Happipoltto. Arto Hotta Foster Wheeler Energia Oy. CCS Seminaari Hanasaari, Espoo

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1 Happipoltto Arto Hotta Foster Wheeler Energia Oy CCS Seminaari Hanasaari, Espoo

2 Contents of Presentation Background Oxyfuel - General Foster Wheeler s activities on Oxyfuel

3 Background Main Technology Options to reduce CO 2 in Power Production with Fossil Fuel Short and medium term approach to CO 2 reduction: Increase of efficiency Co-firing of coal with fuels considered CO 2 neutral Main technology options for CO 2 capture in power production Post-combustion capture Pre-combustion capture Oxy-fuel combustion

4 Impact of efficiency improvement and co-firing on CO 2 reduction CO 2 emission (g/kwh) % coal % biomass Average Europe % % biomass CFB today 37% Thermie SR Thermie Ultimo % biomass on LHV Net efficiency (lhv, %)

5 Principle of Oxyfuel Technology In Oxyfuel combustion nitrogen oxides in boiler flue gas are replaced with CO 2 The air separation unit (ASU) is used to separate O 2 and N 2 from air and produce nearly pure oxygen for combustion O 2 mixed with recycled flue gas is used as oxidant, which replaces the combustion air. The O 2 content in combustion can be the same as in air firing. The flue gas from boiler will consist mainly of CO 2 and water vapour, which will enable the capture of CO 2 in CPU (Carbon Processing Unit)

6 Oxyfuel Combustion Process Air Air separation N 2, (Ar) % O 2, (Ar, N 2 ) Flue gas recycle Vent gas Coal Boiler Flue gas cleaning CO 2 /H 2 O Condensation Compression Purification CO 2 Steam turbine G H 2 O Transport Storage

7 Source: Vattenfall Oxy-Fuel Combustion Process

8 Status of Oxy-fuel development Vattenfall has successfully operated Schwarze Pumpe 30 MWth Oxy pilot: PC boiler supplied by Alstom Construction of Callide Oxyfuel 30 Mwe Demonstration in Australia has started Totals pilot in Lacq started oxyfiring (oil, gas) Babcock Willcox has started testing in 30 MWth Oxy-Coal Test Facility (PC) Doosan Babcock Energy has started up 40 MWth Oxyfuel Combustion System (PC) Construction of CIUDEN s CCS technology Platform started. Oxy CFB and PC piloting in 30 MWth scale Several other pilot and demonstration projects planned or under condtruction Source: Vattenfall EEPR (European Energy Program for Recovery) proposes two Oxyfuel projects out of total six demonstrations to be funded: Vattenfall (Oxy PC) 250 Mwe Jänswalde ENDESA/CIUDEN (OXY CFB) 300 Mwe Compostilla

9 CCS Technology Development at Foster Wheeler CCS will be essential in meeting the challenge to cut the global GHG emission Of the main technology options, FW is mainly focusing on Oxyfuel combustion in Circulating Fluidized Bed (CFB) boilers (PC technology in North America). Development carried out in parallel as Internal development (modeling/design tools, boiler engineering, economics,...) Partnership in R&D with research institutes and universities (pilot testing, modelling, etc.) Participation in public R&D Demonstrations

10 Foster Wheeler Developes CFB Technology for Oxyfuel Combustion CFB Technology is proven and available in utility scale Foster Wheeler is the market leader in CFB Technology with nearly 30 years and 22 GWe 350 CIRCULATING FLUID BED (CFB) BOILERS Tot. >24 GWe CFB Total MWe CFB sold 309 in operation for variety fuels: coal, lignite, petroleum coke, biomass, RDF, etc. 32 under construction 465 Mwe OTU CFB in commercial operation 18 % 9 % 4 % 2 % 67 % COALS PET COKE BIO LIGNITE OTHERS Offering up to 800 MWe

11 Oxyfuel CFB Technology Flexi-Burn Main Benefits Further potential to use high O 2 contents Reduce boiler size The established CFB advantages exist also in CFB oxycombustion: low furnace temperatures, hot circulating solids, long solid residence time Multi-fuel capability (coal, petroleum coke, lignites, biomasses), simple feed systems capability to utilize cheap fuels emphasized due to CCS efficiency penalties NO x and SO x reduction without back-end cleaning Good fuel burnout and sorbent utilization Efficient heat transfer and uniform heat flux Enables Flexi-Burn CFB boiler design: the same boiler can be operated in air firing or oxy firing mode with CCS Limited capability for air firing "Flexi-Burn TM " is trademark of Foster Wheeler AG

12 Challenges of Oxyfuel CFB Technology Understand the significant change in gas atmosphere in OXY mode Changes in hydrodynamics Behaviour of materials Emissions prediction Adaptation of design tools Achieve high gross efficiency to minimize penalty Aim at steam parameters > 600 C, 270 bar Reduce oxygen production costs System-level integration to reduce investment costs and to improve efficiency Oxy-fuel CFB is considered technically viable Experiments in bench scale and pilot test facilities combined with modelling required to confirm the process performance and material behaviour in the CO 2 rich atmosphere Demonstration in 10 s of MW scale and commercial scale required to proof the concept - design, performance and economics

