Science Direct - Coal and Biomass Cofiring - Fundamentals and Future Trends
Science Direct - Coal and Biomass Cofiring - Fundamentals and Future Trends
Chapter Outline
5.1 Introduction
According to the Technology Roadmap on Delivering Sustainable Bioenergy of the
International Energy Agency (IEA), the current rate of bioenergy deployment is
well below the levels required within IEA long-term climate models. Acceleration is
urgently needed to ramp up the contribution of bioenergy across all sectors. Moreover,
bioenergy is a complex subject with many potential feedstocks, conversion processes,
and energy applications. It interacts strongly with the agriculture, forestry, and waste
management sectors, and its prospects are linked to the growth of a broader bio-
economy (IEA, 2017).
The use of renewable energy is nowadays an unavoidable measure to attain sustain-
able development in the world. However, combustion of fossil fuels is still the main
source of energy on the earth and a major contributor to atmospheric carbon dioxide
emissions, which are directly related with the global warming and climate change con-
cerns. Coal is a cheaper and more abundant resource than other fossil fuels, such as oil
and natural gas, while at the same time it is a reliable fuel for power production (Tof-
tegaard et al., 2010). Over 40% of the worldwide electricity is produced from coal
(IEA, 2016), and it is expected that coal plays an important role on the energy supply
if the global energy demand continues to rise in the near future.
Biomass is considered as a renewable energy source for mitigating greenhouse
gases (GHGs), nitrogen oxides, and sulfur oxide emissions. Biomass is carbon neutral,
and it has low contents of nitrogen and sulfur. Combustion of biomass is the most inex-
pensive option of converting biomass fuels to energy. The carbon dioxide generated
from the combustion of biomass has been previously removed from the atmosphere
by the photosynthesis process while the plant grows, hence net carbon emissions
are null. Biomass can be derived from different organic matter resources such as dedi-
cated energy crops, forestry and agriculture residues, seaweed, animal manure, and
organic wastes. Thus, biomass can be classified based on its origin into the following:
(1) primary residues such as wood, straw, cereals, maize, etc., obtained from the by-
products of forest products and food crops; (2) secondary residues such as saw and pa-
per mills, food and beverage industries, apricot seed, etc., derived from processing
biomass material for industrial and food production; (3) tertiary residues such as
wastes and demolition wood, etc., that are derived from other used biomass materials;
and (4) energy crops (Bhuiyan et al., 2018).
Biomass cofiring consists of burning biomass along with coal in coal-fired power
plants to generate electricity. Biomass cofiring with coal is recognized as one of the
most attractive short- to medium-term options for using biomass in the power gener-
ation industry. Solid biomass cofiring involves the combustion of wood chips or pel-
lets in coal-fired power plants, whereas gas biomass cofiring means the firing of
gasified biomass with natural gas or pulverized coal (PC) in gas power plants (indirect
cofiring) (Agbor et al., 2014). In this context, cofiring of biomass with coal may be
considered a bridge between the energy production systems based on fossil fuels
and those based on renewable energy sources, which would contribute to reduce
CO2 emissions and the dependency on fossil fuels. In addition, the use of biomass
in combination with coal in the same power plant would avoid the typical problems
associated with small biomass-fired power plants, i.e., high specific cost (due to the
larger size of coal power plants) and low efficiency, while at the same time it would
reduce the risk of a biomass shortage (Valero and Uson, 2006). Modern coal power
plants are more efficient than smaller-scale dedicated biomass power plants. There
Coal and biomass cofiring: fundamentals and future trends 119
is no need for continuous biomass supply because the plant can burn coal if biomass is
not available. Biomass cofiring in coal-fired power plants therefore offers significant
advantages: modern coal-fired power plants are highly efficient (>44%), they have
coal supply facilities that also facilitate biomass supply, and they also have advanced
flue gas cleaning equipment, which in some cases may obviate separate cleaning for
biomass. During the last years, different forms of biomass have been co-combusted
in existing coal-fired boilers, where biomass is used as a supplementary fuel to substi-
tute for up to 10% of the coal in terms of energy content. The costs of adapting existing
coal power plants for cofiring biomass are significantly lower than building new dedi-
cated biomass systems (Fernando, 2005).
