Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon...

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Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS Experiences, Trichy, India, 31 st October to 3 rd November 2012 Saravanan Swaminathan, Gerry Hesselmann Plant Group R&D

Transcript of Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon...

Page 1: Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS.

Oxyfuel Capture Technology

International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS Experiences, Trichy, India,  31st October to 3rd November 2012

Saravanan Swaminathan, Gerry HesselmannPlant Group R&D

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Our Vision

Enabling energy to realise opportunities for our customers and the world we live in.

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2011

Heritage

Acquired by Doosan Power Systems and renamed Doosan Lentjes

Doosan Power Systems is formedbringing Skoda and Babcock together

Acquired by Doosan

Acquired by Doosan to become Doosan Babcock Energy

Lentjes GmbH formed

Company becomes Skoda Power

Skoda Energo formed

Skoda daughter companies privatised

Babcock Power Ltd formed

Ferdinand Lentjes founds boiler manufacturing company

Babcock & Wilcox established

Engineering workshop founded

Babcock

Škoda Power

Lentjes

20051928

2004199819931859

200619791891 2009

2009

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Products and Services

Doosan Power SystemsCEO JM Aubertin

Turnover 2011: £800mEmployees: 5,800

Doosan BabcockDoosan Lentjes Skoda Power Doosan Babcock

Boiler & Air Pollution Control Turbogenerators Plant Service

Doosan Heavy Industries

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Outline

Oxyfuel Technology Overview

Air Separation and CO2 ProcessingProof of Concept TestingDemonstration of Oxyfuel Combustion SystemThermal PerformancePlant DemonstrationSafety Issues

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Overview

Oxyfuel Technology

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CO2 Capture – Oxyfuel Technology

N2 removed from air prior to combustion in an Air Separation Unit (ASU)

Oxidant is nearly pure O2 (over 95%)

Recycle flue gas is used to

Moderate the high temperatures arising from combustion with oxygen → replicate radiant heat transfer in air-fired plant

Maintain volumetric flow through the boiler → replicate convective heat transfer in air-fired plant

Flue gas contains a high level of CO2

CO2 typically over 75%v/v dry basis

Simple compression process for purification and capture

Oxyfuel is based on the removal of nitrogen from the combustion process

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CO2 Capture – Oxyfuel Technology

Illustration courtesy of Vattenfall

The oxyfuel process comprises of three basic blocks – the Air Separation Unit (ASU), the boiler and turbine island, and the CO2 compression & clean-up plant

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CO2 Capture – Oxyfuel Technology

Power consumption in the ASU and CO2 compression plant dominate the operating costs of an oxyfuel plant

Baseline Oxyfuel

Generated Power (MWe) 625.2 634.4

Auxiliary Power (MWe) for Boiler & Turbine Island

48.4 45.8

ASU Power (MWe) 0.0 77.3

CO2 Compressor Power (MWe) 0.0 63.1

Power Dispatched to Grid (MWe) 576.8 448.2

Slight increase in gross power generated due to recovery of compression heat into feed water heaters

Slight reduction in boiler island auxiliary power due to SCR being out of service for oxyfuel firing; more than compensates for FGR fan power

Reduced power output from is equivalent to a reduction in efficiency of ~10 %age points; improvements in integration and ASU / CO2 compression lead to an estimated 6 %age point reduction for the n th plant

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CO2 Capture – Oxyfuel Technology

Relatively simple process

ASU, boiler island, gas clean-up & compression, FGR

No impact on steam cycle

Uses existing power plant technology (well proven components)

Can be retrofitted to existing plant or installed as new build

Minimal impact of oxyfuel firing on boiler thermal performance

Boiler designed for air-firing can operate under oxyfuel, without pressure part modifications

Potential to avoid requirement for FGD and/or SCR

Capture of NOx and SOx is integral to the CO2 compression process

Can be designed to fire a wide range of fuels

Robust to changes in fuel quality

Costs are comparable to the other CO2 capture technologies

Power consumption of ASU is significant, but penalty is similar in magnitude to steam consumption in PCC

Key to the success of oxyfuel technology is it’s demonstration

Combustion system, burners

Thermal performance

Oxyfuel is one of the most promising capture technologies

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CO2 Capture – Oxyfuel Technology - Doosan Power Systems Activities

For 20 years, Doosan Power Systems has been a leading player in the development of oxyfuel technology.

