Research Ac*vi*es Laboratory of Steam Boilers & Thermal plants - - PowerPoint PPT Presentation

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Research Ac*vi*es

Laboratory of Steam Boilers & Thermal plants

Short Overview

• Prof. Dr.-Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. So*rios Karellas

Laboratory of Steam Boilers & Thermal plants School of Mechanical engineering NaDonal Technical University Athens

• 9. Herroon Polytechniou str.,

Zografou Campus, Athens Email: sotokar@mail.ntua.gr URL: www.lsbtp.mech.ntua.gr Tel.: 00302107722810 Fax: 00302107723663

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

2 2

School of Mechanical Engineers NTUA

The school of Mechanical Engineers is

• ne of the 9 schools of the NTUA
• At 1975 there has been a separation between

mechanical and electrical engineers

• At 1982 the school of Naval Engineering has ben

separated from the school of Mechanical Engineering

• Today there are 43 Professors
• 200 new students every year

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

3 3

The school of mechanical engineering

The school of mechanical engineering has the following sections

• Section of industrial administration
• Thermal section
• Construction and automatic control
• Nuclear technology
• Fluid section
• Materials processing section

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Laboratory of Steam Boilers & Thermal plants

• Prof. Dr.-Ing. Emmanuel Kakaras Assoc. Prof. Dr.-Ing. So*rios Karellas

Director of the Laboratory

Dr.-Ing. Aggelos Doukelis Dr.-Ing. Panagio*s Vourlio*s

• Lab. Teaching staff and Senior researchers
• 1 Post-Doc Student
• 10 PhD Students
• 2 MSc engineers
• 8 Post-graduate students
• 30 Diploma-students
• 2 Secretaries
• 20 External Experts
• 4 Guest Researchers

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Introduc*on

The Laboratory has been working for the last 25 years having acquired a wealth of experience

• n the following subjects.
• ExaminaDon of heat transfer phenomena on the exchange surfaces of steam boilers.
• TesDng and checking of heaDng systems as for their efficiency and their exhaust gas quality.
• ExaminaDon of phenomena which affect and determine the process of combusDon in furnaces
• f convenDonal and non-convenDonal steam boilers.
• Developing of own built codes for the simulaDon of heat transfer processes and pollutants

formaDon.

• The formaDon of pollutants and the technologies for their reducDon.
• The energy saving from Thermoelectric Power Plants.
• Process simulaDon and the development of advanced cycles for power generaDon.
• The development of new technologies and combusDon systems such as solid fossil fuels and

biomass combusDon in a Fluidised Bed.

• The predicDon and coping with problems through the computaDonal simulaDon of flow fields,
• f transfer and combusDon phenomena.

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Exis*ng Basic infrastructure – Facili*es (1/4)

• 1. Thermal Power plant supplied with light oil or natural gas. It consists of:
• Steam boiler of thermal output 2.5MWth with 100m2 heat exchange surface and external

super heater with 96m2 heat exchange surface for producing saturated and superheated steam, respecDvely. The steam boiler has a 4t/h nominal steam producDon and operaDng pressure of 10 bar.

• Steam Turbine of 200kW nominal heat output associated with nominal power 260kVA

generator to produce electricity.

• 2. CHP Plant producing electricity - heat - cooling, using natural gas which in full operaDon

yields 1573 kWth and 1527 kWe.

• 3. Tes*ng – Control Laboratory of Hot Water Boilers supplied with solid, liquid and gaseous fuel

with capacity up to 1250kW.

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Exis*ng Basic infrastructure – Facili*es (2/4)

• 4. Cer*fica*on Unit for Heat Systems (CUHS) accredited by the Hellenic AccreditaDon System

(E.SY.D) according to the European Standard EN ISO/IEC 17065 (Cer*ficate Number 127-5 with renewal date 26/03/2019) and the field of cerDficaDon is Hot Water Boilers with usage of solid,

• il and gaseous fuel. CUHS is a No*fied Body in European Union with CE 0617 idenDfier number

and is the only one, which has tesDng laboratory of hot water boilers in Hellas. Test rig for Hot Water Boiler testing of NTUA/LSBTP.