13 CCS technologies Oxy-Fuel Technologies Efficiency Penalty Maximizing gross efficiency to minimize penalty Reduction of oxygen production costs High internal power consumption Air separation and CO 2 compression requires massive amounts of energy... System-level integration Space requirements...resulting in 8-12 %- points lower efficiency Fuel input 2026MW 100% Original electricity output 865MW (42.7%) Air separation 137 MW 6.8% CO 2 compression 71 MW 3.5% 689MW output 34% Efficiency (net), % Cooling 1084MW (53.5%) Source: Auxiliaries 45 MW 2.2% Chalmers / Andersson Reference plant O2/CO2 plant

14 Oxy-Fuel power plant requires large space for ASU and CPU Flue gas recycle Flue gas condenser 80 m 200 m BOILER ISLAND Oxygen 80 m 100 m ASU 1 ASU m CO 2 COMPR.

15 Secondary air flue gas to stack n n+1 n-1 n Primary air Development of OXY CFB Technology Integrated Experimental and Modeling Work for Scale-Up Bench scale Pilot scale 10 MW scale Boiler scale BENCH SCALE REACTOR (BFB/CFB) CIRCULATING FLUIDIZED BED REACTOR ŁAGISZA 460 MWe supercritical OTU CFB Observation port Cooler Cyclone Gas cooling Sampling port/deposit probe EXPERIMENTAL SCALES To Stack Filter Cooler/heater Fuel batch feed Continuous fuel feed To stack Observation and sampling port/ Deposit probe Sampling port Primary Zone 4 cyclone Zone 3 Zone 2 Secondary cyclone Sampling port Secondary air Sampling port Fuel container 1 and 2 Additive container Zone 1 CO2 / N 2 O 2 Sampling port O2, CO2, CO, N2, SO2, NO Secondary gas (preheated) Air PC control and data logging system Primary gas heating Air PC control and data logging system Primary gas heating 1D-MODEL n τv = b exp( A/ T)( d / d ref ) MODELS AND DESIGN TOOLS Model analyses Volatile, moisture release CO combustion Mixing Char combustion dy CO = kefy d CO t kef = 1/(1/ k CO + τm) dmc n rc = = kmc XO2 dt kw /m 2 Models for phenomena 1-D process models (stationary, dynamic) kw/m 2 1-D design model 3-D process model

16 Development of Flexi-Burn CFB Main Activities Of the main CCS technology options, Foster Wheeler is mainly focusing on oxy-fuel combustion, having been developing it since 2003: Knowledge and design tool development Test activities (VTT bench scale & small pilot CFB) Conceptual and feasibility studies (boiler design) Pilot test activities at larger scale facilities ~0.1 MW th (current) ~1 MW th (2009) 30 MW th CIUDEN (2011) In parallel, scale-up of air-fired CFB boilers has continued. The world largest and first SC-OTU CFB at PKE s Lagisza plant in Poland is in commercial operation and and FW has developed the OTU CFB boiler concept further up to MW e size with 600 C steam temperature. The Spanish government has decided on investment for the CIUDEN 30 MWth class pilot CFB facility, which provides a full experimental CCS platform for the demonstration and validation of oxy/air fuel combustion in sufficient scale to allow continuation to commercial scale.

17 Development of Flexi-Burn CFB Main Activities The Oxy-CFB 300 MW e project of ENDESA and CIUDEN has been shortlisted as one of the CCS demonstration project to be funded from EEPR (European Energy Program for Recovery) program FW has prepared a feasibility study for the 500 MWe Oxy CFB Power plant with CCS for ENDESA FW is a cobeneficiary in Oxy-CFB 300 EEPR project and will develop the technology for the Oxy CFB boiler Feasibility studies with other utilities Vattenfall 500 MWe CHP power plant with Oxyfuel CFB PVO 500 MWe multifuel Oxy ready CFB plant (biomass cofiring) EU FP7 project "FLEXI BURN CFB aiming at the development of technology to be ready for demonstration FW participates in the development of 50 MW e Oxy-CFB demonstration project at Jamestown plant in New York state and the 78 MW e Oxy-CFB project developed by Praxair and New Holland Board of Public Works.

18 Development of Flexi-Burn CFB Scale-Up Path Existing know-how Supply of over 300 CFB boilers up to 460 MW e Long-term development of design tools Background for engineering Commercial scale Flexi-Burn Oxy CFB technology demonstration in <500 MW e size by 2015 Lagisza 460 MW e OTU CFB Scale-up information from the world's largest CFB Experiences of the world's first SC OTU CFB Design model validation CIUDEN - demonstration of Flexi-Burn CFB Air- / oxy-fuel combustion with fuel flexibility CO 2 separation Scale-up criteria Air- / oxyfiring + CCS expertise Flexi-Burn Oxy CFB technology commercial up to 800 MW e size by 2020

19 Conclusions The piloting done both with PC and CFB technologies have shown the viability of Oxyfuel Oxyfuel is a realistic option for CCS Large scale demonstration of Oxyfuel will be supported by EU The Oxy CFB development targets to have the commercial scale CCS demonstration plant in operation in 2015 and the technology to be commercial in 2020

20 Thank You!