Current Status and Developments in Carbon Capture ... · Convective Section of the boiler MILL COAL...

Current Status and Developments in Carbon Current Status and Developments in Carbon Capture Technologies for Power GenerationCapture Technologies for Power Generation

(What are the Challenges Involved)(What are the Challenges Involved)

by:

Stanley SantosIEA Greenhouse Gas R&D Programme

Presented at:

CO2 Capture and Storage (CCS) – A Global Business Vision(Indonesia CCS National Workshop)

30th October 2008Jakarta, Indonesia

http://www.ieagreen.org.uk*Corresponding Author’s Email: [email protected]

Presentation OutlinePresentation Outline• Overview to Carbon Capture Technologies and

current R&D Activitiescurrent R&D Activities○ Post-Combustion Capture○ Oxy-Combustion Capture○ Pre Combustion Capture

• Some of the key issues looking onto the different capture technologiesp g

• CO2 Transport and its Challenges• Concluding Remarkshttp://www.ieagreen.org.uk 2

• Concluding Remarks

Overview to Different Leading Overview to Different Leading COCO22 Capture Technologies for PowerCapture Technologies for PowerCOCO22 Capture Technologies for Power Capture Technologies for Power

GenerationGeneration

http://www.ieagreen.org.uk

Current View on CCS and Efficiency IncreaseCurrent View on CCS and Efficiency Increase

CarbonReduction

`Zero Emissions`Trajectory

Key issue will be value of CO2

`IncreasedIncreasedEfficiency`Trajectory

Zero emissions will need the most efficient plant

TimeNear term Mid t L t

http://www.ieagreen.org.uk 4

TimeNear-term Mid-term Long-term

COCO22 Capture technologiesCapture technologiesGeneral OverviewGeneral OverviewGeneral OverviewGeneral Overview


Figure adapted from BP

PostPost Combustion CaptureCombustion CapturePostPost--Combustion CaptureCombustion Capture


PostPost--Combustion CaptureCombustion Capture

CapturePower generation

Air N2, O2, H2O to atmosphere

Fuel Boiler or gas turbine

Solvent scrubbing

(FGD)turbine scrubbing

Steam

PowerCO2 to storageSteam

turbineCO2

compression


Chemical Absorption ProcessChemical Absorption Process


COCO22 Based Solvent ScrubbingBased Solvent Scrubbing• Use of Amine scrubbing to capture CO2 is the most mature among the 3

mostly considered capture technology options for the power generation.• Amine based solvent is currently the commonly used for CO2 capture

○ widely used in food processing (ie. carbonated drinks) and chemical industries (ie. Urea plant)( p )

○ Large scale demonstration (> 1 MT/yr of scale) – mostly in oil and gas fields applications

○ For example in Sleipner and In Salahp p• Current R&D Focus

○ Development of new type of solventsDe elopment is also on going for application to coal fired po er plant○ Development is also on-going for application to coal fired power plant


pMHI’s Evolution Development of Flue Gas CO2 Recovery Plant

00 01 090807060504030299989796959493929190Evolution

1 Ton/Day

Coal FiredFlue Gas

Application

yPilot Test Completed

Long Term Demo. Plant

Test Starts

3000 Tonnes /Day 6000 Tonnes/Day

Large Scale DemonstrationPlant Design Ready

1 Ton/Day Pilot Plant

Long Term Demo. Plant

Enlargement

3000 Tonnes /DayDesign Completed Design Completes

FGD

Nanko Pilot Plant (2 Tonnes/day)R&D for Process Improvement

3000 Tonnes /Day PlantLarge Scale Test Plant

Experience

Start of Development

CommercialPlant

Malaysia Kedah (200 Tonnes/day)Japan, Chemical Company

(330 Tonnes/day)India, Fertilizer Company

(450 Tonnes/day x 2)

10

(450 Tonnes/day x 2)Abu Dhabi, Fertilizer Company

(400 Tonnes/day)330 Tonnes/day PlantMalaysia kedah Plant

R&DR&D EffortEffort inin EuropeEurope• Castor / Caesar Post-

Combustion Pilot Plant Projectj○ Installed at the Esbjerg Power

StationPil t C it 1000 k CO• Pilot Capacity: 1000 kg CO2per hour (25 TPD)

• 5000 Nm3/h flue gas (coal• 5000 Nm3/h flue gas (coal combustion)

• Now in operationNow in operation○ started in March 2006○ both MEA and 2 types of

