Oxy-Fired Tangential Boiler Development and Large-Scale

(15 MWth) Validation

2nd International Oxy-Combustion Conference

Yeppoon, Queensland, Australia September 14, 2011

Armand Levasseur David Turek, James Kenney, Carl Edberg,

Shin Kang, Patrick Mönckert, Frank Kluger Alstom Power

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 2 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

The Alstom Group: A Worldwide Leader in Power Generation

Full Power Systems Portfolio and Technology Mix

Recent acquisition of solar and wind

N°1 in services for electric utilities

N°1 in air quality control systems

N°1 in integrated power plants

• Clean Power

N°1 in hydro power

N°1 in conventional nuclear power island

• CO2-Free & Renewables

• Carbon Capture - Post-Combustion - Oxy-Combustion

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 3 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

Oxy-Combustion Technology - Why Oxy?

Flue Gas Recirculation

• Cost Competitive (with other CCS, Wind, Solar, Biomass) • Reliability / Low Development Risk: Adapts Conventional Components • New and Retrofit Applications • High CO2 Capture Rates (>90%) • Near Zero Emissions • CO2 “Ready” Approach • Potential for O2 Production Cost Reduction • Scale-up to Large Commerical Sizes (1000 MWe)

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 4 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

Large Pilot Plants

Demonstration

Commercial

2008

2014-2016

Alstom Oxy-PC Combustion Technology Development Steps

Lab Scale

2000

<1 MWth

15- 30 MWth

150- 400 MWe

600-1100 MWe

Reference Design Studies 1999

Modeling & Tool Dev.

<2020

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 5 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

15 MWth Oxyfuel Pilot Plant: Alstom Boiler Laboratories, Windsor, CT

15 MWth Boiler Simulation Facility - Multi-burner, Tangentially-fired

Flexible operating conditions - air & oxy-firing, gas recycle configuration, oxygen injection, firing system design

Generation of detailed design and performance data -combustion, emissions, heat transfer, deposition, corrosion

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 6 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

6

Oxy T-Fired Boiler Development Project

Project Team: Alstom Power DOE NETL ICCI NDIC Advisory Group

Project Start: Oct 2008 Duration: 5 Yrs

10 Utility Members Ameren ATCO Dominion Energy Great River Energy Luminant (TXU) LCRA and Austin Energy MidWest Generation NB Power OG&E Vattenfall

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

Task 1 - Project Management 60% Completed

Task 2 - Bench Testing 30% Completed

Task 3 – Screening Evaluations 100% Completed

Task 4 - 15 MWth Testing 85% Completed4.1 Test Planning Done4.2 Test Preparations Done4.3 Facility Shakedown Done4.4 Campaign 1 Done4.5 Campaign 2 Done4.6 Campaign 3 Done4.7 Campaign 4 Done4.8 Campaign 5 Done4.9 Campaign 6 On-Going

Task 5 - Test Data Analysis 55% Completed

Task 6 – Model Simulations 25% Completed

Task 7 – Oxy Guidelines Milestone Completed 10% Completed

Task 8 - Oxy Boiler Demo Design Milestone Scheduled 15% Completed

Task 9 – Commercial Ref. Designs 10% Completed

DOE FY13Period 5

Task Description

DOE FY11Period 3

DOE FY12Period 4Period 1

DOE FY09 DOE FY10Period 2

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 7 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

Develop and validate an oxyfuel T-fired boiler system as part of commercially attractive CO2 capture solutions.

• Design and develop an oxyfuel firing system for T- fired boilers

• Evaluate the performance in pilot scale tests at 15 MWth testing - - operation, combustion, heat transfer, pollutants, ash deposition and corrosion

• Evaluate and improve engineering and simulation tools for oxy-combustion by applying detailed test data

• Develop design guidelines

• Develop the design, performance and costs for a demonstration-scale oxyfuel boiler and auxiliary systems

• Develop the design and costs for both industrial and utility commercial-scale reference oxyfuel boilers

Oxy T-Fired Boiler Development Project Objectives

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 8 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

Accomplished • Process and CFD Screening Completed • Modifications For Oxy-Firing Completed • Campaign 1 Testing Completed Sept. 2009 – Subbituminous coal • Campaign 2 Testing Completed Feb. 2010 - Low S Bituminous coal • Campaign 3 Testing Completed April 2010 - High S Illinois Bituminous coal • Campaign 4 Testing Completed Oct. 2010 - North Dakota Lignite • Campaign 5 Testing Completed August 2011- Schwarze Pumpe Lignite

Next • Campaign 6 Testing of 2nd Generation Concepts • Tools & Modeling Refinement and Validation on-going • Design guidelines On-going • Reference & Demo designs On-going

Project Status

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 9 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

Oxy-PC Boiler Development areas investigated

Heat transfer : radiative / convective

Oxy tangential firing system design

Oxygen Injection

Excess O2 Flue gas recycle (comp./ratio)

