Stanley Santos IEA Greenhouse Gas R&D Programme Cheltenham, UK.

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1 Oxy-Combustion for Coal Fired Power Plant with CO2 Capture Review of the Past 20 Years of R&D Activities What are the Different Technical Issues and Challenges to Its Development By Stanley Santos IEA Greenhouse Gas R&D Programme Cheltenham, UK *Corresponding Author s stanley@ieaghg.org

2 Presentation Outline IEA Greenhouse Gas R&D Programme Introduction to IEAGHG and its activities. Introduction to Oxy-Coal Combustion with CO2 Capture in Power Generation General overview of the Oxy-Combustion Historical perspective in development of oxy-coal combustion with CCS for application in power generation Technical considerations and issues in the development of oxy-coal combustion with CCS in the perspective of power generation (retrofit or new built power plants) Concluding Remarks 2

3 Introduction ti to IEA Greenhouse Gas R&D Programme (IEAGHG)

4 Introduction to IEAGHG The IEA (Legal) Framework: Common rules for participation in IEA Implementing Agreements (IA); Some 40 of these IA are listed at Participants can be: Contracting Parties (intergovernmental organisations, countries or designated representatives) Sponsors (private sector enterprises not designated by a government) IEA GHG is an IA in which the Participants contributing to a common fund to finance the activities. Funding is approximately 2 million US$/year. 4

5 Current Membership The Programme is supported by 17 governments, EC and 17 sponsors 5

6 Introduction to IEAGHG A collaborative research programme which started in 1991 Its main role is to evaluate technologies that t can reduce greenhouse gas emissions. The Programme s Objective: To provide members with definitive information on the role that technology can play in reducing greenhouse gas emissions 6

7 Activities of IEAGHG What does the Programme do now? New 5-year phase started in 2005: 3 Main activities: Generate technology and market information Confidence building Information dissemination Aimed at answering: How do mitigation options compare? Can the option be done safely and legally? What needs to be done to introduce the mitigation option and be confident it will be successful? 7

8 IEAGHG Activities This IA has been operating for 15 years. IEAGHG has: Accumulated >100 studies covering carbon capture and storage (CCS), other mitigation technologies, and alternative energy carriers. Succeeded in establishing CCS as a mitigation option capable of major reductions in the emission of CO2 to atmosphere. 8

9 IEAGHG - Completed Studies In the previous year, some of the member s studies completed, include: Comparison of power plants with CO 2 capture technologies CO 2 capture at low rank coal power plants Near-zero emission power plants Environmental assessment for CO 2 capture and storage Permitting issues for CO 2 capture and storage Cost and capacity for CO 2 storage in Europe and N America Monitoring requirements for CCS Safe storage of CO 2 analogies with the natural gas industry Use of CDM for CCS More than 100 studies completed

10 IEAGHG Studies (cont d) For 2007, IEAGHG will be releasing the following member s studies: Report on Capture Ready Plant Work done in cooperation with IEA under task required by the Gleneagles G8 meeting Techno-economic evaluation of co-production of hydrogen and electricity with carbon capture CO 2 capture in the cement industry Many others Full Listing of our studies please contact us at mail@ieaghg.org 10

htm p IEAGHG manages 6 Research Networks International CO2 Capture Network International Oxy-Combustion Network Biofixation

11 Objectives IEAGHG Research Network To provide an avenue for discussion on specific issues toward development of CCS and support any confidence building activities p IEAGHG manages 6 Research Networks International CO2 Capture Network International Oxy-Combustion Network Biofixation Network Monitoring Network Risk Assessment Network Well Bore Integrity Network Participants from 2 nd Oxy-Combustion Workshop (CT, USA Jan. 2007) 11

GHGT Conference Series IEA GHG is the guardian of the GHGT

attracted more than 950 delegates Premier international

conference (GHGT-9) will be held at Washington D.C.

