cfb technology: clean, economic and efficient steam and
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POWER SYSTEMS
Sc o t t Da r l i n gOc t ob er 1 1 , 2007
CFB Tec h n o l o gy :Cl ea n , Ec on om i c an d Ef f i c i en t St eam an d Power Gen er a t i o n
f o r t h e Oi l San d s In d u st r y
Agen d a
St eam /Power Need s
Ava i l a b l e Fu e l s
Al s t om CFB Tec h n o l o gy
CFB f o r Oi l San d s Ap p l i c a t i o n s
Su m m a r y o f CFB Ben ef i t s
Can ad a : Wo r l d ’s Sec on d La r gest Oi l Reser v es
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Economic
Si gn i f i c a n t Oi l Sa n d s Pr o d u c t i o n Ex p a n si o n P l a n n ed
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Oi l San d s Ex p a n si o n Pr o j ec t s P l a n n ed In c l u d e:
• Mi n e
− In c r ea se p r o d u c t i o n o f b i t u m en
• St eam Assi s t ed Gr a v i t y Dr a i n a ge (SAGD)
− In c r ea se p r o d u c t i o n o f b i t u m en
• Up gr a d e r
− Up gr a d e b i t u m en t o sy n t h e t i c c r u d e o r
l i gh t e r , h i gh e r - va l u e p r o d u c t s
Oi l San d s Ex p a n si o n : Si gn i f i c a n t St eam an d Power Need s
• Min e
− 1 00,000 b /d
− El ec t r i c a l d em an d - 75 MW
− St eam Requ i r em en t s - 770 t /h r
• SAGD
− 50,000 b /d
− El ec t r i c a l d em an d - 40 MW
− St eam Requ i r em en t s - 820 t /h r
• Up gr ad e r
− 1 00,000 b /d
− El ec t r i c a l d em an d - 1 00 MW
− St eam r equ i r em en t s - 590 t /h r
Mi n i n g
Illus tra tio n courtesy o f Im pe ria l O i l Limi ted Illus tra tio n courtesy o f Im pe ria l O i l Limi ted
SAGD
Illus tra tio n co urtesy o f OPTI CA NADAIllus tra tio n co urtesy o f OPTI CA NADA
Agen d a
St eam /Power Need s
Ava i l a b l e Fu e l s
Al s t om CFB Tec h n o l o gy
CFB f o r Oi l San d s Ap p l i c a t i o n s
Su m m a r y o f CFB Ben ef i t s
Fu e l Op t i o n s
• Na t u r a l Gas− Cu r r en t f u e l o f c h o i c e
• Bi t u m en− Pr od u c t o f m i n i n g, SAGD
• Coa l− Lo c a l l y a va i l a b l e
• Pet c o k e/Asp h a l t en e− By p r o d u c t o f u p gr a d i n g p r o c esses
Al t e r n a t e Fu e l s Ava i l a b l e
Fu e l Pr i c es
Low- Cost Fu e l = Low- Cost St eam /Power
-5 0 5 10 15
Pet Coke
Asphaltene
Coal
Bitumen
Natural Gas
$CAN/GJ
Agen d a
St eam /Power Need s
Ava i l a b l e Fu e l s
Al s t om CFB Tec h n o l o gy
CFB f o r Oi l San d s Ap p l i c a t i o n s
Su m m a r y o f CFB Ben ef i t s
• Fu e l Fl ex i b i l i t y• Tr a d i t i o n a l So l i d Fu e l s (Coa l , B i om a ss, e t c )
• Op p o r t u n i t y Fu e l s (Pe t c o k e, Asp h a l t en e , B i t u m en , e t c )
• Low Em i ss i o n s• SO2
• NOx ,
• Pa r t i c u l a t e
Key CFB Ad van t a ges: Fu e l Fl ex i b i l i t y , Low Em i ss i o n s
0
200
400
600
800
1000
1976
1980
1984
1988
1992
1996
2000
2004
Year of Order Year of Order
MWe NumberCumulative Capacity (MWe) Cumulative Number of Units