Operation/load change: dynamic response

Effect of coal quality

Control Logics & Safety

Corrosion - high temperature - low temperature

Ash Properties

Fouling & Slagging

SCR adaptation

Air in-leakage

Gas pre-heater adaptation

Emissions

Acid dew point

Mill adaptation / integration

Evaluated Under Design Studies

Evaluated Under Pilot-Scale Testing

Comprehensive Test Program Addresses Several Areas

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 10 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

Air to Oxy Transition Oxy to Air Transition

Transitions Air-to-Oxy or Oxy-to-Air about 30 mins

0

20

40

60

80

100

19:25 19:40 19:55 20:10Time

O2,

CO

2, a

nd D

ampe

r P

ositi

on (%

)

0

2000

4000

6000

8000

10000

% dry CO2

ppm dry SO2

Air intake damper

% wet O2

0

20

40

60

80

100

2:40 2:55 3:10 3:25Time

0

600

1200

1800

2400

3000

SO

2 co

ncen

trat

ion,

ppm

dry

% dry CO2

ppm dry SO2Air intake damper

% wet O2

15 MWth Oxyfuel Pilot Plant: Switch from air to oxy firing demonstrated

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 11 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

Changes in Oxy-Firing Gas Compositions – Illinois High Sulfur Coal

Significant Increase in SO2 even with sulfur capture from recycle

0

20

40

60

80

100Co

mpo

sitio

n in

Flu

e G

as (%

)

0

4000

8000

12000

16000

20000

Com

posi

tion

in F

lue

Gas

(ppm

)

% dry CO2

ppm dry SO2

% wet O2

% H2O

Oxy w/o Sulfur Capture

Oxy w/ Sulfur Capture

Air

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 12 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

Similar SO3 Conversion Rate As Air Firing - Economizer Outlet Measurements in BSF

0

50

100

150

200

250

300

0 5,000 10,000 15,000SO2 ppmv

SO

3 pp

mv

AirOxy w/o SOx controlOxy w/SOx control

1% Conversion

2%

3%

Illinois Bituminous Economizer Outlet SO3 results

North Dakota Economizer Outlet SO3 results

Alstom 15MWth BSF

Lignite SO3 Testing - Economizer Outlet

0

25

50

75

100

0 500 1,000 1,500 2,000 2,500 3,000 3,500

SO2 ppmv

SO

3 p

pm

v

AirOxy w/o SOx controlOxy hot FGROxy w/SO3 spike

1% Conversion

2%

3%

Similar SO2 to SO3 conversion rates

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 13 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

Alstom 15MWth BSF Lignite SO3 Testing

0

20

40

60

80

100

Windbox Furnace Economizer

Location

SO3

ppme

Oxy w/o SOx ControlOxy w/ SOx additionOxy hot FGR

Conversion Checked By SO3 Addition: SO3 Measurements Along System Path

FurnaceOut

GRSecondaryFe n

nppmppm

•≡

For windbox ppme is the equivalent ppm impact @ the economize outlet

Recycled SO3 does not impact outlet emissions

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 14 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

0.1

0.2

0.4

0.3

0.00

0.05

0.10

0.15

0.20

0.25

Air

Oxy

NOx Emissions During BSF 15MWt Testing

Main Burner Zone Stoichiometry

Powder River Basin WV Bituminous Illinois Bituminous

0.3

0.4

0.2

0.1

0.00

0.05

0.10

0.15

0.20

0.25

Air

Oxy

NO

x k

g/M

Wh

0.3

0.4

0.2

0.1

0.00

0.05

0.10

0.15

0.20

0.25

NO

x lb

/MM

Btu

x

Air

Oxy

Air firing NOx consistent with field; NOx during Oxy firing more than 50% less

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 15 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

15 MWth BSF furnace mapping

Probe Mapping

Measurements Gas Temperatures Heat Flux:

-Total Incident - Radiant

Gas Species: - O2 - CO - CO2 - SO2 - H2O - TCH

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 16 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

20 25 30 35 40

Oxy

Air

30%

35%

40%

45%

50%

55%

60%

Hea

t A

bso

rpti

on

Global Oxygen Conc.

WV Bituminous

Furnace WW heat flux – gas recycle rate impacts

WV Bituminous

5

10

15

20

25

Furnace Height

33% 24%

28%

VW Bituminous

Heat Flux

Global O2 Conc.

