Happipoltto

Arto HottaFoster Wheeler Energia Oy

CCS Seminaari 28.10.2009 Hanasaari, Espoo

Contents of Presentation

• Background

• Oxyfuel - General

• Foster Wheeler’s activities on Oxyfuel

Background

Main Technology Options to reduce CO2 in Power Production with Fossil Fuel

• Short and medium term approach to CO2reduction:• Increase of efficiency

• Co-firing of coal with fuels considered CO2neutral

• Main technology options for CO2 capture in power production• Post-combustion capture

• Pre-combustion capture

• Oxy-fuel combustion

Impact of efficiency improvement and co-firing on CO2 reduction

100% coal

Thermie Ultimo

Thermie SR

Average Europe

CFB today

10% biomass

20% biomass

400

500

600

700

800

900

1000

1100

1200

25 30 35 40 45 50 55 60Net efficiency (lhv, %)

2 CO emission (g/kWh)

% biomass on LHV

37%

21%

Principle of Oxyfuel Technology

In Oxyfuel combustion nitrogen oxides in boiler flue gas are replaced with CO2

The air separation unit (ASU) is used to separate O2 and N2 from air and produce nearly pure oxygen for combustion

O2 mixed with recycled flue gas is used as oxidant, which replaces the combustion air. The O2 content in combustion can be the same as in air firing.

The flue gas from boiler will consist mainly of CO2 and water vapour, which will enable the capture of CO2 in CPU (Carbon Processing Unit)

Oxyfuel Combustion Process

Steam turbine

Flue gas recycle

Boiler CompressionPurification

Flue gas cleaning

CO2

Air Air separation N2, (Ar)

G

CoalCO2/H2O

H2O

Condensation

TransportStorage

Vent gas95-99+% O2, (Ar, N2)

Oxy-Fuel Combustion Process

Source: Vattenfall

Status of Oxy-fuel development

•Vattenfall has successfully operated Schwarze Pumpe 30 MWth Oxy pilot: PC boiler supplied by Alstom• Construction of Callide Oxyfuel 30 Mwe Demonstration in Australia has started• Totals pilot in Lacq started oxyfiring (oil, gas)• Babcock Willcox has started testing in 30 MWth Oxy-Coal Test Facility (PC)• Doosan Babcock Energy has started up 40 MWth Oxyfuel Combustion System (PC)• Construction of CIUDEN’s CCS technology Platform started. Oxy CFB and PC piloting in 30 MWth scale• Several other pilot and demonstration projects planned or under condtruction

EEPR (European Energy Program for Recovery) proposes two Oxyfuel projects out of total six demonstrations to be funded:• Vattenfall (Oxy PC) 250 Mwe Jänswalde• ENDESA/CIUDEN (OXY CFB) 300 Mwe Compostilla

Source: Vattenfall

CCS Technology Development at Foster Wheeler

• CCS will be essential in meeting the challenge to cut the global GHG emission

• Of the main technology options, FW is mainly focusing on Oxyfuelcombustion in Circulating Fluidized Bed (CFB) boilers (PC technology in North America).

• Development carried out in parallel as• Internal development (modeling/design tools, boiler engineering, economics,...)

• Partnership in R&D with research institutes and universities (pilot testing, modelling, etc.)

• Participation in public R&D

• Demonstrations

Foster Wheeler Developes CFB Technology for Oxyfuel Combustion

• CFB Technology is proven and available in utility scale• Foster Wheeler is the market leader in CFB Technology with nearly 30 years and 22 GWe

67 %

18 %

9 % 4 % 2 % COALSPET COKEBIOLIGNITEOTHERS

350 CIRCULATING FLUID BED (CFB) BOILERS

• Total 24 000 MWe CFB sold• 309 in operation for variety fuels:coal, lignite, petroleum coke, biomass, RDF, etc.