Relying solely on biomass is risky due to unpredictable feedstock supply because
of the seasonal nature of biomass resources as well as poorly established supply infra-
structure in many parts of the world. Other constraints of generating power solely
from biomass are the low heating values and the fuel’s low bulk densities, which
create the necessity of transporting large amounts of biomass (Agbor et al., 2014).
Biomass cofiring for power generation provides an effective way to overcome these
challenges because cofiring plants have the option to revert to dedicated coal combus-
tion for mitigating the effect of biomass fuel shortages (Karampinis et al., 2014). On
the other hand, the energy use of biomass can add value to the forestry and agriculture
sectors of developing and emerging countries. Likewise, industries such as construc-
tion, manufacturing, food processing, and transportation may be beneficiaries of
cofiring.
Although biomass and coal cofiring provides the benefit of reduction of GHG emis-
sions to the atmosphere, it presents some logistical and performance issues that should
be analyzed, such as the availability of biomass resources, their transport to the power
plant, the different cofiring technologies, as well as the technological and environ-
mental issues associated with biomass cofiring.
Biomass differs significantly from coal in terms of physical and chemical proper-
ties, as well as composition and energy content. Biomass usually contains less carbon,
more hydrogen and oxygen, less sulfur and nitrogen, more volatile matter (VM), lower
heating value, and lower bulk density. These properties affect the design, operation,
and performance of cofiring systems.
dictates the amount of air required for combustion (stoichiometry), and if less air is
required, less nonreacting components of the air (mostly N2) need to be heated to
the flame temperature (Madanayake et al., 2017). The higher O content of biomass
means that less air is required for combustion, compared with typical hydrocarbon
fuels (Jenkins et al., 1998). Hence, biomass fuels have the potential to achieve higher
combustion efficiencies compared with other hydrocarbon fuels. The higher volatility
of biomass improves its reactivity and ignition characteristics compared with coal, and
this usually results in a lower activation energy barrier to devolatilization and oxidation
(Agbor et al., 2014).
Biomass Biomass
ash ash
Direct co-combustion Indirect co-combustion Parallel co-combustion
capital cost required because the needed additional installations in an existing coal-
fired power plant are kept to a minimum. Direct cofiring of biomass and coal takes
advantage of the high efficiencies obtainable in large coal-fired power plants and im-
proves combustion due to the higher volatile content of the biomass, although it pre-
sents several limitations such as the tendency of producing ash deposition, the limited
range of cofiring, and the lack of flexibility to use different types of biomass (Roni
et al., 2017). Biomass is directly fed into the furnace with coal. Biomass can be milled
jointly with the coal in the same milling equipment (typically less than 5% in terms of
energy content) or premilled and then fed separately into the same boiler. Common or
separate burners can be used, with the second option enabling more flexibility with re-
gard to biomass type and quantity. As more modifications are introduced, higher cap-
ital investment is required, and a more significant technological risk is involved if the
modifications also affect the boiler itself. However, the degree of control that can be
achieved on combustion conditions is greater, and the risk to boiler operation through
the impact of biomass is minimized. In most cases, the biomass thermal input in direct
cofiring schemes is around 10% owing to technical and economical restraints (Karam-
pinis et al., 2014). This limitation could be minimized by torrefying and densifying
biomass so that it behaves more like coal in terms of energy content and grinding
behavior (Tumuluru et al., 2012).
not affected by the addition of a biomass fuel. Combustion residues are also produced
separately and can be handled independently.
industry, waste wood, and energy crops. Using wastes for cofiring would minimize the
environmental problem associated with its disposal. Woody biomass is considered to
be the most convenient option for cofiring activities due to its naturally low content in
ash, sulfur, and nitrogen, but other biomass feedstocks, such as forest residues, mill
residues, or agricultural products such as straw, switchgrass, corn stover, rice hulls,
and olive pits, could be used in cofiring with coal.
