Development of High Efficiency CFB Technology to Provide Flexible Air/Oxy Operation for Power Plant with CCS FLEXI BURN CFB CO2NET seminar and EU CCS conference, 24 th 26 th May 2011, London
Project objective Aim : to develop and demonstrate FLEXI BURN CFB concept enabling to reach the target of near zero emission power plants The FLEXI BURN CFB concept: High efficiency Circulating Fluidized Bed (CFB) power plant with CCS capable of air/oxy operation with a wide range of fuels including biomass The FLEXI BURN CFB concept has a set of important advantages: 1. fuel flexibility in order to decrease dependency on imported coals and in order to improve power plant economics especially with CCS operation 2. operational flexibility in order to apply air-firing and oxygen-firing with CO 2 capture 3. lower NO x production due to reduced and more uniform furnace temperature profiles, and lower SO x concentration in flue gases due to in-furnace capture, thus reducing the need for downstream flue gas cleaning 4. overall concept for phased transition into CCS technology with minimised risks through high efficiency air-oxy flexible CFB combustion 5. lower specific CO 2 emissions from the reduced consumption of fuel due to the intrinsic high efficiency of the technology. In addition, by substituting e.g. 20% of coal input with renewable fuels, CO 2 emissions can further be reduced by 15-20%. 6. Provides utilities an attractive alternative to take into use the new technology and decommission old capacity with lower efficiency and poorer emission performance 2
FLEXI BURN CFB diagram allowing operation under normal air-firing as well as oxygen-firing with CCS The FLEXI BURN CFB concept: High efficiency Circulating Fluidized Bed (CFB) power plant with CCS capable of air/oxy operation with a wide range of fuels including biomass Fuel Bituminous coal Lignite Biomass Pet coke etc. Large scale high efficiency CFB boiler with FLEXI BURN design Fluegas (CO 2 -rich) Flue gas cleaning Switch Stack CO 2 capture and storage (CCS) Condensation Compression Purification Transport Storage Air Switch Air Separation Unit (ASU) 95-97% O2 Mixing Flue gas recirculation 3
Role of FLEXI BURN CFB Partners Endesa, EDP, PKE UAP Utilities Development steps VTT, LUT, CzUT UNIZAR-LITEC, AICIA Research institutes Concept FWEOY, FWESA, ADEX, Siemens, Praxair Manufacturers Laboratory and small pilot scale test (0.1-1MW th ) FLEXI BURN CFB project 2009-2012 Demonstration Pilot Plant 30 MW th, CIUDEN 1 st Commercial scale FLEXI BURN CFB Power Plant Industrial applicability
FLEXI BURN CFB - General project approach WP7: Coordination and dissemination WP6 Feasibility and readiness for the utilization of the technology within different regions in EU WP1 Comparison of airand oxy-firing Supporting R&D work WP2 Development of design tools WP3 Demonstration tests at large pilot unit and commercial scale air fired unit WP4 Boiler design and performance Viable boiler design WP5 Power plant integration, optimization and economics Viable power plant 5 Technology demonstration and background for the commercial scale design process
Development and demonstration in multiple scales (1/2) Bench scale Pilot scale Boiler scale BENCH SCALE REACTOR (BFB/CFB) Flue gas recirculation PILOT SCALE CFB COMBUSTOR FTIR sampling port Gas analysator Bag filter Gas cooling Deposit probe port AGISZA 460 MWe supercritical OTU CFB To Stack Cooler Filter Cyclone To stack Observation port Secondary cyclone Cooler/heater Fuel batch feed Zone4 Primary cyclone FTIR sampling port EXPERIMENTAL SCALES Secondary air Continuous fuel feed Fuel containers 1 and 2 Additive container Zone3 Zone 2 Zone1 Secondary gas O2, CO2, N2 M O2, CO2, CO, N2, SO2, NO Primary gas heating Air PC control and data logging system Primary gas heating Air PC control and data logging system 1D-MODEL flue gas to stack n n+1 MODELS AND DESIGN TOOLS Model analyses Volatile, moisture release COcombustion Mixing Char combustion n v b exp( A/ T)( d / d ref ) dy CO kef YCO d t k /(1/ ) ef 1 k CO m n-1 n-2 dm c rc kmc X dt n O2 Secondary air 3 2 1 Primary air kw/m 2 kw /m 2 MODELS FOR PHENOMENA 1-D PROCESS MODELS 3-D PROCESS MODELS
