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.     

Kinetic study of domestic limestone (Daesung)

Sulfidation and sulfation reactions of Daesung limestone, which is a calcium-based sorbent chosen out of domestic limestone for the removal of H₂S and SO₂, were investigated by using TGA (thermal gravimetric analyzer) Effects of H and H₂S on the sulfidation were also investigated The conversion rate of CaS to CaSO₄ in oxidation was low since the concentration of SO₂ used for this study was low and CaO was not completely converted into CaS It was observed that the effects of H₂ concentration on the sulfidation were relatively small and the maximum conversion rate and reaction rate increased with increase of H₂S concentration In the sulfation reaction, conversion rate could be raised with the injection of air at a sulfation reaction temperature above 800 °C However, the conversion rate decreased without the injection of air due to the blockage of sorbent pores.     

In situ desulfurization during combustion of high-sulfur coals added with sulfur capture sorbents

Two Chinese coals, added with two types of sulfur capture sorbents, were combusted in a drop tube furnace to investigate effect of reaction temperature on sulfur removal during coal combustion. Limestone was used as sorbent and mixed with coal physically for sulfur removal. In addition, another sorbent, calcium acetate, synthesized from natural limestone, was also used for in situ removal of sulfur; it was impregnated into raw coals before combustion. The first series of experiments were carried out in the furnace having downside temperature of 1173 K (the upper side of furnace was at 1573 K). The results proved that calcium acetate captured more sulfur than limestone. In order to understand the effect of reaction temperature on in situ sulfur removal of sorbents, the second series of experiments were carried out at the uniform furnace temperature ranged from 1373 to 1673 K. Moreover, the sulfur removal capability of ashes, taken from combustion of coal with sorbents in drop tube furnace, was studied at 1173 K using thermogravity. The calcium distribution in ashes was analyzed using a novel calcium-based compounds CCSEM category. The results indicated that at certain temperature, higher sulfur removal efficiency was obtained for calcium acetate than that for natural limestone, which is mainly due to the fine dispersion of calcium in impregnated coal so that a good contact was obtained between calcium and sulfur-containing coal particles; increasing the temperature lowered the sulfur removal capabilities of sorbents since the sorbents were captured by inherent aluminosilicate; the sulfur content in raw coal affects the utilization of sorbents significantly in coal combustion. In addition, ashes, rich in calcium, can adsorb SO₂ at 1173 K; the sulfur removal efficiency of fly ash is at least the same as that of natural limestone.     

Comprehensive sulfation model verified for T-T sorbent clusters during flue gas desulfurization at moderate temperatures

An empirical sulfation model for T-T sorbent clusters was developed based on amassed experimental results under moderate temperatures (300-800 °C). In the model, the reaction rate is a function of clusters mass, SO₂ concentration, CO₂ concentration, calcium conversion and temperature. The smaller pore volume partly results in a lower reaction rate at lower temperatures. The exponent on SO₂ concentration is 0.88 in the rapid reaction stage and then decreases gradually as reaction progresses. The exponent on the fraction of the unreacted calcium is 1/3 in the first stage and then increases significantly in the second stage. The CO₂ concentration has a negative influence on SO₂ removal, especially for the temperature range of 400-650 °C, which should be avoided to achieve a high effective calcium conversion. The sulfation model has been verified for the T-T sorbent clusters and has also been applied to CaO particles. Over extensive reaction conditions, the predictions agree well with experimental data.     

Sulfation Rates of Particles in Calcium Looping Reactors

The sulfation reaction rate of CaO particles in three reactors comprising a post‐combustion calcium looping system is discussed: a combustion chamber generating flue gases, a carbonator reactor to capture CO₂ and SO₂, and an oxy‐fired calciner to regenerate the CO₂ sorbent. Due to its strong impact on the pore size distribution of CaO particles, the number of carbonation/calcination cycles arises as a new important variable to understand sulfation phenomena. Sulfation patterns change as a result of particle cycling, becoming more homogeneous with higher number of cycles. Experimental results from thermogravimetric tests demonstrate that high sulfation rates can be measured under all conditions tested, indicating that the calcium looping systems will be extremely efficient in SO₂ capture.     

