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Design Criteria for Carbon Capture Ready Power Stations and

Technological Options under Development by Power Plant Suppliers

IZEC CCR Symposium, Tokyo, November 19th, 2009

Dr. Christian Bergins

Research & DevelopmentHitachi Power Europe GmbH, Duisburg

[email protected]

2Hitachi Power Europe GmbH © 2009IZEC Symposium, Tokyo, November 19th, 2009

Content

Technology steps towards the CO2 free power station

Political background, Technology overview for Carbon Capture

and Storage (CCS) and development/demonstration issues

Strategy and definitions for Carbon Capture Ready (CCR)

Feasibility study results, ongoing development work and

implications for the power plant design (CCR and future new build)

Oxyfuel / Combustion

Post Combustion Capture

Summary


Power plant supply by HITACHIToday, tomorrow and in future

Boiler

Turbine/Generator

DeNOx

FGD

Engineering

BOP

I & C System

Civil works

Infrastructure

BOP others

More than 65 % of a high efficient powerstation can besupplied bygroupmembers

Efficiencies for coal fired PP

Up to >46 % for bituminous coal*

Up to 43 % for lignite

*depending on fuel characteristics and location



Increase of efficiency will be a key for futurecommercial success

of CCS implementation

Increased efficiencies to allow CCS in future

700°C for bituminous coal: >50 % efficiency

Dry lignite fired boilers: >47 % efficiency

700°C dry lignite fired: >50 % efficiency

Boiler Technologies available

and to be demonstrated

in first Prototype plants



CO2 Separation

ASU (Air Separation Unit)

Dry ESP

Boiler

FGD

RecirculationLine

SCR

Dryer

CO2 Compression

Transport & StoragePower Station

with CO2 Capture

Pipeline

Deep SalineAquifier

Depleted Oilor Gas

Reservoirs

UnminableCoal beds


Content









Summary


Carbon capture and storage:Capture Technologies considered

Pre-combustion

(Gasification & CO2-capture)

Pre-combustion

(Gasification & CO2-capture)Post-combustion

(capture added downstream)

Post-combustion

(capture added downstream)Oxyfuel

(combustion with oxygen)

Oxyfuel

(combustion with oxygen)

source : Vattenfallsource: Vattenfall source : Vattenfall

Processes most probably capable for retrofits on actual new build and existing coal fired power stations

CCS retrofit only possibleafter major equipment

changes


Why and how considering CO2 capture readiness?Regulatory Background – EU

Directive 2009/31/EC of the European Parliament and of the Council, 23 April 2009

Article 33 / Amendment of Directive 2001/80/EC :

(1) for getting construction / operation licence operators of all combustion plants with a

rated electrical output of 300 megawatts or more have to assess whether:

• suitable storage sites are available,

• transport facilities are technically and economically feasible,

• it is technically and economically feasible to retrofit for CO2 capture.

(2) … the competent authority shall ensure that suitable space on the installation sitefor the equipment necessary to capture and compress CO2 is set aside. The

competent authority shall determine whether the conditions are met on the basis of

the assessment referred to in (1) and other available information, particularly

concerning the protection of the environment and human health

Hitachi Power Europe GmbH © 2009IZEC Symposium, Tokyo, November 19th, 2009


Development of Coal GasificationActual step: Testing of CO2 scrubbing in IGCC process

Project Name Plant size Objectives

HYCOL 50t/d '90 ～ ' 93 Gasifier basic conceptAsh treatment method

EAGLE I 150t/d ‘02～ ‘06 Scale-up technologyReliability improvement

Duration

GasificationGasification

Air SeparationAir Separation

Gas CleanGas Clean--upupGTGT100m100m

200m200m

60m60m

CO2 Recovery

HYCOL: Hydrogen from CoalEAGLE: Energy Application for Gas, Liquid and ElectricityEAGLE project


CO2 Capture Facilities

Project Name Plant size Objectives

EAGLE II 150t/d ‘06～Scale-up technologyReliability improvement withCO2 recovery test

Duration

CO2 Capture unit


Status of Pre-combustion Capture in EUaccording to ETP-ZEP

Dust removalReforming (gas)

CO shift

H2 coproduction

Gasification (coal) CO2 capture and desulphurization

Overall process integration

Fuel handling(Lignite/Biomass)

ASU

CO2 purification & compression

H2 gas turbine

Validationstatus

Fully

Not

Partially

Gasification (Lignite)

Source : Vattenfall & ETP-ZEP

But: - high availability always requires cold gas cleaning and several temperature cycles

and so reduces the efficiency!- CCR design difficult regarding gas use (GT/Combustor design either flexible or high efficient!)


