apgtf uk post combustion carbon dioxide capture r&d …...what is post combustion capture (pcc)?...

APGTF

UK Post Combustion Carbon Dioxide Capture R&D Activities

Hans Jensen February 2008

© Fluor

© Statoil

© Statoil

© IPCC

Contents

The need for CCS

Post Combustion Capture

R&D needs

R&D activities – UK universities, UK industry and Europe / Worldwide

Who’s got the problem?

The problem

Fossil fuels are needed!

– A range of analysis show that fossil fuels is likely to remain a major energy source in 2030

The introduction of renewable energy sources in the energy system will play a large role, but not large enough and soon enough

In several countries nuclear power is currently not an option

What is Post Combustion capture (PCC)? Carbon dioxide is absorbed from the flue gas by a liquid solvent(typically aqueous amine solution)

The solvent is then pumped to a desorber, where it is heated to drive off the CO2. The regenerated solvent is then cooled and reused.

Amine absorption technology has been used in the oil and gas industry for many years. Application to power station flue gas involves new challenges: much greater scale and more difficult chemistry.

Capable of 90%+ CO2 capture

Relatively easy to retrofit to an existing power plant

Possible to test the process on part of the flue gas stream

PCC Impact on Host Power Station

Boiler Steam Turbine Generator

Condenser

5%

boiler losses

1%

feedwaterheating

43.7%

condenser heat

rejection

3.3%

power plant auxiliaries

1%

generator losses


Condenser

5%

boiler losses

1%

feedwaterheating

43.7%

condenser heat

rejection

3.3%


1%

generator losses

Reduces efficiency from approx. 45% to approx. 35%

Requires about half steam from LP turbine

Energy penalty comprises steam for reboiler 45%, pumps and fans 10% and CO2 compression 45%

Increased capital cost

Substantial land area

Impact on flexibility

High impact means that even incremental improvements can make a big difference


Condenser

5%

boiler losses

1%

feedwaterheating

23.7%

condenser heat

rejection

25.7%

capture plant steam

4.3%

capture plant electric load

3.3%


1%

generator losses

Capture and

Compression


Condenser

5%

boiler losses

1%

feedwaterheating

23.7%

condenser heat

rejection

25.7%

capture plant steam

4.3%

capture plant electric load

3.3%


1%

generator losses

Capture and

Compression

Research RequirementsUnderstanding and minimising costs and impact on host plant

Understanding environmental issues (emissions, waste streams)

Understanding process chemistry, corrosion, solvent degradation

Process integration and optimisation

Gas cleaning requirements

Evaluating technologies

Improvement in process technology / reduction in efficiency penalty

Developing modelling capability

Understanding implications for power plant flexibilty, grid code and commercial implications

Understanding Engineering issues for retrofit

Understanding implications for CCGTs

Understanding regulatory and legislative requirements

UK Research Projects (current)

Aberdeen, BGS, Cambridge, Cranfield, Edinburgh, Glasgow, Heriot-Watt, Imperial, Leeds, Manchester, Newcastle, Nottingham, Plymouth Marine Lab, Reading

UK Research Councils’TSEC

All aspects of CO2 capture and storage including PCC

UK Carbon Capture &Storage Consortium Project

RWE npower, BOC Linde, Doosan BabcockLeeds UniversityTSB (UK Govt)Modelling of capture plant integration

Eco-copps

Eon, RWE npower, Doosan Babcock and others

Imperial College, CranfieldUniversity, Cardiff University

BCURA + othersAmines chemistry, corrosion and performance, plant integration, CO2 transport

PhD studentships

RWE npower, PPC (Greece)Leeds, AUTH (Greece), ISFTA (Greece)

EC Research Fund for Coal and Steel

Hybrid / amine oxyfuel process

Ecoscrub

RWE npower, Doosan Babcock, Scottish & Southern Energy, EdF, Scottish Power, Drax Power, Visser Smit Hanab UK

Imperial CollegeTSB (UK Govt)Amine post-combustion capture and test rig

Casscap

Industrial PartnersAcademic Partners

Funding Body

ScopeProject

RWE npower post-combustion capture strategy

FGD/SCR interfaceIntegration with turbinesMass transfer issuesConstruction methodsFull CCS chain (includingcompression)

Scale up capabilityEfficiency optimisation (e.g. heat recovery options)Availability/flexibilityMaterials issuesReliable operating costs

Chemistry of capture solventsEnvironmental issuesEnergy requirementsModelling capability for scale-upOperational capabilityAssess technologies

