Development and demonstration of oxy-fuel CFB technology

Transcription

1 Development nd demonsttion of oxy-fuel CFB technology by A. Hott*, R. Kuivlinen*, T. Eiksson*, M. Lupion, V. Cotes, A.S.-B. Scist n, J.M. Jubiteo, nd J.C. Bllesteos J o u n l Synopsis Reduction of CO 2 emissions is the key diving foce behind the development nd implementtion of new solutions fo enegy poduction. One solution is ciculting fluidized bed (CFB) combustion technology combined with high-efficiency once-though wte-stem cycle. Foste Wheele s CFB technology is tody commecilly vilble in cpcities up to 800 MW e with ult-supeciticl stem pmetes. Simultneously, the Flexi-Bun CFB technology is being developed to povide cpbility of flexible opetion in i fiing nd oxycombustion fo cbon cptue. CFB technology cn offe n ttctive solution fo the eduction of CO 2 emissions, owing to dvntges such s fuel flexibility nd low emissions tht the i-fied CFB technology offes tody. Pilot test fcilities povide infomtion bout the pefomnce of CFB oxy-combustion technology, nd the cquied knowledge is being incopoted in boile modelling nd design tools. One of the Euopen R&D inititives on cbon cptue nd stoge (CCS) is the Technologicl Cente fo CO 2 Cptue nd Tnspot, which is suppoted by the Spnish Govenment though the Fundción Ciudd de l Enegí (CIUDEN). CIUDEN is esech nd development institution ceted by the Spnish dministtion in 2006 nd fully conceived fo collbotive esech in CO 2 cptue, tnspottion, nd stoge. The Technology Development Cente fo CO 2 Cptue nd Tnspot compises two technologies on oxycombustion: pulveized col (PC) nd ciculting fluidized bed (CFB). This ppe will focus on the design nd min chcteistics of the 30 megwtt-hou theml cpcity (MW th ) oxy-cfb boile. Foste Wheele is the technology povide of the Flexi-Bun CFB unit, fo which commissioning hs been completed in the fist qute of The CFB unit design llows opetion eithe unde conventionl combustion with i o unde oxy-fuel conditions. The size of this expeimentl boile is sufficient to llow the scling of the esults to commecil units. In this wy, multiple fuels nd opeting conditions cn be tested economiclly. The esults will vlidte the design of futue 330 MW e supeciticl Oxy-Combustion Powe Sttion (OXY-CFB-300 Compostill Poject) intended to demonstte the CCS technology t commecil scle. The Compostill OXY-CFB-300 Poject is one of the six CCS demonsttion pojects funded unde the Euopen Enegy Pogmme fo Recovey (EEPR) of the EU. The poject is bsed on futue 330 MW e CFB supeciticl oxy-combustion plnt, with CO 2 stoge in deep geologicl fomtion. The fist phse of the poject, gnted by the EEPR pogmme nd led by the Spnish utility ENDESA, includes ll studies nd chcteiztion wok needed on CO 2 cptue, tnspot, nd stoge, s well the costs, finncing, nd egultoy nd pemitting equied, pio to the finl investment decision fo the constuction phse of the plnt by the end of Keywods oxyfuel, CFB, once though stem cycle, supeciticl stem, col fiing, pilot testing. Intoduction Figue 1 shows simplified pocess flow scheme of powe plnt designed fo both ified nd oxygen-fied opetion modes. It consists of n i seption unit (ASU), high-efficiency stem cycle utilizing FW Flexi- Bun ciculting fluidized bed (CFB) boile technology, nd CO 2 compession nd puifiction unit (CPU). Fo oxy-fuel combustion, which is the pimy opetion mode, oxygen is mixed with ecycled flue gses, which cetes mixtue of pimily O 2 nd CO 2 (nd H 2 O) used s oxidnt in combustion insted of i. The bsence of nitogen poduces flue gs stem with high concenttion of CO 2, mking it much esie to septe the CO 2. In the i-fiing mode, which seves iskmitigtion