Fluidized Bed Combustion Research Articles

Investigating combustion efficiency and NOx emission reduction in fluidized bed ammonia-coal co-firing

Ammonia, a carbon-free fuel, can significantly reduce CO2 emissions when co-fired with coal in power plants. Fluidized bed combustion, known for its excellent gas-solid mixing and low NOx emissions, is a promising method for ammonia-coal co-firing. However, challenges remain in optimizing ammonia injection and controlling nitrogen oxide emissions. This study investigates these aspects using a lab-scale fluidized bed reactor with flexible ammonia injection points. Key variables, such as ammonia co-firing ratios, injection location, temperature, and outlet oxygen concentration, are examined. The results show that with ammonia injection ratios up to 70 %, NO and N2O emissions slightly increase, while ammonia escape is maintained below 5 ppm. Air staging effectively controls NOx emissions, and higher temperatures promote N2O decomposition, but increase NOx levels. Ammonia injection does not raise unburned carbon content. Rate of production and sensitivity analyses highlight the role of OH radicals in ammonia conversion and identify the critical reactions affecting NO generation. This study highlights the feasibility of fluidized bed ammonia-coal co-firing technology.

Utilization of circulating fluidized bed coal ash in autoclaved aerated concrete manufacture by mineral carbonation

Using circulating fluidized bed combustion (CFBC) ash discharged from thermal power plants, we identified factors affecting mineral carbonation to sequester CO2 and produced autoclaved aerated concrete (AAC). To use CFBC ash as a raw material for AAC, free-CaO, which causes volume expansion, was replaced through hydration and carbonation. During the raw material replacement process, carbonation behavior was confirmed through pH and temperature. A Ca(OH)2 to liquid ratio similar to a fly ash to liquid ratio of 0.25 is considered to provide sufficient diffusion distance, and the reaction rate may increase due to the rise in water temperature caused by Ca2+ leaching. Additionally, the results of XRD, XRF, TG-DTA, and SEM analyses indicate that hydration and carbonation reactions were stably achieved in the materials, suggesting that CO2 sequestration allows the materials to be used as alternative raw materials. After identifying the characteristics of the CFBC ash and the substituted material, AAC was manufactured through pressurized carbonation. The weight change rate, carbonation depth, ventilation rate, pore structure, and compressive strength of the manufactured AAC were measured. As a result, the alternative raw material exhibited higher permeability and a larger pore size range in the specimens compared to the original material, indicating easier CO2 penetration into the specimens. Consequently, this experiment suggests the potential of using the material in AAC production by providing a theoretical basis for solving volume expansion issues associated with concrete admixtures and CO2 sequestration in waste materials.

Towards cleaner energy: An innovative model to minimize NOx emissions in chemical looping and CO2 capture technologies

The urgent global challenges of climate change and environmental issues have catalyzed the development of CO2-capture-ready technologies incorporating fluidization, such as fluidized bed (FB) and circulating fluidized bed (CFB) combustion under oxy-fuel conditions, chemical looping combustion (CLC), chemical looping with oxygen uncoupling (CLOU), in-situ gasification chemical looping combustion (iG-CLC), and calcium (or carbonate) looping (CaL) systems. While these technologies have the potential to reduce CO2 emissions significantly, the persistent presence of nitrogen oxides (NOx = NO + NO2) as pollutants remains a critical environmental concern.This paper introduces a comprehensive fuzzy logic-based model for predicting NOx emissions (FuzzyNOx model) from solid fuel combustion in fluidized beds of chemical looping systems. This innovative model takes into account a wide range of operating parameters, including fuel type, fuel particle size, fuel moisture content, air/fuel ratio, and temperature. It also explores advanced coal and biomass combustion modes, including air-firing, oxyfuel, iG-CLC, and CLOU. Furthermore, it delves into the intricacies of two distinct facilities: the 5 kWth dual-fluidized bed Chemical-Looping-Combustion of Solid-Fuels (DFB-CLC-SF) facility at Czestochowa University of Technology, Poland, and the calcium looping dual-fluidized bed (CaL DFB) facility at Niigata University, Japan.Bituminous coal, semi-anthracite, and wood chips are utilized as fuels. Moreover, three various oxygen carriers (OCs) for chemical looping combustion were employed, namely ilmenite, copper oxide (60 % wt.) supported by carbonate waste from ore flotation, and copper oxide (60 % wt.) supported by ilmenite (20 % wt.) and fly ash. Bituminous coal, semi-anthracite, and wood chips are utilized as fuels.The developed knowledge-based fuzzyNOx model allows the optimization of operating parameters to reduce NOx emissions from CO2 capture technologies.

