CIUDEN´S FACILITIES FOR ADVANCED ON CO CAPTURE AND …

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II Avenida de Compostilla, nº 224400 Ponferrada (León)Tel.: +34 987 456 323Fax: +34 987 419 570www.ciuden.es

CIUDEN´S

TEST FACILITIES FOR ADVANCED

TECHNOLOGIES ON CO2 CAPTURE AND

STORAGE IN COAL POWER GENERATION

EL BIERZO, SPAIN

May 2009

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1. INTRODUCTION

At present fossil fuels are the dominant source of the primary energy global demand, and will likely remain so for the next decades. Sustainable development demands a balance between social, economic and environmental considerations. The current challenge is to reduce CO2 emissions while meeting world energy demand which is expected to increase by over 50% by 2030. Energy projection made by the World Energy Council, the International Energy Agency (IEA) and the US Energy Information Administration give similar pictures of future energy requirements.

In December 2008, the European Union took a set of key decisions to address the future of energy in Europe: to drive an energy sector able to make cuts in greenhouse gas emissions and to make renewable energy a major part of Europe's energy mix. At the New Year, Europe was faced with a gas crisis which highlighted the risks to security of supply. It underlined weaknesses not only in terms of diversity in imports, but in terms of the ability of the EU to transfer energy inside the Union to where it was most needed.

The European Commission presents the Strategic Energy Technology Plan (SET Plan) to accelerate the development and deployment of cost-effective low carbon

technologies.

Carbon Capture and Storage technologies (CCS) have the potential to play a key solution in reducing CO2 as required by international protocols. Energy efficiency and renewables are in the long term the most sustainable solution both for security of supply and climate. But the portfolio of solutions considered for reducing the emissions must include capturing CO2 from industrial installations and storing it in

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geological formations, to reach the target of world emissions reduction by 50% in 2050. This would allow Europe to take full advantage of its indigenous supplies of coal, oil and gas. The development of the CCS technology would give European industry an important market opportunity in a technology of global relevance.

CCS is a complex technology which may take years to reach commercial viability. Therefore, there are still important challenges necessary to overcome before the commercial implementation of CCS technologies. The European Council recognised the potential of CCS by setting a target of having up to 12 demonstration projects in place and running by 2015. The European Council decided last December to guarantee funding for CCS through a share of revenues from ETS auctioning.

Additionally, the Spring European Council approved in March 2009 the allocation of 3,5 billion Euros to energy projects, financed by the EU budget within the European Economic Recovery Plan (EERP). In the particular case of CCS technologies, the Commission proposed a core set of projects, each one allocating to 180 million Euros. This selection included 2 projects in Germany, 4 in the United Kingdom, 3 in The Netherlands, 1 in Poland and 1 in El Bierzo, Spain (The Compostilla project). A second category includes 2 additional projects in Italy and France respectively. However, the Commission will retain no more than one project per Member State, which must fulfil main award criteria such as (1) maturity of the project, defined as reaching the investment stage and incurring substantial capital expenditure by the end of 2010, (2) the extent up to which lack of access to finance is holding back the implementation of the action; (3) capability of capturing at least 85% of the CO2 stream in industrial and power installations, and (4) large scale with minimum size of 250 MWe.

The Spanish project is composed of a set of actions being developed in coordination between the Fundación Ciudad de la Energía (CIUDEN) and the Spanish utility ENDESA. This is the only one public-private partnership (ppp) project existing nowadays.

The Spanish energy policy objectives are consistent with the broader EU targets on energy, particularly to promote security of supply and environmental sustainability. In this context, the contribution of fossil fuels to the Spanish energy mix in terms of primary energy and power generation is shown below. There is a significant increase in the share of renewables for the next coming years but fossil fuels, specially coal and natural gas used in a sustainable way, will remain as the main contribution in power generation.

