CCS & OxyCFB The Challenges Ahead...

Transcription

1 CCS & OxyCFB The Challenges Ahead... Stanley Santos IEA Greenhouse Gas R&D Programme Juho Lipponen International Energy Agency FLEXIBURN Workshop 24 th March 2011

2 IEA Greenhouse Gas R&D Programme A collaborative research programme founded in 1991 Aim: Provide members with definitive information on the role that technology can play in reducing greenhouse gas emissions. Producing information that is: Objective, trustworthy, independent Policy relevant but NOT policy prescriptive Reviewed by external Expert Reviewers Subject to review of policy implications by Members IEA GHG is an IEA Implementing Agreement in which the Participants contribute to a common fund to finance the activities. Activities: Studies and Reports (>120); International Research Networks : Wells, Risk, Monitoring, Modelling, Oxyfuel, Capture, Social Research, Solid Looping; Communications (GHGT conferences, IJGGC, etc); facilitating and focusing R&D and demonstration activities e.g. Weyburn 2

3 Members and Sponsors

4 Global Policy Context International Policy Setting Implementation actions National/Corporate policy setting National/Corporate research programmes 4

5 2 nd International Oxyfuel Combustion Conference 12 th 16 th September 2011 Capricorn Resort, Yeppoon, Australia 5

6 Overview Overview to CO2 Capture and Storage Status of CCS Challenges ahead Where are We in the Development of Oxyfuel Combustion... Overview to the Technological Development of Oxyfuel Technology Boiler and Burner Development Oxygen Supply CO2 Processing Global Perspective on CFB the Challenge for OxyCFB Conclusions 6

7 Introduction STATUS OF CO2 CAPTURE AND STORAGE 7

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9 Over the past 20 years... Growth in Interest in CCS has been significant Conference Attendees Papers presented 9

10 Introduction CO2 CAPTURE AND STORAGE OVERVIEW 10

11 CO2 Capture and Storage (Full Chain) 11

12 CO2 Capture Options EPRI

13 CO 2 Transport Option Pipeline Mode of Transport Motor Trucks Rail CO2 transport, Cortez pipeline Ocean-going ships 13

14 Geological Storage Options Unminable Coal Seams 30 Gt CO 2 Able to store <2 Years of 2030 Emissions Depleted Oil & Gas Fields 930 Gt CO 2 Able to Store 50 Years of 2030 Emissions Deep Saline Aquifers Gt CO 2 Able to store Years of 2030 Emissions 14

15 Current CCS Projects Source: CO2CRC 15

16 Commercial Application of CCS (to date) Sleipner 1Mt/y CO2 Weyburn 2.5 Mt/y CO2 In-Salah 1.2 Mt/y CO2 Snohvit 0.7Mt/y CO2 Gorgon 3Mt/y CO2 350km overland pipeline 160km sub sea pipeline

17 Commercial Application of CCS (to date) 20 Integrated Demonstration Projects Sleipner 1Mt/y CO2 Weyburn 2.5 Mt/y CO2 In-Salah 1.2 Mt/y CO2 Snohvit 0.7Mt/y CO2 Gorgon 3Mt/y CO2 350km overland pipeline 160km sub sea pipeline

18 Key Message: Moving to demonstration Full scale demonstration of CCS is needed to establish confidence in the technology The G8 have set the goal of 20 demonstration projects by 2020 The IEA CCS Road Map has set out the case for 100 demonstration projects by 2020 and 3000 by

19 Introduction CHALLENGES AHEAD FOR CO2 CAPTURE AND STORAGE 19

20 Technical Status in Power Sector Post combustion capture demonstrated at 1Mt scale on natural gas Pilot plants on flue gas need to be scaled up Pre combustion capture (coal based IGCC) not yet demonstrated in integrated mode at scale Oxy fuel We are learning from the different pilot plants operation... Need the Demo experience for Scale Up 20

21 Energy Efficiency Penalty Adding CCS to a power plant will result in a reduction in power plant efficiency of between 4 and 10% Development of CCS in the power sector must go hand in hand with increased efficiency EC policy We advocate deploying CCS only on the most efficient power plant Coal plant (state of art) 47% LHV (sea water cooling) 43% LHV on lignite Higher temperatures will take to 50% LHV Gas Fired plant (state of art) 55% - 59% LHV New turbine designs will take this to 60% LHV 21

22 Challenges - Costs CCS costs Firm costs not available 1st of kind plants/near market conditions Currently capture costs about 75% of CCS project costs Studies by IEA GHG on plant replication have indicated that costs could decrease by 10-40% Technology developments could drive this lower EC R&D targeting 70% reduction 22

