Development in Oxyfuel Combustion Technologies for Coal Fired Power Plants with CCS (An Overview) Stanley Santos

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1 Development in Oxyfuel Combustion Technologies for Coal Fired Power Plants with CCS (An Overview) Stanley Santos IEA Greenhouse Gas R&D Programme Cheltenham, UK

2 3 rd Oxyfuel Combustion Conference Ponferrada, Spain 9 th 13 th September 2013 Full Programme Announcement: 17 th May

3 3

4 Alstom Schwarze Pumpe MWth Lignite Hitachi Babcock Schwarze Pumpe MWth Lignite Doosan Babcock Schwarze Pumpe MWth Lignite IHI Callide MWth Coal Alstom / AL Lacq MWth Gas/Oil? CIUDEN El Bierzo CFB Facility MWth Coal CIUDEN El Bierzo PC Facility MWth Coal 1980 s EC Joule Thermie Project - IFRF / Doosan Babcock / Int l Combustion NEDO / IHI / Jcoal Project ANL/Battelle/EERC completed the first industrial scale pilot plant Updated by S. Santos (18/07/13) Vattenfall (ENCAP ++) CS Energy / IHI Callide Project CANMET US DOE Project / B&W / Air Liquide KEPCO/KOSEP - Yongdong (PC - 100MWe) -??? FutureGen2 - Illinois (PC - 168MWe) Endesa/CIUDEN - El Bierzo (CFB - 300MWe) -??? 2009 Lacq first 30MWt retrofitted Oxy-NG boiler w/storage FIRST 30 MWt full chain demonstration at Schwarze Pumpe B&W CEDF (30MWt) large scale burner testing started First large scale 35MWt Oxy-Coal Burner Retrofit Test done by International Combustion China: 2 Oxyfuel Projects in progress UK: White Rose Project (PC 426MWe) 2012 Callide retrofitted Oxy-coal power plant 2012 CIUDEN Oxy-CFB Pilot Plant By Demonstration of MWe full scale power plant HUST Industrial Project for 35 MWt Oxyfuel Pilot Plant w/storage Target : Commercialised by 2020 By the end of 2011, Users (i.e. Power Plant Operators) will have 6 burner manufacturers give a high level of confidence toward demonstration B&W CEDF MWth Coal Alstom Alstom CE MWth Coal Doosan Babcock DBEL - MBTF MWth Coal 4

5 CO2 Capture Options EPRI

6 Oxy-Combustion Technology Use of oxygen instead of air in a boiler demonstration. With significant R&D investment in the past decade, this technology has achieve a maturity similar to the other leading options for power generation with CCS Presentation Outline Boiler and Burner Development Air Separation Unit Flue Gas Processing Unit CO2 Processing Unit 6 6

7 Oxyfuel Combustion Overall Schematic Diagram 7

8 SOME EXAMPLES OF OXY-COAL FIRED POWER PLANTS 8

9 Oxy-Coal Plant Configurations Very High Sulfur Coals ASU Secondary (FD) Fan Air Intake To Storage CPU Sorbent for SO 3 Recycle Damper Burners Boiler Recycle Heater PJFF Gas Cooler ID Fan WFGD WFGD/ DCC Gas Htr Coal Primary Fan Recycle Damper Cold Recycle Process Air Intake Pulverizers 9

10 Oxy-Coal Plant Configurations High Sulfur Coals To Storage Secondary (FD) Fan ASU Air Intake Stack Damper CPU Vent CPU Gas Htr Sorbent for SO 3 Secondary Recycle Damper Burners Boiler Recycle Heater PJFF Gas Cooler ID Fan WFGD WFGD/ DCC Gas Htr Coal Cool Recycle Process Primary Fan Air Intake Primary Recycle Damper Pulverizers 10

11 Oxy-Coal Plant Configurations Medium Sulfur Coals To Storage Secondary (FD) Fan ASU Air Intake Stack Damper CPU Vent CPU Secondary Recycle Damper Burners Boiler Recycle Heater Gas Cooler SDA PJFF ID Fan WFGD/ DCC Gas Htr Coal Cool Recycle Process Primary Fan Air Intake Primary Recycle Damper Pulverizers 11