Phase 2Government funded Demonstrator

Phase 1Pilot plant

Phase 0CTF development

Timescale

Benefits

H2H1H2H1H2H1H2H1H2H1H2H1H2H1H2H1H2H1H2H1H2H1H2H1H2H12020201920182017201620152014201320122011201020092008

CCS tested and commercially available for 2020

Storage

2014 20102008Operation

Transport

Constraints

Phase 0

Capture

Phase 2Phase 1Issue

Test ProgrammeFeatures

8m column height0.07 MWe (50 kg/h CO2)SO2 and NOX pre-treatmentMultiple solvent sampling locationsProvision for corrosion coupons and alternative material test sitesTrace gas injectionContinuous analysis

Test programmeMEA reference tests with heat and material balances and parametric studiesAlternative solvents e.g. MDEA, hindered amines and blendsValidation of baseline process economics and assessment of plant flexibilityTests on different flue gases and fuels including biomass

Aberthaw pilot facility (2010)Key role in capability development

– building operational experience– assisting in technical decisions for

demonstration and in troubleshooting plant in early years

Evaluating issues requiring longer operation and larger scale

– Long-term degradation of solvent

– Materials and corrosion

– Scale-up

– CO2 Purity and implications for compression

– Performance on a real power station

UK Government Competition

Competition launched by BERR in November 2007

Aims to be first large scale coal power station CCS scheme in the world

Post combustion capture

300-400 MWe (will accept staged approach)

15 year project

Operational by 2014

Three consortia under consideration

Some PCC Pilot Plant Projects

Cato pilot Plant (2008)

ENEL /ENI pilot Plant – Brindisi(2009)

European CO2 Test Centre (Mongstad)

NiederaussemPilot Plant (2009)

Didcot test rig (2008) Esbjerg Pilot Plant

(2006)

BerlinAmsterdam

Karlshamn

HeydenWilhelmshaven

London

7 MWel2009

5.5 MWel2009/10

7 MWel2009/10

<1 MWel2009

3,0 MWel2008

0.5 MWelMay 2008

w. Electrabel 1 MWel, 2009

Maasvlakte

Kopenhagen

Phase I of E.ON’s broad programme to develop2nd generation post combustion capture with world market leaders ongoing

� R&D CCS-budget with a commitment of about 100 Million €

UK Government CCS Competition entry

Kingsnorth

CCS - View from Industry: E.ON 19th September 2008 E.ON UK Seite 15

CESAR Project

EU FP7 funded project

19 partners including power companies, OEMs, research organisations and universities

Builds on findings of Castor project – will use the Castor Esbjerg pilot plant to test novel amines

Aims to reduce cost of capture below 15 euro / tonne

Looking at novel solvents, membrane processes and environmental performance

International Academic Links

University of TexasResearch programme into all aspects of post combustion capture including energy efficiency, amine degradation, analytical techniques

Supported by a number of industrial partners including UK utilities

Pilot plant offers opportunity to test different amines

University of ReginaInternational Test Centre supports a range of research activities including degradation, materials performance, EOR

ITC houses an amine pilot plant and University runs the Boundary Dam Pilot plant where CO2 capture using the MEA process is tested on real coal flue gas

Supported by a wide range of international companies including UK utilitiies

Links with Technology Providers

In September 2008, Doosan Babcock signed an agreement with HTC Purenergy of Canada to license the company’s technology for post-combustion capture of CO2 and will take advantage of the series of demonstration projects in which HTC Purenergy are involved.

Other UK companies have been sponsoring research projects internationally

Continuing dialogue between UK power companies and international technology providers such as Fluor, MHI, HTC, Cansolv etc

Research Requirements

LimitedUnderstanding regulatory and legislative requirements

( )Understanding implications for CCGTs

Limited -site specificUnderstanding Engineering issues for retrofit

Understanding implications for power plant flexibilty, grid code and commercial

Developing modelling capability

Improvement in process technology / reduction in efficiency penalty

Evaluating technologies

Gas cleaning requirements

Site specific research needed

Process integration and optimisation

Understanding process chemistry, corrosion, solvent degradation

Understanding environmental issues (emissions, waste streams)

Understanding and minimising costs and impact on host plant

Conclusions

Coal is likely to be a necessary part of the fuel mix needed for power generation at least until 2030 and action is required from industry to address GHG emissions

A range of capture options is available for fossil-fired plant but all require further R&D investment and assessment

Transportation of CO2 is possible by on-shore or off-shore pipe line or by specially adapted tankers

CO2 storage is possible but a number of technical and legal obstacles need to be overcome

