Stage 1 – Capture at Callide A Power Station Commissioning

2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 1

Stage 1 – Capture at Callide A Power Station Commissioning Experience

Chris Spero, Lyle Chapman, Franco Montagner

2nd IEA GHG Oxyfuel Combustion Conference Tuesday, 13 September 2011 Plenary / Panel Session 01


1.Statement of design intent – what is our target planned 2.Callide A site and retrofit issues – what we did 3.Commissioning activities boiler and ASU – post conversion

activity 4.Operational issues – what we have learnt

• Furnace pressure control • Safety systems • OH&S issues

5.Environmental Requirements – what are our precautions 6.CPU commissioning and overall program – what comes next 7.Site Activities to Date – SOME PICTURES

Presentation Outline


Features of the Oxyfiring system: 1. The boiler has two operation /combustion modes; Air mode and Oxy mode

• Air mode - Coal is burned with air (as normal)

• Oxy mode - Coal is burned with the mixed gases of 98% pure oxygen produced with ASU and RFG (recirculated flue gas) instead of air.

2. Normal start and stop operation is conducted only in Air mode only

3. Overall plant operating target are as follows:

• Ramp rate in Oxy mode 1% / minute (nominal)

• Minimum load (Turndown) in Oxy mode 80%

• Mode change time (Air mode to Oxy mode) 60 minutes

• Mode change time (Oxy mode to Air mode) 60 minutes

4. Mode change can be conducted between 80%MCR and 100%MCR – No requirement for Oxy mode start/stop or low load.

Boiler Design Intent


Pulverised Coal Consumption

5.5 kg/s 20 tph

Quality

CV 19MJ/kg a.r. Ash 21% a.r.

Sulfur 0.3% daf Anglo Callide Coal mine

Steam Flow 37.7kg/s or 136 t/h Pressure 4.1MPa, Temperature 460oC

Oxygen Gaseous

Purity 98%Vol Oxygen Pressure 180kPa(a)

Flow 7.6kg/s 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 – Mass Balances (Simplified)


General Site Positives and Negatives

Site Layout

Parasitic Load

Cooling Requirements

Restarting a Stored Unit

Control System

Plant Identification

Industry Norms

Boiler Conversions

Retrofit Challenges/Issues for Callide A


• Liabilities - Asbestos, Undocumented Underground Services, AS1657 – Stairs, walkways, ladders, Emergency Lighting, Ash Storage, Turbine Hall Crane, Bunding of Tanks, PCBs, Fire system Issues, Construction Site Amenities, Site Access for large loads

• Advantages – Size, it is available, Refurbished in 1998 and operated for 2-3years before mothballing in 2001, New control system installed in 1998, many support possibilities with Callide B/C nearby



Callide A - Site Layout



Site Layout

Parasitic Load



Control System


Industry Norms

Boiler Conversions



Control Systems



Site Layout

Parasitic Load



Control System


Industry Norms

Boiler Conversions



Primary air heater • tubular type heat exchanger

• to avoid low temperature corrosion in PF pipes

FGLP heater • avoid high temperature damage to fabric filters

• heats feed water for efficiency

Feed water booster pumps

H2O remover

O2 pipe and injection points

Burners

Boiler Conversions


Boiler Conversion


Boiler Conversion


Boiler Conversion


Boiler Conversion


Boiler Conversion


Operating and Commissioning Status


New boiler Draught fans – higher pressure FD fan ID FAN

OLD NEW OLD NEW 2 x 50% 1 x 100% 2 x 50% 1 x 100% 97 kW each 420 kW 179 kW each 530 kW 1340 m3/m ea 2380 m3/m 1950 m3/m ea 4220 m3/min 985 rpm 1485 rpm 980 rpm 1485 rpm 3.3 kPa 7.6 kPa 3.9 kPa 5.5 kPa 40 C 150 C 149 C 150 C