12 Oxy-Coal Plant Configurations Low Sulfur Coals To Storage ASU Secondary (FD) Fan Air Intake CPU Recycle Damper PJFF Burners Boiler Recycle Heater Gas Cooler SDA PJFF ID Fan DCCPS Gas Htr Coal Primary Fan Recycle Damper Warm Recycle Process Air Intake Pulverizers 12

13 Oxyfuel Combustion Technology BOILER AND BURNER DEVELOPMENT 13

14 Historical Perspective The Early Days 1982: Initial suggestion by Abraham et. al. (OGJ) of using Oxy-Coal Combustion to produce CO2 for EOR 1 st public document looking at capturing CO2 from flue gas using oxy-combustion. However... in the development of oxy-coal combustion with recycled flue gas 1974: Japan initial conception of using oxy-coal combustion for power generation. (To reduce pollution?) 1978: Economic feasibility of oxy-coal combustion was investigated for EOR application (H. Farzan, Babcock & Wilcox / A. Wolsky, ANL) 14 14

15 Technology Development Japan s initial conception of oxyfuel combustion application for power generation (1974) Oxygen 3rd Workshop, IEAGHG International Oxy-Combustion Network, Yokohama, Japan 15

16 ANL - EERC Study -Coal Combustion Industrial Pilot Scale Study Tower Furnace (~ 3MWth) 16

17 Convective Section of the boiler heat transfer profile ash deposition and fouling issue Burner design issue Ignition flame stability devolatilisation & char burnout Radiant Section of the Boiler heat transfer profile slagging issue fireside corrosion issue Prior to any retrofit of carbon capture technology, it is essential to repower the plant in order to achieve the highest possible efficiency 17 17

18 Air vs. Oxy Firing of Coal 18

19 Factors affecting Recycle Ratio Critical factors affecting the optimum amount of recycled flue gas Burner and boiler design (heat transfer and flame stability oxygen distribution through burner) Air ingress Purity of oxygen from the ASU Coal type Level of moisture content in comburent Comburent (oxidant) temperature 19 19

20 Flame Description (Courtesy of IFRF) Impact of Recycle Ratio 20

21 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%) 21 21

22 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 =

23 Effect of Different Oxygen Concentrations (and Recycle Rates) on Flame Pattern Universität Stuttgart Air Oxyfuel 28% O 2 Recycle rate 77% Oxyfuel 38% O 2 Recycle rate 66% Source: J. Smart,

24 Premixed / hybrid mode Premixed mode DST burner Hybrid mode DST burner M M M M M M Flue gas Flue gas + O 2 Flue gas M O 2 O 2 O 2 M O 2 M 2nd International Oxyfuel Combustion Conference, 12th-16th September 2011, Yeppoon, Australia Hitachi Power Europe GmbH 24

25 Burner Development for Oxyfuel Combustion Burners are critical to combustion, emissions, and thermal efficiency / capacity of the utility boilers Critical importance to burner development is a full scale testing This is an important exercise to establish reference data that could be used in the development and validation of different modeling tools. This is also to gain experience in operating full scale burner. (i.e. start up/shut down, flame stability, efficiency, heat 25 25

26 Burner Development for Oxyfuel Combustion Development of Full Scale Burner Testing Programme could either be accomplished by: Retrofitting of Full Scale Burner Test Rigs o o Doosan o Alstom th CEDF Facility (Ohio, USA) th MBTF Facility (Renfrew, Scotland) th BSF Facility (Connecticut, USA) Testing in a Full Chain Oxyfuel CCS Pilot / Demo Plant o o o Schwarze Pumpe Pilot Plant (Cottbus, Germany) Lacq Facility (Lacq, France) o CIUDEN Demo Facility (El Bierzo, Spain) 26

