全氧燃烧玻璃窑炉的寿命浅析

通过对国内外部分全氧燃烧玻璃窑炉的寿命统计,非正常停炉和常见故障等问题分析,找出影响窑炉寿命的因素,提出要以规范化、科学化、系统化的思维,通过新材料、新技术、新工艺的运用有效延长全氧燃烧玻璃窑炉的寿命,对目前全氧燃烧窑炉的建设、推广应用有积极的参考价值。     

Impact of air staging along furnace height on NOx emissions from pulverized coal combustion

Experiments were carried out on an electrically heated multi-path air inlet one-dimensional furnace to assess NO_x emission characteristics of an overall air-staged (also termed air staging along furnace height) combustion of bituminous coal. The impact of main parameters of overall air-staged combustion technology, including burnout air position, air stoichiometric ratio, levels of burnout air (the number of burnout air arranged at different heights of the furnace), and the ratios of the burnout air flow rates and pulverized coal fineness of industrial interest, on NO_x emission were simulated to study in the experimental furnace, as well as the impact of air staging on the carbon content of the fly ash produced. These results suggest that air-staged combustion affects a pronounced reduction in NO_x emissions from the combustion of bituminous coal. The more deeply the air is staged, the further the NO_x emission is reduced. Two-level air staging yields a greater reduction in NO_x emission than single-level air staging. For pulverized coal of differing fineness, the best ratio between the burnout air rates in the two-level staging ranges from 0.6 to 0.3. In middle air-staged degree combustion with f_M = 0.75, pulverized coal fineness, R₉₀ (%), has a greater influence on NO_x emission, whereas R₉₀ has little influence on NO_x emission for deep air-staged degree with f_M = 0.61. Air-staged combustion with proper burnout air position has little effect on the burnout. For overall air-staged combustion, proper burnout air position and air-staged rate should be considered together in order to achieve high combustion efficiency.     

Oxyfuel boiler design in a lignite-fired power plant

In the context of CO₂ capture and storage, the oxyfuel technology provides a promising option applicable in centralised power production schemes. This technology is based on combustion with pure oxygen instead of air and the flue gas mainly consists of CO₂ and H₂O. The work presented in this paper is focused in the application of the oxyfuel technology in a lignite-fired power plant. Significant design issues are the required extended flue gas recirculation in order to provide the ballasting effect of the absent N₂ and moderate the furnace temperatures. Therefore, a modified design of heat exchange surfaces of the oxyfuel steam boiler was formulated and was compared to a conventional air-fired boiler. A typical modern Greek air-fired power plant has been used as reference. The dominating factors that affect the dimensioning of the oxyfuel boiler are the higher radiative heat transfer - due to the high concentrations of CO₂ and H₂O in the flue gas - and the different flue gas mass flow, compared to a conventional air-fired boiler. For the determination of the thermodynamic cycle characteristics, simulations were made with the use of a thermodynamic cycle calculation software [Stamatelopoulos GN. Calculation and optimisation of power plant thermodynamic cycles, VDI-Regulations, Series 6, Nr. 340. Braunchweig, Mechanical Engineering Department; 1996 [in German]].     

典型尺寸燃煤颗粒富氧燃烧特性及燃烧本征动力学研究

利用微型流化床加热速度快、温度分布均匀以及气体近平推流等优势,在直径20 mm自动控温的微型流化床反应分析仪中研究了粒度分布为1.7~3.35 mm和0.12~0.23 mm两种典型尺寸燃煤颗粒在790~900℃温度范围内的富氧燃烧行为。通过快速响应过程质谱对燃烧产生的烟气进行实时监测,成功地识别和记录了粗颗粒燃烧过程中经历的挥发分燃烧和原位新生半焦燃烧两个主要阶段。挥发分析出速度最快,然后快速燃烧,而半焦燃烧速度较慢。相比之下,细颗粒燃烧的这两个阶段具有几乎相同的速率,因而相互耦合而难以区分。根据实验结果,挥发分析出和燃烧为快速反应,煤颗粒燃烧过程速率受原位新生半焦燃烧过程控制。进一步研究了挥发分和原位新生半焦燃烧动力学行为,获得其本征动力学的活化能分别为107.2和143.9 kJ/mol。     

