Callide Oxyfuel Project Development and Progress Dr Chris Spero Oxyfuel Capacity Building Course Tokyo Institute of Technology 2 3 September 2012
Presentation Overview Project history and structure Process description and permitting Oxyfuel boiler construction Comparison of oxy firing with air firing CO2 capture plant Future deployment of oxyfuel technology
Project history
Project structure
COP Work flow
Callide A Demonstration Simplified Steam Flow 37.7kg/s or 136 t/h Pressure 4.1MPa, Temperature 460 o C Pulverised Coal Consumption 5.5 kg/s 20 tph Quality HHV: 19 MJ/kg ar Ash: 21% ar Moisture: 14% ar Sulfur: 0.3% daf Anglo Callide Coal mine Oxygen (GOX) Purity: 98 vol% Oxygen Pressure : 180kPa(a) Flow: 7.6kg/s Size: 2 x nominal 330 TPD Air Liquide Sigma cryogenic ASUs Boiler Exit Flue Gases 350 o C 44.9kg/s Recirculated Flue Gases Flow: 30kg/s CO2: ~67% mass Chimney Stack Flow: 13.2kg/s Height: 76m Feed Gas to CO 2 Plant Flue Gas Processed Flow: 1.7kg/s Temp ~ 150 o C CO 2 Purification and Compression CO 2 Product: 75t/day CO 2 Purity: 99.9% mol CO 2 Temperature: -20 o C CO 2 Pressure: 1,600kPa Road Transport B Double 30t Single Tanker 20t
Permitting Stage 1 Callide A Exempted from development approval under local Government Planning Scheme not deemed to be a material change of use Amendments proposed to existing Callide A environmental authority Vented gas streams from CO 2 CPU Condensates from flue gas scrubber columns Define additional release points and monitoring regime Stage 2 CO 2 road transport Carbon Dioxide (CO 2 ) is a Dangerous Good (Class 2.2) under the Queensland Transport Act Stage 2 CO 2 storage Greenhouse Gas Storage Act 2009 (QLD) Greenhouse Gas Storage Regulation 2010 (QLD) Environmental Protection Act 1994 (QLD
Callide A Unit 4 Original 8
Boiler Plant/Equipment Removed Ready for New Equipment U3 Multiclone to Remain Cable Tray to Fabric Filters to Remain Walkway to Fabric Filter to Remain 9
Callide A Unit 4 After Oxfuel Retrofit New Primary Gas Heater New Feedwater Heater Oxygen Flue Gas Before Air Heaters Flue Gas After Air Heaters Flue Gas (Clean after FF bags) Recycled Gas Rich CO2 Flue Gas to CPU Secondary Recycled Gas Cold Primary Recycled Gas to Mills Hot Primary Recycled Gas to Mills 1 of 1440 Fabric Filter (FF) Bags Fabric Filter FROM ASU Existing Air Heater TO CPU v Air Intake Stack Dust FDF (1x100%) PRE SCRUBBER IDF(1x100%) FDF = Forced Draft Fan IDF = Induced Draft Fan H2O Remover Pumps & Heat Exchangers 10
Callide A Unit 4 After Oxfuel Retrofit 11 11
Oxy firing schematic O2 FD fan
Oxy firing mode changes Flue Gas Composition Air Firing mode O2 Sequence RFG Mode Oxy mode O2 vol %, dry 4.7 6.0 6.8 5.4 CO2 vol %, dry 15.0 16.2 59.9 68.3 CO ppm, dry 18 20 12 12 SO2 ppm, dry 220 230 800 890 NO ppm, dry 550 720 1195 965 NO2 ppm, dry 9 10 45 46 H2O vol % 8 8.5 20.5 21.6 NOx ppm, dry @ 7% O2 480 680 1220 910 NOx ppm, dry @ 12% CO2 445 540 250 180 Flue Gas to Stack kg/s (wet basis) 54 59 15.4 14.0 NOx g/s 43 61 21 15 Air firing mode means normal air firing O2 sequence means increased O2 to the boiler via O2 injection nozzles but no recirculation of flue gas RFG mode means that the recirculated flue gas sequence has been completed Oxy mode means that on completion of the RFG sequence the overall O2 is reduced to normal levels and full oxy mode is achieved
Flue gas mass balance To boiler: 28 kg/s FDF From boiler: 42 kg/s IDF Stack: 13 kg/s Blower CPU: 1.7 kg/s Parameter Unit CPU inlet CO 2 product Flow rate kg/s 1.7 0.9 Composition % 65% (CO2) 99.9 (CO2) Temperature C 145 30 Pressure kpa (abs) 101 1,600
Carbon dioxide capture plant Compressor LP Scrubber HP Scrubber Driers Cold box/ inerts separators Courtesy of Air Liquide
COP Site Works Oxygen and CO 2 Capture Plant Oxygen plant CO 2 capture plant
Hybrid Oxyfuel Power Plant (HOPP) Concept 1 year NEDO Study led by IHI together with CS Energy and Air Liquide Option 1 1000 MWe Oxyfuel boiler Option 2 250 MWe oxyfuel boiler Option 3 Hybrid Oxyfuel Power Plant (HOPP) concept 750 MW Ultra supercritical boiler + 250 MW ultra supercritical boiler
Concluding comments 1. Callide Oxyfuel Project ASU and Oxyfuel plant has been operating since March 2012 2. Over 300 hours of oxyfuel operation since 22 August 2012 3. CO2 capture plant commissioning in progress 4. NEDO study on future CCS commenced in July 2012 5. COP is still evaluation options for CO2 storage or sale of CO2 for industrial applications
Callide Oxyfuel Project Participants Thank you for more information: www.callideoxyfuel.com