Capture 1 – Oxy-Combustion Capture

IEA GHG Summer School

Perth, Western Australia, December 6-12 2015

Martin Oettinger

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Need for a retrofit option

Oxy-combustion capture (Oxy) Principles (of first generation Oxy technologies)

Oxy Advantages

Significant Oxy demo project – Callide Oxyfuel

Oxy Challenges/Issues

2nd and 3rd generation Oxy technologies – definitions and examples

The challenge of timely scale-up for cost-effective Oxy technology

Summary

Outline

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The presenter would like to specifically thank Prof Terry Wall (University of Newcastle), Dr Chris Spero (Callide Oxyfuel Project), Glencore and ACALET for access to resources and feedback

Need For A Retrofit Option471 GW of recently installed coal-fired generation capacity exists

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Installed total coal‐fired power capacity in all countries and breakdown by age and capacity

Source: IEA – “CCS Retrofit – Analysis of the Globally Installed Coal-Fired Power Plant Fleet”, 2012

Need For A Retrofit Option1188 GW of conventional coal-fired generation in-construction or planned

(much of it HELE technology)

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0.0

100.0

200.0

300.0

400.0

500.0

China India Indonesia Vietnam Turkey South Korea South Africa Philippines Pakistan Bangladesh

Top 10 Countries - GW Capacity of Coal-fired UnitsIn Construction and Planned

Total Top 10 = 1033 GWTotal Top 10 = 87% of Global In Construction and Planned

Global = 1188 GW

CON(GW)

PLN(GW)

Source: Platt’s UDI WEPP database 2014 & Glencore

The recently installed conventional coal-fired generation plant capacity is large

The planned and in-construction conventional coal-fired generation plant capacity is even larger

There is a need for carbon capture retrofit options to be applicable to this type of generation plant

Oxy-combustion carbon capture technology has the capability to provide a retrofit option to this type of generation plant

Need For A Retrofit Option

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Where the combustion process takes place in a relatively pure oxygen environment, resulting in flue gases with high concentrations of CO2, which after particulate removal and flue gas desulphurisation the CO2 is suitable for transport and storage

Treated flue gases are recycled back to the combustion process to provide necessary dilution of pure oxygen to control combustion conditions

Oxy-combustion CaptureLow Pressure (First Generation) Processes

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Oxy-combustion Capture from Power Generation Boiler

Source - ZEP7

Coal-fired power generation boiler technology is typically either pulverized fuel (PF) or circulating fluidized bed (CFB) type technologies

Oxy-combustion versions of these technologies are known as Oxy-PF and Oxy-CFB respectively

The vast majority of coal-fired boiler technology in operation or planned for deployment internationally is PF type technology

2 x 660MW Supercritical PF BoilerConventional Coal-fired – No Capture – 43% efficiency (HHV)

Source - Alstom8

Flue gas recycle is required to control combustion conditions

The source and destination locations and relative amount of flue gas recycle is dependent on the type of coal (which has different relative amounts of contaminants, such as sulphur and trace elements)

Recycle locations are chosen so as to achieve best overall outcome, trading off efficiency, capex, opex and operability

Oxy-combustion CaptureFirst Generation Technology – Locations for flue gas recycle

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Simplified schematic flow diagram of oxy-PC coal fired power plant with CO2 capture, including possible locations for flue gas recirculation and O2 addition – adapted from Davidson and Santos (2010); Source: Stanger et al, IJGGC 40 (2015), p56

First generation low pressure oxy-combustion technology is required to start operation in Air Mode (combustion air firing)

Operation can then be transitioned to Oxy Mode (oxygen and recycled flue gas firing) for normal operation

It is preferable to transition back to Air Mode prior to a shut down of the generator

Oxy-combustion CaptureFirst Generation Technology – Air Mode and Oxy Mode

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Source: Stanger et al, IJGGC 40 (2015), p113

Oxy-combustion CaptureDifferent flue gas composition under air-fired and oxy-fired conditions

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Source: OTPL, GCCSI

Flue gas in an Oxy plant contains significantly higher concentrations of H2O and CO2

The change in the flue gas composition alters its behavior in combustion burners, its radiative and convective characteristics, the burnout of solid fuel, corrosion properties and impacts on boiler materials of construction, and formation of trace compound oxides *

Extensive operation of pilot and demonstration facilities with lessons learned have allowed required changes to be made to boiler equipment and materials of construction *