“C t ” S l t l t d


“Castor” Solvents were evaluated

Vattenfall’s CCS demo project at Nordjyllandsværket

Nordjyllandsværket

Vattenfall s CCS demo project at Nordjyllandsværket

jy

Vedsted On-shore StructureTransport by pipeline

On February 6, 2008 Vattenfall On February 6, 2008 Vattenfall Nordic Thermal Power Nordic Thermal Power Generation announced the Generation announced the intention to develop a fullintention to develop a full--scale scale Carbon Capture & Storage Carbon Capture & Storage (CCS) demonstration project(CCS) demonstration project

© Vattenfall ABIEA Greenhouse Gas R&D Programme 11th MEETING of the INTERNATIONAL POST-COMBUSTION CO2 CAPTURE NETWORK20th-21st May, 2008, Vienna, Austria

Some Other Current ActivitiesSome Other Current Activities• UK (2014) – investment decision by next year.

○ BERR CCS Competition (4 of 9 bidders selected as semi-finalists)BP (revival of Peterfields and Miller Field???)EOn UK (Kingsnorth Project) – Arup, MHI, Flour, EPRI, Tullow oilPeel Power (Peel Holding Dong Energy Mott MacDonald)Peel Power (Peel Holding, Dong Energy, Mott MacDonald)Scottish Power (Longannet Project) – Aker Kavaerner, Marathon oil

• Germany (2012) – investment decision by next yeary ( ) y y○ Vattenfall’s Janschwalde Project

• Doosan Babcock partnership with HTC Purenergy / EESTechp p gy○ China Project in the pipeline: 330 MWe of Tainjin DaGang Huashi

Power Generation Co. Ltd.


• … (many more) …13

PostPost--combustion capture: KEY ISSUEScombustion capture: KEY ISSUES• Solvent life

○ Requires very low SOx (< 10 ppm) and NO2 (< 20 ppm)○ Solvent could be very expensive – target: lower solvent losses

• Corrosion• Corrosion○ Stainless steel v carbon steel○ Inhibitors can contain V, Sn, Sb (antimony)

• Energy consumption○ Regeneration of solvent○ Regeneration of solvent

• Environmental impacts


○ Some degradation products known and regulated; others are not.

Future Direction of ResearchFuture Direction of Research• Cost and Process Optimisation of the current MEA based Technologies

○ Design of the Absorption columng p○ Reduction of Energy consumption of the regenerative column

• Improvement of Current solvents○ Improving kinetics○ Improving additives to reduce degradation

• Development of new solventsDevelopment of new solvents○ For Examples: Chilled Ammonia process, Cansolv solvent, KS2, etc...

• Environmental Impact Assessment○ Impact assessment due solvent degradation○ Fugitive emissions (especially NH3 as one of the by-product of degradation)


OxyOxy Coal Combustion TechnologyCoal Combustion TechnologyOxyOxy--Coal Combustion TechnologyCoal Combustion Technology


OxyOxy--Coal Combustion TechnologyCoal Combustion Technology

Air ti

Air

yy gygy

separation

Oxygen VentRecycled flue gas

Fuel Boiler Purification/ i

Cooling

Oxygen

CO2compression(+FGD)

Steam

PowerSteam turbine


turbine

Convective Section of the boiler

MILL

COAL

HPADVANCED

SUPERCRITICAL BOILER

Convective Section of the boiler• heat transfer profile• ash deposition and fouling issue

Burner design issue• Ignition• flame stability• devolatilisation & char burnout

HP HEATER

MILLSTACK (START

UP)

devolatilisation & char burnout

ID FAN

DEAERATOR

IP

ESP

DEAERATOR

LP

FGD

Radiant Section of the Boiler• heat transfer profile• slagging issue• fireside corrosion issue

HP PUMP

CONDENSORPrior to any retrofit of carbon capture technology it is essential to repowerLP HEATER

COLD FD FAN

LP PUMP

technology, it is essential to repower the plant in order to achieve the

highest possible efficiency

18

AIR IN

COAL

HP HEATER

MILL

3

STACK (START

UP)

COAL

NITROGEN

ASU

ADVANCED SUPERCRITICAL BOILER

HP

4HEATER

ID FAN

AIR

IP

2

ESP

DEAERATOR

LP

SECONDARY RECYCLE

PRIMARY RECYCLE

OXYGEN

HP PUMP

4FD /

RECYCLE FAN

GAS

/

GAS

LP

CONDENSOR

Gas / Gas

Heater

LP HEATER GAS DRIER

AIR INTAKE

START UP

COLD PA FAN

LP PUMP

CO2 PRODUCTFOR1 2 3 4

1 - IP STEAM BLEED 2 - HEAT FROM ASU ADIABATIC MAC 3 - CO2 COMPRESSOR STAGE HEAT 4 – FLUE GAS FEEDWATER HEATING

GAS COOLER & WATER REMOVAL

CO2 PRODUCT FOR COMPRESSION

3 4

CO2 PURIFICATION

INERTS3

19

OxyOxy--Combustion TechnologyCombustion Technology• Use of oxygen instead of air in a boiler – “Oxy-

Combustion” is the least mature among the 3Combustion is the least mature among the 3 mostly considered capture technology options for th tithe power generation.

