Commercialisation of CCS on CCGT Power Plants

Transcription

1 Commercialisation of CCS on CCGT Power Plants Autors: Matthew Hunt CCS Sales Manager Pramurtta Majumdar Specialist Turbine Engineer Disclaimer The contents in this presentation are for information purposes only and are not intended to be used or relied upon by the reader and are provided on the condition that you 'use it at your own risk'. Doosan Power Systems Limited does not accept any responsibility for any consequences of the use of such information. All rights are reserved and you may not disseminate, quote or copy this presentation written by Doosan Power Systems Limited without its written consent. Doosan Power Systems Limited 201

2 Doosan Power Systems Vision To be a global leader in delivering advanced clean energy technologies, products and services. 1

3 Part of the Doosan Group Doosan Group Doosan Heavy Industries & Construction Casting and Forging Nuclear Doosan Power Systems Power Plant Construction Desalination Turnover Employees Doosan Group Doosan Heavy Industries & Construction Doosan Power Systems $15 Billion $1.3 Billion $5 Billion* 36,400 5,800* 6,000 *Figures exclusive of DPS data and correct to the end of the financial year for

4 Doosan Power Systems Organisation Doosan Group Doosan Heavy Industries & Construction Doosan Power Systems Boilers Doosan Babcock Turbines Škoda Power Plant Services Doosan Babcock Wind 3

5 Post Combustion Capture Leading Edge Technology

6 Doosan Power Systems HTC Purenergy Our Goal To be recognised as the market leader in Post Combustion Carbon Capture technology and application, with proven product leadership to support the Core Power Island EPC product offering throughout the Doosan organisation. An Alliance Global licence agreement signed in 2008 between Doosan Power Systems and HTC Purenergy. HTC if the CO2 Capture Technology licensee of the University of Regina who have been working on carbon capture since Technology transfer up to 30 engineers and specialists from Doosan Power Systems seconded to Regina, Saskatchewan. Future Development Doosan and HTC participate in collaborative research with the University of Regina which has some of the most comprehensive carbon capture research and development facilities in the world This enables the latest technological advancements to be provided to our Customers. 5

7 Technology Leaders Advanced Solvent designer (RS family) solvent providing: Low cost commercially available ingredients High efficiency system Low degradation rates Tailored to meet operating and flue gas conditions Scale-up validated against actual operating data from several plants as large as 800 TPD (with +/- 3% accuracy) Most importantly, scale-up is only achievable through a complete and thorough understanding of: All physical and chemical properties (kinetics, diffusivity, etc.) Operating conditions Proper application of numeric modeling tools Patents in place for high efficiency configured to advanced solvent Patents in place for steam side plant integration Optimised Process Design Heat Integration Reduction in Steam Advanced solvent, advanced process and optimised integration provide maximum customer value 6

8 POST COMBUSTION CARBON CAPTURE TECHNOLOGY Coal CCGT 12%-14% CO2 concentration 4% CO2 concentration High SOx levels Low O2 levels Low SOx levels High O2 levels Doosan Power Systems 7

9 PCCC for Gas Turbine Plants A top-level assessment of TECHNICAL interface issues pertaining to the operation of gas turbine plants either in simple cycle or in combined cycle mode affecting the post combustion carbon capture (PCCC) process are considered: Primary Features of Gas Turbine Plants influencing PCCC Compatibility with diverse fuel compositions Pressure AND temperature variation Carbon capture during start-up transients Power vs. Steam Maps Steam availability for regeneration Variability of Steam properties HRSG process for compatibility with PCCC HRSG layout for compatibility with PCCC Retrofitting existing CCGT plants with PCCC would be based on design considerations outline above 8

10 Primary Features of Gas Turbine Plants influencing PCCC Gas Turbine Plants can operate on simple cycle (incomplete Brayton cycle) or combined cycle (bottoming cycle to Brayton cycle) for highest efficiency and power output. Capability of operation with a wide variety of fuels with varying carbon contents, including bio-diesel. Primarily operated as Peak Load plants, with rapid response to transients as in merchant plants. Combined cycle operation with HRSG s with triple pressure reheat steam. Supplementary firing in HRSG s. 9

