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WO2008013843A2 - Combustion enrichie en oxygène dans des processus industriels - Google Patents

Combustion enrichie en oxygène dans des processus industriels Download PDF

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Publication number
WO2008013843A2
WO2008013843A2 PCT/US2007/016709 US2007016709W WO2008013843A2 WO 2008013843 A2 WO2008013843 A2 WO 2008013843A2 US 2007016709 W US2007016709 W US 2007016709W WO 2008013843 A2 WO2008013843 A2 WO 2008013843A2
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WO
WIPO (PCT)
Prior art keywords
oxygen
industrial process
heat
rankine cycle
combustion
Prior art date
Application number
PCT/US2007/016709
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English (en)
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WO2008013843A3 (fr
Inventor
Dante Patrick Bonaquist
Minish Mahendra Shah
Vijayaraghavan Srinivasan Chakravarthy
Monica Zanfir
Raymond Francis Drnevich
Stefan Laux
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Praxair Technology, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by Praxair Technology, Inc. filed Critical Praxair Technology, Inc.
Priority to US12/374,646 priority Critical patent/US20090308073A1/en
Publication of WO2008013843A2 publication Critical patent/WO2008013843A2/fr
Publication of WO2008013843A3 publication Critical patent/WO2008013843A3/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L7/00—Supplying non-combustible liquids or gases, other than air, to the fire, e.g. oxygen, steam
    • F23L7/007—Supplying oxygen or oxygen-enriched air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K13/00—General layout or general methods of operation of complete plants
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K25/00—Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for
    • F01K25/08—Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for using special vapours
    • F01K25/10—Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for using special vapours the vapours being cold, e.g. ammonia, carbon dioxide, ether
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22—STEAM GENERATION
    • F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B1/00—Methods of steam generation characterised by form of heating method
    • F22B1/02—Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers
    • F22B1/16—Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being hot liquid or hot vapour, e.g. waste liquid, waste vapour
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C9/00—Combustion apparatus characterised by arrangements for returning combustion products or flue gases to the combustion chamber
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F25J3/04527—Integration with an oxygen consuming unit, e.g. glass facility, waste incineration or oxygen based processes in general
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F25J3/04527—Integration with an oxygen consuming unit, e.g. glass facility, waste incineration or oxygen based processes in general
    • F25J3/04533—Integration with an oxygen consuming unit, e.g. glass facility, waste incineration or oxygen based processes in general for the direct combustion of fuels in a power plant, so-called "oxyfuel combustion"
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F25J3/04527—Integration with an oxygen consuming unit, e.g. glass facility, waste incineration or oxygen based processes in general
    • F25J3/04551—Integration with an oxygen consuming unit, e.g. glass facility, waste incineration or oxygen based processes in general for the metal production
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F25J3/04527—Integration with an oxygen consuming unit, e.g. glass facility, waste incineration or oxygen based processes in general
    • F25J3/04551—Integration with an oxygen consuming unit, e.g. glass facility, waste incineration or oxygen based processes in general for the metal production
    • F25J3/04557—Integration with an oxygen consuming unit, e.g. glass facility, waste incineration or oxygen based processes in general for the metal production for pig iron or steel making, e.g. blast furnace, Corex
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F25J3/04593—The air gas consuming unit is also fed by an air stream
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L2900/00—Special arrangements for supplying or treating air or oxidant for combustion; Injecting inert gas, water or steam into the combustion chamber
    • F23L2900/07005—Injecting pure oxygen or oxygen enriched air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2230/00—Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/22—Compressor driver arrangement, e.g. power supply by motor, gas or steam turbine
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2240/00—Processes or apparatus involving steps for expanding of process streams
    • F25J2240/70—Steam turbine, e.g. used in a Rankine cycle
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/34—Indirect CO2mitigation, i.e. by acting on non CO2directly related matters of the process, e.g. pre-heating or heat recovery

Definitions

  • the present invention generally relates to the field of cogeneration of power and heat, and particularly to recover heat lost to ambient air using oxygen enhanced combustion.
