Callide Oxyfuel Project Development and Progress Oxyfuel Project Development and Progress Dr Chris...
Transcript of Callide Oxyfuel Project Development and Progress Oxyfuel Project Development and Progress Dr Chris...
Callide Oxyfuel Project Development and Progress
Dr Chris Spero
Oxyfuel Capacity Building Course – Tokyo Institute of Technology
2 – 3 September 2012
Presentation Overview
•
Project history and structure
•
Process description and permitting
•
Oxyfuel boiler construction
•
Comparison of oxy‐firing with air‐firing
•
CO2 capture plant
•
Future deployment of oxyfuel technology
Project history
Project structure
COP – Work flow
Pulverised Coal Consumption
5.5 kg/s20 tph
Quality HHV: 19 MJ/kg ar
Ash: 21% arMoisture: 14% ar
Sulfur: 0.3% dafAnglo Callide Coal mine
SteamFlow 37.7kg/s or 136 t/h Pressure 4.1MPa, Temperature 460oC
Oxygen (GOX)Purity: 98 vol% Oxygen
Pressure : 180kPa(a)Flow: 7.6kg/s
Size: 2 x nominal 330 TPD Air Liquide Sigma cryogenic ASUs
Recirculated Flue Gases
Flow: 30kg/sCO2: ~67% mass
Chimney Stack
Flow: 13.2kg/sHeight: 76m
CO2 Purification and CompressionCO2 Product: 75t/dayCO2 Purity: 99.9% molCO2 Temperature: -20oC CO2 Pressure: 1,600kPa
Road TransportB Double – 30tSingle Tanker – 20t
Boiler Exit Flue Gases350oC44.9kg/s
Feed Gas to CO2 PlantFlue Gas Processed Flow: 1.7kg/sTemp ~ 150oC
Callide A Demonstration –
Simplified
Stage 1 –
Callide A
•
Exempted from development approval under local
Government Planning Scheme – not deemed to be a
material change of use
•
Amendments proposed to existing Callide A
environmental authority
Vented gas streams from CO2
CPU
Condensates from flue gas scrubber columns
Define additional release points and monitoring
regime
Stage 2 – CO2
road transport
•
Carbon Dioxide (CO2
) is a Dangerous Good (Class 2.2)
under the Queensland Transport Act
Stage 2 – CO2
storage
•
Greenhouse Gas Storage Act 2009 (QLD)
•
Greenhouse Gas Storage Regulation 2010 (QLD)
•
Environmental Protection Act 1994 (QLD
Permitting
Callide A Unit 4 ‐
Original
8
Boiler Plant/Equipment Removed Ready for New Equipment
Walkway to Fabric Filter to Remain
U3 Multiclone to Remain
Cable Tray to Fabric Filters to Remain
9
Callide A Unit 4 ‐
After Oxfuel RetrofitOxygen
Flue Gas Before Air Heaters
Flue Gas After Air Heaters
Flue Gas (Clean after FF bags)
Recycled Gas
Rich CO2 Flue Gas to CPU
Secondary Recycled Gas
Cold Primary Recycled Gas to Mills
Hot Primary Recycled Gas to Mills
v
New Feedwater
Heater
New
Primary
Gas Heater
TO CPU
FROM ASU
1 of 1440
Fabric Filter
(FF) Bags
Dust
FDF = Forced Draft Fan IDF = Induced Draft Fan
CPU = CO2 COMPRESSION & PURIFICATION UNIT
PRE SCRUBBER
H2O Remover
Pumps & Heat Exchangers
Stack
Fabric Filter
IDF(1x100%)
Air
Intake
FDF
(1x100%)
10
Existing
Air
Heater
11
Callide A Unit 4 ‐
After Oxfuel Retrofit
11
Oxy‐firing schematic
FD fan
O2
Oxy‐firing mode changes
Flue Gas Composition Air‐Firing mode O2 Sequence RFG Mode Oxy‐mode
O2 vol %, dry 4.7 6.0 6.8 5.4
CO2 vol %, dry 15.0 16.2 59.9 68.3
CO ppm, dry 18 20 12 12
SO2 ppm, dry 220 230 800 890
NO ppm, dry 550 720 1195 965
NO2 ppm, dry 9 10 45 46
H2O vol % 8 8.5 20.5 21.6
NOx ppm, dry @ 7% O2 480 680 1220 910
NOx ppm, dry @ 12% CO2 445 540 250 180Flue Gas to
Stack kg/s (wet basis) 54 59 15.4 14.0
NOx g/s 43 61 21 15
Air‐firing mode means normal air firing
O2 sequence means increased O2 to the boiler via O2 injection nozzles but no recirculation of flue gas
RFG mode means that the recirculated flue gas sequence has been completed
Oxy‐mode means that on completion of the RFG sequence the overall O2
is reduced to normal levels and full oxy‐mode is
achieved
Flue gas mass balance
Parameter Unit CPU inlet CO2
product
Flow rate kg/s 1.7 0.9
Composition % 65% (CO2) 99.9 (CO2)
Temperature C 145 ‐30
Pressure kPa (abs) 101 1,600
Blower
IDF
FDF
CPU: 1.7 kg/s
Stack:13 kg/s
To boiler:28 kg/s
From boiler:42 kg/s
Carbon dioxide capture plant
Courtesy of Air Liquide
LP ScrubberDriersHP Scrubber
Compressor
Cold box/inerts separators
Oxygen plant CO2
capture plant
COP – Site Works – Oxygen and CO2
Capture Plant
1 year NEDO Study led by IHI together with CS Energy and Air LiquideOption 1 –
1000 MWe Oxyfuel boilerOption 2 – 250 MWe oxyfuel boilerOption 3 – Hybrid Oxyfuel Power Plant (HOPP) concept 750 MW Ultra supercritical boiler +
250 MW ultra supercritical boiler
Hybrid Oxyfuel Power Plant (HOPP) Concept
Concluding comments
1.
Callide Oxyfuel Project – ASU and Oxyfuel plant has been operating since March 2012
2.
Over 300 hours of oxyfuel operation since 22 August 2012
3.
CO2 capture plant commissioning – in progress
4.
NEDO study on future CCS commenced in July 2012
5.
COP is still evaluation options for CO2 storage or sale of CO2 for industrial applications
Thank you
for more information: www.callideoxyfuel.com
Callide Oxyfuel Project –
Participants