US20200392884A1 - Method of producing heat in a power station - Google Patents

Method of producing heat in a power station Download PDF

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US20200392884A1
US20200392884A1 US16/970,972 US201916970972A US2020392884A1 US 20200392884 A1 US20200392884 A1 US 20200392884A1 US 201916970972 A US201916970972 A US 201916970972A US 2020392884 A1 US2020392884 A1 US 2020392884A1
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combustion
fuel
catalyser
gas
reducing
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Reijo Lylykangas
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VOCCI Oy
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/86—Catalytic processes
    • B01D53/8643—Removing mixtures of carbon monoxide or hydrocarbons and nitrogen oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2066—Selective catalytic reduction [SCR]
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N1/00—Silencing apparatus characterised by method of silencing
    • F01N1/14—Silencing apparatus characterised by method of silencing by adding air to exhaust gases
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
    • F01N3/025—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using fuel burner or by adding fuel to exhaust
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
    • F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0814—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/101—Three-way catalysts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2006—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating
    • F01N3/2033—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating using a fuel burner or introducing fuel into exhaust duct
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/30—Arrangements for supply of additional air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/36—Arrangements for supply of additional fuel
    • 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 
    • F23C13/00—Apparatus in which combustion takes place in the presence of catalytic material
    • F23C13/06—Apparatus in which combustion takes place in the presence of catalytic material in which non-catalytic combustion takes place in addition to catalytic combustion, e.g. downstream of a catalytic element
    • 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 
    • F23C6/00—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion
    • F23C6/04—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion in series connection
    • F23C6/042—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion in series connection with fuel supply in stages
    • 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 
    • F23C6/00—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion
    • F23C6/04—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion in series connection
    • F23C6/045—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion in series connection with staged combustion in a single enclosure
    • F23C6/047—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion in series connection with staged combustion in a single enclosure with fuel supply in stages
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J15/00—Arrangements of devices for treating smoke or fumes
    • F23J15/02—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/01—Engine exhaust gases
    • B01D2258/012—Diesel engines and lean burn gasoline engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
    • F01N2240/14—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a fuel burner
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
    • F01N2240/20—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a flow director or deflector
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
    • F01N2570/14—Nitrogen oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/02—Adding substances to exhaust gases the substance being ammonia or urea
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0828—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents characterised by the absorbed or adsorbed substances
    • F01N3/0842—Nitrogen oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2219/00—Treatment devices
    • F23J2219/10—Catalytic reduction devices
    • 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
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
    • Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
    • 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
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the invention relates generally to the reduction of emissions of combustion gases in energy plants.
  • the invention also relates to the production of heat in boilers, gas turbines, and diesel power plants and similar power stations.
  • the present invention relates to a method, according to the preamble to claim 1 , for the catalytic cleaning of combustion gases containing nitrogen oxides and carbon monoxide, hydrocarbons and soot particles of energy plants using fuels with a hydrocarbon content.
  • the invention also relates to a method, according to the preamble to claim 19 , for producing thermal energy from a fuel with a hydrocarbon content.
  • the fuel is burned at an increased temperature, the heat obtained from the combustion is recovered, and the exhaust gases and soot particles from the combustion are cleaned using catalytic exhaust-gas combustion.
  • SCR Selective Catalytic Reduction
  • SNCR Selective Non-Catalytic Reduction
  • SCR apparatuses requires a separate reducing agent, urea or ammonia, and its dosing equipment, which leads to significant investment and operating costs.
  • Urea disintegrates in a catalyser to form ammonia (NH 3 ) and carbon monoxide (CO).
  • Ammonia and urea are transported and stored in water solutions. The ammonia content is 27% and urea 32%.
  • Ammonia is a highly toxic gas.
  • an SCR plant an NOx emission level of about 7-30 ppm is achieved.
  • the CO emission limits demand a separate oxidation catalyser.
  • the use of ammonia as a reducing agent is based on its ability to selectively reduce NOxs in a lean gas mixture.
