DEVELOPMENT AND DEMONSTRATION OF OXY CFB FOR POWER PLANTS WITH CO2

CAPTURECAPTURE

Arto Hotta,Foster Wheeler Energia OyFoster Wheeler Energia Oy

1st International Oxyfuel Combustion Conference, Cottbus, Germany, 7th – 11th September 2009

Contents of Presentation

• Introduction: Oxy CFB boiler (Flexi-BurnTM)Introduction: Oxy CFB boiler (Flexi Burn

• Development of Flexi-Burn CFB technology

• The 300 MWe demonstration project of ENDESA and CIUDEN

"Flexi-BurnTM" is trademark of Foster Wheeler AG

Introduction: Oxy CFB boiler

• Benefits of Oxyfuel combustion in CFBBenefits of Oxyfuel combustion in CFB

• Flexi-Burn CFB boiler

• Challenges for the development

Oxyfuel CFB TechnologyMain BenefitsMain Benefits

• The established CFB advantages exist also in CFB foxycombustion: low furnace temperatures, hot circulating

solids, long solid residence time

• Multi-fuel capability (coal, petroleum coke, lignites, biomasses), simple feed systems – capability to utilize cheap fuelssimple feed systems – capability to utilize cheap fuels emphasized due to CCS efficiency penalties

• NOx and SOx reduction without back-end cleaning• Good fuel burnout and sorbent utilization• Good fuel burnout and sorbent utilization• Efficient heat transfer and uniform heat flux• Enables Flexi-Burn CFB boiler design: the same boiler can be

t d i i fi i fi i d ith CCSoperated in air firing or oxy firing mode with CCS

Further potential to use high O2 contents

• Reduce boiler size• Limited capability for air firing

Flexi-Burn CFB Power Plant

N (Ar)• 1st generation OXY CFB

Flue gas recycle

AirAir separation

N2, (Ar)

95-97% O2, (Ar, N2)with oxygen content of the oxidant close to air firing

• Boiler designed to be capabable for both oxy

Flexi-Burn CFB

boilerFlue gas cleaning

CO

Fuels CO2/H2O

H O

CondensationCompressionPurification

Vent gas

capabable for both oxy and air firing

• Oxy-ready design for subsequent

Steam turbine

CO2

G

H2O

TransportStorage

qimplementation of CCS

• The plant can be built in functional stages

• Retrofit possibility

Challenges of Oxyfuel CFB technology

• Understand the significant change in gas atmosphere in OXY modeOXY modeChanges in hydrodynamicsBehaviour of materialsEmissions predictionAdaptation of design toolsAdaptation of design tools

• Achieve high gross efficiency to minimize penaltyAim at steam parameters > 600 °C, 270 bar

• Reduce oxygen production costs• System-level integration to reduce investment costs and

to improve efficiency

Oxy-fuel CFB is considered technically viable Experiments in bench scale and pilot test facilities combined with modelling required to confirm the Experiments in bench scale and pilot test facilities combined with modelling required to confirm the process performance and material behaviour in the CO2 rich atmosphere Demonstration in 10’s of MW scale and commercial scale required to proof the concept - design, performance and economics

Development of Flexi-Burn CFB technology

• Roadmap for Oxy CFB developmentRoadmap for Oxy CFB development• Piloting (laboratory scale, CANMET, CIUDEN)• Feasibility studies

Development of OXY CFB TechnologyI t t d E i t l d M d li W k f S l UIntegrated Experimental and Modeling Work for Scale-Up

Bench scale Pilot scale Boiler scale10 MW scaleCIRCULATING FLUIDIZED BED REACTOR

S e c o n d a ryc y c lo n e

G a s c o o l in g

P r im a ryc y c lo n e

O b s e r v a t io n p o r tS a m p l in g p o r t/D e p o s it p ro b e

Z o n e 3

Z o n e 4T o s ta c k

O b s e rv a tio n a n d s a m p lin g p o r t/D e p o s i t p ro b e

S a m p l in g p o r t

B E N C H S C A LE R E A C TO R (B F B /C F B )

Fue l batch feed

C oo ler/h eater

C oo ler C yclone

F ilte rTo S tack

B E N C H S C A LE R E A C TO R (B F B /C F B )

Fue l batch feed

C oo ler/h eater

C oo ler C yclone

F ilte rTo S tackFue l batch feed

C oo ler/h eater

C oo ler C yclone

F ilte rTo S tack

ŁAGISZA 460 MW e supercritical OTU CFB

EXPERIMENTAL SCALES

F u e l c o n ta in e r 1 a n d 2 Z o n e 1

Z o n e 2

Z o n e 3

S a m p lin g p o r t

S a m p lin g p o r t

A d d i tiv ec o n ta in e r

O 2

S e c o n d a ry g a s(p re h e a te d )