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PRIMARY

COAL

13,7%

OIL

43,8%

NATURALGAS

21,8%

+

RENEWABLES

7,0%

NUCLEAR

9,8%

TOTAL 147 MTep

POWER GENERATION

COAL

24%

OIL

6%

NATURALGAS32%

+

RENEWABLES

19%

NUCLEAR

18%

TOTAL 312 GWh

DOMESTIC COAL ACCOUNTS FOR ca. 30% OF POWER GENERATION IN SPAIN

DOMESTIC COAL ACCOUNTS FOR ca. 30% OF POWER GENERATION IN SPAIN

*2007

Contribution of fossil fuels to Spanish energy mix

Additionally, Spain’s coal-based electricity generation relies on a large number of relatively mature power stations which will require a deep transformation in the forthcoming years.

INST

ALLE

D P

OW

ER (M

W)

YEARS FROM CONSTRUCTION BY 2020

0

1000

2000

3000

4000

5000

50-60 40-50 30-40 20-30

1231

8UNITS

4582

14UNITS

4413

11UNITS

562

1UNIT

Maturity of Spanish coal-based power stations

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2. FUNDACION CIUDAD DE LA ENERGIA

One of the current European initiatives in terms of R&D on CCS is the El Bierzo Ex-perimental Platform which is supported by the Spanish Government through The Fundación Ciudad de la Energía (CIUDEN). CIUDEN is a research and development institution created by the Spanish Administration in 2006 and fully conceived for collaborative research in CCS thus contributing to the strengthening of the indus-trial and technological base in Spain and by extension in Europe.

CIUDEN is founded by three Ministries of the Spanish Administration

CIUDEN is open for international cooperation to enhance European competitiveness through strategic research partnerships with industry, SMES, Universities and research institutions. In this sense, CIUDEN is part of the European Energy Research Alliance (EERA), aimed to accelerate the development of new energy technologies by conceiving and implementing Joint Research Programmes in support of the Strategic Energy Technology (SET) Plan.

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European TechnologyPlatform for Zero

Emission Fossil Fuel Power Plants

European Fossil Fuels Forum

International EnergyAgency GreenHouseGas R&D Programme

European EnergyResearch Alliance

SET PLAN

ExecutiveCommitee

CIUDEN International presence

3. THE CIUDEN CO2 CAPTURE PROGRAMME

CIUDEN´s main objectives are the research, development and demonstration of efficient, cost effective and reliable CCS as well as third generation flue gas cleaning through the design and operation of a large scale integrated test facility for advanced technologies on CO2 capture in coal power generation which incorporates the following technologies:

- Pulverized coal boiler, PC, (20 MWth) operating from air-mode to full oxymode

- Circulating fluidized bed boiler , CFB, (15 MWth air-mode, 30 MWth full oxy-mode)

- Flue gas cleaning train for NOx, dust and SOx

- CO2 capture: compression train (oxy) / absorption unit (air)

The test facility for CO2 capture is already under construction. The investment on the plant is of 84 million Euros, an amount which indicates the project magnitude and relevance, and will place Spain at the forefront of world’s CCS development initia-tives.

The facility is located in Northwestern Spain in the province of León, close to the 1312 MWe Compostilla Power Station, owned by Endesa.

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CIUDEN CCS large scale test Platform, close to the Compostilla PS

As already mentioned, the test facility includes oxyfuel pulverised coal and circulating fluidised bed combustors with flue gas cleaning for NOx, dust and SOx (SCR, fabric filter and wet FGD units respectively). The main oxyfuel train is followed by CO2 purification unit capable of producing a high concentration CO2 stream ready for transport and storage. This technology is to be complemented at a later stage with other CO2 separation alternatives such as absorption.

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Simplified process diagram

The configuration of the test facility is flexible, modular and versatile in order to test a wide range of operating conditions including different types of coal and combustion conditions from air mode to oxymode in independent but interconnected modules for simultaneous or separate operation.

The fuel variety to be used entails different ranges of coal and biomass, in particular, anthracites, bituminous and sub-bituminous European indigenous coals and pet coke.

