Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... ·...
Transcript of Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... ·...
![Page 1: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/1.jpg)
Development and Demonstration of Waste
Heat Integration with Solvent Process for More
Efficient CO2 Removal from Coal-Fired Flue Gas
DE-FE0007525 Project Review Meeting
July 10, 2012
![Page 2: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/2.jpg)
Presentation Outline
• Project Overview • Technology Description and Background • Technical Approach • Techno-economic Results • Summary and Path Forward
![Page 3: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/3.jpg)
Project Overview
![Page 4: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/4.jpg)
Project Scope
• Develop viable heat integration methods for CCS • Integrate a waste heat recovery technology termed
Mitsubishi High Efficiency System (HES) into an existing amine-based CO2 capture process and host coal unit
• Evaluate improvements in the energy performance and emissions profile of the integrated plant
![Page 5: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/5.jpg)
High Efficiency System
Work Plan • A 25-MW High Efficiency System will be designed and installed to
operate for 12 months in conjunction with the existing 25-MW MHI KM-CDR CCS pilot process at Southern Company’s Plant Barry.
• Waste heat in flue gas and CO2 will be recovered to preheat a 25 MW slipstream of boiler condensate in the Plant Barry steam cycle.
• A 0.5 MW pilot ESP will be installed to test the tangential benefits of HES.
Steam
REBOILER
STRIPPER
C.W.
New Boiler Condensate
Pre-heater
BOILER CONDENSATE
BOILER CONDENSATE
CO2 PRODUCT
Flue Gas Cooler
Boiler ESP
FGD
![Page 6: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/6.jpg)
Goals • Quantify energy efficiency improvements to the integrated
process. • Identify and resolve operational and control problems of the
integrated plant. • Assess the flue gas cooler long term deployment in an acid mist
environment. • Quantify the tangential benefits of the HES technology
– Improved ESP performance – SO3 concentration reduced in existing systems – Reduced solvent consumption by reducing impurity load to the CO2
capture process island – Reduced water consumption in FGD due to lower flue gas
temperature at the inlet
![Page 7: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/7.jpg)
Relevance of Work • Typical steam systems extract a significant amount of
steam from the turbines to preheat boiler feed water • Heat integration system between boiler and CO2 plant
will reduce LCOE by minimizing the amount of steam extracted for reheating condensate and reduce steam to the CCS plant
• Trace metals and SO3 in flue gas result in amine solvent wastage, hazardous waste, and additional costs.
![Page 8: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/8.jpg)
Project Budget
DOE Share Recipient Share % Cost Share BP1 $515,630 $150,558 BP2 $8,573,466 $2,503,363 BP3 $2,894,610 $845,196 TOTAL $11,983,706 $3,499,117 22.5%
![Page 9: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/9.jpg)
Project Team Organization Project Manager/
Project Engineer SCS Nick Irvin, Todd Wall, Morgan
French MHIA Dale Wilterdink, Takahito
Yonekawa, Shintaro Honjo, Cole Maas
URS Katherine Dombrowski DOE-NETL Bruce Lani
Host Site: Southern Company’s Plant Barry: 25 MW amine-based CO2 capture process
![Page 10: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/10.jpg)
Schedule
• Budget Period 1: through June 2013 (extended) – Task 2: Front End Design and Target Cost Estimate – Task 3: Permitting
• Budget Period 2: July 2013 – July 2014 (delayed) – Task 4: Engineering, Procurement, and Construction
• Budget Period 3: Aug 2014– February 2016 (delayed) – Task 5: Operations – Task 6: Field Testing and Analysis
![Page 11: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/11.jpg)
Completed Work in BP1: Tasks 2 and 3
• Task 2: FEED and Target Cost Estimate – Deliverable: Final design package with cost to build – Basic Engineering
• Heat and material balances • General arrangement drawings (3D Model) • Equipment sizing and duties • Control system architecture • Process control philosophy
• Task 3: Permitting – Confirmed that no permits required, received approval
letter from AL Department of Environmental Management
![Page 12: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/12.jpg)
Technology Description and Background
![Page 13: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/13.jpg)
25 MW KM-CDR at Plant Barry
![Page 14: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/14.jpg)
25 MW KM-CDR at Plant Barry
• Funded by an industry consortium • Started operation: June, 2011 • Fully integrated CO2 capture and compression facility
– Replicates conditions of a commercial unit – Designed for 90% CO2 capture and compression to 1500
psig – Produces 500 metric tons CO2 per day (>99.9% purity)
• Transport and storage in a saline formation at a nearby oil field (SCS and SECARB)
![Page 15: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/15.jpg)
Flue Gas Cooler • Low temperature flue gas cooler with finned
tubes • Carbon Steel construction • Captures waste heat at APH outlet (300ºF) • Corrosion mitigated by controlling ash to SO3
ratio in flue gas, metal surface temperature, and SO3 condensing onto ash
• Several installations in Japan – low-sulfur, coal-fired power plants in Japan – Re-heat scrubbed flue gas to eliminate
visible plumes • Technology has not been demonstrated in U.S.