1992 to 1995

2005 to 2008

2007 to 2009

2008 to 2010

2011 to 2012

Proof of concept testing at 0.55mmBtu/h (160kWt) scale – several “first’s” (Renfrew, Scotland)

Numerous high level feasibility studies for retrofit and new-build oxyfuel installations.

Development of thermal performance prediction models.

Collaborative R&D projects.

Full scale demo of OxyCoalTM burner on lignite at 102mmBtu/h (30MWt) (Schwarze Pumpe, Germany)

FEED studies for Young Dong and Janschwalde

Full scale demonstration of an OxyCoalTM burner on bituminous coal at 136mmBtu/h (40MWt) (Renfrew, Scotland)

Fundamentals and underpinning technology development

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A Quick Overview

(With thanks to Vince White, Air Products)

Air Separation and CO2 Processing

3rd APP OFWG Oxy-fuel Capacity Building Course, 11-12th September 2011, Queensland, Australia

http://www.newcastle.edu.au/project/oxy-fuel-working-group/capacity-building-courses/Australian-Course-2011.html

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Page 27: Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS.

Proof of Concept Testing160kWt Pilot Scale Tests

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“Proof of Concept” Testing

Retrofitted 160kWt test facility to oxyfuel firing

Demonstrated oxyfuel firing concept

– CO2 typically 80 to 85%v/v dry; 95% max

– NOx reduces with flue gas recycle rate

– Early data on slagging and fouling effects (world-first by “industry”)

– Early data on impact of oxyfuel on ash pozzolanic activity (world-first)

– Smooth transition from air to oxyfuel firing

– Many practical lessons learned

Over the period 1992 to 1995, the project “Pulverised Coal Combustion System for CO2 Capture” demonstrated the viability of the oxyfuel process

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Emissions Reduction Test Facility

Test facility relocated and extensively upgraded

Oxygen Supply

CO2 SupplyCoal Feeder

ESP

FGR Fan

FGR HeaterSCR Unit

Combustion Chamber

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RIG

SO2

NOx

Inlet Outlet

NOx & SO2 Capture

Further testing was undertaken in the period 2007 to 2009 with Air Products. Almost all the NOx and SO2 is captured in the first compression stage of the CO2 compression & clean-up plant – the first time their process was demonstrated with “real” flue gas.

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Demonstration of Oxyfuel Combustion SystemFull Scale Component Tests - Renfrew

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Demonstration of Combustion System – Importance

It is only by undertaking “real” projects that we learn to make the hard decisions

It is too easy to put off decisions in paper studies

From Doosan Power System’s perspective, we have gained valuable practical experience during the engineering of our test facility oxyfuel retrofit, even before we started testing

It is only by undertaking “real” projects that we can gain confidence in a process

The prospect of massive quantities of nearly pure O2 and CO2 in a utility environment is a frightening one for the uninitiated

Experience of the process allows those fears to be rationalised and properly addressed

It is only by undertaking “real” projects that we can commercialise the technology

No matter how much information and experience we gain from reduced scale facilities, there is always a degree of uncertainty in the performance of the “first-of-kind” full scale plant

Until we are fully confident in our design process it is impossible to deliver a plant under truly commercial conditions with performance guarantees

Real projects give us the essential experience to commercialise oxyfuel

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Demonstration of Combustion System – OxyCoal-2

Lead Company Prime Sponsor

Sponsors

University Participants

UK Government Support

The OxyCoal-2 collaborative project was led by Doosan Power Systems and supported by the Department of Energy and Climate Change.