23 Transport Snohvit 160km Sub sea pipeline Permian Basin, 3000km pipeline network operating since mid 80 s Weyburn 300km transboundary pipeline Long distance transport of CO2 by pipeline is established technology 23

24 Challenges Financing the infrastructure Government? Industry? Allowing unrestricted access Avoiding filling up nearest reservoirs first Impacts of impurities Gas blends? Monitoring and liability for leakage? 24

25 CO2 Storage Snohvit capturing and injecting 0.7Mt/y CO2 since 2006 Rangeley injecting 3 Mt/y CO2 since 1984 Sleipner capturing and injecting 1Mt/y CO2 since 1996 Weyburn capturing and injecting 1Mt/y CO2 since 2000 In-Salah capturing and injecting 1Mt/y CO2 since

26 Challenges - Geology Long term monitoring needs? Storage capacity is there enough? Need to rely on aquifers Addressing security Pressurisation impacts? Brine displacement/water contamination? 26

27 Public Engagement We have work to do! The populace seem to be becoming more sceptical about climate change Politicians need to act Public opposition has stopped a number of CCS projects already Scientific community and industry 27

28 Public Engagement Need to learn from both positive and adverse experiences US study from Regional Partnerships Programme Barendrecht, the Netherlands Altmark, Germany Communications research network established by GCCSI and IEAGHG Aims to share experiences and establish best practise guidelines 28

29 Oxyfuel Combustion Technology STATUS IN THE DEVELOPMENT OF OXYFUEL COMBUSTION 29

30 ANL - EERC Study World s 1st Oxy-Coal Combustion Industrial Pilot Scale Study Tower Furnace (~ 3MWth) 30

31 Current Status: Oxy-Fuel Combustion Boiler Projects

32 Large Scale Pilot and Demo Projects Updated by S. Santos (01/12/10) PROJECT Location MWth Start Up Year 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 Bituminous Alstom (Windsor Facility) USA Pilot PC (Tangential) Bit., Sub B., PRB Vattenfall Germany Pilot PC Lignite (Bit.) With CCS Total, Lacq France Industrial boiler NG With CCS Callide Australia MWe PC Bituminous With CCS CIUDEN PC Spain Pilot PC Anthra. Bit, Lig. Coke With CCS CIUDEN CFB Spain Pilot CFB Anthra. Bit, Lig. Coke With CCS Vattenfall (Janschwalde) Germany ~ ? ~300 MWe PC Lignite (Bit.) With CCS Endesa/CIUDEN Spain ~ ? ~300 MWe CFB?? With CCS FutureGen2 USA ~ ? ~200 MWe PC Bituminous Coal With CCS KOSEP/KEPRI Yongdong Korea ~ ? ~100 MWe PC??

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34 CS Energy/IHI Burner Testing Programme at Callide A Power Station Callide A Project would be the world s 1 st oxyfuel retrofitted power station. First oxyfuel pilot plant that will actually produce electricity. Installation of 2 new Wall Fired Burners A unique position to provide information related to the burner burner interaction Project Scope (2-4 years operation): o Oxygen plant (nominal 2 x 330 tpd ASUs) o Boiler refurbishment and oxy-fuel retrofit (1 x 30 MWe Unit) o CO2 compression & purification (75 tpd process plant from a 20% side stream) o Road transport and geological storage (~ 30 tpd liquid CO2) Courtesy of CS Energy, IHI 34 34

35 CIUDEN CO2 Capture Programme. First oxyfuel pilot plant that will demonstrate in large scale the Oxy- CFB technology. Oxy-PC facility is very complimentary to Vattenfall s and Callide s facilities. Could be in a unique position to provide information related to the burner burner interaction (in smaller scale). 1 st facility to investigate Anthracite (this would be first in the world), Petcoke and Biomass. 35

36 Today... There are 3 Major Full Scale PC Burner Testing Facilities Worldwide Retrofitted for Oxyfuel Babcock and Wilcox (B&W) 30MWth CEDF Barberton, Ohio, USA Start of Operation: Oct Wall Fired Burner Development Doosan Babcock 40MWth in 90MWth MBTF Renfrew, Scotland, UK Start of Operation: Jun Wall Fired Burner Development Alstom Power Plant Lab. 15MWth in 30MWth BSF Windsor, Connecticut, USA Start of Operation: Nov T-Fired Burner Development Courtesy of Alstom, B&W and Doosan Babcock 36 36