  • Oxygen enhanced combustion is utilized in industrialized furnace applications to increase throughput and has additional advantages such as lower emissions, improved flame stability and heat transfer. Although increased thermal efficiency is claimed for processes that use oxy- fueled combustion, making use of the unavoidably generated waste heat remains a challenge. Unlike air- fired processes, where the excess thermal energies from the flue gases are used to preheat the air for combustion, in oxygen enhanced combustion, the hazards of handling hot oxygen-enriched streams limit this type of heat integration. Therefore, in some processes, conversion to oxygen enriched combustion (e.g., cement manufacturing processes) may lead to a higher waste heat rejection resulting in a decrease of thermal efficiency.
  • conversion to oxygen enriched combustion e.g., cement manufacturing processes
  • Cogeneration of power and heat by production of electricity and/or steam stands as an alternative.
  • energy recovery and power generation through steam becomes inefficient.
  • Limitations related to low- grade heat recovery to generate power can be overcome by making use of alternative Rankine cycles, where the working fluid is not steeim, but rather an organic substance or a mixture . Power generated from such low grade heat sources can be utilized to meet oxygen supply system needs, strengthening the incentive for conversion to oxygen enhanced combustion.
  • U.S. Patent No. 6,701,712 B2 discloses a method and an apparatus based on an ORC to recover the heat from the hot air used to cool the clinker in cement manufacturing in order to produce power.
  • the waste heat recovery unit contains specific equipment to extract particulate matter from the hot air, a combination of heat exchangers where waste heat is transferred from the source to the ORC working fluid by means of an intermediate fluid, such as thermal oil or air. Examples of applications disclosed in U.S. Patent No. 6,701,712 Bl are reported by Baatz et al . (Baatz E., Heidt G., ZKG Intl . , Vol. 8, pp.
  • 8.2 MW can be recovered by cooling the hot air from 275 0 C to 125 0 C, generating about 1.15 MW power.
  • the amount of power generated reduces the power demand of cement manufacture by 10%.
  • Typical temperatures of air available after clinker cooling are usually less than
  • U.S. Patent No. 7,062,912 identifies the need for increased efficiency of oxygen-enriched combustion in industrial furnaces through integrated heat recovery strategies; main emphasis is on power generation using steam Rankine cycles from flue gases produced in oxy- enhanced combustion. Further, mechanical power is generated, which is integrated with an air separation unit that supplies the oxygen for oxy-enhanced combustion, in order to partially cover the demand for power of air separation.
  • U.S. Patent No. 7,062,912 uses steam as working fluid for the Rankine cycle and therefore for power generation and it does not teach a method or system of heat recovery at lower temperatures where steam is not an appropriate working fluid. Furthermore, it does not teach a method or system for generating electrical power.
  • U.S. Patent No. 6,077,072 discloses a firing scheme that uses at least one injector for oxidant and fuel in a cement rotary kiln, which allows an increase in the amount of heat released toward the load, resulting in significant increases in kiln efficiency and production.
  • U.S. Patent No. 6,077,072 uses oxy-enhanced combustion only for throughput increase.
  • cement manufacturing can be classified in wet-processes and dry-processes.
  • dry-process the raw materials are fed to the kiln in a dry state, whilst in a wet-process a slurry is formed by adding water (see LEA's Chemistry of Cement and Concrete, ed. Hewlett PC, New York, 1998) . Nearly 33% additional kiln energy is consumed in evaporating the slurry water.
  • the drying process makes a better use of the available heat by preheating the raw materials and using flue gases, still the thermal efficiency of a cement plant is low.
  • the present invention relates to a system for carrying out oxygen-enhanced combustion in an industrial process wherein the industrial process, an oxygen supply system or a source of oxygen, a heat recovery network, and an alternative Rankine cycle system based on a working fluid other than steam are integrated to achieve improved throughput and efficiency, and a method for oxygen- enhanced combustion in an industrial process using said system.
  • industrial processes include cement production, steel reheat applications, glass production, aluminum and copper melting, as well as any industrial process that uses process heater, furnaces where combustion is carried out using an oxidant stream with oxygen content higher than that in ambient air and up to 100%.
  • the oxygen supply system can be any type of air separation unit (e.g., cryogenic, pressure swing adsorption (PSA) , vacuum pressure swing adsorption (VPSA), membrane, etc.), or other type of oxygen supply (e.g., liquid delivery, pipeline supply) .
