Callide Oxyfuel Project: From Concept to Commissioning
Transcript of Callide Oxyfuel Project: From Concept to Commissioning
Callide Oxyfuel Project: From Concept to Commissioning
Chris Spero
2nd IEA GHG Oxyfuel Combustion Conference Tuesday, 13 September 2011
Keynote Address
Presentation Overview
• Project history
• Project structure, management and contracting strategy
• Project outline & permitting
• Current status of Callide A works
• Key issues and lessons learned
• Future deployment of oxyfuel technology
Central Queensland – The Morning Bulletin (May 1965)
The name ‘Callide’ was first used by pastoralist Charles Archer in 1853 to describe his holdings in the area, and is based on the Greek ‘Kallos’ meaning good’.
Project history
Project structure
Contracting and project management
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
Steam Flow 37.7kg/s or 136 t/h Pressure 4.1MPa, Temperature 460oC
Oxygen (GOX) Purity: 98 vol% Oxygen
Pressure : 180kPa(a) Flow: 7.6kg/s
Size: 2 x nominal 330 TPD Air Liquide Sigma cryogenic ASUs
Recirculated Flue Gases
Flow: 30kg/s CO2: ~67% mass
Chimney Stack Flow: 13.2kg/s Height: 76m
CO2 Purification and Compression CO2 Product: 75t/day CO2 Purity: 99.9% mol CO2 Temperature: -20oC CO2 Pressure: 1,600kPa
Road Transport B Double – 30t Single Tanker – 20t
Boiler Exit Flue Gases 350oC 44.9kg/s
Feed Gas to CO2 Plant Flue Gas Processed Flow: 1.7kg/s Temp ~ 150oC
Callide A Demonstration – Simplified
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 CO2 CPU
Condensates from flue gas scrubber columns
Define additional release points and monitoring regime
Stage 2 – CO2 road transport
• Carbon Dioxide (CO2) is a Dangerous Good (Class 2.2) under the Queensland Transport Act
Stage 2 – CO2 storage
• Greenhouse Gas Storage Act 2009 (QLD)
• Greenhouse Gas Storage Regulation 2010 (QLD)
• Environmental Protection Act 1994 (QLD
Permitting
Callide A Unit 4 - Original
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Boiler Plant/Equipment Removed Ready for New Equipment
Walkway to Fabric Filter to Remain
U3 Multiclone to Remain
Cable Tray to Fabric Filters to Remain
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Callide A Unit 4 - After Oxfuel Retrofit 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
New Feedwater Heater
New Primary Gas Heater
TO CPU
FROM ASU
1 of 1440 Fabric Filter (FF) Bags
Dust
FDF = Forced Draft Fan IDF = Induced Draft Fan
CPU = CO2 COMPRESSION & PURIFICATION UNIT
PRE SCRUBBER
H2O Remover
Pumps & Heat Exchangers
Stack
Fabric Filter
IDF(1x100%)
Air Intake
FDF
(1x100%)
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Existing Air Heater
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Callide A Unit 4 - After Oxfuel Retrofit
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Boiler/Stack/CO2CPU - Flue gas mass balance
Blower
GRF
FDF
CPU: 1.7 kg/s
Stack:13.2 kg/s
To boiler:30 kg/s
From boiler:44.9 kg/s
CO2 CPU - Schematic
Courtesy of ALE
LP Scrubber
Driers
HP Scrubber
Ammonia refrigeration plant
Cold box/ inerts
separators
CO2 CPU – process details
75 t/day liquid product
Parameter Units CPU Inlet CO2 Productkg/s 1.3 0.9Am3/s 1.7
Temperature oC 145 -30Pressure kPa (a) 101 1600Composition H2O mole % 20.0 < 0.002 O2 mole % 4.2 < 0.003 N2 (+ Ar) mole % 18.6 < 0.1 CO2 mole % 55.9 99.9 SO2 mole % 0.06 < 0.003 NOx mole % 0.03 < 0.003 Particulate mg/Nm3 < 100 < 1 Trace elements (As, Be, Cd, Hg, V) ppbv < 1 < 0.1
Flow rate
Oxygen plant CO2 capture plant
COP – Site Works – Oxygen and CO2 Capture Plant
COP key demonstration items – CO2 capture
• Oxyfuel and CO2 capture plant operation, including effects of variable flue gas composition
• Safety • Durability • Plant efficiency • CO2 capture rate & CO2 purity • Cost data • Process control and optimization • Design inputs for scale-up (e.g., corrosion rate of
Ferritic & Austenitic steels and Nickel-based boiler S/H tube materials
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• Project budget has been the dominating factor • EPCM approach with a very small team
Limited provisions included in construction contracts to minimise Contractors risk and therefore cost premiums
Alliance approach to contracting has proven to be of limited success
• Upfront engineering detail Very difficult to fully define some of the workscopes prior to contract
award
Many contract and physical interfaces
• Budget control has been good, but schedule has been very difficult to manage
• Results of R&D work have been invaluable in making important engineering and commercial decisions during the detailed design phase
Key issues/lessons learned
Technology Deployment
Hybrid Oxyfuel Power Plant (HOPP) concept Oxyfuel cannot be applied as a partial retrofit to the whole system One option for next scale-up is to apply oxy-firing to one or more units in a multi unit
plant 750 MW Ultra supercritical boiler + 250 MW ultra supercritical boiler
Hybrid Oxyfuel Power Plant (HOPP) Concept
CO2 storage potential
Storage volumes (based on current production): • East coast – 70 years • West coast > 200 years • CO2 storage capacity of gas and oil fields is ~ 16.5 giga tonnes
(Source: National Low Emissions Coal Council)
Queensland Government: Carbon Geo-storage Initiative (CGI)
Potential CO2 storage tenements
Callide A
EPQ7 (CTSCo Pty Ltd)
Scale: 0 – 108 km
Concluding comments
1. Callide Oxyfuel Project – ASU and Oxyfuel plant are now in commissioning phase; the CO2 capture plant is under construction.
2. Budget limitations , first-of-a-kind issues, and other major Coal Seam Gas developments in Queensland have resulted in a very difficult contracting environment.
3. An EPCM and alliance type contracting approach has resulted in good budget control but schedule control has been somewhat problematic.
4. Oxyfuel science/R&D has been very helpful in supporting engineering and commercial decisions, especially in the detailed design phase.
5. The implementation of carbon capture is still a long way ahead of the implementation of carbon storage in the Australian environment.
Thank you
for more information: www.callideoxyfuel.com
Callide Oxyfuel Project – Participants