Challenges to Demonstration “Review of Technology ... the boiler.pdf · Alstom SchwarzePumpe 2008...

Challenges to Demonstration

“Review of Technology Development Beyond

the Oxyfuel Combustion Boiler”

Stanley Santos

IEA Greenhouse Gas R&D Programme

39th IFRF TOTEM & RELSCOM Workshop

Pisa, Italy

18 June 2013

IEA Greenhouse Gas R&D Programme

• A collaborative research programme founded in 1991

• Aim: Provide members with definitive information on the role that technology can play in reducing greenhouse gas emissions.

• Producing information that is:

� Objective, trustworthy, independent

� Policy relevant but NOT policy prescriptive

2

� Reviewed by external Expert Reviewers

� Subject to review of policy implications by Members

• IEA GHG is an IEA Implementing Agreement in which the Participants contribute to a common fund to finance the activities.

• Activities: Studies and Reports (>120); International Research Networks : Wells, Risk, Monitoring, Modelling, Oxyfuel, Capture, Social Research, Solid Looping; Communications (GHGT conferences, IJGGC, etc); facilitating and focusing R&D and demonstration activities e.g. Weyburn

Members and Sponsors

3

3rd Oxyfuel Combustion ConferenceLeon, Spain9th – 13th September 2013

Full Programme Announced

17th May 2013

4

5

UPDATE TO THE CURRENT

DEVELOPMENT OF OXYFUEL

COMBUSTION

Alstom Schwarze Pumpe 2008 30MWth Lignite

Hitachi Babcock Schwarze Pumpe 2010 30MWth Lignite

IHI Callide 2011 30MWe

Alstom / AL Lacq 2009 30MWth Gas/Oil?

CIUDEN El Bierzo CFB Facility 2011 30MWth Coal

El Bierzo PC Facility 2011 20MWth Coal

Coal

CIUDEN

2008

World’s FIRST 30 MWt

full chain demonstration

at Schwarze Pumpe Pilot

2009 – Lacq –

World’s first 30MWt

retrofitted Oxy-NG

boiler2011 – CIUDEN –


Oxy-CFB Pilot Plant

2011 – Callide –

World’s first

30MWe retrofitted

Oxy-coal power

plant

By 2014-2018

Demonstration of

50– 300MWe full

scale power plant.

Target :

“Commercialised by 2020”

KEPCO/KOSEP - Yongdong (PC - 100MWe)

FutureGen2 - Illinois (PC - 168MWe)

Drax’s White Rose Oxyfuel Project (300MWe)

Endesa/CIUDEN - El Bierzo (CFB - 300MWe) - ???

China: 3 Oxyfuel Projects – in progress

1980’s

ANL/Battelle/EERC completed the first

industrial scale pilot plant

1990 - 1995

EC Joule Thermie Project

- IFRF / Doosan Babcock / Int’l Combustion

NEDO / IHI / Jcoal Project

First large scale 35MWt

Oxy-Coal Burner Retrofit

Test done by

International Combustion

1998 – 2001

CANMET

US DOE Project / B&W / Air Liquide

2003 - 2005

Vattenfall (ENCAP ++)

CS Energy / IHI Callide Project

B&W CEDF 2008 30MWth Coal

Alstom Alstom CE 2010 15MWth Coal

Doosan Babcock DBEL - MBTF 2009 40MWth Coal

2007

B&W CEDF (30MWt)

large scale burner testing started

Updated by S. Santos (20/08/12)


Plant

By the end of 2010/2011, Users (i.e. Power Plant

Operators) will have 6 burner manufacturers fully

demonstrating “Utility Size Large Scale Burners” which should

give a high level of confidence toward demonstration

Concluding Remarks –Update to Key Demonstration Projects

• Based on the Conclusions from 2nd Oxyfuel Combustion Conference – This Technology is READY for DEMONSTRATION

• Lost of Janschwalde Project is a setback…

• Success in the commissioning of Callide Project is an important milestone.

7

• Three important projects on-going…

• FutureGen2 (USA)

• White Rose Project (UK)

• Yong Dong Project (South Korea)

• Other new projects – currently under development

• Huazhong Project (China)

• 2 Other Oxyfuel Demonstration Projects under considersation in China

Presentation Outline…

Oxygen

Production

8

CO2 Processing Unit

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 CO capture…

9

plant with CO2 capture…

• 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

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 Presented at Yokohama

Workshop, March 2008

10

• 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.

