challenges to demonstration what is the current status to ... · challenges to demonstration what...

Challenges to DemonstrationWhat is the Current Status to the Development

of Oxyfuel Combustion Technology

Stanley SantosIEA Greenhouse Gas R&D Programme

2nd Flexiburn Workshop6th February 2013

2

IEA Greenhouse Gas R&D Programme

• A collaborative research programme founded in 1991• Aim: Provide members with definitive information on the role that

technology can play in reducing greenhouse gas emissions.• Producing information that is:

Objective, trustworthy, independentPolicy relevant but NOT policy prescriptiveReviewed by external Expert ReviewersSubject to review of policy implications by Members

• IEA GHG is an IEA Implementing Agreement in which the Participants contribute to a common fund to finance the activities.

• Activities: Studies and Reports (>120); International Research Networks : Wells, Risk, Monitoring, Modelling, Oxyfuel, Capture, Social Research, Solid Looping; Communications (GHGT conferences, IJGGC, etc); facilitating and focusing R&D and demonstration activities e.g. Weyburn

3

Members and Sponsors

4

3rd Oxyfuel Combustion ConferenceLeon, Spain9th – 13th September 2013 ABSTRACTS Deadline:

Extended – 6th February 2013

5

UPDATE TO THE CURRENT DEVELOPMENT OF OXYFUEL COMBUSTION

1980’s

ANL/Battelle/EERC completed the first industrial scale pilot plant

1990 - 1995

EC Joule Thermie Project - IFRF / Doosan Babcock / Int’l Combustion

NEDO / IHI / Jcoal Project

First large scale 35MWt Oxy-Coal Burner Retrofit

Test done by International Combustion

1998 – 2001

CANMETUS DOE Project / B&W / Air Liquide

2003 - 2005

Vattenfall (ENCAP ++)CS Energy / IHI Callide Project

B&W CEDF 2008 30MWth CoalAlstom Alstom CE 2010 15MWth CoalDoosan Babcock DBEL - MBTF 2009 40MWth Coal

Alstom Schwarze Pumpe 2008 30MWth LigniteHitachi Babcock Schwarze Pumpe 2010 30MWth LigniteIHI Callide 2011 30MWeAlstom / AL Lacq 2009 30MWth Gas/Oil?CIUDEN El Bierzo CFB Facility 2011 30MWth Coal

El Bierzo PC Facility 2011 20MWth Coal

Coal

CIUDEN

2007

B&W CEDF (30MWt) large scale burner testing started

Updated by S. Santos (20/08/12)

2008

World’s FIRST 30 MWtfull chain demonstration at Schwarze Pumpe Pilot

Plant

By the end of 2010/2011, Users (i.e. Power Plant

Operators) will have 6 burner manufacturers fully

demonstrating “Utility Size Large Scale Burners” which should give a high level of confidence

toward demonstration

2009 – Lacq –World’s first 30MWt retrofitted Oxy-NG

boiler2011 – CIUDEN –

World’s first 30MWt Oxy-CFB Pilot Plant

2011 – Callide –World’s first

30MWe retrofitted Oxy-coal power

plant

By 2014-2018

Demonstration of 50– 300MWe full scale power plant.

Target :“Commercialised by 2020”

KEPCO/KOSEP - Yongdong (PC - 100MWe)FutureGen2 - Illinois (PC - 168MWe)

Endesa/CIUDEN - El Bierzo (CFB - 300MWe) - ???

China: 3 Oxyfuel Projects – in progressUK: Drax Power Plant Oxyfuel

7

Concluding Remarks –Update to Key Demonstration Projects• Based on the Conclusions from 2nd Oxyfuel Combustion

Conference – This Technology is READY for DEMONSTRATION

• Lost of Janschwalde Project is a setback…• Success in the commissioning of Callide Project is an important

milestone.

• Two important projects on-going…• FutureGen2 (USA)• Yong Dong Project (South Korea)

• Other new projects – currently under development• White Rose Project (UK)• SIEG Project (China)• Datang Project (China)• Huazhong Project (China)

8

WHERE WE ARE TODAY…

Thank you

for more information: www.callideoxyfuel.com

Callide Oxyfuel Project

Callide A Unit 4 - Original

10

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

11

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

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%)

12

Existing Air Heater

13

Callide A Unit 4 - After Oxfuel Retrofit

13

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

16

Key Messages from Callide Project

• Callide Project has demonstrated the retrofittability of the oxyfuel combustion to an old boiler…

• Given the another year to operate – therefore helping to achieve the 10000 hours operation milestone – which could be used as reference for performance guarantees.

