The field of the disclosure relates generally to fuel combustion systems. More specifically, the field of the disclosure relates to modular pressurized coal combustion (MPCC) for flexible energy generation.
The rapid addition of intermittent renewable energy (IRE) has created a growing need for responsive, dispatchable generation to provide grid stability. However, existing coal power plants, which have been pressed into operating more flexibly than originally designed in response to the growth of IRE, are being retired at alarming rates due in some cases to not being cost competitive (e.g., in the U.S., where cheaper natural gas power often prevails), environmental concerns, or not being able to be flexible enough, and these retirements are putting the reliability of the grid at risk. Moreover, coal adds to the diversity of the overall generational mix, an important hedge against future changes, e.g., price volatility of natural gas. In view of this, a new breed of coal power plants is needed that is clean, efficient and flexible to meet the changing market demands. Also, due to the impact of CO2 on climate change, the potential ability to be readily retrofitted a carbon capture plant is also an important feature for future coal power plants.
Due to its large reserves, ease of transportation and storage, low price, coal is expected to persist as one of main energy sources for generating power into the distant future. As more of the grid electricity is generated from intermittent renewable sources (IREs), the existing coal-fired power plants, optimized for baseload, are being increasingly relied on as load-following resources, which adds challenges to plant operations and hurts the economics of the plant. There is a need for a new concept for coal plants, where the plant will have a high efficiency (>40% HHV), increased operational flexibility with high ramp rates and minimal reduction of efficiency at part load, modular construction with low capital cost, and low emissions with the potential to be retrofitted for carbon capture without significant plant modifications. Additional features include integration with energy storage, minimized water consumption, reduced design, construction and commissioning schedules, enhanced maintenance features, integration capability with coal upgrading, and natural gas co-firing capability. The following disclosure is designed to address this need. The systems and methods described herein are intrinsically modular in design, flexible, carbon-capture ready, and have high efficiency and low water use.
In one aspect, a modular pressurized combustion system for flexible energy generation is provided. The system comprises a plurality of pressurized combustion boilers, at least one compressor configured to provide pressurized oxidizer gas to each of the plurality of pressurized combustion boilers in parallel, and at least one feeder configured to provide fuel to each of the plurality of pressurized combustion boilers in parallel. The system further comprises a flue gas input unit configured to provide recycled flue gas to each of the plurality of pressurized combustion boilers in series, at least one pressurized heat recovery unit configured to receive a flue gas output stream from each of the plurality of pressurized combustion boilers, and at least one particle filter configured to filter a flue gas output stream from the pressurized heat recovery unit. The system also comprises an integrated pollutant removal unit.
In another aspect, a process for flexible energy generation using a modular pressurized combustion system is provided. The process comprises providing, with at least one compressor, pressurized oxidizer gas to each of a plurality of pressurized combustion boilers in parallel, providing, with at least one feeder, fuel to each of the plurality of pressurized combustion boilers in parallel, and providing, with at least one flue gas input unit, recycled flue gas to each of the plurality of pressurized combustion boilers in series. The process further comprises recovering, with at least one heat recovery unit, heat from a flue gas output stream received from each of the plurality of pressurized combustion boilers, filtering, with at least one particle filter, a flue gas output stream from the at least one pressurized heat recovery unit, and cooling, with at least one integrated pollutant removal unit, a particle-free flue gas output stream received from the at least one particle filter.
In yet another aspect, a system for controlling wall heat flux in a pressurized coal combustion environment is provided. The system comprises at least one burner and at least one low-mixing, axial-flow boiler.
The following drawings illustrate various aspects of the disclosure.
Those of skill in the art will understand that the drawings, described below, are for illustrative purposes only. The drawings are not intended to limit the scope of the present teachings in any way.
The proposed concept incorporates pressurized coal combustion with a modular boiler design. A high-level process flow diagram for the proposed concept is given in
Downstream of the pressurized boilers, the flue gas streams are combined and fed into a pressurized heat recovery unit. In this unit, heat is extracted and integrated into the power cycle and the flue gas is cooled to slightly above the acid dew point temperature. After the pressurized heat recovery unit, fly ash particles in the flue gas are removed by a particle filter.
After particulate removal, the flue gas is further cooled in an integrated pollutant removal (IPR) unit. The IPR unit is a single, direct-contact cooling (DCC) column, in which the flue gas flows against a stream of cooler water, thereby reducing the flue gas temperature and resulting in condensation of the flue gas moisture. The water leaving the bottom of the column is at sufficiently high temperature that can be used for boiler feed water heating and the plant thermal efficiency is improved. Due to the high-pressure operation, sulfur-and nitrogen-containing species are dissolved in the cooling water and removed. This process of pollutant removal, which is effective only under pressure, combined with latent heat recovery, are key benefits of the MPCC process.