puposes but my lso be pplied duing high lod demnd, the ASU nd CPU e out of sevice (o on stndby) nd the plnt is opeted like conventionl powe plnt, emitting flue gses to the tmosphee. Resech nd technology development (RTD) ctivities fo the Flexi-Bun CFB development The RTD Fmewok Foste Wheele hs been developing oxy-fuel CFB combustion since 2003 though: **Flexi-Bun is tdemk of Foste Wheele Enegi Oy, egisteed in the US, the EU, nd Finlnd * Foste Wheele Enegi Oy, Finlnd. Fundcio n Ciudd de l Enegi, Ciuden. ENDESA Genecio n SA, Spin. The Southen Aficn Institute of Mining nd Metllugy, SA ISSN X/ This ppe ws fist pesented t the, Industil Fluidiztion South Afic Confeence, Novembe 2011, Cdle of Humnkind, South Afic. P p e The Jounl of The Southen Aficn Institute of Mining nd Metllugy VOLUME 112 JUNE

2 Development nd demonsttion of oxy-fuel CFB technology Mix 95-97% O 2 (A, N 2 ) N 2, (A) Ai seption Ai Flue gs ecycle Fuels Flexi-Bun CFB boile Flue gs clene CO 2 / H 2 O Condenstion Compession Puifiction Vent gs H 2 O CO 2 Stem tubine G Tnspot Stoge Figue 1 Schemtic of Flexi-Bun CFB powe plnt Figue 2 Scle-up ppoch bsed on integted expeimentl nd modelling wok 1 Knowledge nd design tool development Test ctivities (bench-scle (VTT), smll CFB test ig (VTT), nd ~0.8 MWth CFB pilot (CANMET)) Conceptul nd fesibility studies (boile design). In the development of Flexi-Bun CFB technology, FW pplies n ppoch illustted by Figue 2, which hs been used in the scle-up of CFB boiles in the pst two decdes. Bench- nd pilot-scle CFB funces povide well-contolled envionments fo studying diffeent phenomen elted to combustion, het tnsfe, nd emissions. Pocess undestnding gined fom smll-scle expeiments nd modelling cn be linked to designing of full-scle CFB boiles1. Even though the once-though (OTU) CFB technology hs been commecilly demonstted fo conventionl i fiing, dditionl effots e equied to ensue the technologicl pplicbility to oxy-fiing. Fo this pupose, the fmewok of poweful collbotion between ENDESA, CIUDEN, nd FOSTER WHEELER hs been estblished. Within this collbotion, the following min RTD ctivities will be executed: Test pogmme in the i-fied efeence plnt (Lgisz 460 MW e OTU CFB) Smll-scle pilot testing of oxy-combustion in the CFB pocess Chcteiztion of the design fuels nd limestone in i nd oxy-fuel conditions in lbotoy-scle plnt of ound 0.8 MW th t CANMET in Cnd Vlidtion tests t CIUDEN s oxy-fied CFB t 1:30 scle 432 JUNE 2012 VOLUME 112 The Jounl of The Southen Aficn Institute of Mining nd Metllugy

3 Development nd demonsttion of oxy-fuel CFB technology Development of opeting modes nd contol sttegies of the fully integted CIUDEN Technology Development Cente fo CO 2 Cptue nd Tnspot in Spin Developing models fo optimizing the finl design fo oxy-combustion Economic nd isk ssessment studies. Once-though CFB technology scle-up The Polish utility compny Południowy Koncen Enegetyczny SA (PKE) selected Foste Wheele Enegi Oy s 460 MW e supeciticl CFB boile in 2003 fo thei Łgisz powe plnt. The new 460 MW e powe unit of Łgisz ws synchonized to the electicl netwok fo the fist time on 15 Febuy 2009, nd eched full output powe of 460 MW e on 10 Mch. Commissioning continued with fine tuning of the boile contols nd pefomnce pio to the stt of 720 h til opetion. The Łgisz CFB powe pln ws hnded ove to the client on 27 June Afte opeting fo moe thn 2 yes, it cn be stted tht the opetionl expeience of the Łgisz boile hs been excellent. Ove the whole lod nge, the boile hs pefomed s designed, nd opetion hs been stedy nd esily contollble. All pefomnce tgets wee demonstted duing til opetion. Thus, Łgisz hs vlidted Foste