Workshop, March 2008

Presented at OCC2 -

Yeppoon , Australia

September 2011

Cryogenic Air Separation – Capacity Increase

Bey/L/092009/Cottbus.pptLinde AG Engineering Division 11

1902 :5 kg/h

(0,1 ton/day)

2006 :1,250 Mio kg/h

(30.000 ton/day)

Experience - Large ASU Projects and Train Scale-up

5000

� Market drives ASU scale-up

� Proven 70% scale-up

� Quoting 5,000+ MTPD today

Chevron Nigeria

EastmanTexas

A5000 / A7000

12

0

1000

2000

3000

4000

MTP

D O

2

1987 1993 1996 1996 2006 2009 2011

Startup date

Buggenum

Oryx GTL

Polk

Plaquemine

NigeriaTexas

Rozenburg

Overview Of The Process

Main and Boost

Air Compression

Air Cooling and

Pretreatment Storage

Cryogenic

Separation

14

Heat

Air

Heat

Oxygen

Air Separation Process Conventional Design (mit Einblaseturbine)

tauscher

PGAN

GOX

derdruckkolonne

5.5-6 bar

1.05 bar


Wärmet

Booster

Turbine

Kondensator

Nied

Hochdruckkolonne

UKG

5.3-5.8 bar

� Oxygen: 95%, gaseous, at ambient pressure

Features:

� PNitrogen: up to 30% of airflow available

ASU for Oxyfuel Combustion Applications

• There will be several ASU cycles for low purity oxygen requirements

• Leading ASU Cycle for

16

• Leading ASU Cycle for Oxyfuel Combustion

• 3 Columns

• Dual Reboiler

• Key Features:

• Lower compression requirements for the air input to the cold box

16

McCabe Thiele Diagrams

Double ColumnSingle Pressure SideColumn Reboiler

Equilibrium

line

Operating

lines

17

Cold Compressed Side Column Reboiler

Case Studies Done by

Air Products

18

ASU Cycle Comparison Results� Without GAN, three column

cycle is best

– 158 kWh/t (base)

� With GAN, three column cycle has lowest gross power -increases dramatically for elevated pressure (EP) cycles as they make more GAN

19

as they make more GAN

� If GAN can be used (crediting avoided compression power) EP cycles are best

– EP: 128 kWh/t (-19%)

– 3 Col: 147 kWh/t (-7%)

� If GAN has no use and power is recovered with expander (no external heat), three column cycle is still best

– 157 kWh/t (-1%)

CAPEX vs OPEX(Source: NETL Report 2008)

20

ASU Interface to the Boiler

21

An important aspects to this interface is the stability of the flame and you need to understand that flame stability envelope

For RETROFIT Case…

22

ASU Addressing Flexibility

Requirements

• Power plant requirements (i.e. regulatory framework) will define the design of the ASU

• choice between 2 trains vs multiple trains

23

ASU Addressing Flexibility

Requirements

• Other options include the installation of liquid gas storage system could provide additional flexibility and opportunities…

24

Key Concluding Remarks

• 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

25

•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.

• Other emerging technologies such as ITM, OTM, etc… are not ready in the near term.

Oxyfuel Coal “Reference ASU”

� Designs developed for a scalable reference plant

� Column diameters within manufacturing capabilities (referenced to 7000 te/d)

26

Size te/d O2 Machinery options Power MW

3,000 – 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 train 30-45

5,500 – 7,000 Centrifugal 2 train or axial 1 train 41-58

7,000 -10,000 Centrifugal or axial 2 train 53-82

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 Dehydration Unit

o Cryogenic Separation of Inerts (Cold Box development)

27

o Cryogenic Separation of Inerts (Cold Box development)

o Additional capture of CO2 from the CPU

• Other key 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

Overview of Development of

CPU over the last 8 years...

• Recognition of the NOx and SOx reaction by Air Products (presented during GHGT Conference –June 2006)

• This has led to the rapid technology development among

the industrial gas producers.

28

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.

