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1 Current Status and Developments in Carbon Capture Technologies for Power Generation (What are the Challenges Involved) by: Stanley Santos IEA Greenhouse Gas R&D Programme Presented at: CO2 Capture and Storage (CCS) A Global Business Vision (Indonesia CCS National Workshop) 30 th October 2008 Jakarta, Indonesia *Corresponding Author s stanley@ieaghg.org

2 Presentation Outline Overview to Carbon Capture Technologies and current R&D Activities Post-Combustion Capture Oxy-Combustion Capture Pre Combustion Capture Some of the key issues looking onto the different capture technologies CO2 Transport and its Challenges Concluding Remarks 2

3 Overview to Different Leading CO2 Capture Technologies for Power Generation

4 Current View on CCS and Efficiency Increase Carbon Reduction Key issue will be value of CO 2 `Zero Emissions` Trajectory `Increased Efficiency` Trajectory Zero emissions will need the most efficient plant Near-term Mid-term Long-term Time 4

5 CO2 Capture technologies General Overview Figure adapted from BP

6 Post-Combustion Capture

7 Post-Combustion Capture Power generation Capture Air N 2, O 2, H 2 O to atmosphere Fuel Boiler or gas turbine (FGD) Solvent scrubbing Steam Steam turbine Power CO 2 compression CO 2 to storage 7

8 Chemical Absorption Process 8

9 CO2 Based Solvent Scrubbing Use of Amine scrubbing to capture CO2 is the most mature among the 3 mostly considered capture technology options for the power generation. Amine based solvent is currently the commonly used for CO2 capture widely used in food processing (ie. carbonated drinks) and chemical industries (ie. Urea plant) Large scale demonstration (> 1 MT/yr of scale) mostly in oil and gas fields applications For example in Sleipner and In Salah Current R&D Focus Development of new type of solvents Development elopment is also on-going for application to coal fired power plant 9

10 Evolution 90 <Experience and R&D Facilities> MHI s Evolution Development of Flue Gas CO 2 Recovery Plant Coal Fired Flue Gas Application 1 Ton/Day Pilot Test Completed Long Term Demo. Plant Test Starts 1 Ton/Day Pilot Plant Long Term Demo. Plant Large Scale Demonstration Plant Design Ready 3000 Tonnes /Day Design Completed 6000 Tonnes/Day Design Completes Enlargement FGD Experience Start of Development Large Scale Test Plant Nanko Pilot Plant (2 Tonnes/day) R&D for Process Improvement 3000 Tonnes /Day Plant Commercial Plant Malaysia Kedah (200 Tonnes/day) Japan, Chemical Company (330 Tonnes/day) Malaysia kedah Plant 330 Tonnes/day Plant India, Fertilizer Company (450 Tonnes/day x 2) Abu Dhabi, Fertilizer Company (400 Tonnes/day) 10

11 R&D Effort in Europe Castor / Caesar Post- Combustion Pilot Plant Project Installed at the Esbjerg Power Station Pilot Capacity: 1000 kg CO2 per hour (25 TPD) 5000 Nm 3 /h flue gas (coal combustion) Now in operation started in March 2006 both MEA and 2 types of Castor Solvents were evaluated 11

12 Vattenfall s CCS demo project at Nordjyllandsværket Nordjyllandsværket Vedsted On-shore Structure Transport by pipeline On February 6, 2008 Vattenfall Nordic Thermal Power Generation announced the intention to develop a full-scale Carbon Capture & Storage (CCS) demonstration project Vattenfall AB IEA Greenhouse Gas R&D Programme 11th MEETING of the INTERNATIONAL POST-COMBUSTION CO2 CAPTURE NETWORK 20th-21st May, 2008, Vienna, Austria