Ability to control heat flux magnitude with recycle rate Reduced recycle rate shifts heat duty to furnace

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ND Lignite Testing

0%

10%

20%

30%

40%

50%

20 25 30 35 40

Global O2 content, %

Hea

t abs

orpt

ion

up to

HFO

P

Oxy

Air

High S. Bituminous Testing

0%

10%

20%

30%

40%

50%

20 25 30 35 40Global O2 content, %

Hea

t abs

orpt

ion

up to

HFO

P

OxyAir

A reduced recycle rate shifts more heat absorption to the furnace

In each case, a global O2 of ~26 -28% gives the same furnace absorption as air firing in the BSF

PRB Sub-Bit. Testing

0%

10%

20%

30%

40%

50%

20 25 30 35 40Global O2 content, %

Hea

t ab

sorp

tion

up

to H

FO

POxyAir

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 18 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

The heat flux profile can also be controlled by adjusting the O2 injection

Furnace heat flux changed with oxygen flow rate and concentration

• Oxygen was varied between the overfire and windbox locations

• Oxygen was varied among the different windbox compartments

15 MWt BSF – High S bituminous

0

5

10

15

20

25

Total Heat Flux

FurnaceHeight

(ft)

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 19 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

The oxy-fired heat flux profile can be controlled to match the air fired

Air Oxy

Alstom 15MWth BSFND Lignite Long-Term Testing

Oxy

Air

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 20 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

Oxy Reference Plant and Demonstration Boiler Designs

• Application of test results and design tools • Development of reference oxy- fired utility boiler design for future market • Development of a full-scale oxy- fired boiler design for demonstration opportunities • Optimization, detailed design, performance assessment and costing

Oxy T-Fired Boiler Design

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Plant or Integrated Boiler island DCS

Optimization of FG composition along the oxy-chain

Thermal

Process

Operation

Layout

Plant or Integrated Boiler island DCS

Optimization of FG composition along the oxy-chain

Thermal

Process

Operation

Layout

Plant or Integrated Boiler island DCS

Optimization of FG composition along the oxy-chain

Thermal

Process

Operation

Layout

Plant or Integrated Boiler island DCS

Optimization of FG composition along the oxy-chain

Thermal

Process

Operation

Layout

Oxy-firing integrated approach: Reference plant design

• Numerous parameters impacting performance and cost – Integration is key (process, thermal, operation, arrangement)

• Globally optimize cost of electricity

• Balance trade-offs between main subsystems (performance and costs)

• Determine specification for the new subsystems

• Power plant operation and control

• Optimize arrangement and minimize footprint

An integrated approach minimizes the cost of electricity

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UK Oxy CCS Demo Project

Largest Oxyfuel CCS Demo

• A new modern 426MWe Gross Oxyfuel Power Plant

• PC Boiler; ultra-supercritical conditions

• Clean power generation with the entire flue gas treated to capture 2 MTA CO2

• Biomass co-firing leading to zero CO2 emission

• Located at the existing Drax Power Station Site at Selby, North Yorkshire

• A part of Yorkshire/Humber cluster for transport and offshore storage of CO2

• FEED under way

• NER funding application under evaluation

Project Promoters

ALSTOM DRAX ASU NATIONAL GRID

Oxyfuel Power Plant

CO2 Transportation & Storage

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 23 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

Concluding Remarks

• No technical barriers - Combustion, emissions, and thermal performance can be controlled to similar levels as air firing.

• An oxy boiler design does not require major changes.

- For oxy-combustion retrofit, only minor pressure part changes

- For new applications, additional control under oxy-firing may be used improve oxy-fired boiler performance and costs.

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 24 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

Concluding Remarks

• Detailed test data from this project and other Alstom R&D programs is being applied to

- refine and validate design tools and design procedures.

- support overall oxy plant integration and optimization efforts

- develop and optimize designs for demonstration opportunities and future commercial plants

IEA OCC2 September 14, 2011 Yeppoon, Queensland, Australia 25 ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. .

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Disclaimer

Parts of this document were prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. This this document was also prepared with support, in part, by grants made possible by the Illinois Department of Commerce and Economic Opportunity through the Office of Coal Development and the Illinois Clean Coal Institute. Neither Alstom Power, nor any of its subcontractors, nor the Illinois Department of Commerce and Economic Opportunity, Office of Coal Development, the Illinois Clean Coal Institute, nor any person acting on behalf of either:

(A) Makes any warranty of representation, express or implied, with respect to the accuracy, completeness, or usefulness of the information contained in this report, or that the use of any information, apparatus, method, or process disclosed in this report may not infringe privately-owned rights; or

(B) Assumes any liabilities with respect to the use of, or for damages resulting from the use of, any information, apparatus, method or process disclosed in this report.

Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring; nor do the views and opinions of authors expressed herein necessarily state or reflect those of the Illinois Department of Commerce and Economic Opportunity, Office of Coal Development, or the Illinois Clean Coal Institute. Information disclosed herein is furnished to the recipient solely for the use thereof as has been agreed upon with ALSTOM and all rights to such information are reserved by ALSTOM. The recipient of the information disclosed herein agrees, as a condition of its receipt of such information, that ALSTOM shall have no liability for any direct or indirect damages including special, punitive, incidental, or consequential damages caused by, or arising from, the recipient’s use or non-use of the information

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