CCS needs to be recognised in the EU ETS to encourage development

More confidence is needed with CCS so risks can be better understood, the regulatory regime is smoothed and requirements for new plant are understood

Public acceptability is a critical issue

Visit us on our web-site:

www.rwe.com RWE Group Research & Development

RWE Forschung & EntwicklungResearch & Development

Contact me: [email protected]

Back up slides

ECO-Scrub ConceptSeveral potential benefits

– potential for net reduction of operating cost due to increased capture efficiency (opex)

– potential for slight reduction in size of post-combustion capture plant (capex)

– reduced-cost retrofit option or potential for savings in new plant through advanced combustion optimisation and reduced boiler size

– may also be able to reduce size of SCR plant

– no issues with air in-leakage

Project39 month project funded by EC Research Fund for Coal and Steel, co-ordinated by RWE npower in collaboration with three universities, two research institutes and three utilities from five EU member statesEnhanced combustion with oxygen and scrubbing

– either no recirculation or partial recirculation of flue gas with replacement of some air by oxygen

• reduces volume of flue gas• enhances CO2 concentration of flue gas

Referencecase

Retrofit Case(post-

combustion)

RetrofitCase

(oxyfuel)

RetrofitCase

(ECOS-Scrub)

Gross electric power MWe 330.67 299.44 357.44 312.19

Gross electrical efficiency % 42.45 38.44 45.89 40.08

Net electric power MWe 304.15 243.43 258.62 248.24

Net electrical efficiency % 39.05 31.25 33.20 31.87

Pumps (electric) MWe 18.15 18.87 20.16 19.27

CO2 compressors (electric) MWe - 21.24 21.24 21.23

Fans and compressors (electric) MWe 8.37 15.9 57.42 23.35

Reboiler duty MWth - 268 - 256.85

O2 in secondary air % vol. 21 21 95 30

Referencecase

Retrofit Case(post-

combustion)

RetrofitCase

(oxyfuel)

RetrofitCase

(ECOS-Scrub)



Referencecase

Retrofit Case(post-

combustion)

RetrofitCase

(oxyfuel)

RetrofitCase

(ECOS-Scrub)





Pumps (electric) MWe



Pumps (electric) MWe 18.15 18.87 20.16 19.27



18.15 18.87 20.16 19.27



Reboiler duty MWth - 268 - 256.85

O2 in secondary air % vol. 21 21 95 30Data courtesy of CERTH/ISFTA, National Technical University of Athens

Output of simulations for a lignite-fired power plant

Post-combustion capture at Didcot

Testing different flue gas compositions.Parametric tests of solvent loading and desorption temperature and pressure.Alternative solvents e.g. MDEA, hindered aminesValidation of baseline process economics and assessment of plant flexibility

SpecificationTreat 33% of 0.5 MW CTF flue gasCarbon dioxide removal using MEA of 1 tonne per day (>85%)SO2 and NOX pre-treatment

Test programmeComparison of energy requirements for range of solventsCompatibility with bio-mass

Multiple solvent sampling locationsProvision for corrosion and alternate material test sites

Overview of oxyfuel programme

Desktop Studies

Regulation issues – CO2 purity limits for oxyfuel

Pre-investment issues compared with post-combustion capture

Required footprint for retrofit (e.g. air separation unit)

Safety Fuel Issues

Process Development

OptimisationAir leakage

Optimum recycle ratio

Air heater design

Optimisation of mixing strategy (where to add oxygen (PA/SA/TA or overfire air etc.)

Gas recirculation

Oil burner operation on oxyfuel

Flexibility - start-up/shutdown limited by air separation unit so cold-start on air

CTF StudiesSelection of coals (optimise purchasing)

Use of biomass

Furnace slagging

Furnace Corrosion

Fouling

NOX chemistry not well understood)

Heavy metal recycling and ash composition

Safety handling and storage of O2 and CO2

Flame detection issues (higher moisture and CO2 may affect UV and IR absorption)

Safety of mixing oxygen/CO2

Flame stability

Safe switch-over the oxyfuel combustion

Safety of staff with CO2 / and flue gas leaks

Purging for safetyBurner design

Carbon burnout

Heat transfer (radiative/convective properties)

Schematic of CTF

Amine Test Rig Process Flow Diagram

What is an Amine?

Ammonia (NH3) in which one or more hydrogen atoms have been replaced by organic groups.

Monoethanolamine

MEA or 2-aminoethanol C2H7NO or NH2.CH2.CH2OH

OHHN

H

Methyldiethanolamine (MDEA)

CH3

NHO

OH

apgtf uk post combustion carbon dioxide capture r&d …...what is post combustion capture (pcc)?...

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