13 Some Other Current Activities UK (2014) investment decision by next year. BERR CCS Competition (4 of 9 bidders selected as semi-finalists) BP (revival of Peterfields and Miller Field???) EOn UK (Kingsnorth Project) Arup, MHI, Flour, EPRI, Tullow oil Peel Power (Peel Holding, Dong Energy, Mott MacDonald) Scottish Power (Longannet Project) Aker Kavaerner, Marathon oil Germany y( (2012) investment decision by next year Vattenfall s Janschwalde Project Doosan Babcock partnership p with HTC Purenergy / EESTech China Project in the pipeline: 330 MWe of Tainjin DaGang Huashi Power Generation Co. Ltd. (many more) 13

14 Post-combustion capture: KEY ISSUES Solvent life Requires very low SOx (< 10 ppm) and NO2 (< 20 ppm) Solvent could be very expensive target: lower solvent losses Corrosion Stainless steel v carbon steel Inhibitors can contain V, Sn, Sb (antimony) Energy consumption Regeneration of solvent Environmental impacts Some degradation products known and regulated; others are not. 14

15 Future Direction of Research Cost and Process Optimisation of the current MEA based Technologies Design of the Absorption column Reduction of Energy consumption of the regenerative column Improvement of Current solvents Improving kinetics Improving additives to reduce degradation Development of new solvents For Examples: Chilled Ammonia process, Cansolv solvent, KS2, etc... Environmental Impact Assessment Impact assessment due solvent degradation Fugitive emissions (especially NH3 as one of the by-product of degradation) 15

16 Oxy-Coal Combustion Technology

17 Oxy-Coal Combustion Technology Air Air separation Oxygen Recycled flue gas Vent Fuel Boiler Cooling Purification/ (+FGD) compression CO 2 Steam Steam turbine Power 17

18 Convective Section of the boiler heat transfer profile ash deposition and fouling issue HP HP HEATER ADVANCED SUPERCRITICAL BOILER MILL Burner design issue IgnitionCOAL flame stability devolatilisation & char burnout STACK (START UP) IP ID FAN LP DEAERATOR Radiant Section of the Boiler heat transfer profile slagging issue fireside corrosion issue HP PUMP ESP FGD CONDENSOR LP PUMP LP HEATER Prior to any retrofit of carbon capture technology, it is essential to repower the plant in order COLD FD FAN to achieve the highest possible efficiency AIR IN 18

19 COAL HP HP HEATER 3 4 ADVANCED SUPERCRITICAL BOILER MILL ASU NITROGEN AIR STACK (START UP) IP 2 ID FAN DEAERATOR OXYGEN LP HP PUMP SECONDARY RECYCLE PRIMARY RECYCLE Gas / GAS Gas Heater / ESP FD / RECYCLE FAN 4 CONDENSOR LP PUMP LP HEATER IP STEAM BLEED 2 - HEAT FROM ASU ADIABATIC MAC 3 - CO2 COMPRESSOR STAGE HEAT 4 FLUE GAS FEEDWATER HEATING 3 CO2 PURIFICATION INERTS GAS DRIER CO2 PRODUCTFOR COMPRESSION 3 GAS COLD PA FAN GAS COOLER & WATER REMOVAL AIR INTAKE START UP 4 19

20 Oxy-Combustion Technology Use of oxygen instead of air in a boiler Oxy- Combustion is the least mature among the 3 mostly considered capture technology options for the power generation. 3 key development issues Boiler and burner development Air Separation Unit Cost and capacity of oxygen production CO2 processing Removal of impurities 20

21 ANL - EERC Study World s 1 st Oxy-Coal Pilot Scale Study Tower Furnace (~ 3MWth) 21

22 Coal Flame Photos: Air Fired vs Oxy-Fired (Courtesy of IHI) Air mode(o 2 :21%) Oxy mode(o 2 :21%) Oxy mode(o 2 :30%) 22

23 O 2 -RFG flame with recycle ratio = 0.58 Recycle Ratio = 0.58 (~ 0.61 include the CO2 to transport coal) O 2 -RFG flame with recycle ratio = y Courtesy of IFRF Recycle Ratio = 0.76