Important barriers associated with cofiring biomass and coal can be the unstable
supply of biomass and the availability of quality biomass fuels, which limit the per-
centage of biomass that can be fired. The costs of biomass acquisition and transporta-
tion determine to a large extent the economic feasibility of cofiring. The acquisition
costs depend on possible competition with other biomass energy uses (e.g., biofuels)
or nonenergy applications. A stable and cheap flow of biomass is needed to sustain a
biomass cofiring project. The price of biomass is strongly dependent on the following:
(1) the feedstock’s origin, type, and composition; (2) the cost of handling, preparing,
and transporting the feedstock; and (3) the plant’s geographic location. The transpor-
tation cost over long distances is influenced strongly by the energy density or the heat-
ing value of the biomass feedstock (Agbor et al., 2014).
35
Coal Coal (anthracite)
30
Solid wood
Energy density (GJ/m3)
25 Wood chips
Processed biomass Sawdust
20 Black liquor
15 Wood pellets
Raw biomass Torrefied wood pellets
10 Pyrolysis oil
Straw (baled)
5
Organic waste
0
0 500 1000 1500
Bulk density (kg/m3)
Figure 5.2 Energy density of biomass and coal.
Adapted from IEA-ETSAP and IRENA (2015).
of coal particles (Karampinis et al., 2014). Particle shape and size affect char burnout
because biomass does not melt, and irregular shapes are maintained during combustion
(Backreedy et al., 2005). Overall, despite the unfavorable sizing, fuel conversion can be
maintained in high levels, especially when the biomass thermal share is low.
different fuels are involved, with biomass being much more reactive and having higher
volatiles and moisture content than coal. Combustion models based on coal need to be
modified to account for the effects of biomass cofiring on the overall combustion
behavior. To achieve good modeling results, the use of appropriate submodels for
the description of the behavior of biomass particles is very important. Some models
for burning blends of biomass and coal have been developed with a focus on predicting
combustion efficiency, fouling, and emission of pollutants for different fuels and their
mixtures in commercial-scale FBCs (Gayan et al., 2004).
Computacional fluid dynamics (CFD) and modeling techniques are becoming
increasingly important tools to assess the impact of biomass cofiring in the operation
of burners and boilers (Alvarez et al., 2014). They have been shown to be reasonably
effective in predicting the in-furnace temperature profiles and heat fluxes, as well as
slag deposition (Degereji et al., 2012). Future developments in the field of computer
simulation would be extremely useful in predicting ash deposition problems, without
the need for expensive and time-consuming field tests. The current state-of-the-art
CFD-based models are capable of solving the complex interdependent processes
such as fluid flow, turbulence, heat transfer, heterogeneous and homogeneous chemi-
cal reactions involved in cocombustion. However, the complete description of particle
trajectories, chemistry of devolatilization, char oxidation, and volatile combustion is
still, mainly, based on simple models (Tabet and G€okalp, 2015).
Secondary air
Fuel
Primary air
Ash
Grated combustor
Pulverized fuel combustors. In PFCs, the solid fuel has to be mechanically reduced
in particle size, and the fine particles are then introduced pneumatically into the burner
(Fig. 5.4). Pulverized coal combustion (PCC) boilers are the most widespread technol-
ogy used in converting energy from coal to heat energy and electricity due to the high
efficiency and low NOx emissions. The reduced emissions are one of the reasons for
choosing this technology, but the low-energy density of biomass means a higher vol-
ume flow to the boiler and a high volume of locally available biomass. These boilers
could be adapted to direct cofiring with biomass, but fuel properties, along with fuel
blending and feeding, should be carefully controlled. Fuel quality in PFC needs to
be maintained, with a maximum fuel particle size of 10e20 mm, and the moisture con-
tent should be no more than 20 wt.%, which lowers its application in cofiring projects
(Agbor et al., 2014). The burning time requires small particles that will burn out
completely before exiting the furnace.
Fluidized bed combustors. FBCs contain a bed of a medium (such as silica sand or
limestone) mixed with the fuel. The bed acts as a buffer to maintain high combustion
temperatures, even if the fuel contains impurities, high moisture, or low calorific value.
