Engineered Fuel Sorbents for Coal Cofiring Emission Control
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Solution Overview
Problem
Existing coal-fired power plants face challenges in reducing SOx, NOx, and CO2 emissions due to outdated emission control technologies, and cofiring biomass with coal is limited by cofiring ratios and increased corrosion issues, leading to inefficient combustion and high operational costs.
Innovation Solution
A method for varying the overall cofiring ratio of a combustion system by using engineered fuels with sorbents, optimized for different combustion environments, to reduce emissions and mitigate corrosion, allowing for a wide range of cofiring ratios without affecting individual system component operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If flue gas desulfurization (FGD) and selective catalytic reduction (SCR) technologies are installed to meet emission regulations, then SOx and NOx emissions are reduced, but parasitic power consumption, water utilization, and waste generation increase
Solution Approach 1:
The patent converts the harmful effect of sulfur combustion into a beneficial process by using sorbent materials that chemically react with sulfur compounds during combustion. The sorbents transform sulfur into solid sulfates that can be easily removed from flue gas, converting a harmful emission problem into a controlled chemical reaction process that reduces both SOx and NOx emissions simultaneously.
Solution Approach 2:
The patent changes the chemical parameters of the combustion process by introducing sorbent materials with specific chemical compositions and ratios. By adjusting sorbent type, concentration, and combustion temperature parameters, the system achieves effective sulfur and nitrogen oxide control without requiring separate FGD and SCR systems, thereby reducing parasitic power consumption.
2Object-generated harmful factors
If FGD and SCR technologies are installed to reduce emissions, then air pollution is controlled, but installation and operational costs increase significantly
Solution Approach 1:
The patent merges the functions of sulfur control and nitrogen oxide control into a single combustion process by using composite sorbent materials that address both pollutants simultaneously. This integration eliminates the need for separate FGD and SCR systems, reducing capital installation costs and operational expenses while maintaining effective emission control.
Solution Approach 2:
The patent employs inexpensive sorbent materials that can be easily replaced or regenerated, avoiding the need for expensive, complex FGD and SCR equipment. The sorbents are designed to be cost-effective consumables that reduce emissions during combustion and can be managed through simple replacement cycles, significantly lowering both installation and operational costs.
3Productivity
If high sulfur coals are combusted to meet energy demands, then power generation continues, but SO3 related corrosion and blue plume issues become more prevalent
Solution Approach 1:
The patent converts the harmful effect of sulfur combustion into a beneficial process by using sorbent materials that chemically react with sulfur compounds during combustion. The sorbents transform sulfur into solid sulfates that can be easily removed from flue gas, converting a harmful emission problem into a controlled chemical reaction process that reduces both SOx and NOx emissions simultaneously.
Solution Approach 2:
The patent introduces sorbent materials as intermediary substances that mediate between the sulfur in high sulfur coals and the flue gas. These sorbents act as chemical intermediaries that capture sulfur compounds and transform them into removable forms, preventing SO3 formation and associated corrosion while allowing continuous high sulfur coal combustion for power generation.
4Object-generated harmful factors
If biomass is cofired with coal to reduce emissions and costs, then CO2 net production is reduced, but combustion efficiency decreases and control coordination becomes difficult
Solution Approach 1:
The patent changes the combustion parameters by using sorbent-enhanced engineered fuels with optimized chemical compositions. The sorbents modify the combustion chemistry to improve burn rate, complete combustion, and thermal efficiency while maintaining the CO2 reduction benefits of biomass cofiring. This parameter optimization resolves the coordination difficulties between biomass and coal combustion.
Solution Approach 2:
The patent uses composite engineered fuels that combine biomass with sorbent materials and coal. This composite approach creates a unified fuel mixture that burns more efficiently than separate biomass or coal combustion, improving combustion efficiency while maintaining the emission reduction benefits. The composite fuel structure ensures proper combustion characteristics and control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively reduces air emissions, minimizes the need for expensive flue gas treatment technologies, and enhances combustion efficiency, achieving thermal efficiencies up to 40% while maintaining safe and smooth cofiring operations.
Implementation Method 1
engineered fuels with sorbents, optimized for different combustion environments, to reduce emissions
Implementation Method 2
combustion system by using engineered fuels with sorbents
Data Source
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AI summary
An integrated process of cogasifying an engineered fuel, formulated to be suitable for working under reducing environment, with co and co firing another engineered fuel, formulated to be suitable for working under oxidizing environment, with coal to produce electri power. Apparatus and methods of combustion systems for co firing an engineered fuel and a fossil fuel. In some embodiments, the present invention provides an integrated method of a combustion system comprises introducing a first engineered fuel and a first fo fuel into a gasifier. The method further comprises cogasifying the first engineered fuel and the first fossil fuel to produce syngas. Th method further comprises introducing a second engineered fuel, a second fossil fuel and the produced syngas into a combustion reactor. The method also comprises cofiring the second engineered fuel, the second fossil fuel, and the produced syngas.