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Demonstration of Combustion System – Test Facility

Doosan’s 90MWt test facility in Renfrew, Scotland allows the testing of full-scale burners firing pulverised coal, heavy fuel oil, or natural gas. The facility was upgraded for oxyfuel firing in 2009.

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Demonstration of Combustion System – “Virtual Tour”

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Demonstration of Combustion System – OxyCoalTM Burner

Design based on our current Mk III low NOX axial swirl burner

Proven design with over two decades of operational experience in numerous coal-fired boilers worldwide

Applicable to new build and retrofit coal-fired boilers.

Volumetric flow of the primary gas for oxyfuel firing maintained as per air firing

Coal transport considerations

Oxygen content of the primary gas controlled to 21%v/v dry

Safe operation of coal milling plant

Overall stoichiometric ratio controlled to ~1.2

Maintain combustion efficiency

Flue gas recycle rate chosen on consideration of the adiabatic flame temperature and furnace heat transfer characteristics

The 40MWt OxyCoalTM burner design is based on our existing knowledge, experience and expertise of low NOx air-fired burner technology.

Page 37: Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS.

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Demonstration of Combustion System – Test Overview

Isothermal testing to characterise the aerodynamics of the OxyCoalTM burner

Flow split vs. damper setting

CFD burner model validation

Burner proving tests to demonstrate

Flame stability

Operation and controlability

Air to oxyfuel transition

Start-up, load change, and shutdown

Parametric tests to investigate

Emissions

Combustion efficiency

Full-scale testing of the Doosan Power Systems’ 40MWt OxyCoal™ combustion system: Burner Proving (Q3 and Q4 2009) Parametric Testing (Q1 and Q2 2010)

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Demonstration of Combustion System – Air to Oxyfuel Transition

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)

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Demonstration of Combustion System – Turndown

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

40MWt

32MWt

24MWt

20MWt

16MWt

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Demonstration of Combustion System – NOx

NOx, expressed as mg/MJ, is significantly lower (approximately 50%) under oxyfuel firing compared to air firing

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Demonstration of Combustion System – SO2

SO2, expressed as mg/MJ, is significantly lower (approximately 25%) under oxyfuel firing compared to air firing

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Demonstration of Combustion System – Combustion Efficiency

Combustion efficiency, as expressed by Carbon in Ash (CIA) and CO, is comparable for air and oxyfuel firing

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Demonstration of Combustion System – Summary

A full scale 40MWt OxyCoal™ burner was successfully demonstrated on air and oxyfuel firing, achieving safe and stable operation across a wide operational envelope

Oxyfuel flame stability and flame shape was comparable to air firing experience

Safe and smooth transitions between air and oxyfuel operation were demonstrated

Realistic CO2 levels were achieved (in excess of 75% v/v dry, and up to 85% v/v dry)

40MWt OxyCoal™ burner turndown proven from 100% load to 40% load – a comparable turndown to Doosan Power Systems’ commercially available air firing low NOX axial swirl burners

NOx and SO2 is significantly lower under oxyfuel firing compared to air firing

Combustion efficiency under air and oxyfuel conditions, as expressed by CIA and CO, is comparable

The results from successful testing demonstrate Doosan Power Systems’ pioneering expertise in the carbon capture field and mark a major step towards making full-scale carbon capture a reality

Air Firing

Oxyfuel Firing

Page 44: Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS.

Demonstration of Oxyfuel Combustion SystemFull Scale Component Tests – Schwarze Pumpe

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Demonstration of Combustion System - Schwarze Pumpe

Doosan Power Systems has joined the Technology Partnership for the Oxyfuel Pilot Plant (OxPP) project

– Agreement signed between Vattenfall Europe Technology Research GmbH and Doosan Power Systems in December 2010

Doosan Power Systems is responsible for providing a 30MWth OxyCoal™ burner for testing on the 30MWth pilot plant in Schwarze Pumpe, Germany.

