Experiences from Commissioning and Test Oppyeration of ... · Experiences from Commissioning and...
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Experiences from Commissioning and Test Operation of Vattenfall’s Oxyfuel Pilot Plant p y
1st International Oxyfuel Combustion Conference1 International Oxyfuel Combustion Conference Germany, Cottbus, 7th – 11th September 2009
Uwe BurchhardtProject Manager Oxyfuel Pilot PlantVattenfall Europe Generation, Germany
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Agendag
1. Introduction
2. Technical Concept of Oxyfuel Pilot Plant2. Technical Concept of Oxyfuel Pilot Plant
3. Oxyfuel experiences from test operation
4. Outlook and summary
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Decision process for the Oxyfuel Pilot PlantDecision process for the Oxyfuel Pilot Plant
2002
GAP Analysis
2005
Decision for2003
Technology
2004
Feasibility StudyGAP Analysis Oxyfuel Pilot Plant
• Building site: Lausitz area• Start of project• Available
TechnologyBenchmark
• Evaluation ofdifferent steps of
Feasibility Study
• Financial frame• Comparing scales • Scale: 30 MWth
• Complete process chainfrom ASU to CO2- processing
Availablecomponents
• Known processsteps
• Degree ofdevelopment
different steps ofdevelopment
• Decision todevelop Oxyfuel
Comparing scales• Possible sites• Risks
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Design considerations for Oxyfuel Pilot PlantDesign considerations for Oxyfuel Pilot Plant
• Basic purpose is to provide operating information to be able to later p p p p gscale-up the technology to a 400-600 MW demonstration power plant
• Realization a complete process of coal input and oxygen production p p p yg pup to separation of CO2
• Possible to operate on full load in air-firing mode and oxyfuel modePossible to operate on full load in air firing mode and oxyfuel mode
• Designed to be able to operate on lignite and in a second phase on bituminous coalbituminous coal
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Location of the Oxyfuel Pilot PlantLocation of the Oxyfuel Pilot Plant
Power plant “Schwarze Pumpe”Power plant Schwarze Pumpe
Building site
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Time schedule and milestonesTime schedule and milestones
July `05 project start 23.11.06 notice of approvalpp March `08 end of construction 05.06.08 first fire (ignition burner)
26.06.08 first coal fire (main burner)
20.08.08 first Oxyfuel operation 03.09.08 first separation of CO2
09.09.08 official inauguration
Planning
2005 2006 2007 2008 2009 2010 2011
Approval processConstruction phaseCommissioningOperation
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Operation
View on the Oxyfuel Pilot PlantView on the Oxyfuel Pilot Plant
BoilerThermal capacity: ´ 30 MWthCoal demand: 5.2 t/hOxygen demand: 10 t/hCO2 (liqu ) production: 9 t/h
Electrostatic precipitator
CO2 (liqu.) production: 9 t/hCO2 Capture rate: > 90 %
Air separation unit
Flue gasdesulphurization
Social and switchgear
Flue gas condenser
gbuilding
CO plant
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Webcam: www.Vattenfall.de/CCSCO2-plant
Main ContractorsMain Contractors
General planerVATTENFALL EUROPE P C lt G bHVATTENFALL EUROPE PowerConsult GmbH
Boiler / ESPOxyfuel technology
ASU / CO2 plantCO2-process technology
FGDOxyfuel technology CO2-process technology
FGCI&C system Burner,Combustion technology
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Main operating results (until August 2009)Main operating results (until August 2009)
• Summation Operating hours : 3.100 h• Operating hours air mode : 1.500 h• Operating hours Oxyfuel : 1.600 h
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• Captured amount of CO2 : 1.400 t
2. Technical Concept of Oxyfuel Pilot Plant
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System overview of Oxyfuel Pilot PlantSystem overview of Oxyfuel Pilot Plant
Cold Recirculation
