Development in Oxyfuel Combustion Technologies for

Coal Fired Power Plants with CCS(An Overview)

Stanley SantosIEA Greenhouse Gas R&D Programme

Cheltenham, UK

2

3rd Oxyfuel Combustion ConferencePonferrada, Spain

9th – 13th September 2013Full Programme

Announcement:

17th May 2013

33

4

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

CANMETUS DOE Project / B&W / Air Liquide

2003 - 2005

Vattenfall (ENCAP ++)CS Energy / IHI Callide Project

B&W CEDF 2008 30MWth CoalAlstom 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 (18/07/13)

2008

FIRST 30 MWtfull chain demonstration

at Schwarze Pumpe

By the end of 2011, Users (i.e. Power Plant Operators) will have 6 burner manufacturers

give a high level of confidence toward demonstration

2009 Lacqfirst 30MWt

retrofitted Oxy-NG boiler w/storage

2012 CIUDEN

Oxy-CFB Pilot Plant

2012 Callide

retrofitted Oxy-coal power plant

Alstom Schwarze Pumpe 2008 30MWth Lignite

Hitachi Babcock Schwarze Pumpe 2010 30MWth Lignite

IHI Callide 2011 90MWthAlstom / AL Lacq 2009 30MWth Gas/Oil?

CIUDEN El Bierzo CFB Facility 2012 30MWth Coal

El Bierzo PC Facility 2012 20MWth Coal

Coal

CIUDEN

Doosan Babcock Schwarze Pumpe 2012 30MWth Lignite

KEPCO/KOSEP - Yongdong (PC - 100MWe) - ???FutureGen2 - Illinois (PC - 168MWe)

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

China: 2 Oxyfuel Projects – in progressUK: White Rose Project (PC – 426MWe)

2015 HUST Industrial Project for 35 MWtOxyfuel Pilot Plant w/storage

By 2014-2018

Demonstration of 100300MWe full scale power plant.

Target :“Commercialised

by 2020”

5

EPRI 2007

CO2 Capture Options

66

Oxy-Combustion Technology

Use of oxygen instead of air in a boiler

demonstration.

With significant R&D investment in the past decade, this technology has achieve a maturity similar to the other leading options for power generation with CCS

Presentation Outline

Boiler and Burner Development

Air Separation Unit

Flue Gas Processing Unit

CO2 Processing Unit

7

Oxyfuel CombustionOverall Schematic Diagram

8

SOME EXAMPLES OF OXY-COAL FIRED POWER PLANTS

Oxy-Coal Plant Configurations

9

Pulverizers

Coal

Boiler

PJFF WFGD

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

Recycle Heater

Recycle Damper

Air Intake

Air Intake

Recycle Damper

Gas Cooler

Cold Recycle Process

CPU

To Storage

Gas Htr

WFGD/DCC

Sorbent for SO3

Very High Sulfur Coals

Oxy-Coal Plant Configurations

10

Pulverizers

Coal

Boiler

PJFF WFGD

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

Recycle Heater

Air Intake

Air Intake

Gas Cooler

Cool Recycle Process

CPU

To Storage

Gas Htr

WFGD/DCC

Gas Htr

Sorbent for SO3

CPU VentStack Damper

Secondary Recycle Damper

Primary Recycle Damper

High Sulfur Coals

Oxy-Coal Plant Configurations

11

Medium Sulfur Coals

Pulverizers

Coal

Boiler

PJFFSDA

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

Recycle Heater

Secondary Recycle Damper

Air Intake

Air Intake

Primary Recycle Damper

Gas Cooler

Cool Recycle Process

CPU

To Storage

Gas Htr

WFGD/DCC

Stack DamperCPU Vent

Oxy-Coal Plant Configurations

12

Low Sulfur Coals

Pulverizers

Coal

Boiler

PJFFSDA

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

PJFF

Recycle Heater

Recycle Damper

Air Intake

Air Intake

Recycle Damper

Gas Cooler

Warm Recycle Process

CPU

To Storage

Gas Htr

DCCPS

13

BOILER AND BURNER DEVELOPMENT

Oxyfuel Combustion Technology

14

Historical Perspective The Early Days

1982: Initial suggestion by Abraham et. al. (OGJ) of using Oxy-Coal Combustion to produce CO2

for EOR

• 1st public document looking at capturing CO2 from flue gas using oxy-combustion.

However ...in the development of oxy-coal combustion with recycled flue gas• 1974: Japan initial conception of using oxy-coal combustion for power

generation. (To reduce pollution?)