After the IPR unit, the clean, particle-free flue gas is heated back to a higher temperature using part of the IPR heat. The heated flue gas then goes through a single- or multi-stage expansion turbine to produce power. If multi-stage compressors and multi-stage expansion turbines are employed, the compression heat will be recovered by intercooling and then this heat will be used to heat the flue gas between turbine stages to increase the power output. In this way, most of the work used by the compressors is compensated by the power generated from the expansion turbines. The remaining part of the compressor work becomes the auxiliary load of the plant. The proposed concept has several important advantages over the conventional atmospheric-pressure PC plant. Advantages include:
1) Higher efficiency through recovering flue gas latent heat—As mentioned above, with high pressure, the latent heat from the flue gas can be utilized to increase plant efficiency. The temperature at which moisture condensation occurs in the flue gas is strongly dependent on operating pressure. The significant increase in condensation temperature makes it feasible to utilize the latent heat at pressure. Also, the extra power produced by integrating this latent heat into the power cycle is considerably higher than the net auxiliary load for pressurization, so that a power plant incorporating the proposed concept has a higher plant efficiency. Calculations show that, for the plant configuration shown in
2) Economical pollutant removal—In a pressurized system, SOx and NOx and some mercury can be removed simultaneously in a cooling column. The advantages of this approach over others include: 1) the capture of SOx and NOx occurs simultaneously, which is more economical than separate removal processes such as selective catalytic reduction (SCR) for NOx removal and sorbent injection for SO2; 2) large pieces of equipment, like SOx scrubbers and SCRs, are eliminated, resulting in significant capital cost savings; and 3) acid gas condensation is controlled to occur only in a single vessel, eliminating the chances of corrosion in other parts of the system.
3) Reduced gas volume—Compared with atmospheric pressure PC combustion, the overall volume of gas is significantly reduced in a pressurized system. This provides further opportunity to reduce the size of the boiler, pumps, and other equipment. Heat loss to the ambient is also reduced. Importantly, the volume of gas undergoing treatment for removal of ash and other contaminants is reduced, while the concentrations of these contaminants is increased, making their removal easier and more cost effective.
4) Improved coal combustion rate—In coal-fired combustion systems, the amount of air supplied is kept to a minimum to avoid efficiency loss and to minimize the auxiliary load associated with air delivery. In addition, it is important to keep the amount of unburned carbon in the fly ash below levels required for fly ash reuse applications. In a conventional PC plant, the oxygen concentration in the flue gas is normally kept above a minimum value, typically 2.5 vol %. However, studies have shown that coal conversion rates under pressurized conditions are higher, because both char oxidation and gasification rates increase. Also, the gas volume in a boiler decreases proportionally with pressure, reducing velocity and increasing residence time. This further increases the coal conversion at the exit of the boiler. Therefore, the oxygen concentration in the flue gas can be smaller in a pressurized boiler. This effectively reduces the amount of air needed. In addition, with enhanced coal combustion rate, the coal particle size can be larger, which means the auxiliary load for coal pulverizing can be reduced.
5) Increased combustion performance of lower-quality fuels—Some low-rank fuels, such as lignite, have limited use due to their high moisture and low energy content. Since much of the latent heat in the flue gas can be captured in pressurized combustion, the effective heating value of “low-Btu” fuels can be significantly increased.
6) Modular boiler construction—An important advantage of the proposed process is the ability to modularize the construction of the pressurized boiler. Because of the long, thin nature of pressure vessels, they can be built in a factory using skilled labor and high-quality control procedures, and then shipped to the power plant location. This approach is particularly important to the U.S., as some recent advanced coal technology projects have encountered construction delays and cost overruns due to the inability to ensure large numbers of experienced craftsmen to work in remote, rural locations where power plants are often sited. The use of modular construction will facilitate lower construction costs, on-time and within-budget plant construction, and better quality control.
7) Improved plant flexibility—Compared with a conventional PC power plant, the operating flexibility of the proposed plant is increased due to the parallel boiler design. The minimal load for a typical conventional PC plant is ˜25%. There is an efficiency drop at part-load operation, due in part to the mismatch of heat transfer in the radiant and convective sections of the boiler. For the proposed conceptual plant, 25% load can be easily achieved by just shutting down three boiler modules. The efficiency drop caused by heat transfer mismatch can be minimized as the operating condition of the remaining module is full load. Thus, a much deeper turn-down can be achieved with the modular design. Also, the ramp rate and cool/warm start-up time of the proposed conceptual plant should also be higher than a conventional PC plant since the size of each boiler module is relatively small.