Development and demonstration in multiple scales (2/2) Demonstration of FLEXI BURN CFB CIUDEN 30MW th - air-/ oxy-firing with fuel flexibility - CO 2 separation Field measurements at OTU CFB Lagisza 460 MWe - scale-up information from the world first and largest OTU CFB - design model validation Scale up criteria Commercial scale FLEXI BURN CFB Technology WP1 WP2 WP3 WP4 WP5 WP6 R&D support Design tools Demonstration Boiler design Power plant concept Commercial Scale FLEXIBURN
Process scale-up Reference plant for the project 800 600 500 Unit Capacity (MWe) 800 MWe 400 Lagisza 300 JEA 200 Turow 1 Tri-State Nova Scotia 100 Vaskiluodon Oriental Chem Pilot Plant General Motors 0 1970 1975 1980 1985 1990 1995 2000 2005 2010 Start-Up Year CFB technology is scaling up with the latest high-efficiency SC-OTU-references Lagisza (460 MWe). The Lagisza power plant (460 MWe), located in the southern Poland, is the world's largest CFB boiler, which is also the world's first supercritical CFB once-through unit (OTU) CFB800 agisza Turow 4-6 JEA Turow 1-3 Furnace - Width m 40 27.6 22.0 26.0 21.2 - Depth m 12 10.6 10.1 6.7 9.9 - Height m 50.0 48.0 42.0 35.1 43.5
Validation runs at a 460 MWe SC-OTU CFB boiler Balance test runs at Lagisza CFB boiler Unit loads (100%MCR, 80%MCR, 60%MCR and 40%MCR) High/low level of bed pressure within combustion chamber Measurement parameters during test runs : Temperature within the combustion chamber (rear wall) Vertical pressure profile within furnace (front wall) Gas profiles (at level 13.00m) Process data (including emission data) Solid samples coal, limestone, bottom ash, fly ash, in-furnace sample and circulating material Solids Bituminous coal Bottom ash Fly ash In-furnace sample Circulating material Limestone Solids Bituminous coal Bottom ash Fly ash In-furnace sample Circulating material Limestone Load unit: 100% MCR, 80% MCR Load unit: 60% MCR, 40% MCR Sampling frequency 4 (every two hours) 4 (every two hours) 4 (every two hours) 4 (every two hours) 4 (every two hours) 1 (in half of test balance) Sampling frequency 3 (in half of test balance) 3 (in half of test balance) 3 (in half of test balance) 3 (in half of test balance) 3 (in half of test balance) 1 (in half of test balance) Location of measurement ports at OTU-SC 460MWe Lagisza boiler
Validation runs at a 460 MWe SC-OTU CFB boiler OTU SC CFB Boiler layout at PKE S.A. Lagisza Power Plant EMISSION ( at 6% O 2, dry flue gas) (follows EU s LCP directive), mg/nm 3 SO 2 200 NO x (as NO 2 ) 200 CO 200 Dust 30 Low Emissions 400 400 Concentration of SO 2 [mg/m 3 ] n (at O 2 = 6% in dry flue gases) 350 300 250 200 150 100 50 SO 2 measuring data Concentration of NO x [mg/m 3 n ] (at O 2 = 6% in dry flue gases) 350 300 250 200 150 100 50 NO x measuring data 200 250 300 350 400 450 500 200 250 300 350 400 450 500 Temperature [ C] 950 925 900 875 850 825 800 775 Measured calculated by model Concentration of CO [mg/m 3 n ] (at O 2 = 6% in dry flue gases) 200 175 150 125 100 75 50 25 Unit load [MW e ] CO measuring data Concentration of dust [mg/m 2 n ] (at O 2 = 6% in dry flue gases) 200 180 160 140 120 100 80 60 40 20 Unit load [MW e ] Dust measuring data 750 0 5 10 15 20 25 30 35 40 45 50 Height [m] 200 250 300 350 400 450 500 Unit load [MW e ] 0 200 250 300 350 400 450 500 550 Unit load [MW e ]
BENCH SCALE REACTOR (BFB/CFB) FLEXI BURN CFB Demonstration steps CIUDEN 30MW Concept for 300 MW e Demonstration scales VTT 0.3kW BENCH SCALE REACTOR (BFB/CFB) VTT 0.1MW Flue gas recirculation To stack Bag filter PILOT SCALE CFB COMBUSTOR FTIR sampling port Gas analysator Gas c ooling Observation port Zone4 Zone3 Pr imary cyclone Depositprobe port FTIR sampling port Secondary cyclone S am pling por t CANMET 1MW Aim : to develop and demonstrate FLEXI BURN CFB concept enabling to reach the target of near zero emission power plants Cooler Cyclone Zone2 To Stack Filter Fuel batch feed Fuel containers 1 and 2 Additive c ontainer Zone1 Secondarygas O2, CO2, N2 Cooler/heater Secondary air Continuous fuel feed M PC control and data logging system Primary gas heating Air Completed PC control and data logging system O2, CO2, CO, N2, SO2, NO Primary gas heating A ir In progress 2009 Time 2012