A more efficient heat transfer during combustion results in lower combustion temper-
atures, between 800 and 900 C, which prevents ash sintering and lowers the NOx and
SOx emissions compared with other combustion technologies. The costs for SO2 cap-
ture may be lower because limestone can be added directly to the fluidizing medium at
relatively low cost compared with installing postcombustion scrubbers. An FBC is the
most suitable reactor for cofiring. Also, existing coal-fired FBCs can be easily adapted
to cofiring. There are two major types of FBC systems: bubbling fluidized bed
Coal and biomass cofiring: fundamentals and future trends 131
Secondary air
Fuel
+
Primary air
Ash
Pulverized fuel
combustor (PFC)
combustors and circulating fluidized bed combustors (Fig. 5.5). In general, fluidized
bed boilers can substitute higher levels of coal with biomass than pulverized coal-
fired or grate-fired boilers. Fluidized bed boilers can handle biomass with higher mois-
ture content (10%e50% instead of <25%) and larger particle sizes (<72 mm instead
Bed Bed
Fuel Fuel
Ash Ash
Bubbling fluidized bed Circulating fluidized bed
combustor (BFBC) combustor (CFBC)
of <6 mm) than pulverized boilers (Agbor et al., 2014). They can achieve high fuel-to-
steam efficiency, typically over 90%, even with challenging, low-grade fuels. One
problem that is exclusive to this design is the probability of bed agglomeration occur-
ring when biomass with a high alkali/alkaline earth metal content is used.
Cyclone boilers. They are designed with large, water-cooled burners that are placed
in a horizontal position, and its external furnace can reach combustion temperatures in
the range of 1650 and 2000 C. The boiler allows the fuel’s mineral matter to form a
slag capturing the oversized particles and to combust the fine and volatile fuel particles
in suspension. The intense heat that radiates from this design burns up the layer of slag
formed. For optimum performance, the ash content of the biomass fuels must exceed
6%, volatiles should be greater than 15%, and, except in a dried form, the moisture
content of the fuel must not be less than 20% (Agbor et al., 2014). This technology
is suitable for biomass cofiring, although a few modifications may be necessary to
enhance the feeding and mixing of the biomass and the coal.
Gasifiers. The gasification technology is used in indirect cofiring systems. Fixed bed
gasifiers require mechanically stable fuel particles of limited size (10e30 mm) to facil-
itate passage of gas through the bed (Dai et al., 2008), and they are generally used in
small-scale applications (<10e15 MWe power capacity). The fluidized bed gasification
has been identified as the most effective gasification technology for indirect biomass
cofiring, where both bubbling fluidized bed gasification and circulating fluidized bed
gasification can be applied because they permit the use of a wide variety of biomass fuels
and waste-derived fuels. An efficient performance of fluidized bed gasifiers requires
relatively small fuel particles to ensure good contact with bed material. Entrained
flow gasifiers convert mixtures of fuel and oxygen into a syngas at high temperatures
(>1200 C, even as high as 2000 C) in very short periods of time (a few seconds)
and at high pressures (50 bar). To achieve reliable feeding and high conversion of the
feedstock, particles should be smaller than 1 mm (Maciejewska et al., 2006).
Direct cofiring results in slightly higher efficiencies (around 2% points) than indirect
and parallel cofiring due to the conversion losses in the biomass gasifiers and boilers.
The overall efficiency of direct cofiring falls with higher percentages of biomass due
to fouling and slagging, associated corrosion, especially in pulverized coal-fired or
grate-fired boilers. The overall efficiency of direct cofiring in coal-fired power plants
with fluidized bed boilers is less sensitive to higher levels of biomass, although high
levels require more sophisticated boiler and fuel handling control systems. In general,
cofiring in modern, large, and highly efficient coal power plants results in a biomass con-
version efficiency that is significantly higher than what can be achieved in small
(<10 MW) and medium-scale (10e50 MW) dedicated biomass power plants with effi-
ciencies of 14%e18% and 18%e33%, respectively (IEA-ETSAP and IRENA, 2013).
to reduce their GHG emissions significantly by substituting a portion of their base fuel
with a “carbon-free” fuel such as biomass. Biomass cofiring helps to reduce carbon
dioxide emissions, other airborne emissions such as oxides of sulfur and nitrogen,
as well as trace metals.
can be used in cofiring systems with little or no modification (Dai et al., 2008), but the
catalysts of the SCR system are susceptible to poisoning from volatile inorganic com-
pounds, such as alkalis and phosphates, which are expected to be present in increased
amounts in the flue gases from cofiring plants. The issue of the cofiring impact on SCR
operation still requires further research (Karampinis et al., 2014).