• Time now to review and re-evaluate our options… What is the best business model to demonstrate oxyfuel combustion technology

Boiler

Coal Bunkers

Ash SiloGypsum

Pile

CPU

ASU

PJFF

Recycle Heater

(Airheater)

WFGD

DCCPS

PR Fans

ID Fans

SR Fans

Reagent Prep

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

24

Scope of Work• Boiler retrofit led by Doosan Heavy Industry

• Conversion of downshot anthracite fired boiler to a wall fired boiler using sub-bituminous coal.

• Deployment of in-furnace DeSOx• Development of the Flue Gas Processing or

Environmental Island led by KC Cotrell• Demonstration of both Dry and Wet ESP• FG Condenser (FGC) – based on 2 column design –

combined with NaOH/Na2CO3 wash• ASU and CPU based on process design to be

developed by Daesung.

Organization

Project Coordinator

Project 1 Project 3Project 2

Role : Management/Adjustment/Guide)

Organization : KEPCO RI

Role- Development of Technology of

Process Control & Operation forOxy- PC Power System

- Basic Design of Demo. Plant

Organization : KEPCO RI

Consortium : KOSEP, DIGC, DHIC,KITECH

Role : Development of Environmental Control System for Oxy-PCPower System

Organization : KIMM

Consortium : KC-Cottrell, Yonsei Univ.

KAIST

Project Outline

25

Role : Basic Design of Oxy-PC Boiler

Organization : DHIC

Coal Yard

FGD

TBN & Gen

ASU & CPU

Boiler Island

ESP

Ash Pond

Arrangement Plan of Main Facilities

26

What We Have Done

27

Tentative Demo. Site (Youngdong TPP) Project Outline

Feasibility Study Result (Boiler) What We Have Done

28

The Retrofit Case was selected to apply for verified Oxyfuel technology maximizing use of exiting boiler components & layout

Basic Design Conditions for ASU Remarks

ASU Type Double Column Cryogenic

O2 Purity 95%

Oxy modeGO2 Producing, 20,000 Nm3/hLO2 Back-up, 40,000 Nm3/h

1/3 Vs Full Load

Demand

Air Mode 20,000 Nm3/h LO2

Capacity of LO2 Tank

8,000 m3 For 6days Oxymode Operation

Time for LO2production

11 ~ 12 days For During Air Mode

Basic Design Conditions for CPU Remarks

CPU Type Cryogenic

Capacity 10% Vs Full Load Demand

CO2 Phase GCO2, LCO2Depend on Operation

Mode

ASU & CPU

29

What We Have Done

< deSOx System >

Environment Control System

CPU

Wet-EP

FGR-2

FGR-1

Dry-EP

FGC

In-furnacedeNOx, deSOx

Dust : 22 /NDust : 22 /NSO : 150ppmSO : 6ppm

Dust : 1.23Dust : 1.23 /NSO : 6ppmSO : 0.144ppm



Dust : 1.23 /NDust : 1.23 /NSO : 6ppmSO : 0.144ppm

< Dry-EP >

< Wet-EP >

30

What We Have Done

Test Bed -Environment Control System

217OC1155Am3/hr

In-furnacedeSOx

Dry EP

Heat ExchangerWet EP

FGC

31

What We Have Done

Demo.100MWe

Detail Design/ Construction

Basic Design

ConceptualDesign

Commercialization500MWe

Developmentof Advanced

Oxy-PC PowerPlant

[2007~2010]

[2010~2012]

[2012~2015]

[2015~2017][2017~2020]

[2020~]

KOCRO Plan What We Will Do

37

Development of Oxyfuel Combustion in China is now geared toward full scale

demonstration of the technology... Consequence of shelving of Janschwalde Project means that Europe could lose

grounds in the development of oxyfuel combustion

38

Oxyfuel CombustionR&D Development – HUST • Features of the 35MWt Oxyfuel Pilot

Plant• Supported granted under MOST 863

Programme• Project led by Huazhong University of

S&T and Others.• Goal:

• To set up a full demonstration plant combiningcarbon capture, storage and utilization

