The IFRF Triennial Report 2004-2006 and Research Planning has been compiled by Professor Hartmut Spliethoff, IFRF Superintendent of Research, Dr. Neil Fricker, IFRF Deputy Superintendent of Research, and Professor Leonardo Tognotti, IFRF Director. 

From an introduction which documents the reasons for the move from IJmuiden and the decision to relocate the IFRF to Livorno, and then clarifies the mission of the “New” IFRF, the text moves through four major sections:

• IJMUIDEN: ACHIEVEMENTS 2004 – 2006
• IFRF FACILITIES
• MEMBERS’ RESEARCH PROGRAMME 2006 – 2009
• CONCLUDING REMARKS

IJMUIDEN: ACHIEVEMENTS 2004 – 2006 revisits the research projects carried out in this period, describing each individually and listing the reports which resulted.  The projects were MECBURN, BioFlam, PowerFlam 1 & 2, HEC-EEC, and CAFENOX.  Space is then dedicated to Other smaller studies and publications and then to the IFRF’s regular publications, the Online Combustion Handbook and the Online Journal.  The Topic Orientated Technical Meetings (TOTeMs) held during the triennial are also listed.

IFRF FACILITIES provides the details of the test rigs, laboratories and computing equipment accessible by Members at the Livorno plant.  This information will shortly be amplified in the form of a fully illustrated guide which is currently being compiled and will be made available on the IFRF website.

MEMBERS’ RESEARCH PROGRAMME 2006 – 2009 explains the mechanism behind the funding of the Members’ Research Programme, both historically and in the new dispensation, and identifies the various types of reports which are produced at different stages of a research project.  The status of the three projects currently underway is then outlined.  The projects are:

• Validation of combustion modelling for practical combustion systems
• Development of a solid (coal and secondary) fuel data base
• Hydrogen production and utilisation- IGCC. 
  

Pulverised coal fired power plants in Europe are facing increasingly tight limits on emissions of Nitrogen Oxides (NOX). After recalling the main EU regulations facing power station boilers and other large combustion plant, this report presents a review of the mechanisms of NOX  formation in pulverised-coal fired boilers, and of the technical options available to reduce NOx. Both in-furnace and post furnace options are considered, in addition to the impact of coal type on emissions. The effectiveness and cost of the different options have also been reviewed. This work was cofunded by the European Commission.

In the 1970s and 1980s, the IFRF undertook several furnace trials to provide user guidance on the use of Works By-Product Gases on high temperature and low temperature steelworks plant. The studies covered beneficiation techniques and their influence on plant efficiency and NOx formation, as well as an examination of low CV gas flame stability, and the control of low CV gas flames by radiation measurements. More recently, the IFRF has undertaken a survey of the current issues facing IFRF metals sector members relating to the increased use of their Works By-Product Gases . The survey also reviewed the previous IFRF work and identified opportunities arising from recent technical advances, together with the R&D that would be needed to exploit them. The survey was undertaken by Jeff Rhine and Neil Fricker of the University of Glamorgan as part of the European Commission supported EUROFLAM programme.

IFRF Report G130/y/01 summarises the main findings of the IFRF's earlier work. The review includes summaries of the key findings relating to efficiency, NOx emissions flame stability and process control. It was also recognised that the technology has moved on in a significant way since those trials were undertaken. In particular, developments of:

• compact regenerators for higher air and fuel preheat
• flameless combustion
• computer based simulation techniques
• modern sensors
• real-time computer based flame control to take advantage of such sensors.

offer the prospect of step changes in the effectiveness and economics of low calorific value gases as industrial fuels.

This report contains the results of an analysis undertaken by the IFRF Research Station BV as its contribution to the EC co-funded MECBURN Project. The topic of the analysis is burner scaling, with particular application to natural gas firing of firetube boilers (so called ‘shell boilers’). In addition to providing a further interpretation of the burner scaling experiments of MECBURN, the scaling rules described and tested in the MECBURN project will also be of general application in a range of process situations of interest to IFRF Members.

