An Overview of Developments in Oxyfuel Combustion Technologies for Power

Plants with CCS

Dr Kelly Thambimuthu FTSE Chairman,

IEA Greenhouse Gas R&D Programme Cheltenham, UK

and Emeritus Scientist, CO2CRC, Australia

AFG 2011, Dec 2011, Shanghai

2

Members and Sponsors

3

What IEAGHG does • Technical evaluations of mitigation options

• Comparative analyses with standardised baseline • Over 100 technical studies published since 1991

• Assist international co-operation • International research networks in capture and

storage • Assist technology implementation

• Assist in research collaboration (i.e. Weyburn) • GCCSI

• Disseminate information

4

IEA GHG Oxyfuel Combustion Research Network

• We have Established a forum to discuss the different issues on the development of Oxyfuel Combustion, promoted and encouraged cooperation and collaboration since 1995

• We have provided a centre of knowledge for this technology through • Young Researchers Forums (3) • APP OFWG Capacity Building Courses (3) • Workshops (3) and Conferences (2)

5

Oxyfuel Combustion Meetings in Numbers

Meetings 1st Workshop 2005

2nd Workshop 2007

3rd Workshop 2008

1st Oxyfuel Combustion Conference

2009

2nd Oxyfuel Combustion Conference

2011

Location Cottbus, Germany

Windsor, CT, USA

Yokohama, Japan

Cottbus, Germany

Yeppoon, Australia

Host Vattenfall Alstom IHI, J-Power and Jcoal Vattenfall CS Energy /

COSPL

Participants 64 88 103 286 202

No. of Countries 17 16 18 26 20

No. of Presentations 13 30 36 94 108

6

EPRI 2007

CO2 Capture for CCS

7

Oxy-Combustion Technology

• Use of oxygen instead of air in a boiler – “Oxy-Combustion” is a feasible option for power plant with CO2 capture. • With significant R&D investment in the past decade,

this technology is now one of the leading options for power generation with CCS

• 3 key areas of development • Boiler and Burner Development • Air Separation Unit – “Cost and capacity of oxygen

production” • CO2 Processing Unit – “Removal of impurities”

8

Oxyfuel Combustion Overall Schematic Diagram

9

Schwarze Pumpe, Germany

10 10

Radiant Section of the Boiler • heat transfer profile • slagging issue • fireside corrosion issue

Convective Section of the boiler • heat transfer profile • ash deposition and fouling issue

Burner design issue • Ignition • flame stability • devolatilisation & char burnout

Prior to any retrofit of carbon capture technology, it is essential to repower

the plant in order to achieve the highest possible efficiency

11

Today... There are 3 Major Full Scale PC Burner Testing Facilities Worldwide Retrofitted for Oxyfuel

• Babcock and Wilcox (B&W) 30MWth CEDF

• Barberton, Ohio, USA • Start of Operation: Oct. 2008 • Wall Fired Burner Development

11

• Doosan Babcock – 40MWth in 90MWth MBTF

• Renfrew, Scotland, UK

• Start of Operation: Jun. 2009

• Wall Fired Burner Development

• Alstom Power Plant Lab. – 15MWth in 30MWth BSF

• Windsor, Connecticut, USA

• Start of Operation: Nov. 2009

• T-Fired Burner Development

Courtesy of Alstom, B&W and Doosan Babcock

12

CS Energy/IHI Burner Testing Programme at Callide A Power Station • Callide A Project – would be the world’s

1st oxyfuel retrofitted power station. • First oxyfuel pilot plant that will actually

produce electricity. • Installation of 2 new Wall Fired Burners • A unique position to provide information

related to the burner – burner interaction • Project Scope (2-4 years operation):

o Oxygen plant (nominal 2 x 330 tpd ASUs) o Boiler refurbishment and oxy-fuel retrofit (1 x 30

MWe Unit) o CO2 compression & purification (75 tpd process

plant from a 20% side stream) – 1st to demonstrate the “Auto-Refrigeration Cycle”

o Road transport and geological storage (~ 30 tpd liquid CO2)

12

Courtesy of CS Energy, IHI

13

R&D work in boiler and burner development continues... • Burner development

• Coal devolatilisation • Char burnout • Heat transfer modelling • Air ingress management

• Emissions • NOx, SOx, Hg, HCl, HF, etc...