Calcium-based sorbents behaviour during sulphation at oxy-fuel fluidised bed combustion conditions

Sulphur capture by calcium-based sorbents is a process highly dependent on the temperature and CO₂ concentration. In oxy-fuel combustion in fluidised beds (FB), CO₂ concentration in the flue gas may be enriched up to 95%. Under so high CO₂ concentration, different from that in conventional coal combustion with air, the calcination and sulphation behaviour of the sorbent must be defined to determine the optimum operating temperature in the FB combustors.In this work, the SO₂ retention capacity of two different limestones was tested by thermogravimetric analysis at typical oxy-fuel conditions in FB combustors. The effect of the main operating variables affecting calcination and sulphation reactions, like CO₂ and SO₂ concentrations, temperature, and sorbent particle size, was analysed.It was observed a clear difference in the sulphation conversion reached by the sorbent whether the sulphation takes place under indirect or direct sulphation, being much higher under indirect sulphation. But, in spite of this difference, for a given condition and temperature, the CO₂ concentration did not affect to the sulphation conversion, being its major effect to delay the CaCO₃ decomposition to a higher temperature.For the typical operating conditions and sorbent particle sizes used in oxy-fuel FB combustors, the maximum sorbent sulphation conversions were reached at temperatures of about 900 °C. At these conditions, limestone sulphation took place in two steps. The first one was controlled by diffusion through porous system of the particles until pore plugging, and the second controlled by the diffusion through product layer. As a consequence, the maximum sulphation conversion increased with decreasing the particle size and increasing the SO₂ concentration.     

Influence of SO3 on mercury removal with activated carbon: Full-scale results

Activated carbon injection is considered one of the most cost-effective options for mercury control at PRB-fired power plants. However, roughly 30% of sites firing PRB coal use SO₃ for flue gas conditioning. The presence of SO₃ in flue gas can decrease mercury capture by activated carbon, sometimes dramatically. Overcoming activated carbon performance limitations caused by SO₃ conditioning for units with this configuration is essential to enable these plants to cost-effectively meet pending mercury emission regulations. Ameren's Labadie Unit 2 fires PRB coal and uses SO₃ to enhance particulate capture in the electrostatic precipitator (ESP). Full-scale sorbent injection tests at Labadie were conducted from 2005–2007. Six sorbents were tested at SO₃ injection concentrations ranging from 0 to 10.7 ppm. Sorbent performance was evaluated at two injection locations (the air preheater (APH) inlet and outlet). Native mercury capture on fly ash was typically less than 15%. When the mercury sorbents were injected downstream of the air preheater, the SO₃ concentration resulted in a decrease in mercury capture from 85% (no SO₃ injection) to 17% (SO₃ injection set at 10.7 ppm). Mercury sorbents were more effective when injected upstream of the air preheater. With the SO₃ system off, mercury removal increased from 75% when injecting 5.1 lb/MMacf of brominated carbon at the APH outlet, compared to 95% when injecting at the inlet. With the SO₃ system on, test results indicated an increase from about 30% injecting at the outlet to 58% injecting at the inlet. Tests evaluating the ADA-ES patented onsite milling process showed that 85% mercury capture was achieved injecting 4 lb/MMacf of milled activated carbon compared to a requirement of 10 lb/MMacf to achieve the same removal using as-received carbon, representing a 60% reduction in activated carbon consumption. No changes in opacity, APH and ESP performance, or other balance-of-plant effects were observed in these tests.     

SO2 removal from flue gas with dry limestone

SO₂ removal from flue gas with an efficiency of over 90% can be achieved by the furnace limestone injection (FLI) process in combination with the recently developed ash recycle activation (ARA) process. The ARA process uses a mixture of fly ash and CaO sorbent that comes out of the furnace for further SO₂ removal. The dust is separated from the flue gas, treated with low pressure steam and then added to the flue gas again. The activation of the Ca compounds occurs during steam treatment. Capillary condensation occurs and aqueous electyrolyte solution reactions within the particle become effective. A differential particle model is formulated.     