The report starts with a comprehensive review of the main options for burner scaling. This includes an extensive bibliography of other relevant IFRF reports as well as publications by the IFRF and others over a 50 year period.

The experimental arrangements to test similar burners at three different scales (7 MW, 500kW and 150kW) are described. Babcock-Wanson, Gaz de France and TU Karlsruhe undertook these tests respectively. The 7MW rig was also tested at 3.5MW.

The results of these tests are presented, and scaling rules considered in terms of:

•  Temperature fields in the flames
•  Temperature in the post-flame zone
•  Carbon monoxide concentrations
•  Nitrogen oxides
  

This report was originally prepared by the IFRF Research Station BV in 1999 as part of the EC co-funded CLEAN GLASS projects.  The report has been reviewed by the IFRF for publication to IFRF members. In May 2006 it has been republished in this site. 

Bulk glass melters use large reversing regenerators to preheat the combustion air in order to enhance thermal efficiency of the melting process. One of the downsides of this is a high level of NOx in the flue gases, with values exceeding 3000 ppm not uncommon in the past. NOx formation in glass melting furnaces is mostly due to thermal NOx, and should be amenable to primary reduction measures by altering the fuel air mixing arrangement to reduce peak flame temperatures while maintaining heat transfer to the glass and avoiding excessive refractory temperatures. The Clean Glass program attempted to better understand the formation of NOx in glass melting furnaces. The IFRF program consisted of an experimental part and a modelling part, which are combined to validate the improvements of the mathematical modelling. Specific objectives of this study were as follows:

1.  To reduce the NOx emission to less than 500mg/Nm3 @8percent O₂ with complete combustion by primary means

Several oil atomiser conditions, burner configurations and atomisation media were tested to better understand the NOx and CO emission behaviour.

2.  To maintain optimum heat flux and distribution while reducing NOx

The heat release profile in the glass tank condition should be maintained similar while arranging the burner gun configurations to get the target NOx level. Detailed in-flame measurements were undertaken to distinguish the flame properties of low NOx and high NOx performance.

Experimental work

Experiments were executed in February 1999. Heavy fuel oil was fired in the glass melting furnace simulator (~1MWt) at the IFRF Research Station. Air preheats of  over 1000C were achieved by means of a direct fired air preheater with oxygen addition to return to oxygen levels to  21percent. Air assisted oil atomisers were prepared by Hotwork-Köster. The following parameters were evaluated to investigate the NOx and CO emission behaviour.

• Atomisation medium (air, nitrogen, natural gas, steam)
• Atomisation air flow and pressure
• Combustion air velocity (14m/s, 24m/s)
• Firing modes (6 different burner gun arrangements)
• Atomiser angle (5^O - 18^O)

At the same time in-flame measurements were carried out in three different flames to assess the flame properties of high NOx and low NOx flames.

A monochromatic infrared camera for tomographic flame reconstruction was applied in the glass melting furnace simulator in co-operation with IST (Instituto Superior Técnico).

Results

 Research Report F45/y/2 contains a detailed description of the way in which the IFRF furnace was used to simulate a full scale glass melter. It also gives complete data on the experimental conditions, fuels, parametric studies of the effect of the experimental parameters on flue NOx levels, and the detailed in-flame data collected.

It was shown that the primary measures listed above can achieve reductions in NOx emissions of 30 percent to 50 percent. The specific conditions giving rise to the best NOx/CO/Heat transfer  combinations are identified in the body of the report. It was also recognised that application of different firing modes also offer further potential, but that additional studies will be needed to explore and exploit this potential.

IFRF Report F36/y/20 was first published in 1992 as part of the Dutch NOVEM sponsored MMF5-2 Investigations. The report contains detailed laser doppler based measurements of gas velocities, turbulence and compositions in the inlet and quarl zone of swirling low-NOx  pulverised coal flames. In addition to the experimental data, the report describes a mathematical model used to simulate the flames studied, and makes comparisons between the measured and modeled parameters. Parameters explored include temperature, gas composition, char burnout, and radiative heat fluxes together with NOx and nitrogen precursors concentrations.