Capture ProcessesPost Combustion CO2 Capture (PCC)

Fly ashBottom ash

FGDESP

SCR

boiler

Gypsum

CO2 lean gas

cooler

Absorber

Rich Solvent

Lean Solvent

condenserReflux

Drum

product CO2

amine scrubbing

NaOHDesorber

airpre-

heatercoal

General Opinions„CO2 scrubbing development most advanced“„Integration simple as downstream arrangement“„Only process available for retrofits “ … BUT


Capture ProcessesIntegration of post combustion capture to power plants

flue gas w/o CO2

Cooler

Absorber

Rich Solvent

Lean Solvent

CondenserReflux

Drum

product CO2

Amine scrubbing

NaOH

Process engineering, design and chemistry:dynamic behaviour of a “chemical plant”Absorbent: corrosion, degradation, emissions….

Heat recovery /cooling demand

Advanced flue gas

treatment(dust, NOx,

SOx)heat (and cooling)

demandup to 1/3 of the thermal PP heat

without heat integration

(95% for desorber)

compression:buffer

compressor drivewaste heat

Desorber


Capture ProcessesOxyfuel Combustion with a CO2/O2 mixture instead of air

CO2(purification)compression

ESPCoal

ASU AirN2

O2

DeNOx

FGD

H2O CO2

steam cycle

HRS FG cooling

sulfurH2O

ESP

ash

Coal

ASU

N2

O2

flue gas recycle (mostly CO2 and H2O)

boiler DeNOx

FGDHRS FG coolingESPcoal

ASU

N2

O2

DeNOx

DeSOx FG cooling

air

ASU: Air Seperation Unit

ChallengesReduction of energy consumption, especially by optimized ASU and heat integrationAir tightness whole system Specific components to be re-designed (AQCS, firing) and materials to be checked Some new components to be proven, design basis needed (FG cooling, CO2 purification)

AdvantagesFiring design for operation with oxyfuel & air firing possible Plant design for retrofits and new build plantsAll technologies basically exist in adequate size

CPU

CPU: CO2 Processing Unit


Roadmap for CCS & power plant business

1994 today 2015 2020

Demo plantsIn operation

Pilot Plant tests CO2scrubbing (EU) and oxyfuel

FEED Studies

full scale plants∆effic. < 8 %in operation

Pilot Plant testsJapan

Feasibiliy Studies, CCR Design

CCS Design(commercial)

CCS

normal power plant business

Capture, transportation and storage expected to be technically available

CCS will have to be acceptable by politics and public within a clear regulatory framework for demos and full scale plants (permits)

Most old plants may be not CCR due to efficiency and commercial reasons

Most recently built or currently being built plants are CCR

New build plants will have to be CCR (regulatory issue)


Content









Summary


Strategies for the prove of capture readiness

CCR check always based on the base of individual projectCCR may require some design work in advanceto ensure maximum efficiency and profitability of retrofit

CCR prove e.g. can be done by

Certification by TÜV according to TÜV NORD Standard: TN-CC 006Voluntary examination of conventional power plants and CO2emitting plants, in respect to the readiness to retrofit CO2 capturesystems (CC-systems) in futureJoint study of plant supplier, utility and companies involved in theCO2 transportation and storage to develop specific ideas for anindividual project

..........

Up to now there are no official standards for CCR!


Carbon Capture Readiness Selection of criteria, based on TÜV TN-CC 006

Site specific basic technical concept (e.g. feasibility study of plant manufacturer for capture)

There shall not be any site specific items or conditions that could hinderthe retrofit by 2020 at the latest (e.g. proof, that there is sufficient space)

Checking of e.g. official regulations/restrictions, environmental issues(i.e. emissions, cooling water, noise)

The plant operator should show active contribution to CCS R&D

Preparatory measures for a retrofit shall not have a significant negative effect on the efficiency of the plant, i.e. no waste of energy in advance

A site-specific concept for CO2 transportation must be presented

A site-specific long-term storage concept must be presented

More details at http://www.tuev-nord.de/en/


CCS effect on efficiency

In the worst case CCS may decrease the efficiency of coal fired power stations from 46% to less than 32% (based on LHV)

Efficiency increase will support the commercial CCS implementation for all new power stations. Development work for those measures and demonstration have to be done in parallel!

