alstom’s overview of a manufacturer’s efforts to ... capricorn...alstom’s overview of a...

Alstom’s Overview of a Manufacturer’s Efforts to Commercialize Oxy-

Combustion for Steam Power Plants

2nd International Oxy-Combustion Conference

Yeppoon, Queensland, Australia September 14, 2011

John L. Marion Andreas Brautsch, Frank Kluger, Mikael Larsson, Thierry Pourchot

ALSTOM © 2011 We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden

Alstom – Overview of Mfr’s Efforts to Commercialize Oxy-Combustion for Steam Power Plants – J. Marion IEA 2ndInt. Oxy-Combustion Conference, Yeppoon, Queensland, Australia, 14 Sept. 2011 - P 2

The Alstom Group: a Worldwide Leader in Power Generation

Full Power Systems Portfolio N°1 in air quality control systems

N°1 in services for electric utilities

N°1 in integrated power plants

N°1 in hydro power

N°1 in conventional nuclear power island

Recent acquisitions of solar & wind power

Lagisza

Medupi

Maritza Belchatow

Neurath

RDK8

Flamanville

Santo Antonio Kwinana

Tallawara Colongra

Muara Tawar

Nhon Trach 1

Guatami

Utran

SoharFujairah

Dubai GTX

GhannouchRelizane

Terga

Malaga

Soto de Ribera

LangageAghada

Flevo

KW Emsland

Moscow TPP 26

Combigole

GissiModugno

Scandale

Grain

Gariep

Cahora BassaTucurui

Chief Joseph

Rocky Reach

Eastmain

La Sarcelle

Itaipu

Fozdo Chapeco

Estreito

Chicoasen

Peribonka

CSA

Manapouri

3 Gorges

Son La

Yangyang

Lower Jurala

Vishnuprayag

Subansiri

Deriner

Karun

Merowe

BujagaliAfourer

AlquevaLa Muela

Grand'maison

Nant De Drance Birecik

Hong Yan He

Ling Ao 3+4

Fuqing, NingdeFang Jiashan

Taishan

Lagisza

Medupi

Maritza Belchatow

Neurath

RDK8

Lagisza

Medupi

Maritza Belchatow

Neurath Lagisza

Medupi

Maritza Belchatow

Neurath

RDK8

Flamanville


Tallawara Colongra

Muara Tawar

Nhon Trach 1

Guatami

Utran

SoharFujairah

Dubai GTX

GhannouchRelizane

Terga

Malaga

Soto de Ribera

LangageAghada

Flevo

KW Emsland

Moscow TPP 26

Combigole

GissiModugno

Scandale

Grain


Tallawara Colongra

Muara Tawar

Nhon Trach 1

Guatami

Utran

SoharFujairah

Dubai GTX

GhannouchRelizane

Terga

Malaga

Soto de Ribera

LangageAghada

Flevo

KW Emsland

Moscow TPP 26

Combigole

GissiModugno

Scandale

Grain


Tallawara Colongra

Muara Tawar

Nhon Trach 1

Guatami

Utran

SoharFujairah

Dubai GTX

GhannouchRelizane

Terga

Malaga

Soto de Ribera

LangageAghada

Flevo

KW Emsland

Moscow TPP 26

Combigole

GissiModugno

Scandale

Grain

Gariep

Cahora BassaTucurui

Chief Joseph

Rocky Reach

Eastmain

La Sarcelle

Itaipu

Fozdo Chapeco

Estreito

Chicoasen

Peribonka

CSA

Manapouri

3 Gorges

Son La

Yangyang

Lower Jurala

Vishnuprayag

Subansiri

Deriner

Karun

Merowe

BujagaliAfourer

AlquevaLa Muela

Grand'maison


Gariep

Cahora BassaTucurui

Chief Joseph

Rocky Reach

Eastmain

La Sarcelle

Itaipu

Fozdo Chapeco

Estreito

Chicoasen

Peribonka

CSA

Manapouri

3 Gorges

Son La

Yangyang

Lower Jurala

Vishnuprayag

Subansiri

Deriner

Karun

Merowe

BujagaliAfourer

AlquevaLa Muela

Grand'maison

Nant De Drance

Gariep

Cahora BassaTucurui

Chief Joseph

Rocky Reach

Eastmain

La Sarcelle

Itaipu

Fozdo Chapeco

Estreito

Chicoasen

Peribonka

CSA

Manapouri

3 Gorges