This report is the 2nd of a series of Research Reports prepared at the IFRF Research Station in the period 1994-1995.  The IFRF work was part of a wider co-operative programme co-funded by the European Commission within the JouleII programme. The general objective was to assess the technical and economic feasibility of carbon dioxide separation from the flue gas of coal fired power plant for subsequent sequestration.

This process could permit near zero carbon dioxide emissions from power production from fossil sources. It can be achieved by increasing the concentration of carbon dioxide in the flue gas to levels where efficient liquefaction becomes feasible; which can generally be done by eliminating nitrogen from the system by burning the coal with oxygen instead of air. 

The overall programme was divided into three project areas, with overall coordination by the IFRF. The Project Areas were:

1. Pulverised coal combustion systems for CO₂ capture 

Coordinated by Babcock Energy Limited

Participating partners were:

• University of Ulster (GB)
• University of Naples (IT)
• Air Products (GB)

2. Evaluation of advanced coal-based systems for power generations

Coordinated by IFRF

International Advisory Group: IFRF European Members

3. Coal combustion in advanced burners for minimal emissions and carbon dioxide reduction technologies

Coordinated by Rolls Royce International Combustion Limited

 Participating partners were:

• Imperial College (GB)
• Lambda Technical (GR)
• IST Lisboa (PT)
• Electr. de Portugal (PT)

This programme, although a decade old, set the scene for the present day major research thrust on this aspect of Carbon Sequestration.               

The present report describes the second phase of the APG experiment performed at the IFRF Research Station.

This report is the 1st of a series of Research Reports prepared at the IFRF Research Station in the period 1994-1995.  The IFRF work was part of a wider co-operative programme co-funded by the European Commission within the JouleII programme. The general objective was to assess the technical and economic feasibility of carbon dioxide separation from the flue gas of coal fired power plant for subsequent sequestration.

This process could permit near zero carbon dioxide emissions from power production from fossil sources. It can be achieved by increasing the concentration of carbon dioxide in the flue gas to levels where efficient liquefaction becomes feasible; which can generally be done by eliminating nitrogen from the system by burning the coal with oxygen instead of air. 

The overall programme was divided into three project areas, with overall coordination by the IFRF. The Project Areas were:

1. Pulverised coal combustion systems for CO₂ capture 

Coordinated by Babcock Energy Limited

Participating partners were:

• University of Ulster (GB)
• University of Naples (IT)
• Air Products (GB)

2. Evaluation of advanced coal-based systems for power generations

Coordinated by IFRF

International Advisory Group: IFRF European Members

3. Coal combustion in advanced burners for minimal emissions and carbon dioxide reduction technologies

Coordinated by Rolls Royce International Combustion Limited

 Participating partners were:

• Imperial College (GB)
• Lambda Technical (GR)
• IST Lisboa (PT)
• Electr. de Portugal (PT)

This programme, although a decade old, set the scene for the present day major research thrust on this aspect of Carbon Sequestration.               

The present report describes the first phase of the APG experiment performed at the IFRF Research Station. This work was probably the first demonstration of the process at a near industrial scale.  

Chemical-looping combustion (CLC) is a combustion technology with inherent separation of the greenhouse gas CO2. This combustion process involves the use of a metallic oxygen carrier to allow indirect burning of gaseous fuel to yield CO2-rich flue gas to facilitate carbon sequestration. 

Two reactors in the form of interconnected fluidized beds are used in the process. The metallic oxygen carrier undergoes cyclic oxidation (in air) and reduction (with gaseous fuel) reactions so that combustion takes place without contact between the fuel and air.  Combustion of the fuel takes place in the absence of nitrogen, yielding flue gas consisting mainly of CO2 and water vapour. 