Effects of steam on the sulfation of limestone and NOx formation in an air- and oxy-fired pilot-scale circulating fluidized bed combustor

The existing fluidized bed combustion literature on sulfation shows that above 30% conversion, direct sulfation via reaction with CaCO₃ is faster than indirect sulfation with CaO. However, while this is true for dry flue gases, it is not the case if steam (H₂O_(g)) is present at realistic levels for coal combustion, and it has been confirmed by experiments employing thermogravimetric analysis (TGA) and tube furnace (TF) testing that direct sulfation is in fact slower than indirect sulfation for nearly all levels of conversion if steam (H₂O_(g)) is present. In this work we have also examined the effects of H₂O_(g) on SO₂ capture and NH₃ oxidation to NO_x over calcium-containing compounds under air- and oxy-fired conditions in a pilot-scale circulating fluidized bed combustor (CFBC) utilizing limestone addition. The results of the pilot-scale tests confirm suggestions from our previous work that sulfur capture from the air firing of low-moisture fuels benefits from steam-sulfation. For petroleum coke, the addition of 8%vol H₂O_(g) resulted in increased SO₂ retention and Ca utilization, as well as decreased NO_x emissions by up to 44%. The simultaneous reduction of SO₂ and NO_x was attributed to enhanced solid-state diffusion (sintering) by H₂O_(g). Under oxy-fuel-firing conditions, H₂O_(g) addition also resulted in decreased NO_x emissions, but the pilot-scale tests showed poorer sulfur capture performance and calcium utilization as compared to air firing when H₂O_(g) was present, thereby reconfirming the TGA/TF results. It appears that most bench-scale work on sulfation to date has underestimated the true rate of reaction for sulfation in the presence of H₂O_(g). This conclusion explains at least in part why indirect sulfation is often faster than direct sulfation in pilot plant studies on oxy-fuel circulating fluidized bed combustion. Moreover, this work stresses the importance of including H₂O_(g) in bench-scale experiments that attempt to simulate real combustion environments.     

Improving the SO<Subscript>2</Subscript> absorption rate of CeFeMg-based sorbent promoted with titanium promoter

To improve the poor SO₂ absorption rate of CeFeMgTi sorbent with high sulfur removal capacity and fast regeneration, a new sorbent, CeFeMgTi-sol was prepared by the modified co-precipitation method and tested in a packed bed reactor at RFCC conditions (sulfation of MgO to MgSO₄ in the presence of low concentration of SO₂ at 973 K, regeneration of MgSO₄ to MgO and H₂S in the presence of H₂ at 803 K). The CeFeMgTi-sol sorbent showed excellent SO₂ absorption and sulfur removal capacity (46.2 sulfur g/g absorbent×100). It was found that the SO₂ absorption rates were related to the structure of the Mg and Ti and the textural properties such as surface area and pore volume. In the case of the fresh state of CeFeMgTi sorbent, CeO₂, MgO and MgTiO₃ structures were observed. But the new CeFeMgTisol sorbent before SO₂ absorption, showed a separated MgO and TiO₂ peak only. These differences in the sorption rates were discussed by the difference in the XRD pattern, surface area and pore volume.     

Fluidized-bed coal combustion: In-bed sorbent sulfation model

A model is developed to account for sulfur capture within the sorbent bed of a fluidized-bed coal combustor. The model is expressed in an analytical form that contains two sorbent specific parameters. The sorbent parameters, which describe the kinetics of the sulfation reaction are obtained from thermogravimetric analysis data on the SO₂-sorbent reaction. Various hydrodynamic and mass transfer properties in relation to the bubbling phenomena are taken into consideration in the model. The predictions of the model which are made without arbitrary parameters, compare favorably with the experimental data on sorbent performance from large scale experimental fluidized-bed coal combustors.     