  • the high costs of SCR technology are caused by the ammonia (NH 3 ) needed for selective reduction or urea in addition as a reducing agent and the expensive storage, dosage, heat transfer, and reduction apparatuses.
  • the EPA has estimated the replacement interval for an SCR catalyser to be 3 years.
  • SRC catalysers the most usual active substance, i.e. the catalyst, is vanadium pentoxide (V 2 O 5 ), which is easily the most toxic of the noble metals.
  • An SCR catalyser is large in size, because its space velocity is low, i.e. 10 000-20 000 l/h.
  • the space velocity of noble-metal catalysers is 5 . . . 10-times greater, i.e. the size of a noble-metal catalyser is about one-fifth to one-tenth of that of an SCR catalyser.
  • catalyst poisons which the combustion gas must not contain.
  • the most important of these are organic silicon, heavy-metal, and phosphoric compounds. They deactivate catalysers permanently. Sulphuric compounds do not damage a catalyser activated with platinum, but sulphuric acid arising as the result of reactions can cause corrosion, if it concentrates on the surfaces of a heat exchanger at temperatures of more than 100° C.
  • the present invention is intended to eliminate at least some of the problems relating to the prior art and create a completely new type of solution for producing thermal energy from fuels containing hydrocarbons and correspondingly for catalytically cleaning the exhaust gases, containing nitrogen oxides and carbon monoxide, hydrocarbons and soot particles, of energy plants using fuel containing hydrocarbons.
  • the energy plant's exhaust gases are led to an exhaust-gas burner, in which the gases are brought to catalytic oxidation and reduction, in order to reduce the NOx, CO, VOC, and particle content of the exhaust gases and to simultaneously produce thermal energy.
  • NOx compounds are first reduced and then the CO, VOC compounds and the particulate impurities of the gases are oxidized and at the same time recoverable thermal energy is produced.
  • thermal energy is produced in at least two units, when thermal energy is first produced in the energy plant by burning a fuel with a hydrocarbon content. Heat is recovered, for example, in a heat exchanger. Fuel and air are fed into the exhaust gases obtained from combustion to form a gas mixture and the gas mixture which is then brought to catalytic combustion, which is performed at a high temperature.
  • the nitrogen oxides contained in the flue gases are reduced and the carbon monoxide, hydrocarbons, and soot particles are oxidized.
  • the heat obtained from the catalytic combustion is also recovered.
  • soot particles can also be burned in a flue-gas burner at a temperature of 600° C. or more.
  • the preferred temperature range for the burner is 850-1000° C. In this range the soot particles also burn rapidly.
  • Simultaneous energy production permits the use of a flue gas of a thermal boiler, turbine, or diesel power plant, etc., as a cooling and heat-transfer agent in catalytic combustion.
  • the inert thermal mass of exhaust and flue gases is then used in combustion to control temperature and transfer heat.
  • the temperature can be kept within desired limits, preferably in the range 850-1000° C.
  • the present solution can be used to increase the thermal energy production capacity of a thermal boiler by up to 60%.
  • a flue-gas burner can be added to all energy-production devices, in which the sulphuric emissions and particle emission are low, and in which there are no so-called catalyser poisons.
  • the amounts of NOx, CO, and VOC emissions of the energy sources are of no practical importance.
  • afterburning the small soot particles produced by, e.g., oil boilers and diesel power plants also burn. Unless there is a storing POC catalyser or filter in connection with the catalysers, it is preferable to arrange an intermediate chamber before heat recovery, in which the particles have time to burn before energy recovery.
  • Nanoparticles contain carbon, water, hydrocarbons, and often sulphur, as well as small amounts of other compounds. They are very porous. Once the hydrocarbon and sulphur compounds have oxidized and the water evaporated, the carbon ignites on all surfaces and burns rapidly, but the gaseous compounds more slowly.
  • the temperature of the exhaust gas in the aforementioned range (850-1000° C.) is advantageous for these reactions, particularly the combustion of carbon.