010000200003000040000500006000070000
1976
1980
1984
1988
1992
1996
2000
2004
Over 63,000 MWe, over 900 units
CFB - Pr o ven Tec h n o l o gy
ALSTOM: CFB Ma r k e t Lead er
10.5
15.2
27.7
ALSTOMALSTOM LICENSEESOTHERS
CFBs > 50 MWGW
48% Market Share
6.96.3
4.7
ALSTOMALSTOM LICENSEESOTHERS
CFBs > 150 MW
GW
65% Market Share
C F B : L o w T e m p e r a tu r e C o m b u s t io n
Fluidized Bed Firing
Furnace Temperature
S toker Firing(Fixed Bed)
Bubbling Fluidized Bed
Fuel FeedS ize
Pulverized Firing(Entrained Bed)
Circulating Fluidized Bed
G a s
F u e l
A ir A s h
G a s
F u e lA ir
A s h
G a s
F u e l & S o r b e n t
A ir A s h
G a s
A s h
A irF u e l & S o r b e n t
Velocity 2 .5 - 3 m /s e c 1 - 3 m /s e c 4 .5 - 1 0 m /s e c4 .5 - 7 m /s e c
3 8 m m x 0 3 8 m m x 0 7 0% b e lo w 0 .0 7 5 m m1 2 m m x 0
1100-1400 °C 800-900 °C 800-900 °C 1400-1650 °C
A ir
CFB Pr o c ess: Sim p l e, Pr o ven
Good Fu e l Bu r n ou tGood So r b en t U t i l i z a t i o n
Lon g So l i d s Resi d en c e Tim e
Han d l es Low Gr ad e Fu e l sSim p l e Feed Sy st em
Ho t Ci r c u l a t i n g So l i d s
Low NOxLow SO2Fu e l Fl ex i b i l i t y
Low Fu r n ac e Tem p er a t u r e
Benef i t sFeat ur es
1500 - 1650 °FFlue Gas
Air
Limestone 1 mm x 0
Fuel12 mm x 0
Air
800 - 900 °C
5-6 m/s
CFB Pr o c ess: Sim p l e, Pr o ven
Cyclone
Furnace
Ash Cooler
Secondary Air
Lim
esto
ne
Day
Bin
Coa
l D
ay S
tora
ge
Primary Air
I.D.
Fan
Stack
Fabric Filter
or
Electrostatic
Precipitator
Fabric Filter
PA Fan SA Fan
FBHE
Seal PotAir Heater
Al s t om CFB ex p e r i en c e i n c l u d es
• An t h r a c i t e
• B i t u m i n o u s c o a l
• Su b - b i t u m i n o u s c o a l
• Li gn i t e
• Br own Coa l
• Op p o r t u n i t y Fu e l s
− Pe t r o l eu m c o k e - d e l a y ed a n d f l u i d
− Bi om a ss - r a n g i n g f r om wood c h i p s t o o l i v e p i t s t o p a p er m i l l s l u d ge
− Coa l wa st es - an t h r a c i t e c u lm , a n t h r a c i t e s i l t , b i t u m i n o u s go b , wa sh e r y
wa st es
− Oi l Sh a l e
− Hea vy Oi l
− Sewage s l u d ge
HHV, MJ/kg 33 2.4H2O, % wt. 62% 3%Ash 76% 4%Carbon 71% 19%Sulfur 8% 0.3%
Constituent LowHigh
A wide range of constituents
Fu e l Fl ex i b i l i t y Dem on st r a t ed
3 01 72 02 5P a r t ., m g /N m 3
2 1 01 3 01 3 01 0 5N O x , m g /N m 3
2 4 02 62 6 01 4 5S O 2 , m g /N m 3
C o a lC o a lP e t c o k eF u e l
C A S A P r o p o s e d G u id e l in e s
A E S P u e r t o R ic o *
G i lb e r t*M a i L ia o *
Low Em i ssi o n s Dem on st r a t ed
Pr o p o sed Al b er t a Em i ss i o n Gu i d e l i n es Dem on st r a t ed
* In c l u d es p o l i sh i n g sc r u b b e r p l u s SNCR
Bo i l e r Si zes t o 340 MWe Dem on st r a t ed
1X300 MW (RH)2X300 MW (RH)2X300 MW (RH)2X300 MW (RH)
1986 1987 1989 1990 1993 1996 2000 2004
BaimaKaiyuan
QinhuangdaoXialongtan
Scott Paper *
1x65 MW
CFB
IONE Westwood
NEPCO Ultra-
Systems
7 Units15-43 MW
CFBThames *