Air Products Oxy-Fuel CO2 Capture and Purification –

with Air Products PRISM® Membrane

Product CO2

Heat

Recovery CO2 Compression

Boiler Steam

Cycle

Commercial

Mature Tech, Needs Data

Needs Engineering Data

29

Raw

Flue Gas

Offgas

[To Atmosphere]

Process

Condensate

Sour

Compression &

AP Acid Gas

Column

Condensate

Collection

TSA UnitMercury

Removal

Auto-Refrigerated

N2, Ar, O2

Removal

Process

Optional

APCI PRISM®

Membrane

O2 and CO2 Rich

[To Boiler]

Major Utilities

Cooling Water

Electric Power

Expander

Activated

carbon filter

Recti-

fication

Compressor

building

Analysis

CO2-tanks

(2x180 m³)

Trailer

docking

station

Analysis

container

NOx SO2 Reactions in the CO2Compression System� We realised that SO2, NOx and Hg can be removed in the CO2

compression process, in the presence of water and oxygen.

� SO2 is converted to Sulphuric Acid, NO2 converted to Nitric Acid:

– NO + ½ O2 = NO2 (1) Slow– 2 NO2 = N2O4 (2) Fast– 2 NO2 + H2O = HNO2 + HNO3 (3) Slow

31

– 2 NO2 + H2O = HNO2 + HNO3 (3) Slow– 3 HNO2 = HNO3 + 2 NO + H2O (4) Fast– NO2 + SO2 = NO + SO3 (5) Fast– SO3 + H2O = H2SO4 (6) Fast

� Rate increases with Pressure to the 3rd power– only feasible at elevated pressure

� No Nitric Acid is formed until all the SO2 is converted

� Pressure, reactor design and residence times, are important.

CO2 Compression and Purification System –Removal of SO2, NOx and Hg

1.02 bar

30°C

67% CO2

8% H2O

25%

Inerts

SOx

NOx

30 bar to DriersSaturated 30°C76% CO2

24% Inerts

� SO2 removal: 100% NOx removal: 90-99%

BFW15 bar

30 bar

Water

32

NOx

Dilute H2SO4

HNO3

Hg

BFW

Condensate

cw

30 bar

cwcw

Dilute HNO3

AB

C

MFC

D

From NRTF

Flue Gas Cooler

Condensate

Separator

Reactor

The effect of Pressure on SO2 and NO Conversion (1 sl/min, 7 and 14 barg)

Presented at the 9th International Conference on Greenhouse Gas Control Technologies (GHGT-9) “Purification of Oxyfuel-Derived

CO2”, Vince White, Laura Torrente-Murciano, David Sturgeon, and David Chadwick, Washington, D.C., November 2009

33

Compressor &

Receiver

Inlet

After

Compressor &

ReceiverInlet

After

Compressor &

Receiver

(Point A) (Point C) (Point A) (Point C)

ppm SO2 900 20 98% 950 150 84%

ppm NOx 520 50 90% 390 120 68%

ConversionConversion

7 bar g14 bar g

DOE/NETL Cooperative Agreement: Air Products’ Sour Compression PDU

34

Acid Reactor (C102)

Side View of PDU

• 1st campaign Jan 2010

• 2nd campaign April-May 2010

U.S. Department of Energy's National Energy Technology Laboratory under Award Number DE-NT0005309

LICONOX™ Process


Sulphuric Acid Method Activated Carbon Method

Auto-Refrigerated Inerts Removal

• Removal of impurities minimises compression and

transportation costs.

• O2 can be removed for EOR-grade CO2

• CO2 capture rate of 90% with CO2 purity >95%

• CO2 capture rate depends on raw CO2 purity which

depends on air ingress

41

depends on air ingress

– Increases from zero at 25mol% to 90% at

75mol%

– Reducing air ingress increases CO2 capture rate

Can we improve on ~90% CO2 Capture?Vent stream is at pressure and is CO2 (and O2) rich

Flue Gas

Vent

1.1 bar

~25% CO2

~25% O2

~50% N2

Flue Gas Expander

Aluminium plate/fin exchanger

Flue GasHeater -55°C

42

Driers

30 bar Raw CO2

Saturated 30°C

75-85% CO2

CO2 product

~96% CO2

~4% Inerts

-60°C dp

76%mol CO2

24% inerts (~ 5 - 6% O2)

96%mol CO2

4% inerts (~ 0.95% O2)

