Callide oxyfuel project update

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Dr. Chris Spero presents an update on the Callide Oxyfuel Project

Dr. Chris Spero presents an update on the Callide Oxyfuel Project

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  • 1. Callide Oxyfuel Project Update クリス・スペロ博士 カライド酸素燃焼プロジェクト・ディレクター 19 June 2014 Global CCS Institute Japan Regional Members’ Meeting
  • 2. Presentation Overview • Purpose of the presentation is to provide an overview of the Callide Oxyfuel Project and considers: • Historical background of PF and oxy-combustion • Callide Oxyfuel technology description (Oxyfuel Boiler and CO2 Capture Plant) • Results of Oxy-fuel boiler and CO2 Capture trials • Results of Storage assessments • Lessons learned
  • 3. Historical development of PF and oxy-combustion
  • 4. The project, as formally established in 2008 has two broad goals, namely to: • Demonstrate a complete and integrated process of oxy-fuel combustion of pulverised coal within a National Electricity Market facility, incorporating oxygen production, oxy-fuel combustion, CO2 processing and liquefaction, and to assess CO2 transport and geological storage; • Obtain detailed engineering design and costing data and operational experience to under-pin the commercial development and deployment of new and retrofit oxy-fuel boiler applications for electricity generation. Configuration: 2 x 330 TPD ASUs, 30 MWe Oxyfuel boiler, 75 TPD CO2 Capture Overall budget: CAPEX AU$180 million; OPEX $64 million Operating Period: 2½ years Project Goals, Cost and Operational Targets
  • 5. Project Structure
  • 6. Project Milestones
  • 7. TECHNOLOGY DESCRIPTION
  • 8. Oxyfuel boiler schematic
  • 9. COP - Boiler works ID Fan H2O remover PAH SAH Outlet FGLPH
  • 10. Carbon dioxide capture plant Courtesy of Air Liquide LP Scrubber DriersHP Scrubber Compressor Cold box/ inerts separators CO2 Capture: 75 t/day (net) CO2 Capture rate: > 85%
  • 11. ASU & CO2 capture plant Compressor Coldbox LP Scrubber Quencher HP Scrubber Driers Filters
  • 12. OXYFUEL BOILER RESULTS AND LEARNINGS
  • 13. Air-mode to Oxy-mode transition
  • 14. 1. Optimisation of mode transition Air → Oxy, Oxy → Air, stable Oxy-mode operation 2. Trials completed with a range of bituminous coals and semi- anthracite/Callide blend 3. Combustion Efficiency: 50 – 60% decrease in unburnt Carbon 4. NOx emissions: Air (90 mg/MJ fuel) → Oxy (40 mg/MJ fuel) 5. Particulates: Air (2 – 2.5 g/s) →Oxy (1.6 – 2.3 g/s) Oxyfuel boiler performance
  • 15. CO2 CAPTURE (CPU) RESULTS AND LEARNINGS
  • 16. CPU – Environmental performance •Low pressure scrubbers utilise a caustic soda wash to remove SO2 from the gas stream (< 10 ppm in gas phase). •Nitrous Oxide (NO) passes through the LP scrubbers but is largely converted to NO2 during flue gas compression. •Trace elements in the gas phase are also effectively extracted from the gas phase in the Low Pressure section of the CPU. •The principal gaseous emissions from the CPU are CO2 and NO2. Considerable work has been done to characterise the behaviour of NOx in the CPU.
  • 17. CPU – Process condensates Test data indicates: • LP area (caustic wet scrubbers and filters) remove particulates, SOX, NO2 and a major portion of trace elements • NO is converted to NO2 in the compressor and a significant portion is removed with the intercooler and aftercooler condensates as Nitric Acid. • Almost all the Hg that has passed through the LP sections (as Hgo) is removed with the compressor condensates.
  • 18. CO2 STORAGE ASSESSMENTS
  • 19. Surat Basin Storage Tenements (South East Queensland)
  • 20. Surat Basin Storage Capacity Courtesy: Coal Bed Energy Consultants Overall Surat Basin storage capacity > 850 Mt CO2
  • 21. • Establishment of the Project (structure, business systems, budgets, and schedules) • Contract management • Communications (with partners, Stakeholders and the Public) • Identification and control of technical risks • Operations and maintenance strategies and experience. • Managing workplace health and safety, and the environment • Transitioning of the power station culture and skill base from conventional coal-fired power plant to more complex and multi-purpose facilities designed to make electricity and capture CO2 and other emissions • Enhancements that would be applied to the next scale up of the Oxyfuel and CO2 capture technology • Efficacy of the technology in general High-level learnings
  • 22. 1. The Callide Oxyfuel Project has been complex for 3 principal reasons: • Large capital investment for a non-commercial demonstration, requiring a number of funding agreements and equity. • Engineer Procure Construct Manage (EPCM) for capital works involving a large number of contracts. • First-of-a-kind project, operating in an electricity market. 2. Supporting R&D and publications: • ANLEC (University Newcastle, Macquarie University) • ACALET • Global CCS Institute (Lessons Learned Report; Appraisal of CO2 storage sites in Surat Basin) • NEDO & METI (IHI R&D) • Air Liquide R&D 3. The Project has demonstrated over 6500 hours of oxyfuel boiler operation, routine mode changes air-oxy mode, over 3200 hours of CO2 capture plant operation and capture rates exceeding 85% 4. Next step is to consolidate the learnings from Callide A and to apply these to new projects Concluding comments
  • 23. Thank you for more information: www.callideoxyfuel.com Callide Oxyfuel Project – Participants