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Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU...

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“We are passionate about innovation and technology leadership” Steve Moorman Manager -Business Development Advanced Technology Oxy-Combustion for CCUS
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Page 1: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

“We are passionate about innovation and technology leadership”

Steve MoormanManager -Business Development

Advanced Technology

Oxy-Combustion for CCUS

Page 2: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

Solar Receivers

Oxy-combustion Post-Combustion Capture

Biomass Systems

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Page 3: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

Oxy-Coal Path to Commercialization

Page 4: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

Oxy-combustion Development Path

Small pilot 1.5 MWth

Oxy-coal Combustion Development• Multiple Oxy Eng Studies, including

ASU / CPU Optimization & Process Heat Integration completed

• Small & Large Scale Oxy Pilot testing, completed, Lacq Oxy-Gas & CPU test, Callide CPU test in progress

• Reference plant design complete at 680/450 MWe net SCPC

• Next step - FutureGen 2.0

Large pilot 30 MWth

FutureGen 2.0 - 200MWe gross

2000 2008

2016

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Page 5: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

.5

90

80

70

60

50

30

20

10

0

Bituminous PRB Lignite

NO

x R

educ

tion

%

DRB-XCL Burner

Enhanced Ignition Burner

PAX-XCL Burner

NOx Reduction Air vs. Oxy Firing

Combustion Performance• Significant NOx reduction verified

• CO slightly lower with oxy-combustion

• LOI similar for air or oxy

• Attached stable flames with all fuels

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Page 6: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

.6

Wet Scrubber Performance

SO2• Relative performance showed oxy-

firing SO2 removal 5 % to 10 % better than air-firing removal (91.2% to 92 % SO2 removal)

WFGD Tower Installation

1.00

1.50

2.00

2.50

Bituminous Coal

1

1

2

SO2R

emov

al (N

TU)

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Page 7: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

Flue Gas after WFGD

O2

Oxy-Coal Combustion Principles

25 to 30% flow rate to CO2capture process

Conventional Combustion

25

50

75

100

Perc

ent

by V

olum

e

N2 N2

CO2

H2O

Oxygen

Nitrogen

CO2

Nitrogen

+ Coal

Oxygen CO2

+ Coal

CO2

CO2

CO2

0

25

50

75

100

Perc

ent

by V

olum

e

SyntheticAir

CO2

Flue Gas to CPU

O2

H2OH2O

Lb/hr

Oxy-Coal Combustion

Flow rate to CPU

100% flow rate to stack

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Air

Page 8: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

Oxy-Coal Plant Configuration

AirSeparation

UnitBoiler CO2

Compression

Air In

Pure Oxygen

(O2 )

Nitrogen (N2 )Out Recycled Flue Gas

CO2 andFlue Gas

Coal In

CO2 Capture(liquid)

Ash SO2

OtherCaptured

Emissions

EnvironmentalCleanup

Equipment

H2O

Boiler Island CPUASU

Other gases (NCGs)

8

Page 9: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

Power Block Configuration

FutureGen 2.0 Oxycombustion Carbon Capture Plant

.

Recycle Damper

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Pulverizers

Coal

Boiler

Steam; 2400psi, 1000F/1000F

PJFF WFGD

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

Recycle Dampers

Air Intake

Air Intake

Recycle Damper

Cool Recycle Process

CPU

To Storage

Gas Htr

DCCPS

Gas Htr

Sorbent for SO3

Recycle Heater

FD Fan

Page 10: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Future Gen 2.0 Project Participants

Power Generation & CO2 Capture CO2 Transport and Storage

Page 11: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Prove the Oxy-combustion process at commercial scale• Establish a cost and schedule baseline for the technology• Equipment Design Considerations – Primarily Boiler

Reliability – component design, materials of constructionMaintainability – erosion, corrosion, outage cyclesNot designed for high efficiency – designed for flexibility & learningProve basic process and heat transfer parameters – can move to higher efficiency, larger capacity w/o incremental steps

• Process DesignsSafety, Functionality, Operability

• Integrated operation of ASU – Boiler & AQCS – CPU – StorageStart-up, Shutdown, Load Swing, Capacity Factor, System Dynamics

Oxy Project Objectives

Page 12: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

FutureGen 2.0 – Oxy-Combustion Project

• Meredosia, IL: Owned by AER

• 3-coal fired units(2 retired)

• Unit 4, 200 MWe oil-firedboiler built in 1975, 2400 psig 1000/1000F Steam Cycle, low operating hours

• 3500 TPD CO2 to Storage

Meredosia Plant

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Page 13: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

FG2.0 Oxy-Coal Capture Plant

Boiler

PJFF

CPU

WFGD

ASU

Not the optimal equipment arrangement for a new plant but the best possible in this case due to site space limitations. Will be a common occurrence with existing plant retrofits and repowering

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Page 14: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

Boiler

Coal Bunkers

Ash SiloGypsum

Pile

CPU

ASU

PJFF

Recycle Heater

(Airheater)

WFGD

DCCPS

PR Fans

ID Fans

SR Fans

Reagent Prep

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Page 15: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

Steam & Water Flow Path

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Page 16: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

Oxy-Combustion ProsBoiler and AQCS equipment utilize conventional designs, materials of construction and arrangements. Combination of equipment and processes that are known to industry usersPilot Testing results indicate that the oxy process will operate like a conventional power plant. Minimal impact to boiler combustion and little change to thermal performance. AQCS performance is unchanged. • Furnace and Heating surface• Pulverizers• Burners• FGD Systems• Baghouse and ESP• Basic Process Controls

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Page 17: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

Oxy-Combustion Pros Cont’d

Oxy process can utilize a wide variety of coals including lignite, sub-bituminous and bituminous fuelsFor retrofit or repowering it is a less complex integration into the existing plant energy balance than PCCNo new chemicals or waste streams are introduced into the plant process. Bottom ash, fly ash, FGD waste streams unchanged.No major change to the plant water balance. For low rank fuels may be a positive water balance from condensation of water from the flue gas stream

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Page 18: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

Oxy-Combustion Challenges

Cost – CAPEX and OPEX but no different than the other CCS technologiesAuxiliary Power – same here Oxygen making and CO2 Compression are still energy intensiveNot a partial capture technology – all or nothingNeed to prove the integrated operation of a large scale ASU – Boiler /AQCS – CPU coupled with the CO2 transportation and storage facility

Start-up, Shut-down, Load Swings, Upsets

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

Page 19: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

FG 2.0 Project Status–Phase 1 Pre-FEED Accomplishments

Phase 1 Pre-FEED work achieved• Plant Design and Equipment Arrangements • Existing Plant Assessment• Preliminary Plant Performance • Detail Project Cost Estimate • Preliminary Project Schedule • Preliminary Construction Plan

Page 20: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

• For business reasons unrelated to FutureGen 2.0, Ameren’s leadership role on project will be reduced

• Ameren will continue providing support

• FutureGen Alliance is requesting DOE’s approval to assume Ameren’s leadership role on the power plant component of the project

• Ameren finalizing terms of sale for the plant with the Alliance• Business structure changes promise additional cost savings

• Value engineering ongoing to identify additional cost saving opportunities

• State of Illinois has initiated a process that will lead to an investment-grade power purchase agreement

• Anticipate start of FEED July 2012

Current Status

Page 21: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.

• Development of commercial near-zero emission coal-fueled power plants has proved challenging in the current economic and regulatory environment

• Many project cancellations on many continents

• Oxy-Combustion offers great promise as a competitive solution for CO2 capture from coal fired plants

• FutureGen 2.0 continues to be the nation’s best hope for a near-zero emission coal-fueled power plant

• >90% Carbon Capture at 1.3 MMT/yr• Near-zero emissions for conventional pollutants• Fully integrated pipeline and storage• Deep saline storage – the workhorse geology in

carbon-constrained world with CCUS

Summary

Page 22: Oxy-Combustion for CCUS · 2019-12-11 · •Multiple Oxy Eng Studies, including ASU / CPU Optimization & Process Heat Integration completed • Small & Large Scale Oxy Pilot testing,

“We are passionate about innovation and technology leadership”

Steve MoormanManager -Business Development

Advanced Technology


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