Son La

Yangyang

Lower Jurala

Vishnuprayag

Subansiri

Deriner

Karun

Merowe

BujagaliAfourer

AlquevaLa Muela

Grand'maison


Hong Yan He

Ling Ao 3+4

Fuqing, NingdeFang Jiashan

Taishan

Over 41 GW under execution

Nuclear Hydro Steam Gas



Alstom’s strategy to stabilize CO2 emissions

1. Technology Mix Balancing the generation portfolio by

significantly increasing the share of renewables and CO2 free technology

2. Production Efficiency and Energy Management

(Smart Power) Efficiency is a key to emissions reduction

3. Carbon Capture and Storage With 60% of the installed base in 2030

expected to use fossil fuels, CCS is a must.

Efficiency: Plant optimisation & retrofit

Wind & Geothermal

N° 1 Nuclear (conv. PP components) & biomass

N° 1 Hydro Tidal Power

Leader in CCS by Oxy and Post capture



At Alstom, we believe coal and gas can and must be clean

CO2 capture pursued by Alstom

Post-combustion Oxy-combustion (New + retrofit) (New + retrofit)

• Chilled Ammonia • Advanced Amines

Oxy is a robust and economically attractive solution

• Oxy-combustion • Chemical Looping



Oxy-Combustion Process

• Reliable: main components exist, only adaptation to power gen and scale-up

• All types of boilers / firing systems adaptable to Oxy-combustion covering a complete fuel range

• Rapid scale-up to large size (1,000 MWe range) possible after large demos

• Retrofit feasible

• High efficiency and competitiveness of supercritical/ultra-supercritical cycles and large unit size will be compatible and key benefits

• Large community involved in development, contributing to reaching solid consensus

Oxy-combustion: a solid option for CO2 capture

Source: Alstom 3D View of an Oxy-PC (800MWe gross)



Oxyfuel Process – Oxy-PC Power Plant Focus of Investigations

Quality & Efficiency of CO2-Separation

Vent Gases

Flue Gas Recirculation

Scale-up

Components - Scaling - Integration - Optimisation

Air Separation Options - Cryogenic - Membranes - Oxide Carrier Materials

Steam Generator - Oxyfuel PF Firing - Oxy CFB - Chemical Looping

Transport & Sequestration

Flue Gas Cleaning - Particle Removal - NOx-Removal - Desulphurisation - Mercury Removal - Flue Gas Drying - Separation of N2, O2, ...

Dynamic Behaviour

Control & Safety Concepts Integration

Air Inleakage

Materials



Large Pilot Plants

Demonstration

Full-Scale 2008

2014-15

< 2020

Alstom Oxy-Combustion Technology Development Steps

Lab Scale

1998

<3 MWth

15- 30 MWth

150- 300 MWe

600-1100 MWe

Reference Design Studies

Modeling & Tool Dev.



2008

2014-15

< 2020

Alstom Oxy-Combustion Technology Lab Scale Completed

Lab Scale

1998

<3 MWth

Since 1998 and up to 3 MWt Oxy Coal Testing • Alstom Labs – 100 KWt to 3 MWt • U. Stuttgart • U. Cottbus • U. Hamburg-Harburg • U. Dresden • ENCAP (EC Co-funded Project) • ADECOS I & II (GER Co-funded Project) • OxyBurner (EC Co-funded Project) • OxyCorr (EC Co-funded Project)

Combustion

Materials

Gas cleaning

and



Simulation and Modeling for Oxy-Fired Power Plants

Commercial Scale Units: CFD

• System modeling – ASPEN, ANSYS, APECS

• Boiler perf. modeling – Alstom RHBP & ALPRO

• Dynamic performance modeling – Alstom APROS • CFD modeling submodel improvements:

– soot, radiation, NOx • Validation in small combustors and pilot plants

• Apply to scale up for full scale reference designs and demonstration projects

APECS Process model with component CFD models

Oxy Combustion CFD: Validation and Submodel Enhancement

850 MWt 250 MWt

500 KWt Air/Oxy

15 MWt Air/Oxy

30 MWt Air/Oxy



Oxy-PC Power Plant - Optimized Integration with Boiler, AQCS, FGC, and GPU

ESP at Oxy Schwarze Pumpe Alstom NID™ Dry FGD Alstom Wet FGD Alstom FGC



View of the Alstom GPU pilot unit in containers

Mobile GPU pilot unit for multiple testing possibilities

• Designed for stringent (>99% Vol.) or relaxed CO2 specification (>95% Vol.)

• Within the oxy process, the GPU represents : ~30% of the energy penalty & ~40% of the incremental capture system cost

• Developed from already-existing process

• Pilot configuration in containers to allow mobility to different sites

• Compression & Purification tests:

- 1st phase (on-going) with synthetic gases in Alstom R&D center in Växjö, Sweden

- 2nd phase (2012) on actual oxy-combustion flue gases on the 15 MWth BSF in Windsor, CT USA

Alstom’s Gas Processing Unit (GPU)



Oxy-firing Integrated Approach Reference Plant work

• Globally optimize cost of electricity

• Balance trade-offs between main subsystems (performance and costs)

• Determine specification for the new subsystems

• Optimize power plant operation behaviour

• Optimize arrangement and minimize footprint

Guides the oxy-program and defines future commercial



Oxy-firing Integrated Approach Reference Plant

An integrated approach minimizes the cost of electricity

Learnings from subsystems development and pilots & demo projects are continuously integrated in the Reference Plant

• Guide component developments

• Optimize integration of plant system

• Support the demo projects

• Offer oxy-ready power plant designs in the pre-commercial period

• Offer oxy-effective power plants once demo projects will have been validated.

Plant or Integrated Boiler island DCS

Optimization of FG composition along the oxy-chain

Thermal

Process

Operation

Layout



Thermal

Process

Operation

Layout



Thermal

Process

Operation

Layout



Thermal

Process

Operation

Layout



177

68

0

100

200

300

400

Nuclear

Hydro

Geotherm

al

Onsho

re W

ind

PC Hardc

oal C

CS 2015

Offsho

re W

ind

Solar P

V

Solar T

hermal

€ / M

Wh

CoE - Low Carbon technologies ordered in 2011-2016 period

Reference cases

Source : Alstom analysis 2011. CCS 2015 costs, including on shore T&S and CO2 price = 18 €/T CCS PC Hard coal 800 MWe net includes both PCC Amine and Oxy approaches, European reference scenario

Under realistic assumptions and variation range, Oxy CCS is already competitive from 2015, but further cost/efficiency improvements forecast

Oxy CCS competitive against other low carbon alternatives

14%

15%

16%

17%

18%

19%

20%

2010 2015 2020 2025 2030 2035

CCS OXY

CCS PCC

% A

GA

INS

T M

We

net

RE

F P

LA

NT

CCS PLANT – ENERGY PENALTY



Large Pilot Plants

2008 to present

Alstom Oxy-Combustion Technology Development Steps – Large Pilots

15- 30 MWth



Objective

• Investigation and Demonstration of the complete technology path for CO2 separation in pilot scale as basis for realisation of a demonstration plant

Alstom-Scope

• Extent of Supply: Steam generator, ESP and other components of the flue gas path

• Technology Partnership with Vattenfall to advance of the Oxyfuel technology

Status of Operation as of 2011

• Start of operation in September 2008

• Total operation hours 10,000 hours (3,500h air, 6,500h oxyfuel)

• Captured CO2 ~10,000 tons

• Tests with two lignites (low/high sulfur)

