02 Nigel Simms

Biomass Combustion Systems: Assessing Component Durability and Emissions
Nigel Simms Energy Technology Centre Cranfield University
Energy Technology Centre
Outline
Background Potential biomass fuels Issues Component durability Deposition Corrosion Emissions Summary
Combustion systems
Biomass only Grate Fluidised bed Purpose built Feed systems Combustion chamber Heat exchangers Steam systems Gas clean-up Scale up to ~30MWe Biomass co-fired Pulverised fuel Designed for coal firing Biomass additions of 5-20% (thermal input) Higher steam temperatures Scale up to 4000MWe (660 MWe units)
Heat exchanger tubing cross-section through tube wall
Fireside
TUBE WALL
Steam-side
Corrosion Allowance Load Bearing Thickness
Oxidation Allowance
Component life as f(corrosion rate, corrosion allowance)

100,000 90,000 80,000 70,000 Life (hours) 60,000 50,000 40,000 30,000 20,000 10,000 0 0 10 20 30 40 50 60 70 80 90 100 Corrosion rate (m/1000 hour) Corrosion Allowance 1 mm 2 mm 3 mm 1.5 mm 2.5 mm 3.5 mm
Comparison of corrosion data for 347H and 347HFG with coal and straw firing (plant data) and co-firing (pilot plant data)
(median data)
1.4 Corrosion rate (mm/1000hr) 1.2 1.0 0.8 0.6 0.4 0.2 0.0 400
Straw Coal Co-firing data
450
500
550 Temperature ( C)
o
600
650
700
Flow Diagram for Component Life Modelling

Component Specification
Component Geometry
Operating Conditions
Inlet & outlet
gas P & T
Fuel Spec. & Reactor System
Thermal Model
Aerodynamic Model
Gas flow rate P & T distributions
Metal surface temperature
Thermochemical Model
Alloy specification
Deposition flux & composition
Transport & Deposition Models
Contaminant levels & species
Corrosion & Erosion/Corrosion Models

Damage rates Component design & life criteria
Particle deposition flux
Mechanical Property Data
Life Predictions Contaminant effects Operating condition effects
Biomass fuels
Potential biomass fuels

Specifically cultivated biomass (energy crops), e.g.: coppiced willow miscanthus reed canary grass switchgrass Waste biomass various straws wood waste / forest residues World traded biomass products, e.g.: olive residues pelletised wood almond waste cereal co-product (CCP) Sewage sludge, animal wastes
Coppiced willow
Miscanthus
Fuel Properties (1)

100
Willow Fir/pine/spruce Poplar Miscanthus Olive waste
10
Wheat Coal
0.1
0.01 Wt% wet Wt% dry Wt% daf Wt% daf Wt% daf Wt% daf Wt% daf Wt% daf Wt% daf Water content Ash Volatiles C H
Fuel parameter
Cl
Fuel Properties (2): Minor / Trace Element Concentrations

25000 Willow Fir/pine/spruce Concentration (mg/kg dry) 20000 Wheat Coal 15000 Poplar Miscanthus Olive waste
10000
5000
0 Al Ba Ca Fe K Mg Element Mn Na P Si Ti
Potassium and Chlorine Levels in Selected Biomass

12000 10000 Chlorine (ppm) 8000 6000 4000 2000 0 0 5000 10000 15000 20000 25000 30000 Potassium (ppm) Sander (1997) Christensen (1998) Review data
Wheat Barley Oil Seed Rape
Sulphur and Chlorine Contents of Fuels Delivered to Two UK Power Stations Between 1992 and 1994 (Grey is Mean Values for UK Stations in 1983)
Evaluation of potential heat exchanger operating conditions
Combustion heat exchanger issues - outline

Gas stream characteristics
Gaseous species e.g. CO2, SO2, HCl, NOX, H2O, O2, N2 Vapour species e.g. Na, K Particles From ash in fuel Condensed vapour species Gas temperature
Heat exchanger characteristics

Water / steam temperature (& pressure) Metal temperature (& heat flux) Deposit rate of formation composition Alloy used corrosion damage rate viable life times ? cost
Fuel combustion
Fly ash 0.1-1mm
Coagulation Heterogeneous condensation Homogeneous nucleation
Fly ash with surface condensation
Convective transport Mineral inclusions
Vaporisation
Vapour Reaction Fly ash
Pyrolysis
Char burning and fragmentation
Excluded minerals
Mineral coalescence and fragmentation
Fly ash 1-100mm
Effect of Fuel Composition Variability on Predicted Gas Compositions

1000
UK Coal
800
Willow wood Coal - wood
HCl (vpm)
600
Coal - straw
400
Wheat straw
200
0 0 200 400 600 800 1000 1200 1400 1600 1800 2000
SOx (vpm)
Deposition on Superheater Tubing

