Alstom Development of Oxyfuel PC and CFB Power Plants

Transcription

1 Alstom Development of Oxyfuel PC and CFB Power Plants Frank Kluger & John Marion 3 rd Oxy-Combustion Workshop Yokohama, Japan March 06, 2008

2 Improvement Measures for Fossil Power Plants Regarding CO2 Mitigation 1 Efficiency Increase 2 CO 2 Capture & Storage 2

3 Pathway to Zero Emission Power for Fossil Fuels Carbon Reduction 90% CCS Zero Emission Trajectory Zero Emissions Target 20% Efficiency Trajectory The pathway to zero emissions can best be achieved by addressing the issues of improved energy efficiency of fossil fuel power plants together with the development, adoption and effective integration of CO2 capture technologies. These routes are not mutually exclusive, and it is essential that carbon dioxide capture plant is based on the best available and appropriate underlying technology.iea Near-term Mid-term Long-term Time Integrated strategy for `zero emission` 3

4 Oxy-fuel Firing Complementary with conventional boiler and steam power plant technology, including efforts towards ultra-supercritical conditions (for efficiency improvement), as well as environmental control developments Applicable for new and retrofit plants 4

5 Oxy-combustion opportunities and challenges Innovation Opportunities Low technological risk option Large power plant size possible Repowering and Retrofit possible All boiler technologies adaptable Fuel flexibile Steam Cycle increases possible Potential boiler size reduction Advanced O2 supply Cost Challenges Cryogenic oxygen CO2 Quality CO2 compression Heat flow optimisation Integration Time On time Development Technology Scale-up validation Adaptation to installed base Innovation 5

6 CO2 Product Quality Discrepancies Alstom compilation from published reference data 6

7 Oxy-PC Power Plant - CO2 product quality impact on ASU, APC, and GPU equipment Cartridge Filter 3-stages M Aftercooler & knock- out H 2 O to vent gas Flashing CO 2 liquid Vent Gas (N 2, O 2 ) H 2 O Mol. Sieve for drying M GPU Gas Heater Regeneration Steam Turbine Boiler (Indirect Firing System) Gas Pre-Htr Cooler O 2 Heater FF/ ESP Cooler FGD FGC ASU CO 2 to pipeline Mill 7

8 Oxy-CFB Concept CFB Steam Generator Unit INDUCED DRAFT FAN CO 2 -RICH PRODUCT TO GAS PROCESSING SYSTEM Cyclone AIR INFILTRATION COMBUSTOR BACKPASS HEAT EXCHANGERS CONDNESATE Gas Cooler PFWH COAL LIMESTONE External Heat Exchanger Heat Exchanger MBHE OXYGEN HEATER PARTICULATE REMOVAL SYSTEM GAS RECIRCULATION FAN ASH COOLER FLUIDIZING GAS BLOWER NITROGEN 3 MWt pilot CFB Windsor, CT, USA Potential for Reduced recycle FGR and resultant smaller boiler & APC Market segmentation as with air-fired CFB s (low quality fuels) AIR OXYGEN AIR SEAPARATION UNIT 8

9 Going Down The Experience Curve for Oxy Combustion CO2 Capture Energy Heat requirements of Reaction [KWh (BTU/lb) / TCO2] ENCAP studies Process Optimisation Large Demos Large ASU Chemical looping Integration & Process Improvt Scale economy Process Innovation CO2 /T lower Non cryo O2 production 9

10 Oxy-Fuel Power Plant with Advanced O2 Production Technology Cleanup & Cooling CO 2 Rich Flue Gas Combustion & Boiler System O 2 + CO 2 CO 2 Fuel O 2 Advanced ASU Turbine / Generator Compressor ~ Breakthroughs will improve oxy-firing performance and economics What is the status of developments? Air O 2 Depleted Air 10

11 Oxy-combustion: Chemical Looping Combustion (CLC) Air reactor Air Ox N 2 + O 2 Me or CaS MeO or CaSO4 Fuel Re CO 2 + H 2 O Fuel reactor CLC features 100% CO2 Capture Lowest Cost CO2 Capture No Air Separation Unit High Net Plant Efficiency Alstom Pilot in USA Solids Heater Spray Coolers & Filters (5) Reducer Sealpot Control Valves (2) Ash Coolers (6) 2-Stage Cyclones (2) Product Gas Burner Oxidizer 11

