Oxycombustion Project Integration Considerations - CSLF · Proprietary and Confidential •Capture,...

Kevin J. McCauley

Director Strategic Planning, Global Technology

Global CCS Institute / CSLF Meeting on Project Integration 2011

November 3, 2011; London , England

“We are passionate about innovation and technology leadership”

Oxycombustion Project Integration Considerations

Proprietary and Confidential

Introduction

2© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.


• Capture, transport, storage integration

• Overall plant and site integration

• Steam cycle integration

• Combustion/Environmental integration

Project Integration


Global Reach Product Line Portfolio

• Traditional Power• Steam Generation (eg: USC-PC)

• Service and O&M

(Operation & Maintenance)

• Construction and EPC

(Engineer-Procure-Construct)

• Boiler Cleaning and Material Handling

• Clean Coal

• Environmental Systems and Service

• SO2, NOx, Mercury, PM

• CO2 RSAT Scrubber, Oxycombustion

• Renewables

• Biomass

• Solar

• Energy-from-Waste

Total Employees: ~ 8,700

Including JV employees

• Installed 38% of boilers in North American

coal-fired power plants

• Supplied worldwide capacity of more

than 300,000 MW in 800+ utilities

in 90+ countries

• Manage operations and maintenance

of North America power facilities

Major locations

B&W – Power Generation Group

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. 4


Oxygen

Nitrogen

CO2

Nitrogen

+ Coal

Air0

25

50

75

100

Perc

en

t b

y V

olu

me

N2

Flue Gas

after WFGD

O2

N2

CO2

H2O

Oxygen CO2

+ Coal

CO2

CO2

CO2

0

25

50

75

100

Perc

en

t b

y V

olu

me

Synthetic

Air

CO2

Flue

Gas to CPU

O2

H2OH2O 70-80%

reduction in

flow rate to

CO2

compression

process Lb/hr

Typical Air Fired Combustion Oxy-Coal Combustion


Modern Pulverized Coal

Power Plant

6

Coal

Pulverizer

Supercritical

Boiler

Electrostatic

Precipitator (Ash)

Wet FGD

Scrubber (SO2)

Dry FGD

Scrubber (SO2)

Fabric Filter

Baghouse (Ash)

Additional Systems Dry sorbent injection (DSI) for Hg/SO3 Ash management systems Boiler cleaning and auxiliaries Instrumentation and Controls Operation and maintenance

Stack

© 2011 The Babcock & Wilcox Company. All rights reserved.

Selective Catalytic

Reduction (NOX )


OxyCombustion Plant Configuration

Air

Separation

Unit

Boiler CO2

Compression

Air

In

Pure

Oxygen

(O2 )

Nitrogen (N2 )

Out Recycled Flue Gas

CO2 and

Flue Gas

Fuel

In

CO2 Capture

(liquid)

Ash SO2

Other

Captured

Emissions

Environmental

Cleanup

Equipment

H2O

Boiler Island CPUASU

Other gases

(NCGs)

7


Flue Gas Composition

Warm Recycle

Air Fired Oxy Fired

CO2 21.26% 77.25%

H2O 8.15% 12.49%

SO2 0.07% 0.13%

O2 2.95% 2.80%

N2 67.57% 4.50%

Ar 0.00% 2.83%

100.00% 100.00%

GAS COMPOSITION (mass)


Plant size

(MWe)

2003 2005 2007 2013

SBS I – Pilot tests

30 MWth CEDF

Demo

2009 2011 2015

1000

10

1

100

Eng

Studies(25-790MWe)

Integration

Study

200-350 MW Projects

EfficiencyOptimization

650 MWe

Eng Study

700 MWe

Reference

SBS II – Pilot tests



Design Considerations



• Process Selection

• Gas Quality Control Equipment Selection

• Recycle Quantity

• Corrosion

• Air infiltration


• Process Selection

Coal composition

Permissible sulfur level in the boiler

Composition required to compression process

Economics

• Gas Quality Control Equipment Selection

Wet or Dry Scrubber

Permissible sulfur level in the boiler

SO3 control

Economics

Fabric Filter or Precipitator


Constituent

Heating Value 10,500 Btu/lb

(24,780 kJ/kg)