Study on ash deposition under oxyfuel combustion of coal/biomass blends

Combustion in an O₂/CO₂ mixture (oxyfuel) has been recognized as a promising technology for CO₂ capture as it produces a high CO₂ concentration flue gas. Furthermore, biofuels in general contribute to CO₂ reduction in comparison with fossil fuels as they are considered CO₂ neutral. Ash formation and deposition (surface fouling) behavior of coal/biomass blends under O₂/CO₂ combustion conditions is still not extensively studied. Aim of this work is the comparative study of ash formation and deposition of selected coal/biomass blends under oxyfuel and air conditions in a lab scale pulverized coal combustor (drop tube). The fuels used were Russian and South African coals and their blends with Shea meal (cocoa). A horizontal deposition probe, equipped with thermocouples and heat transfer sensors for on line data acquisition, was placed at a fixed distance from the burner in order to simulate the ash deposition on heat transfer surfaces (e.g. water or steam tubes). Furthermore, a cascade impactor (staged filter) was used to obtain size distributed ash samples including the submicron range at the reactor exit. The deposition ratio and propensity measured for the various experimental conditions were higher in all oxyfuel cases. The SEM/EDS and ICP analyses of the deposit and cascade impactor ash samples indicate K interactions with the alumina silicates and to a smaller extend with Cl, which was all released in the gas phase, in both the oxyfuel and air combustion samples. Sulfur was depleted in both the air or oxyfuel ash deposits. S and K enrichment was detected in the fine ash stages, slightly increased under air combustion conditions. Chemical equilibrium calculations were carried out to facilitate the interpretation of the measured data; the results indicate that temperature dependence and fuels/blends ash composition are the major factors affecting gaseous compounds and ash composition rather than the combustion environment, which seems to affect the fine ash (submicron) ash composition, and the ash deposition mechanisms.     

Study of ash deposition during coal combustion under oxyfuel conditions

This paper presents a comparative study on ash deposition of two selected coals, Russian coal and lignite, under oxyfuel (O₂/CO₂) and air combustion conditions. The comparison is based on experimental results and subsequent evaluation of the data and observed trends. Deposited as well as remaining filter ash (fine ash) samples were subjected to XRD and ICP analyses in order to study the chemical composition and mineral transformations undergone in the ash under the combustion conditions. The experimental results show higher deposition propensities under oxyfuel conditions; the possible reasons for this are investigated by analyzing the parameters affecting the ash deposition phenomena. Particle size seems to be larger for the Russian coal oxy-fired ash, leading to increased impaction on the deposition surfaces. The chemical and mineralogical compositions do not seem to differ significantly between air and oxyfuel conditions.The differences in the physical properties of the flue gas between air combustion and oxyfuel combustion, e.g. density, viscosity, molar heat capacity, lead to changes in the flow field (velocities, particle trajectory and temperature) that together with the ash particle size shift seem to play a role in the observed ash deposition phenomena.     

CO2‐Abtrennung für fossil befeuerte Kraftwerke

An overview of technologies for fossil fuel power plants with drastically reduced CO₂ emissions is given. Post combustion capture, Pre combustion capture, and Oxyfuel technology are introduced and compared. Current research results indicate that Post combustion capture may lead to slightly higher losses in power plant efficiency than the two other technologies. However, retrofitting of existing plants with Oxyfuel technology is complex and costly, and retrofitting of Pre combustion capture is not possible. On the other hand, Post combustion capture is suited for retrofitting. Based on the mature technology of reactive absorption, it can be implemented on a large scale in the near future. Therefore, Post combustion capture using reactive absorption is discussed here in some detail.     