11 PCCC for GT Plants- compatibility with diverse fuel compositions PCCC for Gas Turbine Plants would have to consider the variety of fuel sources available at a particular site at different times. The compatibility of the absorber for carbon dioxide (amine based for Doosan) would have to be evaluated with all the chemical properties of the fuel sources. 10

12 PCCC for GT Plants- exit pressure AND temperature variation Compressor Direct Contact Cooler for Flue Gas Stripper Absorber GT Plants are operated both in simple cycle and combined cycle with HRSG. The flue gas exit pressure at DCC inlet would vary with HRSG pressure drop similar to load following on a coal fired plant.. The placement of a blower (in series) to counteract PCCC pressure drop would effect GT exit pressure and/or HRSG heat transfer regimes. Therefore the ΔP would be part of the design of the absorber. Inlet temperatures to PCCC would be affected by supplementary firing in HRSG.The DCC is designed to accommodate this. 11

13 PCCC for GT Plants- carbon capture during start-up transients Gas Turbine Plants are subjected to frequent starts and stops as Peak Load Plants. Frequent starts and stops significantly increase CO emissions (to several multiples of normal operation values) Lack of Steam during open cycle start-up makes solvent regeneration for PCCC very difficult. Either a aux boiler required or a simple bypass depending on client. Response time for PCCC plant (with chemical kinetics) to start-up requirements of simple cycle and/or combined cycle are and process designed accordingly. 12

14 PCCC for GT Plants- Power vs. Steam Maps Power vs. Steam Maps for predicting power and steam export needs with or without SF are vital for evaluating operational flexibility to encompass carbon capture regimes. Gross Power Output (MW) Steam Export (t/h) 13

15 PCCC for GT Plants- Steam availability for regeneration Triple pressure HRSG (w or w/o supplementary firing) for three steam injection points are widely used. Doosan patent on Steam Extraction and Return pending. 14

16 PCCC for Gas Turbine Plants- variability of Steam properties Steam properties for regeneration are widely variable for the third pressure HRSG tap-off. Typical variability of properties within Single Pressure HRSG s are illustrated below. Regeneration of Lean Solvent in Re-Boiler accommodates this wide variety of design conditions prevalent in a triple pressure HRSG. 15

17 PCCC for Gas Turbine Plants- HRSG process for compatibility with PCCC Additional steam requirement for PCCC can be most easily incorporated with an external deaerator. This provides robust operational flexibility together with simpler phosphate dosing for Flow Assisted Corrosion (FAC) rather than the inherently more complicated All Volatile Treatment (AVT) regime. 16

18 PCCC for Gas Turbine Plants- HRSG layout for compatibility with PCCC Vertical arrangement can create additional pressure drop issues Additional plot space required for PCC plant Planning consent for additional plant if retrofitted Horizontal HRSG s (shown on right) are more suitable for integration with PCCC plants than vertical HRSG s (shown above) due to low level tie-in s 17

19 Doosan Product Development and Commercialisation

20 Doosan Power Systems Post Combustion Capture Projects Development Roadmap Target Slipstream 100t/d CO 2 5MW e Ferrybridge Large Demonstration Project (s) Slipstream ~3000t/d CO 2 150MW e Commercialisation Full Scale Plant 10,000t/d CO 2 500MW e 15,000 t/d CO MWe Emissions Reduction Test Facilities 1t/d to 5t/d CO 2 19