Shady Point *
5X80 MW (RH)
CFB Texas-New
Mexico
2X155 MW (RH)
CFB WarriorRun *
1X210 MW (RH)
CFB ProvenceKEPCO
1X250 MW (RH)2X220 MW (RH)
CFB
CFB
Guayama *Red HillsSeward *
E. Kentucky* Sulcis
2X250 MW (RH)2X250 MW (RH)2X290 MW (RH)2X260 MW (RH)1X340 MW (RH)
CFB+ 50.0 m
± 0.0 m- 1.5 m
Coal Bunker
SH 3
Evap
orat
or W
ings
SH 2
Ash Cooler
ECO
Prim. AirSec. Air
TAPH
ECO
SH1/2
SH1/1
* Construction by Alstom
0102030405060708090
100
Pforzheim
Koehler
Twin Oak
es
Emile H
uchet
Prove
nce
Warrior R
un
Mai Liao
Note: Reliability calculated as 100% - Forced Outage Rate (FOR)
H i gh Re l i a b i l i t y Dem on st r a t ed
7 y r s 9 y r s7 y r s 9 y r s 4 y r s 4 y r s 2 y r s
Bo i l e rRe l i a b i l i t y
Agen d a
St eam /Power Need s
Ava i l a b l e Fu e l s
Al s t om CFB Tec h n o l o gy
CFB f o r Oi l San d s Ap p l i c a t i o n s
Su m m a r y o f CFB Ben ef i t s
CFB Desi gn f o r Oi l Sa n d s Ap p l i c a t i o n s
30 - Pa r t i c u l a t e , m g/Nm 3
* Pr o p o sed Al b e r t a gu i d e l i n es
21 0 - NOx , m g/Nm 3
240 - SO2, m g/Nm 3
Em i ss i o n s *
Pet c o k e - 1 00%Asp h a l t en e/B i t u m en - 40%
Desi gn Fu e l s
1 49Feed wa t e r Tem p er a t u r e , C
541 - Tem p er a t u r e , C
1 29 - Pr essu r e , b a r
500 - Fl ow, t /h r
St eam Con d i t i o n s
St a n d a r d Bo i l e r Si z e f o r Mu l t i p l e Ap p l i c a t i o n s
• Su i t a b l e f o r Mi n e , SAGD, Up gr a d e r Ap p l i c a t i o n s
• Power Gen er a t i o n v i a Ba c k p r essu r e T/G
• Low- Cost Fu e l s
• Low Em i ss i o n s
• Pr o ven Desi gn
• Mi n im u m Wa t e r Use
CFB Desi gn f o r Oi l Sa n d s Ap p l i c a t i o n s
Pet c o k e: H i gh Su l f u r , H i gh Van ad i u m , Low Vo l a t i l e Fu e l
Ca r b on 80.70 % (wt .)
Hy d r o g r en 3.71 %
Ox y gen 1 .69 %
Ni t r o gen 1 .37 %
Su l p h u r 7.33 %
Mo i s t u r e 5.00 %
Ash 0.20 %
Va 1 200 p pm
Ni 430 p pm
Vo l a t i l es 9 %
HHV 33 MJ/k g
Ty p i c a l Pe t c o k e An a l y s i s
Lim est o n e r ea c t s w i t h van ad i u m t o f o r m st a b l e , n on - c o r r o s i v e c om p ou n d s
Van ad i u m
Ho t c i r c u l a t i n g so l i d s p r o v i d e c on t i n u o u s, st a b l e i gn i t i o n
Lon g so l i d s r es i d en c e t im e p r o v i d es h i gh c a r b on b u r n ou t
Low Vo l a t i l es
Su l f u r c ap t u r e v i a l im est o n e, p o l i sh i n g sc r u b b er (i f n eed ed )
H i gh Su l f u r
Benef i t s of CFBPet coke Feat ur es
CFB: Tec h n o l o gy o f Ch o i c e f o r Pet c o k e Fi r i n g
Site Type of Petcoke MWe Operation Torrance Delayed 12 1986 Bay Area #1- Pittsburgh Fluid 20 1989 Bay Area #2- Pittsburgh Fluid 20 1989 Bay Area #3-Antioch Fluid 20 1989 Bay Area #4-Antioch Fluid 20 1990 Bay Area #5- Pittsburgh Fluid 20 1990 New Brunswick Power Delayed 20 1990 Hanford Delayed 27 1991 Ft. Howard- Rincon Delayed 35* 1991 Ft. Howard- Green Bay Delayed 45* 1991 CEMEX – Tamuin Delayed 130 2002 CEMEX – Tamuin Delayed 130 2002