P r im a ry g a s h e a t in g

C O 2 / N 2

P C c o n tro l a n d d a ta lo g g in g s y s te mP C c o n tro l a n d d a ta lo g g in g s y s te m

S a m p l in g p o r t

A ir

A ir

O 2, C O 2, C O , N 2 , S O 2 , N O

S econda ry a ir

C o ntinuousfue l feed

P rim a ry gas heatingPC con tro l and da ta logg ing sys tem

A ir

O 2, C O 2, C O , N 2 , S O 2 , N O

S econda ry a ir

C o ntinuousfue l feed

P rim a ry gas heatingPC con tro l and da ta logg ing sys tem

A ir

O 2, C O 2, C O , N 2 , S O 2 , N O

S econda ry a ir

C o ntinuousfue l feed

P rim a ry gas heatingPC con tro l and da ta logg ing sys tem

SCALES

COefCO Ykt

Y

dd

nrefv ddTAb )/)(/exp(

M d l CO combustionVol

atile, m

oisture

releas

e

1D -M O D E Lflue g a s

n n+ 1

to s ta ck

n-1

n-2

MODELS ANDn

c Xkmtm

r O2cc

dd

ftd)/1/(1 mCOef kk

Modelanalyses

CO combustionMixingChar combustion

k W /m 2

1Prim ary a ir

S econ da ry a ir

2

3

kW /m 2

Models for 1-D process models 1-D design model

MODELS AND DESIGN TOOLS

Models for phenomena

1-D process models (stationary, dynamic)

1-D design model3-D process model

Development of Flexi-Burn CFBMain ActivitiesMain Activities

• Of the main CCS technology options, Foster Wheeler is mainly focusing on oxy fuel combustion having been developing it since 2003:oxy-fuel combustion, having been developing it since 2003:

• Knowledge and design tool development• Test activities (VTT bench scale & small pilot CFB)• Conceptual and feasibility studies (boiler design)Conceptual and feasibility studies (boiler design)

• Pilot test activities at larger scale facilities • ~0.1 MWth (current) → ~1 MWth CANMET (2009) → 30 MWth CIUDEN (2010-11)

• In parallel, scale-up of air-fired CFB boilers has continued. The world largest and first SC-OTU CFB at PKE’s Lagisza plant in Poland is in commercial operation and and FW has developed the OTU CFB boiler concept further up to 600-800 MWe size with 600 °C steam temperature.

• The Spanish government has decided on investment for the CIUDEN 30 MWth class pilot CFB facility, which provides a full experimental CCS platform for the demonstration and validation of oxy/air fuel combustion in sufficient scale to allow continuation to commercial scaleallow continuation to commercial scale.

Development of Flexi-Burn CFBMain Activities

•The Oxy-CFB 300 MWe project of ENDESA and CIUDEN aims to be one of the 10 -12 CCS commercial size demonstration plants in Europe

Main Activities

-12 CCS commercial size demonstration plants in Europe.• FW prepared a feasibility study for the 500 MWe Oxy CFB Power plant with CCS • FW will provide the technology for the CFB boiler

• Feasibility studies with other utilities• Vattenfall 500 MWe CHP power plant with Oxyfuel CFB

• PVO 500 MWe multifuel Oxy ready CFB plant (biomass cofiring)• EU FP7 project "FLEXI BURN CFB” aiming at the development of technology to be ready for demonstration

•FW participates in the development of 50 MWe Oxy-CFB demonstration project at Jamestown plant in New York state and the 78 MWe Oxy-CFB project developed by Praxair and New Holland Board of Public Works.

Development of Flexi-Burn CFBScale Up PathScale-Up Path

Commercial scale Fl i B O CFBFlexi-Burn Oxy CFB

technology demonstration in

The 300 MWe demonstration project of ENDESA and CIUDEN

• ENDESA Generación and CIUDEN are promoting a CCS integral Commercial Demonstration Project, including CO2 capture, transport andCommercial Demonstration Project, including CO2 capture, transport and storage, based on a circa 323 MWe Circulating Fluidised Bed (CFB) supercritical oxycombustion plant, with CO2 storage in a saline aquifer.

• The main target of this Demo project is to validate, at commercial plantThe main target of this Demo project is to validate, at commercial plant size, a CCS technology that will allow the renovation of the existing fossil thermal plants from 2020, using a wide range of domestic coals, as well as imported fuels (coals, pet coke…), and biomass.