21 Test Facilities and Demonstration Projects Facilities & Technology create a winning edge 20+ Years of Demo Industry Leading Scale ITC 1t/day Opened in 2003 Flue gas from natural gas combustion Includes equipment to study corrosion, material selection, solvent degradation and kinetics ERTF, 1t/day Commissioned in 2010 Ability to test using wide range of fuels including natural gas High degree of flexibility and accuracy to test wide range of Solvents and other modifications Boundary Dam, 4t/day Commissioned in 1987 Dedicated to post-combustion capture since 2000 Captures CO2 from flue gas emitted from lignite-fired boiler Upgraded in 2007 to evaluate advanced process with RS-2 Ferrybridge, 100 t/day Largest PCC demonstration plant in the UK Long-term testing and validation of process and solvent performance Evaluate transient conditions and process control Extensive monitoring planned Performance demonstrated on wide range of fuels and different plant configurations 20

22 Demonstration Projects Emissions Reduction Test Facility Emissions Reduction Test Facility (ERTF) Upgrade for PCC Solvent Scrubbing A 160kW t combustion test facility at our R&D Centre in Renfrew, United Kingdom Capable of firing a very wide range of coals or natural gas. Originally constructed to test primary NO x reduction measures, subsequently adapted and upgraded to test secondary NO x reduction measures. Upgraded for oxyfuel operation as part of the OxyCoal-UK: Phase 1 project a collaborative project sponsored by the UK government with industrial and academic participation. 21

23 Demonstration Projects Emissions Reduction Test Facility ERTF Solvent Scrubbing Process - Equipment Absorber column 10 NB (DN250) 4-off packed bed sections (with multiple solvent feed inlet points) Stripper column 8 NB (DN200) 4-off packed bed sections Water Wash Column 8 NB (DN200) 1-off packed bed section Heat exchangers Gasketed (plate and frame) Pumps Duties met by triplex diaphragm pumps for high head low flow duties Variable speed drives for efficiency and ease of control 22

24 Boundary Dam Demonstration Plant Technology Demonstration Plant Operating since 1987 Donated to UoR in 2000 Upgraded 2007 Capture capabilities are 4 TPD Operating on lignite fuel or simulated natural gas Technology demonstration facility for client-specific parameters BDPS CO 2 Capture Plant Performance < 1.1kg steam/ 1 kg CO 2 captured which equates to less then 2.4 GJ/Ton CO 2 Total Capture System equates to ~110 MWe on an 800MWe Minimised impact to existing plant performance Industry leading plant efficiency 23

25 Demonstration Projects CCPilot100+ SSE Ferrybridge CCPilot t/day CO 2 PCC Demonstration Plant Post Combustion Capture Demonstration Plant using Doosan Power System s technology 100 t/day slip stream on SSE s Ferrybridge Power Station Largest PCC Demonstration in the UK Funding by the project partners, Scottish & Southern Energy, Vattenfall, Doosan Power Systems, TSB, DECC and The Northern Way. Fast track, for operation during 2011 Two year test programme Lessons learned will be incorporated into future designs Off gas analysis amine carryover and degradation products On-site amine and degradation product atmospheric sampling and analysis 24

26 CCPilot100+ Project Location 25 Pictures courtesy Google Earth

27 CCPilot100+ Process Layout and Key Parameters PCC Design Design CO2 removal efficiency CO2 Absorber Dimensions (i.dia x height; m) 100 metric tpd 90% 2.3 x 39 Stripper Column Dimensions (i.dia x height; m) 1.1 x

28 CCPilot100+ Project Execution Current Status In Construction Absorber Fabrication Simulation Stripper Column Delivery P&IDs 3D Modelling Testing Programme 27 Construction

29 In Summary Doosan utilises process technology that was invented and developed in Canada by UoR and HTC Purenergy which has been in operation for over 20 years. Doosan and HTC are at the forefront of PCC technology development providing solutions for both coal and gas fired power plants. Doosan has a proven highly efficient process and product which it will guarantee (performance and commercial) Doosan will undertake full EPC Doosan have available resources and can leverage the historic experience from recent projects to achieve clients goals Low impact, high efficiency, integrated EPC Carbon Capture Solutions 28

30 THANK YOU