Comparison of DeNOx additives in SNCR fluidized bed boiler system

Due to decreasing BAT emission limits of NOx the owners of heating plant are looking for DeNOx solution, especially by solid fuel firing boilers. Fluidized-bed boil-ers combustion temperature is generally lower, and some primary precautions were sufficient. Nowadays lots of plants install secondary precautions (especially SNCR) into their boilers due to increasing periods of exceeding emission NOx limits. The article is about comparison of water solution of urea (41 % wt.), ammonium sulfate (33 % wt.) and am-monia (22 % wt.) and their utilization in SNCR technol-ogy. Laboratory determination specified exact content of functional substance and content of redox nitrogen. Also, significant content of heavy metals was not detected. Operational tests were realized in CFB coal-biomass boiler (steam parameters: 140 t·h-1, 525 °C, 12.5 MPa). Dosing of DeNOx additives were only during boiler per-formance higher than 92 %, for lower performance pri-mary precautions were sufficient. There was higher tem-perature through the combustion chamber during active SNCR dosing (877 °C, standard temperature 850 °C), alt-hough the amount of combustion air was increased. Com-plication connected with high emission of NH3 was not detected. Lower emission of CO was also detected. All three additives are suitable for application in SNCR technology. To reach emission limits were needed 3.7 l·h-1 of ammonia solution, 5.04 l·h-1 of urea solution and 5.74 l·h-1 of ammonium sulfate solution. After recal-culation it means 0.65 kg·h-1 (ammonia), 1.1 kg·h-1 (urea) and 0,38 kg·h-1 (ammonium sulfate) of redox nitrogen content.

Quantitative Analysis of Catalytic Oxidation Reactions in Oxygen Carrier Aided Fluidized Bed Combustion

Quantitative Analysis of Catalytic Oxidation Reactions in Oxygen Carrier Aided Fluidized Bed Combustion

Feasibility of using red mud as bed material for treating N2O in fluidized bed combustion

Red mud, a type of industrial waste, currently can’t be utilized effectively, and there are no efficient methods for controlling N2O emissions in circulating fluidized bed (CFB) boilers. Based on characteristics of N2O and the components of the red mud, the red mud was used in this study as bed materials of fluidized bed to treat N2O produced by coal combustion. The decomposition effect of red mud on N2O under various operating conditions during the coal combustion process was quantified in a bubbling fluidized bed, and the decomposition of N2O and NO after the flue gas passed through the bed material was investigated. In a variety of operational conditions, the presence of red mud has been observed to exert a pronounced inhibitory effect on the formation of N2O, while concurrently exhibiting the capacity to diminish the nitrogen conversion rate of N2O to varying degrees. Comparative analysis of N2O and NO emissions from char and coal revealed different levels of reduction, with the combination of CO and red mud being the most effective method. Red mud demonstrated superior N2O removal capabilities, while CO was more effective for NO removal. The issue of increasing NO can be resolved by balancing the iron-aluminum ratio of red mud, allowing the flue gas to pass through the red mud in the CFB’s low-temperature zone, and focusing on N2O removal in the furnace.

Combustion characteristics on ammonia injection velocity and positions for ammonia co-firing with coal in a pilot-scale circulating fluidized bed combustor

Ammonia (NH3) co-firing with coal in thermal power plant offers a viable solution for reducing CO2 emissions. Optimizing the NH3 injection method is crucial to achieving comparable performance and pollutant emissions in NH3–coal co-firing compared to coal only combustion in a circulating fluidized bed combustion system. The impact of NH3 co-firing with coal on the injection velocity and location in related to the NH3 supply method was evaluated. Injection velocity was controlled by varying the number of ammonia supply ports and their heights (0.2 m and 1.8 m from the distributor). Injecting NH3 through one port at a high velocity of 2.4 m/s increases CO emissions while decreasing NO emissions due to the formation of a reducing environment. Conversely, utilizing two ports with low NH3 injection velocity of 1.2 m/s exhibited the opposite trend in CO and NO emissions, achieving the highest combustion efficiency without the formation of N-containing components. This injection velocity promotes better mixing of gases (air and NH3) and solids (bed materials and coal) without hindering coal combustion. Regarding greenhouse gases emissions, the part of CO2 emissions decreased by considering CO2 concentration and flue gas flow rate, while the part of N2O emissions significantly increased due to N-chemistry by > 5 times.

Characteristics of Circulating Fluidized Bed Combustion (CFBC) Ash as Carbon Dioxide Storage Medium and Development of Construction Materials by Recycling Carbonated Ash.