24 1 st Large Scale Oxy-Coal Combustion Experience (International Combustion Ltd.) 35 MWth Low NOx burner Although it was not able to achieve the desirable CO2 composition the first combustion trial gained significant experience in burner start up 24

25 Oxy-Combustion Technology What are the Enabling Studies in the near future that will provide a big step forward for Oxy-Coal Combustion

26 Vattenfall Schwarze Pumpe Pilot Project Time Table for Implementation of Oxy-Fuel Project Pre- and Order planning Permission planning Execution planning Erection Commissioning Operation Courtesy of Vattenfall 26

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28 Callide A Project: Japanese-Australian Collaboration Nth Denison Trough Callide-A APower Station ti Capacity: 4 x 30 MW e Commissioned: Refurbished: 1997/98 Steam Parameters: 4.1 MPa, 460 o C Steam Flowrate: 123 t/h steam Figure 2: Location of Callide-A AProject. APl Planned retrofit fitto a coal lfired power plant with an oxy-combustion boiler 28

29 Oxy-Combustion: KEY ISSUES Air Ingress Estimated that every 1% of air ingress should result to about 3-5% reduction of the CO2 concentration in the flue gas. Several failures have been noted from previous experiences of not reaching the desired concentration of CO2 due to air ingress. This is a big challenge especially retrofitting a power plant. Boiler and Burner Development We need to build our confidence in running an oxy-fired burner/boiler especially at the same scale of our current PC boiler. Various technical issues elucidated - these include heat transfer aspect, ash and slagging, equipment scaling up, emissions control, etc Largest burner test as of today operated with oxy-firing mode for coal was done by International Combustion during the 1990 s - what have we learned from this test? Cost and capacity of producing your oxygen 29

30 Oxy-Fuel Combustion Boiler Projects 1 MWe = 3 MWt = 10 MMBtu/hr) Demo Projects Vattenfall MW We Utility Boilers Industrial Furnaces International Comb 11.7 JSIM/NEDO(oil) Youngdong Jamestown Callide A Pearl Plant Vattenfall 13.3 Oxy-coal UK B&W CIUDEN CIUDEN Jupiter TOTAL(NG) IFRF ANL/EERC ENEL B&W/AL 0.4 PowerGen ANL/BHP IHI 0.3 Test 0.2 IVD-Stuttgart Furnaces CANMET 0.1 RWE-NPOWER Year

31 Large Scale Pilot and Demo Projects PROJECT Location MWth Start up Boiler Type Main Fuel CO2 Train B&W USA Pilot PC Bit, Sub B., Lig. Jupiter USA Industr. No FGR NG, Coal Oxy-coal UK UK Pilot PC Vattenfall Germany Pilot PC Lignite (Bit.) With CCS Total, Lacq France Industrial Nat gas With CCS Pearl Plant USA MWe PC Bit Side stream Callide Australia MWe PC Bit. With CCS Ciuden - PC Spain Pilot PC Anthra.(Pet ck)? Ciuden - CFB Spain Pilot CFB Anthra.(Pet ck)? Jamestown USA MWe CFB Bit. With CCS Vattenfall (Janschwalde) Germany ~ ~250 Mwe PC Lignite (Bit.) With CCS Youngdong Korea ~ ? ~100 MWe PC???

32 Pre-Combustion Capture (Considering only Coal Power Plant)

33 Pre-Combustion Capture IGCC with CO 2 capture CO+H 2 O H 2 +CO 2 Coal Gasification Shift conversion CO 2 compression Acid gas removal CO 2 Sulphur H 2S Sulphur recovery Oxygen Fuel gas (mainly H 2 ) Air Air separation Nitrogen Combined cycle Power Air Air 33

34 34

35 IGCC without Capture 5 coal-based IGCC demonstration plant in the USA, Europe and Japan IGCC is not at present the preferred technology for new coal-fired power plants Main commercial interest in IGCC is for use of petroleum residues Several plants built and planned at refineries IGCC has some intrinsic advantage over PC plant when CCS is to retrofitted or added d 35