FPC - Mai Liao Delayed 150 2003 FPC - Mai Liao Delayed 150 2003 CEMEX – Tamuin Delayed 130 2004 CEMEX – Tamuin Delayed 130 2004
FPC - Point Comfort Delayed 150 2009 FPC - Point Comfort Delayed 150 2009 *Equivalent Electrical Output - Steam Production Only
Al st om : Si gn i f i c a n t CFB Ex p er i en c e f i r i n g 1 00% Pet c o k e
CFB: Cap ab l e o f Fi r i n g Bi t u m en , Asp h a l t en e
B i t u m en , a sp h a l t en e l i m i t ed t o 40% MCR l o a d p en d i n g f u r t h e r t est s
230
630
-
0.7
4.9
0.4
-
1 0.3
83.7
40.9
Asp h a l t en e
42.633HHV (MJ/k g)
75400Ni c k e l (p pm )
1 200
5
0.2
7.33
1 .37
1 .69
3.71
80.7
Pe t c o k e
250
-
0.7
4.9
0.4
1 .2
1 0.3
83.7
B i t u m en
Mo i s t u r e
Ni t r o gen
Ox y gen
Hy d r o gen
Ca r b on (% b y w t )
Van ad i u m (p pm )
Su l p h u r
Ash
Si d e Vi ew
Fr o n t Vi ew
Li q u i d Fu e l
Fu e l Lan c e: Al l ows Fi r i n g Hea vy Li q u i d s
CFB f o r Oi l San d s Pl a n t : Ba sed on Ma i Li a o Desi gn
• Cu st om er : Fo r m o sa P l a st i c s Co r p .
• Lo c a t i o n : Ma i Li a o , Ta i wa n
• Fu e l : Pe t r o l eu m c o k e
• Fu e l su l p h u r c o n t en t : 6.5%
• Su l p h u r r em o va l : 98%
• Com m i ss i o n i n g : 2002/3
• St eam Con d i t i o n s: − Fl ow: 500 t /h r− Pr essu r e : 1 29 b a r− Tem p .: 541 °C
Ma i Li a o : 1 00% Pe t c o k e Fi r i n g w i t h Low Em i ss i o n s
Al st om ’s Fl a sh Dr y er Ab so r b er (FDA): Mi n im i z es Co st o f Su l f u r Cap t u r e
• SO2 c ap t u r e sp l i t b e t ween CFB an d FDA
− Red u c es l im est o n e f eed t o CFB
• CFB f l y a sh c o n t a i n s CaO
− Cap t u r es SO2 i n FDA
• No s l u r r y h a n d l i n g
• Low wa t e r c o n su m p t i o n
• Dr y p r o d u c t
TC
Fabr i c Fi l t er
Reci r cul at i on
Humi di f i er
Wat er
Li me( i f needed)
Fl yas h t o Di s pos al
Fl ue Gas f r om CFB
FDA Dem on st r a t ed a t Ma i Li a o
Agen d a
St eam /Power Need s
Ava i l a b l e Fu e l s
Al s t om CFB Tec h n o l o gy
CFB f o r Oi l San d s Ap p l i c a t i o n s
Su m m a r y o f CFB Ben ef i t s
CFB Ben ef i t s:
• Su i t a b l e f o r Mi n e, SAGD, Up gr a d e r ap p l i c a t i o n s
− Power gen e r a t i o n v i a b a c k p r essu r e T/G (op t i o n a l)
• Low- c o st f u e l c a p a b i l i t y
− Red u c ed op er a t i n g c o st s
• Po t en t i a l b i om ass f i r i n g
− CO2 em i ss i o n c r ed i t
• Low em i ss i o n s (NOx , SOx , PM)
− Pr op o sed em i ss i o n gu i d e l i n es d em on st r a t ed
• Ref e r en c e b o i l e r i n su c c ess f u l op er a t i o n on p e t c o k e
− Pr o ven d es i gn , f u e l c ap ab i l i t y , em i ss i o n s
• Red u c ed wa t e r u se
− Su p er h ea t ed st eam (vs sa t u r a t ed )− Dr y SO2 c ap t u r e (vs WFGD)
• Dr y b o t t om / f l y a sh
− Man y p o t en t i a l b en e f i c i a l u ses
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