was effective for decreasing fuel-NOx and thermal-NOx emissions; the primary equivalence ratio was set depending on CH4 concentration in the fuels.
- Adopting the auxiliary-combustion chamber was effective for stabilizing combustion of low calorific fuel in reducing flame.
- In oxygen-blown medium-Btu fuels, the combustion method, in which direct injection of surplus N2 by-product from the oxygen production unit was combined with rapid dilution by combustion air, was effective in reducing thermal-NOx emissions.
- The surplus N2 direct injection method improved plant thermal efficiency by 0.3 points.
- To simultaneously reduce thermal-NOx and fuel-NOx emissions, the method that combined surplus N2 direct injection with two-stage, reducing combustion was effective. It is also necessary to adopt an auxiliary-combustion chamber for stable combustion.
Air-blown IGCC
Oxygen-blown IGCC
Economical evaluation
- IGCC plant output: 250 MW class
- IGCC plant operation rate: 24 hours × 333 days per year
- NH3 concentrations: NH3 concentrations in the cases of air-blown gasified fuel and oxygen-blown gasified fuel are set at 1000 ppm and 500 ppm, respectively.
- Rate of DeNOx cost estimation: NOx removal efficiency, NH3 supply quantity and NOx removal catalyst quantity are different for each type IGCC. DeNOx facility is based on conventional denitration equipment; spatial velocities at DeNOx rates of 28%, 72%, 83% and 90% are set at 220,000, 50,000, 33,000 and 20,000 [hour−1], respectively. An air-blown IGCC with hot/dry type synthetic gas cleanup adopting a 1573 K-class gas turbine is set as a standard, and the rate of DeNOx cost is the calculated proportion of each case to the standard, due to fluctuations in unit prices of catalysts’ supplied NH3, and exchange rates.
Nomenclature
CO/H2 | Molar ratio of carbon monoxide to hydrogen in fuel |
C.R. | Conversion rate from ammonia to NOx [%] |
D.R. | Decomposition rate from NH3 or NO to N2 |
HHV | Higher heating value of fuel at 273 K, 0.1 MPa basis [MJ/m3] |
LHV | Lower heating value of fuel at 273 K, 0.1 MPa basis [MJ/m3] |
Ic | Combustion intensity at 273 K basis [W/(m3·Pa)] |
M | The third body |
N2/Fuel | Nitrogen over fuel supply ratio [kg/kg] |
NOx(16%O2) | NOx emissions corrected at 16% oxygen in exhaust [ppm] |
NOxth | Thermal NOx emissions [ppm] |
Pr | Reaction pressure in tubular flow reactor [MPa] |
q | Dynamic pressure at cross-sectional surface of combustor-exit |
Tad | Adiabatic flame temperature [K] |
Tair | Temperature of supplied air [K] |
Tex | Average temperature of combustor exhaust gas [K] |
Tfuel | Temperature of supplied fuel [K] |
Tn2 | Temperature of supplied nitrogen [K] |
Tr | Averaged reaction temperature in tubular flow reactor [K] |
tr | Averaged reaction time in tubular flow reactor [s] |
Ur | Mean velocity of cross-sectional flow of air at 273 K basis [m/s] |
φex | Average equivalence ratio at combustor exhaust |
φp | Average equivalence ratio in primary combustion zone |
ΔP/q | Total pressure loss coefficient (characteristic section is combustor-exit) |
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Hasegawa, T. Gas Turbine Combustion and Ammonia Removal Technology of Gasified Fuels. Energies 2010, 3, 335-449. https://doi.org/10.3390/en3030335
Hasegawa T. Gas Turbine Combustion and Ammonia Removal Technology of Gasified Fuels. Energies. 2010; 3(3):335-449. https://doi.org/10.3390/en3030335
Chicago/Turabian StyleHasegawa, Takeharu. 2010. "Gas Turbine Combustion and Ammonia Removal Technology of Gasified Fuels" Energies 3, no. 3: 335-449. https://doi.org/10.3390/en3030335