  • the heat recovery network comprises heat exchangers that enable heat transfer between the heat source and the working fluid of the alternative Rankine cycle, and may employ an intermediate heat transfer fluid such as thermal oil or air.
  • the invention seeks to integrate in an efficient manner the utilization of the power generated with the oxygen supply system, or any demand of electrical power within the industrial process considered.
  • the power output of the alternative Rankine cycle could be in the form of electricity, and .the alternative turbine of the alternative Rankine cycle can be directly coupled to one of the power consuming devices through a shaft or through a motor/generator assembly for reducing equipment cost associated with generating electricity and distributing it to different devices. Having a motor/generator assembly will provide flexibility in operation.
  • Oxygen enhanced combustion is utilized in many industrial applications to increase throughput, which decreases the need for building new plants and thus minimizing capital investment.
  • the power generated from heat sources produced as a consequence of oxy-fuel combustion reduces the net demand of electricity of the oxygen supply system. Therefore, the present invention helps to lower the cost of power and/or lower the cost of oxygen for oxy-fuel conversion.
  • the oxygen demand for a typical cement plant for a 25% throughput increase is 650-1450 tpd, whilst the power generated can range between 4-7 MW.
  • Figure 1 is a schematic of an industrial process employing oxygen enhanced combustion integrated with an oxygen supply system, heat recovery network, and alternative Rankine cycle system.
  • Figure 2 is a schematic of an industrial process employing oxygen enhanced combustion integrated with an oxygen supply system, heat recovery network, and alternative Rankine cycle system having at least two heat sources 106, 201 generated from the industrial process 10.
  • Figure 3 is a schematic of an industrial process employing oxygen enhanced combustion integrated with an oxygen supply system, heat recovery network, and alternative Rankine cycle system wherein the flue gas is recirculated 203 for additional heat recovery.
  • Figure 4 is a schematic of an industrial process employing oxygen enhanced combustion integrated with an oxygen supply system, heat recovery network, alternative Rankine cycle system, and an additional firing heater 13 used to enhance the temperature level of the recoverable heat .
  • Figure 5 is a schematic showing an industrial process wherein the industrial process 10 is a cement manufacturing process .
  • Figure 6 is a schematic of an industrial process employing oxygen enhanced combustion integrated with an oxygen supply system, heat recovery network, and alternative Rankine cycle system wherein at least one heat source stream 201 is represented by flue gases generated by oxygen enhanced combustion.
  • Figure 7 is a schematic showing an industrial process employing oxygen enhanced combustion integrated with an oxygen supply system, whesrein there is no heat recovery and partial recirculation of flue gases.
  • Figure 8 is a schematic showing an industrial process employing oxygen enhanced combustion integrated with an oxygen supply system, heat recovery network, and alternative Rankine cycle system, wherein the industrial process is a steel reheat process.
  • the present invention relates to a system for carrying out oxygen-enhanced combustion in an industrial process wherein the industrial process, an oxygen supply system or a source of oxygen, a heat recovery network, and an alternative Rankine cycle system based on a working fluid other than steam are integrated to achieve improved throughput and efficiency, and a method for oxygen- enhanced combustion in an industrial process using said system, wherein a) the oxygen supply system supplies oxygen to the industrial process, b) the industrial process generates waste heat as at least one heat source which is sent to the heat recovery unit, c) the waste heat is then sent from the heat recovery unit to the alternative Rankine cycle system, d) the alternative Rankine cycle system converts the waste heat to power, which is utilized by the oxygen supply system or the industrial process or is exported to a utility system.
  • the oxygen supply system can be any type of air separation unit (e.g., cryogenic, pressure swing adsorption (PSA) , vacuum pressure swing adsorption (VPSA), membrane, etc.), or other type of oxygen supply (e.g., liquid delivery, pipe line supply) .
  • the heat recovery network comprises heat exchangers that enable heat transfer between the heat source and the working fluid of the alternative Rankine cycle, and may employ an intermediate heat transfer fluid such as thermal oil or air.
  • the invention seeks to integrate in an efficient manner the utilization of the power generated with the oxygen supply system, or any demand of electrical power within the industrial process considered.