Wheele s supeciticl CFB design pltfom, poviding solid bse fo futhe units3. Bsed on continuous development wok, including the expeience fom ove 350 efeence boiles in opetion o unde constuction woldwide, the cpbility to offe supeciticl CFB technology up to 800 MW e scle with full commecil guntees hs been ceted. Recently Foste Wheele hs been wded the design nd supply of fou 550 MW e (goss megwtt electic) supeciticl CFB stem genetos fo the Smcheok Geen Powe Poject fo Koe Southen Powe Co. Ltd. (KOSPO). The design nd opeting expeience of the Łgisz unit will fom the foundtion fo the development of the Flexi- Bun CFB technology. In suppot of this development, field test cmpign ws cied out in 2010 in conjunction with poject ptnes of the FP7 FLEXIBURN CFB poject Smll pilot testing of oxy-combustion the CFB pocess FW hs cied out sevel test cmpigns t bench scle nd smll pilot scle since 2004 t VTT. In ddition, FW hs pticipted in sevel public pojects in which fundmentl undestnding hs been ceted on the oxy-fuel pocess nd elted phenomen. Bench-scle testing is well suited fo poducing dt on specific combustion phenomen, whees the pilot tests give pocess dt on ctul ciculting fluid bed conditions. Results of these tests e pesented in pevious confeence ppes nd pesenttions1,2,4. Chcteiztion of the design fuels in 0.8 MWth scle CFB pilot fcility CnmetENERGY Technology Cente, Ottw, (CETC-O) hs etofitted its 0.8 MWth CFB pilot plnt fo oxy-fuel combustion. The min components of the pilot plnt (Figue 3) e the ise with n intenl dimete of m nd n intenl height of 6.6 m, hot cyclone, etun leg, flue gs coole, bghouse, nd feedes fo fuel nd sobent. Rise tempetue is contolled with up to fou wte-cooled byonet tubes, which cn be inseted o etcted duing opetion by motoized winch system. A ntul gs sttup bune pehets the CFBC to the ignition tempetue of the test fuel. Duing etofitting, flue gs ecycle line ws dded, including ecycle blowe, flue gs condense, nd pessue contol nd sfety equipment. The flue gs is dwn fom the exit of the bghouse. Oxygen fom stoge tnk is mixed with the ecycled flue gs to mintin combustion in the CFBC. Opeting pmetes emin bsiclly the sme s in the i-fiing mode. Howeve, the fcility is un unde slightly positive pessue to pevent i in-lekge, nd oxygen level in the combustion gs cn ech 29 pe cent. Flue gs fom the CFBC is continuously nlysed fo CO 2, CO, O 2, SO 2, nd NO x. The system cn opete4 t tempetues up to 1000 C nd supeficil velocity of 4 6 m/s. J o u n l P p e COAL LIMESTONE COMBUSTOR FUE GAS COOLER BAGHOUSE INDUCED DRAFT FAN WEIGH BELT FEEDERS SAND CYCLONE FLY ASH DRUMS RECYCLE GAS COOLER SCREW CONVEYORS FORCED DRAFT BLOWER BED DRAIN OXYGEN AIR Figue 3 CnmetENERGY 0.8 MWth oxy-fuel CFB combustion pilot fcility The Jounl of The Southen Aficn Institute of Mining nd Metllugy VOLUME 112 JUNE

4 Development nd demonsttion of oxy-fuel CFB technology An extensive test pogmme to chcteize the potentil design fuels nd sulphu sobents fo the plnned 330 MW e Flexi-Bun CFB demonsttion boile, ws conducted with coopetion of FW, ENDESA, nd CETC-O. The test cmpign commenced in Fll 2009 nd continued until the end of August The test pln consisted of fouteen weeks of pilot-plnt opetion, including efeence tests in i mode, followed by one o two weeks of testing in oxy mode. The typicl vied test pmetes wee: fiing te, limestone feed te (C/S tio), combustion tempetue, excess i, i distibution, nd oxygen/ecyle gs tio (oxidnt O 2 ). Anlyses of the test fuels e pesented in Tble I. In dditon, the blends of both Spnish nthcite nd petcoke nd bituminous col nd Spnish lignite wee tested. The poject povided plenty of dt bout