PulverisedCoal
Burner
Cold Recirculation
Steam-HEx
Sealgas <1,2 bar
Sealgas6 bar
Furnace
Steam-HEx Air
ESP FG-Condenser
CO2-ProcessFGD
2. Pass
DeNOx
Fan 1 Fan 2
Steam-
3. Passhot Recirculation
Dry Ash
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SteamHEx
AirASUSteam-HEx
Air
Oxygen
Nitrogen
Specific plant featuresSep. start burneron gas basis (propane)
Coal-Inputwith dry and CO2 rich Specific plant features
Cold Recirculation
PulverisedCoal30 MW burner performance
good Scale-up possibility
on gas basis (propane) yflue gasSeal gas systems
to reduction of air inleakage
Burner
Cold Recirculation
Steam-HEx
Sealgas <1,2 bar
Sealgas6 bar
good Scale-up possibility
Fl l
Furnace
Steam-HEx AirFlue gas cooler
test inlet temperature in FGD
ESP FG-Condenser
CO2-ProcessFGD
2. Pass
(DeNOx)
Fan 1 Fan 2O2-Mix with
static
Steam-
3. Pass hot Recirculation
Dry Ash Sulfur rich recirculation
A t SO2 / SO3 i h t
mixers
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SteamHEx
AirASUSteam-HEx
Air
Oxygen
NitrogenAssessment SO2-/ SO3 enrichment in boiler and recirculation necessary
3. Oxyfuel experiences from test operation
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Experiences with boilerExperiences with boiler
• Proven start burners (propane) having problems in Oxyfuel atmosphere due to high dust loads (Fl d d i t ll ti it ti(Flame guards and installation situation had to be optimized)
• Authority demand: Individual burner examinations for all operating statesexaminations for all operating states
• Good flame stability in Oxidant at O2 > 21%(w)• 25 -30 % humidity in hot recirculation
• Supplying of pure O2 and mixture in the burner possible
• Use of a single burner influences the burning g gbehavior and the flue gas composition
• Different burner swirls necessary for air and oxyfuel operation
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Change load Air to Oxyfuel in 20 minutesg y
Flue gas after fan
Air stream
O2 stream
Recirculation flue
h l di ti O f l tichange loadair operation Oxyfuel operation
a. 20 min.
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Requirements on flue gas scrubbingRequirements on flue gas scrubbing
Component Composition Reductionfrom* to* Capture ratefrom to
ESP Ash 11.200 mg/m³ < 20 mg/m³ > 99 %
SO2 11.500 mg/m³ < 100 mg/m³ > 99 %
FGD
2 g g
SO3 50 mg/m³ < 20 mg/m³ > 50 %
Ash 20 mg/m³ < 10 mg/m³ > 50 %
FG-Condenser
H2O 30 vol-% 4 vol-% > 85 %
SO2 100 mg/m³ < 20 mg/m³ > 80 %Condenser SO3 20 mg/m³ < 5 mg/m³ > 75 %
Ash 10 mg/m³ < 1 mg/m³ > 90 %
All d i d t f lfill d !
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All design data are fulfilled !
* all mg/m³ in Norm (dry)
CO2 - Process (Cleaning, compression, drying, liquefaction)CO2 Process (Cleaning, compression, drying, liquefaction)
FG- InputCO2 ~ 85 %
O2 ~ 5 % Ventgas
< 10 % CO2-Loss
Use Ventgasesfor regeneration of
N2+Ar ~ 5 %H2O ~ 4 %
CO < 600 mg/m³NOx < 750 mg/m³SOx < 20 mg/m³
CO2 ~ 35-40 %O2 ~ 30-35 %
CO ~ 500 mg/m³ SO2 ~ 10 mg/m³NO ~ 10 mg/m³
for regeneration of Adsorber
ca. 50 %
CO2- Output1 ppm H2O
Pre-Compressor
Main-Compressor
Activatedcarbon filter
0,3 bar 21,5 bar
19,0barFGC
CO2 > 99,7 %17 bar, -25°C2-stage Adsorber
CO2 (liqu.)
H2O H2O H2OSO2, SO3, HCl,Heavy metals
> 90 % CO2- recovery
Coolant circulation
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2 2(SOx / NOx)
2Heavy metals(Hg, Cd, ….) (Ammonia/CO2)
All %-details in Vol.-%
Attainable CO2 puritiesAttainable CO2 purities
CompositionCO2, liquid
Oxyfuel pilot plant (Technical CO2)
Comparison to Food quality2, q ( 2) q y
CO2 > 99,7 % > 99,99 %
N2+Ar+ O2 < 0,3 % < 30 ppm
H2O < 50 ppm < 50 ppm
SO2 < 2,5 ppm < 1 ppm
SO3 < 0,5 ppm -
CO < 10 ppm < 10 ppm
NO < 5 ppm < 2,5 ppm
NO2 < 15 ppm < 2,5 ppm
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4. Outlook and summary
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Outlook on test programp g
• Variation of coal quality (moisture, sulphur content, particle size).