New control dampers – linkage backlash

Furnace press. control method – closed loop, feed forward

Original O2 trim logic – no bump-less switch

Tuning expertise – to confirm stability limit & control block

Furnace pressure control


Pulverised Coal Mills

• Original Riley-Dodd hammer mill design

• 3 Mills per unit – 2 Duty and 1 standby

• generally 2 Mills in service at Loads between 40 and 100% in air firing

• Hammer mill type - 2,500 operating hours between major services

• Fuel Oil start up burners

Pulverised Coal Burners

• 6 Burners per Boiler – 4 duty and 2 standby

• 2 Burners per Mill

• C Row burners – Top – Existing design – Riley Dodds 1960s design

• A Row burners – Middle – New – IHI design replaced in 2010

• B Row burners – Bottom – Existing – Riley Dodds 1960s design

Coal Pulverising Mills/Burners


Original boiler and turbine protection in DCS (Siemens Teleperm XP installed in 1998)

Compliance of the retrofitted plant in accordance with Queensland Legislation and the IEC EN 61508 & 61511 standards.

Process

Power Plant Safety System

HAZOP Safety Integrity Level (SIL) Study

Implementation Independent Functional Safety Assessment (FSA)

Safety Integrity Level (SIL) Study • Objectives

• target safety performance

• Boiler coal firing , for both Air / Oxyfiring modes, and ignition fuel oil

• Outcomes - 23 Safety Instrumented Functions (SIFS) identified for the Boiler • Air Firing - 13xSIL1, 5xSIL2

• Oxy Firing - 15xSIL1, 3xSIL2

Implementation • Fork in the Road

• Common Process control and protection system

• Standalone new safety system

• Standalone pathway chosen • Why? – least expensive option for short

term demonstration

• Duplication between boiler control and protection logic. This introduced ‘two masters’ resulted in more complex trip investigation as both systems required examination


Control Systems


Potential hazards identified as follows:

• OH&S issues with leakage of Recycle Flue Gas (CO2, CO, NO, NO2, SO2, SO3)

• OH&S and fire issues with leakage of O2

Nodes/systems identified:

• RFG from existing and new plant From furnace in the event of a

pressure excursion

Downstream of FD fan (Secondary gas and Primary gas )

• O2 from oxygen valve skid to point of entry to Secondary gas duct

RFG & O2 – Operational Hazard Assessments


Assessment methodology

• Releases modelled based on Explosive Atmospheres method in AS/NZS 60079.10

• Assessment for RFG made on the basis of 4 parameters: Release rate (through a notional hole, crack, perforation, etc)

Notional volume into which the constituent is released (open, confined etc)

Short term exposure limits (STEL) for CO2, CO, NO2, etc.

Persistence time

• A standard likelihood and consequence of each hazard is identified

• Countermeasures are proposed to address the potential hazards

• Similar approach applied to oxygen based on a Lower Limit for a fire hazard of 23.5 mol%.

Hazard assessment methodology


Callide A Power Station Construction Activities Site Hours as at 31 August 2011


Operating and Commissioning Look Ahead


Oxygen plant

CO2 capture plant

COP – Site Works – Oxygen and CO2 Capture Plant


Heavy Lifts #1 – Boiler Primary Air Heater Lift - 27 Nov 2011

Triple Crane Lift • Weight: 64,000kg (not incl rigging)

• Final height – 18m above ground

Cranes • 280t Sumitomo Crawler

• 2x130t Grove All Terrain Cranes

27 Nov 2011 attempt cancelled due to high wind

Successfully completed on 29 Nov 2011.


Heavy Lifts #2 - Oxygen Plant Cold Box Column Lift – 30 Apr 2010

Dual Crane Lift • Weight: 72,573kg (not incl rigging)

• 29.3mH x 4.8mW x 4.4mL

Cranes • 280t Sumitomo Crawler Crane

• 130t Grove All Terrain Crane


Heavy Lifts #3 – Co2 Plant

Flue Gas Compressor • Compressor baseframe 33,000kg (gross)

• Compressor other 23,694kg

CPU Cold Box • 27,248kg

• 16m Tall

• 3.94m x 3.1m

Liquid CO2 Tank (capacity 100t) • 36,000kg

• 3.1m Internal diameter


Callide A - Construction


Concluding comments

1. Contracting strategy

• Terminal point management

• Flexible arrangements

2. Construction on an Operating Site

3. Multiple Stakeholder interests and expectations


Thank you

for more information: www.callideoxyfuel.com

Callide Oxyfuel Project – Participants

Documents

Stage 1 – Capture at Callide A Power Station Commissioning