Development of Post Combustion Capture Technology

IEAGHG 1st Post Combustion Capture Conference, 17th to 19th May 2011, Abu Dhabi

1

Doosan Power Systems – Vision

“To be a global leader indelivering advanced cleanenergy technologies, products and services.”

2

$15 Billion

Part of the Doosan Group

Doosan Heavy Industries & Construction

Doosan Group

Casting and Forging Nuclear

Doosan PowerSystems

Power Plant Construction Desalination

Doosan Group

Doosan Heavy Industries& Construction

Doosan Power Systems

Turnover Employees

*Figures exclusive of DPS data and correct to the end of the financial year for 2009.

$1.3 Billion

$5 Billion*

36,400

6,000

5,800*

3

Doosan Power Systems – Organisation

3

Doosan Group

Doosan Heavy Industries & Construction

Doosan Power Systems

Plant WindBoilersDoosan Babcock

Turbines Škoda Power

ServicesDoosan Babcock

Post Combustion CaptureLeading Edge Technology

5

One stop for solvent development, process enhancement and plant Integration

HTC Purenergy Overview

5

HTC is the CO2 Capture technology licensee of the University of Regina, who has specialised in Carbon Capture since 1987.

HTC’s Technology Centre is commercially aligned with Doosan, InternationalTest Centre for CO2 Capture, and the International Risk Assessment Centre

Laboratories for solvent development, materials and process design. CO2 enhanced oil recovery technical expertise commercialized through

subsidiary EHR Enhanced Hydrocarbon Recovery Corp.

Smaller scale modular capture systems for SAGD and Heavy Oil consolidatedinto Calgary based subsidiary HTC CO2 System Corp.

5

6

Doosan Power Systems – HTC Purenergy

Global licence agreement signed in 2008 between Doosan Power Systems and HTC Purenergy

Technology transfer – up to 30 engineers and specialists from Doosan Power Systems seconded to Regina, Saskatchewan.

Doosan and HTC participate in collaborative research with the University of Regina – which has some of the most comprehensive carbon capture research and development facilities in the world

This enables the latest technological advancements to be provided to our Customers.

An Alliance…

To be recognised as the market leader in Post Combustion Carbon Capture technology and application, with proven product leadership to support the Core Power Island EPC product offering throughout the Doosan organisation.

Our Goal…

Future Development…

7

Technology Leaders

Advanced Solvent designer (RS family) solvent providing:

– Low cost commercially available ingredients (~$2.60/kg)

– High efficiency system

– Low degradation rates

– Tailored to meet operating and flue gas conditions

Scale-up validated against actual operating data from several plants as large as 800 TPD (with +/- 3% accuracy)

Most importantly, scale-up is only achievable through a complete and thorough understanding of:

– All physical and chemical properties (kinetics, diffusivity, etc.)

– Operating conditions

– Proper application of numeric modeling tools

Patents in place for high efficiency configured to advanced solvent

Patents in place for steam side plant integration

Advanced solvent, advanced process and optimised integration provide maximum customer value

7

Optimised Process Design

Heat Integration

Reduction in Steam

8

Test Facilities and Demonstration ProjectsFacilities & Technology create a winning edge

Performance demonstrated on wide range of fuels and different plant configurations8

20+

Yea

rs o

f Dem

oIn

dust

ry L

eadi

ng S

cale ERTF, 1t/day

Commissioned in 2010

Ability to test wide range of coals and other fuels

High degree of flexibility and accuracy to test wide range of Solvents and other modifications

Ferrybridge, 100 t/day

Largest PCC demonstration plant in the UK

Long-term testing and validation of process and solvent performance

Evaluate transient conditions and process control

Extensive monitoring planned

Boundary Dam, 4t/day

Commissioned in 1987

Dedicated to post-combustion capture since 2000

Captures CO2 from flue gas emitted from lignite-fired boiler

Upgraded in 2007 to evaluate advanced process with RS-2

ITC 1t/day

Opened in 2003

Flue gas from natural gas combustion

Includes equipment to study corrosion, material selection, solvent degradation and kinetics

Doosan Product Development and CommercialisationProcess Technology Status and Scale-up

10

Doosan Power Systems Post Combustion Capture Projects

Development Roadmap

Emissions Reduction Test Facilities 1t/d to 5t/d CO2

Target Slipstream

100t/d CO2 • 5MWeFerrybridge

Large Demonstration Project (s) Slipstream

~3000t/d CO2 • 150MWe

CommercialisationFull Scale Plant

10,000t/d CO2 • 500MWe

15,000 t/d CO2 • 800 MWe

11

Demonstration Projects – Emissions Reduction Test Facility

Emissions Reduction Test Facility (ERTF) Upgrade for PCC Solvent Scrubbing – A 160kWt combustion test facility at our R&D Centre in Renfrew, United Kingdom

Capable of firing a very wide range of coals or natural gas.