• Ash deposition / Slagging and Fouling • Corrosion mechanism

• Under furnace and convective conditions...

14

Oxygen Production • As of today, the only available technology for

oxygen production in large quantities is cryogenic air separation. • For a 500MWe Oxyfuel (Coal) Power Plant – you

would need >10,000 TPD of Oxygen! • Advances and Development in ASU could result to

25% less energy consumption. • These design would be based on either a

3 column design or dual reboiler design. • ASU should address the needs of the requirements

of power plant (i.e. Flexibility, Turn-down, etc...)

15

Overview Of The Process

Heat

Air

Heat

Oxygen

Main and Boost Air Compression

Air Cooling and Pretreatment Storage

Cryogenic Separation

16

Power Savings Progression

Significant Power Savings Compared to Current State of Art is Possible

60

70

80

90

100

110

Rel

ativ

e Se

para

tion

Pow

er

Current state of art

17

Challenges Ahead...

• Cryogenic ASU • Reducing the cost of oxygen production • Flexibility and Adaptability to the requirements of

oxyfuel power plant • Utilisation of large volume, low grade, dry N2

• Future Oxygen Production • ITM • OTM • Chemical Looping Combustion

18

Flue Gas Processing Units (Summary of Results @ Schwarze Pumpe Pilot Plant)

• Test on Electrostatic Precipitator (ESP) • Completed and results better than expected as

compared to air firing.

• Test on Flue Gas Desulphurisation (FGD) • Different design – with external oxidation tank. • SO2 removal (achieved up to 99.7% removal) • SO3 removal (achieved ~65% reduction)

Confidentiality - Medium (C2)

19 | 2nd Oxyfuel Combustion Conference | 2011.09.05

Experiences from the pilot plant Impact on slurry chemistry

• No major differences have been encountered. • No negative impact of higher CO2 partial pressure on reaction system.

- CO2 seems to enhance the limestone/chalk dissolution - Degassing of dissolved CO2 in the external reaction tank.

• Slightly lower pH during Oxyfuel operation • Higher moisture content led to water condensation in pre-cooler during Oxyfuel conditions.

Water condensation could be prevented by reduction of cooling duty to avoid local sub-cooling.

Samples taken during operation without hydrocyclone. Actual values (especially Chloride) are expected to be higher. 5,89

98,8

0,45

214

6,3

94,25

4,55

166

220

1540

1143

248

1510

1123

0

20

40

60

80

100

120

140

160

180

200

220

240

pH Gypsum [%]

Carbonate [%]

HCO3 [mg/l]

Nitrate [mg/l]

Chloride [mg/l]

Desity[mg/cm³]

0

150

300

450

600

750

900

1050

1200

1350

1500

1650

1800

Oxyfuel Air-firing

FGC System

• Flue Gas Condenser operates very similarly to typical flue gas condensers used in various biomass fired CHP plant in Sweden.

• Potential improvement for heat recovery has been identified by various equipment manufacturers

20 | Lars Strömberg, IEAGHG OCC2 Australia | 2011.09.12

21

Overview of Development of CPU over the last 5 years • Recognition of the NOx and SOx reaction by Air Products

(presented at GHGT 8 Conference – June 2006) • This has led to the rapid technology development among the

industrial gas producers. • Identification of potential impact of Hg to the operation of the

CPU. • Development of the use of impure CO2 as refrigerant driven

mostly by reducing energy penalty. • Work on further recovery of CO2 from the vent of the CPU.

22

NOx SO2 Reactions in the CO2 Compression System We realised that SO2, NOx and Hg can be removed in the CO2 compression process, in the presence of water and oxygen. SO2 is converted to Sulphuric Acid, NO2 converted to Nitric

Acid: – NO + ½ O2 = NO2 (1) Slow – 2 NO2 = N2O4 (2) Fast – 2 NO2 + H2O = HNO2 + HNO3 (3) Slow – 3 HNO2 = HNO3 + 2 NO + H2O (4) Fast – NO2 + SO2 = NO + SO3 (5) Fast – SO3 + H2O = H2SO4 (6) Fast

Rate increases with Pressure to the 3rd power – only feasible at elevated pressure

No Nitric Acid is formed until all the SO2 is converted Pressure, reactor design and residence times, are important.