Optimization of the CCS integration has to be done in addition by suppliers

optimized energy supply for CCS

waste heat recovery systems

optimized components and processes for PCC unit, ASU and CPU forOxyfuel

Solvent improvement for PCC


Potentials for efficiency increaseRecent high efficient steam generators

effici

ency

incr

ease

180 220 240 260 280 300 380

700

620

600

580

560

540

Hitachi-Naka #1

Tachibana Wan #2

Matsuura #2

Shinchi #1 Noshiro #1 Hekinan #2

Nanao-Ohta #1

Haramachi #2 2000MW

39,000 MW

6600MW

700°Cdemonstration

Lippendorf

Niederaußem K

Boxberg

Neurath F/G

Schkopau

Boxberg RRKW NRW

Altbach 2 Staudinger 5 Rostock

Bexbach 1 Studstrup

Moorburg

DattelnWalsum

MedupiKusile

Genese #3Keephills #3

Council Bluffs #4Elm Road

Cliffside #6

Japansince 1995

Chinasince 2002

Germany, ligniteGermany, bituminous

South Africa

USA,Canada

since 2005

SH O

utle

t Tem

pera

ture

[°C

]

SH Outlet Pressure [bar]


CO2 Emissions of Power Plantswith different Fuels

0

200

400

600

800

1000

1200

1400

1600

0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6

lignite(rhenish)

GasSource:

Marheineke T., Krewitt W., Neubarth J., Friedrich R., Voß A.IER-Bd. 74, IER, University of Stuttgart, Germany, 2000

Bituminous coal(Average)

CurrentAverage

EU15-countries Reference PS NRW(State of the art)

Averageworldwide -35 %

Thermie700, 2RH

Average ChinaRussia 2003

Besides saving of energy CO2 Emissions can be effectivly lowerby encreasing efficiency using coal for electricity production

CO

2Em

issi

ons

[g/k

Wh]

Net efficiency η [-]


700°C technology:HPE’s steam generator for 500 MWel (PP > 50% efficiency)

HP-Part:Life steam pressure 365 barLife steam temperature 705 °C

RH-Part:Inlet pressure 74 barOutlet temperature 720 °C

Bituminous coalBenson® steam generator


Content









Summary


Oxyfuel Process Retrofit StudySelection of flue gas recycle and process

ESP

ash

coal

ASU airN2

O2

flue gas recycle

boilerDeNOx

DeSOx

H2O CO2

CO2compression

Steam cycle

dryer

sulfur

blower

1

2

3 54 6

H2O

air

blower

ESP

ash

coal

ASU airN2

O2

flue gas recycle

boilerDeNOx

DeSOx

H2O CO2

CO2compression

Steam cycle

dryer

sulfur

blower

1

2

3 54 6

H2O

air

blowerflue gas recycling

hot gas recycling

Selection of hot gas recycle : - avoid gas gas heat exchanger in flue gas path

where the space is limited- heat recovery is not possible without

major changes in the steam cycle (in retrofit case)

Recycled flue gas: shall be cold, cleaned and partially driedminimise changes in the boiler house avoid corrosion and erosionkeep reliability of ductwork / components designed for air operation


Oxyfuel Process: required measures for retrofit

Steamgenerator

Forced-draught fan

Primary

DeNOxcatalyst

ESP

FGDO2

Exhaust gas

Flue gaspreheater

CO2

ID fan

Airpreheater

Overfire air

FD fan

Primary aircooler

Fuel

Burner system

CO2

PA fan

Mills

(red components from retrofit)

DryerCO2-

Compression

Hot gasrecirculation

ASUASU

Ambientair

preheaterO2-


Oxyfuel component re-designMPS 245 Operation with sealing gas CO2

A

C

B

D

) () (

) ( Replace air as sealinggas by CO2

Retrofit sealing designto avoid CO2 leakageto boiler house

CO2


Oxyfuel component re-designOxygen preheating arrangement in parallel to „air“ preheater