Small pilot scale CFB experiments (0.1MW) under air- and oxygen-firing conditions Operational point of views: Combustion process dynamics Transition between air- and oxygen firing Air-firing Oxygen-firing Oxygen-firing Air-firing
Small pilot scale CFB experiments (0.1MW) under air- and oxygen-firing conditions Small pilot scale CFB experiments (0.1MW) under air- and oxygen-firing conditions have been completed with totally 33 experiments Transition between air- and oxygen firing conditions could be carried out smoothly and safely with the renovated automation system which included an automated transition mode between air- and oxygen-firing Combustion process could be operated in the both modes without any major drawbacks Bottom ash Air-firng (Test 19) CaCO3 [%] CaO [%] CaSO4 [%] Based on the dynamic tests the reliable control of oxidant oxygen concentration is very important from the safety operation and process controllability point of view Bottom ash Oxygen-firing (Test 20) If the inlet gas (oxidant) oxygen concentration is controlled effectively the combustion process stability seems to be comparable to corresponding air-firing conditions If flue gas emissions are expressed in milligrams per megajoules the emission levels between air- and oxygenfiring have not remarkable differences CaCO3 [%] CaO [%] CaSO4 [%]
Model based analysis of the CANMET test data Test program at CanmetENERGY, Ottawa 15 test weeks Runs: 88 of which 35 in air combustion 53 in oxy combustion Detailed analysis of solids mass balance Furnace vertical temperature profile Combustion and energy release profile Solids density profile Heat flux profile Furnace heat transfer 1000 950 900 850 800 Temperature 750 700 650 600 550 500 High load OXY High load AIR Furnace height 0 2 4 6
Demonstration runs at a 30 MWth CFB pilot plant FLUE GAS CLEANING GASES RECIRCULATION AND MIXTURE DCS CFB BOILER PC BOILER FUEL PREPARATION CO 2 COMPRESSION & PURIFICATION TECHNICAL & INDUSTRIAL BUILDINGS
Demonstration runs at a 30 MWth CFB pilot plant CIRCULATING FLUIDIZED BED BOILER FLOW DIAGRAM FLY ASH SILO LIMESTONE SILO AMMONIA, DeNOx FLY ASH FEEDING SYSTEM LIMESTONE, DeSOx BOILER FEED WATER FLUE GAS FLY ASH RECIRCULATION LIMESTONE SAND FUEL FEED LIMESTONE FEEDING SYSTEM FLY ASH SYSTEM SAND SILO FUEL SILO SAND FEEDING SYSTEM MIXER MIXER FAN PRIMARY OXIDANT CB1 FUEL FEEDING SYSTEM MIXER FAN SECUNDARY OXIDANT CB2 NATURAL GAS START-UP BURNER SKID OXYGEN BOTTOM ASH
Demonstration runs at a 30 MWth CFB pilot plant NEXT STEPS PLANNING OF TEST MATRIX FLEXI BURN TEST PERIOD FLEXI BURN PROJECT DEADLINE 01 02 03 04 05 06 07 08 09 10 11 12 2011 01 02 03 04 05 06 07 08 09 10 11 12 2012 CFB CONSTRUCTION & COMMISSIONING CFB FUNCTIONALITY TEST COMPILATION OF RESULTS 17
Specifications for a FLEXI BURN CFB demonstration plant Plant size: Two cases considered: Flexi Burn CFB demonstration plant: 300-350 MWe gross. (Detailed technical scope, main focus) Full Commercial plant - post-2020: 800 MWe gross (techno-economical feasibility study)
Specifications for a FLEXI BURN CFB demonstration plant Steam parameters: CO 2 compressed to transport by pipeline Main steam temperature Main steam pressure Reheated steam pressure Reheated steam temperature 598 ºC 270 bar 57 bar 600 ºC H 2 O CONCENTRATION < 500 ppm CO < 2000 ppm O2 + N2 + Ar < 4 vol% SO x < 100 ppm NO x < 100 ppm CO 2 >95.5 % Operating parameters: Dynamic requirements for the power plant Operational Mode Base Load Load change rate Max ramping 4%/min Minimum load 40% Start-up time (cold) <24h Start-up time (ASU cold) <8h Oxy mode Air mode TOTAL Annual equivalent operating hours 6500 h 500 h 7000 h
Specifications for a FLEXI BURN CFB demonstration plant Other oxycombustion criteria: Air inleakage: Base case 1% (sensitivity analysis up to 3%). O 2 /CO 2 ratio: close to air concentration (24% O 2 wet). Oxygen purity: Oxygen purity 96,6 % vol Pressure 1,2 bar Temperature 20 ºC