• Scale:• 35 MWt oxy-fuel combustion boiler with

100,000 t/a CO2 storage

• Location: Yingcheng, Hubei Province• Technology:

• Oxy-fuel combustion + storage in salt mines

• Status: Expected Start Up - 2014

39

Datang Oxyfuel Demo Project• Daqing 350MWe + heat Project • Full size Oxyfuel Combustion

CO2 Capture • Cogeneration of Heat and

Power based on SC PC Boiler using lignite

• Location: Daqing, Heilongjiang province

• EOR and CO2 storage: adjacent to PetroChina’sDaqing oil field for EOR, near Songliao basin for geological sequestration

40

SIEG Oxyfuel Demo Project• Shanxi SIEG Project is

based on 350MWe Power Plant (To capture ~2 MTPY CO2)• Project Based on Joint US-

China Fossil Energy Protocol• Pre-feasibility Study

Completed• Partnership with Shanxi

International Energy Group (SIEG)

• Key Technology Partners:o B&W – providing technology for

boiler and environmental islando APCI – providing ASU and CPUo WVU – providing support for CO2

storage

41

Concluding Remarks - China• Success to demonstrate oxyfuel

combustion technology in China would require the following:• Cost effective CCS technology • Reliable CO2 Storage • Outside funding for project execution • Special power tariff / EOR or other utilisation

schemes • MOST endorsement of CCS capture technology

and storage technology • NDRC approval of project execution

42

LOOKING BACK AND WHERE WE ARE IN THE DEVELOPMENT OF OXY-CFB…

Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005

OXYCFBRoadmap/OxyCFB development

Foster Wheeler OXYCFB Concept

-Design 500 MWe

PHASE 1:OXYCFB Process study OXYCFB power plantCost studyMarket study

2004

Private R&D

Demo OXYCFB OTU Unit-250 MWe

OXYCFB Demo 1-20 – 50 MWe-O2 (21 – 35 %)

2006 2008 2010 2012 2014

R&D in consortiums

EU/US Demo 2

EU/US Demo 1

CiudenCFB Test

Facility

300MWe OxyCFB

Demo.(2015)

Inaugural Workshop on OxyFuel Combustion, Cottbus, November 29.-30., 2005

Air Design 60 % O2 Design

OxyCFB boiler performanceCombustion process, 3-D study

Air Design 60 % O2 Design

Oxygen concentration Temperature

Prof. Dr. V. J. Cortes

FUNDACIÓNCIUDADDE LA

ENERGÍA

EL BIERZOFACILITY FOR

CO2 ABATEMENTAND

CAPTURE

January 2007

45

PROCESS DIAGRAM

AIR

FGR2

COAL

AIR

AUXILIARYBOILER

UB-01-01B

ESPPE-10

CO2

ABSORPTIONPLANTU-05

SUPER-CRITICALSECTION

MAINBOILER

UB-01-01A

CO2

HIGH EFFICIENCYDeSOXU-03

O2

COALFEEDER

BALLMILL

HYBRID COLLECTOR

BAG FILTERFM-10

CO2

COMPRESSION TRAIN

CONDENSER COMPRESSORS

PREHEATINGTRAIN

DeNOXU-02

H2O

FGR1

STACKCH-50

CALCINATORU-04BCARBONATOR

U-04A

NG O2

CARBONATION/CALCINATION

BIOMASS

O2, N2, Ar

EXPANDER

COOLERE-51

BAGFILTERFM-50

Presented at the 2nd Oxyfuel Combustion Workshop – Windsor, CT, USA

46

3RD OXYFUEL COMBUSTION WORKSHOP AT YOKOHAMA, JAPAN IS A BIG MILESTONE FOR OXY-CFB DEVELOPMENT…

TEST FACILITY FORCO2 CAPTURE

TECHNOLOGIESEL BIERZO



Prof. Dr. V. J. CortésMarch 2008

The upgradeORIGINAL DESIGN JANUARY 07

+

POSTCOMBUSTIONADSORPTION

(1 MWth)

POST-COMBUSTIONABSORPTION(O,5 MWth)

+

OXYBOILER(4 MWth)

CONVENTIONALBOILER(4 MWth)

REVISED DESIGN NOVEMBER 07

+ +

OXYBOILER(20 MWth)