A three-dimensional numerical study of the combustion of coal blends in blast furnace

The practice of blending coals for pulverized coal combustion is widely used in ironmaking blast furnace. It is desirable to characterize the combustion behaviour of coal blends and their component coals. A three-dimensional numerical model is described to simulate the flow and combustion of binary coal blends under simplified blast furnace conditions. The model is validated against the experimental results from a pilot-scale combustion test rig for a range of conditions, which features an inclined co-axial lance. The overall performance of coal blend and the individual behaviours of their component coals are analysed, with special reference to the influences of particle size and coal type. The synergistic effect of coal blending on overall burnout is examined. The results show that the interactions between component coals, in terms of particle temperature and volatile content, are responsible for the synergistic effect. Such synergistic effect can be optimized by adjusting the blending fraction. The model provides an effective tool for the design of coal blends.     

Modelling coal combustion: the current position

At the present time, computer models for coal combustion are not sufficiently accurate to enable the design of combustion plant or the selection of a coal based on combustion behaviour. Most comprehensive combustion models can predict with reasonable accuracy flow fields and heat transfer, but usually with a much lesser degree of accuracy than the combustion of the coal particles through to char burnout. Many research programmes are aimed at developing a much more accurate predictive tool for assessing coals specially fired in burners or furnaces employing a range of NO_x abatement technologies. Some of the current developments in CFD coal combustion modelling are outlined here. Particular attention is paid to the first step, where the devolatilisation pre-processor code is used to compute the pyrolysis rate, the yields and the composition of volatiles and char. These parameters are used as inputs to the devolatilisation and volatile combustion sub-models, where various options can be used, and also the char burnout sub-models. The accuracy of the sub-models is examined using data from four well-studied coals, three from the UK and one from the US. The main network devolatilisation codes are compared with experimental data. Two char combustion models have also been investigated in order to compare char burnout predictions and the development of char morphology and surface area during burnout are considered. The applications of these sub-models to two combustion situations were considered. These involve reactions in a drop tube furnace and a low NO_x industrial burner and in both cases, the model predictions were compared with experimental measurements.     

Co-firing of coal and biomass in oxy-fuel fluidized bed for CO2 capture: A review of recent advances

The co-firing of coal and biomass in oxy-fuel fluidized beds is one of the most promising technologies for capturing CO₂. This technology has attracted wide attention from academia and industry in recent years as a negative emission method to capture CO₂ produced by carbon contained in biomass. In the past decades, many studies have been carried out regarding experiments and numerical simulations under oxy-fuel combustion conditions. This paper firstly briefly discusses the techno-economic viability of the biomass and coal co-firing with oxycombustion and then presents a review of recent advancements involving experimental research and computational fluid dynamics (CFD) simulations in this field. Experimental studies on mechanism research, such as thermogravimetric analysis and tube furnace experiments, and fluidized bed experiments based on oxy-fuel fluidized beds with different sizes as well as the main findings, are summarized as a part of this review. It has been recognized that CFD is a useful approach for understanding the behaviors of the co-firing of coal and biomass in oxyfuel fluidized beds. We summarize a recent survey of published CFD research on oxy-fuel fluidized bed combustion, which categorized into Eulerian and Lagrangian methods. Finally, we discuss the challenges and interests for future research.     

Modeling of oxy-fuel combustion for a western Canadian sub-bituminous coal

The motivation of this research is to develop practical oxy-coal combustion techniques in order to facilitate the conversion of coal-fired utility power plants so as to recover a CO₂ rich flue gas stream for use and/or sequestration. The objective of this study is to ascertain the applicability and accuracy of a modeling tool to assist with future pilot scale oxy-fuel combustion experiments and burner scale-up studies. Two modes of oxy-coal combustion, O₂ enriched air (OEA) and recycled flue gas (RFG), were experimentally tested in a 0.3 MW_th pilot-scale combustor using a western Canadian sub-bituminous coal. The computational fluid dynamic tool was utilized to model the combustion, heat transfer and pollutant formation characteristics of these test cases and to examine the impact due to changes in the combustion medium, burner swirl and burner configuration. The model provided insights for the observed variation in NO_x production among the test cases: the dramatic increase in the OEA mode, the drop at higher burner swirl settings and the surprisingly small reduction in the RFG mode. Overall the model results compared well with measured data in all test cases and established confidence in using the model to explore new design concepts for oxy-coal combustion.     

