futuregen2.0: asu and cpu design and integration
TRANSCRIPT
FutureGen2.0: ASU and CPU design and integration
Fred Lockwood, Etienne Sturm
Air Liquide Engineering and Construction 2nd IEA GHG Oxyfuel Combustion Conference, Yeppoon, Australia, 15th September 2011
The world leader in gases for industry, health and the environment 2
Agenda
Air Liquide’s CRYOCAPTM OXY development roadmap FutureGen 2.0: ASU and CPU design and integration (This material is based upon work supported by the US Department
of Energy under Award DE-FE0005054)
Conclusions
The world leader in gases for industry, health and the environment 3
CRYOCAPTM OXY roadmap priorities AL roadmap priorities:
Low energy consumption process scheme Developing Robust processes Pilot scale demonstration & testing Parallel development of 1st & 2nd generation
technologies
Lab-scale tests Pilot tests
Commercial-scale demonstration
2005 2010 2015
The world leader in gases for industry, health and the environment 4
CO
NC
EP
TU
AL
S
TU
DIE
S
PIL
OT
F
IEL
D
TE
ST
S
LA
RG
E S
CA
LE
P
LA
NT
S
COMMERCIAL PLANTS
2006 2010 2014 2012 2008 2020
Lacq
Callide
FutureGen 2.0
Dust Filtration
CRYOCAPTM OXY Development Roadmap
SaskPower Study
CIUDEN
Updated R&D & Engineering Studies
The world leader in gases for industry, health and the environment 5
Partner in key pilot and large scale projects
Experimental blast furnace with CO2 capture European program, 48 partners AL’ scope: CO2 removal unit (PSA)
ULCOS MEFOS - SWEDEN (Low CO2 Steelmaking
Industrial blast furnace with CO2 capture & storage AL’ scope: CO2 Capture FEED study
ULCOS Florange - FRANCE Low CO2 Steelmaking
30 MWth oxy-combustion boiler with CO2 capture & storage AL’ scope: burner, O2 , CO2 dryer
TOTAL Lacq - FRANCE CO2 Free Steam Generation
20 MWth PC & 30 MWth CFB & PC oxy-combustion boilers
AL’ scope: CPU
CIUDEN – Spain Carbon Capture test facility
210 MWe Oxy-coal Power plant with CO2 capture for CCS
AL’ scope: ASU, CPU & mixer
FUTUREGEN 2.0 – USA Clean coal power plant
30 MWe coal oxy-combustion boiler with CO2 partial capture and storage AL’ scope: ASU, CPU
CS Energy – AUSTRALIA Clean power pilot plant
The world leader in gases for industry, health and the environment 6
Dust - filtration down to very low level
Industrial size plant: 250 000Nm3/h => ~10st/yr AL aim is to mitigate the risk of compressor fouling with
high performance filtration Pilot test facility :
Tested on flue gas from B&W oxycombustion coal fired facility
Ready for scale-up
Tests successfully completed in 2009
The world leader in gases for industry, health and the environment 7
Lacq – Oxy Flue Gas Drying
Key facts: Dryers unit on flue gas from 30MWth natural gas fired
boiler
Test objectives: Adsorbent qualification (ageing, performance) Study of emissions throughout cycle Vessel materials qualification
Test status: <1ppmv H2O attained, campaigns on-going..
