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Callide CO2 Capture Pilot Plant Design
Ph. COURT, A. BRIGLIA, A. DARDE, J.-P. TRANIER, N. PERRIN 2nd IEA GHG Oxyfuel Combustion Conference, Yeppoon, Australia, September 13th 2011
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Introducing the Callide CO2 Plant
CPU Area
ASUs Area
Flue gas Recycling
Boiler / Steam Turbine Building
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Callide Site Aerial View – December 2010
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CO2 Plant Main Characteristics
Flue Gas
NH3 cascade for CO2 liquefaction CO2
O2, N2, Ar
Flue Gas
NH3 cascade for CO2 liquefaction CO2
O2, N2, Ar
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Liquid CO2 production for truck transport 75 mtpd Purity 99.99%+
Challenging Inlet Conditions: warm flue gas downstream Fabric Filters 145°C CO2 Content: 55%v. (wet) SOx: 0.07% NOx: 0.14%
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Objectives of Callide CO2 CPU Pilot Plant
Demonstrate up scalable technologies designed for future industrial size oxy-power plants
Test performances for the whole oxy-coal flue gas compression and purification chain @ Start-up but also over years of operations
Fine Tuning performance + Feed-Back on impurities management options will enable to reduce cost and improve performance for
large scale plants
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Flue Gas
NH3 cascade for CO2 liquefaction CO2
O2, N2, Ar CO2
Flue Gas
Demonstrate Up Scalable Technologies
Compression and Purification Unit
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Demonstrate Up Scalable Technologies
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Demonstrate Up Scalable Technologies
Capacity of CPU pilot: set by the selection of the tailor made centrifugal flue gas compressor Atlas Copco GT026T2K1/GT021T2K1 2 pinions with 2 impellers on 1 bull gear Power: 1 MW Commercially available materials:
• Impellers, volutes and coolers
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Compressor mechanical tests in workshop
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Flue Gas Compressor delivery and installation:
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Flue Gas
NH3 cascade for CO2 liquefaction CO2
O2, N2, Ar CO2
Flue Gas
Demonstrate Up Scalable Technologies
Compression and Purification Unit
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Cryogenic Core Technologies
O2, N2, Ar CO2
Flue Gas
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NO2
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Multi-fluid compact and efficient heat exchangers: Aluminium Brazed technology
Distillation columns with advanced separation structured packings
Pre-assembled in « Cold Box » packages
Cryogenic Core Technologies
O2, N2, Ar CO2
Flue Gas
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NO2
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CO2 Cold Box delivery and installation:
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SOx, NOx HCl, HF
Flue Gas
NH3 cascade for CO2 liquefaction CO2
Liquid CO2
Liquid CO2
NO2
O2, N2, Ar
Test Performances
O2, N2, Ar H2O
Dust
Liquid analysis (manual sampling)
Gas analysis ( to R&D MODIN)
~ 30 Sampling points:
c
Wide range of challenging conditions for gas and condensate analysis: Pressure Temperature Moisture and Impurities
NOx
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AL R&D Modin on Callide site:
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Fine Tune the Cryogenic Process
CO2 Recovery: Operations as close as possible to Triple Point
Distillation efficiency: achieving 99.99% v. CO2 at low energy cost
NOx: Bridging Cryogenics and Impurity Management
NOx will partly transfer to the process water condensates as pressure increases and will be partially removed by adsorption
Cryogenics provide to oxy-combustion a near zero chemical De-NOx alternative integrated with CO2 capture
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Flue Gas
NH3 cascade for CO2 liquefaction CO2
O2, N2, Ar
Impurities Management: H2O Adsorption Unit
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H2O Adsorption Unit
Callide CPU drying unit is based on the dryers design implemented on the pilot unit in TOTAL Lacq (France)
Lacq tests : H2O < 1 ppm vol. in the dried gas
demonstrated as per expected targets
NOx speciation analysis on-going to illustrate NOx mass balance cyclic patterns during the switch adsorption process
On the Callide CPU drying unit, adsorbents will be regenerated with non-condensable off-gases separated from CO2 in the cryogenic section
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Feed back on Impurities Management options
Dust: Callide: ~ 500 kg of dust expected to enter the CPU in a year
Industrial size plant: ~10 tons per year Test High Efficiency Filtration with on-line regeneration: near zero
particulate matter emissions End of the operating period: possible to test operations without filtration
SOx: Low pressure De-SOx polisher: will reduce SOx at ppm levels Robust approach to allow wider material possibilities downstream
Hg: Estimating Hg speciation in the flue gas is indeed a challenge! Up scalable Hg Removal design alternative for Callide is ready for
installation if need be (HAZOP, installation area and connections) Specific BAHX1 design has been implemented to mitigate Hg induced
corrosion risks
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Note 1: BAHX Brazed Aluminium Heat Exchangers
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Acknowledgement:
Thank you for your attention!
