FUSEC
Future Fuels for Sustainable Energy Conversion
2011-2013
FUSEC organization
Own
work
Top A
Own
work
Coordination
FW
UPM
Own
work
fee+TEKES
fee+TEKES
Core Program
ÅAU (scientific co-ordination)
VTT
fee+TEKES
fee+TEKES
HUT
Andritz
TUT
Metso
Own
LUT
work
fee+
TEKES
fee+
TEKES
IP
CBW
• Core total budget about 2.2 M€
Own
work
FUSEC core
• Detailed information of chemical details influencing
the future progress of the biofuel utilization
• Topics related to long term issues
• Purpose not to solve short-term problems in the
industry
• Results will be (finally) public domain, to a large
extent academic theses
Research connected to thesis works
1. Dorota Bankiewicz
High temperature corrosion of steam tube
materials exposed to zinc and salt mixtures
2. Oskar Karlström
Characterizing biomass fuel samples for particle
combustion modelling
3. Juho Lehmusto
Reactions of potassium chloride with solid oxides
in conditions relevant to combustion
4. Bingzhi Li
CFD modelling of deposition in the post-smelter
stages of the flash smelting process
5. Na Li
Laboratory testing of high temperature corrosion
of ceramic refractory in alkaline environment
6. Patrycja Piotrowska Combustion and gasification properties of residues
from production of liquid or gaseous biofuels
7. Pasi Vainikka
Fate of inorganic aerosols during fluidised bed ‘
(20 December, 2011) co-combustion of solid recovered fuel
8. Emil Vainio
Measurement of gaseous compounds in the
lower furnace
Research connected to thesis works
9. Hao Wu
Halogen induced high temperature
corrosion
10. Niklas Vähä-Savo Thermochemical conversion of black liquor
and lignin - release kinetics of sulfur and sodium
11. Tapio Sorvajärvi
Laseranalytical methods in biomass combustion
12. Markku Nikku
3D-modelling of biomass combustion
13. Alexander Maximov Radiation heat transfer
14. Ari Vepsäläinen
Reactivity of fuels in fluidised beds
15. Perttu Jukola
Modelling of boiler furnace processes - particle
modelling
16. Marko Huttunen
Modelling of boiler furnace processes - radiation
FUSEC core - reporting
• Reporting twice per year during technical meetings
lasting for two/three days
• Reporting with presentations ; 19 presentations in last
meeting in December 2011
• 12 participants from industry and about 35 from research
organizations
• Steering group meetings in connection to technical
meetings
• http://web.abo.fi/fak/tkf/cmc/fusec/
WORKPACKAGES,
TASKS AND TASK
LEADERS
Task title
WP 0 Scientific co-ordination
Co-ordination (research, web-pages, seminars, etc.)
Characterization of fuels and fuel mixes with
WP1
novel and advanced methods
1.1 Advanced fuel analyses
1.2 Physical and chemical conversion characteristics
1.3 S and Cl release and elemental release
1.4 Agglomeration characteristics
1.5 Ash/sand erosivity
1.6 Deposit adhesion to tube surfaces
WP 2 Modelling
Advanced thermodynamic modelling and database
2.1
development
2.2 Homogeneous gas phase modelling
2.3 Radiation heat transfer modelling
2.4 Biomass sub-models for CFD
2.5 Models for Kraft recovery boilers
WP 3 High temperature corrosion
3.1 Corrosion effects of synthetic ashes
3.2 Corrosion after different pre-treatments
3.3 Effect of temperature gradient on corrosion
3.4 Gaseous release during corrosion layer formation
3.5 Refractory materials
Development of equipment and methods for
WP 4
high temperature research
4.1 Laboratory fluidized bed reactor
4.2 Erosion test unit
Gaseous alkali and aerosol laboratory
4.3
measurements
4.4 Corrosion temperature gradient furnace
WP 5 Information and international co-operation
5.1 Fuel database (www-interface)
Highlights from conferences, seminars and
5.2
workshops
5.3 Invited speakers to project meetings
5.5 International co-operation
Task leader
PY
MZ
AK/NDM
JW
PP/PY
LH
TL
DL
AB
TH
AB
LK/ME
DB/PY
JuL/PY
DB/DL
JuL/PY
LH
PY
LH/JL
JT/NDM
DL
PY
PY
PY
PY
Examples of research within FUSEC
Task 1.4 Laboratory fluidized bed reactor
Experiment with SiO2 and KCl
Experiment with SiO2 and KCl
-defluidization at KCl melting temp. (770°C)
Only K and Cl
Experiment with SiO2 and K2CO3
Punkt 1
Punkt 2
Punkt 3
Punkt 4
O
49.27
52.74
54.12
44.75
Al
0.27
0.33
Si
29.91
29.76
29.50
19.99
P
Cl
0.09
0.14
0.08
K
20.73
17.08
16.29
18.27
Ti
16.67
Temperature 800°C
Formation of K-silicate.
