cfb technology solutions for co2 capture presentations/1_occ3_hotta_20130703...- inlet gas velocity=...
TRANSCRIPT
CFB Technology Solutions for CO2 Capture
September 10-13, 2013, 3rd Oxy-Fuel Combustion Conference, Ponferrada Spain
Arto Hotta, Foster Wheeler Energia Oy
• Where are we today with CFB technology
– Atmospheric CFB
– OXY-CFB - Flexi-Burn™
– Challenges and potential to improve 1st
generation OXY-CFB
• Emerging technologies
– 2nd generation OXY-CFB - High-O2 design
– BioCCS
– Carbonate looping
– Chemical looping
• Conclusions
Presentation Outline
1
Where Are We Today with CFB Technology
2
CFBs Has Succesfully Entered in Utility Market
Pilot Plant Oriental Chem
General Motors
Tri State
Vaskiluodon Voima
Nova Scotia
Turow 1
JEA
0
100
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600
700
800
1979 1981 1984 1986 1987 1990 1993 1998 2001 2009 2015
Unit Size in MWe's
Unit Start-up Year
Lagisza SC
Global CFB Market Share over 2007-2011
Source: FW sales database and FW-McCoy database for FW served markets
FW 68 %
Others 32 %
All CFB's
FW 91 %
Others 9 %
CFB's over 200 MWe
Samcheok USC 4 X 550 MWe UNITS
3
Foster Wheeler CFB Evolution
Sold 415 CFB Units, (32 GWe) logging over 30 million hours of operation
Samcheok 4 x 550 MWe
Coal & Biomass Co-Fired Supercritical CFB Project
• 4 x 550 MWe supercritical OTU-CFB
to feed 2 x 1100MWe turbines
– 437/356 kg/s, 25.6/5.4 MPa, 603/603 °C
– Efficiency 42.4% (net)
• Fuel flexibility
– Lignite/subbituminous coal max. 5%
share of wood pellets
• End client:
KOSPO, Korean Southern Power Co. Ltd.
• Foster Wheeler scope:
Basic design of boiler plant and delivery
of hot loop pressure parts etc.
• Contract signed (NTP): June 2011
• Commercial operation: 2015
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Cu
mu
lati
ve
Th
erm
al
Ca
pa
city
[G
Wth
]
Delivery year
Coal Is the Dominant Fuel for CFB
Fuel Flexibility the Main Driver
Jyväskylä 2013
Coal70 %
Biomass10 %
Waste3 %
Peat5 %
Petcoke11 %
Oil-shale1 %
CFB’s fuel flexibility is available for oxy-fuel
5
Sold 415 CFB Units, (32 GWe) logging over 30 million hours of operation
6
OXY-CFB technology has been succesfully tested for carbon
capture in large pilot scale at the CIUDEN Technology
Development Plant.
FUEL
PREPARATION
BIOMASS
GASIFIER
PC BOILER
20 MWth
CFB
BOILER
30 MWth
TECHNICAL
BUILDINGS AND
CONTROL ROOM
FLUEGAS
CLEANING
FLUE GAS
RECIRCULATION
AND MIXING
CO2
PURIFICATION
CO2 TRANSPORT RIG
CFB for Oxy-Fuel - Flexi-Burn™ CFB
PO
mixer
SCAH
HRC
To CPU
Oxygen
SO
Boiler house
• 300 MWe Flexi-Burn CFB
boiler has been developed in
the OXY-CFB-300
Compostilla project.
• The capture technology is
considered ready for
demonstration in large
commercial scale.
• The same advantages as
with atmospheric CFB are
expected for oxy-fuel
combustion
7
OXY-CFB-300 Boiler Scale-Up
Parameter Unit CIUDEN OXY-CFB-300 Lagisza
Furnace dimensions
Height m 20 37 48
Width m 2.9 28 27.6
Depth m 1.7 7 10.6
Number of separators - 1 4 8
Thermal power(1
Oxy mode (max.) MW 30 708 --
Air mode MW 14.5 647 966
Steam parameters(2
SH steam flow t/h 47.5 845 1300
SH steam temperature °C 250(3
600 560
SH steam pressure bar 30 279 275
RH steam flow t/h -- 745 1101
RH steam temperature °C -- 601 580
RH steam pressure bar -- 56.5 50.3
Feedwater temperature °C 170 290 290
Notes: 1) At CIUDEN fuel input; in others heat to steam
2) Steam parameters in Lagisza at turbine inlet
3) After spraying
8
TECHNICAL risks are manageable and can
be solved in demonstration and further R&D
– Long term reliability and performance
– Integration and efficiency
improvement
– Dynamics and load change flexibility
– Boiler materials
– Widening fuel experience
BUT:
– CCS has to prove its merits and the
safety of storage to public
– High costs are evident and will remain
higher than conventional technology
> business case
What Is Needed from
Commercial Demonstration and Future R&D
9
Emerging Technologies for CO2 Capture
10
• BioCCS
• 2nd generation
OXY-CFB - High-O2 design
• Chemical looping
• Carbonate looping
Emerging CFB Technology Solutions for CO2 Capture
11
• Biomass cofiring was tested in
CIUDEN
• OXY-CFB allows same fuel
flexibility as air fired CFB.
• Additional work needed to verify
agglomeration, corrosion etc.
• For CCS large unit size will not
favor 100% biomass but cofiring
with coal will be a realistic
option.
BioCCS
12
-200
0
200
400
600
800
1000
Average Europe
CFB today CFB today+20%
biomass
CCS CCS+20% biomass
CO2 emission (g/kWh)
Carbon sink?
