CIUDEN CARBON CAPTURE TECHNOLOGY DEVELOPMENT PLANT. Monica Lupion CO 2 Capture Programme CIUDEN

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1 CIUDEN CARBON CAPTURE TECHNOLOGY DEVELOPMENT PLANT Monica Lupion CO 2 Capture Programme CIUDEN

2 Content CIUDEN Attributes and objectives Activities on CCS CIUDEN s vision International Context The Capture TDP Technical description Overview of the R&D programme Construction Contribution to oxycombustion technological development OXYCFB300 The Storage TDP Objectives Ayoluengo Experimental Area Hontomin

3 Fundacion Ciudad de la Energia CIUDEN

4 CIUDEN Fundación Ciudad de la Energía An initiative of the Spanish Administration

5 CIUDEN Attributes

6 CIUDEN General objectives on CCS THROUGH

7 CIUDEN Activities on CCS Ciuden is designing, constructing and will operate Technology Development Plants (TDPs)

8 CIUDEN Vision for CCS technology development

9 CIUDEN International Context SET PLAN

10 CIUDEN International Context

11 The Capture TDP Technical Description

12 Capture TDP Zep Recommendations Recommendations for RTD, Support Actions and International Collaboration activities Pilot plant tests (10s of MWth) of full oxy-fuel pulverised fuel (PF) process, to validate results from scale-up based on laboratory tests Pilot plant tests (10s of MWth) of full oxy-fuel CFB Final Version Recommendations for Research within EU and National Programmes in support of deployment of CCS in Europe Beyond th April 2008 Final Draft 13th December 2009 The importance of recognizing the need for medium-sized pilot plants, both risky and costly, and which are a limiting factor for new developments

13 Capture TDP Technologies and Fuels Oxycombustion Pulverized Coal 20 MWth Circulating Fluidized Bed 30 MWth DeNO X Dedust DeSO X CO 2 purification and compression Fuels: anthracites, bituminous, subbituminous coals, pet coke, sustainable biomass

14 Capture TDP Some important data

15 Capture TDP Characteristics

16 Capture TDP The site COMPOSTILLA II PS ENDESA CIUDEN s CO 2 CAPTURE TDP

17 Simplified process diagram FROM BIOMASS PREPARATION FROM COAL PREPARATION 20 MWth PC BOILER O 2 STORAGE AND VAPORISATION PHASE II ABSORPTION SECTION STACK BIOMASS BIN PC BIN DeNOX AIR CO 2 GAS TREATMENT FGR2 FGR1 CPU CO 2 C Y C L O N MWth CFB BOILER PREHEATING TRAIN CFB BIN BIOMASS GASIFIER ENGINE O 2 PREHEATING MIXERS BAG FILTER HIGH EFFICIENCY DeSOX EXPANDER TORCH FGR2 RECIRCULATION FGR1 RECIRCULATION BAG FILTER

18 Capture TDP DEPÓSITO GAS NATURAL LICUADO EDIFICIO TÉCNICO - Oficinas - Sala Control - Laboratorios EDIFICIO INDUSTRIAL - Taller - Almacén GASIFICADOR BIOMASA DEPURACIÓN GASES ALMACENAMIENTO BIOMASA CALDERA LFC SILOS CARBÓN TRITURADO COMPRESIÓN Y PURIFICACIÓN DE CO 2 SERVICIOS AUXILIARES OXÍGENO PREPARACIÓN DE COMBURENTES CALDERA CP TANQUES AGUA MOLIENDA Y DOSIFICACIÓN CARBÓN PULVERIZADO CRIBADO, TRITURACIÓN Y MUESTREO CARBÓN TOLVA DESCARGA CARBÓN

19 Capture TDP Virtual images

20 Capture TDP Virtual images The two boilers and the fuel preparation unit

21 Capture TDP Virtual images The fuels reception area

22 Coal preparation section Indirect combustion COAL UNLOAD FAN RAW COAL BUNKER BAG FILTER BAG FILTER FAN FAN COAL SAMPLER CRUSHED COAL SILO INERTIZED (CO 2 ) INERTIZED (CO 2 ) PC BIN DOSSIFIERS TO PC BOILER FAN TO CFB TO PC BAG FILTER INERTIZED (CO 2 ) CFB BIN TO CFB FEEDER HOT GASES MILL CLASSIFIER BUCKET ELEVATOR PARTIAL RECIRCULATION

