test facility for advanced … mtg/07-03 v. cortez...test facility for advanced technologies for co...

TEST FACILITY FOR ADVANCED

TECHNOLOGIES FOR CO2 CAPTURE IN COAL

POWER GENERATION

UPDATE AND UPGRADE

Prof. Dr. Vicente J. Cortés CO2 Capture Program Director CIUDEN, SPAIN

TEST FACILITY FORCO2 CAPTURE

TECHNOLOGIESEL BIERZO



Prof. Dr. V. J. Cortés

I. Fundación Ciudad de la Energía

II. Conceptual design. Size and technologies

III. The site. Design criteria and plant configuration

IV. Virtual walkthrough

V. Project structure

VI. Research Program

VII. Time schedule






Fundación Ciudad de la Energía A brief introduction

Fundación Ciudad de la Energía A brief introduction






Fundación Ciudad de la Energía

MINISTERIODE

EDUCACIÓNY CIENCIA

MINISTERIODE

INDUSTRIA

An initiative of the Spanish Administration

MINISTERIODE

MEDIOAMBIENTE






Promote and financially support R&D+d for CO2 capture and storage technologies and abandoned mines restoration

TEST FACILITYFOR CO2

CAPTURE TECHNOLOGIESADDRESSING

OXYFUELAND POST-COMBUSTION

TECHNOLOGIESAT

EL BIERZO

PROGRAMA

CO2 GEOLOGICALSTORAGE

ADDRESSING

FULL SIZE INJECTION TESTS

IN SUITABLE GEOLOGICAL

FORMATIONS IN SPAIN

PROGRAMB

ABANDONED LANDACTION PLAN

ADDRESSING

RESTORATION OFLAND RESOURCES

THROUGH REVEGETATIONFOR LANDSCAPE

RECOVERY

PROGRAMC

Objectives and activities






Conceptual design:Size and technologies

Conceptual design:Size and technologies






Revised Version 6th Draft 15th February 2008

1. Pilot plant tests (10s of MWth) of full oxy-fuel pulverised fuel (PF) process, to validate results from scale-up based on laboratory tests.

2. Development of PF burner designs and piloting in 10s of MWth scale

3. Pilot plant tests (10s of MWth) of full oxy-fuel CFB

R&D area: Developing and implementing OXY-FUEL combustion for boilers

Recommendations for RD&D priorities Recommendations for RD&D priorities within FP7 Energy and National RTD Work Programmes 2008within FP7 Energy and National RTD Work Programmes 2008

ZEP Recommendations






Suitable/applicable Does not require

Technology ExistingPF Plant

NewPF Plant

CFBPlant

Capture- ready Plants

Slip- stream of flue gas

O2 supplyCO2 capture

prior to compression

Post

Pre

Oxy

Comparison of main characteristics of CCS options

X X X X X

XXX

X: Desirable characteristic

Adapted from: Wall, T.F.: Combustion Processes for Carbon Capture. Proc. Comb. Inst., 31 (2007) 31-47

X

X

X,But

unlikely

X,But

unlikely

Addressed at El Bierzo






The upgradeORIGINAL DESIGN JANUARY 07

+

POSTCOMBUSTIONADSORPTION

(1 MWth)

POST-COMBUSTIONABSORPTION(O,5 MWth)

+

OXYBOILER(4 MWth)

CONVENTIONALBOILER(4 MWth)

REVISED DESIGN NOVEMBER 07

+ +

OXYBOILER(20 MWth)

LFC(15-30 MWth)

POST-COMBUSTIONABSORPTION

(4 MWth)

POSTCOMBUSTIONADSORPTION

(X MWth)






The siteThe site






Design criteria and plant configuration Design criteria and plant configuration






General design criteria

LAY-OUT AS INDEPENDENT BUT INTERCONNECTED MODULES (OXYCOMBUSTION, FLUE GAS TREATMENT…) ALLOWING SIMULTANEOUS OR SEPARATE OPERATION FOR INDEPENDENT STUDY OF PROCESSES

MODULARITY

FLEXIBILITYOPERATION UNDER A WIDE RANGE OF CONDITIONS, INCLUDING DIFFERENTS COALS AND COMBUSTION FROM AIR MODE TO OXYMODE

EXTENSIONLAY-OUT ALLOWING FOR EXTENSIONS AT A LATER STAGE IN LINE WITH ANY TECHNOLOGICAL PROGRESS AND/OR STRATEGIC DEVELOPMENT

EFFICIENCYCONCEIVED TO EXPLORE HEAT INTEGRATION AND PERFORMANCE OPTIMISATION WITHOUT PUTTING INTO COMPROMISE REQUIREMENTS FOR FLEXIBLE TESTING

INTEGRATION DESIGNED TO STUDY FULL PROCESS INTEGRATION OF THE DIFFERENT UNITS AND SYSTEMS






A. COMBUSTION SECTIONFUEL PREPARATION/FEEDING WITH INTERMEDIATE STORAGE OF PULVERIZED COALLIMESTONE PREPARATION/FEEDINGPC BOILER, 20 MWthCFB BOILER, 15 MWth (AIR), 30 MWth (OXYGEN)HEAT RECOVERY SECTION