  • the exhaust-gas burner can be combined with a boiler or heat exchanger to clean all kinds of gases containing NOx, CO, and VOC emissions, because catalytic combustion operates below the LEL limit. There is then not the same kind of safety risk as in thermal combustion boilers, in which the combustion of VOCs has led to fatal accidents.
  • the exhaust-gas burner is also suitable for operating energy plants that do not meet the emissions requirements of ever-tightening norms. Emissions-reducing investments are often worth making, because the plants have a long life and demand large investments. New plants form another application.
  • FIG. 1 shows a process diagram of one embodiment
  • FIG. 2 shows a process diagram of a second embodiment
  • FIG. 3 shows a process diagram of a third embodiment
  • FIG. 4 shows a process diagram of a fourth embodiment.
  • energy plant refers mainly to a combustion plant producing thermal energy, i.e. heat energy, in which energy is produced from a fuel with a hydrocarbon content, with the aid of boilers, diesel turbines, or gas turbines.
  • the term “fuel with a carbon content” refers to a fuel that contains compounds comprising mainly, but not necessarily only, carbon and possibly hydrogen, such as hydrocarbons.
  • the fuel may contain compounds with an oxygen content, such as ethers, esters, and alcohols.
  • Examples of fuels with a carbon content according to the first embodiment are oils, petrol, diesel, and natural gas.
  • the term “fuel with a carbon content” also refers to a fuel that contains mainly alcohol (hydroxy) groups, ether groups, or ester groups, or combination of these comprising carbon compounds, for example, hydrocarbon compounds, which are substituted with these groups.
  • These fuels are various biofuels, which are produced from a biomass, such as lignocellulose, vegetable oils and animal fats, cultivated plants.
  • CO and “VOC emissions” and correspondingly “NOx emissions” and “soot particle emissions” refer to the amount (as mass) of the CO, VOC, and NOx gases and correspondingly soot particles contained in the exhaust gases.
  • a “rich” fuel/oxygen (or fuel/air) mixture contains a greater stoichiometric amount of fuel (relative to oxygen), and “lean”, in turn, a smaller stoichiometric amount of fuel.
  • a solution is generally created for treating exhaust gases and producing energy using a catalytic exhaust-gas burner.
  • the method can be applied to both producing heat and cleaning exhaust gases, as described below in greater detail.
  • exhaust gases, fuel, and air are mixed together evenly to produce a homogenous gas mixture.
  • additional air and fuel can be fed to the exhaust-gas burner and their feed can be controlled by the temperature after the catalyser and a linear oxygen sensor according to the air/fuel mixture ratio needed by each catalyser.
  • a second catalyser When operating with a rich mixture, a second catalyser is most suitably used, when an additional air feed required by a lean mixture is arranged for it. The best result is obtained using separate oxidation and reduction stages.
  • fuel and air are mixed in a nested perforated feed pipe and a static mixer, to form an evenly mixed gas mixture.
  • the static mixer can be used to ensure the homogeneity of the gas mixture, which is particularly preferred to ensure even combustion.
  • catalytic combustion is performed in one or more stages in reducing and correspondingly oxidizing conditions.
  • catalytic combustion is performed in at least two stages, to reduce partitularly nitrogen oxides and to oxidize carbon monoxide, hydrocarbons, and soot particles.
  • the gas mixture can then be burned, for example, in the three-way catalyser using a stoichiometric oxygen/additional-fuel ratio in the combustion plant to oxidize the CO and VOC compounds that have remained unburned in the combustion plant and to reduce NOx emissions, and oxidize soot particles.
  • a rich mixture is used to reduce NOx emissions into nitrogen (N 2 ) and oxygen (O 2 ) and to oxidize most of the CO and VOC emissions into carbon dioxide (CO 2 ) and water (H 2 O).