The net chemical reaction over the two reactors is the same as for normal combustion with the same amount of heat released, but with the important difference that carbon dioxide is inherently separated from nitrogen, and no extra energy is needed for this separation.

Although the technology is still in its infancy, CLC offers the same advantages as oxy-fuel combustion with the added advantage of potentially higher thermal efficiency.  This paper reviews the fundamental principles of CLC, key results of oxygen carrier characterization studies, some CLC system concepts with associated design issues and thermo-economic assessments.  The potential for related applications such as hydrogen production are also discussed along with promising directions for future research.     

In 2001 the IFRF commenced a programme of research aiming to provide information through which process industries could improve the thermal efficiency of their heating processes, reduce costs, NOx emissions and net CO2 emissions. This is the IFRF High Efficiency Combustion Research Programme.

Following from developments at IJmuiden the research was based on application of modern regenerative burner operating in “flameless” mode. In the work described in the paper the IFRF cooperated with Corus RD&T and Gasunie Engineering & Technologies; the specific industrial application envisaged was steel slab-reheating, in particular, pusher type furnaces.

The IFRF set up a 1MW semi-industrial scale test facility to simulate the reheating process equipped with two commercially available HEC burners. The paper gives details of the facility design and operation and the measurement capability with details of the results of both natural gas and coke oven gas firing campaigns.

In order to investigate the application of the experience gained in the experimental investigations to a pusher type slab-reheating furnace, CFD modelling was developed based on a commercial code. Details of these developments and the application of the model are described.

Finally there is a comparison between the operational data of a conventionally fired furnace and the predicted HEC fired furnace, with analysis of the gains to be made, leading to conclusions and the planning of full scale application.

The ratification of the Kyoto Protocol and the implementation of the EU directives for greenhouse gas emissions trading present a mounting pressure to the coal utilisation community (including coal users in the power generation industry) to mitigate their CO₂ emissions.  This is an environmental challenge that is greater than any it has previously faced. The magnitude of the problem will require parallel actions to be implemented by the industry; and these include options such as the increase in efficiency, co-firing with renewable fuels, and CO₂ capture and sequestration.

This report presents a general review on Oxy-Coal Combustion with Recycled Flue Gas, one of the potential techniques for CO₂ capture and sequestration. The aim of this work is to provide an overview of the current state of the technology from the point of view of both technical and economic issues.

The report briefly described the various semi-industrial scale studies undertaken for this technology during the past decades. The review also presented the key results obtained from various laboratory scale studies made. The technical issues related to this kind of combustion were summarized.

Furthermore, the report discussed the expected additional economic and thermodynamic costs for the production of O₂ and for the recovering and storage of CO₂ from the exhaust flue gas. The various solutions and methods for lowering these costs were also shown.

 
The Final Research Report - F104/y/03 - is published as a pdf file. This may be downloaded by clicking on the Icon on the left hand side below "Contents" - check on the file size before commencing the download.

The abstract of the report is published as an html file. Click on the "Executive Summary" title to the right of the pdf icon, to review the summary on screen. We recommend you to do this prior to downloading the report.

This report presents the observations and experimental data collected during the final phase of the IFRF HEC Project. A 5m x 2m x 2m furnace fitted with a pair of proprietary compact regenerative burners was fired with Coke Oven Gas in a flameless combustion mode. The regenerative burners reversed at approximately 30-second intervals, and provided combustion air preheat levels of up to 1250C.

Input/output measurements and in-flame measurements were made at a range of throughputs between 300kW and 1MW. Measured parameters included gas temperatures, wall temperatures, gas compositions, NOx concentrations and radiative heat fluxes to the furnace walls. In addition, an extensive set of photographs and some video recordings of the flames were made. The approaches to measuring in flame parameters in a rapidly cycling combustion system developed in earlier phases of the HEC project were deployed. This has resulted in a consistent set of in-flame data for both natural gas and COG fuels.

