Investigation of co-combustion of coal and olive cake in a bubbling fluidized bed with secondary air injection

In this study, a bubbling fluidized bed of 102 mm inside diameter and 900 mm height was used to burn olive cake and coal mixtures. Tunçbilek lignite coal was used together with olive cake for the co-combustion tests. Combustion performances and emission characteristics of olive cake and coal mixtures were investigated. Various co-combustion tests of coal with olive cake were conducted with mixing ratios of 25%, 50%, and 75% of olive cake by weight in the mixture. Operational parameters (excess air ratio, secondary air injection) were changed and variation of pollutant concentrations and combustion efficiency with these operational parameters were studied. The results were compared with that of the combustion of olive cake and coal. Flue gas concentrations of O₂, CO, SO₂, NO_x, and total hydrocarbons (C_mH_n) were measured during combustion tests.For the setup used in this study, the optimum operating conditions with respect to NO_x and SO₂ emissions were found to be 1.35 for excess air ratio, and 30 L/min for secondary air flowrate for the combustion of 75 wt% olive cake and 25 wt% coal mixture. The highest combustion efficiency of 99.8% was obtained with an excess air ratio of 1.7, secondary air flow rate of 40 L/min for the combustion of 25 wt% olive cake and 75 wt% coal mixture.     

Olive cake combustion in a circulating fluidized bed

In this study, a circulating fluidized bed of 125 mm diameter and 1800 mm height was used to find the combustion characteristics of olive cake (OC) produced in Turkey. A lignite coal that is most widely used in Turkey was also burned in the same combustor. The combustion experiments were carried out with various excess air ratios. The excess air ratio, λ, has been changed between 1.1 and 2.16. Temperature distribution along the bed was measured with thermocouples. On-line concentrations of O₂, SO₂, CO₂, CO, NO_x and total hydrocarbons were measured in the flue gas. Combustion efficiencies of OC and lignite coal are calculated, and the optimum conditions for operating parameters are discussed. The combustion efficiency of OC changes between 82.25 and 98.66% depending on the excess air ratio. There is a sharp decrease observed in the combustion losses due to hydrocarbons and CO as the excess air ratio increases. The minimum emissions are observed at λ=1.35. Combustion losses due to unburned carbon in the bed material do not exceed 1.4 wt% for OC and 1.85 wt% for coal. The combustion efficiency for coal changes between 82.25 and 98.66% for various excess air ratios used in the study. The ash analysis for OC is carried out to find the suitability of OC ash to be used as fertilizer. The ash does not contain any hazardous metal.     

Comparisons of pulverized coal combustion in air and in mixtures of O2/CO2

Pulverized coal combustion in air and the mixtures of O₂/CO₂ has been experimentally investigated in a 20 kW down-fired combustor (190 mm id×3 m). Detailed comparisons of gas temperature profiles, gas composition profiles, char burnouts, conversions of coal–N to NO_x and coal–S to SO₂ and CO emissions have been made between coal combustion in air and coal combustion in various O₂/CO₂ mixtures. The effectiveness of air/oxidant staging on reducing NO_x emissions has also been investigated for coal combustion in air and O₂/CO₂ mixtures. The results show that simply replacing the N₂ in the combustion air with CO₂ will result in a significant decrease of combustion gas temperatures. However, coal combustion in 30% O₂/70% CO₂ can produce matching gas temperature profiles to those of coal combustion in air while having a lower coal–N to NO_x conversion, a better char burnout and a lower CO emission. The results also confirm that air/oxidant staging is very effective in reducing NO_x emissions for coal combustion in both air and a 30% O₂/70% CO₂ mixture. SO₂ emissions are proved to be almost independent of the combustion media investigated.     

Soot oxidation on a catalytic NOx trap: Beneficial effect of the Ba–K interaction on the sulfated Ba,K/CeO2 catalyst

The Ba,K/CeO₂ catalyst is active both for NO_x trapping and soot combustion. In this work we report a Ba–K interaction that prevents K sulfation when NO_x is present, thus preserving the activity of K towards soot combustion during the working period of the trap. This effect is originated in the K₂SO₄(s) + Ba(NO₃)₂(s) → 2KNO₃(s) + BaSO₄(s) reaction, which is thermodynamically favored. In the absence of NO_x, the soot combustion reaction is strongly depressed by SO₂ whereas when NO_x is present both the sulfated and the non-sulfated catalysts present similar TPO patterns.     

