KOH FLUE GAS RECIRCULATION POWER PLANT WITH WASTE HEAT AND BYPRODUCT RECOVERY

• US 20030097840A1
• Filed: 11/23/2001
• Published: 05/29/2003
• Est. Priority Date: 11/23/2001
• Status: Active Grant

• Current Assignee: Justin Chin-Chung Hsu
• Original Assignee: Justin Chin-Chung Hsu
• Inventors: Hsu, Justin Chin-Chung
• Granted Patent: US 6,574,962 B1
• Time in Patent Office: Days
• US Class Current: 60/670
• CPC Class Codes: F23C 9/00 Combustion apparatus characterised by arrangements for returning combustion products or flue gases to the combustion chamber fluidised bed combustion apparatus with means for recirculation of particles entrained from the bed F23C10/02; fluidised bed combustion apparatus with devices for removal and partial reintroduction of material from the bed F23C10/26
• CPC Class Codes: F23J 15/006 Layout of treatment plant
• CPC Class Codes: F23J 15/06 of coolers
• CPC Class Codes: F23J 2219/70 Condensing contaminants with coolers
• CPC Class Codes: F23J 2900/15061 Deep cooling or freezing of flue gas rich of CO2 to deliver CO2-free emissions, or to deliver liquid CO2
• CPC Class Codes: F23L 2900/07001 Injecting synthetic air, i.e. a combustion supporting mixture made of pure oxygen and an inert gas, e.g. nitrogen or recycled fumes
• CPC Class Codes: F23L 7/007 Supplying oxygen or oxygen-enriched air
• CPC Class Codes: Y02E 20/30 Technologies for a more efficient combustion or heat usage
• CPC Class Codes: Y02E 20/32 Direct CO2 mitigation
• CPC Class Codes: Y02E 20/34 Indirect CO2mitigation, i.e. by acting on non CO2directly related matters of the process, e.g. pre-heating or heat recovery
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel

Abstract

The invention relates to an integrated power plant, which burns fuel using an oxygen-enriched stream in a combustion furnace and converts emissions of air pollutants and carbon dioxide into byproducts. The combustion flue gas stream, after leaving an economizer of a steam generation system, splits into stream A and stream B. Stream A recirculates back to the combustion furnace through the first flue gas recirculation fan for combustion temperature control. Stream B, after passing through a dust collector for fly ash removal, a series of condensers for byproduct recovery, and the second flue gas recirculation fan, mixes with an oxygen-enriched stream from an air separation unit and flows back to the combustion furnace. The plant does not need an exhaust stack and does not discharge combustion flue gases into the atmosphere.

Claims

1. A process of a KOH flue gas recirculation power plant, wherein the process uses at least one air separation unit, two flue gas recirculation loops, at least one adsorption refrigeration unit, and condensers for combustion temperature control, waste heat recovery, elimination of air pollutants, and production of liquid sulfur dioxide, liquid nitrogen dioxide, and liquid carbon dioxide.

2. The process of claim 1, wherein the process comprising the steps of:

(a) an air separation unit to separate air into an oxygen-enriched stream and a nitrogen-enriched stream;

(b) a combustion furnace to burn fuel with an oxygen-enriched stream and a recirculated combustion flue gas stream;

(c) a fuel loading system with a carbon dioxide blanketing system to prevent air from entering combustion chamber with fuel;

(d) a bottom ash collection and management system with water seals to remove bottom ash from the combustion furnace and to prevent air from entering the combustion furnace;

(e) a steam and electricity generation system including a steam boiler equipped with a superheater and a reheater, an economizer, steam turbines, and a waste steam collection and recovery unit;

(f) a flue gas manifold to receive the combustion flue gas stream from the economizer and to split the combustion flue gas stream into stream A and B;

(g) one (first) flue gas recirculation fan to recirculate combustion flue gas stream A back to the combustion furnace for combustion temperature control.

(h) an oxygen-enriched stream heater to transfer thermal energy of combustion flue gas stream B to an oxygen-enriched stream;

(i) a dust and acid gas removal system with water seals to remove suspended particulate matters and acid gases such as sulfur trioxide and hydrogen chloride found in combustion flue gas stream B from the oxygen-enriched stream heater and to prevent air from mixing with combustion flue gas stream B;

(j) a water vapor condenser to liquefy water vapor and any condensable materials found in combustion flue gas stream B from the dust and acid gas removal system;

(k) a nitrogen dioxide condenser to liquefy nitrogen dioxide and any condensable materials found in combustion flue gas stream B from the water vapor condenser;

(l) a sulfur dioxide condenser to liquefy sulfur dioxide and any condensable materials found in combustion flue gas stream B from the nitrogen dioxide condenser;

(m) a carbon dioxide condenser to liquefy carbon dioxide and any condensable materials found in combustion flue gas stream B from the sulfur dioxide condenser;

(n) another (second) flue gas recirculation fan to mix combustion flue gas stream B from the carbon dioxide condenser with the oxygen-enriched stream from the air separation unit in an oxygen-enriched stream manifold;

(o) a waste steam recovery system including at least an adsorption refrigeration unit to collect waste steam from steam turbines for heating and cooling.

3. The process of claim 2, wherein a liquid carbon dioxide or water feed pump is used to inject liquid carbon dioxide or water into the combustion furnace for combustion temperature control during the plant'"'"'s start-up mode or any emergency situation.

4. The process of claim 2, wherein said combustion furnace includes a water-wall combustion furnace, a refractory-wall combustion furnace, or any conventional combustion furnace.

5. The process of claim 2 wherein said fuel includes solid fuel, liquid fuel, gaseous fuel, or any combination thereof.

6. The process of claim 4, wherein said solid fuel includes coal, wood, refuse derived fuel, any combustible solid waste including hazardous waste, or any combination thereof.

7. The process of claim 4, wherein said liquid fuel includes distillate fuel oil, residual fuel oil, gasoline, any combustible liquid waste including hazardous waste, or any combination thereof.

8. The process of claim 4, wherein said gaseous fuel includes natural gas, propane gas, landfill gas, any combustible gaseous waste including hazardous waste, or any combination thereof.

9. The process of claim 2, wherein said air separation unit, water condenser, nitrogen dioxide condenser, sulfur dioxide condenser, carbon dioxide condenser, and adsorption refrigeration unit are integrated cooperatively to optimize heating, cooling and condensation.

10. The process of claim 2, wherein said dust and acid gas removal system includes a wet cyclone or multiple-cyclone collector, a dry cyclone or multiple-cyclone collector, a packed bed absorber, a venturi scrubber, a baghouse, an electrostatic precipitator, or any combination thereof.

11. The process of claim 9, wherein said baghouse is equipped with a carbon dioxide injection system instead of a conventional air injection system for bag filter cleaning and preventing air from entering the combustion flue gas stream.