The facility

C. CO2 CAPTURE SECTIONCOMPRESSION/COOLING UNIT FOR OXY-FLUE GASESCHEMICAL ABSORPTION UNIT FOR AIR-FLUE GASES (PHASE II)

D. O2 SUPPLY SECTIONCRYOGENIC STORAGE + VAPORIZING SYSTEMAIR SEPARATION UNIT (PHASE II)

B. FLUE GAS CLEANING SECTIONSCR WET FGDFF






Coal preparation section“Indirect” combustion

CRUSHER

MILL

CLASSIFIER

BAGFILTER

PCBIN

CRUSHEDCOAL SILO

CFBBIN

COALUNLOAD

FGR1 TO COMBUSTORTO CFB FEEDER

RAW COALBUNKER

FEEDHOPPER






Proximate analysis as received (wet) Anthracite l Bituminous

Coal

Sub- Bituminous

CoalPet Coke

Moisture (%) 8.8 7.5 26.8 6.8

Volatiles (%) 6.5 22.3 36.8 10.6

Ash (%) 32.0 13.8 1.5 0.8

Fixed carbon (%) 52.7 56.4 34.9 81.8

Ultimate analysis as received (wet)

C (%) 52.59 66.91 52.66 79.82

H (%) 1.68 3.37 3.76 3.93

N (%) 0.88 1.65 0.66 1.78

S (%) 1.07 0.38 0.09 5.11

O (%) 2.95 6.34 14.59 1.70

High heat value

H.H.V. (kcal/kg) as received (wet) 4888 6550 4941 7785

Design coals






Height (m) 19.5Wide(m) 4.3Depth (m) 2.4Burners 2 vertical + 2 horizontalHeat transfer system Evaporator + drum + superheater + economizerDesign data (for Cupo Bierzo Coal) Air mode OxymodeThermal Power (MW HHV) 20 20Air flow (kg/h) 27068 0Oxygen flow (kg/h) 0 7880Recirculation gas (kg/h) 0 19757Exhaust gas (kg/h) 29213 27814Exhaust gas temperature (°C) 350 350Coal consumption (kg/h) 3278 3278Steam generation (t/h) 32 32Steam Pressure (bar) / Temperature (°C) 30 / 250

PC boiler (by FW) main characteristics






CFB (by FW) main characteristics

Height (m) 21Wide(m) 2.7Depth (m) 2.4

Heat transfer system Evaporator + drum + intrex + superheater + economizer

Design data (for Cupo Bierzo Coal) Air mode Oxy modeThermal Power (MW HHV) 14 16 30Air flow (kg/h) 21240 0 0Oxygen flow (kg/h) 0 4748 8775Recirculation gas (kg/h) 0 24327 25532Exhaust gas (kg/h) 23040 29520 28800Exhaust gas temperature (°C) 346 358 355Coal consumption (kg/h) 2703 2846 5469Limestone consumption (kg/h) 278 354 720Steam generation (t/h) 21.6 22.7 44.6Steam Pressure (bar) / Temperature (°C) 30 / 250






Simplified process diagram

PREHEATINGTRAIN

AIRDeNOX

FGR1

O2 STORAGEAND

VAPORISATION

CFB BOILER

FGR2 RECIRCULATION

O2PREHEATING

FGR2

HIGHEFFICIENCY

DeSOX

FROM COALPREPARATION

CFBBIN

MIXERS

BAG FILTER

PC BIN

PC BOILERPHASE II

ABSORPTIONSECTION

STACKCH-50

COMPRESSION TRAIN

BAG FILTER

CO2

EXPANDER

CO2






Virtual walkthroughVirtual walkthrough






Model of the plant

Fuel preparation

Oxygen supply

CombustionIslandFGC

CO2 compressionChemical absorption

ControlRoom






Combustion island and O2 supply






Flue gas cleaning section






CO2 capture section






CFB by Foster Wheeler






Project StructureProject Structure






ENGINEERING

Project structure

OXYGEN SUPPLYAND

CO2

CAPTURE

DETAIL ENG.AND CONSTRUCTION

EQUIPMENTSUPPLIERS

OXYCOMBUSTION BOILERS INSTRUMENTATION

AND CONTROL

MoUs signed

Contract awarded

Conversations for MoUs initiated

UTILITIES






Research programResearch program






EXPERIMENTALPROGRAMME

PROMOTED BY CIUDEN ANDPERFORMED BY RELEVANT SPANISH RESEARCH INSTITUTIONS

PERFORMED AT THE FACILITY IN COOPERATION WITH RESEARCH INSTITUTIONS, TECHNOLOGY PROVIDERS AND TECHNOLOGY USERS

The R&D programme structure

RESEARCH PROGRAMMEOF

EL BIERZO TEST FACILITY

SCIENTIFICPROGRAMME






Experimental Programme

PROCESS PERFORMANCE IN CONTINUOUS, PART-LOAD OPERATION AND LOAD FOLLOW-UP

TARGETSTARGETS

VALIDATION OF ENGINEERING AND DESIGN TOOLS AND PROCESS MODELS FOR SCALE-UP






Time scheduleTime schedule






Time schedule

2

1

4

5

6

3

CONSTRUCTION

OPERATION PERMITS

PERMITTING

BASIC ENGINEERING

OFF-SITES DETAIL ENGINEERING

SPECIFICATION, PROC. AND DETAIL ENGINEERING OF MAIN UNITS

2007 20102008 2009

TEST FACILITY FOR ADVANCED

TECHNOLOGIES FOR CO2 CAPTURE IN COAL

POWER GENERATION

UPDATE AND UPGRADE

Prof. Dr. Vicente J. Cortés CO2 Capture Program Director CIUDEN, SPAIN

test facility for advanced … mtg/07-03 v. cortez...test facility for advanced technologies for co...

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