Capture 2 – Oxyfuel Introduction to Oxy-fuel technologies

M. Balfe (C. Béal, S. Kang, A. Levasseur, O.Stallmann)

July 7th 2014

Capture 2 – OxyfuelIntroduction to Oxy-fuel technologies

Austin Texas

•© ALSTOM 2013. 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.

Capture 2 - Oxyfuel: Introduction to Oxy-fuel technology 07/07/2014 - P 2

Agenda

• General Overview

• Oxy-fuel Combustion: Overview, Technical Considerations

• Gas Processing Unit (GPU): Overview, Technical Considerations

• Chemical Looping: Overview, Technical Considerations

• Summary, Development Steps and Projects



CO2 Separation

Absorption

Chemical

Amine

Primary

Secondary

Tertiary

Sterically Inhibited

Alternative Absorbent

Ammonia

Alkaline Compound

Salts of AminoAcids

Physical

Rectisol

Selexol

Other

Adsorption

Adsorber Beds

Alumina

Zeolite

Activated Carbon

Carbonate / RCC

Regeneration Methods

Pressure Swing A.

Temperature Swing A.

Electro-thermal Swing A.

Vacuum Swing A.

Washing

Alternative Technologies

Cryogenic

Frosting / Anti-sublimation

Membranes

Gas Separation

Gas Absorption

Ceramic based

Oxy Combustion

Oxy Conventional

Chemical Looping

Other

Ionic Liquids

Microbial/ Algal

General OverviewTechnology Options for Carbon Capture

Based on Oexmann J. and Kather A.: Postcombustion CO2 Separation in VGB PowerTech ½, pp 92-103, 2009



Agenda








Oxy-fuel combustion: OverviewOverview Oxy-Pulverized Coal



Oxy-Combustion: OverviewTechnology - Principle

Conventional Air:

21 Vol.-% O2

79 Vol.-% N2

Coal

> 21 Vol.-% O2

< 79 Vol.-% FG

Air

Coal

Air ASU

N2

Oxy-Combustion:

FG

Flue gas (FG) recirculation

FG

% Vol. Mass

N2 68.8 66.2

O2 2.8 3.1

CO2 13.9 21.1

Ar+Inerts 0.8 1.1

H2O 13.6 8.5

SO2 0.03 0.07

% Vol. Mass

N2 5.7 4.5

O2 2.8 2.5

CO2 61.5 75.5

Ar+Inerts 3.8 4.2

H2O 26.2 13.2

SO2 0.08 0.14

PRB Subbituminous Coal



Air Oxy

Alstom 15MWth BSFND Lignite Long-Term Testing

Oxy

Air

Oxy-fuel combustion: Technical Considerations15 MWth BSF - Heat flux profile

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



Oxy-fuel combustion: OverviewOxy-PC Boiler: Development areas investigated

Heat transfer : radiative / convective

Oxy tangential firing system design

Oxygen Injection

Excess O2Flue 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



Oxy-fuel combustion: Technical ConsiderationsOxy-PC Pilot Testing - AQCS, FGC, and GPU

ESP at Schwarze Pumpe Oxy Pilot

Alstom NID™Dry Flue Gas Desulfurization

Alstom Wet Flue Gas Desulfurization

Alstom Flue Gas Condenser

Alstom Mobile Pilot Gas Processing Unit



Boiler

BowlMills

Fuel

ESP

Gas-Gas Heater

SRF

PRF

WFGD GPUDCC

Pri

mar

y re

circ

ula

tio

n

Sec

on

dar

y re

circ

ula

tio

n

ASU

Oxygen Injection

Purging & Pressurized Sealing Systems

Flue Gas

Inlet

To

Furnace

From

Furnace

To

ESP

Purging Reduces

Entrained Leakage

Pressurized Sealing Reduces Direct Leakage

Rotation

21% O2

Oxidant

Recirculated Flue Gas From FGD Outlet

Oxy-fuel combustion: Technical ConsiderationsOxy Boiler Design: Examples of Specific System Features

Static Mixer

Grid-type Mixer

CFD Mixing Evaluations

1 2

3 4

56

789

10

1112131415

Ljungstrom® Gas-Gas Preheaters

Special Sealing System



Agenda








Gas Processing Unit: Process OverviewProcess Overview

New key components of the oxy-chain

Similar systems existing for gas purification HOWEVER:

• Energy optimized;

• Specific design due to coal species;

• Relaxed or stringent CO2 spec.;

• Significant reduction in Air Emissions;

Proven design adapted to new operation conditions



Gas Processing Unit: Process Overview Flow scheme Overview

Process steps :