– Recovered heat can be used in the turbine cycle
![Page 16: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/16.jpg)
History of Flue Gas Cooler Hirono P/S Japan - 600MW
Flue Gas Cooler Low Temp ESP FGD Reheater
Flue Gas Cooler
ESP
Tubes after 2 yrs operation
![Page 17: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/17.jpg)
![Page 18: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/18.jpg)
![Page 19: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/19.jpg)
Technical Approach
![Page 20: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/20.jpg)
Air Pre-heater Dry ESP FGD
Steam Cycle
Boiler Feed Water
CO2 Capture
Plant
Flue Gas Boiler Feed Water High
Efficiency System
350°
202°
90°
269° 167°
SCR 700°
Miniature ESP
25 MW
0.5 MW
Fly Ash
To SCR Outlet
Heat Integration with Power Plant
![Page 21: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/21.jpg)
Boiler System • Highly integrated heat recovery system can simplify
the LP steam cycle
![Page 22: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/22.jpg)
Simplified Boiler System
Reduce/Replace LP Feedwater Heaters
![Page 23: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/23.jpg)
CO2 Capture Plant Tie-in
Steam
REBOILER
STRIPPER
C.W.
New Boiler Condensate
Pre-heater
BOILER CONDENSATE
BOILER CONDENSATE
CO2 PRODUCT
![Page 24: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/24.jpg)
General Layout
Unit 5
SCR
CCS
Flue Gas Cooler
CO2 Cooler
![Page 25: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/25.jpg)
Flue Gas Cooler Area-Plan View
SCR Flue Gas Take-Off
Flue Gas Cooler
Flue Gas Return
![Page 26: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/26.jpg)
Flue Gas Cooler Area – Plan View
Flue Gas Tie-in
Flue Gas Cooler Inlet
Pilot ESP
Balance of Plant
Booster Fan
Flue Gas Return
Flow
![Page 27: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/27.jpg)
With Grating
![Page 28: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/28.jpg)
CO2 Cooler General Arrangement
CO2 Cooler
Plant Barry CO2
Absorber
Regenerator
![Page 29: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/29.jpg)
CO2 Cooler
![Page 30: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/30.jpg)
Techno-Econ Snapshot Plant Configuration Subcrit-
PC Base w/MEA Base*
w/MHI KM-CDR*
KM-CDR & HES
Net Plant Efficiency (HHV) 36.8% 26.2%
(29% Drop) 28.9%
(21% Drop) 29.7%
(19% Drop)
Overnight Cost** $MM 1,098 1,991 1,800 1,771
COE** Mills/kWh 59.4 117.6 101.5 98 COE Ratio - 1.0 1.98 1.71 1.65
* SBS injection (atomized sodium carbonate) for SO3 Control ** 2007 $$ Note: Base cases outlined in Cost and Performance Baseline for Fossil
Energy Plants (DOE/NETL, 2010)
![Page 31: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/31.jpg)
Field Testing and Analysis
• Baseline Testing • Test Campaigns
– Corrosion and Erosion – Feedwater Purity Testing – SO3 and Trace Metal Removal Performance
• Data Analysis – Verification of heat integration effect – Heat recovery for boiler feedwater – Reduction of FGD water consumption
![Page 32: Development and Demonstration of Waste Heat Integration ... Library/events/2013/co2 capture/T... · Work Plan • A 25-MW High ... • A 0.5 MW pilot ESP will be installed to test](https://reader034.fdocuments.us/reader034/viewer/2022042801/5aecb5497f8b9ab24d905fe5/html5/thumbnails/32.jpg)
Future Plans
• Awaiting approval of continuation application for BP2 • Begin EPC phase in 2013 (BP2) • Start operations and testing in 2014 (BP3)