• 3 key development issues○ Boiler and burner development○ Air Separation Unit – “Cost and capacity of oxygen y yg

production”○ CO2 processing – “Removal of impurities”


ANL ANL -- EERC StudyEERC StudyWorld’s 1World’s 1stst OxyOxy--Coal Pilot Scale StudyCoal Pilot Scale StudyWorld s 1World s 1 OxyOxy--Coal Pilot Scale StudyCoal Pilot Scale Study

Tower Furnace (~ 3MWTower Furnace (~ 3MWthth))


Coal Flame Photos:Coal Flame Photos:Air Fired vs OxyAir Fired vs Oxy--FiredFired

(Courtesy of IHI)(Courtesy of IHI)

Air mode（O2：21%）


Oxy mode（O2：21%） Oxy mode（O2：30%）

Recycle Ratio = 0.58(~ 0.61 include the CO2 to transport coal)

O2-RFG flame with recycle ratio = 0.58

O2-RFG flame with recycle ratio = 0.76

Recycle Ratio = 0.76

2 y

Courtesy of IFRF

11stst Large Scale OxyLarge Scale Oxy--Coal Combustion ExperienceCoal Combustion Experience(International Combustion Ltd.)(International Combustion Ltd.)

35 MWth Low NOx burner35 MWth Low NOx burner

Although it was not able to achieve the desirable CO2 composition – the first combustion trial gained significant


combustion trial gained significant experience in burner start up

OxyOxy--Combustion TechnologyCombustion TechnologyOxyOxy--Combustion TechnologyCombustion Technology

What are the Enabling Studies in the near future that will provide a big step forward for Oxy-Coal Combustion…


VattenfallVattenfall SchwarzeSchwarze PumpePumpe Pilot ProjectPilot Project

2009 2010 20112005 2006 2007 2008

Time Table for Implementation of Oxy-Fuel Project

Pre- and Order planning

Permission planning

Execution planning

Commissioning

Erection

Operation

C t f V tt f ll


Courtesy of Vattenfall

Callide A Project: Callide A Project: JapaneseJapanese Australian CollaborationAustralian CollaborationJapaneseJapanese--Australian CollaborationAustralian Collaboration

Nth Denison Trough

C llid A P St tiCallide-A Power Station Capacity: 4 x 30 MWe Commissioned: 1965 – 1969 Refurbished: 1997/98 Steam Parameters: 4.1 MPa, 460oC Steam Flowrate: 123 t/h steam

Fi 2 L ti f C llid A P j t A Pl d t fit t l fi d l t ith b ti b il


Figure 2: Location of Callide-A Project. A Planned retrofit to a coal fired power plant with an oxy-combustion boiler

OxyOxy--Combustion: KEY ISSUESCombustion: KEY ISSUES• Air Ingress

○ Estimated that every 1% of air ingress should result to about 3-5% reduction of the CO2 concentration in the flue gasof the CO2 concentration in the flue gas.

○ Several failures have been noted from previous experiences of not reaching the desired concentration of CO2 due to air ingress.

○ This is a big challenge especially retrofitting a power plant○ This is a big challenge especially retrofitting a power plant.• Boiler and Burner Development

○ We need to build our confidence in running an oxy-fired burner/boiler especially at the same scale of our current PC boilerespecially at the same scale of our current PC boiler.

○ Various technical issues elucidated - these include heat transfer aspect, ash and slagging, equipment scaling up, emissions control, etc…

○ Largest burner test as of today operated with oxy-firing mode for coal was g y p y gdone by International Combustion during the 1990’s - what have we learned from this test?