36 IGCC Currently in Operation Nuon Buggenum 250 MWel

37 250MWe Air Blown IGCC (Fukushima, Japan) 37

38 CO2 Capture in IGCC Advantages of IGCC for CO2 capture High CO2 concentration and high overall pressure Lower energy consumption for CO2 separation Compact equipment Proven CO2 separation technology can be used Possibility of co-production of hydrogen Disadvantages IGCC is unfamiliar technology for power generators Existing coal fired plants have low availability IGCC without CO2 capture has generally higher costs than pulverised coal combustion 38

39 IGCC IGCC with pre-combustion capture has been the fundamental building blocks in various programme for co-generation of electricity and dhydrogen Some examples Europe: Japan: China: HYPOGEN Programme EAGLE Project GreenGen Project 39

40 Pre-Combustion Capture: Key Barrier Will reliability hinders the deployment of IGCC? Record for IGCC s availability has been poor but improving. i Complexity of the plant could be a turn off to both prospective investors and power plant operator Cost is another issue Source: EPRI 40

41 Pre-Combustion Capture: Key Development Area Development in Gasifier Technology Development in Shift Reactor Choice of Sour vs Sweet Shift Reaction Development in Separation of CO2 using Physical Absorption technology Development in the Gas Turbine technology Development of gas turbine firing H2 rich fuel using the current DLN technology 41

42 What are the current trend of development in IGCC Based Technology New fleet taking advantage of 10+ years of operation in the U.S. and Europe Materials of construction Spare equipment Gasifier refractory / membrane wall Burner design Range of suppliers to choose from, for a wide variety of coals and other feedstocks EPC alliances can provide important guarantees 42

43 GE Bechtel Reference Plant 43

44 CO2 Transport

45 CO 2 Transport Pipeline Mode of Transport Motor Trucks Rail Ocean-going ships 45

46 Compressors / Pumps Main Considerations This could vary depending di on mode of transport. t For ship, train and trucks expect a CO2 liquids to be transported For pipeline expect either gaseous CO2 or supercritical CO2. Transport mode Pipeline transport is probably the most economical for long distance transport. 46

47 CO2 Delivery to Weyburn Regina Weyburn Manitoba Saskatchewan Montana Estevan Canada Canada USA North Dakota Beulah Bismarck Beulah 47

48 CO2 Compression in a Commercial Operation (Dakota Gasification Plant CO2 to Weyburn EOR) Operation Profile MAN Turbo RV 042/07 Motor Driven (~19500 HP) Mass Flow: kg/hr Inlet Pressure: 1 Bar Discharge Pressure: 190 Bar 2 units started operation in 2000 (each unit transporting ~55 mmscfd) 3 rd units started operation in June

49 Considerations in the Design for High Pressure Pipeline Transport of CO2 Captured from Power Plants 2 phase flow: impurities affect the 2 phase flow envelop profile. How do we model the EOS to cover this phenomena? Transport capacity: impurities reduced transport capacity in the pipeline Fluid Toxicity: impurities could affect ruling on safety exposure. Vapour Pressure: impurities could raised Vap. Pressure thus requiring higher initial pressure or shorter re-compressor/booster station. Corrrosion critical elements to consider is the oxygen, water and acidic components that could enhance corrosion. Water solubility and hydrate formation conditions Pipeline integrity during de-pressurisation.

50 Concluding Remarks

51 Concluding Remarks Several activities have been initiated worldwide in the development of Carbon Capture for Power Generation industry. There are two set of horse race among the three options for newly build and retrofit plant. There is no leader at the moment! We need large scale demonstration of the carbon capture technology to build the confidence necessary for a rapid deployment. It is now time to discuss about the acceptable quality of CO2 that could be stored. 51

52 Recent IEA GHG Studies on CO 2 Capture Plants Post combustion capture Fluor MHI IGCC Foster Wheeler Oxy combustion Mitsui Babcock, Air Products and Alstom 52