HYDROGEN FIRING FOR A HIGH CAPACITY ROTARY KILN

Transcription

1 HYDROGEN FIRING FOR A HIGH CAPACITY ROTARY KILN Ralph L. Coates, L. Douglas Smoot, Kent Hatfield Combustion Resources, Inc. Provo, Utah 29 th Oil Shale Symposium Colorado School of Mines Golden CO 20 October,

2 PRESENTATION TOPICS PROCESS Characteristics KILN Characteristics KILN FIRING Hydrogen PLANS Full process demonstration 2

3 Combustion Resources, Inc. / Test Facility 20,000 sq ft Provo, Utah 3

4 First DOE/SBIR grant completed (March 2007) Second DOE/SBIR grant completed (June 2009) Utah Center of Excellence Grant (June 2009) Shale oil process patent application (2007) Preliminary designs of 5 tpd pilot, 300 tpd demo, 6000 bpd commercial plants Constructed pilot-scale rotary kiln Completed kiln firing and heating tests Rotary kiln patent application (2009) Process water reduction design (2009) Spent shale vegetation tests (2009) DOE/SBIR Phase II Grant (2009) 4

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6 Efficient, flexible continuous plant operation Simple, advanced design horizontal kiln Minimal process water use Upgrading shale oil on-site - gasoline and diesel Near-complete elimination of CO 2 - Option Low cost on-site hydrogen source - Option Compliant disposal of spent shale 6

7 Natural Gas Kiln Firing with Oil/Gas Separation On Site Shale Oil Upgrading Hydrogen Kiln Firing CO 2 Control On Site Hydrogen Production - Kiln Firing with H 2 - H 2 for Oil Upgrading 7

8 1. INDIRECT-FIRED ROTARY KILN WITH H 2 /AIR COMBUSTION 2. CONTROLLED PEAK SHALE ORE KILN TEMPERATURES NO CARBONATE DECOMPOSITION 3. NO RECOVERY OF SPENT SHALE CARBON 4. RECYCLE OIL SHALE OFF GASES 5. CO 2 CAPTURE 8

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10 Simple, horizontal, low fabrication cost Advanced design technology - High throughput rates - Local control of shale and oil product temperature - Elimination of shale carbonate CO 2 emissions H 2 Firing Option Handles shale process fines 10

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12 Advantages No carbon dioxide emissions Complete, rapid combustion High energy content Wide temperature/composition range Disadvantages Flame flash-back Cost Kiln start-up 12

13 (Kanury, Glassman) Property/Units Natural Gas (CH 4 ) 1. Molecular Weight, g/gmol Heat of Combustion, Kcal/g 12 Hydrogen Adiabatic (stoich) Flame Temp. K Spontaneous Ignition Temperature (air), o C Min. Ignition Energy (10-5 cal) Max. Laminar Flame Speed, cm/s Flammability Limits (air), vol% Lean Rich

14 A d i a b a t i c F l a m e T e m p e r a t u r e ( K ) K CH 4 stoich Adiabatic Flame Temperature (K) Adiabatic Flame Temperature (K) vs Flammability Limits (vol%) 2394 K H 2 stoich H2 case H 2 case CH4 case CH 4 case Adiabatic Flame Temperature, o F T a, o F Flammability Limits (vol%) Volume Percent of Fuel in Air 14

15 Maxon-natural gas, hydrogen Wide Range Burner Standard Commercial Units Maximum firing rate 150,000 BTU/hr Pre-purge of gas manifold Ignition with natural gas 15

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19 Tests Firing Rate (10 3 BTU/h) % Excess Air Range Probe Temperature Range, o F Flame Natural Gas Transparent Hydrogen Orange 19

20 FR = Firing rate, 1000 s BTU/hr FR 147, H 2-17% xs air FR 90, H 2-52% xs air FR 147, H 2 +32% xs air FR 90, H 2-23% xs air FR 90, H 2 +97% xs air FR 157, H 2-5% xs air FR 90, H 2-2% xs air NATURAL GAS, +13% xs air FR 157, H 2 +10% xs air FR 90, H 2 +50% xs air 20

21 Temperature (K) Stoichiometric Adiabatic- CH 4 H 2 Calculated (CH 4 ) Measured (NG) Temperature (F) Excess Fuel Excess Air Limit 910% Excess Air % Stoichiometric Air 21

22 Commercial Burners Available - Hydrogen Ignition with NG increases reliability/safety Hydrogen air clearly visible to monitor H 2 NG combustion temperatures similar Hydrogen-air flames stable over very wide air/fuel range - Minimize cost - Control temperature 22

23 New DOE contract 2009 Demonstrate Full C-SOS Process - Pilot plant, 5 tpd - Kiln firing (NG, H 2 ) - Shale oil separation, recovery Demonstrate shale oil upgrading - Hydrotreating - to gasoline, diesel - Hydrocracking C-SOS Commercial Plant Design tpd 23

24 Acknowledgment Coauthors Coates and Hatfield U.S. Department of Energy/SBIR Grant (Chandra Nautiyal, NETL) State of Utah Center of Excellence Grant (Nicole Toomey Davis) 29 th Oil Shale Symposium 20 October