Alstom s Oxy-Firing Technology and Demonstration: Near, Medium and Long Term CO2 Solutions

Transcription

1 Alstom s Oxy-Firing Technology and Demonstration: Near, Medium and Long Term CO2 Solutions John L. Marion 1 st International Oxy-Combustion Conference Cottbus, Germany September 08, 2009

2 The Alstom Group: a worldwide leader in its activities Total orders 2008: 25 Billion Transport N 1 in hydro power N 1 in integrated power plants Power N 1 in conventional nuclear power island Recent acquisition of wind power Coal, Gas, Hydro, Nuclear, Wind = Full Power Systems Portfolio IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 2 N 1 in air quality control systems N 1 in services for electric utilities

3 CO 2 Capture Solutions within Alstom Power Plant with CO2 capture Post-combustion (New + retrofit) Oxy-combustion (New + retrofit) Pre-combustion (New only) Source: Vattenfall Solutions developed by Alstom CCS must be also applied to the installed base IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 3

4 CO 2 Capture Solutions Post-combustion (New + retrofit) Oxy-combustion (New + retrofit) Alstom Actively Developing Carbon Capture Technologies for More Than a Decade Post Combustion Scrubbing - Chilled Ammonia - Advanced Amine Oxy Combustion - Oxy Pulverized Coal - Oxy Circulating Fluid Bed - Chemical Looping IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 4

5 Oxy-Combustion Process Advantages Reliability: main components exist, only adaptation to power gen and scale-up All types of boilers / firing systems adaptable to Oxy covering a complete fuel range Rapid scale-up to large size (1,000 MWe range) possible after large demos. Retrofit in Oxy feasible High efficiency and competitiveness of supercritical/ultra-supercritical cycles and large unit size will be compatible and key benefits Large community involved in development, contributing to reaching solid consensus Oxy-combustion : a solid option for CO2 capture IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 5 3D View of an Oxy-PC (800MWe gross) Source: Alstom

6 Alstom Oxy Combustion Technology Development Steps < 2020 Scale Up Full-Scale MWe 2000 Demonstration MWe Large Pilot Plants MWth Lab Scale <1 MWth IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 6 *Startup years

7 Alstom Oxy Combustion Technology Development Steps < 2020 Reference Design Studies Scale Up Full-Scale MWe 2000 Demonstration MWe Lab Scale <1 MWth Large Pilot Plants MWth IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 7 Modeling & Tool Dev.

8 800 MW Oxy-PC Reference Plant IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 8

9 Oxy-PC Power Plant - Optimized Integration with ASU, Boiler, APC, FGC, and GPU Boiler Gas Preheater 100% 43% 57% FGD - NID Gas Condenser 36% Gas Processing Unit Pipeline CO 2 coal Fabric Filter secondary recirc 21% primary recirc Pulverizer oxygen nitrogen Air Separation Unit air IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 9

10 Alstom Oxy Combustion Technology Development Steps Exhaust Gas Analysis/Data Acquisition Systems: Filter CO 2, CO, O 2, NOx, N 2O, SO 2, THC Cyclone Observation Port Pressure Sensor Fuel/Sorbent Screw Feeder Cooling Coil Heating Element Thermocouple Port Insulation < 2020 Weigh Scale Thermocouple Port Rotary Air Lock Pressure Sensor Reactant Gas Preheater Freeboard Thermocouple Pressure Sensor Bed Thermocouple Grid Plate Air O 2 CO 2 N 2 Pressure Sensor Bed Drain Underfire Gas combustion Scale Up materials 2000 Lab Scale <1 MWth 2008 IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 10 Since 1998 and up to 500 kwth Oxy Coal Testing Alstom Labs U. Stuttgart U. Cottbus U. Hamburg-Harburg U. Dresden ENCAP (EC Co-funded Project) ADECOS I & II (GER Co-funded Project) OxyBurner (EC Co-funded Project) OxyCorr (EC Co-funded Project) Gas cleaning and condensers

11 Simulation and Modeling for Oxy-Fired Power Plants CFD modeling submodel improvements: soot, radiation, chemistry Validation in small combustion tests Application to pilot tests and further validation Applied to scale up for full scale reference designs and demonstration projects System modeling ASPEN, ANSYS APECS Boiler performance modeling Alstom ALPRO 15 MWt BSF Oxy Simulations Temp [K] Case 1 Case 2 AIR OXY 850 MW Boiler Simulations IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 11

12 Alstom Oxy Combustion Technology Development Steps Scale Up 2008 to present Large Pilot Plants MWth IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 12

13 Oxy-Combustion Pilot - TOTAL Lacq 30 MWth Main features Retrofit to Oxy of a 30 MWth existing boiler (natural gas) Located in SW of France Oxyfuel process to start mid 2009 Approx 150,000 t CO2 to be stored on a 2 year-period in a depleted gas field Source: Total 30 MWt retrofitted Boiler Lacq, France ALSTOM scope : Boiler retrofit First CCS with pipeline transportation & storage IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 13