PHASE II

PREHEATINGTRAIN

AIR

DeNOX

FGR1

O2 STORAGEAND

VAPORISATION

15-30 MWthCFB BOILER

O2PREHEATING

FGR2

HIGHEFFICIENCY

DeSOX

FROM COALPREPARATION

CFBBINC

MIXERS

BAG FILTER

PCBIN

20 MWth PC BOILER

STACK

BAG FILTER

CO2

EXPANDER

COMPRESSION TRAIN

ABSORPTIONSECTION

CO2

FGR2 RECIRCULATION

FGR2 RECIRCULATION

PHASE IIPHASE II

PREHEATINGTRAIN

PREHEATINGTRAIN

AIRAIR

DeNOXDeNOX

FGR1FGR1

O2 STORAGEAND

VAPORISATION

15-30 MWthCFB BOILER 15-30 MWthCFB BOILER

O2PREHEATING

O2PREHEATING

FGR2FGR2

HIGHEFFICIENCY

DeSOX

HIGHEFFICIENCY

DeSOX

FROM COALPREPARATION

CFBBINCCFBBINC

MIXERSMIXERS

BAG FILTERBAG FILTER

PCBINPCBIN

20 MWth PC BOILER20 MWth PC BOILER

STACKSTACKSTACK

BAG FILTERBAG FILTER

CO2

EXPANDEREXPANDER

COMPRESSION TRAINCOMPRESSION TRAIN

ABSORPTIONSECTION

CO2

ABSORPTIONSECTION

CO2

FGR2 RECIRCULATION

FGR2 RECIRCULATION

FGR2 RECIRCULATION

FGR2 RECIRCULATION

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Proximate analysis as received

(wet) Anthracite l Bituminous Coal

Sub-Bituminous

CoalPet Coke

Moisture (%) 8.8 7.5 26.8 6.8

Volatiles (%) 6.5 22.3 36.8 10.6

Ash (%) 32.0 13.8 1.5 0.8

Fixed carbon (%) 52.7 56.4 34.9 81.8

Ultimate analysis as received (wet)

C (%) 52.59 66.91 52.66 79.82

H (%) 1.68 3.37 3.76 3.93

N (%) 0.88 1.65 0.66 1.78

S (%) 1.07 0.38 0.09 5.11

O (%) 2.95 6.34 14.59 1.70

High heat value

H.H.V. (kcal/kg) as received (wet) 4888 6550 4941 7785

Design coal types for the CIUDEN test facility on CO2 capture

The main part of the test facility is the combustion island which contains the PC and CFB combustors.

CIUDEN CCS test facility configuration

The Pulverized Coal unit was dimensioned following the criteria generally used in commercial boilers, taking into account the peculiarities of a pilot plant in order to generate data / information in the experimental unit for a comparison between full-

Test Facility Facts: 20 MWth PC combustor 30 MWth (oxy) CFB combustor Coal consumption: 5.5 t/h O2 consumption: 8.8 t/h CO2 production: 10.5 t/h Construction start up: November 2008 Operation: May 2010

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scale operation. The combustor has been designed to operate with air whilst taking into account all necessary constraints in order to allow the unit to operate with oxygen such as limits of flammability, fuel injection, flame temperature, and furnace behaviour and heat transfer surfaces, providing the pilot boiler the necessary flexibility to achieve the testing objectives sought with oxy combustion:

• Technological development of oxy combustion for the energy sector

• Development of technological processes and fossil CO2 capture and treatment

PC combustor schematic view

The CFB unit design allows either the operation under conventional combustion or under oxycombustion conditions. The size of this combustor is sufficient to allow the scaling of the results to commercial units while maintaining the investment cost and operating expenses relatively low. In this manner, multiple fuels and operating conditions can be tested economically in this experimental unit.

The requirement for flexibility and component substitution in the unit, necessary in a pilot plant in order to conduct research / development has been taken into account during the design. By the same token, the ease of maintenance and inspection of all unit components has been maximized as well as increasing the usual instrumentation with extra instrumentation to extract data from future operation.

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CFB combustor 3D view

4. CIUDEN CO2 GEOLOGICAL STORAGE PROGRAMME

CIUDEN´s immediate and short-term objective is to develop scientific and technological knowledge in Spain on geological storage of CO2 in saline aquifers; the aim is to get training and to optimize all the tasks implied in the life cycle of an industrial CO2 geological storage. Therefore, a capacity on these technologies will be obtained in a European Member State that doesn't have important gas and oil resources.

This objective will be achieved in a Pilot Plant aimed at R&D on CO2 geosequestration and training in reservoir engineering. The final goal is to make the CO2 geosequestration environmentally safe and technological and economically viable.