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Exis*ng Basic infrastructure – Facili*es (3/4)

• 5. Measurement Environmental Unit (MEU) is mobile accredited by the Hellenic AccreditaDon

System (E.SY.D) according to the European Standard EN ISO/IEC 17025 & CEN TS 15675 (Cer*ficate Number 648-2 with renewal date 28/01/2018) in the field of Stack emissions from staDonary sources. Types of tests/ proper,es to be measured are:

a) IsokineDc sampling and determinaDon of mass concentraDon of parDculate maher. b) Sampling and determinaDon of emissions of PM10 and PM2.5 parDcles. c) DeterminaDon of water vapor in ducts. d) Sampling and DeterminaDon of the concentraDon for O-2, CO2,CO, SO2, NOx & N2O. e) Sampling and DeterminaDon of the mass concentraDon Total Organic Carbon (TOC) with flame ionizaDon detector (FID). f) Sampling for the determinaDon of PCDDs/PCDFs and like dioxin PCBs. g) Sampling for the determinaDon of As, Cd, Cr, Co, Cu, Mn, Ni, Pb, Sb, Ti and V. h) Sampling for the determinaDon of total Hg.

Isokinetic sampling for the measurement

• f Hg & Heavy metal concentration.

Isokinetic sampling for the measurement of PCDD’s, PCDF’s & PCB’s concentration.

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Exis*ng Basic infrastructure – Facili*es (4/4)

• 6. Two fluidized beds of solid fuel combusDon, of which the first is an air bed with recirculaDon

(Atmospheric CirculaDng Fluidised Bed Combustor, ACFBC) of 150kW power, while the second is a laboratory scale bench Air Bubble (Atmospheric Bubbling Fluidised Bed Combustor, ABFBC).

• 7. A fuel cell, capable of generaDng electricity up to 2 kW for household equipment applicaDons,

supplied with pure hydrogen.

Fluidized Beds Fuel Cell

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Decentralized Energy ApplicaDons

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

G Expander Condenser Generator Pump Heat exchanger Cooling water QORC,in Pel 1 2 3 4 HSin HSout Cwin Cwout

• QORC,out
• T

S 1 2 3 4

ORC overview

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

The Organic Rankine Cycle – an applica*on for small power range

The ORC uses organic syntrhetic or natural substances instead of water as working fluid

water

• rganic fluids

ORC vs water-steam Rankine cycle

• Operation at lower temperatures

with better efficiency

• Smaller equipment
• Simple construction and operation
• Reduced capital cost

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

ORC applica*ons - Waste heat recovery

Waste heat recovery-to-power generation WHR-ORC

Waste heat Electricity

G

Benefits:

Reduce primary energy consumption Decrease in GHG (CO2, CO) and pollutants (NOx, SOx) emissions Potential for economic benefits in cement, glass and steel industry Primary process

Utilization of waste heat otherwise rejected to the environment for electricity generation Purpose: Concept:

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Development of a low-temperature ORC engine experimental prototype for waste heat recovery onboard ships

Marine ORC project

NTUA – DNV-GL collaborative project

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Expander Condenser ORC pump Heat exchanger Pump Heat source

G

Generator

M

Motor

M

Motor Cooling water

Marine ORC opera*on principle

ü Waste heat recovery unit for Marine Auxiliary Diesel Engines ü Design and opDmizaDon ü Test bench erecDon ü Automated Control system ü Experimental invesDgaDon ü On-board operaDon and long- term evaluaDon

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

Associate Professor Sotirios Karellas

LSBTP

16

Schema*c diagram of Marine ORC circuit

!