Computational modeling of furnace sorbent injection for SO2 removal from coal-fired utility boilers

Furnace sorbent injection (FSI) is used to remove SO₂ formed during coal combustion by injecting sorbent into the high temperature zone of a furnace above the fireball. FSI is cost effective for older coal-fired boilers, especially when space or capital budgets are limited. To optimize the design and performance of FSI, an SO₂/sorbent modeling scheme that simultaneously considers calcination (or dehydration), sintering, and sulfation has been developed and implemented. It is coupled with a three-dimensional combustion model based on computational fluid dynamics to determine the most desirable locations for sorbent injection and to optimize the amount of sorbent needed to achieve a targeted SO₂ removal efficiency. A sensitivity analysis was conducted to determine the effect of flue gas temperature, particle diameter, and SO₂ concentration on the extent of sulfation. This SO₂/sorbent sub-model was applied to a 126-MW front-wall fired boiler firing eastern bituminous coal. The SO₂ removal efficiencies predicted by the model agreed well with those measured in the field. The modeling results indicated that sorbent injected directly into the furnace through boosted over-fired air ports is more effective at removing SO₂, due to longer residence time and better mixing, relative to ports higher in the furnace with poor mixing. This modeling approach is optimized for full-furnace application to facilitate the design process.     

Influence of woody biomass (cedar chip) addition on the emissions of PM10 from pulverised coal combustion

Co-combustion of pulverised coal with a woody biomass, cedar chip was conducted in a lab-scale drop-tube furnace (DTF) to investigate the synergetic interaction between the inorganic elements of different fuels and the emissions of sub-micron particles (particles smaller than 1.0 μm in size, PM₁) and super-micron particles (particles in the size range of 1.0-10 μm, PM₁₊) during co-firing. The mass fraction of cedar chip in fuel blend ranged from 10% to 50%. All the fuels were burnt in air at two furnace temperatures, 1200 and 1450 °C. The results indicate that, under an identical calorific input, combustion of cedar chip alone favored the emission of sub-micron PM₁, which is dominated by volatile elements including K, Ca, Fe, Na and P. A large fraction of K and Na were most probably present as gaseous vapors in the furnace. The other metals mainly condensed into nano-scale nuclei which subsequently coagulated into a variety of sizes in flue gas. Coal combustion alone favored the release of super-micron particles rich in Al and Si. Emission of PM upon co-firing was a function of both cedar chip share and furnace temperature. At a small mass fraction for cedar chip in fuel blend, e.g. 10% tested here, interaction between the inorganic elements of single fuels was insignificant at either furnace temperature. Accordingly, the quantities of PM₁ and PM₁₊ emitted from co-firing at 10% cedar chip were slightly higher than from the combustion of coal alone, due to the contribution of cedar chip. Significant interaction between the inorganic elements of single fuels was observed for co-firing of coal with >10% cedar chip at the furnace temperature of 1450 °C. As has been confirmed, adding 20-30% cedar chip to coal resulted in the shift of approximately 90% of PM₁ and 50% PM₁₊ into coarse ash particles. For the cedar chip-derived alkali vapors and nano-scale/sub-micron particles, the rates of their shift into larger particles were influenced by two competing routes, homogeneous coagulation and surface reaction with coal-derived kaolin. In contrast, the shift of super-micron particles was primarily determined by their collision probability with the coal-derived mineral grains in bulk gas. A sticky surface for particles is also essential. The shift of individual metals into coarse ash differed distinctly from one another.     