ET

+ 52,335 m NN

+ 29,700 m NN

+ 35,075 m NN

+ 43,400 m NN

recyled flue gas preheater

+ 52,335 m NN

+ 43,400 m NN

Flue gas to ESP

+ 35,075 m NN

+ 29,700 m NN

Oxygenpreheater

damper

8600

1880

08200

recyled flue gas


Oxyfuel component re-designBurner

Coreair

Primary air +Coal dust

Secondaryair

TertiaryairBurner operation targets

air mode and oxyfuel modesimilar flame shapesimilar flame temperature /adiabatic combustion temperatureburnout progress

atmospheric condition

oxyfuel condition

1770168616021518143413501266118210981014

930846762678594510426342258174

90

Burner operation measuressame volume flow of primary gas in both modes (requirement from mill)same momentum flow of secondaryand tertiary gas in both modesvariable oxygen content of primary, secondary and tertiary gas


Design of Water-/Steam System

Heat transfer in the convective path adjusted by means of recycled flue gas mass flow

250

300

350

400

450

500

550

600

650

1 2 3 4 5 6 7

Tem

pera

ture

°C

air

oxyfuel

ECO Evaporator SH1 SH2 SH3Spiral Vertical

Steam parameters matchthe air combustion case

Water / steam temperaturesdo not exeed design values

Boiler efficiency dropsslightly

Flue gas mass flow increasesFlue gas exit temp. increases

RH-Spray increases


Oxyfuel component re-designImproved SOx removal and FG drying

flue gas to CPU

NaOH

20°C

25°C57.5°C

30°C

153 MW26,500 m³/h

SOx < 5 mg/Nm³

PM < 1 mg/Nm³

SOx > 100 mg/Nm³

PM > 10 mg/Nm³

condensationPM & SO3

∆T 27.5°C

condensateca. 185 m³/h

flue gas from FGD

reduction of moisture from ca. 8%wt to < 2%wt


Oxyfuel overall arrangement (partially optimized) and actual/future development work

Cooling tower

Steam lines

CoalFGD

Flue gasdesulphurisation

Draught fan

Cooling water

PAfan

Coalmills Ash

removal

TurbineGenerator

Feed watertank

Feedpump

ElectrostaticprecipitatorLP

preheaterHP

preheater

Condenser

GypsumFly ashFDfan

DeNOx


FGCooling

Heatrecovery

Recycled flue gas

air

ASU

Nitrogen

Oxygen

CO2

Transport & Storage

FGCooling

H2O

Combustion testing in small scale and CFD model validation

4-30MWth burner / combustion testing

AQCS testing for all components

In parallel: materials testing for all components

Overall process optimization


4 MWth combustion test facility, Hitachi Japan

PAF, GRF

Oxygen supply equipment

Heater

IDF

CycloneAir Heater

Spray tower（remove dust）

Horizontal furnaceBurner

Over fire air ports(OFA)

Combustion air

Fuel pipe

Primary gas pipe

Test itemsBurner, CombustionAsh propertiesHeat transfer propertiesSafety


1.5 MWth Air/Oxyfuel combustion Pilot Plant, Hitachi Japan

Flue gas treatmentTotal system Furnace

Simultaneous evaluation for Oxy-Combustion at furnace and flue gas behavior (NOx, SOx, dust, trace elements)

O2Tank

Pulverized coalBunker Catalyst

GGH

Dry-EP

BF

GGH

FGD

Furnace

CO2 Flue gas Circulation Line

A/H

GOALSHigh Performance DeNOx/Hg oxidation catalyst at high conc. H2O and SO2High efficiency SO2 removal by wet FGD （SO2 < 5 ppm for CO2 compression）Trace pollutants (Hg, SO3, HF etc.) removalOptimization of AQCS process


Vattenfall 30 MWth Oxyfuel PlantHPE‘s DS® Oxyfuel Burner and Combustion test in 2010

boiler

ESP

CO2-purification andcompression

air separation unit DeSOx

flue gascondenser

source: Vattenfall

Offices and storage rooms


Future optimization potential for commercial size implementation of oxyfuel

Decrease specific energy requirement of ASU and improve load change behaviour (process design and investment)

Develop new optimized process design

Checking of SCR requirement depending on CPU capability

SO2/SO3 removal options and way of fg reciculation

CO2 compression and purification (depending on legislation) design

Waste water treatment (from FGD, flue gas condenser and CPU)