Testing Facilities Worldwide Retrofitted

30MWth CEDF Barberton, Ohio, USA Start of

2008 Wall Fired Burner Development Doosan

27 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 27 27

28 OxyCoal 2 Demonstration of an Oxyfuel Combustion System Officially opened on 24 th July 2009 Doosan Power Systems 40MW th OxyCoal demonstration became the world s largest demonstration of an oxyfuel combustion system September 2011 D W Sturgeon

29 OxyCoal 2 Demonstration of an Oxyfuel Combustion System Safe and smooth transitions between air and oxyfuel operation were demonstrated, with realistic CO 2 levels achieved (in excess of 75% v/v dry, and up to 85% v/v dry). Oil Air Firing (TFGR, PA, SA) Secondary Air to Secondary Flue Gas Recycle Transition Oil Air/Oxyfuel Firing (TFGR, PA, SFGR) Oil/Coal Air/Oxyfuel Firing (TFGR, PA, SFGR) Coal Air/Oxyfuel Firing (TFGR, PA, SFGR) Primary Air to Primary Flue Gas Recycle Transition Coal Oxyfuel Firing (TFGR, PFGR, SFGR) September 2011 D W Sturgeon

30 OxyCoal 2 Demonstration of an Oxyfuel Combustion System 40MW th OxyCoal burner turndown proven from 100% load to 40% load. 40MW t 32MW t 24MW t 20MW t 16MW t Stable rooted flame maintained for all loads down to 40% with coal ignition within the burner throat/quarl. Comparable turndown to Doosan Power Systems commercially available air firing low NO X axial swirl burners. 14 September 2011 D W Sturgeon 30

31 View on Oxyfuel Pilot Plant 31 Lars Strömberg, IEAGHG OCC2 Australia

32 Some Burners Tested Burner Type A Burner Type B Achieved ~20,000 Hours in Both Air and Oxyfuel Operation!

33 Boiler (furnace) - Temperature Comparison (Front View) Oxy 24% Oxy 28% Oxy 32% Oxy 36% Air (21%) The gas temperatures increases with increased O2 in oxidant as expected The temperature levels for air case corresponds to OXY OCC, U.Burchhardt

CS Energy/IHI Burner Testing Programme at

Installation of 2 new Wall Fired Burners A

34 CS Energy/IHI Burner Testing Programme at Callide A Power Station Callide A Project would be 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 Courtesy of CS Energy, IHI 34 34

35 Callide Oxyfuel Project Overview Australia QLD CO 2 storage area Callide A P/S Brisbane Callide A Power Station Owned by CE Energy 4 x 30 MWe Steam 136 t/h at 4.1MPa, 465 o C Commissioned: Refurbished 1997/98 Placed in storage in 2002 Scope: No.4 Boiler refurbishment 2 x 330 TPD ASU Oxyfuel combustion Retrofit 70 TPD liquid CO 2 recovery Trucking to CO 2 reservoir Injection and monitoring Copyright 2012 IHI Corporation All Rights Reserved. 35

36 COP Site Works Oxygen and CO 2 Capture Plant Oxygen plant CO 2 capture plant

37 Oxyfuel Combustion Technology AIR SEPARATION UNIT (OXYGEN PRODUCTION) 37

38 Oxygen Production Facts: Today, only the Cryogenic Air Separation Unit or ASU is capable of delivering the oxygen demand of a large oxyfuel combustion boiler for power plant with CO2 For every 500MWe net output you will require ~10,000 t/d O2 o Low Purity (95-97%)* o Low Pressure (nearly atmospheric) At 95% purity will have 2% N2 and 3% Ar 38

Current Status and Challenges to Cryogenic ASU Advances and Development in ASU could result to 25-35% less energy consumption than what could be delivered by the current

A target of 140 kwh/t O2 is achievable These ASU would not be based on the conventional one but it could be hybrid based on 3 columns design or dual reboiler design.