This study validates the attributes of the mineral carbonation process employing circulating fluidized bed combustion (CFBC) ash, which is generated from thermal power plants, as a medium for carbon storage. Furthermore, an examination was conducted on the properties of construction materials produced through the recycling of carbonated circulating fluidized bed combustion (CFBC) ash. The carbonation characteristics of circulating fluidized bed combustion (CFBC) ash were investigated by analyzing the impact of CO2 flow rate and solid content. Experiments were conducted to investigate the use of it as a concrete admixture by replacing cement at varying percentages ranging from 0% to 20% by weight. The stability and setting time were subsequently measured. To produce foam concrete, specimens were fabricated by substituting 0 to 30 wt% of the cement. Characteristics of the unhardened slurry, such as density, flow, and settlement depth, were measured, while characteristics after hardening, including density, compressive strength, and thermal conductivity, were also assessed. The findings of our research study validated that the carbonation rate of CFBC ash in the slurry exhibited distinct characteristics compared to the reaction in the solid-gas system. Manufactured carbonated circulating fluidized bed combustion (CFBC) ash, when used as a recycled concrete mixture, improved the initial strength of cement mortar by 5 to 12% based on the 7-day strength. In addition, it replaced 25 wt% of cement in the production of foam concrete, showing a density of 0.58 g/cm3, and the 28-day strength was 2.1 MPa, meeting the density standard of 0.6 grade foam concrete.

Innovative Method of Biomass Combustion in the Binary Fluidised Bed

Abstract In this study, a binary fluidised bed made out of quartz sand and cenospheres for the biomass combustion process was created. Materials were fluidised with air to achieve a vertical density profile (from 0.5 g/cm³ to 1.1 g/cm³) resulting from grains segregation. The density profile was selected to ensure optimal control over the location of the combusted fuel particle. This involved positioning the process as close to the bottom sieve as possible. Fluidised bed combustion was carried out at temperatures of 600 °C, 700 °C, 820 °C and 870 °C using straw, willow and sawmill pellets as fuels. Qualitative and quantitative analysis of flue gases was performed using an FTIR spectrometer. Over 90 % carbon conversion from the biomass to carbon dioxide was achieved at 700 °C. At 820 °C and 870 °C, 100 % of biomass carbon left the reactor as CO2. The composition of organic compounds in the process products remained low, reaching a maximum of 3.0 % wt. at 600 °C. To gain further insights into the processes occurring in the immediate vicinity of biomass samples, a complementary TGA/FTIR analysis was conducted. This aimed to clarify the impact of the biomass particle decomposition stage in the fluidised bed combustion process. The proposed mechanism for biomass combustion in the binary fluidised bed contains the particle decomposition stage and the subsequent stage resulting from the coalescence of bubbles containing flammable components and bubbles containing oxidiser.

Experimental investigation of combustion characteristics of ammonia with sub-bituminous coal in a pilot circulating fluidized bed combustor

Recent research on power plant technology has focused on employing ammonia as a supplementary fuel with coal to reduce carbon dioxide emissions from coal-fired power plants. However, most of this research has concentrated on pulverized coal systems, with fewer studies on circulating fluidized bed (CFB) combustion systems. Additionally, no research has analyzed combustion and environmental impacts under varying operational conditions with a fixed ammonia co-firing ratio. This study advances the development of coal–ammonia co-firing technology for use in CFB power plants by conducting experiments on a 50 kWth CFB combustion test rig. The co-firing characteristics were evaluated by progressively increasing the ammonia co-combustion rate to 20%, calculated on a high calorific value basis relative to sole coal combustion. Furthermore, this research explored the variations in operational conditions during 20% ammonia co-firing to assess their effects on the temperature distribution within the combustor and the composition of the exhaust gases. The findings elucidate the combustion efficiency, thermal behavior, and emission profiles associated with coal–ammonia co-firing, thereby guiding the optimization of operational strategies to minimize the carbon footprint of CFB power plants.

