combustion Terufumi Kawasaki, Yuji Fukuda, Babcock-Hitachi K.K Song Wu, Hitachi Power Systems America

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1 Overall system development for oxyfuel combustion Christian Bergins, Klaus-Dieter Tigges, Hitachi Power Europe GmbH Terufumi Kawasaki, Yuji Fukuda, Babcock-Hitachi K.K Song Wu, Hitachi Power Systems America Osamu Ito, Hitachi Ltd., Energy & Environmental Systems Laboratory st IEA GHG International Oxyfuel Combustion Conference, Cottbus

2 Hitachi Activities towards Commercial Oxyfuel Plants Experimental verification of design tools and combustion Firing design, CFD, Heat transfer AQCS Materials (corrosion, slagging, fouling) Basic process design studies for retrofits and new builds Overall system design for retrofits of actual power stations Modifications of components towards optimized oxyfuel systems Large scale testing New burner design (Hitachi testing up to 35 MW) Oxyfuel combustion tests at the Vattenfall Schwarze Pumpe plant AQCS testing and modification CO 2 Compressor optimization Hitachi Power Europe GmbH

3 Basic Oxyfuel research & testing Software / CFD development & validation Participation in COORETEC Projects (ADECOS, Oxycoal, Materials) Small Scale Tests (Hitachi facilities, IVD Stuttgart, E.ON UK) RWTH Aachen University 125 kw th E.ON UK 1 MW th IVD University of Stuttgart, 500kW th In parallel: Development of simulation programs/models th CFD calculations: optimize, evaluate process design changed due to oxyfuel requirements Other design issues and activities Validate heat transfer Hitachi 400kW th Investigate ash composition and slagging, material behaviour Dynamic simulation of air/oxyfuel firing (APROS) Hitachi Power Europe GmbH

4 4 MW th combustion test facility, Hitachi Japan Test items Burner, Combustion Ash properties Heat transfer properties Safety Over fire air ports (OFA) Combustion air Air Heater Spray tower (remove dust) Cyclone Primary gas pipe Heater Burner Horizontal furnace Fuel pipe IDF PAF, GRF Oxygen supply equipment Hitachi Power Europe GmbH

5 Oxyfuel Combustion boiler steam cycle DeNOx air seperation unit N 2 ASU Air O 2 Retrofit Recycled flue gas: shall be cold, cleaned and partially dried minimise changes in the boiler house avoid corrosion and erosion keep reliability of components CO 2 (purification) compression Coal ESP HRS DeSOx FGD FG cooling ash sulfur H 2 O CO 2 H 2 O flue gas recycle New Build air oxygen demand and recirculation mass flow should be minimized process and components should be optimized towards lower Capex and Opex different options for process design checked Hitachi Power Europe GmbH

6 Examples for retrofits and newbuilds FGD Flue Gas Recycle Heat Exchanger FG Drier 820 MWel Tower type boiler Retrofit studies for actual new builds finished CO 2 Compression app. 2,000m² ESP Compressor Unit 1-4 Air Separation Unit app. 26,000 m² 4 trains ASU (Air Separation Unit) Boiler SCR Dry EP FGD Compressor Optimization for pure oxyfuel plants ongoing 500m 500 MWel Two pass boiler Recirculation Line 150m Hitachi Power Europe GmbH

7 Burner and firing design Contours of temperature Process design by Experience Own Combustion & Firing Software CFD (Fluent and Hitachi Code) Hitachi Power Europe GmbH

8 30/35 MW Combustion: Design Validation 35MW th DS burner and modifications (Air Combustion) In flame measurements, emissions and burn out Temperature distribution Software, CFD validation and improvement (if necessary) Testing of different fuels and mixtures Bituminous coal (finished) and dry lignite (ongoing) Biomass cofiring ( %, finished) hardcoal sawdust dry lignite DS burner Temperature Distribution at Burner Axis (Top View) Final testing and design check at Schwarze Pumpe oxyfuel plant (Technological partnership Vattenfall for Oxyfuel Combustion) Different test campaigns for air/oxyfuel in 2010 Hitachi Power Europe GmbH

9 1.5 MW th Oxyfuel combustion Pilot Plant Simultaneous evaluation for Oxy-Combustion at furnace and flue gas behavior (NOx, SOx, dust, trace elements) Pulverized coal Bunker Catalyst GGH Flue gas treatment Total system Furnace O 2 Tank Furnace A/H Dry-EP GGH BF FGD CO 2 Flue gas Circulation Line GOALS High Performance DeNOx/Hg oxidation catalyst at high conc. H 2 OandSO 2 High efficiency SO 2 removal by wet FGD (SO 2 < 5 ppm for CO 2 compression) Trace pollutants (Hg, SO 3, HF etc.) removal Optimization of AQCS process Hitachi Power Europe GmbH

10 Carbon Dioxide Compression and Purification Hitachi CO 2 compressor up to 260Bar successful experience intermediate cooling proven robust rotor dynamics design and material selection improvement ongoing towards CCS application Hitachi Power Europe GmbH

11 Hitachi Power Europe GmbH