High temperature desulphurization by fine limestone during staged fluidized‐bed combustion

This paper reviews the SO₂ emission from a 0.3 m² stainless‐steel fluidized‐bed combustor. Fine coal was premixed with fine limestone and fed pneumatically under the bed. The SO₂ emission was found to depend largely on air staging ratio and bed temperature, which agrees with previous observations. The SO₂ emission observed in sorbent‐free tests (reported earlier by Khan and Cibbs, 1995) was found to be proportional to the sulphur content of the fuel when limestone was added, the sulphur capture at a fixed Ca/S molar ratio was dependent on oxygen stoichiometry and bed temperature. Finely sized limestone enhanced the effectivity of the sorbent at low bed temperature and air staging ratio. During staged combustion, the combustion efficiency depended largely on primary air to coal ratio. Around 90% combustion efficiency was observed at 1 m/s fluidizing velocity which was reduced when fluidizing velocity was increased to 1.5 and 2 m/s. This reduction is due to increased elutriation of finer coal particles from the combustor.     

CCSEM analysis of ash from combustion of coal added with limestone

Combustion of three Chinese coals, mixed with limestone physically, was carried out in drop tube furnace. The drop tube furnace consisted of two parts, the top side has a length of about 1.0 m and kept at 1573 K in all the runs, while the bottom-side has a length of 0.5 m and kept at 1173 K. SO₂ removal efficiency of about 80 and 73% were obtained in the combustion of Yanzhou with high and low sulfur, respectively. In contrast, for Datong coal, the De-S efficiency was only about 50% at the molar Ca/S ratio of 2.0; increasing Ca/S ratio to 3.0 had little effect on De-S efficiency. The combustion ashes were analyzed by several techniques including XRD, SEM-EDX and CCSEM (computer-controlled SEM). A novel calcium-based phase definition, based on CCSEM data was developed to investigate the modes of occurrence of added limestone in the ashes. Additionally, the mixture of limestone with kaolinite was injected into the furnace to study their transformation behavior under simulated coal combustion conditions. The governing mechanisms for limestone capturing sulfur and its reaction with the inherited minerals were correspondingly revealed. It was found that under the given coal combustion conditions, the calcium distribution in the ash varied with coal type and residence time. Briefly, more calcium was used for desulfurization or fixed into mineral; as time progressed, the inherited aluminosilicate, small sized excluded particles in the coal matrix, facilitated its reaction with limestone; it also reacted quickly compared to sulfation of limestone in coal combustion. This in turn hampered the efficient utilization of limestone in coal combustion.     

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.     

Sulfation diffusion model for SO2 capture on the T-T sorbent at moderate temperatures

A sulfation model was developed for dry flue gas desulfurization (FGD) at moderate temperatures to describe the reaction characteristics of the T-T sorbent clusters and the fine CaO particles that fall off the sorbent grains in a circulating fluidized bed (CFB) reactor. The cluster model describes the calcium conversion and reaction rate for various size sorbent clusters. The sulfation reaction is first order with respect to the SO₂ concentration above 973 K. The calcium conversion and reaction rate for the CaO particles were obtained by extrapolation. In the model for CaO particle, the reaction rate is linearly related to the calcium conversion and the SO₂ concentration in the rapid reaction stage and linearly related only with the calcium conversion after the product layer forms. The sulfation model accurately describes the sulfation of the T-T sorbent flowing through a CFB reactor. This work was presented at the 7 ^th China-Korea Workshop on Clean Energy Technology held at Taiyuan, Shanxi, China, June 26–28, 2008.     

Sulfur fate during bituminous coal combustion in an oxy-fired circulating fluidized bed combustor

To clarify the sulfur transformation behavior during oxy-fired circulating fluidized bed (CFB) combustion, experiments on SO₂ emission characteristics were carried out in a 50 kWth CFB combustor. Results show that SO₂ emission is quite dependent on the bed temperature in different atmospheres without limestone injection. With Ca/S=2.5, SO₂ emission in 21%O₂/79%CO₂ atmosphere is smaller than that in air atmosphere, but SO₂ emission decreases with the increase of O₂ concentration. The calcium forms in the ash prove the combination of calcination/carbonation and direct sulfation mechanism of limestone under oxy-combustion conditions. And the desulfurization efficiency of limestone (as deducting the self-retention efficiency from the total sulfur removal efficiency) increases from 40% to 52% as the O₂ concentration increases from 21% to 40%.     

