Oxycombustion for carbon capture on coal power plants: advantages, innovative solutions and key projects

Transcription

1 Oxycombustion for carbon capture on coal power plants: advantages, innovative solutions and key projects Jean-Pierre Tranier, Nicolas Perrin, Richard Dubettier, Claire Bourhy-Weber Oxyfuel Combustion Conference (OCC3), 9-13 th September 2013, Ponferrada, Spain

2 Agenda Technical achievements and advantages of OxyC Challenges and innovative solutions Key projects Application of Cryocap TM to industrial processes 2 September 2013 OCC3, Ponferrada, Spain

3 Improvements in energy efficiency of cryogenic ASU* * ASU: Air Separation Unit (O 2 production) 260 Separation Energy* in kwh / t O % 200 Integration benefit Pure O 2 IGCC OXY LE 2013 OXY XLE 2017 Target * Compression energy not included, calculated at 15 C C, 1 atm, 60% humidity 3 September 2013 OCC3, Ponferrada, Spain 3

4 Oxycombustion performances High efficiency: ~ 7% loss today ~ 5 loss % in 2020 Cost effective CO 2 recovery above 95% CO 2 purity up to over 99.99% Lower water usage Near Zero Air emissions and in particular zero chemicals emissions: Over 99% reduction for Hg, SO 2 /SO 3, particulates Over 90% for NO X and CO Very limited liquid and solid wastes Possible reduction in LOI (Loss On Ignition) 4 September 2013 OCC3, Ponferrada, Spain 4

5 Oxycombustion additional advantages Flexibility in design and operation: Smooth operation and transitions Potential for energy storage through cryogenic liquids (ALIVE) Non intrusive in steam turbine cycle O 2 content in comburant (vs 21% fixed in air) Capex / Opex Non chemical Multi decade experience: > 100 years for cryogenic ASUs > 40 years for Oxycombustion in metals, glass, cement 5 September 2013 OCC3, Ponferrada, Spain 5

6 Agenda Technical achievements and advantages of OxyC Challenges and innovative solutions Key projects Application of Cryocap TM to industrial processes 6 September 2013 OCC3, Ponferrada, Spain

7 Oxycombustion challenges & innovative solutions Risk and safety assessment studies e.g. with Fortum and Hitachi Capture rates up to 98% cryogenics + membranes Retrofit studies and actual projects: Fortum, Total, Callide Partial capture Phasing Energy storage ALIVE 7 September 2013 OCC3, Ponferrada, Spain 7

8 Up to 98% capture rate through membranes combination TO ATMOSPHERE FLUE GAS CO 2 8 September 2013 OCC3, Ponferrada, Spain

9 Agenda Technical achievements and advantages of OxyC Challenges and innovative solutions Key projects Application of Cryocap TM to industrial processes 9 September 2013 OCC3, Ponferrada, Spain

10 Main Air Liquide CO 2 Projects (Start-up date) TOTAL Lacq - FRANCE (2010) CO 2 Free Steam Generation 30 MWth oxy-combustion boiler with CO 2 capture & storage AL scope: burners, O 2, CO 2 dryer AIR LIQUIDE Port-Jérôme, FR (2014) Green SMR CO2 capture for liquid production AL scope: investment including CPU & Membrane FUTUREGEN 2.0 USA (2017) Clean coal power plant ~165 MWe Oxy-coal Power plant with CO 2 capture for CCS AL scope: ASU, CPU & mixer CIUDEN SPAIN (2011/2012) Carbon Capture test facility 20 MWth PC & 30 MWth CFB oxy-combustion boilers AL scope: CPU ULCOS Florange - FRANCE Low CO2 Steelmaking Industrial blast furnace with CO 2 capture & storage AL scope: ASU & CPU study ENDESA SPAIN Clean coal power plant 300 MWe Oxy-coal Power plant with CO 2 capture for CCS AL scope: ASU FEED Power / steam Industrial Callide Oxyfuel AUSTRALIA (2012) Clean power pilot plant 30 MWe coal oxy-combustion boiler with CO 2 partial capture and storage AL scope: ASU, CPU 10 September 2013 OCC3, Ponferrada, Spain

11 Total Lacq (France): the only integrated Oxy-CCS operation worldwide Retrofit of a 30 MWth NG boiler to OxyC with CO 2 storage in depleted NG field. Operation AL Scope: Oxy-burners design & supply, oxygen supply and CO 2 Rich Flue Gas dryer Successful > 12,000 h dryer operation with various regeneration gases and NO x in feed gas 11 September 2013 OCC3, Ponferrada, Spain

12 The largest operating Oxy-Coal Pilot Project worldwide ~100 MWth boiler retrofit to Oxycombustion AL scope: 2 ASUs (660 tpd) & CPU (75 tpd) CO 2 Capture Start-up: December 2012 Fully upscalable CO 2 CPU pilot CPU Operation hours : >1800 (LP) and >900 (HP) 12 September 2013 OCC3, Ponferrada, Spain

13 CIUDEN Carbon Capture test platform, Spain Location: Ponferrada, Leon, Spain Owned & operated by CIUDEN 20MWthPC&30MWthCFBboilers CFB AL scope: Cryocap TM Oxy CPU technology >3000 hrs Oxy CFB, > 2200 hrs CPU operation (warm) <1ppm SO 2 at scrubber outlet <1ppm H 2O at dryer outlet Cryogenic operation close to CO 2 triple point 13 September 2013 OCC3, Ponferrada, Spain 13

