CFB Technology Solutions for CO2 Capture

September 10-13, 2013, 3rd Oxy-Fuel Combustion Conference, Ponferrada Spain

Arto Hotta, Foster Wheeler Energia Oy

• Where are we today with CFB technology

– Atmospheric CFB

– OXY-CFB - Flexi-Burn™

– Challenges and potential to improve 1st

generation OXY-CFB

• Emerging technologies

– 2nd generation OXY-CFB - High-O2 design

– BioCCS

– Carbonate looping

– Chemical looping

• Conclusions

Presentation Outline

1

Where Are We Today with CFB Technology

2

CFBs Has Succesfully Entered in Utility Market

Pilot Plant Oriental Chem

General Motors

Tri State

Vaskiluodon Voima

Nova Scotia

Turow 1

JEA

0

100

200

300

400

500

600

700

800

1979 1981 1984 1986 1987 1990 1993 1998 2001 2009 2015

Unit Size in MWe's

Unit Start-up Year

Lagisza SC

Global CFB Market Share over 2007-2011

Source: FW sales database and FW-McCoy database for FW served markets

FW 68 %

Others 32 %

All CFB's

FW 91 %

Others 9 %

CFB's over 200 MWe

Samcheok USC 4 X 550 MWe UNITS

3

Foster Wheeler CFB Evolution

Sold 415 CFB Units, (32 GWe) logging over 30 million hours of operation

Samcheok 4 x 550 MWe

Coal & Biomass Co-Fired Supercritical CFB Project

• 4 x 550 MWe supercritical OTU-CFB

to feed 2 x 1100MWe turbines

– 437/356 kg/s, 25.6/5.4 MPa, 603/603 °C

– Efficiency 42.4% (net)

• Fuel flexibility

– Lignite/subbituminous coal max. 5%

share of wood pellets

• End client:

KOSPO, Korean Southern Power Co. Ltd.

• Foster Wheeler scope:

Basic design of boiler plant and delivery

of hot loop pressure parts etc.

• Contract signed (NTP): June 2011

• Commercial operation: 2015

4

0

10

20

30

40

50

60

70

80

90

100

20

15

20

15

20

13

20

12

20

12

20

11

20

10

20

09

20

08

20

08

20

07

20

07

20

05

20

05

20

04

20

03

20

02

20

00

19

98

19

98

19

96

19

95

19

94

19

92

19

91

19

90

19

89

19

88

19

86

19

83

Cu

mu

lati

ve

Th

erm

al

Ca

pa

city

[G

Wth

]

Delivery year

Coal Is the Dominant Fuel for CFB

Fuel Flexibility the Main Driver

Jyväskylä 2013

Coal70 %

Biomass10 %

Waste3 %

Peat5 %

Petcoke11 %

Oil-shale1 %

CFB’s fuel flexibility is available for oxy-fuel

5

Sold 415 CFB Units, (32 GWe) logging over 30 million hours of operation

6

OXY-CFB technology has been succesfully tested for carbon

capture in large pilot scale at the CIUDEN Technology

Development Plant.

FUEL

PREPARATION

BIOMASS

GASIFIER

PC BOILER

20 MWth

CFB

BOILER

30 MWth

TECHNICAL

BUILDINGS AND

CONTROL ROOM

FLUEGAS

CLEANING

FLUE GAS

RECIRCULATION

AND MIXING

CO2

PURIFICATION

CO2 TRANSPORT RIG

CFB for Oxy-Fuel - Flexi-Burn™ CFB

PO

mixer

SCAH

HRC

To CPU

Oxygen

SO

Boiler house

• 300 MWe Flexi-Burn CFB

boiler has been developed in

the OXY-CFB-300

Compostilla project.

• The capture technology is

considered ready for

demonstration in large

commercial scale.

• The same advantages as

with atmospheric CFB are

expected for oxy-fuel

combustion

7

OXY-CFB-300 Boiler Scale-Up

Parameter Unit CIUDEN OXY-CFB-300 Lagisza

Furnace dimensions

Height m 20 37 48

Width m 2.9 28 27.6

Depth m 1.7 7 10.6

Number of separators - 1 4 8

Thermal power(1

Oxy mode (max.) MW 30 708 --

Air mode MW 14.5 647 966

Steam parameters(2

SH steam flow t/h 47.5 845 1300

SH steam temperature °C 250(3

600 560

SH steam pressure bar 30 279 275

RH steam flow t/h -- 745 1101

RH steam temperature °C -- 601 580

RH steam pressure bar -- 56.5 50.3

Feedwater temperature °C 170 290 290

Notes: 1) At CIUDEN fuel input; in others heat to steam

2) Steam parameters in Lagisza at turbine inlet

3) After spraying

8

TECHNICAL risks are manageable and can

be solved in demonstration and further R&D

– Long term reliability and performance

– Integration and efficiency

improvement

– Dynamics and load change flexibility

– Boiler materials

– Widening fuel experience

BUT:

– CCS has to prove its merits and the

safety of storage to public

– High costs are evident and will remain

higher than conventional technology

> business case

What Is Needed from

Commercial Demonstration and Future R&D

9

Emerging Technologies for CO2 Capture

10

• BioCCS

• 2nd generation

OXY-CFB - High-O2 design

• Chemical looping

• Carbonate looping

Emerging CFB Technology Solutions for CO2 Capture

11

• Biomass cofiring was tested in

CIUDEN

• OXY-CFB allows same fuel

flexibility as air fired CFB.

• Additional work needed to verify

agglomeration, corrosion etc.

• For CCS large unit size will not

favor 100% biomass but cofiring

with coal will be a realistic

option.

BioCCS

12

-200

0

200

400

600

800

1000

Average Europe

CFB today CFB today+20%

biomass

CCS CCS+20% biomass

CO2 emission (g/kWh)

Carbon sink?