the diffeences between oxy-fuel combustion nd conventionl combustion of diffeent fuels. Phenomen of inteest included combustion, fiing te, emissions-elted issues, mixing, het tnsfe, fouling, nd coosion. Figue 4 shows n exmple of the funce tempetue duing one of the nthcite oxy-combustion tests. The combustion pocess ws stedy both in i nd oxy-combustion opetion. An exmple of esults elted to sulphu cptue in petcoke combustion test is shown in Figue 5. Sulfu cptue efficiency ws equl o bette in oxy-combustion comped to i combustion. The impotnt conclusion is tht no mjo issues tht contdict pevious ssumptions nd beliefs wee identified duing the tests. Hence, the oxy-fuel CFB technology continues to be n inteesting option fo CCS. CIUDEN Technology Development Cente fo CO2 Cptue nd Tnspot CIUDEN is esech nd development institution ceted by the Spnish dministtion in 2006 nd fully conceived fo collbotive esech in CCS nd CCTs, thus contibuting to the stengthening of the industil nd technologicl bse in Tble I Anlyses of test fuels SO2 etention [%] Poximte nlysis, % Anthcite Bit. col Lignite Petcoke Moistue Voltiles Ash Fixed cbon Ultimte nlysis (s eceived), % C H N S O Highe heting vlue HHV, MJ/kg (dy bsis) Petcoke_AIR 10 Petcoke_OXY Figue 5 An exmple of SO2 etention vs. bed tempetue in i nd oxy-combustion of petcoke Figue 4 Tempetue in lowe funce duing n oxy-combustion test of nthcite demonsttes stedy combustion pocess 434 JUNE 2012 VOLUME 112 The Jounl of The Southen Aficn Institute of Mining nd Metllugy

5 Development nd demonsttion of oxy-fuel CFB technology Spin nd by extension in Euope. CIUDEN s min objectives within the CO 2 Cptue Pogmme e the esech, development, nd demonsttion of efficient, cost-effective, nd elible CCS nd dvnced CCT, s well s thidgenetion flue gs clening though the design nd opetion of CIUDEN s Technology Development Cente fo CO 2 Cptue nd Tnspot (the es.co 2 Cente)5,6. The es.co 2 Cente fetues ll necessy equipment to povide the CO 2 stem edy fo tnspot t 1:30 scle. Testing cmpigns e to be pefomed jointly by the ptnes, iming to ive t sound bsis fo the efinement of the incopoted technologies, especilly the CFB unde oxy-fiing conditions, but lso the dynmic behviou of the complete unit. Though this ppoch the isks ssocited with the design nd constuction of fist-of-its-kind Flexi- Bun CFB boile will be getly educed, thus esulting in lowe uncetinties bout costs nd vilbility. The Cente is locted djcent to the Compostill II Powe Plnt. The configution of the es.co 2 Cente is flexible, modul, nd vestile in ode to test wide nge of opeting conditions, including diffeent cols nd combustion conditions fom i mode to oxy mode in independent but inteconnected modules fo simultneous o septe opetion. Figue 6 shows n eil view of the es.co 2 Cente with the min units indicted. A genel desciption of the es.co 2 Cente is found elsewhee6-9. Figue 7 shows 3D model of the CFB boile islnd with the min design pmetes. J o u n l P p e Figue 6 CIUDEN s es.co2 Cente Figue 7_Flexi-Bun CFB Boile t the es.co2 Cente The Jounl of The Southen Aficn Institute of Mining nd Metllugy VOLUME 112 JUNE