12 GHGT Conference Series IEA GHG is the guardian of the GHGT conference series Latest GHGT-8 held in Trondheim, Norway attracted more than 950 delegates Premier international conference on greenhouse gas control technology Next conference (GHGT-9) will be held at Washington D.C. USA - November

13 Communication & Information Dissemination Quarterly newsletter Topical Reports 13

14 Oxy-Combustion Application in the Industry (General Overview)

15 Development of Oxy-Fuel Combustion Application in Industry Adapted from slide of Sho Kobayashi, Praxair Pictures from IFRF, Air Liqiude, Asahi Glass, Linde Gas 15

16 Oxy-Combustion with CO2 Capture for Coal Fired Power Station

17 Historical Perspective ( ) 1982: Initial suggestion by Abraham et. al. (1982) of using Oxy-Coal Combustion to produce CO2 for EOR 1 st public document looking at capturing CO2 from flue gas using oxy-combustion. As early as 1978 economic feasibility of oxy-coal combustion was investigated for EOR application (H. Farzan, Babcock & Wilcox / A. Wolsky, ANL) 5 major pilot scale studies between ANL Research Programme Battelle (115 kw) EERC (3 MW) EU IFRF IFRF (2.5 MW) MBEL Air Products Naples & Ulster University (150 kw) International Combustion Imperial College EDP IST (150kW & 35MW) NEDO IHI (1.2 MW) CANMET (300 kw) US DOE B&W / Air Liquide (1.2 MW) 17

18 ANL - EERC Study World s 1st Oxy-Coal Industrial Pilot Scale Study Tower Furnace (~ 3MWth) 18

19 Oxy-Coal / Fuel Oil Combustion Boiler Projects (1 MWe = 3 MWt = 10 MMBtu/hr) SASK Power Utility Boilers MWe 10.0 Industrial Furnaces CS Energy Jupiter 20.0 DOOSAN-Babcock International Combustion 11.7 Vattenfall 10.0 TOTAL 10.0 JSIM/NEDO Jupiter CIEMAT ANL/EERC IFRF ENEL IHI B&W/AL 0.4 PowerGen 0.3 ANL/BHP Test 0.2 RWE-NPOWER Furnaces IVD-Stuttgart 0.2 CANMET Year 19

20 Oxy-Coal Combustion Technology Oxy-Combustion is the use of oxygen instead of air for burning of fuel. this technology is the least mature among the 3 mostly considered capture technology options for the power generation. For boiler application, part of the flue gas is recycled to reduce flame temperature. 3 main development issues Boiler and burner development ( design issues ) Air Separation Unit Cost and capacity of oxygen production CO2 processing Removal of impurities 20

21 Oxy-Coal Combustion Technology Air Oxygen Air separation Recycled flue gas Vent Fuel Boiler Cooling Purification/ (+FGD) compression CO 2 Steam Steam turbine Power 21

22 COAL HP HP HEATER ADVANCED SUPERCRITICAL BOILER MILL STACK (START UP) IP ID FAN DEAERATOR LP HP PUMP ESP FGD CONDENSOR LP HEATER COLD FD FAN LP PUMP AIR IN 22

23 Convective Section of the boiler heat transfer profile Burner design issue ash deposition and fouling issue Ignition HP HP HEATER ADVANCED SUPERCRITICAL BOILER MILL COAL flame stability devolatilisation & char burnout STACK (START UP) IP ID FAN DEAERATOR Radiant Section of the Boiler heat transfer profile slagging issue LP 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 23

24 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 PRODUCT FOR COMPRESSION 3 GAS COLD PA FAN GAS COOLER & WATER REMOVAL AIR INTAKE START UP 4 24

25 Balance fed direct to burner BFW System Steam turbines Maximum 23% Oxygen!! 340º C 105º C Boiler 270º C ESP Coal Mill ASU 330º C Secondary CO2 Recycle Hex Primary CO2 Recycle 250º C Cool & dry CO2 product 25

26 Oxy-Coal Combustion Technology Development (Burner and Boiler)

27 Composition of the Comburent Through the Burner Throat (Secondary Air) (Babcock and Wilcox) 27

28 Composition of Flue Gas (Babcock and Wilcox) 28

29 Gas compositions (omitting non-condensables) and volumes for bituminous coal fired with air and oxygen (Courtesy of Prof. Adel Sarofim University of Utah) Air Firing Oxy-Firing CO 2 17 % by volume 64% H 2 O 8.9% 34% NO x 2770xCR* ppm 10,700xCR 700xCR* ppm SO x 2470 ppm 9400 ppm Moles CR* = fractional conversion of coal nitrogen to NO x + Bituminous Coal Empirical Formula (CH1.1O0.2N0.017S0.015)