Improve heat integration project dependent


Change of Power Station CapacityRetrofit oxyfuel „state of the art“ 2009 vs. 2020

Air Mode Oxyfuel 2009

Thermal Input (fuel) 1669 MW 1674 MW

Gross capacity air mode 829 MWel 829 MWel

Own consumption 61 MWel 63 MWel

Power consumption for ASU + - MWel 192 MWelCO2 compression

2009 retrofit: Overall efficiency drop from 46 to 34.3 % (11.7%points)

2020 expected: New build power station with 50% efficiency

Reduced consumption by ASU + heat recovery for new builds

Waste heat recovery from CPU in power station

⇒ Overall efficiency drop from 50 to 40-42 % (8-10%points)

Net capacity 768 MWel 576 MWel


Examples for retrofits and new build PP design

CO2 Compressionapp. 2,000m²

Retrofit studies for actual new builds finished

Air Separation Unit

app. 26,000 m²

4 trains

Compressor Unit 1-4

ASU (Air Separation Unit)

Dry EP

Boiler

FGD

Compressor

RecirculationLine

SCR

150m

500m

500 MWelTwo pass

boiler

(New build)

Optimization for pure oxyfuel plants

ongoing

ESP

Flue Gas RecycleHeat

Exchanger

FG Drier

FGD

820 MWelTower type

boiler

(Retrofit)∆η = 8-12%points depending on O2 production process details, CO2compression and heat integration/process design,retrofit or new build


Summary of main OxyfuelCapture Ready Requirements

Cooling tower

Steam lines

CoalFGD

Flue gasdesulphurisation

Draught fan

Cooling water

PAfan

Coalmills Ash

removal

TurbineGenerator

Feed watertank

Feedpump

ElectrostaticprecipitatorLP

preheaterHP

preheater

Condenser

GypsumFly ashFDfan

DeNOx


FGCooling

Heatrecovery

Recycled flue gas

air

ASU

Nitrogen

Oxygen

CO2

Transport & Storage

FGCooling

H2O

AQCS- check SCR, ESP, FGDperformance and retrofit options

- leave place for installation of gas cooler/condenser and additionalfan for FGC ∆p

- check possible SO3 sinks

Cooling System/Cooling towerSufficient space for:• Additional circulation pumps• Service water systemSufficient cooling capacity of cooling tower/other sources

CPUleave place for CPU near power plant

Electrical self consumptionSufficient space for:• Additional transformer(s)• Switchyard• Cable routes

Condensate System and LP/HP preheatersSufficient space for:• Heat exchangers for heatrecovery

• Additional piping routes with supporting structure

Mill- check mill drying and outlet temperature

- check replacement of sealing system (retrofit to CO2 as sealing gas)

Boiler & Firing- design heat absorption thesame for oxyfuel/air combustion

- design firing / burner capable for reduced oxygen excess andcapability for both modes

ASU and Oxygen- leave place for ASU (not necessarily at power station), oxygen pipes and O2injectionto combustion air

Flue gas ducts, recirculation, O2- leave space for ductwork (fg and O2)- leave space for recirculation fan or upgradable design of air fan

- consider O2 heating

Raw Water, Cooling Water Supply, Waste Water Treatment• space for upgrade• check water availability,

permit possibilities

„Air“/fg preheatingSpace for heat exchan-gers for heat recovery


Content









Summary


Post Combustion CO2 Capture (PCC)

Cooling tower

Steam lines

Steam generator

Coal

FGDFlue gas

desulphurisation

Draught fan

Cooling water

PAfan

Coalmills Ash

removal

TurbineGenerator

Feed watertank

Feedpump

Electrostaticprecipitator

LP preheater

HP preheater

Condenser

GypsumFly ashFD

fan

DeNOx

Absorber DesorberPre-scrubber

Compressor

CO2

Flue gas with less CO2

Transport & Storage

Challenge for retrofits and new design:heat supply and waste heat recovery,

component design adjustment, interfaces

development tasks PCC unit:

solvent and internal process and component

design


Hitachi´s Experiences in CO2 removal fromCoal-fired Power Plants

Pilot Plant Yokosuka, Japan

Flue Gas Volume: 1000 Nm3/hCO2 removal: 4.5 ton/dCO2 Recovery: 90％


HPE´s mobile Pilot Plant

5000 Nm3/h flue gas

Removal of 1 ton CO2/h

Two train design for highest testing flexibility

Operation on different sites due to installation in containers

CO2 removal > 90 %

CO2 purity > 95 %

Optimized process design for a reduced energy demand

Absorber Desorber

Reboiler

Pumps and Heat Exchanger

Tanks

Partners for solvent development:

IZEC CCR Symposium, Tokyo, November 19th, 2009

Pre-Scrubber


Maximum Flexibility in the Choice of Location

Tests supportedand at locations of:


Scale up and integration of Full Size CCS-Plant

h ~ 50 m

Pilot plant5 MWth

Diameter ~ 1 m

Demo plant~ 350 MWel

Diameter ~ 12 m

Full size plant~ 800 MWel

Diameter ~ 19 m

Absorber diameter of 12 m is state-of-the art in chemical

industry

h ~ 42 m

h ~ 23 m

Hitachi Power Europe GmbH © 2009IZEC Symposium, Tokyo, November 19th, 2009


Interfaces of the Post Combustion Capturing Plant and the Power Plant in detail

Scrubber

FGD

1 2CO2

Clean Gas

HP

FeedwaterTank

LP Preheater

HP Preheater

LP LP LP LP GIP IP

31

2ca. 50°C

CO2 Compressor

Absorber Desorber

Boiler

CondenserA

CondenserB

Stack

Process heat forDesorber and

Amine regeneration bysteam extraction

Process coolingand heat recovery(CO2-Compressor,

Amine-cycle, fluegas cooling)

Optimized flue gas cleaning (dust,

NOx, SOx)

Electrical powerfor CO2-Capture process (pumps,

fan) and integration of

measurement and control

Process steamFluegas

Energy supply ofCO2-Compressor

120°C40°C


Integration in a Full Size Plant(I) without optimization

Scrubber

DeNOx

CO2

Clean gas

HP

FeedwaterTank

LPPreheater

LP LP LP LP GIP IP

ca. 50°C

CO2 Compressor

Absorber Desorber

Boiler

CondensatorA B

Stack

Process steam

Flue gas

Condensator

HD Preheater

FGD

Reboiler

LPIP LP

120°C40°C


Influences on Plant Efficiency

compressionat 200 bar

Plant with

CCS31.0 %

46.9 %

35.0 %

2.8 %

2.8 %

0

5

10

15

20

25

30

35

40

45

50

Effic

ienc

y[%

]

Basis no CCS

Hitachi H3 2800 kJ/kg CO2

- 13.1 % - 9.1 %

820 MW

541 MW

611 MW

MEA 3600 kJ/kg CO2

compression


The Interfaces between the Power Plant and CO2 Capture Equipment

CO2

Air-/Flue gas system

CO2Compression

Water-/steam-circulation,

Turbine,Generator

DepletedFlue gas

Flue gas Cleaning & CO2-Capture

Cooling

El. Leistung

Heat integration

Flue gas

Heat

El. Power

CO2

Air

Fuel

Heat integration

Flue gas

Steam

Condensate


Main disciplines working together at Hitachi on optimized process design for PCC

boiler turbine & water steam cycle AQCS

compressorPCC process& solvent


Integration in a Full Size Plant(II) with optimization

Primaryair

FGD

CO2Clean gas

Pre-scrubber

CO2 Compressor

Process steam

Boiler

Stack

D

1 2

DeNOxG

TP

T P

R

R

V

V

D

11 32

Out of service

FeedwaterTank

HP Preheater

HP LPIP LP

Condensator CondensatorA B

LPPreheater 4-5

LP Preheater 4-5

Absorber Desorber

Reboiler

120°C40°C

Additional component or flow in water steam cycle for CCS operation


Modifications of the Steam Turbine

Steam Extraction (Reheat Steam Line)

GHP IP

Cross over valve forpressure adjustment

Re-Design of castedouter casing of the IP-

Turbine

LP LP

Modified last stage HP blades due to

increased enthalydrop

Smaller LP blades due to modified steam flow

Steam Extraction (Crossover Pipe)


Loss of efficiency by optimized integration

39.4 %39.1 %

31.0%

46.9 %

35.0%

0

5

10

15

20

25

30

35

40

45

50

Effic

ienc

y[%

]