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Marine ORC experimental unit

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Research Interests

5 10 15 20 25 30 4 5 6 7 8 9 10 8500 8700 8900 9100

Temperature (oC) Pressure (barg) / Head (mH2O) Time

Press at pump outlet Press at pump inlet NPSHa - NPSHr Temp at pump inlet Temp at condenser

• utlet

ü ORC pump modeling – operaDonal issues (e.g. cavitaDon) - performance ü Scroll expanders ü OpDmal control strategy ü On-board tesDng of the experimental unit – constraints and potenDal

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Development of a small-scale low-temperature Supercri>cal Organic Rankine Cycle engine with op>mised scroll expander and evaporator

Supercritical ORC project

Hellas Energy Agricultural University of Athens - Coordinator NaDonal Technical University of Athens

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Supercri*cal ORC

50 supercritical ORC subcritical ORC 2 1 3‘ 3 3‘‘ 3 5 4 50 supercritical ORC subcritical ORC 2 1 3‘ 3 3‘‘ 3 5 4

Entropy [kJ/kg]

0,75 1,25 1,75 2,25 50 100 150 200

Temperature [°C]

Subcritical ORC Supercritical ORC

’ 4’ 2 ’

50 supercritical ORC subcritical ORC 2 1 3‘ 3 3‘‘ 3 5 4 50 supercritical ORC subcritical ORC 2 1 3‘ 3 3‘‘ 3 5 4

Entropy [kJ/kg]

0,75 1,25 1,75 2,25 50 100 150 200

Temperature [°C]

Subcritical ORC Supercritical ORC

’ 4’ 2 ’

Specific entropy [kJ/kgK]

50 supercritical ORC subcritical ORC 2 1 3‘ 3 3‘‘ 3 5 4 50 supercritical ORC subcritical ORC 2 1 3‘ 3 3‘‘ 3 5 4

Entropy [kJ/kg]

0,75 1,25 1,75 2,25 50 100 150 200

Temperature [°C]

Subcritical ORC Supercritical ORC

’ 4’ 2 ’

50 supercritical ORC subcritical ORC 2 1 3‘ 3 3‘‘ 3 5 4 50 supercritical ORC subcritical ORC 2 1 3‘ 3 3‘‘ 3 5 4

Entropy [kJ/kg]

0,75 1,25 1,75 2,25 50 100 150 200

Temperature [°C]

Subcritical ORC Supercritical ORC

’ 4’ 2 ’

Specific entropy [kJ/kgK]

Heater G Turbine Condenser Generator Pump Recuperator

Heat source stream Cooling medium

Cwin Cwout HSin HSout 1 2 3 4 5 6

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Advantages of supercri*cal heat transfer

Variable temperature heat transfer reduces exergy destrucDon during heat exchange process

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Op*miza*on of prototype scroll expander design

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Op*miza*on of supercri*cal heat exchanger design

Plate heat exchanger Overall heat transfer coefficient in supercriDcal region

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Development of prototype supercri*cal ORC engine

• Experimental tesDng and modificaDon of SCORC engine
• Development of integrated opDmized SCORC
• CommercializaDon of engine
• Techno-economic invesDgaDons and analysis of market

perspecDves

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Detailed inves>ga>on and op>miza>on of the opera>on and design of a small-scale hybrid Bio-TRI-genera>on system powered by a super-cri>cal ORC

BIOTRIC project

TRI-CO-GENERATION SYSTEM Cooling HeaDng Electricity Biomass Solar power

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP Research interests-Experimental

Bio-TRIC trigeneration unit

• Design and assembly of domestic scale trigeneration unit based on ORC-VCC
• Analysis of operation strategies and configurations
• Off-design simulation
• Dynamic modelling of components (heat exchangers, scroll expanders)
• Estimation of heat transfer correlations for working fluid R227ea

Research interests-Theoretical

Hybrid (solar and biomass) trigeneration system Bio-TRIC

• Thermo-economic assessment
• Analysis of operation strategies and configurations
• Off-design simulation