30 Recyled Flue Gas Ratio Impact to the Flame Properties R = m m + RFG m PFG m RFG

31 Adiabatic Flame Temperature and Flue Gas Volume as Compared to Recycle Ratio 31

32 Optimum Recycle Ratio Critical factors that may affect on these values: Amount water in the recycle flue gas Amount of air in-leakage (Air Ingress) 32

33 Flame Description Impact of Recycle Ratio (Courtesy of IFRF) Figure 3(a): normal air-fired operation Figure 3(b): O 2 -RFG flame with recycle ratio = 0.58 Figure 3(c): O 2 -RFG flame with recycle ratio = 0.76 Figure 3(d): O 2 -RFG flame with recycle ratio = 0.52

34 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%) 34

35 Coal Flame Photos: Impact of Recycled Flue Gas (Courtesy of IFRF) Recycle Ratio = 0.58 (~ 0.61 include the CO2 to transport coal) Recycle Ratio =

36 Ratio of Convective Heat Transfer Coefficientficient (Courtesy of IFRF) h h 1 0 = n 3 Re1 Pr1 Re 0 Pr0 1 k k 1 0 Effect of Recycle Ratio on Convective heat transfer coefficient [IFRF APG1 Trials] 36

37 Radiative Heat Flux Measurements (Courtesy of IFRF) Ellipsoidal Radiometer Results were also obtained by: ANL-EERC CANMET Data from Narrow Angle Radiometer is necessary for radiation modelling development Radiative Flux Using Ellipsoidal Radiometer in Air (Baseline) and O 2 /RFG (Flames B with recycle ratio = 0.73 and Flame C with recycle ratio = 0.58) IFRF APG2 Trials Knowledge gap is in the radiation factor contribution of solid particles in the furnace 37

38 Issue of Air Ingress (Air In-leakage) 1 st Large Scale Demonstration of Oxy- Coal Combustion (35MWth) What Are the Lesson Learned...

39 Problem with Air Ingress 1 st Large Scale Oxy-Coal Combustion Burner Test Experience - International Combustion Ltd. 30 MWth Low NOx burner Because of Air Ingress the desired CO2 composition (only ~ 28% dry basis). 1% of air ingress ~ 4% decrease in CO2 composition. the combustion trial gained significant experience in burner start up 39

Oxy-Combustion: KEY ISSUES SO3 issue is a big

air firing mode We need to know more about this

40 Oxy-Combustion: KEY ISSUES SO3 issue is a big missing link! ANL study (1985) have indicated that SO3 formation is 3 to 4 times greater as compared to conventional air firing mode We need to know more about this potential operational issue. From Chemical Engineering g Progress (Vol. 70) 40

41 Key Challenges Ahead Boiler and burner issues coal properties devolatilisation and ignition properties char burnout (reactivity) slagging, fouling and ash deposition pollutant emission how to deal with air In-leakage boiler materials in relation to corrosion. safety issue particularly in handling oxygen Large scale demonstration o of oxy-coal combustion o process 41

42 Oxy-Coal Combustion Technology Development (ASU / Oxygen Production)

43 For 500 MWe (Net Output) You will require ~10,500 t/d of oxygen! Air Separation Unit O 2 N 2 Cold liquid air Air HP MP LP 3.5 barg 5 barg Cold gaseous air reflux reflux by reboil reboil

44 Process Description: Oxygen supply Two levels of air compression (saves power) Oxygen production in HP/MP/LP 3 column system power reduced to 201kwh/ton Optimum oxygen purity suggested: 95% higher purity not worthwhile due to: Excess O2 requirement (19%) Boiler air in leakage (1%) ESP air in leakage (2%) 44

45 World s Largest ASU Issues involving ASU South Africa (operated by Air Liquide) ~ 5000 TPD Mexico (operated by BOC/Linde N2 production) ~ TPD Opinion i of industrial i gas producers with regard to development of very large scale ASU vs. development of novel oxygen production. Debate with regard to multiple ASU trains vs single large scale ASU train operation flexibility issue! 45

46 Oxy-Coal Combustion Technology Development (CO2 Purification and Compression)

47 Purification of Oxyfuel-Derived CO2 for Sequestration or EOR CO2 produced from oxyfuel requires purification Cooling to remove water Inerts removal Compression Current design has limitations SOx/NOx removal Oxygen removal Recovery limited by phase separation Necessary to define CO2 quality requirement!!!