Basis no CCS

MEA 3600 kJ/kg CO2

Hitachi H3 2800 kJ/kg CO2

-13.1 % - 9.1 %

Hitachi H32800 kJ/kg CO2

- optimized -

Aim: NGS 2500 kJ/kg CO2

- optimized -

- 5.0 %compression

820 MW

541 MW

611 MW

683 MW688 MW

2.8 %2.8 %

2.8 %

2.8 %

- 4.7 %


Plant cycle without CCS

Cooling tower

Steam lines

Steam generator

CoalFlue gasinjection

FGD

Draughtfan

Cooling water

PAfan

Coalmills Ash

removal

TurbineGenerator

Feed watertank

Feedpump

LP Pre-heater

HP Pre-heater

Condenser

GypsumFlyashFD

fan

DeNOx

Flue gas with lessCO2

ESP

30 60

40 50

η

46.9


Plant cycle with CO2 scrubbing

CO2 scrubbing, solvent MEASteam extraction: connection pipe to LP-turbine andcold/hot reheat line

30 60

40 50

η

AbsorberDesorberPre-scrubber

Com-pressor

CO2

Transport &Storage

31

-15.9

to desorber

to desorber

to desorber



CO2 scrubbing, improved solvent, i.e. H3Steam extraction: connection pipe to LP-turbine andcold reheat line, no extraction from hot reheat

30 60

40 50

η

AbsorberDesorberPre-scrubber

Com-pressor

CO2

Transport &Storage

35

-11.9

to desorber

to desorber



30 60

40 50

η37.1

- 9.8

CO2 scrubbingTurbine modificationSteam extraction: connection pipe to LP-turbine


Process integration

30 60

40 50

η

- 8.838.1

CO2 scrubbingTurbine modificationSteam extraction connection pipe to LP-turbineTransfer of waste heat into FD-air resulting in airheater bypass for HP pre-heater

Cooling water

Cooling water


Process integration

30 60

40 50

η

38.6- 8.3

Cooling water

Cooling water

CO2 scrubbingTurbine modificationSteam extraction connection pipe to LP-turbineTransfer of waste heat into FD-air resulting in airheater bypass for HP pre-heaterCCS waste heat shifted to LP pre-heater


Process integration

CO2 scrubbingTurbine modificationSteam extraction connection pipe to LP-turbineTransfer of waste heat into FD-air resulting in airheater bypass for HP pre-heaterCCS waste heat shifted to LP pre-heaterFlue gas heat to LP pre-heater

Cooling water

Cooling water

6030 6030

39.1 50

η

- 7.840


Summary of main PCC Capture Ready Requirements

Cooling tower

Steam lines

Steam generator

Coal

Flue gasinjection

FGDFlue gas

desulphurisation

Draught fan

Cooling water

PAfan

Coalmills

Ashremoval

TurbineGenerator

Feed watertank

Feedpump

LP Pre-

heater

HP Pre -

heater

Condenser

GypsumFlyashFD

fan

DeNOx


EP

Cooling tower

Steam lines

Steam generator

Coal

Flue gasinjection

FGDFlue gas

desulphurisation

Draught fan

Cooling water

PAfan

Coalmills

Ashremoval

TurbineGenerator

Feed watertank

Feedpump

LP Pre-

heater

HP Pre -

heater

Condenser

GypsumFlyashFD

fan

DeNOx


EP

Ab-sorber

De-Pre -scrubber

Com-pressor

CO2

Transport & Storage

sorber

Cooling water

Cooling water

Electrical self consumptionSufficient space for:• Additionaltransformer(s)

• Switchyard• Cable routes

Condensate System and LP/HP preheatersSufficient space for:• Heat exchangers for lowgrade heat utilization

• Additional piping routes with supporting structure

Air PreheatingSpace for heat exchangers for heat utilization

Raw Water, Cooling Water Supply, Waste Water Treatment• space for upgrade• check water availability,permit possibilities

draught fan & flue gas ductsUpgradeable fan design or additional space for installation of secondfan at PCC unit

• Flue gas connection tocapture unit (T-branch)

Cooling System/Cooling towerSufficient space for:• Additional circulation pumps• Service water systemSufficient cooling capacity of cooling tower/other sources

FGDConsider space for internal retrofit measures or provide space for additional FGD/FGC unit

Steam Turbine and Steam Turbine Building• consider steam extraction from cross over system

