Oxy-coal combustion pressurized technology: Status and developments

Transcription

1 Oxy-coal combustion pressurized technology: Status and developments Giancarlo Benelli, Nicola Rossi, Sigali Stefano Enel Engineering & Research SpA IFRF -TOTeM June 2014 Varsaw - Poland

2 Basic concepts and process Process, analyses and peculiarities : ENEL-ITEA main activities and results Zero Emission Power Plant:Feasibility study Remarks References USE: Public Issuing ENEL E&R 2

3 ENEL-ITEA collaboration( ) Main activities and results 2006 The oxy-fuel flameless pressurized combustion process was operated at the 5MWt facility in Gioia del Colle (GdC) with very interesting environmental performances using waste and solid fuels; the 1st phase agreement Enel - ITEA for oxycoal firing assessment was signed (13/10/2006) 2007 After specific coal campaigns in GdC and verification of environmental advantages of the pressurized system for CO2 capture, the evaluation of the application of the innovative process to power station was decided 2008 (April) Phase 2 cooperation agreement Enel ITEA was signed 2008 (June) Upgrade of the 5MW oxyfiring plant in GdC for coal feeding MW waste incinerator based on ISOTHERM process in Jurong island was completed Within ITEA Enel Agreement-Phase 2 the following activities were carried out: Test results obtained on 5MW facility ensured a wide fuels flexibility from waste to low rank coals; Design of the 50 MW pilot plant as intermediate step in process scale-up towards demo power station was completed, relatively to a 50 MW plant, integrated with a coal fired power station Joint development of Enel-MIT analyses suggested to proceed with FEED (at least 300Mwe) Analyses jointly developed by Enel and MIT ( ) proved that the technology could be considered for a 320 MWe plant development, providing very competitive CAPEX compared to others CCS options 2010 ITEA Enel agreement signed for FEED development suitable for Zero Emission Plant demo Development of technologies and testing activities using: liquids, fossil fuels, waste and biomasses Feasibility study in high pressure conditions (in progress) Partnership building for joint development of scale-up and DEMO initiative (50 MWe 400 MWe) 3

4 Why pressurized oxy fuel option? What are the techno-economic statements? Adoption of pressurized oxy-fuel combustion systems leads to better performance compared to atmospheric solutions Process pressure has a huge impact on heat recovery from the flue gas Process has peculiarity of limited flying ashes towards Heat Recovery Steam Generator (HRSG), thanks to a slagging flameless combustor High levels of CO 2 purity Economic benefits from the capability to burn cheap coals Process pressure has shown a small effect on the overall compression work associated to O 2 and CO 2 compression Heat transfer coefficients in the pressurized (10 bar) convective boiler are expected one order of magnitude higher than those of convective sections of conventional boilers; Pressurized boiler capable of ensuring a wide operating flexibility was designed for 50 MWt (patent procedure pending) 320 MWe Zero Emissions Plant economics (max feasible single reactor size) were preliminarily evaluated with respect to others Carbon Capture and Storage options; preliminary analyses on higher efficiency cycles integrating ISOTHERM process were developed since

5 Why pressurized oxy fuel option? What are the techno-economic statements? The coal power station based on pressurized oxy-fuel firing process, can be retrofitted in existing plant saving existing turbo-machinery and limiting its out of service 15 MW ISOTHERM process fed with toxic waste in operation in Jurong Island ISOTHERM process operation experience ensures that it might be a promising option for CCS such as in the following: MWt processes might have potential for application on oil fields to produce CO 2 for Enhanced Oil Recovery (EOR) MWt process can be evaluated for an application as combined heat and power (CHP) and district heating zero-emission plants by systems integration within grid pipelines of coal water slurry, oxygen and CO MWt coal fired Zero Emission Plants based on modular components seem an economical option for green field applications, since modularity might allow easier retrofitting 5

6 Pressurised oxy-coal firing concepts and process ISOTHERM : Process Loop Oxygen Coal water slurry Concentrated Gaseous mixture of Carbon dioxide The peculiarity of ISOTHERM process is flue gas recirculation without any flue gas treatment systems Coals with lower ashes melting points can be used Coal/biomass/waste slurry feeding ensures safety operation and a clean and cheaper logistic 6