  • the power output of the alternative Rankine cycle could be in the form of electricity
  • alternative turbine of the alternative Rankine cycle can be directly coupled to one of the power consuming device through a shaft or through a motor/generator assembly for reducing equipment cost associated with generating electricity and distributing it to different devices. Having a motor/generator assembly will provide flexibility in operation.
  • the working fluid of the alternative Rankine cycle system can be refrigerants (e.g., RIl, R123, HCF 245fa) , hydrocarbons (e.g., ethanol, iso-butane, n-pentane, iso-pentane) , aromatics (e.g., toluene, p-xylene) , aromatic perfluorocarbons (e.g., hexafluorobenzene) , or siloxane and siloxane mixtures .
  • refrigerants e.g., RIl, R123, HCF 245fa
  • hydrocarbons e.g., ethanol, iso-butane, n-pentane, iso-pentane
  • aromatics e.g., toluene, p-xylene
  • aromatic perfluorocarbons e.g., hexafluorobenzene
  • FIG. 1 is a simplified schematic of an industrial process employing oxygen enhanced combustion integrated with an oxygen supply source, heat recovery network, and alternative Rankine cycle system.
  • Any industrial process 10, where oxygen enhanced combustion is used to supply the required thermal energy can be a suitable application.
  • the industrial process 10 uses at least one fuel stream 101, combustion air 102 if required, and adequate raw materials 103.
  • the oxygen used for oxygen enhanced combustion is delivered by an oxygen supply system 11, which can be any air separation process (e.g., cryogenic, PSA, VPSA, membrane, etc.) or liquid oxygen or oxygen pipe delivery system.
  • An oxidant stream 104 with an oxygen concentration higher than that in ambient air and up to 100%, supplies the necessary amount of oxygen for oxygen enhanced combustion.
  • at least one heat source is generated 106.
  • the heat source 106 can be liquid or gas stream, produced either as flue gases as a direct result of oxygen enhanced combustion, or as any stream utilized within process 10 for cooling in order to meet the process needs.
  • the heat source temperature is lower than 600 0 C most preferably between 400-100 0 C.
  • Heat recovery unit 12 comprising at least one heat exchanger or a network of heat exchangers, extracts the recoverable heat from the source 106, which is further used in the alternative Rankine cycle 30 in order to generate a certain amount of power 107.
  • the power generated 107 can be either exported to the utility system, 108, or utilized to meet electrical energy demand of the oxygen supply system, 110, or process demand, 109, or a combination of the above, for example the turbine of the alternative Rankine cycle can be directly coupled to one of the power consuming device through a shaft or through a motor/generator assembly for reducing equipment cost associated with generating electricity and distributing it to different devices. Having a motor/generator assembly will provide flexibility in operation.
  • FIG 2 is another simplified schematic showing at least two heat sources 106, 201 generated from the industrial process 10. Each heat source is sent to a separate heat recovery unit 12 and 13 respectively.
  • An intermediate fluid 112 e.g., thermal oil, air, or pressurized water
  • the intermediate fluid circuit 112 can operate in various modes to recover the available heat in a series, parallel or alternative manner .
  • Figure 3 is yet another simplified schematic, wherein at least one heat source stream, 201 is represented by flue gases generated by oxygen enhanced combustion. These are sent to the heat recovery unit 12. After exiting the heat recovery unit, they are partially re-circulated, as stream 203, within process 10, for dilution of the oxidant stream in order to meet combustion temperature conditions. The remaining part of flue gases is vented as waste stream 202.
  • Figure 4 is another simplified schematic showing an additional firing heater 13, which uses additional fuel 201 and combustion air 202 to increase the temperature level of the recoverable heat sent to the alternative Rankine cycle 30.
  • the recoverable heat from the flue gas 203 generated in the firing heater 13 is further used in the heat recovery unit 12.
  • FIG. 5 is a simplified schematic wherein the industrial process 10 is a cement manufacturing process. Partial oxygen enhanced combustion is used in precalciner 20 and cement kiln 21. Fuel 101 is added to the precalciner as 101a and cement kiln as 101b. The raw materials are preheated in countercurrent by the flue gases. The calcined dust 403 is further fed to the rotary kiln 21.
  • the hot clinker 404 exiting the kiln 21 is further cooled in the clinker cooler 22, using an air stream 102.