25%mol CO2

75% inerts (~ 15% O2)

72%mol CO2

28% inerts

(~ 5 - 6% O2)

98%mol CO2

2% inerts

(~ 0.6% O2)

25%mol CO2

75% inerts

(~ 19% O2)

25%mol CO2

43

72%mol CO2

28% inerts(~ 5 - 6% O2)

99.999%mol CO2

0.001% inerts(~ .0005% 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)

25%mol CO2

75% inerts(~ 15% O2)

Autorefrigeration Process

� J-T expansion of purified LCO2 for refrigeration

� Raw CO2 partially

liquefied by boiling product

Compared to NH3

> 99.9% CO2

DryerDryer

Hg

Vent

4444

Compared to NH3

refrigeration:

� Simpler process

� Lower CAPEX

� Higher CO2

recovery

� Lower power

Cold Box

DistillationColumn

PHX

Reboiler

US Pat. 7,666,251

Air Products Oxy-Fuel CO2 Capture and Purification – with Air

Products PRISM® Membrane

Flue Gas

ExpanderAluminium plate/fin exchanger

Flue Gas

Heater -55°C

Membrane

To Boiler

45

Driers

CO2 product

~96% CO2

~4% Inerts

-60°C dp30 bar Raw CO2

Saturated 30°C

75-85% CO2

VPSA (Vacuum Pressure Swing Adsorption) for Recovering CO2 from Cold Box Vent

80%

90%

100%

Reco

very

, %

Cold box

Cold box + VPSA

Cold boxVent

VPSAVPSA

CO2 –richrecycle

CO2 –leanvent

4949

40%

50%

60%

70%

0% 3% 6% 9% 12%

Air Ingress, %

CO

2 R

eco

very

, %

Feed CO2

Cold Box

Some More Challenges....

• Demand of the quality requirements of the CO2 from the power plant for transport and storage. What are the Required Specification?

• Further recovery of CO from the vent will

50

• 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.

Alstom Schwarze Pumpe 2008 30MWth Lignite

Hitachi Babcock Schwarze Pumpe 2010 30MWth Lignite

IHI Callide 2011 30MWe

Alstom / AL Lacq 2009 30MWth Gas/Oil?

CIUDEN El Bierzo CFB Facility 2011 30MWth Coal

El Bierzo PC Facility 2011 20MWth Coal

Coal

CIUDEN

2008

World’s FIRST 30 MWt

full chain demonstration


2009 – Lacq –


retrofitted Oxy-NG

boiler2011 – CIUDEN –


Oxy-CFB Pilot Plant

2011 – Callide –

World’s first

30MWe retrofitted

Oxy-coal power

plant

By 2014-2018

Demonstration of

50– 300MWe full

scale power plant.

Target :

“Commercialised by 2020”

KEPCO/KOSEP - Yongdong (PC - 100MWe)

FutureGen2 - Illinois (PC - 168MWe)

Drax’s White Rose Oxyfuel Project (300MWe)

Endesa/CIUDEN - El Bierzo (CFB - 300MWe) - ???

China: 3 Oxyfuel Projects – in progress

52

1980’s

ANL/Battelle/EERC completed the first

industrial scale pilot plant

1990 - 1995

EC Joule Thermie Project

- IFRF / Doosan Babcock / Int’l Combustion

NEDO / IHI / Jcoal Project

First large scale 35MWt

Oxy-Coal Burner Retrofit

Test done by

International Combustion

1998 – 2001

CANMET

US DOE Project / B&W / Air Liquide

2003 - 2005

Vattenfall (ENCAP ++)

CS Energy / IHI Callide Project

B&W CEDF 2008 30MWth Coal

Alstom Alstom CE 2010 15MWth Coal

Doosan Babcock DBEL - MBTF 2009 40MWth Coal

2007

B&W CEDF (30MWt)

large scale burner testing started

Updated by S. Santos (20/08/12)


Plant

By the end of 2010/2011, Users (i.e. Power Plant

Operators) will have 6 burner manufacturers fully

demonstrating “Utility Size Large Scale Burners” which should

give a high level of confidence toward demonstration

53

Thank you• Email: [email protected]

• Website: http://www.ieaghg.org

Challenges to Demonstration “Review of Technology ... the boiler.pdf · Alstom SchwarzePumpe 2008...

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