• 1978: Economic feasibility of oxy-coal combustion was investigated for EOR application (H. Farzan, Babcock & Wilcox / A. Wolsky, ANL)

14

15

Technology Development

3rd Workshop, IEAGHG International Oxy-Combustion

Network, Yokohama, Japan

Oxygen

Japan’s initial conception of oxyfuel combustion application

for power generation (1974)

16

ANL - EERC Study-Coal Combustion Industrial Pilot Scale Study

Tower Furnace (~ 3MWth)

1717

Radiant Section of the Boiler

• heat transfer profile

• slagging issue

• fireside corrosion issue

Convective Section of the boiler

• heat transfer profile

• ash deposition and fouling issue

Burner design issue

• Ignition

• flame stability

• devolatilisation & char burnout

Prior to any retrofit of carbon capture

technology, it is essential to repower

the plant in order to achieve the

highest possible efficiency

18

Air vs. Oxy Firing of Coal

19

Factors affecting Recycle Ratio

Critical factors affecting the optimum amount of recycled flue gas

• Burner and boiler design (heat transfer and flame stability oxygen distribution through burner)

• Air ingress

• Purity of oxygen from the ASU

• Coal type

• Level of moisture content in comburent

• Comburent (oxidant) temperature

19

20

Flame Description Impact of Recycle Ratio(Courtesy of IFRF)

2121

Coal Flame Photos:Air Fired vs Oxy-Fired(Courtesy of IHI)

Air mode（O2：21%）

Oxy mode（O2：21%） Oxy mode（O2：30%）

2222

Coal Flame Photos:Impact of Recycled Flue Gas(Courtesy of IFRF)

Recycle Ratio = 0.76Recycle Ratio = 0.58

(~ 0.61 include the CO2 to transport coal)

Universität Stuttgart

23

Effect of Different Oxygen Concentrations

(and Recycle Rates) on Flame Pattern

Source: J. Smart, 2008

Air

Oxyfuel

28% O2

Recycle rate 77%

Oxyfuel

38% O2

Recycle rate 66%

24

Premixed / hybrid mode

Premixed mode

M

DST burner

MM

O2

Flue gas

Flue gas + O2

Hybrid mode

M

M

M

O2

O2

M

DST burner

MM

O2

Flue gas

2nd International Oxyfuel Combustion Conference, 12th-16th September 2011, Yeppoon, Australia © Hitachi Power Europe GmbH

25

Burner Development for Oxyfuel Combustion

Burners are critical to combustion, emissions, and thermal efficiency / capacity of the utility boilers

Critical importance to burner development is a full scale testing

This is an important exercise to establish reference data that could be used in the development and validation of different modeling tools.

This is also to gain experience in operating full scale burner. (i.e. start up/shut down, flame stability, efficiency, heat

25

26

Burner Development for Oxyfuel Combustion

Development of Full Scale Burner Testing Programmecould either be accomplished by:

Retrofitting of Full Scale Burner Test Rigso th CEDF Facility (Ohio, USA)

o Doosan th MBTF Facility (Renfrew, Scotland)

o Alstom th BSF Facility (Connecticut, USA)

Testing in a Full Chain Oxyfuel CCS Pilot / Demo Planto Schwarze Pumpe Pilot Plant (Cottbus, Germany)

o

o Lacq Facility (Lacq, France)

o CIUDEN Demo Facility (El Bierzo, Spain)

27

Today... There are 3 Major Full Scale PC Burner Testing Facilities Worldwide Retrofitted for Oxyfuel

Babcock and Wilcox (B&W)30MWth CEDF

Barberton, Ohio, USA

Start of Operation: Oct. 2008

Wall Fired Burner Development

27

Doosan Babcock

40MWth in 90MWth MBTF

Renfrew, Scotland, UK

Start of Operation: Jun. 2009

Wall Fired Burner Development

Alstom Power Plant Lab.

15MWth in 30MWth BSF

Windsor, Connecticut, USA

Start of Operation: Nov. 2009

T-Fired Burner Development

Courtesy of Alstom, B&W and Doosan Babcock

14 September 2011 | D W Sturgeon

28

OxyCoal 2 Demonstration of an Oxyfuel Combustion System

Officially opened on 24th July 2009 Doosan Power Systems’ 40MWth OxyCoal™ demonstration became the world’s largest demonstration of an oxyfuel combustion system.

14 September 2011 | D W Sturgeon

29

OxyCoal 2 Demonstration of an Oxyfuel Combustion System

Safe and smooth transitions between air and oxyfuel operation were demonstrated, with realistic CO2 levels achieved (in excess of 75% v/v dry, and up to 85% v/v dry).