37 Jänschwalde demonstration plant view from south east NH 3 -storage Cooling water pump PCC CO 2 -compression Fuel feeding Oxyfuel boiler Flue gas cleaning CO 2 -transport CO 2 -compression Preparation and cleaning of Lignite condensate Lignite dryer ASU Vattenfall AB 37

38 Jänschwalde demonstration plant. 500 MW with oxyfuel and post combustion capture Vattenfall AB 38

39 Where is my picture of Compostilla Oxy CFB 300 Project??? 39

40 Key Areas of Development Areas of Development Burner and Boiler Development Oxygen Production CO2 Processing Unit Some of the Challenges... Are we ready to demonstrate in large scale...? Reducing the Cost of Oxygen Production an important aspect to the demonstration and commericialisation of oxyfuel. How will the regulations define the CO2 purity??? 40

41 What are my expectations in today s discussion on OxyCFB... Understanding the key points in boiler development issue (including scale up/down and dual operation mode). Overall Performance (Boiler efficiency, corrosion issue, etc...) Flue Gas Recycle Ratio Heat Transfer Emissions (NOx, SOx, Others) o N2O Emissions (which should impact the design of the CO2 processing unit) Limestone performance Management of Air Ingress issue Etc... Etc... Etc... 41

42 OXYCFB Boiler design options Inaugural Workshop on OxyFuel Combustion, Cottbus, November , 2005 Boiler design Heat balances for varying loads/fuel qualities Optimisation of oxygen/recirc. gases Development of heat surface configurations

43 OXYCFB Roadmap/OxyCFB development Inaugural Workshop on OxyFuel Combustion, Cottbus, November , 2005 Foster Wheeler OXYCFB Concept -Design 500 MWe OXYCFB Demo MWe -O2 (21 35 %) Demo OXYCFB OTU Unit -250 MWe EU/US Demo 1 PHASE 1: OXYCFB Process study OXYCFB power plant Cost study Market study Private R&D R&D in consortiums EU/US Demo 2 Ciuden CFB Test Facility 300MWe OxyCFB Demo. (2015)

44 Cryogenic Air Separation Capacity Increase 1902 : 5 kg/h (0,1 ton/day) 2006 : 1,250 Mio kg/h ( ton/day) Linde AG Engineering Division 44 Bey/L/092009/Cottbus.ppt

45 Oxygen Production As of today, the only available technology for oxygen production in large quantities is cryogenic air separation. Advances and Development in ASU could result to 25% less energy consumption. These design would be based on either a 3 column design or dual reboiler design. 45

46 Points for Discussion ~10,000 TPD of O2 is required for a 500MWe (net) oxy-coal power plant with CCS. This means that you will need 2 single trains of 5000 TPD O2 Largest operating ASU today (single train) ~4000 TPD O2. Remaining Issues What could be the maximum capacity of oxygen production per train? Operation flexibility (i.e. load following, etc ) What will you do about the large volume of Nitrogen produced from this ASU? 46 46

47 Where are the other gaps in R&D for oxygen production? Non-conventional oxygen production ITM ions transport membrane (Air Products) OTM oxygen transport membrane (Praxair) CAR ceramics autothermal recovery (Linde / BOC) Chemical Looping Combustion 47 47

48 Challenges to CO2 Processing Unit The CO2 processing unit could be very competitive business (an important growth area) for industrial gas companies. Challenges are: Demand of the quality requirements of the CO2 from the power plant for transport and storage. What are the Required Specification? Further recovery of CO2 from the vent will make oxyfuel more competitive if high recovery of CO2 is required! Need a large scale demonstration of the CO2 processing unit using impure CO2 as refrigerant. 48

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50 25%mol CO2 75% inerts (~ 15% O2) 25%mol CO2 75% inerts (~ 19% O2) 76%mol CO2 24% inerts (~ 5-6% O2) 96%mol CO2 4% inerts (~ 0.95% O2) 72%mol CO2 28% inerts (~ 5-6% O2) 98%mol CO2 2% inerts (~ 0.6% O2) 25%mol CO2 75% inerts (~ 15% O2) 25%mol CO2 75% inerts (~ 15% O2) 72%mol CO2 28% inerts (~ 5-6% O2) 99.95%mol CO2 0.05% inerts (~.01% O2) 72%mol CO2 28% inerts (~ 5-6% O2) %mol CO % inerts (~.0005% O2) 50

51 Use of Membrane to recover CO2 and O2 at the vent Vent: 7% CO 2 93% inerts (~10% O2) Product 96% CO 2 4% inerts (~0.75% O2) 51

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53 GLOBAL PERSPECTIVE OF CFB AN IMPORTANT CONSIDERATION TO THE DEVELOPMENT OF OXY-CFB 53