LFC(15-30 MWth)

POST-COMBUSTIONABSORPTION

(4 MWth)

POSTCOMBUSTIONADSORPTION

(X MWth)





Prof. Dr. V. J. CortésMarch 2008

Model of the plant

Fuel preparation

Oxygen supply

CombustionIslandFGC

CO2 compressionChemical absorption

ControlRoom

49

50-100 MWe

200-300 MWe

150-200 MWe

400-600 MWe

300-400 MWe

Module

Demonstration will enable scale-up to 600 MWe

CFB Process Scale-up and Modularization

50

Jamestown BPU Power Plant Site

Dresser-Rand

Battelle Labs

Jamestown

Foster Wheeler

University at Buffalo

Praxair Ecology and Environment

Battelle LabsFoster Wheeler

University at Buffalo

E & E

Dresser-RandJamestown

New York StateExisting PC Boilersand Gas Turbine

New 50 MW CFB Site(Base Project)

New ASU andCO2 Plant site

51

WHERE WE ARE TODAY…

524th APP OFWG Oxyfuel Capacity Building CourseTokyo Institute of Technology, Tokyo, Japan – September 2nd- 3rd , 2012

FUEL PREPARATION

BIOMASS GASIFIER

PC BOILER20 MWth

CFB BOILER30 MWth

TECHNICAL BUILDINGS AND CONTROL ROOM

FLUEGAS CLEANING

FLUEGAS RECIRCULATION AND

MIXING

CO2

PURIFICATION

CO2 TRANSPORT RIG

es.CO2 Centre


FUELPREPARATION

SYSTEM

DeNOX

15-30 MWthCFB

BOILER GAS

CLEANINGSYSTEM

COMPRESSIONAND

SEPARATION UNIT

MIX ANDPREHEATING

SYSTEM

20 MWthPC

BOILER

PREHEATINGTRAIN

AIR

FGR1

O2 STORAGEAND

VAPORISATION

O2PREHEATING

FGR2

HIGHEFFICIENCY

DeSOXMIXERSBAG FILTER

STACK

BAG FILTER

CO2

EXPANDER

CPU

FGR2

REC

IRCU

LATI

ON

FGR1

REC

IRCU

LATI

ON

FROM BIOMASSPREPARATION

BIOMASSBIN

GASTREATMENT

BIOMASSGASIFIER

CYCLON

ENGINE

TORCH

es.CO2 Centre


Furnace Dimensions (m) 20x2.9x1.7

MWth maxoxycombustion 30

O2 consumption (kg/h) 8,775

Flue gas recycle (kg/h) 25,532

Flue gas (kg/h) 28,800

Coal consumption (kg/h) 5,469

Limestone feed (kg/h) 720

Steam (t/h) 47.5

P(bar) / T (°C) 30 / 250

CFB Boiler

55

What are my expectations in today’s discussion on OxyCFB...

• Understanding the key points in boiler development issue (including scale up/down and dual operation mode).• Overall Performance (Boiler efficiency, corrosion issue,

etc...)• Flue Gas Recycle Ratio• Heat Transfer• Emissions (NOx, SOx, Others)

o N2O Emissions (which should impact the design of the CO2 processing unit)

• Limestone performance• Management of Air Ingress issue• Etc... Etc... Etc...

56

WHAT COULD BE THE FUTURE OF OXY-CFB…

57

Unit Capacity (MWe)

0

100

200

300

400

500

600

1970 1975 1980 1985 1990 1995 2000 2005 2010Start-Up Year

Pilot Plant Oriental Chem

Lagisza

JEA

Turow 1

VaskiluodonNova ScotiaTri-State

General Motors

20XX

CIUDEN TDP

AIR-FIRED OXY-FIRED

Pilot Plant

Development of OxyCFB

Demo-Scale(100 MWe)

Commercial-Scale(>400MWe Class)

58

Concluding Remarks –CIUDEN & Oxy-CFB Development

• CIUDEN’s Test Facility is very unique in the world…

• Europe can’t afford to lose this asset. Otherwise, lose it core competence in the development of this oxyfuel combustion technology…

• It is important that CIUDEN’s test facility to become the centre of excellence and the hub for training on oxyfuel combustion technology…

• We still have a lot to do and a lot to learn…

challenges to demonstration what is the current status to ... · challenges to demonstration what...

Documents