Oil

Air Firing

(TFGR,

PA, SA)

Secondary

Air to

Secondary

Flue Gas

Recycle

Transition

Oil

Air/Oxyfuel

Firing

(TFGR,

PA, SFGR)

Oil/Coal

Air/Oxyfuel

Firing

(TFGR,

PA, SFGR)

Coal

Air/Oxyfuel

Firing

(TFGR,

PA,

SFGR)

Primary Air

to Primary

Flue Gas

Recycle

Transition

Coal

Oxyfuel

Firing

(TFGR,

PFGR,

SFGR)

14 September 2011 | D W Sturgeon

30

OxyCoal 2 Demonstration of an Oxyfuel Combustion System

40MWth OxyCoal™ burner turndown proven from 100% load to 40% load.

Stable rooted flame maintained for all

loads down to 40% with coal ignition

within the burner throat/quarl.

Comparable turndown to Doosan

Power Systems’ commercially

available air firing low NOX axial swirl

burners.

40MWt

32MWt

24MWt

20MWt

16MWt

31 | Lars Strömberg, IEAGHG OCC2 Australia | 2011.09.12

View on Oxyfuel Pilot Plant

Some Burners Tested

Burner Type A Burner Type B

Achieved ~20,000 Hours in Both Air and Oxyfuel Operation!

33 | 2OCC, U.Burchhardt | 2011-09-13

Boiler (furnace) - Temperature Comparison (Front View)

Oxy 24% Oxy 28% Oxy 32% Oxy 36% Air (21%)

• The gas temperatures increases with increased O2 in oxidant as expected

• The temperature levels for air case corresponds to OXY28

34

CS Energy/IHI Burner Testing Programme at Callide A Power Station

Callide A Project would be st oxyfuel

retrofitted power station.

First oxyfuel pilot plant that will actually produce electricity.

Installation of 2 new Wall Fired Burners

A unique position to provide information related to the burner burner interaction

34

Courtesy of CS Energy, IHI

Scope:•No.4 Boiler refurbishment•2 x 330 TPD ASU•Oxyfuel combustion Retrofit•70 TPD liquid CO2 recovery•Trucking to CO2 reservoir•Injection and monitoring

Callide A Power StationOwned by CE Energy4 x 30 MWeSteam 136 t/h at 4.1MPa, 465oCCommissioned: 1965 – 69Refurbished 1997/98Placed in storage in 2002

Brisbane

Callide A P/SQLD

CO2 storage

area

Australia

Brisbane

Callide A P/SQLD

CO2 storage

area

Australia

Callide Oxyfuel Project Overview

Copyright © 2012 IHI Corporation All Rights Reserved.

35

Oxygen plant CO2 capture plant

COP – Site Works – Oxygen and CO2 Capture Plant

37

AIR SEPARATION UNIT(OXYGEN PRODUCTION)

Oxyfuel Combustion Technology

38

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 CO2

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

39

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 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.

Presented at Yokohama

Workshop, March 2008

Presented at OCC2 -

Yeppoon , Australia

September 2011

Bey/L/092009/Cottbus.pptLinde AG Engineering Division 40

Cryogenic Air Separation – Capacity Increase

1902 :5 kg/h

(0,1 ton/day)

2006 :1,250 Mio kg/h

(30.000 ton/day)

41

Experience - Large ASU Projects

and Train Scale-up

0

1000

2000

3000

4000

5000

MT

PD

O2

1987 1993 1996 1996 2006 2009 2011

Startup date

Market drives ASU scale-up

Proven 70% scale-up

Quoting 5,000+ MTPD today

Buggenum

Oryx GTL

Polk

Plaquemine

Chevron Nigeria

EastmanTexas

Rozenburg

A5000 / A7000

42

43

Overview Of The Process

Heat

Air

Heat

Oxygen

Main and Boost

Air Compression

Air Cooling and

Pretreatment Storage

Cryogenic

Separation

Bey/L/092009/Cottbus.pptLinde AG Engineering Division 44

Air Separation Process

Conventional Design (mit Einblaseturbine)

Wä

rme

tau

sch

er

Bo

oste

r

Tu

rbin

e

1

1

PG

AN

GO

X

Vorkühlung Adsorber

Ko

nd

en

sa

tor

Nie

de

rdru

ckko

lon

ne

Ho

ch

dru

ckko

lon

ne

UK

G

Restgas

POWER

AIR

5.5

-6 b

ar

5.3

-5.8

ba

r

1.2-1.3 bar

1.0

5 b

ar

Oxygen: 95%, gaseous, at ambient pressure

Features:

PNitrogen: up to 30% of airflow available

45

ASU for Oxyfuel Combustion Applications

There are several ASU cycles available for low purity oxygen requirements

Leading ASU Cycles for Oxyfuel Combustion are variants of:

3 Columns

Dual Reboilers

Key Features:Lower compression requirements for the air input to the cold box

45

Lo

w P

ressu

re

Co

lum

n

Hig

h P

ressu

re

Co

lum

n

Cold Box is based on 3 Columns Design

Med

ium

Pre

ssu

re

Co

lum

n

The main compression

of air for this cold box

is only at 3.5 Bara

Only half of the air is

compressed to 5 Bara

47

Case Studies Done by Air Products

48

Summary (ASU)

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 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.

are not ready in the near term.

Oxyfuel Coal “Reference ASU”

49

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

Designs developed for a scalable reference plant

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

50

CO2 PROCESSING UNIT(REMOVAL OF NON-CO2 COMPONENTS)

Oxyfuel Combustion Technology

51

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 Cryogenic Separation of Inert (Cold Box development)

o Additional capture of CO2 from the CPU

Important 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

52

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.

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.

53

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– 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.

54

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 Driers

Saturated 30°C

76% CO2

24% Inerts

Dilute H2SO4

HNO3

Hg

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

BFW

Condensate

cw

15 bar

30 bar

Water

cwcw

Dilute HNO3

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

LICONOX™ Process

55

Auto-Refrigerated Inerts Removal

56

• 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

– Increases from zero at 25mol% to 90% at 75mol%

– Reducing air ingress increases CO2 capture rate

5757

Autorefrigeration Process

J-T expansion of

purified LCO2 for

refrigeration

Raw CO2 partially

liquefied by boiling

product

Compared to NH3

refrigeration:

Simpler process

Lower CAPEX

Higher CO2

recovery

Lower power

> 99.9% CO2

Cold Box

Distillation

Column

PHX

Reboiler

Dryer

Hg

Vent

US Pat. 7,666,251

58

72%mol CO2

28% inerts(~ 5 - 6% O2)

99.999%mol CO2

0.001% inerts

(~ .0005% O2)

25%mol CO2

75% inerts

(~ 15% O2)

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)

72%mol CO2

28% inerts

(~ 5 - 6% O2)

99.95%mol CO2

0.05% inerts

(~ .01% O2)

25%mol CO2

75% inerts

(~ 15% O2)

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

Products PRISM® Membrane

59

Flue Gas Expander

Aluminium plate/fin exchanger

Driers

Flue GasHeater -55°C

Membrane

To Boiler

CO2 product~96% CO2

~4% Inerts-60°C dp30 bar Raw CO2

Saturated 30°C75-85% CO2

63

Summary (CPU)

Demand of the quality requirements of the CO2

from the power plant for transport and storage. What are the Required Specification?

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.

646

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

CANMETUS DOE Project / B&W / Air Liquide

2003 - 2005

Vattenfall (ENCAP ++)CS Energy / IHI Callide Project

B&W CEDF 2008 30MWth CoalAlstom 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 (18/07/13)

2008

FIRST 30 MWtfull chain demonstration

at Schwarze Pumpe

By the end of 2011, Users (i.e. Power Plant Operators) will have 6 burner manufacturers

give a high level of confidence toward demonstration

2009 Lacqfirst 30MWt

retrofitted Oxy-NG boiler w/storage

2012 CIUDEN

Oxy-CFB Pilot Plant

2012 Callide

retrofitted Oxy-coal power plant

Alstom Schwarze Pumpe 2008 30MWth Lignite

Hitachi Babcock Schwarze Pumpe 2010 30MWth Lignite

IHI Callide 2011 90MWthAlstom / AL Lacq 2009 30MWth Gas/Oil?

CIUDEN El Bierzo CFB Facility 2012 30MWth Coal

El Bierzo PC Facility 2012 20MWth Coal

Coal

CIUDEN

Doosan Babcock Schwarze Pumpe 2012 30MWth Lignite

KEPCO/KOSEP - Yongdong (PC - 100MWe) - ???FutureGen2 - Illinois (PC - 168MWe)

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

China: 2 Oxyfuel Projects – in progressUK: White Rose Project (PC – 426MWe)

2015 HUST Industrial Project for 35 MWtOxyfuel Pilot Plant w/storage

By 2014-2018

Demonstration of 100300MWe full scale power plant.

Target :“Commercialised

by 2020”