Development of Oxyfuel Boiler & Update of Callide Oxyfuel Project (COP)

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1 Development of Oxyfuel Boiler & Update of Callide Oxyfuel Project (COP) Presentation to: The 3rd APP OFWG Oxy fuel Capacity Building Course 12 September 2011 Toshihiko Yamada IHI Corporation 1

2 Presentation Outline Background Positioning of COP IHI activities Callide Oxyfuel Project Introduction of IHI new test facility Summary 2

3 Background Development schedule (of IHI) R&D under NEDO in the 1990 s Collaboration study with Australian from 2004, and project start in Stage 1 R&D, FS under NEDO project FS of Callide Support research & study under METI R&D Joint study with J-POWER R&D of new concept oxyfuel boiler Stage 2 Demonstration Retrofit work to Demonstration existing Callide-A Commissioning Stage 3 FS of commercial-scale unit (with A-USC) Commercial Sep., 2011 Work of commercial plant 3

4 Positioning of COP Background Oxyfuel CCS Project 2011: Operation start of Callide A 2015: Operation start of over 200MWe class oxyfuel power plant Key project Janschwalde 250 Compostilla 300( 西 ) Meredosia #4 200( 米 ) 75 R&D start 4

5 Background Commercialization of oxyfuel Items Pilot Demo. Commercial Plant Test facilities of IHI Callide A??? Capacity 1MWt 30MWe MWe Boiler (Furnace) Refractory wall (φ1.3m,l:7.5m) Membrane wall Membrane wall Burner 1 burner 6 burners (Front firing) Multi burners (Opposed firing) Mill - (Batch type) 3 mills 4 6 mills ASU - (From storage tank) 330TPD x 2 units Multi units (Total: max. 17,000TPD) CO2 CPU - (Batch type) 70 t CO2/d (Partial capture) Multi units (Total: max. 19,000 t CO2/d) World largest ASU : 4,000TPD class 5

6 IHI activities Study results Combustion test & simulation Feasibility study 6

7 Combustion test Test facilities Capacity : Max. 150kg/h at coal Furnace : Vertical / Horizontal type I.D. 1.3m x L 7.5m PAF Eletctrical heater Burner : Swirl stabilized type burner PC bin Furnace Gas cooler Heat exchanger Gas cooler Bag filter IDF Stack Air Electrical heater Steam heater Water scrubber FDF/GRF O 2 System configuration Test facilities 7

8 Initial combustion test results Flame condition Flame temperature (by radiation thermometer) Air (Wind-box O 2 : 21%) Oxyfuel (Wind-box O 2 : 21%) Difficult of holding the stable flame in case of wind-box O2 of 21% in oxyfuel Need to increase the inlet-o2 in order to keep the stable flame and radiation heat transfer Oxyfuel (Wind-box O 2 : 30%) 8

9 Simulation results Simulation results Air Oxy 1 Oxy 2 Oxy 3 Gas mass flow 142t/h 117t/h 140t/h 170t/h Inlet-O2 21% 30.2% 26.5% 21.7% FEGT Base Lower Nearly equal Higher Heat absorption Base Higher Nearly equal Lower Furnace heat absorption (MW) O2 content of total gas (wetvol%) Air case Oxy case Air Oxy 1 Oxy 2 Oxy 3 Inlet-O2 of 27% in order to be approximately the same furnace heat absorption with air case 9

10 Combustion test results Flame stability Secondary gas Oil burner (for start-up) PC nozzle Primary gas Wind-box 0.8MWt 0.64MWt Air register Furnace side Combustion characterisitics Air Oxyfuel NOx, Oxy mode (mg/mj) Coal A Coal B Coal C SO2, Oxy mode (mg/mj) Coal A Coal B Coal C Carbon-in-ash, Oxy mode (%) Coal A Coal B Coal C NOx, Air mode (mg/mj) SO2, Air mode (mg/mj) Carbon-in-ash, Air mode (%) 10

11 Callide Oxyfuel Project Outline World first retrofit case oxyfuel power plant Largest capacity of 30MWe Total process from CO2 capture with power generation to CO2 storage ST G Stack N2 Coal Condenser De-dust Non-condensable gas Storage tank Air ASU O2 Boiler Flue gas recirculation CO2 capture unit Transportation P CO2 underground storage Oxyfuel Powr Plant & CO2 capture CO2 transportation & storage 12