7 ISOTHERM : 5MW pilot plant Experimental Facility (2008) O2 Storage HRSG Combustor Mill 7

8 Power station (350 Mwe): Feasibility study Basic design data SITU POWER PRESSURE BATTERY LIMITS Brown field retrofit Minimum integration with other power units in order to get data suitable for other sites 500 MWe gross power using South African Kleincopie coal, Thermal gross power 1200 MWt Power Capacity due to: site space constraints- Modularity; scale up of ISOTHERM LOOP (Heat Recovery Steam Generators +reactors ) Operating pressure: 10 bar(a) Coal park feeders CO 2 compressor exit CO 2 transport and storage not included in cost analyses 8

9 Power station (350 Mwe):Feasibility study Pressurized oxy coal process 9

10 Performance Basicdata Performances and consumptions have been estimated on existing technology options, according to maximum feasibility without any optimization Performance description Units Base load Thermal input (Lower heating value ) MW th Thermal input (Higher heating value ) MW th ST Power generated MWe 500 Auxiliary consumption MWe 149 NET POWER MWe 351 Net efficiency (Lower heating value ) % 33,4 Gross efficieny (Lower heating value ) % 47,6 Net efficiency (Higher heating value ) % 32,4 Gross efficiency (Higher heating value ) % 46,2 Auxiliary services The innovative Heat Recovery Steam Generator could be designed to produce HT steam (700 C) (patent pending) Partnership based on technology developers could optimize the several components and the system integration to reduce auxiliary consumption with substantially improving efficiency 10

11 Remarks Pressurized oxy coal combustion may be considered as a 2nd generation CCS technology option Adoption of pressurized oxy-fuel combustion systems leads to better performance compared to atmospheric solutions Process pressure has a huge impact on heat recovery from the flue gas High levels of CO 2 purity are viable Huge benefits from the capability to burn cheap coals Process pressure has shown a small effect on the overall compression work associated to O 2 and CO 2 compression Heat transfer coefficients in the pressurized (10 bar) convective boiler are expected one order of magnitude higher than those of convective sections of conventional boilers The Pressurized Oxy-firing technology is now already available at commercial scale up to 15 MWt demonstrated in waste to energy applications FEED developed has demonstrated complete feasibility of the innovative process on coal combustion and large scale feasibility. A step by step procedure in scale up is highly recommended, because several design parameters of the innovative components (reactor, slurry system, boiler, gas treatment) must be optimized in order to allow a better integration for energy penalties and cost of energy reduction The solution proposed can be a suitable solution to give future to zero emission power plant fed with coal and waste Being a zero emission power plant fed by coal slurry and oxygen pipelines, and due to the modularity of its thermal components (reactors, boilers) as well as the huge fuel flexibility, the proposed innovative concept might be suitable for green cities 11

12 References G. Benelli and M. Gazzino, "Pressurized Oxy-Coal Combustion Rankine-Cycle for Future Zero Emission Power Plants: Process Design and Energy Analysis," in ASME Conference Proceedings, ASME-ES J. Brisson, G. Chaudhry,, R. Field M. Gazzino,J. Hong, and A. Ghoniem, "Analysis of Oxy-fuel Combustion Power Cycle Utilizing a Pressurized Coal Combustor," Energy, pp , R. Field,, M. Gazzino A. Ghoniem and J. Hong "Operating pressure dependence of the pressurized oxy-fuel combustion power cycle," Energy, pp , G. Benelli, G. Girardi, M. Malavasi and A. Saponaro, Isotherm: A new oxy-combustion process to match the zero emission challenge in power generation, 7th High Temperature Air Combustion And Gasification International Symposium, G. Benelli, M. Gazzino, G. Riccio, and N. Rossi "Pressurized Oxy-Coal Combustion Rankine-Cycle for Future Zero Emission Power Plants: Technological Issues," in Proc. Energy Sustainability, ASME, San Francisco, CA, USA, ASME ES M. Gazzino, A. Mitsos and H. Zebian "Multi-variable optimization of pressurized oxy-coal combustion," Energy, pp , D. Cumbo,M. Gazzino N. Rossi, A. Mitsos and H. Zebian "Optimal Design and Operation of Pressurized Oxy-Coal Combustion with a Direct Contact Separation Column," Energy, vol. 49, G.Benelli, M.Malavasi, N. Rossi Flameless pressurized Oxy-coal: the top of power cost competition for CCS, and the best cost option along the transition to near-zero emission - International Pittsburgh Coal Conference - Beijing September 18 th,

13 THE REAL REVOLUTION IS NOT TO CHANGE THE WORLD RATHER THAN CHANGING THE PLANET, WE HAVE ALWAYS PREFERRED TO CHANGE OURSELVES