30MWth OxyCoal™ Burner Test Plan

– Start-Up

– Air Firing

– Air to Oxyfuel Transition

– Oxyfuel Firing

– Oxyfuel to Air Transition

– Shutdown

Project execution by Doosan Power Systems in close collaboration with Vattenfall Europe Technology Research GmbH

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Demonstration of Combustion System - Schwarze Pumpe

Doosan Power Systems OxyCoal™ burner design is based on our existing knowledge, experience and expertise of low NOX air-fired burner technology.

Doosan Power Systems 40 MWth OxyCoal™ Burner for Clean Combustion Test Facility (CCTF), Renfrew, Scotland

– Multi-fuel Burner Test Facility

– Intermittent operation

– Igniters Combustion Engineering pre-mixed gas flame system

– Heavy fuel oil light-up burner

– Pulverised fuel

» Kellingley (UK bituminous coal)

» El Cerrejón (Columbian bituminous coal)

– Common windbox

» Secondary oxidant

» Tertiary oxidant

– Manual adjustment swirlers

– National Instruments Supervisory Control and Data Analysis (SCADA) system

Doosan Power Systems 30MWth OxyCoal™ Burner for Oxyfuel Pilot Plant (OxPP), Schwarze Pumpe, Germany

– Pilot Plant

– Continuous operation

– DURAG high energy spark igniter

– Gas light-up burner

– Pulverised fuel

» BKS (German lignite coal)

– Individual ducts

» Secondary oxidant

» Tertiary oxidant

– Automatic actuated swirlers

– Siemens Power Plant Automation T3000 (SPPA-T3000) web-based instrumentation & control (I&C) system

Page 47: Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS.

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Demonstration of Combustion System - Schwarze Pumpe

Operational tests will determine the global performance of 30MWth OxyCoal™ burner and Oxyfuel Pilot Plant (OxPP).

Comparison and analysis of results over a range of conditions will identify clear, definitive trends of burner operating behaviour.

Fundamental tests will allow detailed mapping of the combustion conditions at well defined operating points.

Evaluation will provide greater understanding of the combustion operation at discrete points and the underlying mechanisms responsible.

Testing of the Doosan Power Systems’ 30MWth OxyCoal™ burner:First Tranche: October to December 2011 – 9 weeksSecond Tranche: February to July 2012 – 18 weeks

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Demonstration of Combustion System - Schwarze Pumpe

Doosan Power Systems’ burner operated in air firing mode, standard oxyfuel mode, and expert oxyfuel mode

OxyCoal™ Burner Testing

– Air Firing Mode

– Standard Oxyfuel Firing Mode

– Expert Oxyfuel Firing Mode

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Demonstration of Combustion System - Schwarze Pumpe

Parametric tests during 2011 and 2012 demonstrated oxyfuel firing over a wide operating envelope

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Demonstration of Combustion System - Schwarze Pumpe

Oxy Firing

(FGR O2 = 30%vol)

Video and thermography of the flame captured during testing for oxyfuel firing with high and low FGR, and air firing

Oxy Firing

(FGR O2 = 24%vol)

Air Firing Stable rooted flame at all conditions

Comparable flame shape for air & oxyfuel

Reducing FGR increases flame temperature

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Demonstration of Combustion System - Schwarze Pumpe

Automatic control modified to demonstrate safe and smooth transitions between air and oxy firing, and vice versa

300 hours operation of the OxyCoal™ burner on air firing

2500 hours operation of the OxyCoal™ burner on oxy firing

Steady oxy firing operation for extended periods - a requirement for parallel test measurements

Combustion performance optimised to achieve set targets

– O2 < 3 vol% (wet)

– NOX <120ppm (air) <380ppm (oxy)

– CO <40ppm (air) <80ppm (oxy)

Operation of the Doosan Power Systems’ OxyCoal™ burner in the Oxyfuel Pilot Plant for ~2800 hours during 2011 and 2012

Page 52: Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS.