Originally constructed to test primary NOx reduction measures, subsequently adapted and upgraded to test secondary NOx reduction measures.

Upgraded for oxyfuel operation as part of the OxyCoal-UK: Phase 1 project – a collaborative project sponsored by the UK government with industrial and academic participation.

12

Demonstration Projects – Emissions Reduction Test Facility

ERTF Solvent Scrubbing Process - EquipmentAbsorber column

10” NB (DN250)

4-off packed bed sections (with multiple solvent feed inlet points)

Stripper column

8” NB (DN200)

4-off packed bed sections

Water Wash Column

8” NB (DN200)

1-off packed bed section

Heat exchangers

Gasketed (plate and frame)

Pumps

Duties met by triplex diaphragm pumps for high head – low flow duties

Variable speed drives for efficiency and ease of control

13

Boundary Dam Demonstration Plant

Technology Demonstration Plant

Operating since 1987

Donated to UoR in 2000

Upgraded 2007

BDPS CO2 Capture Plant Performance

Capture capabilities are 4 TPD

Operating on lignite fuel

Technology demonstration facility for client-specific parameters

< 1.1kg steam/ 1 kg CO2captured which equates to less then 2.4 GJ/Ton CO2 Total Capture System equates to ~110 MWe on an 800MWe

Minimised impact to existing plant performance – Industry leading plant efficiency13

14

Main Test Campaigns at Boundary Dam CO2 Capture Demonstration Plant

Period Test Objectives

Sep 2002 to Nov 2002 Establishing the baseline operation using MEA solvent

Jun 2003 to Aug 2003 Optimum operation & energy and utilities consumptions

Aug 2003 to Dec 2003 Operating at reduced reboiler pressure and temperature

Feb 2004 to Aug 2004 Optimum lean/rich loading approach and flooding factor

Apr 2005 to May 2006 Solvent performance using single and mixed amines;mass transfer data at various operating conditions;optimum operation conditions

July 2007 to Nov 2007 Upgrading the demonstration plant for patented configuration and plate type heat exchangers

Nov 2007 to May 2008 Simulated NGCC flue gas test using patented configuration and RS-2

Oct 2009 to Apr 2010 EGR (Exhaust Gas Recycling) trials

Sep 2010 Design parameters of Basin CO2 capture plant

15

Scale-up Experience - Slipstream Flue Gas from Coal Power Plant

Simulation of 136 Tonne per day CO2 Capture Plant;

One train & standard design configuration;

MEA solvent, 16 wt%;

CO2 Concentration 12.5 vol%

12 Years in operation;

Slipstream flue gas from Coal power plant.

Absorber diameter: 2.90 m

Stripper diameter: 2.591 m

Solvent & rate: MEA 16 wt%, 159 m3/h

16

Scale-up Experience - Slipstream Flue Gas from Coal Power Plant

Simulation of 825 Tonne per day CO2 Capture Plant;

two trains & standard design configuration;

CO2 Concentration 10.8 vol%

32 Years in operation;

Flue gas from Coal power plant.

Absorber diameter: 4.420 m

Stripper diameter: 3.810 m

Solvent & rate: MEA 20 wt%, 437.85 m3/h

17

Demonstration Projects – CCPilot100+

SSE Ferrybridge CCPilot100+ 100t/day CO2 PCC Demonstration Plant

Post Combustion Capture Demonstration Plant using Doosan Power System’s technology

100 t/day slip stream on SSE’s Ferrybridge Power Station

– Largest PCC Demonstration in the UK

Funding by the project partners, Scottish & Southern Energy, Vattenfall, Doosan Power Systems, TSB, DECC and The Northern Way.

Fast – track, for operation during 2011

Two year test programme

Lessons learned will be incorporated into future designs

Off gas analysis – amine carryover and degradation products

On-site amine and degradation product atmospheric sampling and analysis –University of Leeds

18

CCPilot100+ Project Location

Pictures courtesy Google Earth

19

CO2 Stripper Column

Polishing FGD

Direct Contact Cooler

CO2Absorber

CCPilot100+ Process Layout and Key Parameters

1.1 x 30.5Stripper Column Dimensions (i.dia x height; m)

2.3 x 39CO2 Absorber Dimensions (i.dia x height; m)90%Design CO2 removal efficiency100 metric tpdPCC Design

© Doosan Power Systems

20

CCPilot100+ Project Execution

Current Status – In Construction

Testing Programme

P&IDs

Stripper Column Delivery

Absorber Fabrication

3D Modelling

Construction

Simulation

21

Case Study – Basin Electric FEED

Sized to capture 1.0 MM tons per year of CO2 from Basin Electric’s Antelope Valley Power Plant– 3,000 tons per day