•Direct Contact Cooling reduces H2O to <5%

•Multi Stage Flue Gas Compression to >28 bar

•Purification and Drying

•Regeneration Gas System

•Chilling and CO2 Separation

•Off-gas System

•CO2 Recompression

Downstream oxy-boiler and FGD the flue gas is treated to reach the necessary CO2 purity



Gas Processing Unit: Technical ConsiderationsExternally Refrigerated GPU for SA Quality

Flue gas compressor

Dryer

Cooling by refr. evaporationCO2 flash separation

Refrigeration System

External refrigerant system to optimize energy demand in hot climates

Pump

Vent gas

CO2 product

Yield >80%CO2 in product >95%O2 in product <1%

Pilot Configuration



Gas Processing Unit: Technical ConsiderationsAuto-refrigerated GPU for SA Quality

Flue gas compressor

Mercuryadsorber

Dryer

Cooling by CO2 evaporationCO2 flash separation

CO2 compressor

Without use of additional refrigerantsProduced CO2 provides the required duty for condensation

Pump

Vent gas

CO2 product

Yield >90%CO2 in product >95%O2 in product <1%



Gas Processing Unit: Technical ConsiderationsAuto-refrigerated GPU for EOR Quality

Flue gas compressor

Mercuryadsorber

Dryer

Cooling by CO2 evaporationCO2 distil.

Vent gas

CO2 compressor

CO2 product

Without use of additional refrigerantsProduced CO2 provides the required duty for condensationCO2 recycle provides the additional duty to operate the distillation

Pump

Yield >90%CO2 in product >99%O2 in product <0,01%



Gas Processing Unit: Technical ConsiderationsExternally Refrigerated GPU for EOR Quality

Flue gas compressor

Dryer

Cooling by refr. evaporationCO2 distil.

Vent gas

CO2 product

External refrigerant system to optimize energy demand in hot climatesDistillation ensures CO2 quality for EOR

Pump

Yield >80%CO2 in product >99%O2 in product <0,01%

Refrigeration System



Gas Processing Unit: Technical ConsiderationsSummary

• Autorefrigerated GPU for recovery rates of 90% and above−Not too high cooling water temperatures (SA <25°C EOR

<28°C)−More sensitive to trace substances, e.g. Hg reaction with

Aluminum

• Externally refrigerated GPU for yields of 80% and above−Less sensitive to cooling water temperature−No mercury removal required−Robust design using mainly simple materials like carbon

steel

• Main targets for Pilot operation CO2-capture and purity achieved

−CO2 purity > 95%−CO2 capture > 90 %



Gas Processing Unit: Technical ConsiderationsGPU Pilot - CO2 Recovery Rate and Purity

80

82

84

86

88

90

92

94

96

98

100

65 70 75 80 85 90

Inlet CO2 concentration, %vol (dry)

CO2 in product, %vol (dry)

Recovery rate, %

•Targeted recovery rate of >90% reached at CO2 inlet concentrations of 80%. •Design point regarding CO2 inlet concentration is 82%.•Commercial unit performance higher due to reduction of heat losses.



Gas Processing Unit: Technical ConsiderationsGPU Pilot - SO2 Removal in DCC

90

91

92

93

94

95

96

97

98

99

100

0 20 40 60 80 100 120 140 160 180 200

DCC inlet, ppmv dry

Rem

ova

l eff

icie

ncy

, %

•High performance SOx scrubbing ensures relaxed operating conditions in the compression section and reduced corrosion risks.



Gas Processing Unit: Technical ConsiderationsGPU Pilot - NOx Removal in GPU



Gas Processing Unit: Technical ConsiderationsHg Removal in Activated Carbon Bed



Agenda








Oxy-fuel SummaryIntegrated Approach - Reference Plant work

• Globally optimize cost of electricity

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

• Integration of flue gas cleaning strategy

• Optimize heat integration• Optimize operation and

controls• Optimize arrangement and

minimize footprint

Guides the R&D and defines future commercial design

© ALSTOM 2014. 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.