Thermal PerformanceImpact of the Oxyfuel Process on the Boiler

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Heat Transfer in Oxyfuel Boilers

Recycle flue gas flow rate can be used to vary radiant and convective heat transfer

Source: IFRF Report F98/y/1

Increased recycle flow leads to:

Greater mass per unit heat input → lower adiabatic flame temperature and less radiant heat transfer

Greater mass flow through boiler → higher gas velocity and more convective heat transfer

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Thermal Performance - Issues

Radiant heat transfer in the furnace is the dominant factor in coal fired utility boiler design

Key factors include

– Furnace geometry (beam length)

– Gas extinction coefficient (depends on particulate material & non-luminous gases)

– Heat release profile

Design tools include

– Simple “1-D” semi-empirical models (e.g. Doosan’s SteamGen code)

– Engineering performance models (e.g. Doosan’s HotGen code, uses Hottel’s zone method)

– Computational Fluid Dynamics (e.g. commercial codes, such as ANSYS-FLUENT)

– All these tools have been adapted to be capable of simulating oxyfuel plant

– …………but all these tools need good quality data for validation

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Test Experience

Air → Oxyfuel (increasing FGR)

Test experience with the DPS 40MWt OxyCoalTM burner shows that flame shape, length, and luminosity are broadly similar for air and oxyfuel firing; FGR rate has some impact

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Test Experience

0

50

100

150

200

250

300

350

400

450

500

0 2 4 6 8 10 12 14 16

Axial Distance From Burner

Hea

t F

lux

Air Oxy - FGR low Oxy - FGR medium Oxy - FGR high

Lower heat flux near burner for oxyfuel firing due to lower adiabatic flame temperature arising from FGR vs. air flowrate

Drop in heat flux occurs at the same point, suggesting comparable flame length for air and oxyfuel

Comparable heat flux towards furnace exit

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Limitations of Test Facilities

Small-scale test furnaces cannot adequately replicate the radiation processes in utility plant

Specific issues include

– Realistic mean beam lengths

– Estimation of extinction coefficient

– Pendant (radiant) superheaters

– Volumetric utilisation of the furnace

Plant scale demonstration is needed to verify thermal performance on oxyfuel fired boilersTriatomic Gas Emissivity Comparison

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

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Mean Beam Length (m)

Gas

Em

issi

vity

(-)

Utility Boiler Furnaces

Large TestFacilities

Air Firing

Oxyfuel Firing

Illustrations: DPS, Vattenfall, T Wall

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Oxyfuel Plant Thermal Performance

Basis

– 600MWe supercritical coal fired boiler

– Opposed wall fired

– Overfire air

Assumptions (HotGen model)

– Same flow distribution between burners and overfire air ports

– Same heat release profile (based on test experience)

– Gas extinction coefficients calculated from gas composition and particle concentration & size distribution (similar soot content in flame based on observed flame luminosity during burner tests)

– Same deposition in furnace and convective pass (surface emissivity, thermal resistance)

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Oxyfuel Plant Thermal Performance

Compared to air firing, the oxyfuel fired plant has:-

Higher arch level gas temperature

Higher heat absorption to the furnace walls

Higher heat absorption to the platen superheater

Similar furnace exit gas temperature, FEGT

Lower gas temperatures and heat absorption further downstream in the gas pass

Higher local gas temperatures throughout the lower furnace, with less variability in the burner belt

Higher incident heat fluxes to the furnace walls

The predicted impacts on thermal performance arise from the increased gas extinction coefficients and the lower flue gas mass flow rate through the boiler under oxyfuel firing conditions

The predicted impacts are small compared to day-to-day variability due to ash deposition

A boiler designed for air firing can operate in oxyfuel firing mode without change to the boiler

Demonstration at plant scale required to verify this conclusion

Modelling shows a modest impact on thermal performance arising from oxyfuel at the operating conditions simulated

Page 60: Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS.

