alstom's chemical looping combustion prototype for co capture
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Iqbal Abdulally - Alstom PowerHerb Andrus Jr., Carl Edberg, John Chiu - Alstom Power
Paul Thibeault - Alstom Power
Bruce Lani US DOE/NETL
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012
ALSTOM’s Chemical Looping Combustion Prototype for CO2
Capture from Existing Pulverized Coal Fired Power Plants
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 2
Agenda
1st topic General Project & Technology Background
2nd topic Phase 0 to III Activities
3rd topic Phase IV Activities and Status
4th topic Next Steps
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
The Alstom Group: a Worldwide Leader in Power Generation
Full Power Systems Portfolio N 1 in air quality control systems
N 1 in services for electric utilities
N 1 in integrated power plants
N 1 in hydro power
N 1 in conventional nuclear power island
Recent acquisitions of solar & wind power
Over 41 GW under executionNuclearHydro
SteamGas
Chemical Looping Technology Development
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 3
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Project OverviewProject Goals and Objectives
• Chemical Looping Program:
Develop and commercialize chemical looping process to meet the goals for new or existing coal-fired power plants.
• Prototype Project:
Design (BP1), build, and test (BP2) a 3 MWth Prototype to demonstrate Chemical Looping Systematic TestingExtended auto-thermal operation
Obtain engineering and operating information necessary to design and build a reliable follow-on demonstration plant.
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 4
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Alstom’s Chemical Looping DevelopmentTargets:
• Over 90% CO2 capture from coal• Less than $20/ton avoided cost of CO2 capture• Capital cost 20% < conventional steam plant (w/o CO2
capture)• Applicable to retrofit and new coal-fired power plants• Retrofit < 20% increase in COE• Beat steam power and IGCC performance and
economics, world-wide• Medium-Btu syngas or hydrogen without oxygen plant• Economical H2 production at low cost
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 5
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Prototype Schedule As Planned
Phase IVA is on Schedule
4. Start Shakedown
5. Complete Phase IVA Testing
6. Deliver Interim Report
1. Complete Preliminary Engineering
2. Deliver Updated Technical and Cost Information to NETL (for BP1 Decision)
3. Start Installation
7. End of Phase IVA Program
Major Milestones:
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 6
Phase IVA DOE SchedulePhase IVA DOE Schedule.xls
October 2011
Task1.0 Project Management
and Reporting2.0 Prototype Engineering3.0 Prototype Procurement
and Installation4.0 Prototype Operation
ShakedownCold Flow Hot Flow, Non-ReactingHot Flow, Reacting
5.0 Solids Transport Testing6.0 Engineering Support7.0 Analytical Support8.0
Jul - Sep Oct - Dec Jan - Mar Apr - Jun Jul - Sep Oct - Dec Jan - Mar Apr - Jun Jul - Sep Oct - Dec Jan - Mar Apr - Jun Jul - Sep Oct - Dec Jan - Mar Apr - Jun Jul - Sep2008 2009 2010 2011 2012
Alstom FY 08-09 FY 09-10 FY 10-11 FY 11-12 FY 12-13DOE FY 08-09 DOE FY 09-10 DOE FY 10-11 DOE FY 11-12
Testing: - Systematic - Autothermal Optimization
Phase IVABP1 Phase IVA
Milestones:1.Complete Preliminary Engineering2.Deliver Updated Technical and Cost
Information to NETL (for BP1 Decision)3. Start Installation4. Start Shakedown5. Complete Phase IVA Testing6. Deliver Interim Report7. Deliver Final Report
4
5
1
32
6
BP2
Phase IVAExtension
7
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Project Overview – Phase IVFunding
Participants:
Total Budget Period 1 & 2October 2008 to September 2011
DOE Funding $7,395,624 Alstom Funding $1,848,906 Total Budget $9,244,530
Total Budget Period 2 ExtensionOctober 2011 to Present
Alstom Funding $1,500,000
Total Budget 2008to Present $10,744,530
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 7
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Air(O2/N2)
Depleted air,
Ash, CaSO4
Option 1 – Chemical looping combustionExcess air (CaSO4) to fuelProduct gas is CO2Heat produces steam for power
Product Gas
Coal,
CO2H2O
CaS (s)
CaSO4 (s)
Calciner
CO2 (g)CaCO3 (s)
Syngas (CO, H2O
Hotsolids
Coldsolids
Steam toPower Cycle
CaO(s)
CaCO3(s)
H2 (g)
H2O
Option 2 – Chemical looping gasificationExcess fuel to air (CaSO4)Product gas is SyngasNo inherent CO2 capture
Option 3 – Hydrogen productionAdd CaO-CaCO3 to Option 2Add calcinerProduct gas is H2Calciner off-gas is CO2
Alstom’s LCL™ process is suited to coal
Air Reactor (Oxidizer)
CaS + 2O2 -> CaSO4 + Heat
Fuel Reactor (Reducer)
2 Cfuel + CaSO4 + Heat -> CaS + 2 CO2
8 Hfuel + CaSO4 + Heat -> CaS + 4H2O
Main Reactions:
Alstom’s Limestone Based Chemical Looping (LCL™) Concept & Process Options
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 8
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Process:Options and Applications
Re ducer Ox idize r
CaSO4 CaS
N2
AirCoal
CaCO3Steam
Ash, CaSO4to Disposal
CO2
Ste am
Option 1 – Combustion with CO2 Capture
Reducer Oxidizer
CaSO4 CaS
N2
AirCoal
CaCO3Steam
Ash, CaSO4to Disposal
Calciner CO2
H2
Option 3 – Hydrogen with CO2 Capture
R e d u c e r O x id iz e r
C a S O 4 C a S
N 2
A irC o a l
C a C O 3S te a m
A s h , C a S O 4to D is p o s a l
S y n g a sC O ,H 2
Option 2 – Syngas with no CO2 Capture
• CO2 Capture – PC Retrofit• CO2 Capture – CFB Retrofit• CO2 Capture-Ready Power Plant• Advanced Steam Cycles with CO2 capture
• IGCC with Down-Stream CO2 Capture• Industrial Syngas production• Coal-to-Liquid Fuels
• CO2 Capture – PC Retrofit• CO2 Capture – CFB Retrofit• CO2 Capture-Ready PC/CFB Power Plant• Advanced Steam Cycles with CO2 capture• IGCC with CO2 Capture• Fuel Cell Cycles with CO2 Capture• Industrial Hydrogen with CO2 Capture
Applications – LCL™
Flexible technology with low cost2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 9
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Overview Retrofit Options
Existing Steam
TurbinePower Block
Steam
Feed WaterGenerator
Air
Fluegas
ExistingPC Boiler
ExistingCoal
Pulverizer
CoalLimestone
(CaCO3)
Reducer Oxidizer
CaSO4 CaS
N2 to Stack
AirAsh, CaSO4to DisposalCalcinerCO2
H2
CO2-freeBoiler fuel
(H2)
Steam
Concept 1 – Chemical Looping CO2 --free Fuel; Minimum Boiler Modification
Concept 2 – Chemical Looping Oxidizer Replaces/Modifies Boiler
Feed Water
ExistingSteam
TurbinePower Block
Steam
Generator
ExistingCoal
Pulverizer
CoalLimestone(CaCO3)
Reducer Oxidizer
CaSO4 CaS
N2 to Existing Stack
Air
Ash, CaSO4to Disposal
CO2
Steam
Existing Steam
TurbinePower Block
Steam
Feed WaterGenerator
Air
Fluegas
ExistingPC Boiler
ExistingCoal
Pulverizer
CoalLimestone
(CaCO3)
Reducer Oxidizer
CaSO4 CaS
N2 to Stack
AirAsh, CaSO4to DisposalCalcinerCO2
H2
CO2-freeBoiler fuel
(H2)
Steam
Concept 1 – Chemical Looping CO2 --free Fuel; Minimum Boiler Modification
Concept 2 – Chemical Looping Oxidizer Replaces/Modifies Boiler
Feed Water
ExistingSteam
TurbinePower Block
Steam
Generator
ExistingCoal
Pulverizer
CoalLimestone(CaCO3)
Feed Water
ExistingSteam
TurbinePower Block
Steam
Generator
ExistingCoal
Pulverizer
CoalLimestone(CaCO3)
Feed Water
ExistingSteam
TurbinePower Block
Steam
Generator
ExistingCoal
Pulverizer
CoalLimestone(CaCO3)
Reducer Oxidizer
CaSO4 CaS
N2 to Existing Stack
Air
Ash, CaSO4to Disposal
CO2
Steam
Reducer Oxidizer
