Experiences from Commissioning and Test Oppyeration of ... 3 Burchhardt.pdf · Experiences from...

Experiences from Commissioning and Test Operation of Vattenfall’s Oxyfuel Pilot Plant p y

1st International Oxyfuel Combustion Conference1 International Oxyfuel Combustion Conference Germany, Cottbus, 7th – 11th September 2009

Uwe BurchhardtProject Manager Oxyfuel Pilot PlantVattenfall Europe Generation, Germany

1

Agendag

1. Introduction

2. Technical Concept of Oxyfuel Pilot Plant2. Technical Concept of Oxyfuel Pilot Plant

3. Oxyfuel experiences from test operation

4. Outlook and summary

2009-09-08 | IEA Oxyfuel Conference, U.Burchhardt (VE-G) 2

Decision process for the Oxyfuel Pilot PlantDecision process for the Oxyfuel Pilot Plant

2002

GAP Analysis

2005

Decision for2003

Technology

2004

Feasibility StudyGAP Analysis Oxyfuel Pilot Plant

• Building site: Lausitz area• Start of project• Available

TechnologyBenchmark

• Evaluation ofdifferent steps of

Feasibility Study

• Financial frame• Comparing scales • Scale: 30 MWth

• Complete process chainfrom ASU to CO2- processing

Availablecomponents

• Known processsteps

• Degree ofdevelopment

different steps ofdevelopment

• Decision todevelop Oxyfuel

Comparing scales• Possible sites• Risks


Design considerations for Oxyfuel Pilot PlantDesign considerations for Oxyfuel Pilot Plant

• Basic purpose is to provide operating information to be able to later p p p p gscale-up the technology to a 400-600 MW demonstration power plant

• Realization a complete process of coal input and oxygen production p p p yg pup to separation of CO2

• Possible to operate on full load in air-firing mode and oxyfuel modePossible to operate on full load in air firing mode and oxyfuel mode

• Designed to be able to operate on lignite and in a second phase on bituminous coalbituminous coal


Location of the Oxyfuel Pilot PlantLocation of the Oxyfuel Pilot Plant

Power plant “Schwarze Pumpe”Power plant Schwarze Pumpe

Building site


Time schedule and milestonesTime schedule and milestones

July `05 project start 23.11.06 notice of approvalpp March `08 end of construction 05.06.08 first fire (ignition burner)

26.06.08 first coal fire (main burner)

20.08.08 first Oxyfuel operation 03.09.08 first separation of CO2

09.09.08 official inauguration

Planning

2005 2006 2007 2008 2009 2010 2011

Approval processConstruction phaseCommissioningOperation


Operation

View on the Oxyfuel Pilot PlantView on the Oxyfuel Pilot Plant

BoilerThermal capacity: ´ 30 MWthCoal demand: 5.2 t/hOxygen demand: 10 t/hCO2 (liqu ) production: 9 t/h

Electrostatic precipitator

CO2 (liqu.) production: 9 t/hCO2 Capture rate: > 90 %

Air separation unit

Flue gasdesulphurization

Social and switchgear

Flue gas condenser

gbuilding

CO plant


Webcam: www.Vattenfall.de/CCSCO2-plant

Main ContractorsMain Contractors

General planerVATTENFALL EUROPE P C lt G bHVATTENFALL EUROPE PowerConsult GmbH

Boiler / ESPOxyfuel technology

ASU / CO2 plantCO2-process technology

FGDOxyfuel technology CO2-process technology

FGCI&C system Burner,Combustion technology


Main operating results (until August 2009)Main operating results (until August 2009)

• Summation Operating hours : 3.100 h• Operating hours air mode : 1.500 h• Operating hours Oxyfuel : 1.600 h


• Captured amount of CO2 : 1.400 t

2. Technical Concept of Oxyfuel Pilot Plant

10

System overview of Oxyfuel Pilot PlantSystem overview of Oxyfuel Pilot Plant

Cold Recirculation

PulverisedCoal

Burner

Cold Recirculation

Steam-HEx

Sealgas <1,2 bar

Sealgas6 bar

Furnace

Steam-HEx Air

ESP FG-Condenser

CO2-ProcessFGD

2. Pass

DeNOx

Fan 1 Fan 2

Steam-

3. Passhot Recirculation

Dry Ash


SteamHEx

AirASUSteam-HEx

Air

Oxygen

Nitrogen

Specific plant featuresSep. start burneron gas basis (propane)