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Bio-TRIC trigeneration unit

30 32 34 36 38 40 42 44 46 2 2.5 3 3.5 4 4.5 5 Porc (bar) nth,orc (%) Porc - nth,orc R125 R404A R227ea

Working fluid: R227ea

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

BIOTRIC opera*on principle

Expander Condenser ORC pump Heat exchanger Boiler circulator Biomass boiler

G

Generator

M

Motor

M

Motor To heat demand Evaporator Compressor Throttle valve Cooling VCR-valve VCR-valve

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Biomass Boiler 75 kWth Circulation Pump Plate Heat Exchanger Evaporator Receiver Feed Pump 33 lt/min Scroll Expanders Filter Throttle Valve Compressor M Plate Heat Exchanger Evaporator Plate Heat Exchanger Condensers Pressure transducer Thermocouple Flowmeter Valve Cooling Water Pump Thermal oil circuit ORC circuit Cooling water circuit VCC circuit

50 oC 9.2 bar 69.9 oC 9.2 bar 637.5 lt/min 10 oC 2.8 bar 52.4 oC 30.4 bar 110 oC, 30.4 bar 50 oC 9.2 bar 50 oC 9.2 bar 120 oC 5-6 bar 105 oC 66.7 oC 9.2 bar 50 oC 9.2 bar 45 oC 1 bar 20 oC 1bar Working Medium: R227ea Heating oil: BP Transcal N 20 oC 1 bar 0.5 lt/min 17.5 oC 1 bar 43.7 lt/min (trigeneration) 3.7 lt/min (VCC) Condenser 1 (ORC-VCC) Condenser 2 (only VCC)

156.6 lt/min 43 lt/min 150 lt/min 2.63 lt/min 61.6 lt/min 681.2 lt/min 35.7 lt/min 135.6 lt/min

84.1 oC 15.8 bar 335.1 lt/ min 32.7 lt/min

43 lt/min

3a 2 1 3 5 6=7 8 13 9 11

B.C.V=ball check valve B.C.V B.V. B.V B.V.=on-off ball valve M.V.=magnetic valve M.V. B.V. B.V. M.V. B.V. L.P.S. =low pres switch H.P.S. =high pres switch H.P.S 40 bar H.P.S 25 bar H.P.S 15 bar L.P.S H.P.S 15 bar L.P.S

1" 1/8 2" 1/8 2" 1/8 7/8 3/4 3/4 1" 3/8 1" 1/8 1" 1/8 2" 1/8 2" 1/8 2" 1/8 3/4 1" 3/8 2" 1/8 4 1" 1/8

Normally closed Normally

• pen

Sub-cooler C.V. B.V. B.V.

Bio-TRIC

G G

B.V.

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Feed pump Filter Scroll expanders Condenser Feed tank Generators Supercritical HEX

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Supercritical HEX Electrical/control panel

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP Research interests-Experimental

Bio-TRIC trigeneration unit Scroll expander coupled with generator Electrical panel and control unit

Inverters PLC Scroll expander Generator

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP Research interests-Experimental

Bio-TRIC trigeneration unit Thermal oil biomass boiler

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Energy recovery in new and retrofiFed heat pumps using a dedicated expander concept

EXP-HEAT project

NaDonal Technical University of Athens (GR) – Coordinator Universita degli Studi di Firenze Kungliga Tekniska Hoegskolan Thermogas S.A. Officine Mario Dorin SPA Euremec AB Italgroup SRL

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

! !

Throhle Valve = Energy- exergy destrucDon!!!

EXP HEAT concept

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

!

Replacement of the throhle valve with an expander

!

EXP HEAT opera*on principle (1/2)

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Replacement of the throhle valve with an expander

! !