23 CIUDEN s PC Boiler Size (m) 24 x 7.6 x 4.5 Burners MWth PCS max oxycombustion mode 4 horizontal burners 2 vertical burners 20 O 2 (kg/h) 6600 Recirculation gas flow (kg/h) Flue gas flow (kg/h) Coal flow rate (kg/h) 3350 Steam (t/h) 25 P(bar) / T ( C) 30 / 420

24 CIUDEN s CFB Boiler GLOBAL DESCRIPTION OF THE BOILER: (1) water- wall furnace (2) solid separator for the recirculation of bed material (3) ash sealing-direction device (3a) ash duct to the furnace (3b) ash duct to the cooler (4) furnace cooler (5) heat recovery zone (6) steam cooled walls with an convective evaporator bank (7) economizer SYSTEMS: Oxidant preparation (shared with PC Boiler) Limestone feed Sand feed Fly ash recycling / bottom ash extraction

25 CIUDEN s CFB Boiler Dimensions (m) MWth SCP max oxy-combustion 21x2.7x O 2 (kg/h) 8775 Flue gas recycle (kg/h) Flue gas (kg/h) Coal feed (kg/h) 5469 Limestone feed (kg/h) 720 Steam (t/h) 44.6 P(bar) / T ( C) 30 / 250

26 Capture TDP contractors status FUEL PREPARATION ON GOING CFB BOILER AWARDED 01/10 PC BOILER ON GOING INTEGRATION ENGINEERING ON GOING FLUEGAS CLEANING AWARDED 01/10 FLUEGAS RECIRCULATION AND MIXTURE ON GOING CONTROL SYSTEM ON GOING CO2 PURIFICATION CALL FOR TENDERS TECHNICAL BUILDINGS ON GOING

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28 The Capture TDP Overview of the R&D Programme

29 R&D Programme targets Target # 1: Validation of the full chain of processes from fuel preparation to CO 2 purification, producing an stream ready for transport and storage Target # 2 : Production of data for scaling-up the PC, CFB, FGD and CPU technologies Coal and limestone preparation and feeding Plant engineered to test the integrated operation of all units Flue gas recirculating/mixing and heating devices + Flue gas cleaning Pulverized coal and circulating fluidised bed oxycombustions CO 2 purification and compression units

30 R&D Programme targets MAIN SCOPES

31 R&D Programme targets MAIN SCOPES

32 R&D Programme targets MAIN SCOPES

33 R&D Programme targets PHASE II

34 The Capture TDP Construction

35 Capture TDP Time schedule FIRST DESIGN UPGRADED DESIGN PERMITTING AND CONTRACTING CONSTRUCTION OPERACION FOR R&D COMPOSTILLA CCS PROJECT OXYCFB300 BUILDING BLOCKS VALIDATION KNOWLEDGE SHARING AND DISSEMINATION INNOVATIVE TECHNOLOGIES PHASE II

36 Capture TDP Worksite evolution The beginnings

37 Capture TDP Worksite evolution Site preparation

38 Capture TDP Worksite evolution Offices buildings and fuel preparation area civil works

39 Capture TDP Worksite evolution PC boiler components, structure and raw coal hopper building

40 Capture TDP Worksite evolution PC Boiler, conveyor belt and raw coal hopper

41 The Capture TDP Contribution to oxycombustion technological development

42 Oxycombustion: current status of technological development UPSTREAM CAPTURE POWER STATION PURIFICATION AND COMPRESSION ASU CO 2 PURIFICATION CO 2 COMPRESSION FUEL FEEDING PREPARATION OXYCOMBUSTION BOILER FLUE GAS RECYCLE AND O 2 MIXING STEAM CYCLE DISTRIBUTED CONTROL SYSTEM FULL PROCESS INTEGRATION FULLY PARTIALLY NOT Adapted from CO 2 Capture and Storage, Matrix of Technologies, ZEP