• Test phases with Alstom Burners (Design A+B) finished

30 MWth Oxy-Combustion Pilot Plant of Vattenfall in Schwarze Pumpe, Germany

Boiler House

Electrostatic Precipitator

Air Separation Unit

Control Room

CO2 Purification and Liquefaction

Office Building

Flue Gas Desulphurisation

Flue Gas Condenser

CO2 Tanks

Boiler House

Electrostatic Precipitator

Air Separation Unit

Control Room

CO2 Purification and Liquefaction

Office Building

Flue Gas Desulphurisation

Flue Gas Condenser

CO2 Tanks

Alstom Oxy-boiler

30 MWt Oxy Plant

Alstom Oxy-burner



Performance Range Alstom Burner Design A

Performance Range Alstom Burner Design B

30 MWth Oxy-Combustion Pilot Plant – Experience Feedback

Single burner & indirect firing system

• Combustion fundamentals (emissions, burnout, fouling & slagging, excess oxygen, flue gas recycle ratio etc.)

• Heat transfer (radiation, convection)

• Material selection (oxidation issues)

• Validation of oxy-firing CFB models

Dynamic behavior of entire oxy-combustion plant

• Start-up/shut-down, switch between air & oxy

Interaction of ASU, Boiler, AQCS and GPU

• Control of oxy-combustion process and plant

Achievable CO2 capture rate and quality



15 MWth Oxyfuel Pilot Plant BSF Alstom Labs, Windsor, CT, USA

NID Dry Scrubber Fabric

Filter

Oxygen Storage

Coal SupplyCO2 purge gas

Flue Gas Condenser

FGD

Stack

15 MWt Boiler Simulation Facility

NID Dry Scrubber Fabric

Filter

Oxygen Storage

Coal SupplyCO2 purge gas

Flue Gas Condenser

FGD

Stack

15 MWt Boiler Simulation Facility

Objective

• Develop and validate Oxyfuel Tangential Fired Boiler system

Scope

• Design and develop an innovative oxyfuel firing system for T-fired boilers

• Evaluate the performance in pilot scale tests at 15 MWth BSF

− (combustion, heat transfer, pollutant emissions, deposition, corrosion …)

• Evaluate, improve, and validate engineering and numerical tools for oxy-combustion fired boilers

• Development of design guidelines

• Commercial Reference Design

• Demonstration Design



15 MWth Oxy-Combustion Pilot Plant: Alternate Fuels Tested

Air Oxy

Alstom 15MWth BSFND Lignite Long-Term Testing

Oxy

Air

oxyfired heat flux profile can be controlled to match air firedStatus

• Process and CFD Screening Completed • Modifications For Oxy-Firing Completed • Campaign 1 Testing Completed Sept.

2009 – Sub-bituminous coal • Campaign 2 Testing Completed Feb.

2010 - Low S Bituminous coal • Campaign 3 Testing Completed April

2010 - High S Illinois Bituminous coal • Campaign 4 Testing Completed Oct. 2010 North

Dakota Lignite • Campaign 5 Testing Completed August

2011- Schwarze Pumpe Lignite • Tools & CFD Modeling Refinement and

Validation

Next Steps • Campaign 6 2nd Generation Concepts • Data for Reference & Demo designs



Oxy-Combustion Roadmap (Innovative Future Paths)

Reducer Oxidizer

CaSO 4

N2

Air

To Steam Cycle

CO 2

CoalCaCO 3Steam

CaS Ash, CaSO 4to Disposal

Reducer Oxidizer

CaSO 4

N2

Air

To Steam Cycle

CO 2

CoalCaCO 3Steam

CaS Ash, CaSO 4to Disposal

Time Demo’s &

Pilots Reduced FGR

Oxy-Plants Commercial

Advanced Oxygen

Production

Chemical Looping

Commercial

Air – Oxy Commercial

[ Retrofit, CO2 Ready, New ]