Preliminary design of a vapour- compression cycle using an expander Preliminary design of a retrofihed heat pump using an expander

EXP HEAT opera*on principle (2/2)

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Modeling of Piston Expander

Fictitious isothermal envelope 1 3 6 2 4 wloss

ΔPsu min mleak Wsh

su su1 su2

Qex Qsu Qamb

5 ex ex1 ex2

mo

S=ct V=ct V=ct S=ct

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

EXP HEAT Test Bench

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

SNG ProducDon, Power-to-Gas, Energy Storage, Process integraDon

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

INNOVATIVE POWER TO GAS ACTIVITIES

P2G-Cons

NTUA – MHPSE

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Advanced Subs>tute Natural Gas from Coal with Internal Sequestra>on of CO2

CO2freeSNG2.0

Friedrich-Alexander-Universität Erlangen-Nürnberg– Coordinator Air Liquide Główny Instytut Górnictwa Deutscher Verein des Gas NaDonal Technical University of Athens

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Flue Gas

Scavenging)

Air Steam Coal

Coal & Char Syngas Filtration

Syngas)HE) WGS)

Upgrade & Conditioning

Chemical AGR processes Gasification HPR Methanation

Absorber Stripper

HP LP

CO2

Heat)U2liza2on)

Steam)Cycle)

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Scope of the project

• 1. Inves*ga*on of the Benfield Process for acid gas removal
• Carbon dioxide solubility in potassium/sodium carbonate aqueous

soluDons with varying concentraDons

• AbsorpDon acceleraDon by using amine/aminoacid promoters
• Solubility of methane and effect of tars in the capturing process
• Chemical absorpDon efficiency under varying temperature and

pressure condiDons

• IntegraDon of the process in a pilot-scale gas cleaning unit

2. Sampling and analysis of hydrogen sulfide and organic sulfur compounds-detec*on at low concentra*ons

• Development of GC methods for low level analysis of sulfur

compounds in syngas

• Design and integraDon of sampling and analysis system amer a

gasifier, before the methanator

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

CO2 capture technologies

• Adsorption (PSA)
• Membrane separation
• Biological separation
• Cryogenic capture
• Physical absorption (SelexolTM,

RectisolTM)

• Chemical absorption (Amines,

Promoted-Potassium Carbonate) Aqueous K2CO3 absorption units

• lower heat requirements for solvent

regeneration compared to amines

• low corrosive rates and toxicity
• high temperature operation
• low solvent cost
• less prone to degradation

phenomena compared to amines, low volatility Benfield Lo Heat unit Benfield commercial units ü 700+ units worldwide ü 65+ for natural gas treatment ü 200+ for ammonia syngas ü 110 for hydrogen plants ü Other applications: SNG production, partial oxidation, direct iron ore reduction plants, coal gasidfication, petrochemical applications

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP CO2freeSNG2.0 project Project outline Ø Modelling of a coal gasification process (Heatpipe reformer) with internal CO2 sequestration before methanation for SNG production Ø Experimental investigation of contaminant removal with potassium carbonate solutions (CO2, H2S, tars) Ø Experimental tests for sulphur deactivation of methanation catalysts Ø Sampling and analysis of contaminants in the syngas stream Ø Integration of a novel methanation reactor in the process chain Ø Economic feasibility study and unit erection

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP NTUA research (1) Solvent screening experimental setup

• Combined removal of CO2, CH4 and tars with

20-40 wt. % K2CO3 aqueous solutions

• Promoters (amines, amino acids, inorganic

promoters) for improved reaction kinetics (0-10

• wt. %)
• Batch system operation, upgraded for

continuous operation

• Pressure and temperature conditions (P:1-5

bar(a), T=80-120 oC)

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP NTUA research (2) ü CO2 solubility in 25 wt. % and 35 wt. % aqueous K2CO3 solutions and evaluation of PZ, MEA, Glycine or MDEA addition reference results ü CO2 absorption rate in 25

• wt. % and 35 wt. % aqueous

K2CO3 and promotion effect

• f PZ, MEA, Glycine and

MDEA

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP NTUA research (3)

