Institute of Combustion and Power Plant Technology Prof. Dr. techn. G. Scheffknecht Francisco Carrasco, Simon Grathwohl, Jörg Maier, Günter Scheffknecht IFK, University of Stuttgart, Pfaffenwaldring 23, 70569 Stuttgart, Germany Oxy-fuel Investigations with a Cement Kiln prototype Burner CLEARWATER CLEAN ENERGY CONFERENCE June 14th, 2017. Clearwater, USA
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Oxy-fuel Investigations with a Cement Kiln prototype Burner · • Test facility was adapted for relevant oxy-cement tests. • Burner prototype was designed and tested. • Demonstration
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Institute of Combustion and Power Plant Technology Prof. Dr. techn. G. Scheffknecht
Francisco Carrasco, Simon Grathwohl, Jörg Maier, Günter Scheffknecht
IFK, University of Stuttgart, Pfaffenwaldring 23, 70569 Stuttgart, Germany
Oxy-fuel Investigationswith a Cement Kilnprototype Burner
CLEARWATER CLEAN ENERGY CONFERENCEJune 14th, 2017. Clearwater, USA
Oxy-fuel for cement production?Without reduction measures: 2.4 Gt/a in 2050BLUE MAP scenario (with CCS): max 1.6 Gt/a in 2050
Increase of energy efficiencyAlternative fuels useReduction of clinker share
Reduction by:
CCS
2.5
2.0
1.5
Glo
bal C
O2
emis
sion
s of
the
cem
enti
ndus
tryin
Gt/a
0.0
2010 2030 2050
44 %
56 %
Source: IEA Cement Roadmap
• IEA target for 2050: 50 % of all cement plants in Europe, Northern America, Australia and East Asia apply CCS
• Cement plants typically have a long lifetime (30-50 years or more) and very few (if any) are likely to
be built in Europe → Retrofit
Raw meal
Cyclonepreheater
Flue gas
Calciner
Tertiary air duct
Cooler exhasut gas
Fuel/air
Fuel
CoolerCooling air
Rotary kiln 2000 °C
300 - 350 °C
700 - 1000 °C
200 °C - 350 °C
850 °C
700 - 1000 °C
Clinker
60 % Material CO2
40 % Fuel CO2CaCO3, SiO2, Al2O3, Fe2O3
CO2 emissions in the cement industry
Source: ECRA
CEMCAP Project - technologies to be tested Calciner test rigExisting <50 kWth entrained flow calciner (USTUTT) to be used for oxyfuel calcination tests
Clinker cooler To be designed and built for on-site testing at HeidelbergCement in Hannover
Oxyfuel burner Existing 500 kWth oxyfuel burner at USTUTT to be modified for CEMCAP
Source: ECRA
5University of Stuttgart - Institute of Combustion and Power Plant Technology -
Source: ThyssenKrupp
a) Design of a prototype oxy-fuel burner for cement kilns.
Source: ThyssenKrupp- POLFLAME
Burner design
Downscaling criteriao Flame momentumo Primary gas velocity (ca. 250 m/s)o Carrier gas velocity (ca. 15 m/s)o Swirl angle: 0-40°
• Optimized settings: burner position, swirling angle, and primary gas velocity.
• Less quenching water Parameters Firsts experimental campaign
Second experimental campaign
Fuel Petcoke PetcokeTotal O2 in input gases 29% 27%
Burner position 10 mm inside housing 90 mm outside housingSwirl angle 40° 20°Primary gas velocity(approx.)
Air: 117 m/s Oxy-fuel: 108 m/s
Air: 190 m/sOxy-fuel: 150 m/s
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Primary gas (nozzles)
Coal + Carrier gas
482 kW
Secondary gasT = 740 °C
v = 4,5 m/s
O2 = 21%
N2 = 79%
λ = 1,12
O2 = 2,2% vol,dry
CO2= 16,5% vol,dry
Flue gasCC Shell radiation
PG = 21%
Primary gas (nozzles)
Coal + Carrier gas
482 kW
O2 = 53%CO2 = 47% CO2
=100%
Secondary gas
Flue gasCC Shell radiation
AIR CASE OXY-27
T = 712 °C
v = 3 m/s
O2 = 21%
CO2 = 79%
λ = 1,13
O2 = 3,4% vol,dry
CO2= 84,6% vol,dry
Swirling 20°
PG = 24%
22% less flue gas volume (Nm3)
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Air Case Oxy-fuel
Fuel burnout 98,0 98,3
19University of Stuttgart - Institute of Combustion and Power Plant Technology - 19
Air combustion Oxy-fuel combustion
20University of Stuttgart - Institute of Combustion and Power Plant Technology - 20
Summary
• Test facility was adapted for relevant oxy-cement tests.• Burner prototype was designed and tested.• Demonstration tests evinced suitability to obtain similar radiation
profiles under oxy-fuel conditions.
Further Steps• Additional testing with a higher volatile fuel.• Simulation of additional oxy-fuel cases not investigated in facility.
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Acknowledgements
This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement no 641185
This work was supported by the Swiss State Secretariat for Education, Research and Innovation (SERI) under contract number 15.0160
www.sintef.no/cemcap
e-mailphone +49 711 685-fax +49 711 685-
University of Stuttgart
Thank you!
Pfaffenwaldring 23 70569 Stuttgart GermanyInstitute of Combustion and Power Plant Technology