  • the gas mixture is burned in an oxidation and reduction catalyser, first with a rich additional-fuel/oxygen mixture to reduce the nitrogen oxides and then with a lean additional-fuel/oxygen mixture to oxidize the CO and VOC compounds and soot partides.
  • Some of the reactions are direct oxidation and reduction reactions.
  • LEL lower explosion limit
  • the structure of the catalyser should be a recuperative or regenerative heat exchanger, for example, a metallic cross-flow catalyser, or, to maintain combustion, a fuel igniting at a lower temperature, such as methanol or ethanol, should be fed to the fuel mixture as a support fuel.
  • the catalysers used in combustion are most suitably surfaced with stable metal oxides, especially oxides, the cation of which is Al, Ce, Zr, L, or Ba, and to which noble metals, such as Pd, Pt, Rh, or their mixed oxides with base metals are attached.
  • stable metal oxides especially oxides, the cation of which is Al, Ce, Zr, L, or Ba, and to which noble metals, such as Pd, Pt, Rh, or their mixed oxides with base metals are attached.
  • the temperature in a catalyser is at least 600° C., particularly 850-1000° C. in reducing conditions, or in both reducing and oxidizing conditions.
  • the space velocity is kept at a value of 50 000-150 000 l/h, for example about 60 000-100 000 l/h, while in a reducing and oxidizing catalyser the space velocities are, for example, about 60 000-200 000 l/h, preferably 70 000-150 000 l/h.
  • the present technology is applicable particularly in situations, in which the fuel is burned or has been burned in a combustion plant, which is an oil or gas boiler, a gas turbine, a diesel power plant, or a similar energy plant.
  • a combustion plant which is an oil or gas boiler, a gas turbine, a diesel power plant, or a similar energy plant.
  • a one or two-stage only catalytically reducing and oxidizing exhaust or flue gas-cleaning and clean energy producing solution is created.
  • the flue gas has also a heat binding and transfer role.
  • catalytic combustion is considerably faster than thermal, it is preferable to use a flue or exhaust gas that is essentially inert, for binding energy. In this way, an excessive rise in temperature can be avoided.
  • the present technology can be applied to produce thermal energy from a fuel containing hydrocarbons by performing combustion in at least two stages.
  • part of the fuel is burned in the first combustion stage in combustion plant, to produce heat and an exhaust gas with a nitrogen and oxygen-oxide content.
  • the heat and exhaust gas obtained from the first combustion stage are recovered.
  • the second combustion stage the second part of the fuel is fed into the exhaust gas obtained form the first combustion stage. Air too is fed to form a combustible gas mixture.
  • the gas mixture thus obtained is burned to produce heat and break down the nitrogen and oxygen oxides.
  • in at least one catalyser zone reducing conditions are maintained and combustion is performed in these conditions at a temperature of more than 600° C.
  • the heat obtained from the second combustion stage is recovered.
  • the second combustion stage 10%, most suitably 15-80 mol-% of the total amount of fuel with a hydrocarbon content is burned.
  • a significant part, which is about 60%, of thermal energy additional to the primary energy source can be produced in the second combustion stage.
  • flue gas from a boiler, turbine, or diesel power plant is used as a cooling and heat-transfer agent in catalytic combustion.
  • a cooling inert additive in stoichiometric catalytic combustion modelling shows that the temperature will rise to more than 2500° C. This is due to the fact that catalytic combustion is about twenty times faster than thermal.
  • the flue gases of a thermal energy plant are most suitably used as an inert heat storage and transfer agent to keep the temperature of the catalytic combustion within the preselected temperature range. It has been shown that the unburned gases contained in the flue gases, such as nitrogen and carbon dioxide, do not react in the conditions described, but as inert components even the heat and prevent an uncontrolled rise in temperature.
  • the thermal energy contained in the gases obtained from combustion is recovered. Recovery can be made in at least one heat-transfer stage, when the thermal energy is most suitably transferred to water, air, or some other liquid or gaseous medium.