BioCCS - Impact of Efficiency Improvement

Biomass Co-Firing and CCS on CO2 Reduction

-21%

-37%

-91%

-120%

CFB’s fuel flexibility is

available for oxy-fuel Oxy CFB 300

95 gCO2/kWh

13

2nd Generation OXY-CFB - High-O2 Design

O2 40 %

52 x 29.7 x 9.5

O2 24 %

H x D x W (m)

• Development of OXY-CFB with

higher oxidant O2 up to 40%

ongoing in O2Gen project funded

by EU FP7 • To be tested in CIUDEN

• High O2 will result in

– Reduced flue gas recirculation

and flue gas volume

– Reduced fan power

– Reduced CAPEX of the boiler

– Challenge to pack heat surface in

CFB hot loop - 40 % O2

maximum

– Not possible to operate in air

mode 14

42 x 41.8 x 10.5

Design comparison of 40% and 24% O2 content in oxidant

-50%

-31%

+38%

-41% -34%

• Carbonate looping works with CFB’s

– Carbonator is a CFB reactor

– Calciner is oxy fired CFB

• Carbonate looping has been operated with coal

in 1 MWth pilot CFB units both by

Epple (TU Darmstadt) and in 1.7 MWth pilot

by Abanades (CSISC Incar)

– Both have reported stable operation and high

CO2 reduction on coal firing

• Provides potential to reduce efficiency penalty

Carbonate Looping

16

CARBONATORT = 650 °C

CALCINERT = 900 °C

Flue gas from power plant

Decarbonised flue gas

CaCO3

CaO

CO2 to compression

Ash and deactivated

material

Oxygen

Fuel

Make-upCaCO3

24

m

Campaign Coal

• Max. CO2 absorption carbonator: 88 %

• Max. total capture efficiency: 93 %

Results of 20 hours of CO2 capture (calciner coal-fired)

Carbonator Calciner

CO2 absorption carbonator

Total CO2 capture

O2 inlet concentration

CO2 conc. in calciner flue gas

Energy Systems

and Technology Prof. Dr.-Ing. B. Epple

COORETEC Project “LISA” - Limestone based Absorption of CO2

17

Typical example of steady state tests (CSIC-INCAR)

CARBONATOR

- Average carbonator temperature= 660 ºC

- Inlet gas velocity= 3.5 m/s

CALCINER

- Average carbonator temperature= 915 ºC

- Average gas velocity= 4.7 m/s

0.0

0.2

0.4

0.6

0.8

1.0

19:00 19:30 20:00 20:30 21:00 21:30 22:00 22:30 23:00

CO

2 c

aptu

re e

ffic

ien

cy

0

2

4

6

8

10

12

14

Car

bo

nat

or

CO

2 (

%)

CO2 equilibriumCO2 experimentalCO2 inCO2 out

0

20

40

60

80

100

19:00 19:30 20:00 20:30 21:00 21:30 22:00 22:30 23:00

Cal

cin

er

CO

2

(%)

0

10

20

30

40

50

60

Cal

cin

er

SO2

(pp

m)

CO2 out

SO2 out

Source: Spanish Research Council (CSIC-INCAR), Oviedo, Spain

18

Results

CARBONATORT = 650 °C

CALCINERT = 900 °C

Flue gas from power plant

Decarbonised flue gas

CaCO3

CaO

CO2 to compression

COMBUSTORT = 1000 °C

FuelAir

Heat

Standard carbonate looping

Indirectly Heated Carbonate Looping Process

19

• Both Epple and Abanades have

developed advanced carbonate

looping process for CO2

capture to avoid ASU.

• Different solutions for calciner

heat introduction.

• Needs CFB carbonator and

CFB combustor.

Air Coal

CaO

+

CaCO3

Hot

CaO

CO2

Flue Gas

CaO

CFBC> 950 ºC

Carbonator650 ºC

Calciner~900 ºC

Flue gas (low CO2)

CaO CaO

CaCO3

Chemical Looping

20

TU Darmstadt

• Operated the two CFB's in coupled

mode under hot conditions for more

than 2000 hours.

• CO2 capture rate of more than 90%

have been achieved.

• Stable operation for CO2 capture

with more than 300 h burning

Colombian coal.

RFCS Project ECLAIR - Emission Free Chemical Looping Coal Combustion Process

• First Generation OXY-CFB is ready for demonstration

– Allows operation on oxy and air mode reducing commercial risk of

demonstration.

– Same boiler size and scale-up possible as with air fired CFB.

– CFB offers the same benefits in oxy combustions as in air mode, i.e. fuel

flexibility, in-furnace emission capture etc.

– Allows additional potential for CO2 reduction by cofiring carbon neutral

biomass.

– Potential for savings in fuel costs and use of local fuel.

• BUT

– CCS must be approved by public.

– CCS is economically competive with renewables

– similar support mechanisms could make first demonstrations

economically feasible

Conclusions

21

cont.

• Emerging technologies have been successfully tested in pilot scale

but are far from commercial demonstration

– High-O2 design looks technically feasible. Provides CAPEX and OPEX

savings but looses flexibility for air mode operation. 1st generation CCS

technologies need to be demonstrated before any further steps will be

taken.

– Carbonate and chemical looping has been successfully tested in 1 MWth

pilots with coal. Both will have high scale-up challenges and need

smaller scale demonstation. It is unlikely that any demonstration will be

funded until CCS is commercial reality.

Conclusions

22

The work leading to these results has been co-financed under the European Community’s Seventh

Framework Programme (FP7/2007-2013) under grant agreement n° 239188 and the EEPR09-CCS-

COMPOSTILLA Project (European Union's European Energy Programme for Recovery).

www.fwc.com