CaSO4 CaS
N2 to Existing Stack
Air
Ash, CaSO4to Disposal
CO2
Steam
Retrofit Options at < 20% Increase in COE with CO2 Capture2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 10
Concept 1 –Chemical Looping CO2 Free Fuel; Minimum Boiler Modifications (Option 3)
Concept 2 –Chemical Looping Oxidize Replaces/Modifies Boiler (Option 1)
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Agenda
1st topic General Project & Technology Background
2nd topic Phase 0 to III Activities
3rd topic Phase IV Activities and Status
4th topic Next Steps
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 11
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Limestone CLC Development Timeline
• Earlier Program: Hot Solids Gasification: 1996-2001 Process and Sorbent Investigation Economic Evaluation Lead to Chemical Looping Program
• Chemical Looping Development Phase 0 (2001) - Alstom's Internal Development Project,
Construction of the Process Development Unit (PDU) Phase I (2003) - DOE Program Started, Verified Sorbent
Chemistry and Solids Transport Phase II (2005) -Verified Gasification Chemistry and
Process Control Strategy Phase Ill (2006) - Developed Automatic Control System Phase IVA (2008) - Built 3 MW Prototype, Shakedown and
Initial testing2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 12
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Agenda
1st topic General Project & Technology Background
2nd topic Phase 0 to III Activities
3rd topic Phase IV Activities and Status
4th topic Next Steps
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 13
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Main objectives:
Design, engineering, construction, commissioning and operation of a 3 MWth CaS prototype,
Autothermal operation of Limestone-based prototype,
Proof of concept – deliver data required to scale up to Demo and commercial size
• 50 month program Shakedown completed First coal fire completed June 2011 Autothermal operation Scheduled for August/Sept. 2012
• Total approved budget: 9.25 M$, cost share by US-DOE and Alstom
• Partners: US-DOE/NETL & Alstom
Prototype Constrauction and OperationChemical looping – 3 MWth Limestone based Prototype Coal
Rear View of Prototype Building
3 MWth Prototype Model
70 ft
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 14
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping PrototypeComponent Construction
The Prototype was integrated into the existing Multi-use Test Facility (MTF)
70 ft
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 15
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Barracuda Simulation of the Chemical Loop reducer column(color range 0 – 25m/s)
Mixing of solids streams in Cactus above the fluidizing gas grid 0-25 m/s
Prototype Validation: Computational Fluid Dynamics
Improving LCL™Process
Reducer
Oxidizer
Coal Feed
Coal Feed
Reducer
Fluidizing Grid
Fluidizing Grid
Reducer Bottom Outlet
Oxidizer return
Reducer RecycleOxidizer
return
Study and improve:
Fluidization
Solids transport
Mixing in “Cactus”
Residence times
Fixed carbon retention
in reducer
Cactus
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 16
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Prototype Validation: Cold Flow Model Testing
L o o p P re s s u re fo r 4 H o u rs S te a d y R u n (1 7 J A N 2 0 1 1 1 0 :0 0 to 1 4 :5 5 )
P 1 0R x c y c i
P 1 3R x d ip le g
P 2R x r is e r
5 6
P 1c a c tu s
P 5 0X O to R x
P 5 1 X O to O x
P 4 3 P re s s c o lu m n
P 4 0O x s p o
P 3 2 O x r is e r
P 3 8O x d ip i
-2 0
0
2 0
4 0
6 0
8 0
1 0 0
1 2 0
1 4 0
1 6 0
1 8 0
2 0 0
P re ss ure a lo ng L oo p ["wg ]
T R ,T O /F 1 ,T 2 /F 3 8 ,T 3 9 /F 4 0 ,T 4 1 /F 3 1 ,T 3 2 /G5 2 0 8 , 2 9 5 5 / 4 1 .9 ,5 5 .1 / 2 1 .4 ,1 4 .0 /0 ,0 / 6 5 .3