5.6.3 Ash
Concrete admixtures represent an important market for some coal combustion ash by-
products. One of the issues associated with biomass cofiring is how to deal with the ash
left over after the combustion of both fuels in the combustor. The cofiring technology
employed determines the nature of the ash left at the end of the combustion process.
The ash contents of different biomass and coal feedstocks differ significantly in
composition, and it is still not appropriate to use fly ash from cofiring wood with
coal. Literature suggests that herbaceous biomass fuels which contain alkali and
chorine may compromise several important concrete properties, but there is not
enough evidence to preclude the fly ash from biomass energy source for the supply
of concrete additive (Bhuiyan et al., 2018).
Fly ash from the gasification of biomass in fluidized beds can be reused as fuel for
power generation because it may have high energy content due to unburned carbon. On
the other hand, potentially, the ash originating from combustion or gasification of
biomass can be used as natural fertilizer or in fertilizer production, as it is rich in
Mg and Ca (Tumuluru et al., 2012).
from the use of agricultural residues or demolition waste, which would otherwise
constitute a disposal challenge.
The trend in cofiring is to increase the biomass/coal ratio and to utilize a wider range
of biomass fuels. Thus, the development of efficient technologies to cofire new types
of biomass such as energy crops, waste wood, and agricultural residues is needed. The
net electric efficiency of a cofired coal/biomass power plant ranges from 36% to 44%,
depending on plant technology, size, quality, and share of biomass. Although a 20%
cofiring (as energy content) is feasible and more than 50% is technically achievable,
the usual biomass share is below 5% and rarely exceeds 10% on a continuous basis.
However, high biomass shares involve technical issues, such as securing sufficient
biomass, as well as potential combustion problems, such as slagging, fouling (which
reduces heat transfer), and corrosion. A more expensive alternative (in terms of invest-
ment costs) as the introduction of more advanced cofiring modes, such as parallel cofir-
ing or indirect cofiring, in which not only fuel preparation and feeding lines but also
conversion units for biomass and coal are independent, could be an interesting option
in some cases (Tumuluru et al., 2012).
The main difficulties and drawbacks associated to the biomass cofiring technology
are primarily caused by the differences in properties between coal and biomass. There-
fore, pretreatment techniques seem to be a potential and promising way to favor the
development of cofiring. Chemical composition issues of the biomass can be reduced
by methods such as washing and leaching, which can save costs involved in mainte-
nance of cofiring systems and minimize ash-related issues such as slagging and
fouling. The local availability of large quantities of cheap biomass makes biomass
cofiring more economically attractive. However, if local sources are insufficient,
high-energy density and pretreated biomass (e.g., wood pellets) can be used. In these
cases, long-distance transportation and logistics play an important role in the economic
viability. Both handling and combustion characteristics of biomass can be substan-
tially improved through torrefaction and pelletization, which increase the energy den-
sity of biomass, reduce transportation costs, and improve storage performance. The
pelletization of torrefied biomass is a promising option to increase the bulk density
and the net calorific value of biomass to higher levels than the typical pelletization.
Although the biomass pretreatment process has been developed technically, proper
collection and transportation is still required for its efficient utilization, as well as
large-scale application of the pretreatment process has to be developed. Seasonal/
annual fluctuation in biomass supply, due to its biological nature and environmental
diversity, is another important characteristic. Taken together, these issues indicate
that securing good quality feedstock at affordable prices over a plant’s lifetime is
crucial for biomass power projects.
Current operating experience and available solutions indicate that most technical
concerns do not materialize or can be easily solved when cofiring woody biomass at
relatively low thermal shares. As the biomass thermal share increases and more prob-
lematic fuels are utilized, further research and demonstration activities will be needed
to evaluate potential impacts of cofiring (Karampinis et al., 2014).
Coal and biomass cofiring: fundamentals and future trends 137
Acknowledgments
Authors are grateful to the Gobierno del Principado de Asturias (PCTI-GRUPIN14-079) and to
the CSIC (PIE-201780E057) for funding.
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