Vapour species Condensation onto solid particles & aerosols Solid particles & aerosols
Deposition mechanisms:
Particles: Direct inertial impaction Thermophoresis Eddy diffusion Brownian Vapour: Direct condensation Condensation on particles
HCl Condensation into deposit Thermophoresis of fine particles SOx Coarse particles stick Vapours, SOx & HCl diffuse in porous deposits Corrosion Water / steam Heat transfer
Deposit compositions: Al-Si-O compounds can fix Na, K if particle temperatures high enough Ca/Mg carbonates / sulphates Na / K sulphates / chlorides Fe sulphates / chlorides / oxides / sulphides Phosphates Important factors Minerals in fuels Balance between elements Corrosion aggravated by: Low melting point deposits High chloride deposits
Fuel derived deposit compositions
Effect of fuel compositions

3.0 Deposit Cl (% dry basis) 2.5 2.0 1.5 1.0 0.5 0.0 0.1 1.0 10.0 100.0 Sulfur /2*Max (Alkali chloride)
Dependence of deposit chlorine content on fuel sulphur and alkali chloride contents (US DoE Research)
Appearance of chlorides in deposits as a function of maximum alkali chloride, fuel sulphur and % straw (on thermal basis) (EU research)
Additives to reduce deposition & corrosion

Deposition / Corrosion of combustion heat exchangers in biomass-fired systems is regarded as major issue by power plant manufacturers & operators Vattenfalls latest solution: dope flue gas with sulphur containing additive (= Chlorout) ahead of superheater reduces deposition rate, chloride content of deposit and corrosion rate
Supergen Bioenergy - Pilot Scale Trials

Pulverised coal/biomass/air or natural/fuel gas & air
Topics being investigated include:

Fuel feeding & preparation Characterisation of product streams: Gas compositions Bulk gases Trace species Solids analyses Fuel compositions Ash / char compositions Deposit compositions / deposition fluxes on cooled (heat exchanger) probes Co-firing
Biomass
Temperature monitoring
Gases to fan and flue
Feed system
Cooling water out Gas out Cooling water out Cooling water in
Cyclone
Gas analysis Temperature monitoring
Temperature monitoring Gas analysis Temperature monitoring
Fluidised bed
Natural gas/excess air pre-heater
Ash removal system
Cooling water in
Heat exchanger corrosion
Possible corrosion mechanisms in chloride / sulphate rich deposits

Deposit HCl NaCl O2 SO2 + O2 SO2 + O2 + H2O
HCl
Na2O
Cl2 FeCl2 Fe
NaHSO4 Na2SO4
SO2 + O2
Na2S2O7 Fe FeS FeO Fe2O3 O2
FeCl3 O2 Fe2O3
Fe Tube metal
Corrosion products
Alkali sulphate dominated corrosion regimes in combustion gases
Corrosion model requirements

Cover wide range of operating environments Different biomass fuel Superheater / reheater, evaporator, water walls, etc Corrosion damage (in terms of metal loss) as function of: Metal temperature Gas composition (e.g. SOx, HCl, O2, CO2, H2O) Deposit composition Na, K Sulphate vs chloride etc Deposition flux (mg/cm2/hour) Time Median vs maximum metal loss Component life criteria
Corrosion data for model development

Aim: simulation of different specific environments data on materials performance obtained using dimensional metrology Laboratory based corrosion data generation: Deposit re-coat test method Controlled atmosphere furnace Test Variables
Temperatures Time Gas composition: simulated combustion gases Variable SOx, HCl, O2, CO2, H2O, etc levels Deposit composition Simulated ash (Na/K)Cl (Na/K)2SO4 Variable Na/K levels Materials
Dimensional metrology before/after exposure

Controlled atmosphere corrosion furnace

Mass flow Controller 1 Gas mixture 1 (e.g. N2-HCl) Water bath De-ionised water Mass flow Controller 2 Gas mixture 2 (e.g. N2-O2-SO2) Mass flow Controller 3 Gas mixture 3 (e.g. N2-O2) Alumina reaction tube Samples Trace heating Inert safety gas (N2) Safety gas vent
Vent
Gas clean-up system Alumina tube Alumina heat shields Stainless steel containment vessel
Sample Metrology & Data Analysis (1)

Alloy A1 To central reference point
Measurements taken at equidistant points spaced = 300m
B1 Surface scale & deposit