• consider internal modifications Sufficient space & foundation for:• Modification of turbines• Steam and condensate pipes• Installation of heat exchangers

Arrangement planning and spaceConsider additional equipment and minimize distances for heat supply, heat recovery and cooling water

PCC UNIT & CPU•Consider space•Routes for heat supplyand heat recovery


Summary, Outlook

For power generation Hitachi today provides cutting edge technologies withhighest available efficiencies- Actually build power stations are “carbon capture ready”- CCR design continuously updated by new development results

For tomorrow’s demonstrations all processes for CCS are prepared

Hitachi’s mobile pilot plant for PCC CO2 scrubbing is manufactured, tests will start 2010 in EU. Solvent improvement activities are ongoing at BHK, HPE and in cooperation with Uhde

Oxyfuel development at HPT, BHK and HPE is ongoing in different experimental scale for all components

Hitachi will deliver all components required and power trains including carboncapture in future

Hitachi will play an vital role in the global CCS demonstration programs


Carbon Capture ReadinessMost important criteria, based on TÜV TN-CC 006

Site specific basic concept (e.g. feasibility study of plant manufacturer)for a CC system, which is considered a suitable option for retrofitaccording to the current state of knowledge

There shall not be any site specific items or conditions that could hinderthe integration of a CC system into the main plant by 2020 at the latest.E.g. it should be proofed, that there is sufficient space for the retrofit of aCC system at the plant site

Proof of extended / additional investigation must be provided on itemswhich actually can not completely assessed

Furthermore, proof must be provided that no significant obstacles toimplementation will arise from these items, e.g. official regulations andrestrictions (i.e. emissions, cooling water, noise)

The operating company at a reasonable amount contributes to R&D in thefield of CCS



The design of the installation must ensure that there will not be anysignificant negative effects on safety, environment or human health whichcould be later obstacles for the retrofit

The plant operator must ensure eventual preparatory measures for aretrofit do not have a significant negative effect on the efficiency of themain plant, i.e. no waste of energy in advance

The plant design should allow to implement future developments in thefield of CO2 capture technology, i.e. flexibility for the integration of futuretechnologies to minimize e.g. the efficiency penalty

Possible pre-investments should be identified and be subject to atechnical and economic assessment. Positively assessed measuresshould be taken into account in the planning and implementation phaseof the main power plant. These could be related to e.g. control systems,power supply, steam and cooling water supply an other interconnectionsto future equipment



A site-specific concept must be presented for the transportation of theproduced CO2 (e.g technical feasibility, cost estimates and evaluation,influence on efficiency)

A site-specific long-term storage concept must be presented (possiblestorage options and locations, capacities, cost estimates and evaluation)


Firing design, NOx EmissionsOxyfuel (with cryogenic air separation)

For oxyfuel firing of any fuel the same or higher NOx concentrations (but lower NOx freights) is expected depending on process design.

DeNOx can be done in different ways.

NOX

SOX H2O

Sweep gasO2 SCR necessary for longer air mode operation and depending on Hg in fgcoal

H2O CO2SOX SOX NOX

NOX

SOX H2O CO2

Sweep gasO2

simplified process but not proven technologycoal

H2ONOX SOX SOX


Interaction between process design and SOx

High potential of corrosion in flue gas paths and boiler

due to higher SO3concentration

SOX CO2

Sweep gas

coal

O2

NOX

H2O CO2

Sweep gas

H2O

coal

O2

SOX SOX

SOX CO2

Sweep gas

coal

O2

Moderate/low corrosion potential

High potential of corrosion in flue gas path and boiler, flue

gas cooling and compression

Air Products will demonstrate process at Schwarze Pumpe

primary gas

?

FGD FGC

FGD FGC

FGC


SO3 removal options to reduce risk of corrosion

SO2SO3

CO2

Sweep gas

coal

O2

SO3

FGD FGC

SO2 CO2

Sweep gas

coal

O2

SO3

FGD FGC

NaOH

SO2 CO2

Sweep gas

coal

O2

FGD FGCESP

CaCO3

FF

SO3

primary gas

primary gas

pH controlled FGC

GGH + ESP

additional

dry DeSOx +

fabric filter

GGH

ESP

ESP

NaOH

design criteria for carbon capture ready power stations ... · hitachi power europe gmbh, duisburg...

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