Experimental study of ash formation during pulverized coal combustion in O2/CO2 mixtures

The present paper was addressed to mineral transformations and ash formation during O₂/CO₂ combustion of pulverized coal. Four Chinese thermal coals were burned in a drop tube furnace to generate ashes under various combustion conditions. The ash samples were characterized with XRD analysis and ⁵⁷Fe Mössbauer spectroscopy. The impacts of O₂/CO₂ combustion on mineral transformation and ash formation were explored through comparisons between O₂/CO₂ combustion and O₂/N₂ combustion. It was found that, O₂/CO₂ combustion did not significantly change the mineral phases formed in the residue ashes, but did affect the relative amounts of the mineral phases. The differences observed in the ashes formed in two atmospheres were attributed to the impact of the gas atmosphere on the combustion temperatures of coal char particles, which consequently influenced the ash formation behaviors of included minerals.     

Detailed measurements in a laboratory furnace with reburning

This article presents a detailed experimental characterization of the reburning process in a large-scale laboratory furnace. Natural gas, pine sawdust and pulverized coal were used as reburn fuels. Initially, the study involved the collection of in-flame combustion data, without reburning, in order to define appropriate locations for the injection of the reburn fuels. Next, flue-gas data were obtained for a wide range of experimental conditions using the three reburn fuels and, subsequently, detailed measurements of local mean O₂, CO, CO₂, HC and NO_x concentrations, and gas temperatures have been obtained in the reburn zone for three representative furnace operating conditions, one for each reburn fuel studied. The flue-gas data revealed that the sawdust reburning leads to NO_x reductions comparable or even higher than those attained with natural gas reburning, while coal reburning yields much lower NO_x reductions. The detailed data obtained in the reburn zone indicates that the reburning process remains active throughout all the reburn zone in the cases of natural gas and sawdust reburning, while in the case of coal reburning its relatively low volatile matter content is insufficient to establish an effective reburn zone. In the cases of the sawdust and coal reburning the burnout levels remain approximately constant, regardless of the NO_x emissions reduction, with the sawdust reburning leading to higher particle burnout performance than the coal reburning.     

Flame temperatures and species concentrations in non-stoichiometric oxycoal flames

The oxyfuel technology offers the possibility for CO₂ sequestration from coal fired power plants. One drawback is the need for a high external flue gas recirculation to avoid inadmissible high flame temperatures. The concept of controlled staging with non-stoichiometric burners (CSNB) allows a significant reduction of the commonly proposed flue gas recirculation rate while fulfilling all requirements on temperature limitations. The concept aims at a more efficient oxyfuel process with a higher degree of freedom for heat-flux adjustments suitable for a new generation of oxyfuel boilers. The steam generator size could be reduced and in this way a more cost effective steam generator concept is possible. Additionally the energy demand for the flue gas recirculation is lowered.This paper presents the experimental investigations of non-stoichiometric oxycoal flames. Temperature and gas profiles were taken to analyze the combustion behavior of coal with high oxygen concentrations in the oxidizer under oxygen deficiency and accordingly oxygen excess. In addition an optical flame monitoring system allowed a comparison of ignition, flame shape and stability. In the test rig lignite was burned under different stoichiometries ranging from 0.5 to 2.5 and different oxygen concentrations in the oxidant ranging from 30 to 40 vol.%. The thermal input of the burner was 70 kW at a total thermal input of 140 kW and a dry flue gas recirculation was used. The results were compared to a conventional air-blown combustion and showed that similar temperature ranges can be reached even with oxygen concentrations in the oxidizer as high as 40 vol.%.     