•The proposed project programme has been divided in two periods: Technology Development and FEED studies (2009-2011) and the construction of the Demo project infrastructure including capture transport and storage concepts (2012- 2015).t a spo t a d sto age co cepts ( 0 0 5)

• The schedule of the proposed project considers that the Final Investment Decision (FID) of the integrated project will be taken by the end of 2011, once all the final studies (technical, economical, risks, etc.), financial and ( , , , ),permitting issues are finally cleared.

The 300 MWe demonstration project of ENDESA and CIUDENThe 300 MWe demonstration project of ENDESA and CIUDEN

ENDESA has signed (2007) cooperation agreement with FOSTER WHEELERENDESA has signed (2007) cooperation agreement with FOSTER WHEELER ENERGIA SA (FWESA) to participate in the scale-up validation program as well as on the expected construction of the Commercial Demo Plant.

ENDESA and CIUDEN have agreed to establish a Joint-Venture to start theENDESA and CIUDEN have agreed to establish a Joint Venture to start the development of the Commercial Demo Plant jointly with Foster Wheeler

•The technology provider is the Finland based FOSTER WHEELER ENERGIA Oy, responsible of the basic design of CFB units.responsible of the basic design of CFB units.

•In order to support the development, CIUDEN is constructing an Integrated CCS Technology Development Plant in Compostilla featuring a 30MWth Oxy-CFB using exactly the same technology to be incorporated by the commercialCFB using exactly the same technology to be incorporated by the commercial scale demo plant.

CIUDEN - an integrated Technological Development Plant (TDP)(TDP)

A l t t tA complete test program will be carried out in this plant, with the aim of validating the full chain of

f f lprocesses from fuel preparation to CO2purification, producing an stream ready for transport

d t i d tand storage in order to obtain enough data for scaling-up the technology.

The TDP is located next toThe TDP is located next to the Compostilla power plant

CIUDEN - an integrated Technological Development Plant (TDP)(TDP)

The TDP has been engineered to test the integrated operation of

PHASE IIO2 STORAGEAND

VAPORISATIONFROM COAL

PREPARATION

20 MWth PC BOILER

STACK

ABSORPTIONSECTION

PHASE IIPHASE IIO2 STORAGEAND

VAPORISATIONFROM COAL

PREPARATION

20 MWth PC BOILER20 MWth PC BOILER

STACKSTACKSTACK

ABSORPTIONSECTION

ABSORPTIONSECTION

integrated operation of • the coal and limestone preparation and

feeding, biomass in the 2nd phase• circulating fluidised bed oxycombustion,

f /

PREHEATINGTRAIN

AIR

DeNOX

FGR1

15-30 MWthCFB BOILER

FGR2

PCBIN

CO2COMPRESSION TRAIN

CO2

PREHEATINGTRAIN

PREHEATINGTRAIN

AIRAIR

DeNOXDeNOX

FGR1FGR1

15-30 MWthCFB BOILER 15-30 MWthCFB BOILER

FGR2FGR2

PCBINPCBIN

CO2COMPRESSION TRAINCOMPRESSION TRAIN

CO2CO2

• flue gas recirculating/mixing and heating devices,

• flue gas cleaning • CO2 compression and purification units

O2PREHEATING

HIGHEFFICIENCY

DeSOXCFBBINC

MIXERS

BAG FILTER

BAG FILTER

EXPANDER

O2PREHEATING

O2PREHEATING

HIGHEFFICIENCY

DeSOX

HIGHEFFICIENCY

DeSOXCFBBINCCFBBINC

MIXERSMIXERS

BAG FILTERBAG FILTER

BAG FILTERBAG FILTER

EXPANDEREXPANDER

CO co p ess o a d pu cat o u tsand

• auxiliary services, to provide the necessary technical support for its application in the OXY-CFB-300 power

FGR2 RECIRCULATION

FGR2 RECIRCULATION

FGR2 RECIRCULATION

FGR2 RECIRCULATION

FGR2 RECIRCULATION

FGR2 RECIRCULATION

application in the OXY-CFB-300 power plant.

• The TDP also incorporates a PC oxyboiler

SummarySummary

• CFB is very well suited for Oxy-firing

• The benefits of air-fired CFB technology are available for Oxy operation

• Flexi-Burn CFB allows operation of the l t b th i d i dplant both in oxy and air mode

• The Oxy-CFB development targets to have the commercial scale CCS

www.oxygenie.com

have the commercial scale CCS demonstration plant in operation in 2015

Thank You!

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