Current status (1/2) During the first half of the project a lot of experimental work has been carried out in order to support the development of FLEXI BURN CFB concept Combustion tests in different scales and field measurements in a commercial scale power plant provide a base for development and validation of the design tools needed in the concept development Demonstration tests at different scales: VTT 0.1MW, CANMET 1MW has been completed (totally over 100 test balances) with encouraging results If flue gas emissions are expressed in milligrams per megajoules the emission levels between air- and oxygen-firing have not remarkable differences Air Fuel Bituminous coal Lignite Biomass Pet coke etc. Switch Large scale high efficiency CFB boiler with FLEXI BURN design Fluegas (CO 2 -rich) Flue gas cleaning Switch Stack CO 2 capture and storage (CCS) Condensation Compression Purification Transport Storage Emission limits based on the concentrations and volumetric units are not applicable for the CCS processes. Emission limits in CCS applications should be expressed in energy basis. Air Separation Unit (ASU) 95-97% O2 Mixing Flue gas recirculation
Current status (2/2) The basic design parameters for a FLEXI BURN CFB plant, from a technical and functional point of view, have been determined Two cases considered: 1) Flexi Burn CFB demonstration plant: 300-350 MWe gross 2) Full Commercial plant - post-2020: 800 MWe gross The initial conceptual design of the FLEXI BURN CFB boiler has been developed The first conceptual design for the FLEXI BURN has been implemented including a preliminary integration with the Air Separation Unit (ASU) and the Compression and Purification Unit (CPU) Oxidant Boiler Flue gas ASU CPU Integration Steam Integration Power Utilities Cycle Power Utilities
Next steps The second test campaign at Lagisza Power Plant is carried out during the first half of 2011 Demonstration tests at CIUDEN in the beginning of 2012 Concept optimisation for the boiler island and the integrated power plant unit including dynamic simulation of the plant Health and safety assessment related to oxygen-firing conditions Estimate economics for the new concept and evaluate their feasibility on a commercial scale range Identification of the key success factors of the FLEXI BURN CFB technology covering the process efficiency, operability, maintainability, environmental impact and responsiveness to the market requirements, all leading to the economic performance of this new approach for power generation Co-operation with Utility Advisory Panel (UAP)
FLEXI BURN CFB - Summary 1) What has been achieved, what do we now know and what can we now do, technically and commercially? Flexible operation under air- and oxygen-firing modes have been successful demonstrated in the small scales (0.1MW-1MW) The first validation test campaign with the world first and the largest (460 MWe) OTSC-CFB has been successfully completed 2) What is NOT yet achieved? Final concept and demonstration in the large scale (30MW-300MWe) 3) What are the next logical steps, i.e.: what do we still need to do within the subject of the presentation towards the implementation and commercialisation of CCS? Next logical steps: demonstration tests at CIUDEN (30MW) and development of final concept for 300MWe Development of 2 nd generation oxyfuel concept with significantly higher overall plant efficiency Transportation and storage part is not in the scope of the project but it will be the key issue in the implementation and commercialisation of CCS Emission limits for CCS plants must be reconsider (concentration based limits are not valid) 4) Who do you think is best placed to take these next steps forward? Demonstration of FLEXI BURN CFB concept: FLEXI BURN CFB consortium and OXYCFB300 consortium Development of 2 nd generation oxyfuel concept: Organizations who have been involved in the development of the 1 st generation oxyfuel concepts Transportation and storage: all together, public acceptance and political decisions are very important Emission limits for CCS: European Commission is working on the issue
FLEXI BURN CFB Workshops 1 st Flexi Burn CFB Workshop was held in Brussels 24 th March 2011 More information: http://www.vtt.fi/sites/flexiburncfb/ 2 nd FLEXI BURN CFB Workshop will be held in summer 2012 highlighting the final results of the project Welcome! Thank You!