  • Some of the air heated in the first part of the clinker cooler 22a is utilized as combustion air for kiln, 402, and precalciner, 401, in addition to the oxygen enriched streams 104a and 104b to achieve oxygen dilution requirements. Therefore, oxygen concentration in kiln and precalciner can range between 20-60%.
  • the exhaust heat sources are on one hand the flue gases after they are used for raw materials preheating, 201, and the remaining hot air 106 obtained from the clinker cooler 22b.
  • the power generated 107 can be either exported to the utility system, 108, or utilized to meet the electrical energy demand of the oxygen supply system, 110 or cement manufacturing demand 109, or a combination of the above.
  • FIG. 6 is yet another simplified schematic, wherein at least one heat source stream 201 is represented by flue gases generated by oxygen enhanced combustion. These are sent to the heat recovery unit 12. Flue gases 202 after exiting the heat recovery unit 12 are partially recirculated in kiln 21 as stream 502 and in precalciner 20 as 501 to adjust oxygen dilution requirements. The remaining part of flue gases is vented as waste stream 203.
  • Figure 7 is a schematic showing an industrial process employing oxygen enhanced combustion integrated with an oxygen supply system, wherein there is no heat recovery and flue gases 202 are partially recirculated in kiln 21 as stream 502 and in precalciner 20 as 501.
  • Cement production is an energy intensive process.
  • cement manufacturing can be classified in wet-processes and dry-processes.
  • dry-process the raw materials are fed to the kiln in a dry state, whilst in a wet-process a slurry is formed by adding water (see LEA's Chemistry of Cement and Concrete, ed. Hewlett PC, New York, 1998) . Nearly 33% additional kiln energy is consumed in evaporating the slurry water.
  • the dry process makes a better use of the available heat by preheating the raw materials, using flue gases, still the thermal efficiency of cement plant is low. The average thermal efficiency reported for cement kilns used in the U.S.
  • Benchmark An optimized air fueled cement plant has the following throughput and fuel consumption: Plant Capacity: 4000 tpd
  • An increase by 25% in cement plant throughput can be achieved by increasing the fuel input and at the same time using about 47.5% of the oxygen required for combustion as pure oxygen, stream 104 as shown in Figure 4.
  • the heat streams 106, 201 generated in this case are given in Table 3.
  • Table 4 shows the amount of recoverable heat from each stream, the power generated considering an overall efficiency of 18%, and recalculates the exhausted heat related to fuel consumption.
  • the heat streams 106 and 201 # 202 and 203, generated in this case are given in Table 5.
  • Table 6 summarizes the flow rate, temperature and composition of streams 106, 201, 202, and 203 when 100% oxygen enhanced combustion is used at the same time with power generated as shown in Figure 5. It also summarizes the amount of recoverable heat from each stream, and the power generated considering an overall efficiency of 18%.
  • Table 7 gives a comparison of air-fueled and oxygen enhanced combustion cement processes with and without power generation from heat sources available in the process.
  • Column (1) gives the plant capacity.
  • An increase in throughput can be obtained by either using a partial conversion to oxygen enhanced combustion, for example 47.5% of the oxygen needed for combustion is provided as pure oxygen (see Figure 4) , or by total conversion to oxy-combustion, when 100% of the required oxygen is delivered by the oxygen supply system and part of the flue gases are recirculated (see Figure 5) .
  • the increase in throughput comes with a penalty in fuel consumption. About 10% increase of fuel consumed is required for 25% throughput increase.
  • Another potential application of the present invention is related to steel reheat furnaces.
  • the primary concerns in the steel industry are productivity, energy efficiency, and reduced emissions. These demands can and indeed have been satisfied by the use of oxy-fuel combustion in a wide range of both batch and continuous type furnaces.
  • Continuous furnaces such as pusher, walking beam or roller hearth are designed so that the exhaust gases flow counter-current to the in-coming product so that the energy contained can be used in the pre-heat zone at the entrance to the furnace, thus improving the thermal efficiency.
  • the use of oxy-fuel in such furnaces however offers a step change increase in fuel efficiency and productivity not attainable by air- fuel combustion techniques.
  • the exhaust temperature of the flue gases around 450 0 C, makes the application of the present invention suitable for this type of furnace .
  • Figure 8 is a schematic for a steel reheat process using the present invention, integrating an oxygen supply system, a heat recovery unit and an alternative Rankine cycle.