  • the present technology is applied to catalytically cleaning, in reducing and oxidizing conditions, the exhaust gases, containing nitrogen oxides and carbon monoxide, hydrocarbons, and soot particles, of energy plants using fuels containing hydrocarbons.
  • fuel and air are fed to the exhaust gases to form a gas mixture and the gas mixture is brought to one or two-stage catalytic combustion, to be performed at a temperature of more than 600° C., in order to reduce the nitrogen oxides and to oxidize the carbon monoxide, hydrocarbons, and soot particles.
  • the emission level of the NOxs of the gas obtained from catalytic combustion is 1 ppm or less, and the level of CO and VOC emissions is at most 2 ppm.
  • the small soot particles also burn at the preferred operating temperature of the exhaust-gas burner of 850-1000° C., because soot ignites at about 600° C. and burns with increasing speed above it.
  • the present methods are implemented as continuously operating processes.
  • a hydrocarbon is used as the reducer and the energy source.
  • the production of additional energy is another property of the process.
  • the oxidation of particles and the production of clean energy are implemented at a high temperature (at least 1000 degrees). For both of these a temperature is required, which at the same time improves conversion efficiency, as a particle oxidizer and energy producer, and is boosted by a higher temperature.
  • An exhaust-gas burner using the same fuel with a thermal boiler has several advantages compared to selective (SCR) or non-selective (SNCR) NOx emission reducing apparatuses:
  • FIGS. 1 and 2 show two embodiments, with FIG. 1 showing a solution, in which both thermal and electrical energy are produced from fuel in an energy plant (a power plant), when the energy plant's exhaust gas is cleaned primarily using a catalytic combustion process.
  • FIG. 2 shows a solution, in which heat is produced, on the one hand in a thermal power plant and, on the other, by a catalytic combustion process.
  • reference numbers 10 ; 20 ; 30 ; and 50 show a thermically burning boiler, diesel power plant, gas turbine, or other such energy plant or power plant, which uses a gaseous or liquid fuel.
  • the fuel is fed mainly to the energy plant, in which thermal energy is produced, in addition to which electricity is produced from at least part of the thermal energy thus produced.
  • the energy plant's exhaust gas is guided from the exhaust duct to a mixing chamber 12 ; 22 , into which additional air is blown and fuel is sprayed.
  • the mixing chambers can comprise a distribution network.
  • a mixing honeycomb structure is used. Examples of this are the solutions that are disclosed, e.g., in utility models 10627 or CN205001032.
  • the distribution network can consist of diagonally corrugated steel folio sheets, which are stacked or folded on top of each other with the corrugations crosswise.
  • the folio sheets can be attached to each other at the crossing points, for example, using resistance welding or brazing.
  • the flow channels formed in each layer of the honeycomb cross over each other, which causes mixing and turbulence in the flow at the higher flow velocities.
  • a static mixer 13 From the mixing chamber the gas travels through a static mixer 13 ; 23 to a catalyser 14 ; 24 , 25 .
  • a linear lambda sensor Behind the catalyser (in the direction of flow of the gas mixture) is a linear lambda sensor (not shown), which is arranged to measure and, for its part, to adjust the air/fuel ratio, as well a temperature sensor controlling the temperature.
  • the gas travels to a connection made, for example, of a welded ribbed pipe, or to several heat-exchanges 15 ; 27 , in which heat is transferred to water, or some other useful purpose.
  • the heat exchangers 15 ; 27 can be, for example, of welded pipes, such as preferably manufactured of ribbed pipes.
  • FIGS. 3 and 4 show the structure of the catalytic combustion system in greater detail.
  • the primary energy production for example, using a diesel engine, a gas turbine, or a combustion boiler, is marked with reference numbers 30 and 50 , fuel being fed into the exhaust gas obtained from which along a feed duct 31 ; 51 .
  • air is fed by fans 37 ; 57 .
  • the mixture is mixed before the catalyst zone by leading through the static mixer 38 ; 58 .
  • the mixture is preferably rich before being led to the catalyst zone.