– Treating a ~ 120 MW slipstream

– Turnkey EPC Scope including: PCC plant, FGD polishing and CO2 compression and dehydration

Key FEED Deliverables:– Engineering studies to investigate the

integration of the PCCC Plant within the existing AVS and DGC infrastructure

– Proposed EPC Scope of Work, based upon the final design of the PCC Plant

– 15% EPC CAPEX and OPEX Estimate

– Level 2 EPC Project Schedule

Project currently deferred by client Basin Electric Antelope Valley Station (in background) and Dakota Gasification Facility (in foreground)

21

22

CO2 Absorber

Direct Contact Cooler

Polishing FGD

CO2 Stripper ColumnExisting Stack

Offgas Return

Basin Electric – Process Layout and Key Parameters

5.6 x 36.2Stripper Column Dimensions (dia x height; m)

11.8 x 53.3CO2 Absorber Dimensions (dia x height; m)

9.5 x 14.8DCC Absorber Dimensions (dia x height; m)

90%Design CO2 removal efficiency

1,544,000 lb/hrPCC Design Gas Flow (lb/hr)

23

Basin Electric - Boundary Dam 10-Day Test Run Equivalent Steam

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

09/0

8/20

10 1

2:02

09/0

8/20

10 1

8:07

09/0

9/20

10 0

0:22

09/0

9/20

10 0

6:27

09/0

9/20

10 1

5:42

09/1

0/20

10 0

2:22

09/1

0/20

10 0

8:27

09/1

0/20

10 1

4:57

09/1

0/20

10 2

1:02

09/1

1/20

10 0

3:12

09/1

1/20

10 0

9:17

09/1

1/20

10 1

5:03

09/1

1/20

10 2

1:02

09/1

2/20

10 0

3:07

09/1

2/20

10 0

9:12

09/1

2/20

10 1

5:02

09/1

2/20

10 2

1:27

9/13

/201

0 3:

32:2

4 A

M

9/13

/201

0 10

:17:

24 A

M

9/13

/201

0 4:

17:2

7 P

M

9/13

/201

0 10

:22:

27 P

M

9/14

/201

0 4:

27:2

8 A

M

9/14

/201

0 2:

17:3

1 P

M

9/14

/201

0 8:

17:3

2 P

M

9/15

/201

0 2:

27:3

4 A

M

9/15

/201

0 8:

37:3

5 A

M

9/15

/201

0 2:

47:3

7 P

M

9/15

/201

0 9:

07:3

8 P

M

9/16

/201

0 3:

17:3

9 A

M

9/16

/201

0 9:

37:4

0 A

M

9/16

/201

0 3:

47:4

2 P

M

9/16

/201

0 9:

52:4

2 P

M

9/17

/201

0 4:

12:4

4 A

M

9/17

/201

0 10

:47:

45 A

M

9/17

/201

0 5:

42:4

7 P

M

9/20

/201

0 1:

57:1

6 P

M

9/20

/201

0 8:

07:1

8 P

M

9/21

/201

0 2:

12:1

8 A

M

9/21

/201

0 8:

37:2

0 A

M

Date/Time

Ste

am (

kg/k

g)

0

2

4

6

8

10

12

14

16

18

20

Am

bie

nt

Tem

p (

°C)

Prod Steam CO2 Mass Ratio Average Heat Duty AmbientCelcius

24

In Summary

Doosan utilises process technology that was invented and developed in Canada by UoR and HTC Purenergy, Inc.

Doosan and HTC are at the forefront of PCC technology development

Doosan has a proven highly efficient process and product which it will guarantee

Doosan will undertake full EPC

Doosan have available resources and can leverage the historic experience from recent projects to achieve clients goals

Low impact, high efficiency, integrated EPC Carbon Capture Solutions 24

THANK YOU

Development of Post Combustion Capture TechnologyDoosan Power Systems – VisionPart of the Doosan GroupDoosan Power Systems – OrganisationPost Combustion CaptureHTC Purenergy OverviewDoosan Power Systems – HTC PurenergyTechnology LeadersTest Facilities and Demonstration ProjectsDoosan Product Development and CommercialisationDoosan Power Systems Post Combustion Capture Projects Demonstration Projects – Emissions Reduction Test FacilityDemonstration Projects – Emissions Reduction Test FacilityBoundary Dam Demonstration PlantMain Test Campaigns at Boundary Dam CO2 Capture Demonstration PlantScale-up Experience - Slipstream Flue Gas from Coal Power PlantScale-up Experience - Slipstream Flue Gas from Coal Power PlantDemonstration Projects – CCPilot100+CCPilot100+ Project LocationCCPilot100+ Process Layout and Key ParametersCCPilot100+ Project ExecutionCase Study – Basin Electric FEEDBasin Electric – Process Layout and Key ParametersBasin Electric - Boundary Dam 10-Day Test Run In SummaryTHANK YOU