39 Current Status and Challenges to Cryogenic ASU Advances and Development in ASU could result to 25-35% less energy consumption than what could be delivered by the current state of the art ASU today. A target of 140 kwh/t O2 is achievable These ASU would not be based on the conventional one but it could be hybrid based on 3 columns design or dual reboiler design. Challenges are: Cost of production of oxygen (energy consumption) ASU should address the needs of the requirements of power plant (i.e. Delivery, Flexibility, Turn-down, etc...) Utilisation of nitrogen within power plant or other users. Presented at Yokohama Workshop, March 2008 Presented at OCC2 - Yeppoon, Australia September

40 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 40 Bey/L/092009/Cottbus.ppt

41 Experience - Large ASU Projects and Train Scale-up Market drives ASU scale-up Proven 70% scale-up Quoting 5,000+ MTPD today Rozenburg Oryx GTL Chevron Nigeria Eastman Texas A5000 / A7000 MTPD O Plaquemine Buggenum Polk Startup date 41

42 42

43 Overview Of The Process Main and Boost Air Compression Air Cooling and Pretreatment Cryogenic Separation Storage Oxygen Air Heat Heat 43

44 Air Separation Process Conventional Design (mit Einblaseturbine) POWER PGAN GOX AIR bar Vorkühlung Adsorber 1.05 bar bar Restgas Booster 1 Turbine Wärmetauscher 1 Niederdruckkolonne UKG Kondensator Oxygen: 95%, gaseous, at ambient pressure Features: PNitrogen: up to 30% of airflow available bar Hochdruckkolonne Linde AG Engineering Division 44 Bey/L/092009/Cottbus.ppt

45 ASU for Oxyfuel Combustion Applications There are several ASU cycles available for low purity oxygen requirements Leading ASU Cycles for Oxyfuel Combustion are variants of: 3 Columns Dual Reboilers Key Features: Lower compression requirements for the air input to the cold box 45 45

46 Medium Pressure Column High Pressure Column Low Pressure Column Cold Box is based on 3 Columns Design The main compression of air for this cold box is only at 3.5 Bara Only half of the air is compressed to 5 Bara

47 Case Studies Done by Air Products 47

48 Summary (ASU) For the first and second generation Oxyfuel Combustion Technology, cryogenic ASU is the only way to deliver the oxygen demand of the boiler ASU interface to the boiler, operation issues such as flexibility, start up and shut down has been addressed. Delicate balance between CAPEX and OPEX REFERENCE ASU for Oxyfuel Combustion is now in place and ready to be demonstrated. are not ready in the near term. 48

4,000 Centrifugal 1 or 2 train or axial 1 train 22-33 4,000 5,500 Centrifugal 1 or 2 train or axial 1

49 Oxyfuel Coal Reference ASU Designs developed for a scalable reference plant Column diameters within manufacturing capabilities (referenced to 7000 te/d) Size te/d O 2 Machinery options Power MW 3,000 4,000 Centrifugal 1 or 2 train or axial 1 train ,000 5,500 Centrifugal 1 or 2 train or axial 1 train ,500 7,000 Centrifugal 2 train or axial 1 train ,000-10,000 Centrifugal or axial 2 train

50 Oxyfuel Combustion Technology CO2 PROCESSING UNIT (REMOVAL OF NON-CO2 COMPONENTS) 50

51 CO2 Processing Unit Key Areas of Development in CO2 Processing Unit or CPU o Compression and Removal of minor impurities (NOx, SOx and Other Trace elements o Cryogenic Separation of Inert (Cold Box development) o Additional capture of CO2 from the CPU Important driver to the development is the specification of the CO2. o Management of CO2 purity requires good interaction between boiler, flue gas processing and CPU 51

52 Overview of Development of CPU over the last 8 years... Recognition of the NOx and SOx reaction by Air Products (presented during GHGT Conference 2006) June This has led to the rapid technology development among the industrial gas producers. Identification of potential impact of Hg to the operation of the CPU. Development of the use of impure CO2 as refrigerant driven mostly by reducing energy penalty. Work on further recovery of CO2 in the vent of CPU. 52