Coal-Inputwith dry and CO2 rich Specific plant features

Cold Recirculation

PulverisedCoal30 MW burner performance

good Scale-up possibility

on gas basis (propane) yflue gasSeal gas systems

to reduction of air inleakage

Burner

Cold Recirculation

Steam-HEx

Sealgas <1,2 bar

Sealgas6 bar

good Scale-up possibility

Fl l

Furnace

Steam-HEx AirFlue gas cooler

test inlet temperature in FGD

ESP FG-Condenser

CO2-ProcessFGD

2. Pass

(DeNOx)

Fan 1 Fan 2O2-Mix with

static

Steam-

3. Pass hot Recirculation

Dry Ash Sulfur rich recirculation

A t SO2 / SO3 i h t

mixers

2009-09-08 | IEA Oxyfuel Conference, U.Burchhardt (VE-G) 122009-03-04 | VGB Conference 12

SteamHEx

AirASUSteam-HEx

Air

Oxygen

NitrogenAssessment SO2-/ SO3 enrichment in boiler and recirculation necessary

3. Oxyfuel experiences from test operation

13

Experiences with boilerExperiences with boiler

• Proven start burners (propane) having problems in Oxyfuel atmosphere due to high dust loads (Fl d d i t ll ti it ti(Flame guards and installation situation had to be optimized)

• Authority demand: Individual burner examinations for all operating statesexaminations for all operating states

• Good flame stability in Oxidant at O2 > 21%(w)• 25 -30 % humidity in hot recirculation

• Supplying of pure O2 and mixture in the burner possible

• Use of a single burner influences the burning g gbehavior and the flue gas composition

• Different burner swirls necessary for air and oxyfuel operation


Change load Air to Oxyfuel in 20 minutesg y

Flue gas after fan

Air stream

O2 stream

Recirculation flue

h l di ti O f l tichange loadair operation Oxyfuel operation

a. 20 min.


Requirements on flue gas scrubbingRequirements on flue gas scrubbing

Component Composition Reductionfrom* to* Capture ratefrom to

ESP Ash 11.200 mg/m³ < 20 mg/m³ > 99 %

SO2 11.500 mg/m³ < 100 mg/m³ > 99 %

FGD

2 g g

SO3 50 mg/m³ < 20 mg/m³ > 50 %

Ash 20 mg/m³ < 10 mg/m³ > 50 %

FG-Condenser

H2O 30 vol-% 4 vol-% > 85 %

SO2 100 mg/m³ < 20 mg/m³ > 80 %Condenser SO3 20 mg/m³ < 5 mg/m³ > 75 %

Ash 10 mg/m³ < 1 mg/m³ > 90 %

All d i d t f lfill d !


All design data are fulfilled !

* all mg/m³ in Norm (dry)

CO2 - Process (Cleaning, compression, drying, liquefaction)CO2 Process (Cleaning, compression, drying, liquefaction)

FG- InputCO2 ~ 85 %

O2 ~ 5 % Ventgas

< 10 % CO2-Loss

Use Ventgasesfor regeneration of

N2+Ar ~ 5 %H2O ~ 4 %

CO < 600 mg/m³NOx < 750 mg/m³SOx < 20 mg/m³

CO2 ~ 35-40 %O2 ~ 30-35 %

CO ~ 500 mg/m³ SO2 ~ 10 mg/m³NO ~ 10 mg/m³

for regeneration of Adsorber

ca. 50 %

CO2- Output1 ppm H2O

Pre-Compressor

Main-Compressor

Activatedcarbon filter

0,3 bar 21,5 bar

19,0barFGC

CO2 > 99,7 %17 bar, -25°C2-stage Adsorber

CO2 (liqu.)

H2O H2O H2OSO2, SO3, HCl,Heavy metals

> 90 % CO2- recovery

Coolant circulation


2 2(SOx / NOx)

2Heavy metals(Hg, Cd, ….) (Ammonia/CO2)

All %-details in Vol.-%

Attainable CO2 puritiesAttainable CO2 purities

CompositionCO2, liquid

Oxyfuel pilot plant (Technical CO2)

Comparison to Food quality2, q ( 2) q y

CO2 > 99,7 % > 99,99 %

N2+Ar+ O2 < 0,3 % < 30 ppm

H2O < 50 ppm < 50 ppm

SO2 < 2,5 ppm < 1 ppm

SO3 < 0,5 ppm -

CO < 10 ppm < 10 ppm

NO < 5 ppm < 2,5 ppm

NO2 < 15 ppm < 2,5 ppm


4. Outlook and summary

19

Outlook on test programp g

• Variation of coal quality (moisture, sulphur content, particle size).

• Test of different burners with integrated ignition burner

• Special measurement technique for flue gas iti d CO it icomposition and CO2 monitoring.