BioCCS - Impact of Efficiency Improvement
Biomass Co-Firing and CCS on CO2 Reduction
-21%
-37%
-91%
-120%
CFB’s fuel flexibility is
available for oxy-fuel Oxy CFB 300
95 gCO2/kWh
13
2nd Generation OXY-CFB - High-O2 Design
O2 40 %
52 x 29.7 x 9.5
O2 24 %
H x D x W (m)
• Development of OXY-CFB with
higher oxidant O2 up to 40%
ongoing in O2Gen project funded
by EU FP7 • To be tested in CIUDEN
• High O2 will result in
– Reduced flue gas recirculation
and flue gas volume
– Reduced fan power
– Reduced CAPEX of the boiler
– Challenge to pack heat surface in
CFB hot loop - 40 % O2
maximum
– Not possible to operate in air
mode 14
42 x 41.8 x 10.5
Design comparison of 40% and 24% O2 content in oxidant
-50%
-31%
+38%
-41% -34%
• Carbonate looping works with CFB’s
– Carbonator is a CFB reactor
– Calciner is oxy fired CFB
• Carbonate looping has been operated with coal
in 1 MWth pilot CFB units both by
Epple (TU Darmstadt) and in 1.7 MWth pilot
by Abanades (CSISC Incar)
– Both have reported stable operation and high
CO2 reduction on coal firing
• Provides potential to reduce efficiency penalty
Carbonate Looping
16
CARBONATORT = 650 °C
CALCINERT = 900 °C
Flue gas from power plant
Decarbonised flue gas
CaCO3
CaO
CO2 to compression
Ash and deactivated
material
Oxygen
Fuel
Make-upCaCO3
24
m
Campaign Coal
• Max. CO2 absorption carbonator: 88 %
• Max. total capture efficiency: 93 %
Results of 20 hours of CO2 capture (calciner coal-fired)
Carbonator Calciner
CO2 absorption carbonator
Total CO2 capture
O2 inlet concentration
CO2 conc. in calciner flue gas
Energy Systems
and Technology Prof. Dr.-Ing. B. Epple
COORETEC Project “LISA” - Limestone based Absorption of CO2
17
Typical example of steady state tests (CSIC-INCAR)
CARBONATOR
- Average carbonator temperature= 660 ºC
- Inlet gas velocity= 3.5 m/s
CALCINER
- Average carbonator temperature= 915 ºC
- Average gas velocity= 4.7 m/s
0.0
0.2
0.4
0.6
0.8
1.0
19:00 19:30 20:00 20:30 21:00 21:30 22:00 22:30 23:00
CO
2 c
aptu
re e
ffic
ien
cy
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Car
bo
nat
or
CO
2 (
%)
CO2 equilibriumCO2 experimentalCO2 inCO2 out
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Cal
cin
er
CO
2
(%)
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10
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40
50
60
Cal
cin
er
SO2
(pp
m)
CO2 out
SO2 out
Source: Spanish Research Council (CSIC-INCAR), Oviedo, Spain
18
Results
CARBONATORT = 650 °C
CALCINERT = 900 °C
Flue gas from power plant
Decarbonised flue gas
CaCO3
CaO
CO2 to compression
COMBUSTORT = 1000 °C
FuelAir
Heat
Standard carbonate looping
Indirectly Heated Carbonate Looping Process
19
• Both Epple and Abanades have
developed advanced carbonate
looping process for CO2
capture to avoid ASU.
• Different solutions for calciner
heat introduction.
• Needs CFB carbonator and
CFB combustor.
Air Coal
CaO
+
CaCO3
Hot
CaO
CO2
Flue Gas
CaO
CFBC> 950 ºC
Carbonator650 ºC
Calciner~900 ºC
Flue gas (low CO2)
CaO CaO
CaCO3
Chemical Looping
20
TU Darmstadt
• Operated the two CFB's in coupled
mode under hot conditions for more
than 2000 hours.
• CO2 capture rate of more than 90%
have been achieved.
• Stable operation for CO2 capture
with more than 300 h burning
Colombian coal.
RFCS Project ECLAIR - Emission Free Chemical Looping Coal Combustion Process
• First Generation OXY-CFB is ready for demonstration
– Allows operation on oxy and air mode reducing commercial risk of
demonstration.
– Same boiler size and scale-up possible as with air fired CFB.
– CFB offers the same benefits in oxy combustions as in air mode, i.e. fuel
flexibility, in-furnace emission capture etc.
– Allows additional potential for CO2 reduction by cofiring carbon neutral
biomass.
– Potential for savings in fuel costs and use of local fuel.
• BUT
– CCS must be approved by public.
– CCS is economically competive with renewables
– similar support mechanisms could make first demonstrations
economically feasible
Conclusions
21
cont.
• Emerging technologies have been successfully tested in pilot scale
but are far from commercial demonstration
– High-O2 design looks technically feasible. Provides CAPEX and OPEX
savings but looses flexibility for air mode operation. 1st generation CCS
technologies need to be demonstrated before any further steps will be
taken.
– Carbonate and chemical looping has been successfully tested in 1 MWth
pilots with coal. Both will have high scale-up challenges and need
smaller scale demonstation. It is unlikely that any demonstration will be
funded until CCS is commercial reality.
Conclusions
22
The work leading to these results has been co-financed under the European Community’s Seventh
Framework Programme (FP7/2007-2013) under grant agreement n° 239188 and the EEPR09-CCS-
COMPOSTILLA Project (European Union's European Energy Programme for Recovery).
www.fwc.com