Next Generation Oxy: Chemical Looping Combustion

A promising break-through technology avoiding ASU energy penalty & costs

DOE/Alstom Windsor US – 3 MWth - Coal

RFCS EU – Darmstadt Germany – 1 MWth - Coal

Chemical looping CLC Pilots



Alstom - Chemical Looping Process Development Steps

Pilot Plant

Prototype

Demonstration

2014-2016

2000-2004

2011

Commercial Scale

>2020

Bench Tests

1996

10-100 kWth

1& 3MWth

10 - 50 MWe

>100 MWe

Reference Design Studies

Drop-Tube/TGA

Small & Large Cold-Flow-Model

CFD Modeling, Controls and Tool Development



Large Pilot Plants

Demonstration

Full-Scale 2008

2014-15

< 2020

Alstom Oxy-Combustion Development Steps Demonstration

Lab Scale

2000

<1 MWth

15- 30 MWth

150- 300 MWe

600-1100 MWe

READY FOR THE NEXT STEP



UK Oxy CCS Demo Project

Largest Oxyfuel CCS Demo

• A new modern 426MWe Gross Oxyfuel Power Plant

• PC Boiler; ultra-supercritical conditions

• Clean power generation with the entire flue gas treated to capture 2 MTA CO2

• Biomass co-firing leading to zero CO2 emission

• Located at the existing Drax Power Station Site at Selby, North Yorkshire

• A part of Yorkshire/Humber cluster for transport and offshore storage of CO2

• FEED under way

• NER funding application under evaluation

Project Promoters

ALSTOM DRAX ASU NATIONAL GRID

Oxyfuel Power Plant

CO2 Transportation & Storage



Alstom Labs Växjö Sweden – 0.25 MWth

Post C. – multi purpose

Completed

Presentation Title - Presenters Initials - dd mmm yyyy - P 25

Dow Chemical Co. USA, West Virginia Adv. Amines - Coal Transalta

Canada - >200 MWe Post - Coal

Getica - CET Turceni Romania – >250MWe

Chilled Ammonia - Lignite

PGE Belchatow Poland – 260 MWe Adv.

Amines - Lignite

AEP Mountaineer USA – 235MWe

Chilled Ammonia - Coal

Alstom activity on demonstrations 1st and 2nd Generation CCS

Drax - Selby UK - 426 MWe

Oxy – Hard Coal

NER300

DOE/Alstom Windsor US – 3 MWth

Chemical looping, Coal

2 Gen

NER300 NER300

EoN Karlshamn Sweden - 5 MWth

Chilled Ammonia -Fuel

WE – Energie USA WI - 5 MWth

Chilled Ammonia, Coal

ON HOLD

Vattenfall Jänschwalde Germany - 250 MWe

Oxy - Lignite

NER300

ON HOLD

AEP Mountaineer USA - 58 MWth

Chilled Ammonia, Coal

Total Lacq France - 30 MWth

Oxy - Gas

Vattenfall Schwarze Pumpe

Germany - 30 MWth Oxy - Lignite

Alstom BSF Windsor US - 15 MWth

Oxy - Coals

Under Construction

TCM Mongstad Norway - 40 MWth

Chilled Ammonia - Gas

EDF – Le Havre France – 5 MWth Adv.

Adv. Amines - Coal

Operating

RFCS EU - Darmstadt Germany - 1 MWth

Chemical looping, Coal

2 Gen

Pre-commercial Projects

Selected by Alberta and Federal Canadian funding

Selected for receiving EEPR funding NER300: Applied for EU ETS

New Entrant Reserve funding

Oxy Combustion



Strong R&D support to develop oxy-firing with highest technology

standards

In-house expertise to develop key components of the oxy value chain

Capabilities to integrate the oxy value chain

• Adaptation to specific needs

• Reduced risks • Optimized value

chain • Flexibility • Minimized cost of

electricity

Sound, competitive and solid technology path

A large portfolio of oxy-firing solutions for different customer needs

Summarizing Alstom’s oxy-firing for CCS

KEY FEATURES KEY BENEFITS

We are on track with oxy-firing development to commercialize this technology from 2015/16

www.alstom.com

alstom’s overview of a manufacturer’s efforts to ... capricorn...alstom’s overview of a...

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