Plant DemonstrationDoosan Power Systems Activities

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Plant Demonstration – Young Dong Unit #1

Unit #1

125MWe

Downshot boiler firing domestic anthracite and heavy fuel oil

In-service 1973

OEM was Babcock Hitachi KK, boiler was built under license from Doosan and is on our reference list

Steam Conditions Evaporation (tonne/h) 420

Main Steam Pressure (bar) 128.5

Main Steam Temperature (°C) 541

Reheat Steam Pressure (bar) 30.9

Reheat Steam Temperature (°C) 541

Cycle Efficiency 36%

KOSEP’s Young Dong PS has been selected to host a 100MWe oxyfuel demonstration

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Plant Demonstration – Young Dong Unit #1

Source : KEPRI

Project 1 : KEPRI & Daesung

Project 2 : Doosan HI

Air

N2

Coal

Air

O2

CO2 and/or H2O

Wet FGR

H2OSepa-ration

Dry FGR

No Stack

CO2

Power Generation

Flue gas treatment system

Project 3 : KIMM/Cottrell

Stack

ASU

The project objectives are to convert the boiler to bituminous coal firing, and to demonstrate oxyfuel technology.The project was arranged in 3 parts. Project 2 was led by DHI using DPS OxyCoalTM combustion technology. DPS were responsible for the Front End Engineering Design.

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Plant Demonstration – Young Dong Unit #1

Source : KEPRI

The feasibility stage of the project examined three options for the deployment of oxyfuel firing to the plant. Retrofit Case 2 maximizes the use of existing components and was selected.

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Plant Demonstration – Young Dong Unit #1

FGD

Coal Yard

Boiler Island

Ash Pond

ASU & CPU

ESP

TBN & Gen

Proposed site layout

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Plant Demonstration – Young Dong Unit #1

Furnace Super heater Re-heater Economizer

Oxyfuel firing

Air firing

Thermal performance analysis was performed for Air and Oxyfuel firing

Models calibrated to air firing performance (downshot configuration)

Predictions undertaken for air and oxyfuel firing (wall firing configuration)

Design performance achieved across full load range (final steam conditions achieved)

Improved heat flux distribution (lower peaks) for oxyfuel firing

As a result of applying OxyCoalTM technology there is no requirement to change or modify plant convective pressure parts

Detailed furnace thermal performance assessment of OxyCoalTM combustion system using DPS in-house codes BWHOT (Furnace) and SteamGen (Convective Pass). Results show that the heat exchange surfaces behave similarly in Air and Oxyfuel firing mode.

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Plant Demonstration – Janschwalde

250MWe

Opposed wall boiler firing pre-dried lignite

New build

Steam Conditions

Evaporation (tonne/h) 640

Main Steam Pressure (bar) 286

Main Steam Temperature (°C) 600

Reheat Steam Pressure (bar) 51

Reheat Steam Temperature (°C) 610

Photo montage - Vattenfall

Vattenfall had planned to build a 250MWe oxyfuel fired supercritical boiler at Janschwalde PS in Eastern Germany – project recently cancelled

Page 67: Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS.

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Plant Demonstration – Janschwalde

European project

Boiler island bid on fully commercial terms

Pre-dried lignite with indirect firing system.

100% output with air firing or oxyfuel operation.

Client’s specification has conservative FEGT for lignite (slagging concern) and precludes furnace platen superheater surface.

12 DPS OxyCoalTM burners with individual burner rating of 174mmBtu/h (51MWt)

Oxygen injection into secondary flue gas recycle to burner windboxes.

Primary flue gas recycle used for fuel transport only (no mills).

Overfire air system to achieve NOx emission limit when air firing.

Page 68: Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS.

Safety IssuesCO2 & O2

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Safety Issues - CO2

Most of plant will operate under suction

But from FGR fan through to the windbox / burners the system is under pressure, and may leak

CO2 is denser than air and will collect in low level confined spaces

i.e. in the basement areas

Buoyancy helps dispersion

Good ventilation is essential

How do you ensure this?