14 FutureGen 2.0 large scale integrated Oxy-CCS project, USA 167 MWe gross coal power plant repowering ~1.0 Mtpy Capture in Meredosia, IL 25 miles pipeline to geological storage AL: 3200 mtpd ASU, 3500 mtpd CPU, mixer Aug. 2010: $1 billion DOE Grant awarded 2012: Pre-FEED / Phase 1 completed and PPA June 2014: FEED > 99% CO 2 Purity Removes remaining SO X X, moisture, PM, Hg, and NO X 98% CO 2 recovery 14 September 2013 OCC3, Ponferrada, Spain

15 Agenda Technical achievements and advantages of OxyC Challenges and innovative solutions Key projects Application of Cryocap TM to industrial processes 15 September 2013 OCC3, Ponferrada, Spain

16 Cryocap TM Steel for (Top Gas Recycle) Blast Furnaces CO CO 2 H2 (N 2 ) CO, H 2 ( N 2 ) CO, H 2 (N 2 ) PSA CO 2 Rich offgas CPU Export CO 2 O 2 CO, H 2 (N 2 2) ASU TGRBF principle: Nitrogen Free / Full Oxygen Blast Furnace CO 2 separation from CO and H 2 which are recycled to BF Purification and compression of CO 2 before storage / use Cryocap TM Steel ready for industrial i scale demonstration ti 16 September 2013 OCC3, Ponferrada, Spain

17 Cryocap TM H 2 project at Port Jérôme, France First Worldwide reference of Cryocap TM H 2 Technology for SMR Designed and under construction by Air Liquide on an industrial unit: 100 ktpy CO 2 capture, purification (food-grade) and liquefaction Upscalable technologies Start-up end September 2013 OCC3, Ponferrada, Spain

18 Conclusion Oxycombustion is a competitive option for new & retrofit boilers High efficiency and numerous advantages > 10 years of development large scale projects under way OxyC pursues progress versus PreC and PostC OxyC benefits from other large ASUs & Cryocap TM projects 18 September 2013 OCC3, Ponferrada, Spain 18

19 Thank you for your attention i i id nicolas.perrin@airliquide.com Total Lacq, France Callide Oxyfuel, Australia CIUDEN, Spain

20 Air Liquide s portfolio of CO 2 capture technologies Technology for the whole range of CO 2 feed and product purities CO 2 Product Purity Absorption MEDAL TM Membranes Cryogenics (CPU) CRYOCAP H 2 CRYOCAP OXY CRYOCAP Steel (V)PSA 1% 20% 40% 60% 80% 100% Feed CO 2 content 20 September 2013 OCC3, Ponferrada, Spain

21 Partial capture Phasing 4 MAC FULL CAPTURE 2 Cold boxes 100% time in Oxy 2 liquid storages 1 Cold box PHASED CAPTURE ~ 50% time in Oxy 50% time in air O 2 Flue gas 2 MAC O 2 Flue gas ASU 2 x 3500 mtpd BOILER CPU mtpd ASU 1 x 3500 mtpd BOILER CPU mtpd Cut in ASU Investment Power plant output 100 Air %Oxy 110 Power plant output Air 100%Oxy ASU power cons. CPU power cons. ASU power cons. CPU power cons. time time Boiler operated alternatively in air / oxy mode ASU operated continuously CPU stops & goes CPU preferably stopped during peak power price periods Cost efficiency: lower investment Flexibility: possibility to maximize power output during peak time (CPU off) Agility: possibility to add later a second ASU and switch to full capture 21 September 2013 OCC3, Ponferrada, Spain 21

22 Energy storage ALIVE Off-peak: low electricity prices O 2 storage Peak: high electricity prices O 2 consumption Cheap power is valued by generating O 2 ASU power Minimum output is sold to the grid Electricity to grid ASU run at minimal power ASU power Maximum output is sold to the grid Electricity to grid O 2 gas O 2 gas N 2 liquid N 2 liquid O 2 liquid O 2 liquid Surplus of O 2 is stored Stored O 2 supply for additional power generation Cheap generation of O 2 to storage Maximum power sale to the grid 22 September 2013 OCC3, Ponferrada, Spain 22

23 ALIVE principles and typical benefits 1. ASU and boiler operate out of phase 2. Part of the O 2 consumed on peak is separated - at lower cost - off peak 3. O 2 liquefaction energy transferred to liquid nitrogen and vice versa Overall Energy Storage efficiency > 95% ALIVE OPEX : ASU sized for max O 2 consumption (typical) +5% net output on peak; -10% O 2 production cost ALIVE CAPEX : ASU sized for average O 2 consumption (typical) (yp -15% ASU investment cost; -3% O 2 production cost + Improved flexibility and drastic reduction of O 2 venting 23 September 2013 OCC3, Ponferrada, Spain 23

24 Cryocap TM H 2 for Steam Methane Reforming (SMR) 10% 20% increase of H 2 Production capacity with the same SMR Reduced natural gas specific consumption 40% lower CO 2 avoided costs vs MDEA Cryocap H 2 = Smart membrane & Cryogenics integration Nat Gas Reformer Residue to Fuel gas H 2 recycle to PSA Membrane CO 2 Compressor PSA Tail gas Cryo Cold Box H 2 Product CHANGE SCHEME Dryers CO 2 Product 24 September 2013 OCC3, Ponferrada, Spain