Presentation title - 07/07/2014 – P 25

Moving forward to scale-up the technology

Oxy-Combustion Process Update on Alstom roadmap

Commercial

2020 & beyond1990’s

R&D and Lab scale

Large –scale demonstrationPilots

2008 2012

Planned

White Rose

Selby (UK) - 426 MWe

Alstom BSF USA - 15 MWth

Vattenfall Schwarze PumpeGermany - 30 MWth

Total LacqFrance - 30 MWth

GPU Pilot

Tests completed

or in operation



15 MWth Oxyfuel Pilot Plant Alstom Labs, Windsor, CT, USA

Comprehensive Program :• 5 Years (Sept. 2008 – April 2014)

• ~21.5 MUSDLarge Pilot Completed:

• Evaluated the impacts of different oxy process options and boiler design parameters

• Detailed perfromance data (combustion, heat transfer, pollutant emissions, deposition, corrosion …)

• Coals tested (Low S Bit (WV), High S Bit (IL), Sub-bit (WY), Lignite (ND, DE)

• Evaluated, improved, and validated engineering and computational tools

Scale-Up Completed: • Development of design guidelines

• Large-scale Reference Designs

• Demonstration Design

• Ready for large demonstration

•Oxy-Combustion Pilot with AQCS & GPU – Alstom, Windsor, CT, USA

•NDIC



First oxy pilot plant with complete train for CO2 separation and capture

• Alstom supplied the Boiler, ESP and other components of the flue gas path

• Technology Partnership with Vattenfallto advance of the Oxyfuel technology

Operation started September 2008

• Very successful – operated extensively and reliably

• Tests with two lignites (low/high sulfur)

• Test phases with Alstom Burners (Design A+B) finished

• Detailed performance data and operational experience

30 MWth Oxy-Combustion Pilot Plant at Vattenfall’s Schwarze Pumpe station, Germany

•Alstom Oxy-boiler

•Alstom Oxy-burner

© Capture Power Ltd 2014. All rights reservedConference Slides, May 2014 28

Largest Oxy-combustion CCS Commercialisation Project Worldwide

WHITE ROSE CCS PROJECT

Project Snapshot• A new modern ultra-supercritical 426MWe (gross) Oxy-Power Plant

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

• >300 MWe Clean power - equivalent to the needs of 630,000 homes

• 100% of flue gas treated, 90% CO2 capture rate → 2 million tonnes CO2/year

• Biomass co-firing leading to zero - or negative - CO2 emissions

• Anchor project for National Grid’s regional CO2 transport & offshore storage

network

– Yorkshire & Humber CCS cluster covers almost 20% of UK’s CO2 emissions

– Infrastructure planned to be sized for 17 million tonnes CO2/year to enable future

projects

• CO2 to be permanently stored in a deep saline formation offshore, beneath

the North Sea


Location: Drax Power Station, North Yorkshire, UK

Power Station Location


• Owner & operator of the UK’s largest, cleanest, most efficient

coal-fired power station; 7% of the UK’s electricity needs

• Produces more renewable power than any other UK facility

• Committed to reducing Drax & UK power generation carbon

footprint

• A global leader in the world of power generation, power

transmission and rail infrastructure

• A pioneer in large-scale and efficient CCS technologies

• The largest provider of industrial gases in UK

• A member of The Linde Group, a world leading gases and

engineering company

• An international electricity and gas company and one of the

largest investor-owned energy companies in the world

• Expert in running high pressure natural gas system in a safe,

reliable and efficient manner

A Strong Industrial Consortium


OXY-POWER PLANT CO2 TRANSPORT & STORAGE

• Delivery of ASU

• O&M of ASU• O&M of Oxy-PP

• Trading Services

• Site and Site Services

• Fuel Supply

• Electrical Connection

• Delivery of Oxy-PP

• Integration of Oxy-

PP

• Delivery of Transport

& Storage network

• O&M of Transport &

Storage network

• Full-Chain

Integration

Alstom BOC (Linde)Drax

Delivery Plan

Carbon Ltd



1st Generation Oxy-fuelSummary

• Successfully developed over the past ten years

• Alstom oxy pilots have provided a sound foundation for commercial-scale design

• Alstom has addressed all major components and their integration

• Total plant integration is needed to optimize performance and minimize the CoE of oxy power plants

• Cost competitive with other fossil and non-CO2 generation

• Alstom is ready to demonstrate oxy-combustion at large-scale under real commercial conditions

• The White Rose project in the UK is a promising opportunity to demonstratecommercialization



Agenda








Chemical Looping (CLC): OverviewChemical Looping Process Scheme



Chemical Looping: Overview Alstom’s Chemical Looping Development, Since Late 1990s

Alstom is executing two chemical looping programs

Metal Oxide Based (MeOx)Limestone Based (LCL™)

Main Features:

• Metal-based oxygen carriers such as Fe,

Mn, Cu… ores, ilmenite (FeTiO3), or on

substrates

• Process based on CFB solids transport

• Carbon stripper for minimizing UBC

Main Features:

• Limestone based oxygen carrier –CaS, CaSO4

• Process based on “Fast” Bed

• Sorbent reactivation for increased limestone utilization

ÉCLAIR/ACCLAIM Programs – EU RFCS funded

US-DOE funded



Alstom’s LCL™ Concept

Option 1 – Chemical looping combustion• Excess air to fuel• Product gas is CO2

• Heat produces steam for power

Option 2 – Chemical looping gasification• Excess fuel to air• Product gas is Syngas• No inherent CO2 capture• High efficiency, low cost IGCC

Option 3 – Hydrogen production• Add CaO-CaCO3 loop to option 2• Add calciner• Product gas is low cost H2

• Calciner off-gas is CO2

Coal

L

•CO2•H2O

ProductGas

CaSO4

Air

N2Ash CaSO4

CaS

Calciner

CO2 (g)

Hotsolids

Coldsolids

Steam toPower Cycle

CaO

CaCO3

•H2O

Current prototype setup

CaCO3



Alstom’s LCL™Options and Applications

Option 1 – Combustion with CO2 Capture

Reducer Oxidizer

CaSO4 CaS

N2

AirCoal

CaCO3

SteamAsh, CaSO4

to Disposal

Calciner CO2

H2

Option 3 – Hydrogen with CO2 Capture

R e d u c e r O x i d i z e r

C a S O 4 C a S

N 2

A irC o a l

C a C O 3

S t e a mA s h , C a S O 4

t o D is p o s a l

S y n g a sC O , H 2

Option 2 – Syngas with no CO2 Capture

• CO2 Capture – PC Retrofit• CO2 Capture – CFB Retrofit• CO2 Capture-Ready Power Plant• Advanced Steam Cycles

• ICGG with Down-Stream CO2 Capture• Industrial Syngas• Coal-to-Liquid Fuels

• CO2 Capture – PC Retrofit• CO2 Capture – CFB Retrofit• CO2 Capture-Ready PC/CFB Power Plant• Advanced Steam Cycles• IGCC with CO2 Capture• Fuel Cell Cycles• Industrial Hydrogen, CO2

• Lowest Cost CO2 Capture Option• Competitive with or without CO2 Capture

Applications

Reducer Oxidizer

CaSO4 CaS

N2

AirCoal

CaCO3

SteamAsh, CaSO4

to Disposal

CO2

Steam



Alstom’s LCL™Prototype Testing (3 MWt)

Prototype (3 MWt)

• Main objectives: – Design, engineering, construction and operation– Autothermal operation of prototype– Provide data required to design, build and operate a reliable

demonstration plant

• Status: – Engineering & go/no-go (Oct 2008 – Apr 2010)– EPC, Shakedown (Apr 2010 – Dec 2010)– First coal firing - May 2011– Autothermal operation achieved in July 2012; 40 hrs May 2013– Current activity: Phase II Test 1; Facility Move

• Total DOE-funded budget: $9.2 million (80% DOE):– 8.2 for preliminary engineering and EPC– 1.0 for preliminary testing

• Additional Alstom funding of $3.5 million to achieveautothermal operation plus a 40 hour autothermal run

65 feet



Alstom’s LCL™- 3 MWth Prototype PerformanceHighlights

• Achieved 1st autothermal operation on two crushed coals.

• Performance is not perfect, but good enough to see:

– Major chemical looping reactions take place– Test results indicate directions for improvement

• No major concept changes have been required.

•Highlights:

• 40 hour Autothermal Operation • Coal-only operation (Pittsburgh & Adaro)• Chemical looping reactions working• Unburned carbon < 0.5%• Up to 96% carbon capture achieved• Sulfur controllable to near zero• Stable operation for long periods

02

00

400

60

08

00

10

00

12

00

lb/h

r

Thu 05/09 Fri 05/10 Sat 05/11 Sun 05/12

100

01

20

01

40

016

00

180

020

00

°F

coal flow gas flow red temp ox temp



2nd Generation Oxyfuel (LCLTM and MeOx) CombustionSummary

• CLC technology:

− Potential for high efficiency, low cost power and low cost CO2 capture

• CLC flexiblity:

− New or retrofit application− Syngas, hydrogen or power

• CLC appears feasible for limestone and MeOx

• Next steps - field demonstration:

− power or refinery− 10-50 MWe scale

Chemical Looping Potential – Flexible and Low Cost



Acknowledgements and Disclaimer

AcknowledgementSome of work presented was supported by the U S Department of Energy through the National Energy Technology Laboratories under Agreement DE NT-0005290. The guidance and direction of NETL Project Managers Steve Mascaro and Tim Fout is acknowledged and appreciated.

DisclaimerParts of this presentation 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.

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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Capture 2 – Oxyfuel Introduction to Oxy-fuel technologies