43 Oxycombustion: detailed expected evolution of validation status 2012 VALIDATION FULLY PARTIALLY NOT Current 0,1-1MW t COAL BIOMASS PETCOKE X MW t COAL BIOMASS PETCOKE X FUEL PREPARATION OXYCOMBUSTION FLUEGAS RECYCLE AND O 2 MIXING FLUEGAS TREATMENT AND COOLING PC CFB FLUEGAS RECYCLE O 2 /FLUEGAS MIXING SYSTEM O 2 SUPPLY TO BURNERS CONVENTIONAL POLLUTANTS FLUE GAS CONDENSER CO 2 PURIFICATION CO 2 COMPRESSION DISTRIBUTED CONTROL SYSTEM OVERALL PROCESS INTEGRATION Adapted from CO 2 Capture and Storage (CCS) Matrix of Technologies, ZEP

44 Large Scale Oxy-TDPs and Burners Testing in the World Current State of the Technology Past, Present to Future Lab Scale Experiments TD Plants and Industrial Scale Experiments TD PLANTS with Storage Start-up PC, MW th CFB, MW th th FUEL Vattenfall (DE) Lignite/Coal Total (FR) Natural Gas CIUDEN (ES) Anthracite/Coal/Coke CS Energy (AUS) Coal Industrial Large Scale Burner Testing Doosan Babcock (UK) Coal Alstom (USA) Coal Hitachi Babcock (DE) Coal

45 The 6 EEPR CCS projects Hatfield pre Jaënschwalde Oxy PC Rotterdam 2 post Compostilla Oxy CFB Belchatow post Porto Tolle post

46 OxyCFB300 Project CO 2 Compression & purification Flue gas recycle Oxyge n ASU

47 The Store TDP Contribution to oxycombustion technological development

48 STORAGE TDP Objectives Design, construction and operation of a Technology Development Plant Demonstration of CO 2 geological storage feasibility Validation of methods and technologies for Temporary CO 2 storage o Reservoir and seal rock capacity and behaviour o Injection protocols o CO 2 movements and geotrapping mechanisms o Risks analysis o Long term safety and behaviour evaluation Injection Well o Monitoring and remediation strategies o Costs optimization TDP for geological storage of CO 2 ( Nagaoka, Japan ) A Platform for academic, regulatory, technology and industrial development

49 STORAGE TDP Location Ayoluengo experimental area: Implementation of unavailable technologies in Spain for deep geological underground characterization Storage TDP location area (Hontomín): Research related to geological storage of CO 2 Ayoluengo and Hontomin: extremely low density population areas (< 10 inhabitants/km2)

50 STORAGE TDP Ayoluengo Experimental Area Ayoluengo 4 Km Delimited in red, Ayoluengo oilfield

51 STORAGE TDP Ayoluengo Experimental Area 4 Km Ayoluengo test drillings location At Ayoluengo oilfield (West area), reusing some of their wells, technologies which are unavailable in Spain yet, will be implemented for deep geological subsurface characterization. These will be applied in the CIUDEN s future Pilot Plant

52 STORAGE TDP Storage installation location Hontomin Burgos Hontomín 10 Km Perimeter (delimited in red) of: Request for underground structure use (Burgos Mining Local Office, )

53 STORAGE TDP Storage installation location Hontomín 10 Km Reported area for underground geological structure exploitation Most interesting area (4x3 Km) for R+D+d Pilot Plant, located at a little geological dome at 1.200m depth in Hontomín surroundings S Hontomín- 3 Hontomín- 1 N Seismic line which crosses the most interesting area. Reservoir rock is shaded in blue( m depth); upwards geological levels represent the seal rock of this structure

54 STORAGE TDP Storage installation location Isohipsa map showing depth where the Jurassic (Dogger) top appears Geological 3D model of the Jurassic top (reservoir level) In that little dome research will be carried out by CIUDEN, in-situ and on real scale, related to geological storage of CO 2

55 STORAGE TDP Time schedule Lab Studies Regional Studies Reservoirs & seals Basque-Cantabrian Basin Experimental Site Update and development of new tools for characterization and storage engineering TD plant site selection Geological structure characterization Modelling of injected CO 2 behaviour R&D TD Plant Technology development Plant construction Research on storage engineering, monitoring techniques Public acceptance and Communication Natural Analogues Research on natural analogues

56 CIUDEN CARBON CAPTURE TECHNOLOGY DEVELOPMENT PLANT Monica Lupion CO 2 Capture Programme CIUDEN