For those reasons CIUDEN has been promoting the collaboration of: a) Spanish companies with their European equivalents to get training in their future geosequestration tasks and b) among Spanish and European Research Centres and Universities, as well as our presence in Communitarian Institutions.

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Furthermore, CIUDEN expects to

• Get a deep knowledge on the economic costs

• Build up on the social acceptance of geological storage

• Contribute to the development of a legal regulatory normative system

These actions will be carried out by means of the following priority objectives:

Priority objective 1: Selecting suitable geological sites for real scale R&D activities on reservoir engineering related to CO2 geosequestration

After the preliminary study of 46 potential locations by CIEMAT (Energy, Environmental and Technological Research Centre), CIUDEN’s CO2 Geological Storage Program has gathered, over the last two years of field surveys, enough information about the subsurface of some of this geological structures for the proper site characterisation. The results of these studies have allowed establishing specific sites in the Duero and Vasc-Cantabrian Basins for their favourable geology and presence of oilfields; also, Coal Power Plants are located there.

Sedimentary Basins where characterization site selection studies have been carried out in Spanish Territory

Site characterization studies show that the selected sites reaches the conditions established by IPCC-EU:

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IPCC - UE CIUDEN Reservoir depth >800 m >800 m Reservoir minimal thickness 20 – 50 m 100 m Caprock minimal thickness 50 – 100 m 250 m Reservoir porosity 10 % 15 % Water salinity 10 g / L 25 – 90 g / L

CIUDEN site data compared with IPCC-EU criteria

In addition, other potential sites have been selected in an oilfield in the Duero Basin; the advantage of having previous geological information speeds up many R&D technological activities. Other potential sites have valuable geological data from previous exploration and active oil exploitation; they include data of caprock and reservoir rock originated from seismic surveys (2D and 3D) and from more than 50 wells.

Priority objective 2: Design, construction and performance of real scale tests in the selected sites of a R&D Pilot Plant

To overcome the present Spanish weakness on reservoir engineering, CIUDEN is having a double path on its R&D Pilot Plant; so, the "traditional chronogram" for site selection, site characterization and "operational" tasks is simultaneously being carried out with some reservoir engineering tasks of immediate operability and future necessity. Therefore, some activities in the Pilot Plant will immediately start using appropriate sites for specific tests.

All those activities will much better help the Regulatory Body to dispose of more specific and verified criteria on which to base their decisions.

Pilot Plant for R&D on CO2 Storage in Nagaoka (Japan)

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The immediate tasks include update and development of new methodologies and tools for characterization of CO2 reservoirs and seal formations. Among the immediate tasks the following stand out:

• Evaluate in situ the permeability of the reservoir and caprock

• Characterize fluid composition of the reservoir formations; in-situ monitoring of fluid physicochemical parameters during hydraulic and tracer tests

• Piezometric measurements, control, and gradients in seal formations

• Characterization of the strength of the capillary seal

• Validation, adaptation and new geoelectrical tools

• Injection and sealing technologies

Priority objective 3: The role of natural analogues in developing safety and confidence in CO2 geological storage

Natural CO2 deposits allow gathering geoscientific information about the short- and long-term behaviour of an industrial CO2 geological storage as well as to integrate the social acceptance aspects

There are some natural analogues systems identified in Spain. The most important are located in the Duero and Ebro basins as well as in the palaeo volcanic zones in Catalunya and south-western Andalucia. All of them are formed by a high concentration of inorganic CO2, generally associated to Travertine Formations and impermeable traps for water and CO2.

Earth crust is able of gen-

erating and storing CO2 without risks to the public

Lessons learned from Nature

“Industrial” CO2 also can be stored under the

same conditions

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Natural analogues identified in Spain

CIUDEN's main tasks related to natural CO2 deposits and vents are:

• To provide quantitative insights on the processes that control the long term behaviour of the stored CO2 which are directly fed into the safety and risk assessment of storage plants.

• To develop and test the necessary gas monitoring and line base quantification methodologies which will be later applied to the industrial plant.

• The coexistence of local populations with locations with large CO2 gives some insights on the key messages for the social acceptance of storage facilities.

Priority Objective 4: Performance Assessment and Risk Analysis

The injected CO2 modifies the initial conditions of the reservoir geologic formation. The performance assessment and Risk Analysis verify those modifications and evaluate the long term CO2 geosequestration reservoir capacity.

The main tasks imply:

• To identify, quantify and value the risks associated with massive CO2 injection in the storage, and to implement the monitoring remediation and intervention strategies.

• To study how subsystems and components of the storage complex will work during and after the massive CO2 injection.

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Priority Objective 5: Perception and Communication

According to previous studies, this socio technical research aims to understand public perceptions on CO2 storage at the local site, as well as to develop effective strategies to communicate to stakeholders and the public the benefits and risks from the technology, and to involve these parties in local decision-making on CCS projects.

The local believes and concerns will be initially identified and analyzed. Accordingly, a risk communication strategy will be developed. It includes: 1) Study on social perception (Interviews - Survey - Focus groups), 2) Design of risk communication strategy and 3) Implementation of the risk communication strategy (Information and Participation actions).

The CCS communication tasks include carrying out:

• Information, communication and participation actions

• Field research on public perceptions - Develop conflict resolution actions.

5. INTERNATIONAL CONTEXT

The CIUDEN test facility on CO2 capture is first-of-its-class in the world due to its innovative design, flexibility, modularity and versatility in terms of fuels and technologies to be tested.

Comparison of CIUDEN and other oxy-CCS pilot projects and test facilities worldwide

PROJECT LOCATIONMWth

START-UP MAIN FUEL REMARKSPC CFB

VATTENFALL GERMANY 30 2008 LIGNITES 1 BURNER

TOTAL FRANCE 30 2009 NG/HC1 BURNER

INDUSTRIAL BOILER

CIUDEN SPAIN 20 30 2010 ANT./ BIT./ PETCOKE 2+2 BURNERS

PROJECT LOCATIONMWth

START-UP MAIN FUEL REMARKSPC CFB

VATTENFALL GERMANY 30 2008 LIGNITES 1 BURNER

TOTAL FRANCE 30 2009 NG/HC1 BURNER

INDUSTRIAL BOILER

CIUDEN SPAIN 20 30 2010 ANT./ BIT./ PETCOKE 2+2 BURNERS

B&W USA. 30 2007 BIT., SUB B, LIGN. 1 BURNER

OXY-COAL UK UK 40 2008 1 BURNER

B&W USA. 30 2007 BIT., SUB B, LIGN. 1 BURNER

OXY-COAL UK UK 40 2008 1 BURNER

PEARL PLANT USA 66 2009 BIT. JUPITER TECHNOLOGY

CALLIDE AUSTRALIA 90 2010 BIT. _

PEARL PLANT USA 66 2009 BIT. JUPITER TECHNOLOGY

CALLIDE AUSTRALIA 90 2010 BIT. _

LARGE SCALE INTEGRATED PILOT PROJECTSLARGE SCALE INTEGRATED PILOT PROJECTS

OXYBURNERS TEST FACILITIES OXYBURNERS TEST FACILITIES

BOILERS REFURBISHMENT/RETROFITTING BOILERS REFURBISHMENT/RETROFITTING

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The characteristics of the test facility in El Bierzo placed the project on the front line in the international context, which has been recognised by specialised International and European organizations.

As already mentioned, CIUDEN is part of the European Energy Research Alliance (EERA), and represents Spain in the International Energy Agency-Greenhouse Gas Program (IEA-GHG). In addition, CIUDEN has started several contacts with the American Department of Energy (DOE), which is funding an important number of projects on CCS. It is also expected to commence discussions with Australian and UK agencies which have already proposed major cooperation programs with China and India. This is an extremely attractive and challenging scenario that has undergone significant support, especially after the inclusion of the Compostilla project in the EERP.

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6. COST PLANNING

Total costs per year for the construction and operation of both Test Facilities on CO2 Capture and Storage is given below.

CIUDEN test facilities on CO2 capture and storage general costs/year

Main components of the facility are to be contracted along 2009, including fuel storage, preparation and feeding, limestone and ammonia storage and feeding, PC and CFB combustors, heat-exchange trains, bag filter, DeSOx and DeNOx units, CO2 capture, gas compression train, oxygen storage and flue gas recirculation system.

Total investment costs (M €)

0

10

20

30

40

50

60

70

2007 2008 2009 2010 2011

CIUDEN 2007 2008 2009 2010 2011

Investment 801.492 515.901 47.828.922 33.248.134 13.901.699 Engineering 181.220 2.685.144 14.652.111 5.981.225 Personnel Costs 195.297 269.864 1.443.180 2.743.225 3.289.476 Outsourcing: Research Institutions 566.987 1.254.098 2.234.560 1.641.650 1.169.999 Consumables 837.823 1.725.914 Overheads 218.045 301.690 320.457 371.076 418.410 Total Costs 1.963.041 5.026.697 66.479.230 44.823.133 20.505.498

Operation Personnel 7 9 35 35 35Engineering & Construction Personnel 23 132 150Total Staff 7 32 167 185 35

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Consumables include materials and supplies necessary for the operation of the test facility combustors. Other costs include external maintenance and repairing, replacements, sample analysis, taxes, licenses and other.

Consumables + Personnel + Overheads costs (M €)

The construction along 2009 and 2010 will require up to 150 qualified people per year. The operation of the facility, on a three-shift mode, demands 35 additional staff.

0

20

40

60

80

100

120

140

160

180

200

2007 2008 2009 2010 2011

Personnel for construction and operation

0

1

2

3

4

5

6

7

2007 2008 2009 2010 2011

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6. TIME SCHEDULE

The project has been already introduced to Spanish and European Authorities and Institutions as well as International Agencies. Moreover, an agreement with ENDESA to work together in CCS has been already signed, to shape a joint program that will allow the validation of the technology to be implemented by ENDESA in its 500 MWe OXY CFB demo plant.

Minister of Industry, Miguel Sebastián, and ENDESA Executive President, José Manuel Entrecanales. Signature of the CIUDEN-ENDESA Agreement, December 2008

As above-mentioned, the large test facility on CO2 capture is under construction. The basic and detail engineering, including the specifications of the main components, are completed.

Lay out of the test facility for CO2 capture

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Earth works for the Capture Facility started in November 08 finished in February 09.

Earth works finished in February 09

Contracting processes with technology suppliers and engineering companies are currently underway. Main packages contracts are near to be closed. Immediate steps for 2009 are:

- Week 17, 2009: Construction of the technical buildings

- Week 17, 2009: PC combustor manufacture

- Week 25, 2009: Flue gas cleaning train contract awarded

- Week 30, 2009: CFB combustor contract awarded

- Week 38, 2009: CO2 compression and purification contract awarded

The facility on CO2 capture is planned to be in operation in May 2010 and the facility on storage by mid May 2013. The integrated timetable is shown next.

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FIRSTDESIGN

BYCIEMAT

CA

PTU

RE

2010 2011 2012 2013 2014 20152006 2007 2008 2009TR

AN

SPO

RT

+ ST

OR

AG

E

2010 2011 2012 2013 2014 20152006 2007 2008 2009

CIUDEN’SLARGEPILOTS

FORCAPTURE

ANDSTORAGE

UPGRADEDDESIGN

RESEARCHPROJECT 7º FP

BUILDINGBLOCKS

VALIDATION

OPERATIONFOR R&DCONSTRUCTION

KNOWLEDGESHARING AND

DISSEMINATION

ASSISTANCETO ENGINEERING,TECHNOLOGISTS

UTILITIES

PERMITTINGAND

CONTRACTING

PILOT PLANTCONSTRUCTION

SOCIAL PERCEPTION STUDIES

R&D ON FLOW MODEL

IN SITU R&D ON RESERVOIR ENGINEERING, GEOPHYSICAL AND MONITORING TECHNIQUES

LONG TERM PERFORMANCEASSESSMENT AND RISK ANALYSIS

R&D PILOT PLANTSITES SELECTION

GEOLOGICAL STRUCTURECHARACTERIZATION

RESEARCH ON NATURAL ANALOGUES

CIUDENOPERATIONAL

INJECTIONCO2 MONITORING

Time schedule of the CIUDEN CO2 capture and storage project

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