Stable coupled operation with smooth solids transport
P9
P4
P5
INJ2
P7
P10
Reducer Riser
INJ1
P6
Fuel/LS Feed
P8
480 in
P5 P58
G43 Oxider
P37 P36
P38
P4
P47 P46
P43
P54
P55 P56
P41
P48
P31
P33
P35
P32
P3 4
P42
P50 P49
P40
P3
Butterfly Valve
P45
G33 G34
G35 G36
G3 7
P0
F38 T3 9
F31 T32
F40 T41
P21 P23
P17
P1
P14
P2
P13
P15
P16
Butterfly Valve
Laser Probe
load cell
F1 T2
G1
TO
load
BH
P53 G42
P51 P52 TR
P11
BH
P12 P39
P2
37th International Technical Conference on Clean Coal & Fuel Systems June 3-7, 2012 Clearwater, FL, USA P 17
Pre
ssur
e –I
ns W
G
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Hot Coupled Loop Operation Achieved with Coal & Charcoal
Main Milestones:
• June 2011 - First coupled run with Pitts #8 Coal• Sept. – Oct. 2011 - Series of short runs with
Pitt.#8 coal• May 2012 - Reducer tests decoupled, nitrogen
blown runs with Adaro coal and charcoal – All reducer reactions observed
• June 2012 – Extended reducer tests with Adaro Coal – All reducer reactions observed
Prototype Testing Status
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 18
Research Operators in Control Room During Hot Coupled Testing
Major Achievements:• Controlled solids recirculation in CFM & prototype.• Coal firing at low reactor temps with low tar formation.• Coal firing at design temperature with no evidence of
tar formation.• SAHE operation.• Hot restart after main fuel trip.• Production of CO2 (Option 1) and Syngas (Option 2).• Combustion reactions with chemical looping
reactions.
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Prototype Validation: “Decoupled” Tests Towards Autothermal
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 19
Decoupled Reducer Test Decoupled Oxidizer Test
Integrated Autothermal Test
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Hot Coupled Loop Operation Achieved with Coal & Charcoal
Prototype Reducer tests: Preliminary Testing Results
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 20
Significant Observations:• All LCL™ reactions realized• High carbon burnup efficiency > 98%• Negligible carbon carryover to oxidizer • Oxygen demand - 15 to 20%• SO2 release can be minimized by varying excess
air (CaSO4) to fuel ratio
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Agenda
1st topic General Project & Technology Background
2nd topic Phase 0 to III Activities
3rd topic Phase IV Activities and Status
4th topic Next Steps
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 21
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Limestone Based Chemical Looping Path Forward
• Oxidizer Testing: July – August 2012• Coupled Autothermal Operation: August -September
2012
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 22
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
LCL™ Process Development StepsManaged Development and Scale-up
Pilot PlantPilot Plant
PrototypePrototype
Demonstration Demonstration
2015-2020
2000-2004
2008-2012
Commercial Scale
Commercial Scale
2020-2025
Bench TestsBench Tests
1996
10-100 kWth
1& 3MWth
10 50 MWe
>100 MWe
Reference Design Studies
Drop-Tube/TGA
Small & Large Cold-Flow-ModelSmall & Large Cold-Flow-Model
CFD Modeling, Controls and Tool Development
2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 23
© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Acknowledgments
• Funding Partners:− US-DOE/NETL, Alstom
• Key Team Members:− Herbert E. Andrus, John Chiu, Jr., Paul Thibeault, Carl
Edberg, Jim Kenney, Michael Clark
Significant Progress Thanks to These Contributions37th International Technical Conference on Clean Coal & Fuel Systems June 3-7, 2012 Clearwater, FL, USA - P 24
www.alstom.com
Thank You!
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