Although primarily intended to generate data sets for the development and validation of mathematical models of the effect of fuel type on high temperature flameless combustion systems, a number of direct observations of the characteristics were made, and these are set out in the main text of this report.

Utilisation of the "alternative" or "fossil replacement" fuels derived from biomass or waste for electricity production is one of most realisable and economic way to achieve CO2 reduction. Technical information on combustion of pulverised coal has been accumulated over recent decades. The methods of burner design, operation and methodologies of pollutant emissions have been well established. However the co-firing behaviour between biomass and coal is not yet well understood.

This study evaluates the effects of alternative fuels blended with pulverised coal on combustion characteristics in an Isothermal Plug Flow Reactor (IPFR). The aim of the experiments was to assess whether the combustion behaviour of co-firing could be predicted from that of the parent fuels. Several alternative fuels such as paper sludge, pure wood and plant substrates were selected and characterised.

This report is the 4th of a series of Research Reports prepared at the IFRF Research Station in the period 1994-1995.  The IFRF work was part of a wider co-operative programme co-funded by the European Commission within the JouleII programme. The general objective was to assess the technical and economic feasibility of carbon dioxide separation from the flue gas of coal fired power plant for subsequent sequestration.

This process could permit near zero carbon dioxide emissions from power production from fossil sources. It can be achieved by increasing the concentration of carbon dioxide in the flue gas to levels where efficient liquefaction becomes feasible; which can generally be done by eliminating nitrogen from the system by burning the coal with oxygen instead of air. 

The overall programme was divided into three project areas, with overall coordination by the IFRF. The Project Areas were:

1. Pulverised coal combustion sistems for CO₂ capture 

Coordinated by Babcock Energy Limited

Participating partners were:

• University of Ulster (GB)
• University of Naples (IT)
• Air Products (GB)

2. Evaluation of advanced coal-based systems for power generations

Coordinated by IFRF

International Advisory Group: IFRF European Members

3. Coal combustion in advanced burners for minimal emissions and carbon dioxide reduction technologies

Coordinated by Rolls Royce International Combustion Limited

 Participating partners were:

• Imperial College (GB)
• Lambda Technical (GR)
• IST Lisboa (PT)
• Electr. de Portugal (PT)

This programme, although a decade old, set the scene for the present day major research thrust on this aspect of Carbon Sequestration.               

The present report summarises the overall results of the IFRF Research Station work, a programme which was probably the first demonstration of the process at a near industrial scale

The combination of compact regenerative burners with flameless firing delivers the high thermal efficiency needed for reducing carbon emissions and fuel costs while at the same time reducing NOx emissions. The IFRF Research Station is undertaking detailed measurements and modelling of such a system in its High Efficiency Combustion (HEC) furnace, the objective being to provide generic information on the combustion behaviour of regenerative flameless combustion systems, together with data that may be used to develop and validate mathematical models of such processes. Although the HEC furnace design is intended as a simulation of a large steel-reheating furnace, it is anticipated that the output from the HEC tests will find application over a wide range of industrial processes.

G108/y/3 is the third of three reports dealing with the CFD modelling of a high temperature furnace fired by a pair of compact regenerative burners operating in the ‘flameless’ mode. The report describes the validation of a non-isothermal CFD models used to simulate mixing, combustion and heat transfer taking place in the IFRF’s HEC furnace when fired flamelessly.

A comprehensive description of the model configurations adopted is given in G108/y/1 and G108/y/2. Further details of the furnace and burner geometry are available in the HEC Planning report (D108/y/1) and the HEC Furnace Commissioning reports (C108/y/1 and C108/y/2).

In this report, additional comparisons are made between the output of the G108/y/2 CFD model and data collected when firing the furnace on natural gas and which was not available at the time of the original comparisons. At the same time, the opportunity has been taken to better reproduce the actual furnace boundary conditions in the CFD model.

All HEC reports cited in this summary are available to IFRF Members as downloads from:

http://www.research.ifrf.net/research/programmes.html