12 Japanese Government: Funding Support JCOAL: CCT/CO2 geological storage experience Project Structure Australian Government: Funding Support Queensland Government: Funding Support Global CCS Institute: Funding Support Japan IHI: Oxyfuel pilot plant experience Boiler retrofit J POWER: O&M and CCT R&D experience Mitsui: Worldwide Project development experience Oxyfuel Joint Venture CS Energy: Australia Power plant, O&M experience Project Management Australian Coal Association: CCT/CCS knowledge Schlumberger: CO2 geological storage experience Xstrata Coal: CCT/CCS knowledge Air Liquide: ASU and CO2 Processing experience 14

13 Australia QLD CO 2 storage area Project Overview Callide A P/S Brisbane Callide A Power Station 4 x 30 MWe Steam 136 t/h at 4.1MPa, 465 o C Commissioned: Refurbished 1997/98 Placed in storage in 2002 Scope No.4 Boiler refurbishment 2 x 330 TPD ASU Oxyfuel combustion Retrofit 70 TPD liquid CO 2 recovery Trucking to CO 2 reservoir Injection and monitoring 18 May

14 Retrofit of Callide A Power Plant * O2 N2 Coal Bunker ASU * O2 A H A H2O remova l FDF/GMF Air H FGLPH Mill Boiler FF IDF To CO2 capture unit Main features of Oxyfuel Technology High CO 2 concentration in flue gas results in decreasing energy consumption of CO 2 recovery Reduced amount of air pollutants, NOx, SOx and particulates Multi introduction options, brand new power plant, boiler replacement and retrofit of existing boiler 16

15 Evaluation of Heat Absorption on the Furnace Wall Air-Firing Roof 上面 Oxy-Firing Roof 上面 (W/m 2 ) (W/m 2 ) Furnace Left 左面 Front 前面 Right 右面 Rear 背面左面 Left Front 前面 Right 右面 Rear 背面 2ry Super Heater (Furnace outlet) View from 二次 the SH inside of the furnace View from 二次 SH the inside of the furnace 17

16 Optimization of O 2 Mixing with Recycled Flue Gas *O 2 conc. & temp. on the duct wall *O 2 distribution at the inlet of burner wind-box (Optimization of O 2 nozzle) Burner wind-box O 2 Operation load 100% 100% 80% Nozzle type Type1 Type 2 Type 2 (Initial) (Optimum) (Optimum) Wind-box inlet O 2 injection nozzle O 2 conc. on the duct wall [%] (Max.) * (98%) (34%) (34%) O 2 conc. at the wind-box inlet [%] (Max.-Min.) * (3.3%) (1.3%) (0.7%) * Type of injection nozzle is optimized. 18

17 Callide A Unit 4 Original 19

18 Boiler Plant/Equipment Removed Ready for New Equipment U3 Multiclone to Remain Cable Tray to Fabric Filters to Remain Walkway to Fabric Filter to Remain 20

19 Callide A Unit 4 After Oxfuel Retrofit Oxygen Flue Gas Before Air Heaters Flue Gas After Air Heaters Flue Gas (Clean after FF bags) New Primary Gas Heater Recycled Gas Rich CO2 Flue Gas to CPU Secondary Recycled Gas Cold Primary Recycled Gas to Mills 1 of 1440 Fabric Filter (FF) Bags Hot Primary Recycled Gas to Mills New Feedwater Heater Fabric Filter FROM ASU Existing Air Heater TO CPU Air Intake v Stack Dust FDF = Forced Draft Fan IDF = Induced Draft Fan CPU = CO2 COMPRESSION & PURIFICATION UNIT ASU = AIR SEPARATION UNIT FDF (1x100%) PRE SCRUBBER H2O Remover Pumps & Heat Exchangers IDF(1x100%) 21

20 Callide A Unit 4 After Oxfuel Retrofit 22 22

21 ASU & CPU Layout Air Separation Unit O 2 : 2 x nominal 330 TPD (27.5 tph Total) CO 2 Purification and Compression Unit CO 2 Product: 70t/day 23