• 32 under construction•465 Mwe OTU CFB in commercial operation• Offering up to 800 MWe

Tot. >24 GWe CFB

Oxyfuel CFB Technology – Flexi-Burn™Main Benefits

• The established CFB advantages exist also in CFB oxycombustion: low furnace temperatures, hot circulating solids, long solid residence time

• Multi-fuel capability (coal, petroleum coke, lignites, biomasses), simple feed systems – capability to utilize cheap fuels emphasized due to CCS efficiency penalties

• NOx and SOx reduction without back-end cleaning

• Good fuel burnout and sorbent utilization

• Efficient heat transfer and uniform heat flux

• Enables Flexi-Burn CFB boiler design: the same boiler can be operated in air firing or oxy firing mode with CCS

Further potential to use high O2 contents

• Reduce boiler size

• Limited capability for air firing "Flexi-BurnTM" is trademark of Foster Wheeler AG

Challenges of Oxyfuel CFB Technology

• Understand the significant change in gas atmosphere in OXY mode

Changes in hydrodynamicsBehaviour of materialsEmissions predictionAdaptation of design tools

• Achieve high gross efficiency to minimize penaltyAim at steam parameters > 600 °C, 270 bar

• Reduce oxygen production costs• System-level integration to reduce investment costs and

to improve efficiency

Oxy-fuel CFB is considered technically viableExperiments in bench scale and pilot test facilities combined with modelling required to confirm the

process performance and material behaviour in the CO2 rich atmosphere Demonstration in 10’s of MW scale and commercial scale required to proof the concept - design,

performance and economics

CCS technologies Oxy-Fuel TechnologiesEfficiency Penalty

• Maximizing gross efficiency to minimize penalty• Reduction of oxygen production costs• High internal power consumption

Cooling 1084MW (53.5%)

Efficiency (net),%

05

1015202530354045

Ref

eren

cepl

ant

O2/

CO

2pl

ant

Fuel input 2026MW 100%

Original electricity output 865MW (42.7%)

CO2 compression 71 MW – 3.5%

Air separation137 MW – 6.8%

Auxiliaries 45 MW – 2.2%

Air separation and CO2 compressionrequires massive amounts of energy...

...resulting in 8-12 %-points lower efficiency

689MW output –34%

Source: Chalmers / Andersson

• System-level integration• Space requirements

Oxy-Fuel power plant requires large space for ASU and CPU

BOILER ISLAND

80 m

200 m

Flue gas recycle

Oxygen

Flue gas condenser

100 mASU 1

ASU 2

CO2

COMPR.

80 m

100 m

Development of OXY CFB TechnologyIntegrated Experimental and Modeling Work for Scale-Up

CIRCULATING FLUIDIZED BED REACTOR

S e c o n d a ryc y c lo n e

F u e l c o n ta in e r 1 a n d 2 Z o n e 1

Z o n e 2

G a s c o o l in g

P r im a ryc y c lo n e

O b s e r v a t io n p o r tS a m p l in g p o r t/D e p o s it p ro b e

Z o n e 3

Z o n e 4T o s ta c k

S a m p lin g p o r t

S a m p lin g p o r t

O b s e rv a tio n a n d s a m p lin g p o r t/D e p o s i t p ro b e

A d d i tiv ec o n ta in e r

O 2

S e c o n d a ry g a s(p re h e a te d )

P r im a ry g a s h e a t in g

C O 2 / N 2

P C c o n tro l a n d d a ta lo g g in g s y s te mP C c o n tro l a n d d a ta lo g g in g s y s te m

S a m p l in g p o r t

S a m p l in g p o r t

A ir

nc Xkm

tm

r O2cc

dd

==

COefCO Ykt

Y=−

dd

)/1/(1 mCOef kk τ+=

nrefv ddTAb )/)(/exp(=τ

Modelanalyses

CO combustionMixingChar combustion

Volatile, m

oisture r

elease

k W /m 2

1D -M O D E Lflue g a s

1

n n+ 1

to s ta ck

Pr im ary a irS econ da ry a ir

2

n-1

3

n-2

B E N C H S C A LE R E A C TO R (B F B /C F B )

A ir

O 2, C O 2, C O , N 2 , S O 2 , N O

S econdary a ir

C ontinuousfue l fee d

Fue l ba tch feed

C oo ler/hea ter

C oo ler

P rim a ry gas heatin gPC con tro l and da ta logg ing sys tem

C yc lone

F ilte rTo S tack

B E N C H S C A LE R E A C TO R (B F B /C F B )