Optimization of coal reburning in a 1 MW tangentially fired furnace

This paper deals with an experimental study on the influence of coal reburn on NO_x reduction efficiency, unburned carbon in fly ash and the furnace temperature distribution along the height in a 1 MW (heat input power) tangentially firing furnace with multiple low NO_x control technologies. Several variables associated with the reburn system have been investigated in the experiment which includes the air stoichiometry in reburn zone, the location of reburn burner and reburn coal fineness. The optimum location of reburn nozzles has been found where NO_x reduction efficiency is highest. With the decrease of reburn coal size (average diameter from 53.69 μm to 11.47 μm), NO_x reduction efficiency increases slightly, but the burnout performance of coal is improved noticeably. In the process of coal reburning, the temperature of flue gas is 70–90 °C lower in primary combustion, but 130–150 °C higher at the top of furnace as compared to baseline.     

Electron beam flue gas treatment (EBFGT) technology for simultaneous removal of SO2 and NOx from combustion of liquid fuels

Electron beam flue gas treatment technology was applied for removal of SO₂ and NO_x from flue gas, emitted from combustion of high-sulfur fuel oils. The detailed study of this process was performed in a laboratory by irradiating the exhaust gas from the combustion of three grades of Arabian fuels with an electron beam from accelerator (800 keV, max. beam power 20 kW). SO₂ removal is mainly dependent on ammonia stoichiometry, flue gas temperature and humidity and irradiation doses up to 8 kGy. NO_x removal depends primarily on irradiation dose. High removal efficiencies up to 98% for SO₂ and up to 82% for NO_x were obtained under optimal conditions. The flue gas emitted from combustion of high-sulfur fuel oils, after electron beam irradiation, meets the stringent emission standards for both pollutants. The by-product, which is a mixture of ammonium sulphate and nitrate, can be used as a fertilizer as such or blended with other components to produce commercial agricultural fertilizer.     

Characterisation of biomass and coal co-firing on a 3 MWth Combustion Test Facility using flame imaging and gas/ash sampling techniques

Co-firing of biomass with pulverised coal at existing coal power stations remains a practical option available to power plant operators and is being widely adopted as one of the main technologies for reducing greenhouse gas emissions. However, there is a range of technological problems that are not well understood. This paper presents experimental investigations into the co-firing of pulverised coal directly co-milled with 5–20% biomass on a 3 MWth Combustion Test Facility. A number of combustion parameters, including flame temperature and oscillation frequency and particle size distribution, were measured under a range of co-firing conditions. The gas species within the flame and fly ash in flue gas were also sampled and analysed. The experimental data collected are used to study the impact of biomass additions to pulverised coal on the combustion characteristics of the co-firing process. The relationships between the flame characteristics, gas species and ash deposition of the furnace are investigated. The results suggest that, due to the varying physical and chemical properties of the biomass fuels, the biomass additions have impact on the combustion characteristics in a very complicated way. It has been found that the biomass addition to coal would improve the combustion efficiency because of the lower CO concentrations and higher char burnout level in co-firing. In addition, NO_x emission has been found closely linked to the flame stability, and SO_x emission reduced in general for all co-firing cases.     

Improvements in the performance of a medium-pressure-boiler through the adjustment of inlet fuels in a refinery plant

Hydrogen has been considered as a promising alternative for fossil fuel in recent years because it is very “clean”. Fossil fuel generates CO₂, CO, SO_x, unburned hydrocarbon and particles during combustion, while hydrogen only yields NO_x. In this study, a medium-pressure boiler with 130 ton/h boiler loading in a full-scale plant was studied with two inlet hydrogen-rich refinery gas (RG)/fuel oil (FO) volumetric flow rate ratios (inlet RG/FO ratio) and two residual O₂ concentration (vol.%) in flue gases (2%, 4%) to evaluate their influence on the emissions of NO_x and CO₂, flue gas temperatures and boiler efficiencies. The result shows significant improvements in both boiler efficiencies and emissions of air pollutants. By increasing the inlet RG/FO ratio from 1:5 to 1:1.5, the fuel cost was reduced by 11%, NO_x emission down by 12%, and the CO₂ emission 20,200 ton lower per year was achieved. Thus, better economic operating conditions for the boiler are suggested at inlet RG/FO ratio = 1:1.5 with the residual O₂ concentration in flue gases = 2%.     