14 Oxy-Combustion Pilot Alstom BSF 15 MWth Project Objectives: Alstom Boiler Simulation Facility Windsor, CT, USA Tangentially Fired Oxy Demonstration Determine boiler design and performance impacts for oxy-combustion Evaluate and improve engineering and simulation tools for oxy-combustion Design and develop innovative oxy-firing system for T-fired boilers Schedule October 2008 to September Months IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 14

15 Oxy-Combustion Pilot Alstom BSF 15 MWth Project Team: Alstom Power Plant Laboratories Alstom New & Retrofit Boiler Business DOE NETL ICCI Utility Advisory Group Ten Utility Members: Ameren ATCO Dominion Energy Great River Energy Luminant (TXU) LCRA and Austin Energy MidWest Generation NB Power OG&E Vattenfall IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 15

16 Oxy T-Fired 15 MWt Pilot Testing Test Campaigns: BSF Campaign 1 - Subbituminous Coal (PRB) - Baseline Air-firing and Oxy-firing - Evaluate Broad Range of Oxy Process and Firing System Design Options BSF Campaign 2 - Bituminous Coal - Optimize Selected Design BSF Campaign 3 - High Sulfur Illinois Coal - Gas Recycle Before and After FGD BSF Campaign 4 - US Lignite - German Lignite for Link With 30 MWt Schwarze Pumpe Tests Alstom Boiler Simulation Facility IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 16

17 15 MWt Boiler Simulation Facility Modifications Major New Equipment Oxygen Supply and Injection System Gas Recirculation Systems Fabric Filter for Particulate Removal Dry SO2 Scrubbing System (NID) Instrumentation and Controls BSF Test Furnace and C onvection Pass Oxygen Storage and Supply System Existing Gas-Gas Preheater New G as Recycle Fan Air Products Gas Purification PDU New Fabric Filter and NID Scrubber Existing Scrubber General Design Operate Both Air- and Oxy-fired 5 Different Operating Configurations Control of Oxygen Injection - Premixed or Local Injection - Variable Concentrations - Multiple Locations, etc. New Gas Boost Fan Gas Heat Exchanger IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 17

18 Oxy-PC pilot demonstration Schwarze Pumpe 30 MWth Boiler ESP FGD FGC Air Separation Unit CO2 Compression Control Room CO2 Purification Main features Boiler 30 MWth 40t/h Coal 5,2 t/h lignite Cycle 25b/330 C Oxygen 215 t/day CO2 11 t/hr Alstom scope:oxy-boiler + ESP (source: Vattenfall) Boiler started Sept 08 - PAC Dec 08 Testing on-going IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 18

19 Results from Operation Oxy Firing Total Operation Air Operation Oxyfuel Operation Burner Pre-mixed Mode Burner Expert Mode 3000 h 1500 h 1500 h 1000 h 500 h Oxy-Firing (premixed mode) Burner operates in pre-mixed and expert modes stable and reliable Limits for emissions easily met for oxy mode of operation Good burnout with low unburnt carbon in fly ash and slag Testing continues Air-Firing IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 19

20 Scale-up challenge from 2008 to X800 MWe 10 MWe IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 20 Source: Vattenfall

21 Oxy-PC Jänschwalde MWe Main features Existing plant 250 MWe gross Location: 100 km SE of Berlin New oxy-boiler 815t/h SH/RH 535/540 C, 165/40b Lignite fuel Feasibility study recently completed with Alstom participation (source: Vattenfall) EU flagship program candidate IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 21

22 Alstom Oxy Combustion Technology Development Steps < 2020 Scale Up Full-Scale MWe 2000 Demonstration MWe Large Pilot Plants MWth Lab Scale <1 MWth IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 22 *Startup years

23 Oxy-Combustion Process - Main Challenges Development of Oxy-Fired Boilers - Firing system - Air In-Leakage - Heat Transfer - Pollutant Formation - Ash Deposition - Fireside Corrosion - Reduced FGR - Gas Cleanup & Condenser selection - Development and Scale-Up of GPU - Cost & Power reduction of ASU - Systems Integration and Optimization (Cost minimization) - Demonstrations 3D View of an Oxy-PC (800MWe gross) Source: Alstom Oxy-combustion : a solid option for CO2 capture IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 23

24 Oxy-Combustion Roadmap (Innovative Future Paths) CO 2 N 2 To Steam Cycle Performance Coal Reducer Oxidizer Air Cost CaCO 3 Steam CaSO 4 CaS Ash, CaSO 4 to Disposal O 2 FDA Combustor FBHE W/ Bypass Separated Overfire Air 100% Oxy-Fired 100% Oxy-Fired Using FBHE Using FBHE Main Burner Zone Fuel Demo s & Pilots Air Oxy Commercial [ Retrofit, CO2 Ready, New ] IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 24 Time Reduced FGR Oxy-Plants Commercial Advanced Oxygen Production Chemical Looping Commercial

