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CCS Projects Integration Workshop - London 3Nov11 - B&W - Oxycombustion Project Integration Considerations
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CCS Projects Integration Workshop - London 3Nov11 - B&W - Oxycombustion Project Integration Considerations

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This presentation was given at the Global CCS Institute/CSLF meeting on CCS Project Integration that was held in London on 3 November 2011. The aim of the meeting was to share experiences on CCS …

This presentation was given at the Global CCS Institute/CSLF meeting on CCS Project Integration that was held in London on 3 November 2011. The aim of the meeting was to share experiences on CCS project integration; and to identify priority integration topics that need further attention to facilitate CCS project development and deployment.
You can view more presentations from the event at http://www.globalccsinstitute.com/community/blogs/authors/klaasvanalphen/2011/11/25/presentations-global-ccs-institutecslf-meeting-ccs

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  • 1. “We are passionate about innovation and technology leadership”Oxycombustion Project Integration Considerations Global CCS Institute / CSLF Meeting on Project Integration 2011 November 3, 2011; London , England Kevin J. McCauley Director Strategic Planning, Global Technology
  • 2. IntroductionProprietary and Confidential © 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. 2
  • 3. Project Integration • Capture, transport, storage integration • Overall plant and site integration • Steam cycle integration • Combustion/Environmental integrationProprietary and Confidential
  • 4. B&W – Power Generation Group Global Reach Product Line Portfolio • Traditional Power • Steam Generation (eg: USC-PC) • Service and O&M (Operation & Maintenance) • Construction and EPC (Engineer-Procure-Construct) • Boiler Cleaning and Material Handling Major locations • Clean Coal Total Employees: ~ 8,700 • Environmental Systems and Service Including JV employees • SO2, NOx, Mercury, PM • Installed 38% of boilers in North American • CO2 RSAT Scrubber, Oxycombustion coal-fired power plants • Supplied worldwide capacity of more • Renewables than 300,000 MW in 800+ utilities • Biomass in 90+ countries • Solar • Manage operations and maintenance • Energy-from-Waste of North America power facilitiesProprietary and Confidential © 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. 4
  • 5. CO2 Oxygen CO2 Oxygen + Coal + Coal CO2 Nitrogen Nitrogen CO2 100 100 H2O H2O H2O 70-80% Percent by Volume Percent by Volume 75 CO2 75 reduction in flow rate to N2 N2 CO2 CO2 CO2 50 50 compression Lb/hr 25 process 25 O2 O2 0 0 Air Flue Gas Synthetic Flue after WFGD Air Gas to CPU Typical Air Fired Combustion Oxy-Coal CombustionProprietary and Confidential
  • 6. Modern Pulverized Coal Dry FGD Fabric Filter Baghouse (Ash) Power Plant Scrubber (SO ) 2 Stack Selective Catalytic Reduction (NOX ) Wet FGD Scrubber (SO2 ) Electrostatic Precipitator (Ash) Additional Systems  Dry sorbent injection (DSI) for Hg/SO3  Ash management systems  Boiler cleaning and auxiliaries Supercritical Coal Boiler  Instrumentation and Controls Pulverizer  Operation and maintenanceProprietary and Confidential © 2011 The Babcock & Wilcox Company. All rights reserved. 6
  • 7. OxyCombustion Plant Configuration ASU Boiler Island CPU Nitrogen (N2 ) Other gases Out Recycled Flue Gas (NCGs) Pure Air Air Oxygen CO2 and In Separation (O2 ) Boiler Flue Gas Environmental CO2 Unit Cleanup Compression Equipment Ash H2O SO2 CO2 Capture Fuel Other Captured (liquid) In EmissionsProprietary and Confidential 7
  • 8. Flue Gas Composition GAS COMPOSITION (mass) Warm Recycle Air Fired Oxy Fired CO2 21.26% 77.25% H2O 8.15% 12.49% SO2 0.07% 0.13% O2 2.95% 2.80% N2 67.57% 4.50% Ar 0.00% 2.83% 100.00% 100.00%Proprietary and Confidential
  • 9. Plant size (MWe) 700 MWe1000 Integration Reference Study 650 MWe 200-350 MW Projects Eng Study Eng Efficiency Optimization Studies 100 (25-790MWe) 30 MWth CEDF Demo 10 SBS I – Pilot tests SBS II – Pilot tests 1 2003 2005 2007 2009 2011 2013 2015Proprietary and Confidential © 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. 9
  • 10. Design ConsiderationsProprietary and Confidential © 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. 10
  • 11. • Process Selection • Gas Quality Control Equipment Selection • Recycle Quantity • Corrosion • Air infiltrationProprietary and Confidential
  • 12. • Process Selection  Coal composition  Permissible sulfur level in the boiler  Composition required to compression process  Economics • Gas Quality Control Equipment Selection  Wet or Dry Scrubber  Permissible sulfur level in the boiler  SO3 control  Economics  Fabric Filter or PrecipitatorProprietary and Confidential
  • 13. Constituent Heating Value 10,500 Btu/lb (24,780 kJ/kg) Carbon 58.61 % Sulfur 3.2 % Hydrogen 4.2 % Moisture 16.57 % Nitrogen 1.17 % Oxygen 7.1 % Chlorine 0.16 % Ash 8.99 %Proprietary and Confidential
  • 14. Secondary (FD) Fan PAC Airheater PJFF WFGD SCR Boiler Burners ID Fan Coal Primary Fan To Air Fired Plant - Wet Scrubbed Storage Secondary (FD) Fan Secondary Pulverizers ASU Air Intake Recycle CPU Damper Vent CPU Gas Htr Stack Sorbent for SO3 Damper Recycle PJFF Gas DCCPS Gas Heater WFGD Cooler Htr Boiler Burners ID Fan Coal Primary Fan Primary Recycle Air Intake Damper Cool Recycle Process Wet Scrubber PulverizersProprietary and Confidential
  • 15. Secondary (FD) Fan PAC Airheater SCR SDA PJFF Boiler Burners ID Fan Coal Primary Fan To Air Fired Plant - Dry Scrubbed Storage Secondary (FD) Fan ASU Air Intake CPU Pulverizers Vent CPU Stack Secondary Damper Recycle Damper Recycle Gas DCCPS Gas Heater SDA PJFF Cooler Htr Boiler Burners ID Fan Coal Primary Fan Primary Recycle Cool Recycle Process Air Intake Damper Dry Scrubber PulverizersProprietary and Confidential
  • 16. DRY SCRUBBER • Lower capital, higher operating (more economical with lower sulfur coals) • Removal is limited by ability to evaporate the water fed with the reagent as slurry • Limit is set by:  Inlet gas temperature and moisture content  Desired approach to saturation temperature  Saturation temperature (10C-20C higher for oxycombustion due to moisture in flue gas) WET SCRUBBER • Higher capital, lower operating (more economical with higher sulfur coals) • Removal limited by reagent reactivity and mixing • Unaffected by moisture in flue gasProprietary and Confidential
  • 17. ASU Gypsum Ash Silo Pile PJFF ID Fans WFGD Coal Bunkers SR Fans PR Fans DCCPS Recycle Boiler Heater (Airheater) CPUProprietary and Confidential 17
  • 18. Recycle Rate  Typically 70%-80% of the total flue gas leaving the boiler  Significant reduction does not reduce cost  Reduced Recycle  Increases flame temperature  Increases furnace heat fluxes  Increases FEGT (flue gas temperature at furnace exit)  Decreases volume flowProprietary and Confidential
  • 19. Recycle Rate  Significant reduction does not reduce cost  Increases constituent concentrations  Increased corrosion potential  More difficult to achieve high removals  Shifts heat transfer the wrong way  Reheat is more difficult  Increasing steam temperatures (efficiency) is more difficult  Increased cost of materials exceeds weight reduction  GQCS cost reduction is to the square root of volume flow reduction (50% flow reduction ≈ 30% material reduction)Proprietary and Confidential
  • 20. Convection Pass Furnace Subcritical Boiler Supercritical BoilerProprietary and Confidential
  • 21. • Air infiltration • CorrosionProprietary and Confidential
  • 22. To Storage Secondary (FD) Fan ASU Air Intake Steam; 2400psi, 1000F/1000F CPU Recycle FD Fan Damper Sorbent for Gas Htr Stack Vent SO3 Damper PJFF WFGD Gas DCCPS Htr Recycle Boiler Heater Burners ID Fan Coal Primary Fan Recycle Damper Air Intake Cool Recycle ProcessProprietary and Confidential
  • 23. To Storage Secondary (FD) Fan ASU Air Intake Steam; 2400psi, 1000F/1000F CPU Recycle +Sorbent for FD Fan + Damper Gas Htr Stack Vent Damper SO3 + - - - + Gas Recycle PJFF WFGD DCCPS Htr + Boiler Heater Burners ID Fan Coal Recycle + Primary Fan Damper Air Intake + + Cool Recycle Process + Operating pressure above atmospheric - Operating pressure below atmosphericProprietary and Confidential
  • 24. To Storage Secondary (FD) Fan ASU Air Intake Steam; 2400psi, 1000F/1000F S CPU Recycle W FD Fan Damper Sorbent for Gas Htr Stack Vent SO3 Damper S S W S W PJFF WFGD DCCPS Gas Htr W Recycle Boiler Burners Heater W ID Fan S W W Coal W Primary Fan Recycle Damper Air Intake Cool Recycle Process W S Above sulfuric acid dew point W Above water saturation temperatureProprietary and Confidential
  • 25. SummaryProprietary and Confidential © 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. 25
  • 26. Special Design Considerations • Air In-leakage  Use of CO2 for sealing systems uniquely designed  Pressure profile through the system optimized, balanced draft • Use of Nearly Pure Oxygen  Standard industry practices for low pressure operational safety  Oxygen distribution system in flues designed for uniform mixing  Oxygen concentrations monitored closely by control system • Leakage of Flue Gas with High CO2 Concentration  Pressure boundary sealing systems uniquely designed  CO2 monitors in sensitive external confined space areas  Building local ventilation system design, and system internal purge controlsProprietary and Confidential © 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. 26
  • 27. Special Design Considerations • Acid Gases and Corrosion • Sulfur trioxide removal increased, adjusted minimum temperature limits used in boiler design and operation, and expanded use of corrosion resistant materials • Plant Operability • Part load operation, daily cycling flexibility, extended air-firing periods • Heat Integration: Feedwater, Condensate, Oxygen • Heat available from ASU, CPU and Flue GasProprietary and Confidential © 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. 27
  • 28. “We are passionate about innovation and technology leadership” Thank-you WWW.BABCOCK.COM I kjmccauley@babcock.comProprietary and Confidential © 2010 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.