Experimental Study of Oxy-fuel Combustion and Emission Characteristics Using a 10 kWth Pressurized Fluidized Bed Combustor

Experimental Study of Oxy-fuel Combustion and Emission Characteristics Using a 10 kWth Pressurized Fluidized Bed Combustor

Influence of air staging variation on agglomeration behavior of biomass fuels in fluidized bed technology

The fluidized bed system is an effective approach widely accepted and commonly used for the thermochemical conversion of solid fuel such as biomass and agricultural residue. In most instances, there are some demerits usually associated with this approach such as development of eutectic mass, increased process of melting and bed agglomeration. This work was carried out to study the behavior of five readily available biomass fuels (Palm tree fronds, corn straw, plantain peels, sugarcane bagasse and domestic woods) in a bubbling fluidized bed (BFB) combustor. Characterization of the bed materials and ash samples were done using SEM-EDX, XRF and XRD. The effect of physical factors on the composition of obtained ash and particles from the bed was assessed. Also, the interaction between the fuel ash and bed particle was evaluated to reveal its influence on bed materials morphology. The results obtained revealed a combustion efficiency that varies between 96.2 to 99.6 % with the highest value obtained for sugarcane bagasse. The corn straw has the highest Potassium (K) content, while the domestic wood ash contained the highest Calcium (Ca) content. The XRF analysis revealed the conversion of the major potassium content of the corn straw to K2O. Meanwhile, bed agglomeration was absent when combustion was carried out with no staging-air as well as with staging air, despite high temperature above 800 oC used. Data obtained from this work revealed that agglomeration effect will be minimal issue when carrying out fluidized bed combustion of the selected biomass.

Modification of cement-based circulating fluidized bed combustion slag: Physical grinding and chemical excitation

This study investigates the effects of physical grinding (ball, impact, and jet milling) and chemical modification (using various dosages of Na2SO4, CaO, triethanolamine (TEA), and their composite modifiers) on CFBCS. The fluidity, flexural strength, compressive strength, and expansion rate of different modification methods were tested. Microstructural and phase composition analyses were conducted using X-ray diffraction, Fourier transform infrared spectroscopy, scanning electron microscopy, mercury intrusion porosimetry, and thermogravimetry-differential thermogravimetry. The results indicated that impact milling improved mortar fluidity by 2.9 % compared to ball milling, while jet milling reduced it by 5.7 %. Chemical modifications decreased paste fluidity but increased mortar strength and reduced expansion rates. Impact milling and jet milling improved 28-day compressive strength by 13.76 % and 16.01 %, respectively, and reduced the 90-day expansion rate by 0.007 % and 0.012 %, respectively. Composite chemical modification (CM-C) enhanced 28-day compressive strength by 23.88 % and reduced the 90-day expansion rate by 0.019 %. Microscopic analysis shows that modification reduced the pores and pore size of the mortar while increasing the hydration products. After TEA modification, rod-shaped AFt forms a reticulated structure, with C–S–H gel and CH crystals adhering to it. The hydration products of CFBCS mortar formed a network after jet milling, and the addition of composite modifiers resulted in a layered, dense structure.

Phase identification and micromechanical properties of non-traditional and natural pozzolan based alkali-activated materials

Four groups of non-traditional and natural pozzolan (NNP) based (aluminosilicate-based) materials, calcined clays, ground bottom ashes, volcanic ashes, and fluidized bed combustion ashes, were alkali activated using a hybrid solution of sodium silicate and sodium hydroxide. The microhardness and reduced modulus of the phases present in eleven alkali-activated pastes were measured using nanoindentation. At least 800 data points were collected from 28-day old ambiently cured paste samples. Unsupervised machine learning techniques i.e., k-means clustering and Gaussian mixture modeling (GMM) were used for the classification of the micromechanical properties supplemented by scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). The clustering of micromechanical and EDS data revealed five distinct phases in these hardened pastes. The alkali-activated gels identified had reduced modulus values ranging from 12 to 34 GPa. The remnant phases were partly reacted grains and unreacted minerals exhibiting reduced modulus values ranging from 35 to 105 GPa. Micromechanical property contour plots and SEM image pixel count plots were used to validate the phase assemblage. Additionally, the identification capabilities and advantages of the method are assessed by direct comparison with experimental results for different alkali-activated gels.

Recent progress in the operational flexibility of 1 MW circulating fluidized bed combustion

In this study, various experimental tests were carried out with a 1 MWth circulating fluidized bed pilot plant at the Technical University of Darmstadt to investigate the combustion and co-combustion behaviour of different fuels under load change conditions in air and oxyfuel mode. The combustion tests were carried out with low-calorific lignite and hard coal as reference cases for co-combustion. In the co-combustion experimental tests, straw pellets, and refuse-derived fuels (high and low calorific) were used as co-fuels for coal. In addition, a comprehensive dynamic 1.5-D process simulation model was established for a 1 MWth circulating fluidized bed pilot plant. The model created with the “APROS” software precisely reproduces both the gas/solids and the water/steam side of the 1 MWth pilot plant. The dynamic process simulation model was first validated at various steady-state operation points and, in a second step, at various dynamic load changes. The numerical results, such as the pressure drop and temperature profiles along the fluidized bed riser as well as the flue gas concentrations at the cyclone outlet, were compared with the measurements and showed agreement during the long-term tests of the combustion and co-combustion processes.