25 Oxy Combustion Technology Paths AIR N 2 A S U Fuel O 2 C O M B U S T O R B A C K P A S S Pulverized Coal Firing H 2 O VENT GPS AIR N 2 A S U Fuel O 2 C O M B U S T O R B A C K P A S S External Heat Exchanger Circulating Fluid Bed Combustion H 2 O VENT GPS CO 2 IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 25

26 Future potential to reduce boiler size Oxy-Fired CFB Boilers 350 MWe Boiler Low and High Furnace O2 Cases Steam Drum Cyclone & Sealpot Steam Drum Cyclone & Sealpot Panels Backpass Panels Backpass Reduced Size Combustor Air Heater Combustor Plan Area Reduced Size FBHE (Added or Increased) Dual Air-AIR-FIRED and Oxy-Fired CFB BOILER CFB Air heater Reduced Size High Furnace OXY-FIRED O2 Oxy-Fired CFB BOILER CFB IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 26

27 350 MW Oxy-CFB Reference Plant IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 27

28 Oxy-CFB Over 300 hours pilot operations completed by Alstom with oxy-firing Furnace oxygen concentrations ranging from 21% (synthetic air) to >70% Potential for reduced recycle FGR and resultant smaller boiler & APC Market segmentation as with air-fired CFB s (low quality fuels) 3 MWt pilot CFB Windsor, CT, USA Ready for demonstration IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 28

29 Oxy-combustion: Chemical Looping Combustion (CLC) Fuel reactor Combustion products (CO 2 +H 2 O) O2 Coal CLC features 100% CO2 Capture No Air Separation Unit Hot carrier with O 2 MeO or CaSO4 Cold carrier without O 2 Depleted air O2 steam Air reactor Air (O 2 +N 2 ) Lowest Cost CO2 Capture High Net Plant Efficiency IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 29

30 ÉCLAIR: MeOx prototype development Emission Free Chemical Looping Coal Combustion Process 4m 6m 17m 9th March 2009: At the University of Technology of Darmstadt, the foundationstone was laid for the 1 MW metal oxide chemical looping pilot plant - EU RFCS project 9m 32m 23m TECHNISCHE UNIVERSITÄT DARMSTADT IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 30

31 CaS Chemical Looping Development Status Pilot Facility Phase I/II/III programs completed: Tested individual loops and processes 3-year test program successfully completed All chemistry/rates verified Comprehensive solids transport testing Solids Heater 2-Stage Cyclones (2) 3 MWt Spray Coolers & Filters (5) Reducer Sealpot Control Valves (2) Ash Coolers (6) 65 kwt Alstom Pilot in USA Product Gas Burner Oxidizer IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 31 Prototype Facility Phase IV program Oct MWt [1,000 lb/h coal flow] 1st integrated operation Auto thermal operation Engineering/operating information for industrial demonstration

32 Summary - Alstom Oxy-Combustion Technology Development Steps < 2020 Scale Up Full-Scale MWe 2000 Demonstration MWe Lab Scale <1 MWth Large Pilot Plants MWth READY FOR THE NEXT STEP IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 32

33 Summary - Alstom activity on demonstrations Running / Commissioning In construction Study / Engineering We Energies Pleasant Prairie USA - 5 MWth Chilled Ammonia - Coal Vattenfall Schwarze Pumpe Germany - 30 MWth Oxy - Lignite AEP Mountaineer USA - 30 MWth Chilled Ammonia - Coal PGE Belchatow Poland - 20 MWth / 250MWe Adv. Amines - Lignite Vattenfall Jänschwalde Germany MWe Oxy - Lignite EoN Karlshamn Sweden - 5 MWth Chilled Ammonia - Fuel/Gas Total Lacq France - 30 MWth Oxy - Gas Dow Chemical Co. USA, West Virginia Advanced Amines Statoil Mongstad Norway - 40 MWth Chilled Ammonia - Gas Transalta Canada - >200 MWe Chilled Ammonia - Coal Pre-selected for European Energy Programme for Recovery funding IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 33

34 Summary Major large oxy pilot projects underway; Alstom active in Schwarze Pumpe, Lacq, and own labs These pilot programs are providing very positive feedback and, in particular, represent a strong foundation for design of next-step demonstration FGD Flue gas - Condenser ESP Boiler ASU Alstom is ready for large-scale demonstration of oxy-fired PC and CFB power plants CO 2-Plant Switchgear building IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 34

35 Alstom The Clean Power Specialist Today we provide the cleanest air solutions For New Plants For the Installed Base IEA 1 st Int. Oxy-Combustion Conference, Cottbus, Germany, 7-11 Sept P 35

36