Would you trust your life to a CFD model?

The Dangers of Carbon Dioxide

1000ppm 0.1% Prolonged exposure can affect powers of concentration

5000 ppm 0.5% The normal international Safety Limit (HSE, OSHA)

10,000ppm 1% Your rate of breathing increases very slightly but you probably will not notice it.

15,000ppm 1.5% The normal Short Term Exposure Limit (HSE, OSHA)

20,000ppm 2% You start to breathe at about 50% above your normal rate. If you are exposed to this level over several hours you may feel tired and get a headache.

30,000ppm 3% You will be breathing at twice your normal rate. You may feel a bit dizzy at times, your heart rate and blood pressure increase and headaches are more frequent. Even your hearing can be impaired.

40,000-50,000ppm 4-5% Now the effects of CO2 really start to take over. Breathing is much faster - about four times the normal rate and after only 30 minutes exposure to this level you will show signs of poisoning and feel a choking sensation.

50,000-100,000ppm 5-10% You will start to smell carbon dioxide, a pungent but stimulating smell like fresh, carbonated water. You will become tired quickly with laboured breathing, headaches, tinnitus as well as impaired vision. You are likely to become confused in a few minutes, followed by unconsciousness.

100,000ppm-1,000,000ppm 10-100% Unconsciousness occurs more quickly, the higher the concentration. The longer the exposure and the higher the level of carbon dioxide, the quicker suffocation occurs.

15 minutes

8 hours

Can we be sure that we will never exceed safe levels of CO2?

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Safety Issues - O2

< 23.5% pure O2

Treat as air, no real concerns

23.5% to 40% pure O2

Enhanced flammability due to O2 enrichment

Established codes of practice, widespread industrial experience, but questions remain– E.g. some organisations have imposed lower O2 limits in oxyfuel test facilities

40% to 80% pure O2

Discussion needed on case-by-case basis

At some point treat as “pure O2”, but when? (no clear consensus from industry)– Practicality of specifying large FGR ducts, windbox, burners, etc. for “pure O2”?

Need clear guidelines for oxyfuel, backed up by data

80% to 100% pure

Treat as pure O2

Established codes of practice, widespread industrial experience

Concerns arise from lack of familiarity in power generation industry– First applications of oxyfuel to use “simulated air”

– Already pipe natural gas, hot oil to burners, so why not O2?

What is a safe working level of O2?

Page 71: Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS.

Concluding RemarksThe Way Forward

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Concluding Remarks – The Way Forward

Oxyfuel burners have been successfully demonstrated at full utility scale - up to 136mmBtu/lb (40MWt) - on a wide range of coals (lignite & bituminous)

Burner technology is ready and available for plant application

Thermal performance predicted for oxyfuel fired utility boilers is comparable to air firing

Oxyfuel can be retrofitted to existing plant with minimal impact to the boiler

Large scale demonstration is needed to verify boiler operation with oxyfuel

Considerable progress has been made in the development of oxyfuel technology

The process is technically viable

The process is reasonably well understood

The process has been demonstrated at pilot scale

The process has been demonstrated at large scale

Most of the individual components are in commercial operation at the required scale

Oxyfuel combustion is economically competitive with alternative technologies

The time is right for the full scale demonstration of oxyfuel

Page 73: Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS.

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Contact Details

Dr. Saravanan Swaminathan

Senior Engineer, Plant Product Innovation

E [email protected]

Mr. Gerry Hesselmann

Principal Engineer, Boiler Product Development

E [email protected]

Peter Holland-Lloyd

Business Development Manager

E [email protected]

*Doosan Power Systems Limited

Porterfield Road

Renfrew

PA4 8DJ

United Kingdom

T +44 (0)141 886 4141

73© Doosan Power Systems 2012

Page 74: Oxyfuel Capture Technology International Training Programme on Clean Coal Technologies and Carbon Capture and Storage: Learning from the European CCT/CCS.

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