• Cost and capacity of producing your oxygen


Oxy-Fuel Combustion Boiler Projects(Conversion @ 1 MWe = 3 MWt = 10 MMBtu/hr)

1000.0

( @ )

Demo Projects

250.0

100.0100.0

Vattenfall

UtilityBoilers

Jamestown

Youngdong

11.7 10 0

30.0

10 013.322.0

10 010 0

50.0

10 0We International Comb Vattenfall

Callide A

Oxy-coal UK

Pearl Plant

Jamestown

11.7

4.06.7

10.010.010.06.710.010.0

MW

ANL/EERC

JSIM/NEDO(oil)

IFRF

TOTAL(NG)Jupiter

CIUDENIndustrialFurnaces CIUDEN

B&W

1.0

0.5

1.0

0.4 0.3

1.01.0ANL/EERC

ANL/BHP IHI

B&W/AL

ENEL

PowerGen

IVD StuttgartTest 0.2

0.10.2 0.2

0.11980 1990 2000 2010 2020

CANMET

IVD-Stuttgart

RWE-NPOWER

TestFurnaces

1980 1990 2000 2010 2020

Year

Large Scale Pilot and Demo Projects

PROJECT Location MWth Start up

Boiler Type Main Fuel CO2 Train

B & W USA 30 2007 Pilot PC Bit Sub B LigB & W USA 30 2007 Pilot PC Bit, Sub B., Lig.

Jupiter USA 20 2007 Industr. No FGR NG, Coal

Oxy coal UK UK 40 2008 Pilot PCOxy-coal UK UK 40 2008 Pilot PC

Vattenfall Germany 30 2008 Pilot PC Lignite (Bit.) With CCS

Total, Lacq France 30 2009 Industrial Nat gas With CCS

Pearl Plant USA 66 2009 22 MWe PC Bit Side stream

Callide Australia 90 2010 30 MWe PC Bit. With CCS

Ciuden - PC Spain 20 2010 Pilot PC Anthra.(Pet ck) ?

Ciuden - CFB Spain 30 2010 Pilot CFB Anthra.(Pet ck) ?

Jamestown USA 150 2013 50 MWe CFB Bit. With CCS

Vattenfall(Janschwalde)

Germany ~1000 2015 ~250 Mwe PC Lignite (Bit.) With CCS( )

Youngdong Korea ~400 2016? ~100 MWe PC? ? ?

PrePre--Combustion CaptureCombustion Capture(Considering only Coal Power Plant)(Considering only Coal Power Plant)


PrePre--Combustion CaptureCombustion CaptureCO2CO2

compression• IGCC with CO2 capture

Coal Gasification Acid gasShift

Sulphur

H2SCO+H2O→H2+CO2

SulphurGasification Acid gas removal

Shift conversion

Fuel gasO

2 Sulphur recovery

Air CombinedAir

Fuel gas (mainly H2)

Nitrogen Power

Oxygen

Air separation

Combined cycle

Nitrogen Power

Air Air


Air Air

IGCC without CaptureIGCC without Capture• 5 coal-based IGCC demonstration plant in the USA,

Europe and JapanEurope and Japan

• IGCC is not at present the preferred technology for newIGCC is not at present the preferred technology for new coal-fired power plants

• Main commercial interest in IGCC is for use of petroleum residues

• Several plants built and planned at refineries

• IGCC has some intrinsic advantage over PC plant when CCS i t t fitt d dd d


CCS is to retrofitted or added

IGCC IGCC –– Currently in OperationCurrently in OperationNuon – Buggenum 250 MWel

250MWe Air Blown IGCC (Fukushima, Japan)250MWe Air Blown IGCC (Fukushima, Japan)


COCO22 Capture in IGCCCapture in IGCC• Advantages of IGCC for CO2 capture

○ High CO2 concentration and high overall pressureg g pLower energy consumption for CO2 separationCompact equipment

○ Proven CO2 separation technology can be used○ Proven CO2 separation technology can be used○ Possibility of co-production of hydrogen

• Disadvantages○ IGCC is unfamiliar technology for power generators○ Existing coal fired plants have low availability○ IGCC without CO2 capture has generally higher costs than○ IGCC without CO2 capture has generally higher costs than

pulverised coal combustion


IGCCIGCC

• IGCC with pre-combustion capture has been th f d t l b ildi bl k i ithe fundamental building blocks in various programme for co-generation of electricity

d h dand hydrogen• Some examples

○ Europe: HYPOGEN Programme○ Japan: EAGLE Projectp j○ China: GreenGen Project


PrePre--Combustion Capture: Key BarrierCombustion Capture: Key Barrier• Will reliability hinders the

deployment of IGCC?

• Record for IGCC’s availability h b b t i ihas been poor but improving.

