Callide Oxyfuel Project: From Concept to Commissioning

Chris Spero

2nd IEA GHG Oxyfuel Combustion Conference Tuesday, 13 September 2011

Keynote Address

Presentation Overview

• Project history

• Project structure, management and contracting strategy

• Project outline & permitting

• Current status of Callide A works

• Key issues and lessons learned

• Future deployment of oxyfuel technology

Central Queensland – The Morning Bulletin (May 1965)

The name ‘Callide’ was first used by pastoralist Charles Archer in 1853 to describe his holdings in the area, and is based on the Greek ‘Kallos’ meaning good’.

Project history

Project structure

Contracting and project management

Pulverised Coal Consumption

5.5 kg/s 20 tph

Quality

HHV: 19 MJ/kg ar Ash: 21% ar

Moisture: 14% ar Sulfur: 0.3% daf

Anglo Callide Coal mine

Steam Flow 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/s CO2: ~67% mass

Chimney Stack Flow: 13.2kg/s Height: 76m

CO2 Purification and Compression CO2 Product: 75t/day CO2 Purity: 99.9% mol CO2 Temperature: -20oC CO2 Pressure: 1,600kPa

Road Transport B Double – 30t Single Tanker – 20t

Boiler Exit Flue Gases 350oC 44.9kg/s

Feed Gas to CO2 Plant Flue Gas Processed Flow: 1.7kg/s Temp ~ 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

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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

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Callide A Unit 4 - After Oxfuel Retrofit Oxygen

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

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%)

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Existing Air Heater

12

Callide A Unit 4 - After Oxfuel Retrofit

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Boiler/Stack/CO2CPU - Flue gas mass balance

Blower

GRF

FDF

CPU: 1.7 kg/s

Stack:13.2 kg/s

To boiler:30 kg/s

From boiler:44.9 kg/s

CO2 CPU - Schematic

Courtesy of ALE

LP Scrubber

Driers

HP Scrubber

Ammonia refrigeration plant

Cold box/ inerts

separators

CO2 CPU – process details

75 t/day liquid product

Parameter Units CPU Inlet CO2 Productkg/s 1.3 0.9Am3/s 1.7

Temperature oC 145 -30Pressure kPa (a) 101 1600Composition H2O mole % 20.0 < 0.002 O2 mole % 4.2 < 0.003 N2 (+ Ar) mole % 18.6 < 0.1 CO2 mole % 55.9 99.9 SO2 mole % 0.06 < 0.003 NOx mole % 0.03 < 0.003 Particulate mg/Nm3 < 100 < 1 Trace elements (As, Be, Cd, Hg, V) ppbv < 1 < 0.1

Flow rate

Oxygen plant CO2 capture plant

COP – Site Works – Oxygen and CO2 Capture Plant

COP key demonstration items – CO2 capture

• Oxyfuel and CO2 capture plant operation, including effects of variable flue gas composition

• Safety • Durability • Plant efficiency • CO2 capture rate & CO2 purity • Cost data • Process control and optimization • Design inputs for scale-up (e.g., corrosion rate of

Ferritic & Austenitic steels and Nickel-based boiler S/H tube materials

6

• Project budget has been the dominating factor • EPCM approach with a very small team

Limited provisions included in construction contracts to minimise Contractors risk and therefore cost premiums

Alliance approach to contracting has proven to be of limited success

• Upfront engineering detail Very difficult to fully define some of the workscopes prior to contract

award

Many contract and physical interfaces

• Budget control has been good, but schedule has been very difficult to manage

• Results of R&D work have been invaluable in making important engineering and commercial decisions during the detailed design phase

Key issues/lessons learned

Technology Deployment

Hybrid Oxyfuel Power Plant (HOPP) concept Oxyfuel cannot be applied as a partial retrofit to the whole system One option for next scale-up is to apply oxy-firing to one or more units in a multi unit

plant 750 MW Ultra supercritical boiler + 250 MW ultra supercritical boiler

Hybrid Oxyfuel Power Plant (HOPP) Concept

CO2 storage potential

Storage volumes (based on current production): • East coast – 70 years • West coast > 200 years • CO2 storage capacity of gas and oil fields is ~ 16.5 giga tonnes

(Source: National Low Emissions Coal Council)

Queensland Government: Carbon Geo-storage Initiative (CGI)

Potential CO2 storage tenements

Callide A

EPQ7 (CTSCo Pty Ltd)

Scale: 0 – 108 km

Concluding comments

1. Callide Oxyfuel Project – ASU and Oxyfuel plant are now in commissioning phase; the CO2 capture plant is under construction.

2. Budget limitations , first-of-a-kind issues, and other major Coal Seam Gas developments in Queensland have resulted in a very difficult contracting environment.

3. An EPCM and alliance type contracting approach has resulted in good budget control but schedule control has been somewhat problematic.

4. Oxyfuel science/R&D has been very helpful in supporting engineering and commercial decisions, especially in the detailed design phase.

5. The implementation of carbon capture is still a long way ahead of the implementation of carbon storage in the Australian environment.

Thank you

for more information: www.callideoxyfuel.com

Callide Oxyfuel Project – Participants