53 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. 53

54 CO 2 Compression and Purification System Removal of SO 2, NOx and Hg 1.02 bar 30 C 67% CO 2 8% H 2 O 25% Inerts SOx NOx SO 2 removal: 100% NOx removal: 90-99% BFW Condensate 15 bar 30 bar cw Water 30 bar to Driers Saturated 30 C 76% CO 2 24% Inerts cw cw Dilute HNO 3 54 Dilute H 2 SO 4 HNO 3 Hg

55 LICONOX Process Linde AG Engineering Division 55 Bey/L/092009/Cottbus.ppt

56 Auto-Refrigerated Inerts Removal Removal of impurities minimises compression and transportation costs. O 2 can be removed for EOR-grade CO 2 CO 2 capture rate of 90% with CO 2 purity >95% CO 2 capture rate depends on raw CO 2 purity which depends on air ingress Increases from zero at 25mol% to 90% at 75mol% Reducing air ingress increases CO 2 capture rate 56

57 Autorefrigeration Process J-T expansion of purified LCO 2 for refrigeration Vent > 99.9% CO 2 Raw CO 2 partially liquefied by boiling product Dryer Hg Compared to NH 3 refrigeration: Simpler process Lower CAPEX PHX Higher CO 2 recovery Lower power Distillation Column Reboiler Cold Box US Pat. 7,666,251 57

58 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) 58

59 Air Products Oxy-Fuel CO 2 Capture and Purification with Air Products PRISM Membrane Flue Gas Expander Flue Gas Heater To Boiler Membrane Aluminium plate/fin exchanger -55 C Driers bar Raw CO 2 Saturated 30 C 75-85% CO 2 CO 2 product ~96% CO 2 ~4% Inerts -60 C dp

63 Summary (CPU) 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. 63

64 64

65 Alstom Schwarze Pumpe MWth Lignite Hitachi Babcock Schwarze Pumpe MWth Lignite Doosan Babcock Schwarze Pumpe MWth Lignite IHI Callide MWth Coal Alstom / AL Lacq MWth Gas/Oil? CIUDEN El Bierzo CFB Facility MWth Coal CIUDEN El Bierzo PC Facility MWth Coal 1980 s EC Joule Thermie Project - IFRF / Doosan Babcock / Int l Combustion NEDO / IHI / Jcoal Project ANL/Battelle/EERC completed the first industrial scale pilot plant Updated by S. Santos (18/07/13) Vattenfall (ENCAP ++) CS Energy / IHI Callide Project CANMET US DOE Project / B&W / Air Liquide KEPCO/KOSEP - Yongdong (PC - 100MWe) -??? FutureGen2 - Illinois (PC - 168MWe) Endesa/CIUDEN - El Bierzo (CFB - 300MWe) -??? 2009 Lacq first 30MWt retrofitted Oxy-NG boiler w/storage FIRST 30 MWt full chain demonstration at Schwarze Pumpe B&W CEDF (30MWt) large scale burner testing started First large scale 35MWt Oxy-Coal Burner Retrofit Test done by International Combustion China: 2 Oxyfuel Projects in progress UK: White Rose Project (PC 426MWe) 2012 Callide retrofitted Oxy-coal power plant 2012 CIUDEN Oxy-CFB Pilot Plant By Demonstration of MWe full scale power plant HUST Industrial Project for 35 MWt Oxyfuel Pilot Plant w/storage Target : Commercialised by 2020 By the end of 2011, Users (i.e. Power Plant Operators) will have 6 burner manufacturers give a high level of confidence toward demonstration B&W CEDF MWth Coal Alstom Alstom CE MWth Coal Doosan Babcock DBEL - MBTF MWth Coal

Challenges to Demonstration Review of Technology Development Beyond the Oxyfuel Combustion Boiler

Challenges to Demonstration Review of Technology Development Beyond the Oxyfuel Combustion Boiler Stanley Santos IEA Greenhouse Gas R&D Programme 39 th IFRF TOTEM & RELSCOM Workshop Pisa, Italy 18 June