23

CO2 Compression and Purification System – Removal of SO2, NOx and Hg

1.02 bar 30°C 67% CO2 8% H2O 25% Inerts SOx NOx

30 bar to Driers Saturated 30°C 76% CO2 24% Inerts

Dilute H2SO4 HNO3

Hg

SO2 removal: 100% NOx removal: 90-99%

BFW

Condensate

cw

15 bar

30 bar

Water

cw cw

Dilute HNO3

Bey/L/092009/Cottbus.ppt Linde AG Engineering Division

LICONOX™ Process

25

Sulphuric Acid Method Activated Carbon Method

27

Some More Challenges....

• Demand of the quality requirements of the CO2 from the power plant for transport and storage. What is the Required Specification?

• Further recovery of CO2 from the vent will make oxyfuel more competitive if high recovery of CO2 is required!

• Need a large scale demonstration of the CO2 processing unit using impure CO2 as refrigerant.

1980’s

ANL/Battelle/EERC completed the first industrial scale pilot plant

1990 - 1995

EC Joule Thermie Project - IFRF / Doosan Babcock / Int’l Combustion NEDO / IHI / Jcoal Project

First large scale 35MWt Oxy-Coal Burner Retrofit

Test done by International Combustion

1998 – 2001

CANMET US DOE Project / B&W / Air Liquide

2003 - 2005

Vattenfall (ENCAP ++) CS Energy / IHI Callide Project

B&W CEDF 2008 30MWth Coal Alstom Alstom CE 2010 15MWth Coal Doosan Babcock DBEL - MBTF 2009 40MWth Coal

Alstom Schwarze Pumpe 2008 30MWth Lignite Hitachi Babcock Schwarze Pumpe 2010 30MWth Lignite IHI Callide 2011 30MWe Alstom / AL Lacq 2009 30MWth Gas/Oil? CIUDEN El Bierzo CFB Facility 2011 30MWth Coal

El Bierzo PC Facility 2011 20MWth Coal

Coal

CIUDEN

2007

B&W CEDF (30MWt) large scale burner testing started

Updated by S. Santos (01/11/11)

2008

World’s FIRST 30 MWt full chain demonstration

at Schwarze Pumpe Pilot Plant

By the end of 2010/2011, Users (i.e. Power Plant Operators) will have 6 burner manufacturers fully demonstrating “Utility Size

Large Scale Burners” which should give a high level of confidence

toward demonstration

2009 – Lacq – World’s first 30MWt

retrofitted Oxy-NG boiler

2011 – CIUDEN – World’s first 30MWt Oxy-CFB Pilot Plant

2011 – Callide – World’s first 30MWe retrofitted Oxy-coal

power plant

By 2014-2018

Demonstration of 50– 300MWe full scale power plant.

Target : “Commercialised by 2020”

Vattenfall - Janschwalde (PC -250MWe) KEPCO/KOSEP - Yongdong (PC - 100MWe)

FutureGen2 - Illinois (PC - 100MWe) Endesa/CIUDEN - El Bierzo (CFB - 300MWe)

3 Newly announced oxyfuel projects in China. Drax Power Plant Oxyfuel in UK

29

Summary

• Current Pathway to Commercialisation • 1st generation plants – new and retrofit

Reduces technology risk – primarily costs Supports “learning by doing” in integrated plants – through

improvements in energy use and techniques

• Challenges in the Longer Term • Reducing energy penalties and costs of next generation

plants Reducing recycle flows through better materials and new

combustion techniques Improving oxygen separation technologies

Thank you kelly.thambimuthu@bigpond.com www.ieaghg.org

Special Issue:

Oxyfuel Combustion – Working Toward Demonstration and

Commercialisation

September 2011