8000
A2
Internal corrosion
Y DIRECTION (MICRONS
1-HAA-6
6000 4000 2000 0 -2000 -4000 -6000 -8000 -2000 0
An
Where n = 24
Bn
-8000
-6000
-4000
2000
4000
6000
8000
X DIRECTION (MICRONS) ORIGINAL METAL CHANGE IN GOOD METAL 100 micron contour CHANGE IN METAL DEPOSIT & SCALE
Sample Metrology & Data Analysis (2)

0 -20 -40 -60 -80 -100 0 90 180
Position around sample () Change in sound metal (um)
270
360
Data ordered and plotted against probability

Corrosion damage distributions for 2 Cr steel, 347HFG and Alloy 625 all at 560C, deposit D6 and gas 3
Sensitivity of 347HGF to changes in deposit composition and exposure temperature

(Corrosion Damage Evaluated at the 10% Probability of Damage Being Exceeded)
Corrosion damage (m/1000 hours) 120 100 80 60 40 20 0 D0 D1 D2 D3 D4 Deposit D5 D6 D7 D8
Gas 3, 560C (test 6) Gas 3, 600C (test 3)
Correlation between Measured Predicted Corrosion Damage Rates (corrosion damage evaluated at the 10% probability of damage being exceeded)
1000
2.25 Cr 1 Cr
Predicted corrosion rate (m/1000 hours)
X20 AISI 347 625
100
10 10
100 Measured corrosion rate (m/1000 hours)
1000
Emissions
Limits set by regulations vary by: Plant capacity Fuels Policy decisions etc Issues can include: NOX SOX HCl Dust Trace heavy metals Etc Range of technologies developed for: Coal Waste
Examples of particle removal systems

Electrostatic Precipitator (ESP)
Gas Inlet
Bag Filters
+ -
+ +
+ -
+ -
+ -
Electric field
Cleaned Gas Charged particles
Uncharged particles
Summary
Range of potential biomass fuels being considered for combustion systems Heat exchanger durability
Care is required in materials selection for biomass systems Balance between fuel compositions, operating temperatures (system efficiency), component life and materials costs Predictive models being developed within Supergen Bioenergy project relating exposure conditions to component lives for biomass fired systems
Emissions
Control measured developed for other fuels (coal, waste) Appropriate technologies need to be selected to match intended fuel / regulation
Thank you for your attention
Targets for heat exchanger steam operating temperatures and tube lifetimes from COST522 and COST538 programmes
Target lifetime (hours) 100,000 20,000 40,000 40,000 Desired maximum steam temperature (C) 650 580 580 500 Metal temperature (C) 680 700 610 630 610 630 530 550 Maximum acceptable corrosion rate (m/1000 hours) 20 100 50 50
Fuel
Coal Straw Wood Waste

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Biomass Combustion Systems: Assessing Component Durability and Emissions

Nigel Simms Energy Technology Centre Cranfield University

Energy Technology Centre

Energy Technology Centre

Heat exchanger tubing cross-section through tube wall

Corrosion Allowance Load Bearing Thickness

Energy Technology Centre

Component life as f(corrosion rate, corrosion allowance)

Energy Technology Centre

Straw Coal Co-firing data

Energy Technology Centre

Flow Diagram for Component Life Modelling

Fuel Spec. & Reactor System

Metal surface temperature

Deposition flux & composition

Transport & Deposition Models

Contaminant levels & species

Corrosion & Erosion/Corrosion Models

Particle deposition flux

Mechanical Property Data

Life Predictions Contaminant effects Operating condition effects

Energy Technology Centre

Energy Technology Centre

Potential biomass fuels

Fuel Properties (1)

Energy Technology Centre

Fuel Properties (2): Minor / Trace Element Concentrations

Energy Technology Centre

Potassium and Chlorine Levels in Selected Biomass

Wheat Barley Oil Seed Rape

Energy Technology Centre

Evaluation of potential heat exchanger operating conditions

Energy Technology Centre

Combustion heat exchanger issues - outline

Heat exchanger characteristics

Coagulation Heterogeneous condensation Homogeneous nucleation

Fly ash with surface condensation

Convective transport Mineral inclusions

Vapour Reaction Fly ash

Char burning and fragmentation

Mineral coalescence and fragmentation

Fly ash 1-100mm

Energy Technology Centre

Effect of Fuel Composition Variability on Predicted Gas Compositions

Willow wood Coal - wood

Deposition on Superheater Tubing

Energy Technology Centre

Fuel derived deposit compositions

Effect of fuel compositions

Energy Technology Centre

Additives to reduce deposition & corrosion

Energy Technology Centre

Supergen Bioenergy - Pilot Scale Trials

Topics being investigated include:

Gases to fan and flue

Gas analysis Temperature monitoring

Temperature monitoring Gas analysis Temperature monitoring

Natural gas/excess air pre-heater

Ash removal system

Heat exchanger corrosion