22 Callide A Unit 4 Update of Retrofit 18 May June

23 Air firing test before Retrofit : Mar., 2009 Front wall Rear wall Plant performance (static & dynamic) Air ingress Combustion characteristics (NOx/SO2/TE) Heat flux, in furnace temperature Cut mode operation of LP heater Burner throat Inside of furnace Control room Overview of Callide-A 25

24 Site work : Feb., 2011 Boiler before retrofit ASU Site work in the area of ASU and CO2 capture unit Boiler retrofit work 26

25 Commissioning Commissioning of air firing after the retrofit have completed and commissioning of ASU have continued. 23 March, 2011 First fire on fuel oil (diesel) 1 April, 2011 Turbine to 3000rpm 11 April, 2011 First coal fire in the furnace 13 April, 2011 First synchronization 17 May, 2011 Full load (30MWe) (Combustion tuning, load swing & MFT testing) 1 July, 2011 Commissioning start of ASU PC flame First fire on fuel oil (diesel) on 23 March,

26 Demonstration test Objectives Operation of oxyfuel & CO2 capture Obtain the data and knowhow for the commercialization This is the valuable opportunity to obtain the basic data for flame, combustion, heat transfer, ash and trace elements and operation data & knowhow of oxyfuel power plant with CO2 capture, due to the actual power generation plant. 28

27 COP key demonstration items CO 2 capture Oxyfuel & CO2 capture operation Safety Operation flexibility Durability Plant efficiency CO2 capture rate & CO2 purity Cost data Air ingress Process control and optimisation 29

28 Main evaluation items Oxyfuel Plant (Integration operation) Performance : h, CO2 capture rate Control : Oxyfuel, MFT Operation : Mode change, load range Durability and safety Grindability and dry Mixing Coal bin Mill N 2 Air ASU O 2 <Oxyfuel process> Boiler efficiency N & S behavior Hg behavior Boiler AH FGLPH (CO 2, H 2 O, SO 2 ) FF IDF GRF Convective heat transfer Tube corrosion CO2 conc., etc. Ash characteristics Stack Safety Non-condensable gas CO 2 liquefaction Flame stability Radiation heat transfer Combustion characteristics CO 2 tank <CO2 capture process> N & S behavior Purification & compression Cold Box Purity of CO2 Impurities Hg behavior 30

29 Callide Oxyfuel Project Summary Commissioning of oxyfuel will be started from November 2011 and we will have very valuable opportunity to obtain the data and knowhow towards the commercialization of oxyfuel process during the demonstration operation in Callide A. for more information: 31

30 IHI New Test Facility 32

31 Introduction of IHI test facilities Japan D&D Park in AIOI works Aioi 1 Tokyo Large capacity (12MWt) combustion test facilities 5 4 DeSOx test facilities 2 Basic combustion test facilities 3 Vertical furnace combustion test facilities 5 CCTF (Coal Combustion Test Facility) Construction work was completed and is now under commissioning. Test operation will be stared November

32 Introduction of IHI test facilities Coal Combustion Test Facility : CCTF Main R&D Items Development of new coal burner Combustion of new and multi fuel Evaluation of various coal combustion CO2 capture technologies Oxyfuel combustion Post-combustion capture Facility Capacity: 20MWth Furnace: Opposed firing Burner : 15 burners Mill : IHI VS-16 (Capacity : 5tph) Flue gas treatment : DeNOx, DeDust, DeSOx CO2 capture process : Oxy-fuel and Post-Combustion (Chemical absorption) Furnace DeNOx Heat exchanger Bag filter DeSOx Mill Evaporator for O2 34

33 Summary 35

34 Concluding comments Technical main issue 1. Scale up 2. High efficiency 3. Process optimization 4. Optimum application for the capture ready plant ST G Stack Air Condenser N2 Coal De-dust O2 Boiler ASU Flue gas recirculation Non-condensable gas Storage tank CO2 capture unit Transportation P CO2 underground storage 36

35 Concluding comments 1. Callide Oxyfuel Project CO2 capture is well advanced in commissioning. World first oxyfuel combustion in existing power station is planned in December. The Project is a major international collaboration between Japan and Australia at Government level and industry level. 2. Continuous and further development towards the large/commercial scale demonstration is necessary. 37

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