Peach and apricot stone combustion in a bubbling fluidized bed

In this study, a bubbling fluidized bed combustor (BFBC) of 102 mm inside diameter and 900 mm height was used to investigate the combustion characteristics of peach and apricot stones produced as a waste from the fruit juice industry. A lignite coal was also burned in the same combustor. The combustion characteristics of the wastes were compared with that of a lignite coal that is most widely used in Turkey. On-line concentrations of O₂, CO, CO₂, SO₂, NO_X and total hydrocarbons (C_mH_n) were measured in the flue gas during combustion experiments. By changing the operating parameters (excess air ratio, fluidization velocity, and fuel feed rate), the variation of emissions of various pollutants was studied. Temperature distribution along the bed was measured with thermocouples.During the combustion tests, it was observed that the volatile matter from peach and apricot stones quickly volatilizes and mostly burn in the freeboard. The temperature profiles along the bed and the freeboard also confirmed this phenomenon. It was found that as the volatile matter of fruit stones increases, the combustion takes place more in the freeboard region.The results of this study have shown that the combustion efficiencies ranged between 98.8% and 99.1% for coal, 96.0% and 97.5% for peach stone and 93.4% and 96.3% for apricot stones. The coal has zero CO emission, but biomass fuels have very high CO emission which indicates that a secondary air addition is required for the system. SO₂ emission of the coal is around 2400–2800 mg/Nm³, whereas the biomass fuels have zero SO₂ emission. NO_X emissions are all below the limits set by the Turkish Air Quality Control Regulation of 1986 (TAQCR) for all tests. As the results of combustion of two biomass fuels are compared with each other, peach stones gave lower CO and NO_X emissions but the SO₂ emissions are a little higher than for apricot stones. These results suggest that peach and apricot stones are potential fuels that can be utilized for clean energy production in small-scale fruit juice industries by using BFBC.     

Low temperature selective catalytic reduction of NOx with NH3 over amorphous MnOx catalysts prepared by three methods

Unsupported manganese oxide catalysts with amorphous phase were prepared by three methods, and their activities for SCR of NO_x with ammonia were investigated in the presence of O₂. The results showed the catalysts have superior low temperature activity, and the NO_x conversion is about 98% at 80 °C, and nearly 100% NO_x conversion between 100 and 150 °C. Due to competing adsorption with the reactant, H₂O has slight impact on the activity. The activity was suppressed with coexisting of SO₂, however the deactivation of SO₂ is reversible. The excellent low temperature catalytic activity of amorphous MnO_x catalysts is mainly due to their amorphous phase and high specific areas.     

Regeneration of sulfur-poisoned CeO2 catalyst for NH3-SCR of NOx

The effects of regeneration on the activities and structure of CeO₂ catalysts for NH₃-SCR of NO_x have been studied in this article. CeO₂ catalyst is deactivated by SO₂ for NH₃-SCR of NO_x in a 200 h long-term operation at 350 °C due to the formation of sulfates, and its NO_x conversion decreases from 100% to 83% gradually. However, sulfates can be removed from sulfur-poisoned CeO₂ catalysts under high temperature thermal treatment in air. After regeneration, NO_x conversion of sulfur-poisoned CeO₂ catalyst is recovered to about 100% at 350 °C. Moreover, the regeneration temperature is related to the nature of the sulfates formed on the sulfur-poisoned CeO₂ catalysts.     

The evaluation of waste tyre pulverised fuel for NOx reduction by reburning

The combustion of coal for power generation will continue to play a major role in the future, however, this must be achieved using cleaner technologies than we use at present. Scrap tyre arisings in the UK are 400,000 tonnes per year amounting to 30 million tyres and in the EU as a whole, more than 2.5 million tonnes of tyres per year are scrapped. The recent EC Waste Landfill Directive (1999) sets a deadline for the banning of whole and shredded tyres from landfill sites by 2006. Consequently, there is an urgent need to find a mass disposal route for tyres. We describe, in this paper, a novel use for tyre rubber pulverised fuel in a NO_x reburning process which may have an application in power station boilers. This method of disposal could represent a way of combining waste disposal, energy recovery and pollution control within one process. A preliminary study of micronised tyre combustion was undertaken to identify the suitable size ranges for application in NO_x reduction by reburning. Tests were performed in a down-fired, pulverised fuel combustor (PFC) operating at about 80 kW. Superior combustion characteristics, i.e. burnout were achieved with particle sizes less than 250 μm. A South African coal was used as the primary fuel in the reburn tests and the tyre was fed pneumatically via a separate feed system. Parameters studied, were, reburn zone stoichiometry and reburn fuel fraction. Additionally, the carbon content of the ash was carefully monitored for any effect on burnout at the fuel rich reburn stoichiometries. The NO_x reductions achieved with tyres are compared with reburning with coal. NO_x reductions up to 80% were achieved with tyres at half of the reburn fuel feed rate required to achieve the same reductions by coal. The results have been evaluated within the context of other studies available in the literature on NO_x reburning by bituminous coal, brown coal, gas and biomass.     

