power generation group - university of newcastle · © 2011 babcock & wilcox power generation...

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

Lecture 7: Oxycombustion

Considerations for FutureGen

2.0 Design

D.K. McDonald, Technical Fellow, Babcock & Wilcox September 12, 2011, afternoon session

APP Oxy Fuel Working Group Course

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Oxygen

Nitrogen

CO2

Nitrogen

+ Coal

Air0

25

50

75

100

Per

cen

t b

y V

olu

me

N2

Flue Gas after WFGD

O2

N2

CO2

H2

O

Oxygen CO2

+ Coal

CO2

CO2

CO2

0

25

50

75

100

Per

cen

t b

y V

olu

me

SyntheticAir

CO2

FlueGas to CPU

O2

H2

OH2

O 70-80% reduction in flow rate to

CO2 compression

process Lb/hr

Typical Air Fired Combustion Oxy-Coal Combustion


Warm RecycleAir Fired Oxy Fired

CO2 21.26% 77.25%H2O 8.15% 12.49%SO2 0.07% 0.13%

O2 2.95% 2.80%N2 67.57% 4.50%Ar 0.00% 2.83%

100.00% 100.00%

GAS COMPOSITION (mass)


Plant size (MWe)

2003 2005 2007 2013

SBS I – Pilot tests

30 MWth CEDF Demo

2009 2011 2015

1000

10

1

100Eng

Studies(25-790MWe)

Integration Study

200 MWe FutureGen 2.0ASU EfficiencyOptimization

Callide & CIUDEN CPU Pilots

650 MWegEng Study

Lacq Oxy-Gas Tests Burners & CPU Test,

BWRC Component Test

700 MWeg Reference

SBS II – Pilot tests


• Process Selection• Recycle Quantity• Gas Quality Control Equipment Selection• Corrosion• Air infiltration


• Process Selection Coal composition Permissible sulfur level in the boiler Composition required to Compression Process Economics

• Gas Quality Control Equipment Selection Wet or Dry scrubber Permissible sulfur level in the boiler SO3

control Economics

Baghouse or ESP


ConstituentHeating Value 10,500 Btu/lb

(24,780 kJ/kg)Carbon 58.61 %Sulfur 3.2 %

Hydrogen 4.2 %Moisture 16.57 %Nitrogen 1.17 %Oxygen 7.1 %Chlorine 0.16 %

Ash 8.99 %


Pulverizers

Coal

BoilerPJFF

Primary Fan

Secondary (FD) Fan

ID FanBurners

Airhe

ater

Air Fired Plant ‐

Wet Scrubbed

SCR

PAC

WFGD

Pulverizers

Coal

BoilerPJFFSDA

Primary Fan

Secondary (FD) Fan

ID FanBurners

Airhe

ater

SCR

PAC

Air Fired Plant ‐

Dry Scrubbed


Pulverizers

Coal

Boiler

PJFFSDA

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

PJFF

Recycle

Heater

Recycle

Damper

Air Intake

Air Intake

Recycle

Damper

Gas

Cooler

Warm Recycle Process

CPU

To Storage

Gas

Htr

DCCPS

Stack

Damper


Pulverizers

Coal

Boiler

PJFF WFGD

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

Recycle

Heater

Air Intake

Air Intake

Gas

Cooler

Cool Recycle Process Wet Scrubber

CPU

To

Storage

Gas

Htr

DCCPS

Gas Htr

Sorbent for SO3

CPU

Vent

Stack

Damper

Secondary

Recycle

Damper

Primary

Recycle

Damper

Pulverizers

Coal

BoilerPJFFSDA

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

Recycle

Heater

Secondary

Recycle

Damper

Air Intake

Air Intake

Primary

Recycle

Damper

Gas

Cooler

Cool Recycle ProcessDry Scrubber

CPU

To

Storage

Gas

Htr

DCCPS

Stack

Damper

CPU

Vent


Pulverizers

Coal

Boiler

PJFF WFGD

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

Recycle

Heater

Recycle

Damper

Air Intake

Air Intake

Recycle

Damper

Gas

Cooler

Cold Recycle

Process

CPU

To

Storage

Gas

HtrDCCPS

Sorbent for SO3


DRY SCRUBBER • Lower capital, higher operating (more economical with

lower sulfur coals)• Removal is limited by ability to evaporate the water

fed with the reagent as slurry• Limit is set by:

Inlet gas temperature and moisture content

Desired approach to saturation temperature

Saturation temperature (10C-20C higher for oxycombustion due to moisture in flue gas)

WET SCRUBBER• Higher capital, lower operating (more economical with

higher sulfur coals)• Removal limited by reagent reactivity and mixing• Unaffected by moisture in flue gas


Recycle Rate

Typically 70%-80% of the total flue gas leaving the

boiler Significant reduction does not reduce cost

Reduced Recycle Increases flame temperature Increases furnace heat fluxes Increases FEGT Decreases volume flow


Recycle Rate Significant reduction does not reduce cost

Increases constituent concentrations Increased corrosion potential More difficult to achieve high removals

Shifts heat transfer the wrong way Reheat is more difficult Increasing steam temperatures (efficiency) is more difficult

Increased cost of materials exceeds weight reduction

GQCS cost reduction is to the square root of volume flow reduction (50% flow reduction ≈

30% material reduction)


Subcritical Boiler Supercritical Boiler

Convection Pass

Furnace


Coal

BoilerBoiler

Steam; 2400psi, 1000F/1000F

PJFFPJFF WFGDWFGD

Primary Fan

Secondary (FD) Fan

ID Fan

ASUASU

Burners

Recycle Damper

Air Intake

Air Intake

Recycle Damper

Cool Recycle Process

CPUCPU

To Storage

Gas Gas HtrHtrDCCPSDCCPS

Gas HtrGas HtrSorbent for SO3

Recycle Heater

FD Fan

VentStack Damper


0.00%

0.10%

0.20%

0.30%

0.40%

0.50%

0.60%

0.70%

0.80%

0.90%

0% 2% 4% 6% 8% 10% 12%Percen

tage

Points of Net Efficiency Pe

nalty

Air Infiltration (% theoretical air)

Net Efficiency Penalty

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

0.5

0% 2% 4% 6% 8% 10% 12%

Increase in LCO

E ¢/kW


LCOE Penalty

0

10

20

30

40

50

60

70

80

90

100

0% 2% 4% 6% 8% 10% 12%

Breakeven Capital Investm

ent in Millions of $


Capital Investment to Mitigate


Coal

BoilerBoiler

Steam; 2400psi, 1000F/1000F

PJFFPJFF WFGDWFGD

Primary Fan

Secondary (FD) Fan

ID Fan

ASUASU

Burners

Recycle Damper

Air Intake

Air Intake

Recycle Damper


CPUCPU

To Storage



Recycle Heater

FD Fan

VentStack Damper


--+ - ++

+

++

+ +

+ Operating pressure above atmospheric

- Operating pressure below atmospheric


Coal

BoilerBoiler

Steam; 2400psi, 1000F/1000F

PJFFPJFF WFGDWFGD

Primary Fan

Secondary (FD) Fan

ID Fan

ASUASU

Burners

Recycle Damper

Air Intake

Air Intake

Recycle Damper


CPUCPU

To Storage



Recycle Heater

FD Fan

VentStack Damper

S Above sulfuric acid dew point

W Above water saturation temperature

S

WS W

W

W

W

W

W

S

S

S

WW


Thank You!

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