EFFICIENT DESULFURIZATION IN O2/CO2 COMBUSTION: DEPENDENCE ON COMBUSTION CONDITIONS AND SORBENT PROPERTIES

Based on experiments on desulfurization, CaSO₄ decomposition, and a system approach using theoretical analysis, efficient in-furnace desulfurization in O₂/CO₂ combustion was investigated. The influence of combustion conditions and sorbent properties on system desulfurization efficiency was clarified. The global desulfurization efficiency was found to increase with O₂ purity. The global desulfurization efficiency in a dry recycle was higher than that in a wet recycle. The global efficiency of in-furnace desulfurization decreased with initial O₂ concentration. As the temperature increased, the global desulfurization efficiency increased first and then decreased due to the decomposition of CaSO₄. In the temperature range investigated, the global desulfurization efficiency in O₂/CO₂ coal combustion was much higher than that of conventional coal combustion in air. The global desulfurization efficiency decreased with sorbent size. When the particle radius decreased to one quarter, the global desulfurization efficiency doubled, becoming as high as 80%. The global desulfurization efficiency was very different among the three sorbents investigated, whether in O₂/CO₂ combustion or in conventional air combustion. The global desulfurization efficiency increased in the order of Ca(OH)₂, scallop, and limestone in O₂/CO₂ combustion, but in the order of scallop, Ca(OH)₂, and limestone in conventional air combustion. Nevertheless, all three sorbents demonstrated much higher desulfurization efficiency in O₂/CO₂ combustion than in conventional air combustion.     

Coal char combustion under a CO2-rich atmosphere: Implications for pulverized coal injection in a blast furnace

Pulverized coal injection (PCI) is employed in blast furnace tuyeres attempting to maximize the injection rate without increasing the amount of unburned char inside the stack of the blast furnace. When coal is injected with air through the injection lance, the resolidified char will burn in an atmosphere with a progressively lower oxygen content and higher CO₂ concentration. In this study an experimental approach was followed to separate the combustion process into two distinct devolatilization and combustion steps. Initially coal was injected into a drop tube furnace (DTF) operating at 1300 °C in an atmosphere with a low oxygen concentration to ensure the combustion of volatiles and prevent the formation of soot. Then the char was refired into the DTF at the same temperature under two different atmospheres O₂/N₂ (typical combustion) and O₂/CO₂ (oxy-combustion) with the same oxygen concentration. Coal injection was also performed under a higher oxygen concentration in atmospheres typical for both combustion and oxy-combustion. The fuels tested comprised a petroleum coke and coals currently used for PCI injection ranging from high volatile to low volatile bituminous rank. Thermogravimetric analyses and microscopy techniques were used to establish the reactivity and appearance of the chars.     

Removal of SO2 from flue gas using a new semidry flue gas desulfurization process with a powder-particle spouted bed

A spouted bed of binary particle mixture was applied to a low temperature desulfurization process in order to develop a new type of semidry flue gas desulfurization (FGD) technology. We investigated the effects of operating parameters, such as type of SO₂ sorbent, diameter of SO₂ sorbent particles, apparent residence time of gas in the bed, approach to saturation temperature and Ca/S molar ratio, on SO₂ removal in a bench-scale powder-particle spouted bed. We also investigated the utilization rate of SO₂ sorbent and ways to enhance the efficiency of SO₂ removal and SO₂ sorbent utilization. The experimental results showed that SO₂ removal is significantly affected by the approach to saturation temperature and Ca/S molar ratio, and that a high SO₂ removal efficiency and effective sorbent utilization can be obtained under appropriate operating conditions. Thus, this new simple process of flue gas desulfurization is highly efficient and has little impact on the environment.