Resistance to sulfidation of the catalytic reduction of NOx over Ag/Al2O3 by controlling the loadings of Ag and Ag+

SO₂ strongly decreased the catalytic activities of low loading Ag/Al₂O₃ below 500 °C in selective catalytic reduction (SCR) of NO_x by propene with or without the assistance of non-thermal plasma (NTP), which was mainly attributed to the competition between SO₂ and NO. By controlling the loadings of Ag and Ag⁺ over alumina, the resistance of SO₂ was remarkably enhanced between 400 °C and 500 °C in thermal SCR. In the NTP-assisted SCR, most of the NO_x conversions were also apparently recovered from 250 °C to 500 °C.     

NOx and SOx emissions of a high sulfur self-retention coal during air-staged combustion

NO_x and SO_x emissions of air-staged combustion were investigated in a 1 MW tangentially-fired furnace combusting a high sulfur self-retention coal. Two variables including the air stoichiometric ratio of primary combustion zone and the relative location of over-fire air (OFA) injection ports were studied. These results suggest that NO_x reduction efficiency monotonically increases with increasing the relative location of OFA injection ports, and the lowest NO_x emissions are achieved when the air stoichiometric ratio of primary combustion zone is 0.85. In the meantime, SO_x emissions can be effectively reduced when the air stoichiometric ratio of primary combustion zone is 0.85 or 0.95, and SO_x emissions monotonically decrease with increasing the relative location of OFA injection ports.     

Combustion of poultry litter in a fluidised bed combustor

Combustion studies of poultry litter alone or mixed with peat by 50% on weight basis were undertaken in an atmospheric bubbling fluidised bed. Because of high moisture content of poultry litter, there was some uncertainty whether the combustion could be sustained on 100% poultry litter and as peat is very available in Ireland; its presence was considered to help to improve the combustion. However, the results showed that, as long as the moisture content of poultry litter was kept below 25%, the combustion did not need the addition of peat. The main parameters that were investigated are (i) moisture content, (ii) air staging, and (iii) variations in excess air levels along the freeboard. The main conclusions of the results are (i) combustion was influenced very much by the conditions of the fuel supply, (ii) the steady fuel supply was strongly dependent on the moisture content of the poultry litter, (iii) temperature appeared to be still very influential in reducing the levels of unburned carbon and hydrocarbons released from residues, (iv) the air staging in the freeboard improved combustion efficiency by enhancing the combustion of volatiles released from residues in the riser and (vi) NO_x emissions were influenced by air staging in the freeboard. Particles collected from the bed and the two cyclones were analysed to determine the levels of heavy metals and the leachability tests were carried out with ashes collected to verify whether or not they could safely be used in agricultural lands.     

Simultaneous easy CO2 recovery and drastic reduction of SOx and NOx in O2/CO2 coal combustion with heat recirculation

Coal combustion with O₂/CO₂ is promising because of its easy CO₂ recovery, extremely low NO_x emission and high desulfurization efficiency. Based on our own fundamental experimental data combined with a sophisticated data analysis, its characteristics were investigated. It was revealed that the conversion ratio from fuel-N to exhausted NO in O₂/CO₂ pulverized coal combustion was only about one fourth of conventional pulverized coal combustion. To decrease exhausted NO further and realize simultaneous easy CO₂ recovery and drastic reduction of SO_x and NO_x, a new scheme, i.e. O₂/CO₂ coal combustion with heat recirculation, was proposed. It was clarified that in O₂/CO₂ coal combustion, with about 40% of heat recirculation, the same coal combustion intensity as that of coal combustion in air could be realized even at an O₂ concentration of as low as 15%. Thus exhausted NO could be decreased further into only one seventh of conventional coal combustion. Simultaneous easy CO₂ recovery and drastic reduction of SO_x and NO_x could be realized with this new scheme.     