• Material tests for demo plants and 700°C technology under Oxyfuel atmosphereunder Oxyfuel atmosphere.

• Tests of co-firing biomass and bituminous coal.

• DeNOX tests at the boiler and for the vent gas stream from the CO2 plant.

• Test of an “alternative CO2-Process”


est o a a te at e CO ocess

Integration CO2-plant Air Products (AP) in the Oxyfuel Pilot Plant (OxPP)

1 ppm H2O

Pre-Compressor

Main-Compressor Adsorber

Activated carbon filter

Gips Kreide

g 2 p ( ) y ( )0,3 bar 22 bar VentgasOxPP

a 19 barFGC

2

2-stage

p p

liqu.

CO2

FGDCooler

H2O H2O H2OCondensate SO2, SO3, HCl,Heavy metals

2

e3 % t

Ad b

Con

dens

ate

Activated b filt

Ventgas3 % of FG

CO2

rest gasses

FGC

Condensate

15bar

30bar

Adsorber

H2SO4+HNO3

carbon filter

57bar

gas.

COH2SO4


CO2

2-stage SOx/NOx- separation CO2-Recycle MembraneAP

Area and layout of the „Alternative CO2-Process“y „


Roadmap for CCSpCommer. plant:~ 1000 MW

Testrigs:0.1 – 0.5 MWth

Pilot plant:30 MWth

Demonstrationplant:300 – 700 MWth

th ti

Concept-studies

R h Demonstration of the V ifi ti d O ti i ti f E i d

2001 20202008 2014 – 2015 2004• theoretic

Investigations• Research• Basic principles• Combustion

characteristics

• Demonstration of the complete process chain

• Interaction of components• Validation of test rig results• Investigation of scale up

criteria

• Verification und Optimisation of components

• Reduction of risks• Verification of commercial

availability (subsidiaries necessary)

• Economic and competitive power plant concept

• No need for subsidiaries


Layout of Vattenfall’s next generation power unitLayout of Vattenfall s next generation power unit

Amin scrubbingCCS Demo Project Jänschwalde

Oxyfuel boiler

coal drying ASU

CO2 plant


SummarySummary

• Oxyfuel works in pilot scale, emission limits are kept, CO2 quality reached

• Successful integration of plant components from chemical industry (ASU, CO2 plant)

G i d i f i i d i l t ti f• Gained experiences from permission process and implementation of secondary clauses for CCS power plants

• CO monitoring over the whole technology chain (capture – transport –• CO2 monitoring over the whole technology chain (capture – transport –storage) developed for the first time world wide

• First steps towards full scale CCS plants is successfully donep p y

• Very important for the investment of the demo plant is the consent to the public funding.

2009-09-08 | IEA Oxyfuel Conference, U.Burchhardt (VE-G) 252009-03-04 | VGB Conference 25

Thank you for your attention !

26

Available fuels

Fuel Pulverized lignite Dryed lignite Black coalLay-out Range Lay-out Range Lay-out

Granulation Spread

0 – 1 mm60%< 0,1 mm13%> 0,2 mm

3-18% >0,2mm1 mm 0 - 2 mm

<5% >2 mm80%<1 mm

0-5 mm

LHV 21,0 MJ/kg 20,4-22,5 MJ/kg 20,0 MJ/kg 25,1 MJ/kg

AnalysisWater 10,5 Mass% 8-12 M% 15 Mass%

12-20 M% 10,0 Mass%

AshCarbonOxygen

H d

6,0 Mass%56,5 Mass%21,5 Mass%4 0 Mass%

4,5-7,5 M%54-60 M%20-22 M%3 5 4 5 M%

5,7 Mass%54 Mass%20,5 Mass%3 8 Mass%

13,0 Mass%62,0 Mass%8,6 Mass%4 2 Mass%Hydrogen

SulfurNitrogen

Chlorides

4,0 Mass%< 0,8 Mass%0,7 Mass%

3,5-4,5 M%0,4-1,2 M%0,6-1,1 M%

80-260 mg/kg

3,8 Mass%1,0 Mass%0,7 Mass%

0,8-1,4 M%4,2 Mass%

< 0,7 Mass%1,5 Mass%


Chlorides Fluorides

g g15-70 mg/kg

CO2- plant in detailCO2 plant in detail

Recti-fication

Compressor building

ActivatedActivated carbon filter

Analysis container

CO2-tanks(2x180 m³)(2x180 m )

Trailer docking station


Experiences from Commissioning and Test Oppyeration of ... 3 Burchhardt.pdf · Experiences from...

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