48 Flue Gas Vent 1.1 bar 20 C 25% CO 2 75% inerts CO 2 Compression and Purification System Inerts removal and compression to 110 bar Flue Gas Expander Flue Gas Heater Aluminium plate/fin exchanger -55 C Driers bar Raw CO 2 Saturated 30 C 76% CO 2 24% Inerts CO 2 product 110 bar 96% CO 2 4% Inerts -60 C dp

49 CO 2 Purity and Recovery -55 C is as cold as we can make the phase separation CO 2 purity depends on pressure At 30 bar and -55 C, CO 2 purity is 95% Higher pressure gives lower purity CO 2 CO 2 recovery depends on pressure Lower pressure gives lower CO 2 recovery At 15 bar and -55 C, CO 2 recovery is 75% At 30 bar and -55 C, CO 2 recovery is 90% CO 2 recovery depends on feed composition Increases from zero at 25mol% to 90% at 75mol% Reducing air ingress increases CO 2 capture rate 49

50 CO 2 Purity Issues H 2 O CO 2 SO 2 NO O 2 Ar + N 2 + O 2 Basic Design Case < 500 ppm > 90% mol From H&MB From H&MB <4%mol < 4% mol EOR Case < 50 ppm > 90% mol < 50 ppm From H&MB 100 ppm < 4% mol Regulations regarding onshore and off-shore disposal are being drafted world-wide Co-disposal of other wastes (NOx, SOx, Hg) is a sensitive issue Important that the CO 2 can be purified for disposal or EOR 50

51 NOx SO 2 Reactions in the CO 2 Compression System We realised that SO 2, NOx and Hg can be removed in the CO 2 compression process, in the presence of water and oxygen. SO 2 is converted to Sulphuric Acid, NO 2 converted to Nitric Acid: NO + ½ O 2 = NO 2 (1) Slow 2 NO 2 = N 2 O 4 (2) Fast 2 NO 2 + H 2 O = HNO 2 + HNO 3 (3) Slow 3 HNO 2 = HNO NO + H 2 O (4) Fast NO 2 + SO 2 = NO + SO 3 (5) Fast SO 3 + H 2 O = H 2 SO 4 (6) Fast Rate increases with Pressure to the 3 rd power only feasible at elevated pressure No Nitric Acid is formed until all the SO 2 is converted Pressure, reactor design and residence times, are important. 51

52 CO 2 Compression and Purification System Removal of SO 2, NOx and Hg SO 2 removal: 100% NOx removal: 90-99% 1.02 bar 30 bar to Driers 30 C 67% CO 2 8% H 2 O 25% Inerts SOx NOx BFW Condensate 15 bar 30 bar cw Water Saturated 30 C 76% CO 2 24% Inerts cw cw Dilute H 2 SO 4 Dilute HNO 3 52 HNO 3 Hg

53 SOx/NOx Removal Key Features Adiabatic compression to 15 bar: No interstage water removal All Water and SOx removed at one place NO acts as a catalyst NO is oxidised to NO 2 and then NO 2 oxidises SO 2 to SO 3 : The Lead Chamber Process Hg will also be removed, reacting with the nitric acid that is formed (To What Extent???) 53

54 CO 2 Purity - Composition Raw Flue Gas CO 2 Product Vent CO 2 N 35 C, 102b 1.02 bara mol% C, C, 11b 1.1 bar mol% mol% Corrected Corrected O Ar SO NO 400 ppm NO 2 10 ppm H 2 O 5.6 < 10 ppm < 100 ppm < 10 ppm

55 Oxygen removal Option 2 Driers Feed to distillation column bar Raw CO 2 Saturated 30 C 76% CO 2 24% Inerts

56 Oxygen removal Option 2 Recycle to Feed Impure CO 2 30 bar column Pure CO 2 Pump to pipeline pressure or flash to tanker pressure Reboiler heated with feed stream 56

Purity, Recovery and Power Power includes ASU and CO 2 system power Description CO 2 Purity Oxygen Content CO 2 Pressure CO 2 Recovery Relative Specific Power Standard Cycle 95.90 mol% 0.

