Three years operational experiences with the Oxyfuel Pilot Plant of Vattenfall in Schwarze Pumpe

Transcription

1 2 nd IEAGHG Oxyfuel Combustion Conference Three years operational experiences with the Oxyfuel Pilot Plant of Vattenfall in Schwarze Pumpe Uwe Burchhardt a, Göran Lindgren b a Vattenfall Europe Generation AG, D Cottbus, Germany b Vattenfall AB, SE Stockholm, Sweden

2 Agenda 1. Technical concept of Oxyfuel Pilot Plant 2. Experiences from tests and operation 3. Potentials for Oxyfuel technology 2 2OCC, U.Burchhardt

3 Vattenfall s Oxyfuel pilot plant Boiler Air separation unit ESP FGD Germany Federal state of Brandenburg FGC Schwarze Pumpe, location of the Oxyfuel pilot plant CO 2 -Plant Thermal capacity: 30 MW th Coal demand: 5.2 t/h Capture rate: >90% CO 2 (liq.) production: 9 t/h Social- and Switchgear building 3 2OCC, U.Burchhardt

4 Base data and industry partners Thermal capacity: 30 MWth Coal demand: 5.2 t/h CO2 (liqu.) production: 9 t/h Start up test operation Sept Until operating hours in total, from it > in Oxyfuel mode, captured CO2 approx t CO2 removal rate > 90 % High plant availability Experiences for permission, operating and technical service Investment 70 Mio. Industry partner : 4 2OCC, U.Burchhardt

5 System overview of Oxyfuel Pilot Plant Pulverised Coal Cold Recirculation Burner Sealgas <1,2 bar Steam- HEx Steam- HEx Air Sealgas 6 bar Furnace 2. Pass (DeNOx) ESP Fan 1 Fan 2 FGD FG- Condenser CO 2 - Process 3. Pass Dry Ash hot Recirculation Steam- HEx Air Nitrogen Steam- HEx Oxygen ASU Air 5 2OCC, U.Burchhardt

6 Experiences with pre-mixed, Expert mode and Hybrid mode Burne r Burne r Burne r Furnace 2. pass (DeNOx) 3. pass Furnace 2. pass (DeNOx) 3. pass Furnace 2. pass (DeNOx) 3. pass Reci Reci Reci Oxygen Oxygen Oxygen Pre-mixed mode Expert mode Hybrid mode 6 2OCC, U.Burchhardt

7 Boiler and Burner Till now three burners tested (Jet-/spin-, pure spin burner) Igniting burner in main burner integrates Variable spinn during operation necessary Results: Good ignition behavior High flame stability Emission values are kept for certain Alstom-Burner Typ A and Typ B HPE DS -T Burner 7 2OCC, U.Burchhardt

8 Burner : typical operation points 36 pre-mixed Mode Expert-Mode Air operation Hybrid-Mode O2 in Oxidant (Vol.-%,w) ,5 2 2,5 3 3,5 4 4,5 5 O 2 in flue gas (Vol.-%,w) 8 2OCC, U.Burchhardt

9 Boiler (furnace) - Temperature Comparison (Front View) Oxy 24% Oxy 28% Oxy 32% Oxy 36% Air (21%) The gas temperatures increases with increased O2 in oxidant as expected The temperature levels for air case corresponds to OXY28 9 2OCC, U.Burchhardt

10 Requirements on flue gas scrubbing Component Composition Reduction from* to* Capture rate ESP Ash mg/m³ < 20 mg/m³ > 99 % SO mg/m³ < 100 mg/m³ > 99 % FGD SO 3 50 mg/m³ < 20 mg/m³ > 50 % Ash 20 mg/m³ < 10 mg/m³ > 50 % H 2 O 30 vol-% 4 vol-% > 85 % FG- Condenser SO mg/m³ < 20 mg/m³ > 80 % SO 3 20 mg/m³ < 5 mg/m³ > 75 % Ash 10 mg/m³ < 1 mg/m³ > 90 % All design data are fulfilled! 10 2OCC, U.Burchhardt * all mg/m³ in Norm (dry)