The world leader in gases for industry, health and the environment 8
Callide Oxy-fuel project
Retrofit by CS Energy of a 30 MWe PC boiler to oxy-combustion 75tpd CPU, focus on proving 1st generation technologies Technologies demonstrated
Centrifugal compressors Brazed aluminium compact heat exchangers Structured packing for distillation column
Current status: Start-up planned for Q1 2012
The world leader in gases for industry, health and the environment 9
CIUDEN CPU Pilot
CIUDEN CPU will test both 1st and 2nd generation technologies
Key fields for testing will be: Impact of different coals and boiler technology Acid gas washing High performance dust filtration Flue Gas drying Cryogenic purification
Project currently underway, start-up planned for mid-2012
The world leader in gases for industry, health and the environment 10
FutureGen 2.0 - Introduction
Project key facts: 210MWe gross plant 3800mtpd CO2 CPU 3900mtpd ASU Start-up 2015
Schedule Start-up 2015 FEED Phase to start Q4 2011
State of Illinois
2010 2011 2012 2013 2014 2015
Phase 1 - PreFEED
Phase 2 - FEED
Phase 3 – EPC (Detailed Engineering, Procurement & Construction)
The world leader in gases for industry, health and the environment 11
FutureGen 2.0 - Oxyfuel process
Coal
Boiler
Steam; 2400psi, 1000F/1000F
PJFF WFGD
Primary Recycle (PR) Fan
Secondary Recycle (SR) Fan
ID Fan
ASU
Burners
Recycle Damper
Air Intake
Air Intake
Recycle Damper
Cool Recycle Process
CPU
To Storage
Gas
R
ehea
ter
DCCPS
Gas Reheater
Sorbent for SO3
Recycle Heater
Vent
Stack Damper
CPU Damper
Cool recycle process, No SCR
The world leader in gases for industry, health and the environment 12
CPU and ASU in overall plot plan
CPU
ASU
The world leader in gases for industry, health and the environment 13
FutureGen 2.0 – ASU Block Flow Diagram
Extra Low Energy Oxycombustion ASU Optimised to produce LP 96.5% purity oxygen
120
140
160
180
200
220
240
260
2015 Target
2000 Pure O2
2011 OXY LE
2011 OXY XLE
2000 IGCC
Separation Energy in kWh / t O2
Integrationbenefit
-20%
120
140
160
180
200
220
240
260
2015 Target
2000 Pure O2
2011 OXY LE
2011 OXY XLE
2000 IGCC
Separation Energy in kWh / t O2
Integrationbenefit
-20%FutureGen Design
1 train axial compressor
Heat Integration Boiler Feedwater Preheating
GOX to burners
GOX to primary & secondary
Air Purification
Nitrogen Vent
Nitrogen Vent
Cooling Water
Air Booster
Cold Box
Waste Nitrogen
Waste Nitrogen
Cooling Water
LOX Storage
LOX Vaporiser
The world leader in gases for industry, health and the environment 14
FutureGen 2.0 – 3D View of ASU
Cold Box
Front-End Purification
Compressors
The world leader in gases for industry, health and the environment 15
FutureGen 2.0 – CPU Block Flow Diagram
Design based on technologies to be demonstrated at Callide High perf. dust filtration, centrifugal flue gas compressor,
Cold Box technologies (heat exchangers, distillation columns)
Optmised compression using pump
Cold Box
Expander Turbines
Flue Gas Dryers
Flue Gas Compressor
Refrigeration Unit
Process Condensate
CO2 Compressor
CO2 Pump
Supercritical CO2 Product
Flue Gas
Steam
Steam
Dust
Non-condensables to
vent
Turbines for increased energy efficiency
Dryers – design tailored to oxycombustion
High Perf. Filter to protect
compressor
Process Condensate
The world leader in gases for industry, health and the environment 16
Future Gen 2.0 – 3D View of CPU
Dust filtration
Compact layout, optimised to reduce piping quantity
Compressors
Cold Box
Dryers
The world leader in gases for industry, health and the environment 17
Power Plant performance
Near-Zero emissions plant
Emissions Constituent
Reduction vs. air firing(*)
lb/MBtu (HHV)
NOx • ~80% • 1.47x10-2
Particulates (Total) • ~99.9% • 3.1x10-7
SO2 • ~ 90% • 4x10-4
HF • ~99% • 3.4x10-7
Hg • ~99% • 3.1x10-9
CO2 Quality
CO2 Recovery 90% (mass basis)
CO2 mass flow 351 klbs/hr
(4210 st/d / 3820 mt/d)
Pressure 2100 psig
Temperature ~71°F
CO2 content • 99.7% (mass)
Inerts (Ar, N2) • 0.04% (mass)
H2O • 1 ppmw
O2 • 110 ppmw
SOX • 1 ppmw
H2S Negligible
NOX • 1700 ppmw
Hg • 2 ppbw
3800tpd CO2
CO2 Recovery 90%,CO2 Product Purity: 99.8%vol
*: when compared to a state-of-the art air fired PC boiler with AQCS
The world leader in gases for industry, health and the environment 18
Conclusions
Air Liquide has a comprehensive roadmap for CO2 CPU development building on a number of pilots
Oxycombustion is now entering a phase where industrial scale units must be tested
FutureGen 2.0 set to be the first industrial scale test of an oxycombustion power plant Specially adapted ASU design for oxycombustion CPU design based on technologies to be tested at Callide
Thank-you!
For further information please contact: Fred Lockwood Air Liquide Engineering and Construction +33 (0)1 49 83 52 81 [email protected] Etienne Sturm Air Liquide Engineering and Construction +1 713 624 8970 [email protected]