Callide Oxyfuel Project Development and Progress

Dr Chris Spero

Oxyfuel Capacity Building Course – Tokyo Institute of Technology

2 – 3 September 2012

Presentation Overview

•

Project history and structure

•

Process description and permitting

•

Oxyfuel boiler construction

•

Comparison of oxy‐firing with air‐firing

•

CO2 capture plant 

•

Future deployment of oxyfuel technology

Project history

Project structure

COP – Work flow

Pulverised Coal Consumption

5.5 kg/s20 tph

Quality HHV: 19 MJ/kg ar

Ash: 21% arMoisture: 14% ar

Sulfur: 0.3% dafAnglo Callide Coal mine

SteamFlow 37.7kg/s or 136 t/h Pressure 4.1MPa, Temperature 460oC

Oxygen (GOX)Purity: 98 vol% Oxygen

Pressure : 180kPa(a)Flow: 7.6kg/s

Size: 2 x nominal 330 TPD Air Liquide Sigma cryogenic ASUs

Recirculated Flue Gases

Flow: 30kg/sCO2: ~67% mass

Chimney Stack

Flow: 13.2kg/sHeight: 76m

CO2 Purification and CompressionCO2 Product: 75t/dayCO2 Purity: 99.9% molCO2 Temperature: -20oC CO2 Pressure: 1,600kPa

Road TransportB Double – 30tSingle Tanker – 20t

Boiler Exit Flue Gases350oC44.9kg/s

Feed Gas to CO2 PlantFlue Gas Processed Flow: 1.7kg/sTemp ~ 150oC

Callide A Demonstration –

Simplified

Stage 1 –

Callide A

•

Exempted from development approval under local 

Government Planning Scheme – not deemed to be a 

material change of use

•

Amendments proposed to existing Callide A 

environmental authority

Vented gas streams from CO2

CPU

Condensates from flue gas scrubber columns

Define additional release points and monitoring 

regime

Stage 2 – CO2

road transport

•

Carbon Dioxide (CO2

) is a Dangerous Good (Class 2.2) 

under the Queensland Transport Act

Stage 2 – CO2

storage

•

Greenhouse Gas Storage Act 2009 (QLD) 

•

Greenhouse Gas Storage Regulation 2010 (QLD)

•

Environmental Protection Act 1994 (QLD

Permitting

Callide A Unit 4 ‐

Original

8

Boiler Plant/Equipment Removed Ready for New Equipment

Walkway to Fabric Filter to Remain

U3 Multiclone to Remain

Cable Tray to Fabric Filters to Remain

9

Callide A Unit 4 ‐

After Oxfuel RetrofitOxygen

Flue Gas Before Air Heaters

Flue Gas After Air Heaters

Flue Gas (Clean after FF bags)

Recycled Gas

Rich CO2 Flue Gas to CPU

Secondary Recycled Gas

Cold Primary Recycled Gas to Mills

Hot Primary Recycled Gas to Mills

v

New Feedwater 

Heater

New 

Primary 

Gas Heater

TO CPU

FROM ASU

1 of 1440 

Fabric Filter 

(FF) Bags

Dust

FDF = Forced Draft Fan IDF = Induced Draft Fan

CPU = CO2 COMPRESSION & PURIFICATION UNIT

PRE SCRUBBER

H2O Remover

Pumps & Heat Exchangers

Stack

Fabric Filter

IDF(1x100%)

Air 

Intake

FDF

(1x100%)

10

Existing 

Air 

Heater

11

Callide A Unit 4 ‐

After Oxfuel Retrofit

11

Oxy‐firing schematic

FD fan

O2

Oxy‐firing mode changes

Flue Gas Composition Air‐Firing mode O2 Sequence RFG Mode Oxy‐mode

O2 vol %, dry 4.7 6.0 6.8 5.4

CO2 vol %, dry 15.0 16.2 59.9 68.3

CO ppm, dry 18 20 12 12

SO2 ppm, dry 220 230 800 890

NO ppm, dry 550 720 1195 965

NO2 ppm, dry 9 10 45 46

H2O vol % 8 8.5 20.5 21.6

NOx ppm, dry @ 7% O2 480 680 1220 910

NOx ppm, dry @ 12% CO2 445 540 250 180Flue Gas to 

Stack kg/s (wet basis) 54 59 15.4 14.0

NOx g/s 43 61 21 15

Air‐firing mode means normal air firing

O2 sequence means increased O2 to the boiler via O2 injection nozzles but no recirculation of flue gas

RFG mode means that the recirculated flue gas sequence has been completed

Oxy‐mode means that on completion of the RFG sequence the overall O2

is reduced to normal levels and full oxy‐mode is 

achieved

Flue gas mass balance

Parameter Unit CPU inlet CO2

product

Flow rate  kg/s 1.7 0.9

Composition % 65% (CO2) 99.9 (CO2)

Temperature C 145 ‐30

Pressure kPa (abs) 101 1,600

Blower

IDF

FDF

CPU: 1.7 kg/s

Stack:13 kg/s

To boiler:28 kg/s

From boiler:42 kg/s

Carbon dioxide capture plant

Courtesy of Air Liquide

LP ScrubberDriersHP Scrubber

Compressor

Cold box/inerts separators

Oxygen plant CO2

capture plant

COP – Site Works – Oxygen and CO2

Capture Plant

1 year NEDO Study led by IHI together with CS Energy and Air LiquideOption 1 –

1000 MWe Oxyfuel boilerOption 2 – 250 MWe oxyfuel boilerOption 3 – Hybrid Oxyfuel Power Plant (HOPP) concept 750 MW Ultra supercritical boiler + 

250 MW ultra supercritical boiler

Hybrid Oxyfuel Power Plant (HOPP) Concept

Concluding comments

1.

Callide Oxyfuel Project – ASU and Oxyfuel plant has been operating since  March 2012

2.

Over 300 hours of oxyfuel operation since 22 August 2012

3.

CO2 capture plant commissioning – in progress

4.

NEDO study on future CCS commenced in July 2012

5.

COP is still evaluation options for CO2 storage or sale of CO2 for industrial  applications

Thank you

for more information:  www.callideoxyfuel.com

Callide Oxyfuel Project –

Participants