• 1. Experimental: Low-level, inorganic and
• rganic sulphur measurement
• Sampling of H2S, COS, CS2, C2H6S, C4H4S
• Trace analysis by GC-FPD
• Separation of interfering compounds

(hydrocarbons, CO/CO2 quenching effects)

• 2. Modelling activities for syngas cleaning

applications

• Modelling of different configurations and

process parameters for CO2 capture with Benfield units (Aspen PlusTM)

• Modelling of CO2 and H2S absorption

columns operating with promoted K2CO3 solutions

• Modelling of sulphur adsorption on activated

carbons at higher temperatures More…

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

CO2 reducDon in the ETS glass industry by means of waste heat uDlizaDon"

CO2 GLASS

Sustainable Industry Low Carbon scheme (SILC I ) Short-term innovation measures NaDonal Technical University of Athens Drujba Glassworks SA Centre for Research and Technology Hellas

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

CO2 reduc*on in the ETS glass industry by means

• f waste heat u*liza*on

Co-funded by the Sustainable Industry Low Carbon Scheme –Short term innovaDon measures – SILC I Programme under the CompeDDveness & InnovaDon Framework Programme (CIP) of the European Commission, DG Enterprize & Industry

ConsorDum: NTUA, Drujba Glassworks SA, CERTH

OBJECTIVES:

• WHR at the ETS-BG-60 plant DRUJBA STAKLARSKI ZAVODI in Sofia-Bulgaria (~ 40 ktCO2 annual

emissions) tesDng on site & verificaDon.

• Decrease the specific CO2 emission factor by at least 8% and increase energy efficiency by 15%
• Disseminate results to over 400 ETS glass operators.
• Examine replicaDon potenDal for addiDonal ETS plants of the YIOULA Group of Companies (in

Bulgaria, in Romania and in Greece).

33 34 35 36 37 38 39 40 41 42 43 44 2008 2009 2010 2011 2012

kt CO2 Allowances Verified Emissions

ETS-BG-60 AllocaDon & Verified Emissions [2008-2012] Glass Sector AllocaDon & Verified Emissions [2008-2012]

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Budget (€) Eligible Costs EC Contribu*on NTUA 146.294,62 109.720,97 DRUJBA GLASSWORKS S.A 662.518,72 496.889,04 CERTH/CPERI 115.724,94 86.793,70

At the first stage of the project, a mapping of WHR potenDal in the glass industry & opDons for its uDlizaDon was carried out. Furthermore, under the invesDgaDon of WHR system energy recovery potenDals, a batch pre-heaDng process simulaDon tool was developed and energy- mass balance analysis was carried. Several concepts, which can be applied in the glass industry, dealing with fuel reducDon, electricity boosDng reducDon and increased pull were examined. It was resulted that energy consumpDon under full load operaDon could be reduced between 12.3% and 16.2% and CO2 emissions between 3.4% and 10.7%

CO2 reduc*on in the ETS glass industry by means

• f waste heat u*liza*on

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Temperature profiles along the effecDve height of the preheater

6 12 18 100 200 300 400

Preheater height (m) Temperature (oC)

case 4.1.1 case 4.1.2 case 4.1.3

50 100 150 1 2 3 4

Temperature (oC) Preheater length (m)

case 4.1.1 case 4.1.2 case 4.1.3

100 200 300 400 1 2 3 4

Temperature (oC) Preheater length (m)

case 4.1.1 case 4.1.2 case 4.1.3

Temperature profile across the preheater’s effective height at half width and half length (AA') Temperature profile downstream the drying zone at half width (BB') Temperature profile downstream the preheater’s effective height at half width (CC')

Drying zone

case 1 case 2 case 3 case 1 case 2 case 3 case 1 case 2 case 3

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Other acDviDes for decentralized applicaDons

Small energy storage systems Biomass Waste recovered fuels (SRF, RDF) Life Cycle Analysis- Life Cycle Costs