A ir

O 2, C O 2, C O , N 2 , S O 2 , N O

S econdary a ir

C ontinuousfue l fee d

Fue l ba tch feed

C oo ler/hea ter

C oo ler

P rim a ry gas heatin gPC con tro l and da ta logg ing sys tem

C yc lone

F ilte rTo S tack

A ir

O 2, C O 2, C O , N 2 , S O 2 , N O

S econdary a ir

C ontinuousfue l fee d

Fue l ba tch feed

C oo ler/hea ter

C oo ler

P rim a ry gas heatin gPC con tro l and da ta logg ing sys tem

C yc lone

F ilte rTo S tack

ŁAGISZA 460 MW e supercritical OTU CFB

kW /m 2

Bench scale Pilot scale Boiler scale

1-D design model3-D process model

EXPERIMENTAL SCALES

MODELS AND DESIGN TOOLS

Models for phenomena

1-D process models (stationary, dynamic)

10 MW scale

Development of Flexi-Burn CFBMain Activities

• Of the main CCS technology options, Foster Wheeler is mainly focusing on oxy-fuel combustion, having been developing it since 2003:

• Knowledge and design tool development• Test activities (VTT bench scale & small pilot CFB)• Conceptual and feasibility studies (boiler design)

• Pilot test activities at larger scale facilities • ~0.1 MWth (current) → ~1 MWth (2009) → 30 MWth CIUDEN (2011)

• In parallel, scale-up of air-fired CFB boilers has continued. The world largest and first SC-OTU CFB at PKE’s Lagisza plant in Poland is in commercial operation and and FW has developed the OTU CFB boiler concept further up to 600-800 MWe size with 600 °C steam temperature.

• The Spanish government has decided on investment for the CIUDEN 30 MWth class pilot CFB facility, which provides a full experimental CCS platform for the demonstration and validation of oxy/air fuel combustion in sufficient scale to allow continuation to commercial scale.

Development of Flexi-Burn CFBMain Activities

•The Oxy-CFB 300 MWe project of ENDESA and CIUDEN has been shortlisted as one of the CCS demonstration project to be funded from EEPR (European Energy Program for Recovery) program

• FW has prepared a feasibility study for the 500 MWe Oxy CFB Power plant with CCS for ENDESA• FW is a cobeneficiary in Oxy-CFB 300 EEPR project and will develop the technology for the Oxy CFB boiler

• Feasibility studies with other utilities• Vattenfall 500 MWe CHP power plant with Oxyfuel CFB

• PVO 500 MWe multifuel Oxy ready CFB plant (biomass cofiring)• EU FP7 project "FLEXI BURN CFB” aiming at the development of technology to be ready for demonstration

•FW participates in the development of 50 MWe Oxy-CFB demonstration project at Jamestown plant in New York state and the 78 MWe Oxy-CFB project developed by Praxair and New Holland Board of Public Works.

Development of Flexi-Burn CFBScale-Up Path

Commercial scale Flexi-Burn Oxy CFB

technology demonstration in <500 MWe size by

2015

Backgroundfor engineering

Air- / oxyfiring

+ CCS expertise

Existing know-how• Supply of over 300 CFB boilers up to 460 MWe• Long-term development of design tools

Flexi-Burn Oxy CFB technology

commercial up to 800 MWe size by 2020

Lagisza 460 MWe OTU CFB• Scale-up information from the world's largest CFB• Experiences of the world's first SC OTU CFB• Design model validation

Scale-up criteria

CIUDEN - demonstration of Flexi-Burn CFBAir- / oxy-fuel combustion with fuel flexibility• CO2 separation

Conclusions

www.oxygenie.com

• The piloting done both with PC and CFB technologies have shown the viability of Oxyfuel

• Oxyfuel is a realistic option for CCS

• Large scale demonstration of Oxyfuel will be supported by EU

• The Oxy CFB development targets to have the commercial scale CCS demonstration plant in operation in 2015 and the technology to be commercial in 2020

www.oxygenie.com

Thank You!