  • Table 8 summarizes the characteristics of the heat source and the power generated for a steel reheat furnace with a capacity given below.

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  • Physics & Mathematics (AREA)
  • Combustion & Propulsion (AREA)
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  • Manufacturing & Machinery (AREA)
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  • Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)
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Abstract

La présente invention concerne un système destiné à réaliser une combustion enrichie en oxygène au cours d'un processus industriel, le processus industriel, un système d'alimentation en oxygène ou une source d'oxygène, un réseau de récupération de chaleur, et un système à cycle de Rankine alternatif basé sur un fluide de travail autre que la vapeur étant intégrés pour permettre d'obtenir un meilleur débit et une plus grande efficacité. L'invention concerne également un procédé de combustion enrichie en oxygène dans un processus industriel utilisant ledit système. Des exemples de processus industriels comprennent la production de ciment, des applications de réchauffage de l'acier, la production de verre, la fusion d'aluminium et de cuivre, ainsi que tout processus industriel utilisant un appareil de production de chaleur industrielle, des fours dans lesquels la combustion est réalisée au moyen d'un flux oxydant présentant une teneur en oxygène supérieure à celle de l'air ambiant et allant jusqu'à 100 %.
PCT/US2007/016709 2006-07-26 2007-07-25 Combustion enrichie en oxygène dans des processus industriels WO2008013843A2 (fr)

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EP2378089A1 (fr) * 2010-04-13 2011-10-19 ABB Schweiz AG Système de conversion pour convertir une chaleur de déchets en puissance d'arbre
WO2010151163A3 (fr) * 2009-06-18 2013-10-10 S.C. Hellenic Tiler Invest Srl Installation et procédé permettant d'obtenir de l'énergie thermique et électrique
ES2468090R1 (es) * 2012-11-06 2014-11-17 Italcementi S.P.A. Procedimiento integrado para la generación de energía eléctrica y aparato correspondiente
ES2468091R1 (es) * 2012-11-06 2014-11-20 Italcementi S.P.A. Procedimiento integrado para la generación de energía eléctrica y aparato correspondiente
EP3037390A1 (fr) * 2014-12-22 2016-06-29 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Procédé optimisé et installation pour la fusion de matière vitrifiable dans un four chauffé par une flamme
EP3037391A1 (fr) * 2014-12-22 2016-06-29 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Processus et installation à haut rendement énergétique pour la fusion de matière vitrifiable dans un four chauffée par une flamme
WO2016102629A1 (fr) * 2014-12-22 2016-06-30 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Procédé à haut rendement énergétique et installation pour la fusion de matière vitrifiable dans un four à flammes
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WO2010151163A3 (fr) * 2009-06-18 2013-10-10 S.C. Hellenic Tiler Invest Srl Installation et procédé permettant d'obtenir de l'énergie thermique et électrique
EP2529096A4 (fr) * 2010-01-26 2017-12-06 TMEIC Corporation Système et procédé de récupération d'énergie
EP2378089A1 (fr) * 2010-04-13 2011-10-19 ABB Schweiz AG Système de conversion pour convertir une chaleur de déchets en puissance d'arbre
ES2468090R1 (es) * 2012-11-06 2014-11-17 Italcementi S.P.A. Procedimiento integrado para la generación de energía eléctrica y aparato correspondiente
ES2468091R1 (es) * 2012-11-06 2014-11-20 Italcementi S.P.A. Procedimiento integrado para la generación de energía eléctrica y aparato correspondiente
EP3037390A1 (fr) * 2014-12-22 2016-06-29 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Procédé optimisé et installation pour la fusion de matière vitrifiable dans un four chauffé par une flamme
EP3037391A1 (fr) * 2014-12-22 2016-06-29 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Processus et installation à haut rendement énergétique pour la fusion de matière vitrifiable dans un four chauffée par une flamme
WO2016102621A1 (fr) * 2014-12-22 2016-06-30 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Procédé et installation optimisés pour la fusion de matériau vitrifiable dans un four chauffé par flamme
WO2016102629A1 (fr) * 2014-12-22 2016-06-30 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Procédé à haut rendement énergétique et installation pour la fusion de matière vitrifiable dans un four à flammes
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