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP 1: Pressurised Air Vessel, 2: Air pre-heater, 3:Additional gas flow, 4: Flow meter/controller, 5:Gas valve, 6:Distributor flange, 7:Distributor, 8:Electric heater, 9:Fluidized bed,10:Fuel silo, 11/12:Inverter / electric motor, 13: Freeboard, 14/15:Primary / secondary cyclone, 16:Ash collection bin, 17:PC /data collection system, 18:Signal lines, 19:PID controllers, 20:Flue Gas purification, 21:Flue gas safe discharge, 22:Hot-wet analytical instruments, 23:Gas analyser Multor, 24:Additional Sampling line (through washing bottles)

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Fluidized bed gasifier

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

SOFC BioCELLUS

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP Sampling, Analysis and Classifica*on of secondary biogenic fuels according to the emerging standards of CEN/TC 343 “Solid Recovered Fuels” (SRF) and CEN/TC 335 “Solid biofuels” Sampling procedure designed and implemented according to EN standards Sample preparaDon and analysis according to European standards SRF

Standard

Moisture ΕΝ 15414: Ash ΕΝ 15403 VolaDles ΕΝ 15402 Calorific Value ΕΝ 15400 Chlorine ΕΝ 15408 Carbon , Hydrogen, Nitrogen ΕΝ 15407 Sulfur ΕΝ 15408 Major and minor elements ΕΝ 15411 Biogenic contents ΕΝ 15440

Biomass

Standard

Moisture ΕΝ 14774 Ash ΕΝ 14775 VolaDles ΕΝ 15148 Calorific Value ΕΝ 14918 Chlorine ΕΝ 15289 Carbon , Hydrogen, Nitrogen ΕΝ 15104 Sulfur ΕΝ 15289 Major and minor elements ΕΝ 15297

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP Results post-processing ClassificaDon in case of Refuse Derived Fuels Techno-economic analysis and business plan development on faciliDes producing/uDlizing secondary fuels

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

LCA and LCC modelling

SECTOR

Power Refinery Cement/ Steel Chemical

STRATEGY

Environmental sustainability Automotive/ Marine District Heating Waste treatment Economic sustainability

CONCEPTS

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP Ø Sustainability analysis in environmental and economic terms Ø Holistic approach for all stages of manufacture, product use and end-of life Ø Strategic policy making in industry Ø Estimation of the overall environmental footprint Ø Identification of climate change impact and depletion of natural resources Ø Determination of the crucial parameters in environmental and economic terms Ø Categorization and importing of environmental indicators in a database Ø Estimation of the cost externalities based on the life cycle costing principles

Methodology - Contribution

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

• Software: SimaPro
• Main Database: Ecoinvent 3.0
• ISO 14044:2006 standards

The philosophy Indicative tools and databases Environmental impact

Impact categories: 14 midpoint categories and 4 damage categories: a) Human health, b) Ecosystem quality, c) Climate Change and d) Resources

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Other industrial acDviDes applicaDons

Third party services in Power Plants Efficiency measurements Power output measurements Noise measurements Exhaust gas measurements Other (e.g. wind speed) Cycle calculations

Laboratory of Steam Boilers and Thermal Plants

• Prof. Dr. –Ing. Emmanuel Kakaras
• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

L U V O

ECO RH2 SH3 SH2 EVAP

AGIOS DIMITRIOS V

SH1 RH1

IP

• C

HP

LP

Raw Brown Coal

Simulation of a 330 MW lignite-fired power plant

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

Other industrial acDviDes applicaDons

Third party services in CHP Plants Heat output measurements Efficiency measurements Power output measurements Fuel flow Other Cycle calculations

Laboratory of Steam Boilers and Thermal Plants NaDonal Technical University of Athens

• Assist. Prof. Sotirios Karellas

LSBTP

• Assoc. Prof. Dr.-Ing. Sotirios Karellas

LSBTP

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