• Test of different burners with integrated ignition burner
• Special measurement technique for flue gas iti d CO it icomposition and CO2 monitoring.
• Material tests for demo plants and 700°C technology under Oxyfuel atmosphereunder Oxyfuel atmosphere.
• Tests of co-firing biomass and bituminous coal.
• DeNOX tests at the boiler and for the vent gas stream from the CO2 plant.
• Test of an “alternative CO2-Process”
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est o a a te at e CO ocess
Integration CO2-plant Air Products (AP) in the Oxyfuel Pilot Plant (OxPP)
1 ppm H2O
Pre-Compressor
Main-Compressor Adsorber
Activated carbon filter
Gips Kreide
g 2 p ( ) y ( )0,3 bar 22 bar VentgasOxPP
a 19 barFGC
2
2-stage
p p
liqu.
CO2
FGDCooler
H2O H2O H2OCondensate SO2, SO3, HCl,Heavy metals
2
e3 % t
Ad b
Con
dens
ate
Activated b filt
Ventgas3 % of FG
CO2
rest gasses
FGC
Condensate
15bar
30bar
Adsorber
H2SO4+HNO3
carbon filter
57bar
gas.
COH2SO4
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CO2
2-stage SOx/NOx- separation CO2-Recycle MembraneAP
Area and layout of the „Alternative CO2-Process“y „
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Roadmap for CCSpCommer. plant:~ 1000 MW
Testrigs:0.1 – 0.5 MWth
Pilot plant:30 MWth
Demonstrationplant:300 – 700 MWth
th ti
Concept-studies
R h Demonstration of the V ifi ti d O ti i ti f E i d
2001 20202008 2014 – 2015 2004• theoretic
Investigations• Research• Basic principles• Combustion
characteristics
• Demonstration of the complete process chain
• Interaction of components• Validation of test rig results• Investigation of scale up
criteria
• Verification und Optimisation of components
• Reduction of risks• Verification of commercial
availability (subsidiaries necessary)
• Economic and competitive power plant concept
• No need for subsidiaries
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Layout of Vattenfall’s next generation power unitLayout of Vattenfall s next generation power unit
Amin scrubbingCCS Demo Project Jänschwalde
Oxyfuel boiler
coal drying ASU
CO2 plant
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SummarySummary
• Oxyfuel works in pilot scale, emission limits are kept, CO2 quality reached
• Successful integration of plant components from chemical industry (ASU, CO2 plant)
G i d i f i i d i l t ti f• Gained experiences from permission process and implementation of secondary clauses for CCS power plants
• CO monitoring over the whole technology chain (capture – transport –• CO2 monitoring over the whole technology chain (capture – transport –storage) developed for the first time world wide
• First steps towards full scale CCS plants is successfully donep p y
• Very important for the investment of the demo plant is the consent to the public funding.
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Thank you for your attention !
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Available fuels
Fuel Pulverized lignite Dryed lignite Black coalLay-out Range Lay-out Range Lay-out
Granulation Spread
0 – 1 mm60%< 0,1 mm13%> 0,2 mm
3-18% >0,2mm1 mm 0 - 2 mm
<5% >2 mm80%<1 mm
0-5 mm
LHV 21,0 MJ/kg 20,4-22,5 MJ/kg 20,0 MJ/kg 25,1 MJ/kg
AnalysisWater 10,5 Mass% 8-12 M% 15 Mass%
12-20 M% 10,0 Mass%
AshCarbonOxygen
H d
6,0 Mass%56,5 Mass%21,5 Mass%4 0 Mass%
4,5-7,5 M%54-60 M%20-22 M%3 5 4 5 M%
5,7 Mass%54 Mass%20,5 Mass%3 8 Mass%
13,0 Mass%62,0 Mass%8,6 Mass%4 2 Mass%Hydrogen
SulfurNitrogen
Chlorides
4,0 Mass%< 0,8 Mass%0,7 Mass%
3,5-4,5 M%0,4-1,2 M%0,6-1,1 M%
80-260 mg/kg
3,8 Mass%1,0 Mass%0,7 Mass%
0,8-1,4 M%4,2 Mass%
< 0,7 Mass%1,5 Mass%
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Chlorides Fluorides
g g15-70 mg/kg
CO2- plant in detailCO2 plant in detail
Recti-fication
Compressor building
ActivatedActivated carbon filter
Analysis container
CO2-tanks(2x180 m³)(2x180 m )
Trailer docking station
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