• Complexity of the plant could beComplexity of the plant could be a turn off to both prospective investors and power plant

toperator

• Cost is another issue S EPRI


• Cost is another issue Source: EPRI

PrePre--Combustion Capture: Combustion Capture: K D l t AK D l t AKey Development AreaKey Development Area

• Development in Gasifier Technology

• Development in Shift ReactorChoice of Sour vs Sweet Shift Reaction○ Choice of Sour vs Sweet Shift Reaction

• Development in Separation of CO2 using PhysicalDevelopment in Separation of CO2 using Physical Absorption technology

• Development in the Gas Turbine technology○ Development of gas turbine firing H2 rich fuel using the current

DLN technology


gy

What are the current trend of development in What are the current trend of development in IGCC Based TechnologyIGCC Based TechnologyIGCC Based Technology…IGCC Based Technology…

• New fleet taking advantage of 10+ years of operation in the U.S. and Europe○ Materials of construction○ Spare equipment○ Gasifier refractory / membrane wally○ Burner design

• Range of suppliers to choose from for a wideRange of suppliers to choose from, for a wide variety of coals and other feedstocksEPC alliances can provide important guarantees


• EPC alliances can provide important guarantees42

GE Bechtel Reference PlantGE Bechtel Reference Plant


COCO22 TransportTransportCOCO22 TransportTransport


COCO22 TransportTransportPipeline

Motor TrucksMode of Transport

RailRail

Ocean-going ships


Main ConsiderationsMain Considerations• Compressors / Pumps

Thi ld d di d f t t○ This could vary depending on mode of transport.For ship, train and trucks – expect a CO2 liquids to be transportedtransportedFor pipeline – expect either gaseous CO2 or supercritical CO2.

• Transport modeTransport mode○ Pipeline transport is probably the most economical for

long distance transportlong distance transport.


COCO22 Delivery to Delivery to WeyburnWeyburn

ReginaRegina

ManitobaManitobaWeyburnWeyburnReginaRegina

ManitobaManitoba

ReginaRegina

ManitobaManitobaWeyburnWeyburnWeyburnWeyburn

EstevanEstevan

North DakotaNorth DakotaMontanaMontana

SaskatchewanSaskatchewan CanadaCanada

USAUSA

EstevanEstevan



USAUSA

EstevanEstevan



USAUSA

North DakotaNorth DakotaNorth DakotaNorth DakotaNorth DakotaNorth Dakota


BismarckBismarckBeulahBeulah

BismarckBismarckBismarckBismarckBeulahBeulahBeulahBeulah

COCO22 Compression in a Commercial OperationCompression in a Commercial Operation(Dakota Gasification Plant(Dakota Gasification Plant COCO22 toto WeyburnWeyburn EOR)EOR)(Dakota Gasification Plant (Dakota Gasification Plant –– COCO22 to to WeyburnWeyburn EOR)EOR)

• Operation Profilep○ MAN Turbo RV 042/07○ Motor Driven (~19500 HP)○ Mass Flow: 125 000 kg/hr○ Inlet Pressure: 1 Bar○ Discharge Pressure: 190 Bar○ 2 units started operation in

2000 (each unit transporting2000 (each unit transporting ~55 mmSCFD)

○ 3rd units started operation in June 2006

48

Considerations in the Design for High Pressure Pipeline Transport Considerations in the Design for High Pressure Pipeline Transport of CO2 Captured from Power Plantsof CO2 Captured from Power Plantspp

• 2 phase flow: impurities affect the 2 phase flow envelop profile. How do we model the EOS to cover this phenomena?p

• Transport capacity: impurities reduced transport capacity in the pipeline

• Fluid Toxicity: impurities could affect ruling on safety exposure.• Vapour Pressure: impurities could raised Vap. Pressure thus

requiring higher initial pressure or shorter re-compressor/booster station.Corrrosion critical elements to consider is the oxygen water• Corrrosion – critical elements to consider is the oxygen, water and acidic components that could enhance corrosion.

• Water solubility and hydrate formation conditions


Water solubility and hydrate formation conditions• Pipeline integrity during de-pressurisation.

Concluding RemarksConcluding RemarksConcluding RemarksConcluding Remarks


Concluding Concluding RemarksRemarks• Several activities have been initiated worldwide in the

development of Carbon Capture for Power Generation industry.

• There are two set of horse race among the three options for l b ild d t fit l t Th i l d t thnewly build and retrofit plant. There is no leader at the

moment!• We need large scale demonstration of the carbon capture• We need large scale demonstration of the carbon capture

technology to build the confidence necessary for a rapid deployment.y

• It is now time to discuss about the acceptable quality of CO2 that could be stored.


Recent IEA GHG Studies on CORecent IEA GHG Studies on CO22 Capture PlantsCapture Plants• Post combustion capture

○ Fluor○ Fluor○ MHI

• IGCC• IGCC○ Foster Wheeler

• Oxy combustion○ Mitsui Babcock, Air Products and Alstom


Current Status and Developments in Carbon Capture ... · Convective Section of the boiler MILL COAL...

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