57 Purity, Recovery and Power Power includes ASU and CO 2 system power Description CO 2 Purity Oxygen Content CO 2 Pressure CO 2 Recovery Relative Specific Power Standard Cycle mol% 0.91 mol% 110 bar 89.0% 1.00 High Purity Option mol% ppm 110 bar 87.7% 7% bar liquid CO mol% ppm 30 bar 87.7% bar liquid CO mol% ppm 7 bar 87.7% 7%

58 Issues involving CO2 purification process We need to establish what is appropriate and acceptable level of impurities in our CO2 based on aspects of: Health, Safety and Environment considerations What are the regulations to be established without disadvantaging any capture technology (What is acceptable!!!) Quality specifications defined by transportation/delivery of CO2 to the storage sites Also to consider the changes to the CO2 properties by the impurities and its possible reactions Quality specifications defined d by the storage CO2 for different storage options The quality of CO2 (specific level of impurities) should be openly discussed! 58

59 Large Scale Oxy-Coal Combustion Projects that will provide a big step forward for Oxy-Coal Combustion 59

60 Schwarze Pumpe Oxy-Combustion Pilot Plant Time Table for Implementation of Oxy-Fuel Project Pre- and Order planning Permission planning Execution planning Erection Commissioning Operation Courtesy of Vattenfall 60

61 Artist s View of Vattenfall s Pilot Plant Courtesy of Vattenfall 61

62 Schwarze Pumpe Oxy-Combustion Pilot Plant Courtesy of Vattenfall AB 62

63 Doosan Babcock Burner Test (2008/09) 40 MWth 63

64 Callide A Project: Japanese-Australian Collaboration Nth Denison Trough Callide-A Power Station 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 Project. A Planned retrofit to a coal fired power plant with an oxy-combustion boiler 64

65 Japanese and Australian Co-operationoperation Callide-A AOxyCombustion Oxy-Combustion Retrofit Project IHI (Japan) and CS Energy (Australia) Project is also supported by the Australia Coal Association, JCoal, JPower (EPDC) FEED study is expected to be completed by end of this year Construction is expected to start by next year

66 Concluding Remarks Fundamental understanding di of the principles i of Oxy-Coal Combustion with Flue Gas Recycle have been well establish during the past 20 years of R&D activities There are still some gaps in knowledge but we are already ready for large scale demonstration of the technology. - We need to identify other potential show stoppers What is needed right now is to achieve the LARGE SCALE DEMONSTRATION OF OXY-COMBUSTION Oxy-combustion will be a competing option vs. post-combustion for coal fired power plant retrofit Oxy-combustion will be a competing option vs. IGCC for new built coal fired power plant. 66

67 Oxy-Coal / Fuel Oil Combustion Boiler Projects (1 MWe = 3 MWt = 10 MMBtu/hr) SASK Power Utility Boilers MWe 10.0 Industrial Furnaces CS Energy Jupiter 20.0 DOOSAN-Babcock International Combustion 11.7 Vattenfall 10.0 TOTAL 10.0 JSIM/NEDO Jupiter CIEMAT ANL/EERC IFRF ENEL IHI B&W/AL 0.4 PowerGen 0.3 ANL/BHP Test 0.2 RWE-NPOWER Furnaces IVD-Stuttgart 0.2 CANMET Year 67

Purification of Oxyfuel Derived CO 2 for Sequestration or EOR

2nd Workshop International Oxy-Combustion Research Network Hilton Garden Inn Windsor, CT, USA 25th and 26th January 2007 Hosted by: Alstom Power Inc. PRESENTATION - 10 Purification of Oxyfuel Derived for