A novel catalyst for diesel soot oxidation

In this study, cobalt and lead based mixed oxide catalysts were tested for their soot oxidation ability. In addition to a mixed oxide formerly marketed as ceramic paint, a home made set was also prepared by incipient wetness impregnation of a cobalt oxide powder with a lead acetate solution and subsequent calcination. The materials investigated in this study were shown to decrease the peak combustion temperature of home made soot from 500 to 385 °C in air. Soot oxidation tests under inert (N₂) atmospheres revealed that the oxidation took place by using the lattice oxygen of the catalyst. Reaction temperature could be further decreased when these mixed oxide catalysts were impregnated with platinum. An optimum platinum loading was determined as 0.5 wt% based on the peak combustion temperature of the soot. The role of Pt was to assist the oxygen transfer from the gas phase to the lattice. It was observed that NO₂ is a better oxidizing agent as compared to air whereas NO had hardly any activity against soot oxidation reaction. When the mixed oxide catalyst was impregnated with platinum, the peak combustion temperature was measured as 310 °C in the presence of NO_x and air. The catalyst's unique performance was in terms of the rate of soot oxidation. Under the experimental conditions studied here, the soot oxidation was so facile that the oxygen in the gas phase was completely depleted. This stream of oxygen depleted and CO enriched gas phase can be used to reduce NO_x in the presence of a downstream or a co-catalyst.     

Modelling the combustion of pulverized biomass in an industrial combustion test furnace

A CFD model that simulates the combustion of biomass in existing pf coal fired furnaces has been developed and model results for the combustion of a typical wood in a 1 MW industrial test facility have been presented. The model is primarily based on coal combustion submodels using an Eulerian–Lagrangian frame of reference. Biomass specific constants that define the submodels have been investigated and employed in the simulation. In particular, potassium release during biomass combustion and the formation of NO_x have been simulated. Numerical predictions have been compared with some experimental measurements that have been taken and reasonably good agreement has been achieved.     

Co-combustion of coal and olive oil industry residues in fluidised bed

Recently new environmental regulations of fossil fuels have further increased interest in the use of waste and biomass for energy generation. Co-combustion is generally viewed as the most cost-effective approach to biomass and wastes utilisation by the electric utility industry.The aim of this paper is to assess the feasibility of co-firing coal and a very specific biomass waste from the olive oil industry: foot cake, in a fluidised bed. This waste is quite difficult material to be used in combustion process, due to its high moisture content and alkaline content in ashes.Two different Spanish coals were selected for this study: a lignite and an anthracite. The combustion tests were carried out in the CIEMAT bubbling fluidised bed pilot plant. In order to study the effect of different parameters on the emissions and combustion efficiency, the tests were done using different operating conditions: furnace temperature, share of foot cake in the mixtures and coal type.The pilot plant tests show that the combustion of foot cake/lignite or anthracite mixtures in bubbling fluidised bed is one way to utilise this biomass residue in energy generation. The presence of foot cake in the mixtures has not any significant effect on the combustion efficiency. SO₂ and NO_x emissions decrease when the amount of foot cake in the mixtures increases, while N₂O emission increases.     

Calcium-based sorbents for simultaneous NOx/SOx reduction in a down-fired furnace

The performance of a suite of different carboxylic salts of calcium, have been assessed as dual NO_x/SO_x reducing agents. The salts studied include, calcium magnesium acetate (CMA), calcium acetate (CA), calcium formate (CF), calcium benzoate (CB), calcium propionate (CP) and magnesium acetate (MA). The primary fuel was propane operating with a primary zone stoichiometry fixed at λ₁=1.05 and the reburn zone stoichiometry, λ₂, was varied between 1.03 and 0.86. Overall stoichiometry, λ₃, was 1.15. CMA was also tested using a US Blend coal as the primary fuel. Experiments were performed in a down-fired pulverised coal furnace operating at an output of 80 kWth. Results showed that CMA and CP were the best dual NO_x/SO₂ performers followed by CB, CA, MA and CF. Also, the co-injection of urea with the carboxylic salts as an advanced reburning agent was studied. The results showed that real improvements in NO reduction over basic reburning of greater than 70% could be obtained depending to a large extent on the initial effectiveness of the reburn fuel as well as nitrogen stoichiometric ratio within the reburn zone. Decomposition of the carboxylic salts was studied by thermo-gravimetric analysis (TGA) yielding information on the release of organic fractions important as precursors for CH_i radical formation. Examination of structural and thermo-chemical properties of the carboxylic salts identified a correlation of NO reduction under reburning conditions with volatile organic content. Calcium magnesium acetate and calcium propionate showed superior SO₂ capture ability with reductions greater than 70% at Ca/S above 2, around 20% higher than calcium acetate and calcium formate. Magnesium acetate achieved reductions of less than 10% at Mg/S ratios up to 2.5. There is a clear difference in the potential effectiveness of the sorbents as dual NO_x/SO₂ reductants, since the organic input for a given Ca input varies according to the composition of the sorbent. Some compromise may have to be made when choosing the correct operating conditions since good reductions in SO₂ may not give acceptable NO_x reductions. However, the application of advanced reburning under these conditions has been shown here to compensate for low initial NO_x reductions by basic reburning.