Investigation on NO and N2O emissions characteristics in deep peak regulation circulating fluidized bed boilers

Abstract To adapt to the increasing proportion of new energy power generation capacity, coal power must transition from its traditional role as the primary power source to serving as a fundamental backup and system regulation energy source. The circulating fluidized bed technology is known for its wide range of load regulation capabilities; however, emissions of pollutants during load regulation can exhibit significant variability. This study utilized Aspen Plus software to develop a circulating fluidized bed combustion model based on a gas-solid fluid dynamics model, an equivalent coal pyrolysis model, and a multi-phase macroscopic combustion reaction dynamics model of pyrolysis products. This model was used to predict both the temperature distribution within the furnace chamber and the distribution of pollutant concentrations. Predictions of pollutant emissions from 100 % load to 30 % load of the circulating fluidized bed were explored under the original combustion condition and 5 % proportion of recirculated flue gas. Under the primary combustion condition, the emission concentration of NO x showed a decreasing and then increasing trend with decreasing load, while the concentration of nitrous oxide, in contrast to NO x , showed an increasing and then decreasing trend. The effect of recirculated flue gas on pollutant emissions was not significant at reduced loads. This study aims to provide technical support and theoretical guidance for the management of pollutant emissions from the deep peak regulation of actual circulating fluidized beds.

Evaluating the potential of high free-CaO fluidized bed boiler ash as a cement admixture

This study investigates the feasibility of utilizing ash from circulating fluidized bed combustion (CFBC) boilers as a cement admixture. Two types of CFBC ash, distinguished by their free-CaO contents, are examined to evaluate their impact on the hydration reactions and mechanical properties of cement. The incorporation of CFBC ash with elevated free-CaO content into cement facilitates a hydration reaction, which results in accelerated setting and reduced compressive strength. To effectively utilize CFBC ash as a cement admixture, it is necessary to reduce the free-CaO content to an appropriate level, and carbonation curing is found to be an efficient method. It is confirmed that even CFBC ash with a high free-CaO content can effectively be utilized as a cement admixture through pretreatment with carbonation curing. This study may have valuable implications for the ability of CFBC ash to reduce carbon dioxide via mineral carbonation and its potential use as a cement admixture.

Corrosion and Erosion in Pulverized Coal based Fluidized Bed Combustion Boiler in Power Plants

Corrosion and Erosion in Pulverized Coal based Fluidized Bed Combustion Boiler in Power Plants

Experimental investigation on the preparation of macroscopic 0–1 mm powdered coal by a vertical spindle mill

The vertical spindle mill (VSM) is the key equipment to realize the preparation of 0–1 mm fuel used in powdered-coal-fired circulating fluidized bed combustion technology (PC-CFB). In this paper, a pilot-scale VSM test system was set up to explore the feasibility and operating performance of coarse-grained pulverized coal preparation. The effects of loading force, table revolution rate, and ventilation rate on the product size distribution, as well as the energy consumption of the grinding process were emphatically discussed. The results show that the product size of VSM increases with the decrease of loading force and the increase of ventilation rate, but too small a loading force will affect the normal output of VSM. Additionally, the product size of VSM decreases firstly and then increases with the increase of table revolution rate. Further, the energy consumption of the powdered coal preparation process was quantitatively described, and a semi-empirical model of comminution energy based on the powdered coal particle size distribution was proposed and verified by the measured values with an average accuracy of ±30 %. This model can estimate the power consumption of the mill, which can be used as an input parameter of the heat balance calculation model for the PC-CFB pulverizing system.

From bubbling to circulating fluidized bed combustion—development and comparison

The most significant introduction of fluidized bed combustion technology took place about 50 years ago. Initially the combustion beds were of the bubbling type. Once the designs had reached commercial application, several drawbacks were discovered: Erosion on in-bed heat-exchanger tubes, insufficient combustion and desulphurization efficiencies with coal, unfavourable scale-up to electric utility-size. The problems were solved by applying circulating systems. The present text compares these bubbling and circulating designs. It is concluded that the bubbling bed may not be suitable for coal combustion, but for biomass and organic waste most of the drawbacks disappear, and the bubbling bed, being simpler, may have an economic advantage over CFB that should be considered. In addition, combinations of CFB and BFB are quite favourable in many applications.