Carbon 58.61 %

Sulfur 3.2 %

Hydrogen 4.2 %

Moisture 16.57 %

Nitrogen 1.17 %

Oxygen 7.1 %

Chlorine 0.16 %

Ash 8.99 %


Pulverizers

Coal

Boiler

PJFF WFGD

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

Recycle Heater

Air Intake

Air Intake

Gas Cooler

Cool Recycle Process Wet Scrubber

CPU

To Storage

Gas Htr

DCCPS

Gas Htr

Sorbent for SO3

CPU Vent

Stack Damper

Secondary Recycle Damper

Primary Recycle Damper

Pulverizers

Coal

Boiler

PJFF

Primary Fan

Secondary (FD) Fan

ID FanBurners

Air

he

ate

rAir Fired Plant - Wet Scrubbed

SCR

PAC

WFGD


Pulverizers

Coal

Boiler

PJFFSDA

Primary Fan

Secondary (FD) Fan

ID FanBurners

Air

he

ate

r

SCR

PAC

Air Fired Plant - Dry Scrubbed

Pulverizers

Coal

Boiler

PJFFSDA

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

Recycle Heater

Secondary Recycle Damper

Air Intake

Air Intake

Primary Recycle Damper

Gas Cooler

Cool Recycle ProcessDry Scrubber

CPU

To Storage

Gas Htr

DCCPS

Stack Damper

CPU Vent


DRY SCRUBBER • Lower capital, higher operating (more economical with

lower sulfur coals)

• Removal is limited by ability to evaporate the water fed with the reagent as slurry

• Limit is set by: Inlet gas temperature and moisture content Desired approach to saturation temperature Saturation temperature (10C-20C higher for

oxycombustion due to moisture in flue gas)

WET SCRUBBER• Higher capital, lower operating (more economical with

higher sulfur coals)

• Removal limited by reagent reactivity and mixing• Unaffected by moisture in flue gas

Proprietary and Confidential 17

Boiler

Coal Bunkers

Ash SiloGypsum

Pile

CPU

ASU

PJFF

Recycle

Heater

(Airheater)

WFGD

DCCPSPR Fans

ID Fans

SR Fans


Recycle Rate

Typically 70%-80% of the total flue gas leaving the

boiler

Significant reduction does not reduce cost

Reduced Recycle

Increases flame temperature

Increases furnace heat fluxes

Increases FEGT (flue gas temperature at furnace exit)

Decreases volume flow


Recycle Rate

Significant reduction does not reduce cost

Increases constituent concentrations

Increased corrosion potential

More difficult to achieve high removals

Shifts heat transfer the wrong way

Reheat is more difficult

Increasing steam temperatures (efficiency) is more difficult

Increased cost of materials exceeds weight reduction

GQCS cost reduction is to the square root of volume flow

reduction (50% flow reduction ≈ 30% material reduction)


Subcritical Boiler Supercritical Boiler

Convection Pass

Furnace


• Air infiltration

• Corrosion


Coal

Boiler

Steam; 2400psi,

1000F/1000F

PJFF WFGD

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

Recycle

Damper

Air Intake

Air Intake

Recycle

Damper

Cool Recycle Process

CPU

To Storage

Gas

HtrDCCPS

Gas HtrSorbent for

SO3

Recycle

Heater

FD Fan

VentStack

Damper


Coal

Boiler

Steam; 2400psi,

1000F/1000F

PJFF WFGD

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

Recycle

Damper

Air Intake

Air Intake

Recycle

Damper


CPU

To Storage

Gas

HtrDCCPS

Gas HtrSorbent for

SO3

Recycle

Heater

FD Fan

VentStack

Damper


--+ - ++

+

++

+ +

+ Operating pressure above atmospheric

- Operating pressure below atmospheric


Coal

Boiler

Steam; 2400psi,

1000F/1000F

PJFF WFGD

Primary Fan

Secondary (FD) Fan

ID Fan

ASU

Burners

Recycle

Damper

Air Intake

Air Intake

Recycle

Damper


CPU

To Storage

Gas

HtrDCCPS

Gas HtrSorbent for

SO3

Recycle

Heater

FD Fan

VentStack

Damper

S Above sulfuric acid dew point

W Above water saturation temperature

S

W

SW

W

W

W

W

W

S

S

S

W

W


Summary



• Air In-leakage

Use of CO2 for sealing systems uniquely designed

Pressure profile through the system optimized, balanced draft

• Use of Nearly Pure Oxygen

Standard industry practices for low pressure operational safety

Oxygen distribution system in flues designed for uniform mixing

Oxygen concentrations monitored closely by control system

• Leakage of Flue Gas with High CO2 Concentration

Pressure boundary sealing systems uniquely designed

CO2 monitors in sensitive external confined space areas

Building local ventilation system design, and system internal

purge controls

Special Design Considerations



Special Design Considerations


• Acid Gases and Corrosion

• Sulfur trioxide removal increased, adjusted minimum temperature

limits used in boiler design and operation, and expanded use of

corrosion resistant materials

• Plant Operability

• Part load operation, daily cycling flexibility, extended air-firing

periods

• Heat Integration: Feedwater, Condensate, Oxygen

• Heat available from ASU, CPU and Flue Gas

Oxycombustion Project Integration Considerations - CSLF · Proprietary and Confidential •Capture,...

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