  • the catalyst zone comprises a cross-flow catalyser 33 .
  • the catalyst zone comprises a recuperative heat-exchanger-catalyser.
  • the gas mixture obtained from the first, typically reducing, catalyst zone 33 ; 53 is led to the second catalyst zone 35 ; 55 , which typically comprises an oxidation catalyser. Additional air is then fed to the gas mixture by a secondary-air-feed fan 39 ; 59 .
  • the catalyser or catalysers are typically pre-heated, e.g., using a hot-air fan, a gas burner, or some other heater, to above the reaction temperature of the catalyser.
  • the first catalyser of the exhaust-gas burner can be a conventional straight-duct catalyser, if the temperature difference between exhaust gas and the ignition temperature of the fuel is small ( ⁇ 150° C.), if the exhaust gas's carbon monoxide (CO) and nitrogen oxide (NO 2 ) contents are high. Carbon monoxide will ignite in a catalyser already at about 150° C. and the second oxygen of nitrogen oxide detaches easily and reacts aggressively.
  • a cross-flow or rotating honeycomb recuperative heat-exchanger-catalyser 53 is needed when the temperature of the incoming gas is substantially lower (>150° C.) than the ignition temperature of the fuel used in the catalyser.
  • a three-way catalyser's space velocity is, depending on the fuel, 50 000-150 000 l/h, preferably 60 000-100 000 l/h. In reducing and oxidizing catalysers the space velocity is 70 000-200 000 l/h, preferably 60 000-150 000 l/h.
  • the thermal energy of the hot gas obtained is recovered in a heat exchanger 36 ; 56 , in which it is transferred, for example, to water.
  • the heat exchangers 36 ; 56 can be manufactured from, for example, welded pipes, preferably ribbed pipes.
  • the present apparatus for burning a flowing fuel with a hydrocarbon content in the presence of oxygen or air comprises, in the order of flow of the substance flows being treated
  • NOx emissions can be brought to a level of 1 ppm and CO and VOC emissions can be cut to a level of less than 2 ppm using two-stage combustion ( FIG. 4 ).
  • the invention has characterizing aspects that are presented in the independent Claims.
  • the present solution is suitable as the simultaneous power cleaner of the, NOx. VOC, and CO emissions of, for instance, boilers, diesel power plants, gas turbines, and similar.
  • the solution according to the invention is also suitable for burning the particles of, for example, solid-fuel boilers and diesel power plants. It is also suitable for producing additional energy in boilers, diesel power plants, gas turbines, and similar.
  • nitrogen oxides can be reduced so that their residual content is less than 1 ppm
  • carbon monoxide (CO) and hydrocarbons (VOC) can be oxidized so that their residual content is less than 2 ppm. These values can be achieved even though the primary energy source emissions are high. Small soot particles too can be burned in an exhaust-gas burner, so that using the method according to the invention the particle filters of boilers and diesel engines can be replaced.
  • a primary energy plant does not require Low NOX or Ultra Low NOX burners, nor does a diesel engine require EGR or very low mixing ratios to reduce NOX emissions.
  • the output of the primary energy plant can then be maximized.
  • using the method according to the invention as much as about 60% additional thermal energy can be produced for the primary energy source. This is so especially when exhaust gas produced in first combustion is used as a cooling and heat-exchange agent in catalytic combustion, and when fuel is fed to exhaust gases to perform second-stage catalytic combustion.
US16/970,972 2018-03-09 2019-03-11 Method of producing heat in a power station Abandoned US20200392884A1 (en)

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JP4044908B2 (ja) * 2004-03-11 2008-02-06 トヨタ自動車株式会社 内燃機関の排気浄化装置
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US8889587B2 (en) * 2009-08-31 2014-11-18 General Electric Company Catalyst and method of manufacture
US10005016B2 (en) * 2015-12-28 2018-06-26 General Electric Company Hydrophobic filtration of tempering air
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KR20200130261A (ko) 2020-11-18
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