8) Carbon-capture ready—The proposed plant can be readily retrofitted to the staged, pressurized, oxy-combustion (SPOC) process, one of the most promising carbon capture technologies for coal power plants.
Thermal radiation from a particle-laden flue gas stream can be greatly enhanced by pressure. Utilizing conventional coal combustion boiler designs under pressure can lead to excess wall heat fluxes and damages to the water-cooling walls. Therefore, a new boiler design is required for pressurized coal combustion.
A novel method is disclosed herein to control wall heat flux to within an acceptable level under pressurized coal combustion environment. This method incorporates two approaches: creating a low-mixing, axial-flow system and combusting coal particles with a tailored size distribution, to distribute heat release.
Conventional pulverized coal (PC) combustion boilers typically utilize tangential flow to enhance mixing and increase particle residence time, and also utilize very fine coal particles (typical mean and maximum sizes are around 75 μm and 200 μm, respectively) to increase burning rate. All these features are to ensure complete char combustion. In a pressurized combustion boiler, complete char combustion is less of a concern due to the high oxygen partial pressure and longer residence time. Therefore, a low-mixing, axial-flow boiler can be utilized to distribute heat release and thus lower the peak wall heat flux. Unlike a tangentially fired combustion boiler, which releases all the combustion energy in a short distance, a low-mixing, axial-flow boiler can create a longer flame and release combustion energy in a longer distance. Also, a much wider particle size range can be utilized to help distribute heat release. Due to different heating rates, different sized particles ignite at various locations, and burn at different speeds. A wider particle size range can effectively distribute the release of the combustion energy. With a tailored particle size distribution, we can even manipulate the heat flux profile along the height of the boiler, which gives us an opportunity to optimize steam integration.
With above design concepts, different burn configurations can be utilized for enhanced heat flux control in a coal-fired SPOC system. The burner designs can be used independently or coupled with particle size distribution control to enhance the ability to control heat flux to the boiler tubes. This allows additional flexibility to design the boiler tubes for more efficient steam production across a wider variety of operating conditions.
With above design concepts, different burn configurations can be utilized.
The following Examples describe or illustrate various embodiments of the present disclosure. Other embodiments within the scope of the appended claims will be apparent to a skilled artisan considering the specification or practice of the disclosure as described herein. It is intended that the specification, together with the Examples, be considered exemplary only, with the scope and spirit of the disclosure being indicated by the claims, which follow the Examples.
To evaluate the cost and performance of a modular pressurized coal combustion power plant as described above, the following experiments were conducted. A preliminary process analysis was carried out using plant configurations and steam cycles parameters as summarized in Table 1 below. NETL Base Case was selected as representative of a conventional supercritical (SC) steam-Rankine cycle pressurized combustion (PC) plant. MPCC Case 1 employed a SC steam cycle with single reheat. MPCC Case 2 employed an advanced ultra-supercritical (A-USC) steam-Rankine cycle with double reheat. The estimated performance for each of these cases is summarized in Table 1.
The levelized cost of electricity (LCOE) for the MPCC Case 1 was expected to be less than that for a conventional PC plant with the same power cycle. Even though the air compressors and flue gas expansion turbines added capital cost to the plant, the integrated pollutant removal (IPR) unit of MPCC Case 1, which combined latent heat recovery with SOx and NOx removal in a compact direct-contact cooling (DCC) column, replaced the traditional and expensive emission control equipment of the Conventional SC Power Plant. In addition, in pressurized combustion power systems such as MPCC Cases 1 and 2, the boilers, pumps, and other equipment were smaller, and though the pressure vessels for the boilers added additional cost, the modular boiler design allowed mass production of boilers in a factory using skilled labor with high-quality control procedures, which reduced estimated construction costs. Further, for a given-sized plant (i.e., electricity output), the higher efficiency of the MPCC Cases 1 and 2 lead to lower capital and operational costs as compared to the Conventional SC Power Plant. Considering previous economic analyses conducted for SPOC process (not included), the LCOE for MPCC plants is expected to be ˜20% less than a conventional PC plant of comparable size and power cycle configuration.
This application is a continuation of U.S. Non-Provisional application Ser. No. 16,938,725 filed Jul. 24, 2020. This application claims benefit of priority to U.S. Provisional Application Ser. No. 62/878,063 filed on Jul. 24, 2019, which is incorporated herein by reference in its entirety. This application further claims benefit of priority to U.S. Provisional Application Ser. No. 62/880,558 filed on Jul. 30, 2019, which is incorporated herein by reference in its entirety.
This invention was made with government support under RFP-89243319RFE000015 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
Number | Date | Country | |
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62880558 | Jul 2019 | US | |
62878063 | Jul 2019 | US |
Number | Date | Country | |
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Parent | 16938725 | Jul 2020 | US |
Child | 19002716 | US |