12 Long term products: Oxy-fired PC, Oxy-fired CFB and Chemical Looping Lab scale tests (500kWt) Oxy-fired PC 2 Demonstration scale tests (30MWt) 3 Utility scale tests (250MWe) 4 Commercialization 1 Pilot scale (3MWt) Oxy-fired CFB 2 Demonstration Scale tests (10-40MWe) 3 Utility scale tests (>150MWe) 4 Commercialization 1 Lab scale tests ( kwt) Chemical Looping 2 Pilot scale (1-3 MWt) 3 Demonstration scale tests MWe 4 Utility scale MWe 5 Com Source : ALSTOM analysis 12

13 30 MWth Oxyfuel Steam Generator Vattenfall Schwarze Pumpe Site (Erection Status) Boiler House Air Separation Unit ESP FGD FGC CO2-Compression Control Building Source: Vattenfall Jan

14 30 MWth Oxyfuel Steam Generator Process Coal Dust Process Scheme Primary Flue Gas Recycle Gas Ignition Burner Burner Dry sorbent Ammonia Seal Gas <1,2 bar Steam- HEX Steam- HEX Air Seal Gas 6 bar Furnace 2 nd Path De-NOx Filter FGD ID Fan 1 ID Fan 2 FGC CO 2 - Process 3 rd Path Ash Secondary Flue Gas Recycle Steam- HEX Air Nitrogen Steam- HEX Oxygen ASU Air 14

15 30 MWth Oxyfuel Steam Generator Boiler Design DeNOx-Option Ignition Burner Burner ECO 5 SH 1 Gas HEX ECO 4 Catalyst 1 Catalyst 2 SH 2 ECO 3 Catalyst 3 Burnout Oxydant Hydrated Lime ECO 2 ECO 1 ESP 15

16 30 MWth Oxyfuel Steam Generator Boiler Manufacturing Sep

17 30 MWth Oxyfuel Steam Generator Burner for Indirect Firing Systems Niederaussem-K : 8 x 90 MW th OxPP : 1 x 30 MW th ROW Wesseling K5 : 4 x 25 MW th HKW Senftenberg : 2 x 19 MW th 17

18 30 MWth Oxyfuel Steam Generator Burner for Indirect Firing Systems (Reference Niederaussem K) Niederaussem-K : 8 x 90 MW th Since 2003 in operation Start up / Support firing system for a 1000 MW el unit P.F. fire (dried lignite) T-fired 8 burners installed Fuel : Dried Lignite ; 19, MJ/kg Furnace Width : mm Furnace Depth : mm Oil gun Oil fire 18

19 30 MWth Oxyfuel Steam Generator Burner Design Air or Oxygen & Flue Gas Fuel Dam ring Air or Oxygen & Flue Gas Air or Oxygen & Flue Gas or Pure Oxygen Air or Oxygen & Flue Gas, Swirl

20 30 MWth Oxyfuel Steam Generator Burner Operation Modes Green: Air Brown: Fuel Blue: RFG + O2 Brown: Fuel Yellow: RFG Violet: O2 Brown: Fuel Air operation Oxyfuel operation (premixed oxygen) Oxyfuel operation (direct oxygen injection) 20

21 Conclusions New coal fired power plants shall be designed for Highest Efficiency to minimize CO2 and other emissions Oxy-combustion is Complementary with conventional boiler and steam power plant technology, including efforts towards ultra-supercritical conditions (for Efficiency), and Environmental control developments Cost Attractive Options are needed and should be actively supported, particularly, breakthroughs like Chemical Looping & Adv. Oxygen Scale-up and Validation is needed The Schwarze Pumpe project is an important and significant demonstration. Start-up is expected this year 21

22 ALSTOM The Clean Power Specialist Today we provide the cleanest air solutions For New Plants For the Installed Base 22