Large-eddy simulation of coal combustion in 15 MW pilot-scale boiler-simulation facility

High-fidelity modeling provides a useful approach to investigate the multiscale multiphysics mechanism in the pulverized coal combustion. This research focuses on understanding the pulverized coal combustion in a pilot-up facility: General electric (GE) 15 MW pilot-scale boiler simulation facility (BSF). The heat flux to the boiler water wall, O₂ concentration, and gas temperature are the quality of interest (QoI's) for this research, as they are the most important parameters for designing a full-scale pulverized coal boiler. Even the heat flux in boiler is largely determined by the heat transfer mechanism, and other detailed multiphysics mechanisms, including multiphase turbulent flow, radiation heat transfer, ash deposition, coal devolatilization, and oxidation, also need to be accounted. This work applies large-eddy simulation (LES) code on high-performance computing facility to simulate pulverized coal combustion in BSF. The physics-based submodel that contains the significant sensitivity for QoI's has been identified using the detailed impact factor analysis on this high-fidelity modeling. Results indicate that the most sensitive submodel on QoI's is the wall-heat-transfer coupling with the ash-deposition model, which allows us to prioritize to improve this submodel in the LES simulation. Thus, ash deposition and wall-heat-transfer processes have been modeled and integrated into coal combustion numerical simulation. The simulation results show quantitative agreement between the simulation with experimental data regarding gas temperature, O₂ concentration, and heat-flux profile across the exposed boiler walls. Another implication of this research is to demonstrate a positive societal impact of extreme computing and accelerate the development of new combustion technology using a capable exascale computing technique.     

Combustion characteristics of coal in a mixture of oxygen and recycled flue gas

The combustion of coal in a mixture of pure O₂ and recycled flue gas is one variant of a novel combustion approach called oxy-fuel combustion. With the absence of N₂, this approach leads to a flue gas stream highly enriched in CO₂. For many applications, this flue gas stream can then be compressed and sequestered without further separation. As a result, oxy-fuel combustion is an attractive way to capture CO₂ produced from fossil fuel combustion. When coal is burned in this O₂ and CO₂ rich environment, its combustion characteristics can be very different from conventional air-fired combustion. In CETC-O, a vertical combustor research facility has been used in the past years to investigate the combustion characteristics of several different coals with this variant of oxy-fuel combustion. This included flame stability, emissions of NO_x, SO_x and trace elements, heat transfer, in-furnace flame profiles and flue gas compositions. This paper will report some of the major findings obtained from these research activities.     

Partial O2-fired coal power plant with post-combustion CO2 capture: A retrofitting option for CO2 capture ready plants

In the work presented in this paper, an alternative process concept that can be applied as retrofitting option in coal-fired power plants for CO₂ capture is examined. The proposed concept is based on the combination of two fundamental CO₂ capture technologies, the partial oxyfuel mode in the furnace and the post-combustion solvent scrubbing. A 330 MW_el Greek lignite-fired power plant and a typical 600 MW_el hard coal plant have been examined for the process simulations. In a retrofit application of the ECO-Scrub technology, the existing power plant modifications are dominated by techno-economic restrictions regarding the boiler and the steam turbine islands. Heat integration from processes (air separation, CO₂ compression and purification and the flue gas treatment) can result in reduced energy and efficiency penalties. In the context of this work, heat integration options are illustrated and main results from thermodynamic simulations dealing with the most important features of the power plant with CO₂ capture are presented for both reference and retrofit case, providing a comparative view on the power plant net efficiency and energy consumptions for CO₂ capture. The operational characteristics as well as the main figures and diagrams of the plant’s heat balances are included.     

Numerical analysis of pulverized coal combustion characteristics using advanced low-NOx burner

A three-dimensional numerical simulation is applied to a pulverized coal combustion field in a test furnace equipped with an advanced low-NO_x burner called CI-α burner, and the detailed combustion characteristics are investigated. In addition, the validities of the existing NO_x formation and reduction models are examined. The results show that a recirculation flow is formed in the high-gas-temperature region near the CI-α burner outlet, and this lengthens the residence time of coal particles in this high-temperature region, promotes the evolution of volatile matter and the progress of char reaction, and produces an extremely low-O₂ region for effective NO reduction. It is also found that, by lessening the effect of NO reduction in Levy et al.'s model and taking the NO formation from char N into account, the accuracy of the NO prediction is improved. The efficiency factor of the conversion of char N to NO affects the total NO concentration downstream after the injection of staged combustion air.