6 Development nd demonsttion of oxy-fuel CFB technology Tble II Min fetues of Compostill Poject Cptue technology 330 MW e OXY-CFB supeciticl boile Wide design fuel nge (domestic nd impoted), including biomss CO 2 tnspot 12-inch / 16-inch undegound pipeline, 150 km t/dy; ~ 120 b CO 2 stoge Deep geologicl fomtion OXYCFB300 Compostill Poject The OXYCFB300 Compostill Poject is bsed on CCS integted commecil-size demonsttion poject, coveing the entie CO 2 chin: cptue, tnspot, nd stoge. The poject is one of the six selected CCS EU demonsttion pojects co-funded by the Euopen Commission s Euopen Enegy Pogmme fo Recovey (EEPR). The ovell Compostill Poject is bsed on futue ~330 MW e CFB supeciticl oxycombustion plnt, with dense-phse CO 2 tnspot line nd finl undegound CO 2 stoge in deep geologicl fomtion. The min tget of the OXYCFB300 Compostill Poject is to vlidte fuel-flexible nd competitive CCS technology t industil level fo wide nge of fuels: w cols, petcoke, nd biomss. This poject suppots the Euopen sttegy fo cceleting the deployment of CCS fo combting climte chnge, s committed by the EU nd its membe sttes. Tble II summizes the min fetues of the Compostill Poject. This technology will be initilly tested on fist of-itsclss 30 MW th boile t es.co 2, locted in Cubillos de Sil (León), close to ENDESA s Compostill Powe Sttion in the nothwest of Spin. The fcility will povide the knowledge needed to futhe scle the technology to demonsttion size (330 MW e ), once positive finl investment decision is mde. The Compostill EEPR Poject is led by well-blnced consotium of ENDESA, CIUDEN, nd Foste Wheele. All thee consotium membes e dedicted nd committed to the technology development nd pomoting the finl poject stge in ode to chieve the successful commeciliztion of this pomising CCS technology. Acknowledgements The esech leding to these esults hs eceived funding fom the Euopen Community s Seventh Fmewok Pogmme (FP7/ ) unde gnt geement no. TREN/FP7EN/239188/ FLEXI BURN CFB. Poject Compostill is co-finnced by the Euopen Union s Euopen Enegy Pogmme fo Recovey pogmme. The sole esponsibility fo this publiction lies with the uthos. The Euopen Union is not esponsible fo ny use tht my be mde of the infomtion contined heein. Refeences 1. PIKKARAINEN, T., LEINO, T., TOURUNEN, A., nd KUIVALAINEN, R. Development of CFB technology to povide flexible i/oxy opetion fo powe lnt with CCS. The 34th Intentionl Technicl Confeence on Clen Col & Fuel Systems - Clewte Clen Col Confeence, Tmp, FL, 31 My 4 June ERIKSSON, T., NUORTIMO, K., HOTTA, A., MYÖHÄNEN, K., HYPPÄNEN, T., nd PIKKARAINEN, T. Ne zeo CO 2 emissions in col fiing with oxyfuel CFB boile. 9th Intentionl Confeence on Ciculting Fluidized Beds, Hmbug, Gemny, My JANTTI, T. nd PARKKONEN, R. Lgisz 460MW e supeciticl CFB - opetion expeience duing fist ye fte stt of commecil opetion. Russi Powe Confeence nd Exhibition, Moscow, Russin Fedetion, Mch ERIKSSON, T., SIPPU, O., HOTTA, A., FAN, Z., RUIZ, J.A., SACRISTÁN, A.S-B., JUBITERO, J.M., BALLESTEROS, J.C, SHAH, M., PROSSER, N., HALEY, J., nd GIUDICI, R. Development of Flexi-BunTM CFB Technology iming t fully integted CCS demonsttion. Powe-Gen Euope 2009, Cologne, Gemny, My CORTES, V.J. Stte of development nd esults of oxy-col combustion esech inititive by CIEMAT in Spin. 2nd IEAGHG Intentionl Oxy- Combustion Netwok Meeting, Windso, USA, Jnuy Cotes, V.J. CIUDEN s Technology Development Cente fo CO2 Cptue. CCT2011 Confeence, Zgoz, Spin, My LUPION, M., NAVARRETE, B., OTERO, P., nd CORTES, V.J. CIUDEN CCS technologicl development plnt on oxycombustion in col powe genetion, Cottbus, Gemny, Septembe LUPION, M., NAVARRETE, B., OTERO, P., nd CORTES, V.J. Expeimentl pogmme in CIUDEN s CO 2 cptue technology development plnt fo powe genetion. Chemicl Engineeing Resech nd Design, vol. 89, no. 9, Septembe pp LUPION, M., DIEGO, R., LOUBEAU, L., nd NAVARRETE, B. CIUDEN CCS Poject: sttus of the CO 2 cptue technology development plnt in powe genetion. 10th Intentionl Confeence on Geenhouse Gs Contol Technologies, GHGT10, Amstedm, Nethelnds, Septembe JUNE 2012 VOLUME 112 The Jounl of The Southen Aficn Institute of Mining nd Metllugy