11 Possibilities of NOx reduction in Oxyfuel process 1 - high dust SCR-DeNOx/SNCR 2/3 - low dust SCR-DeNOx 4 - combined DeSOx/DeNOx 5 - cold DeNOx in CO2 process 6 - Ventgas DeNOx Vattenfall follows up the versions 1, 4 and OCC, U.Burchhardt

12 CO 2 - Process (Cleaning, compression, drying, liquefaction) FG- Input CO2 > 88 % O2 < 4 % N2+Ar < 3 % H2O ~ 4 % Rest gases: CO, NOx, SOx Use Ventgases for regeneration of Adsorber < 9 % CO 2 -Loss ca. 50 % Ventgas CO2 ~ % O2 ~ % N2 ~ % Rest gases: CO, SO2, NO FGC Pre- Compressor Activated carbon filter Main- Compressor 0,4 bar 21,5 bar 2-stage Adsorber (NOx) 1 ppm H 2 O 19,0 bar CO2- Output CO2 > 99,7 % 17 bar, -25 C CO2 (liqu.) > 91 % CO 2 - removal SO 2, SO 3, HCl, Heavy metals (Hg, Cd,.) H 2 O H 2 O (SOx / NOx) Coolant circulation (Ammonia/CO2) 12 2OCC, U.Burchhardt All %-details in Vol.-%

13 Comparison of CO 2 purities Composition Food quality (liquid) CO2 quality in Oxyfuel pilot plant CO2 quality for demo plant Oxyfuel PCC CO 2 > 99,99 % > 99,7 % > 96 % > 99,9 % N 2 +Ar 2,5 % < 500 ppm < 30 ppm < 0,3 % O 2 0,8 % < 200 ppm H 2 O < 50 ppm < 50 ppm < 100 ppm < 10 ppm SO 2 < 1 ppm < 2,5 ppm < 50 ppm < 1 ppm SO 3 - < 0,5 ppm < 20 ppm - CO < 10 ppm < 10 ppm < 750 ppm < 70 ppm NO < 2,5 ppm < 5 ppm NO 2 < 2,5 ppm < 15 ppm < 100 ppm < 10 ppm 13 2OCC, U.Burchhardt

14 Closed the CCS chain: CO 2 from Oxyfuel Pilot Plant to storage project CO 2 MAN (Ketzin) Aim of project CO 2 MAN: Knowledge to spreading behavior of CO2 in underground and supervision of storage by different monitoring systems CO 2 -Injection: Till now > 45,000 t of pure food CO2 injected Pilot plant Ketzin Oxyfuel-Pilotanlage Schwarze Pumpe Test campagne: CO2 delivery by 71 trailers from the Oxyfuel pilot plant to Ketzin CO2 delivery: t CO2 Basis data: Runtime: May to June 2011 CO 2 purity: > 99,7 % safety injection with monitoring 14 2OCC, U.Burchhardt

15 Potentials for increase efficiency (Oxyfuel) - Optimization of own consumption of all components - Increased life steam parameters (materials) - Realization of hot recirculation (material request) - Use of membrane (ASU, CO2) - Integration of coal drying (PFBD with vapor compression) - Recycle usable gases from ventgas of CO2 plant to boiler - Alternative flue gas and CO2 purification 15 2OCC, U.Burchhardt

16 Alternative flue gas and CO2 purification in Schwarze Pumpe Alternative CO 2 pilot plant 16 2OCC, U.Burchhardt

17 Conclusion Oxyfuel works in pilot scale, emission limits are kept Successful integration of components from chemical engineering (ASU, Flue gas condenser, CO2 plant) Experiences from permission process, operating and technical service Necessary CO2 quality reached, CO2 industrially utilizable Oxyfuel-CO2 delivered for storage in saline aquifer Further potentials for oxyfuel technology are available Ready to scale up 17 2OCC, U.Burchhardt

18 Thank you for your attention!

19 Pressurised Fluidised Bed Dryer (PFBD) Basic data Pilot Plant located at Schwarze Pumpe area Test-operation between October 2008 until October 2012 till now hours, dried coal > t Availability ~ 95% Targets: - Deliver dried lignite to OxPP - Gain knowledge for large scale application Technical data flow rate wet lignite flow rate dry lignite value t/h t/h moisture dry lignite % operation pressure bar (a) 19 2OCC, U.Burchhardt