54 Application of CFB Worldwide (Based on 2009 statistics FW, Alstom) Foster Wheeler Alstom World No. of Units Total Capacity (MW) 24,526 10,193 In South East Asia No. of Units Total Capacity (MW) 64 7, ,076 About 500 CFB units around the world Over 170 CFB units in the US Over 350 CFB units in China 54

55 Application of Coal Fired CFB in S. E. Asia (Case Study: Visayas, Philippines) All the new build coal fired power plant in that small corner of South East Asia are based on CFB technology (80-120MWe per unit) 55

56 Concluding Remarks SUMMARY AND KEY MESSAGES 56

57 Summary CCS Technology has come along way in 20 years Demonstration of CCS is crucial in next 10 years Must win public hearts and minds Must move past demonstration quickly into widespread implementation Need mechanism to support CCS in developing countries 57

58 Alstom Schwarze Pumpe MWth Lignite Hitachi Babcock Schwarze Pumpe MWth Lignite IHI Callide MWe Coal Alstom / AL Lacq MWth Gas/Oil? CIUDEN El Bierzo CFB Facility MWth Coal CIUDEN El Bierzo PC Facility MWth Coal 2008 Vattenfall - Janschwalde (PC -250MWe) KEPCO/KOSEP - Yongdong (PC - 100MWe) FutureGen2 - Illinois (PC - 100MWe) Endesa/CIUDEN - El Bierzo (CFB - 300MWe) 2009 Lacq World s first 30MWt retrofitted Oxy-NG boiler World s FIRST 30 MWt full chain demonstration at Schwarze Pumpe Pilot Plant 2011 Callide World s first 30MWe retrofitted Oxy-coal power plant 2011 CIUDEN World s first 30MWt Oxy-CFB Pilot Plant By Demonstration of MWe full scale power plant. Target : Commercialised by s EC Joule ThermieProject -IFRF / DoosanBabcock / Int l Combustion NEDO / IHI / JcoalProject ANL/Battelle/EERC completed the first industrial scale pilot plant Vattenfall(ENCAP ++) CS Energy / IHI Callide Project CANMET US DOE Project / B&W / Air Liquide B&W CEDF (30MWt) large scale burner testing started First large scale 35MWt Oxy-Coal Burner Retrofit Test done by International Combustion By the end of 2010/2011, Users (i.e. Power Plant Operators) will have 6 burner manufacturers fully demonstrating Utility Size Large Scale Burners which should give a high level of confidence toward demonstration B&W CEDF MWth Coal Alstom Alstom CE MWth Coal Doosan Babcock DBEL - MBTF MWth Coal Updated by S. Santos (01/12/10)

59 Summary Oxyfuel Oxyfuel Combustion Technology is a viable option for any coal fired power plant with CO2 Capture. Oxyfuel Combustion Technology is an option for new build, repowering or retrofit cases. We need to demonstrate Oxyfuel Combustion Technology to build our confidence. Business Sense, it could have a simple business model for power generation companies wherein the operation of the ASU and CO2 processing could be outsourced with a long term supply contract from the industrial gas companies. 59

60 Burner & Boiler Development Demonstration via large scale burner testing is essential to the development of oxycombustion. Key areas of R&D should focus on: Heat transfer and flame properties Coal devolatilisatoin and char combustion Slagging, fouling deposition characteristics Corrosion (low and high temperature regime) Emissions (sulphur chemistry, PM and Hg + trace metals) Development of CFD modelling is an essential tool to help design of future burners and boilers. 60

61 ASU & CPU Air Separation Unit : improvement in performance is available now - But what is balance between CAPEX or OPEX CO2 CPU : feasibility is confirmed but design will remain conservative until pilot plants are started; significant improvements in performance are achievable for cryogenic unit Integration of ASU and CO2 Processing Unit in the overall oxyfuel combustion plant are key to achieve high efficiency and low capital expenditure Should also consider looking at novel oxygen production 61 61

62 Development of OxyCFB 600 Unit Capacity (MWe) Lagisza Pilot Plant Tri-State Oriental Chem AIR-FIRED Nova Scotia Vaskiluodon General Motors Start-Up Year Turow 1 JEA OXY-FIRED CIUDEN TDP Pilot Plant Compostilla

63 Summary OxyCFB Challenge in the Development of OxyCFB should not only be limited to its application in the large (medium) scale (i.e MWe). BUT an important part to this development is the application of OxyCFB in the smaller scale version (i.e MWe) Understanding on how to retrofit Oxyfuel Technology to the current fleet of CFB s should be considered for future application (especially in China and S.E. Asia) 63

64 Thank you Website: