Takashi Kiga – IHI Corporation – Callide Oxyfuel Project: Demonstration and for the Commercialisation

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Takashi Kiga, General Manager, Staff Group, Energy Operations, IHI Corporation, presented on the Callide Oxyfuel Project: Demonstration and for the Commercialisation at the Global CCS Institute's Japanese Members' Meeting held in Tokyo on 8 June 2012

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Takashi Kiga – IHI Corporation – Callide Oxyfuel Project: Demonstration and for the Commercialisation

  1. 1. GLOBAL CCS INSTITUTEJAPAN REGIONAL MEMBERS’ MEETIG8 June 2012 Callide Oxyfuel Project - Demonstration and for the Commercialization - Takashi Kiga 2012.6.8 Energy Operations Copyright © 2012 IHI Corporation All Rights Reserved. 1
  2. 2. CONTENTS  Concept and Feature of Oxyfuel Combustion  Development of Oxyfuel Technology and Project  Callide Oxyfuel Project  Key Factors towards CCS CommercializationCopyright © 2012 IHI Corporation All Rights Reserved. 2
  3. 3. Concept of Oxyfuel Combustion <Air Combustion> As air contains N2 and Ar by 79%, CO2 concentration in flue gas is about 15% in combustion with air. N2 (+Ar) O2 N2 (+Ar) O2 CO2 NOx about 79% about 81% SO2 Coal about 4% about 15% <Oxy-fuel Combustion> In oxy-fuel combustion, since O2 of purity of about 96-98% which is separated from air is used, CO2 concentration in flue gas is theoretically more than 90%. N2 (+Ar) O2 about 79% Ar (+N2) about 5% O2 about 4% NOx SO2 O2 about 96% Coal Coal CO2 about 91% Ar (+N2) about 4% It is possible to condense and recover CO2 directly.Copyright © 2012 IHI Corporation All Rights Reserved. 3
  4. 4. Process & Feature of Oxyfuel Combustion Oxyfuel combustion ; In coal fired power plant, coal combustion by oxygen in stead of air make it possible to concentrate CO2 more than 90% theoretically in the flue gas. Stack ST G Non-condensable N2 gas Dust Liquid Coal removal CO2 tank O2 Air P(N2 ,O2) Transportation CO2 purification, Air separation Boiler compression & CO2 underground unit cooling unit Flue gas recycle storage Power plant with CO2 capture Transportation & storage of CO2 using oxyfuel combustion Process Feature ・Installation of air separation unit ・CO2 is major component in the flue gas ・Flame temperature and heat absorption are ・The amount of flue gas to CO2 purification can be reduced adjusted by flue gas recirculation to be almost one fifth ・NOx emission is remarkably reduced by flue Applicability and potential gas recirculation ・Applicable to both existing and newly-installed power plants ・DeNOx will not to be needed and DeSOx will ・Potential for the reduction of cost and auxiliary power by be compacted in case of new installation scaling-up of ASU and the integration of total processCopyright © 2012 IHI Corporation All Rights Reserved. 4
  5. 5. Development Schedule of Oxyfuel by IHI ・IHI is one of pioneers for oxyfuel development starting R&D in 1989, and basic research and FS were performed in the 1990’s. ・FS of demonstration was performed under the collaboration with Australian partners after 2004 and demonstration project was started in 2008. 1995 2000 2005 2010 2015 2020 Basic research and FS Callide FS Research (NEDO) (NEDO) (METI) Stage 1 Basic Collaboration with J-POWER Upgrading and R&D Stage 2 Application to Callide A Demonstration operation Commissioning Demonstration FS of commercial plant Stage 3 (High efficiency + Oxyfuel) Commercialization Commercialization Now(Jun. 2011)Copyright © 2012 IHI Corporation All Rights Reserved. 5
  6. 6. Development of Oxyfuel Project Utility Key project towards Boilers Demo. large-scale demonstration Bench/Pilot Industrial Furnaces Test Furnaces 0.1 Callide Oxfuel Project is driving the transition from pilot phase to demonstration phase of oxyfuel technology. This “early moving” project will demonstrate CCS integrated system toward large/commercial scale demonstration projects.Copyright © 2012 IHI Corporation All Rights Reserved. 6
  7. 7. Callide Oxyfuel Project - Objectives Outline World first retrofit-case oxyfuel power plant Largest capacity of 30MWe Total process from CO2 capture with power generation to CO2 storage 1. Demonstrate a complete oxyfuel process in a retrofit application 2. Establish the design and operating requirements for large scale (commercial) retrofit and new-build oxy-fuel plants, including geological storage 3. Estimate Capital and Operating Expenditures for the next generation of oxyfuel near zero emission technology plants 4. Demonstrate CO2 storage Injection and monitoring techniquesCopyright © 2012 IHI Corporation All Rights Reserved. 7 7
  8. 8. Callide Oxyfuel Project Overview Callide A Power Station Owned by CE Energy 4 x 30 MWe Steam 136 t/h at 4.1MPa, 465oC QLD Commissioned: 1965 – 69 Callide A P/S Refurbished 1997/98 Australia Placed in storage in 2002 CO2 storage area Brisbane Scope: •No.4 Boiler refurbishment •2 x 330 TPD ASU •Oxyfuel combustion Retrofit •70 TPD liquid CO2 recovery •Trucking to CO2 reservoir •Injection and monitoringCopyright © 2012 IHI Corporation All Rights Reserved. 8 8
  9. 9. Status of Commissioning Commissioning works in air-firing mode 23 March, 2011 - First fire on fuel oil (diesel) 1 April, 2011 - Turbine to 3000rpm 11 April, 2011 - First coal fire in the furnace 13 April, 2011 - First synchronization 17 May, 2011 - Full load (30MWe) (Combustion tuning, load swing & MFT testing) First fire on fuel oil Commissioning works in oxyfiring mode 12 March, 2012 - First oxygen injection to boiler 19 March, 2012 - Successful 100% RFG and oxyfiring (Conversion of firing mode between air-firing and oxyfiring & MFT testing) Commissioning works of CPU will be continued until the end of July, 2012. Control roomCopyright © 2012 IHI Corporation All Rights Reserved. 9
  10. 10. Main Evaluation Items Key demonstration items - Oxyfuel & CO2 capture operation - Safety - Durability - Process control and optimisation <Oxyfuel process> - Operation flexibility - Plant efficiency Boiler efficiency  Convective heat transfer - CO2 capture rate & CO2 purity - Air ingress N & S behavior  Tube corrosion - Cost data Hg behavior  CO2 conc., etc. Coal Boiler bin  Grindability FF Mill AH IDF  Ash characteristics and dry N2 Stack  Safety Air FGLPH GRF O2 Non-condensable gas ASU (CO2, H2O, SO2…) CO2 liquefaction  Mixing  Flame stability  Radiation heat transfer CO2 tank  Combustion characteristics Purification & compression Cold Box <CO2 capture process>  Purity of CO2 N & S behavior  Impurities Hg behaviorCopyright © 2012 IHI Corporation All Rights Reserved. 10 10
  11. 11. Callide Oxyfuel Project - CO2 Storage Activity Bowen Basin 1st phase survey area (Denison Trough) ≒ 300km 2nd phase survey area Callide A P/S (Northern Denison Trough) ≒300km Surat Basin 3rd phase survey areaCopyright © 2012 IHI Corporation All Rights Reserved. 11
  12. 12. Key Factors towards CCS Commercialization Technologies for capture, transportation and storage (reliable, safe, high-efficient & low cost ) • Financial support for large scale demonstration • Information sharing and exchange • Scientific understanding of CO2 storage Storage site • Investigation of storage site by public fund • Smooth procedure to provide exploration right • Open data base Regulation for CO2 storage • Long term liability by government Incentive • Carbon pricing • CDM and bilateral trading • Subsidy for CCS service • Incentive for regional government by development of employment and economy • Development useful and cost effective utilization of CO2 Reliable, continuous and certain governmental policy not to be lonely at the top Public acceptance • Enlightenment • Information sharing and exchange • Scientific understanding of CCSCopyright © 2011 IHI Corporation All Rights Reserved. 12
  13. 13. Callide Oxyfuel Project partners Thank you for your attention!Copyright © 2010 IHI Corporation All Rights Reserved. 13

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