Task 3.1 Corrosion tests
• Tests in tube furnace (temperature, gas atmosphere)
1st step
2nd step
3rd step
4th step
5th step
resin
oxide layer
steel
Polishing,
oxidation &
covering with
synthetic ash
Tube furnace
Before SEM/EDXA
analysis
Casting in epoxy and
cutting
SEM picture
analysis
Oxide layer thickness and its
distribution estimation
Result examples after 168 h
10CrMo
Oxide layer thickness µm
400
350
AISI347
PbCl2
ZnCl2
356
300
240
250
200
150
108
100
80
50
70
X
35
5
5
4
0
250
350
450
350
X
X
450
X
550
Temperature ºC
X = KCl
D. Bankiewicz et al, 2010; Impacts of Fuel Quality on Power Production and Environment
Distribution %
Thickness distribution and SEM-images (450 ºC)
ZnCl2 (Type 1)
5
4
PbCl2 (Type 2)
5
10CrMo
4
mean 5 µm
3
AISI347
3
mean 35 µm
2
2
1
1
0
0
0
50
100 150 200 250 300 350
Oxide layer thickness µm
mean 108 µm
0
50
mean 240 µm
100 150 200 250 300 350
Oxide layer thickness µm
Oxide layer
Oxide layer
steel
Internal attack
D. Bankiewicz et al, 2010; Impacts of Fuel Quality on Power Production and Environment
steel
Erosion test unit for metals and refractories
FI: Flow indicator
PC: Pressure controller
TC: Temperature controller
TI: Temperature indicator
PC
Heat
exchanger
Air outlet
TI
Sand
blasting
furnace
TC
Sand +
air
FI
Fluidization
air
Sample
FI
Sand heating
and
fluidization
furnace
TC
PC
Carrier air
FI
PC
Air 8 bar
PC
Testing of erosive wear at different impact angles
45°
Sand blasting gun
Sample
Results interpretation plan
•
•
•
•
Sample weight change
Visual observation
Confocal optical microscopy
SEM
Stainless steel
Polished
Sa=0.045 μm
Eroded
Sa=0.196 μm
Corrosion and erosion
• Corrosion 550°C, 24 h
• Careful cleaning with
air
• Erosion 1 h, 25°C
0
-20
-40
∆ mg
-60
Ferritic without salt
Ferritic with KCl
-80
Austenitic with KCl
Austenitic without salt
-100
Task 4.4. Furnace for testing effect of
temperature gradient on corrosion
• Study the effect of temperature
gradient on salt-induced corrosion
• Study the effect of temperature
gradient on deposit chemistry; salt
enrichment/depletion
• Construction and testing of a
temperature gradient corrosion furnace
Before
After
Temperature gradient corrosion tests
 Simple design
 Based on air-cooled corrosion/deposit probe used by
Bankiewicz et al. (2011) Energy & Fuels, 25, 3476-3483
and described by Lauren (2007), lic. thesis
 Exchangable test rings
 Addition of insulating cover
Outline of the corrosion/deposit probe.
Length 60 cm
Material sample rings
Thermocouples
Initial tests
•
•
•
•
Sample holder inserted into tube furnace
Ring temperature set to 400 °C
Furnace temperature set to 800 °C
Measured temperature above the rings was 720 °C
• Stable conditions during test runs achieved
Next steps
• Apply salt on the rings
– Heat resistant paste
• Define exposure area
• Prevent molten salt from escaping
– Pure compound (KCl), mixtures (K-Na sulfate, chloride)
• Add more thermocouples to measure the
temperature gradient
• Run short-term corrosion tests with salts
• Study effect of temperature gradient on salt mixtures
THANK YOU