* More detailed coverage can be found in the report by Stanger et al; “Oxyfuel combustion for CO2 capture in power plants”, International Journal of Greenhouse Gas Control 40 (2015) 55-125

The CPU uses a combination of scrubbing, compression and cryogenic processes to remove impurities from the flue gas to produce a CO2final product

There are a range of CPU design options possible to provide different CO2 purities and recovery rates

Oxy-combustion CaptureFirst Generation Technology – CO2 Processing Unit (CPU)

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Schematic of Callide A CO2 Capture Plant (Courtesy Air Liquide); Source: OTPL, GCCSI

Can be retrofitted to existing Pulverized Coal (PC) plants allowing the continued operation of valuable resources

In either new build or retrofit application it enables the continued deployment of the well established PC technologies familiar to power industries worldwide

The continued development of improved materials for Ultra Supercritical (USC) PC plants will increase the efficiency and reduce the CO2 emissions of future PC plants

Oxy-combustion power plants should be able to deploy conventional, well-developed, high efficiency steam cycles without the need to remove significant quantities of steam from the cycle for CO2 capture

Oxy-combustion Capture Advantages – General – 1

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The added process equipment consists largely of rotating equipment and heat exchangers; equipment familiar to power plant owners and operators; no chemical operations or significant on-site chemical inventory

Ultra-low emissions of conventional pollutants can be achieved largely as a fortuitous result of the CO2 purification processes selected, and at little or no additional cost

The potential exists for the CPU to be designed so as to achieve very low volumetric gaseous emissions during oxy-combustion operating mode

The potential exists to make an oxy-combustion facility a net zero or slight producer of water, through appropriate selection and design of CPU and water treatment technologies

On a cost per tonne CO2 captured basis, it should be possible to achieve 98+% CO2 capture at an incrementally lower cost than achieving a baseline 90% CO2 capture

Oxy-combustion costs may be reduced if the CO2 purity requirements could be relaxed

Oxy-combustion Capture Advantages – General – 2

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The best information available today (with the technology available today) is that oxy-combustion with CO2 capture should be at least competitive with Pre- and Post-combustion CO2

capture and may have a slight cost advantage

Compared to Post- and Pre-combustion capture, the number of technology variants is lower, providing focus for development

Significant-scale demonstration of 1st Gen Oxy-PF has occurred

The 30 MWe Callide Oxyfuel retrofit project using IHI and Air Liquide technology successfully completed operation in 2015

Oxy-combustion Capture Advantages – First Generation Technologies

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Project type Demonstration

Industry Power Generation

Project focus Capture

Project status Completed 2015

Commencing date 2008 (funding agreement execution)

2012 (operational)

Technical Details Oxy-combustion retrofit of existing

coal-fired power plant

Scale, CO2 tpd 75

Scale, MWeGross 30

Cost ($ 2008) AU$245M

Partners CS Energy, ACALET, Glencore,

Schlumberger, J-POWER, Mitsui, IHI,

Australian and Queensland

Governments, JCoal, METISource: GCCSI, MIT, OTPL

Sub-commercial scale with Oxy-combustion CaptureCallide Oxyfuel, Biloela, Queensland, Australia

Sub-commercial scale with Oxy-combustion CaptureCallide Oxyfuel, Biloela, Queensland, Australia

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• Potential storage sites (8) examined as part

of project

• Identified sites were ultimately found not to

be suitable for various reasons, including:

• Geological

• Distance to site

• Availability within operating period

• Useful information was generated and has

been reported

• Lack of GHG legislation was a challenge

CO2 StorageCO2 Capture

• The Callide Project is an oxy-fuel retrofit of a

idled facility originally commissioned in 1972

• 30MWegross oxy-combustion pulverised coal

power plant

• CO2 capture plant designed to treat 15% of

flue gas

• Design capacity of the CO2 capture unit was

75 tonnes per day

Source: GCCSI, MIT, OTPL

Callide Oxyfuel ProjectCallide Oxyfuel Process

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Source: OTPL, GCCSI

Callide Oxyfuel Process (ASU – Air Separation Unit; PAH – Primary Air Heater; SAH – Secondary Air Heater; FGLPH – Flue Gas Low Pressure Heater; FF – Fabric Filter; IDF – Induced Draft Fan; CPU – CO2 Purification Unit; GRF – Gas Recirculation Fan/Forced Draft Fan)

Callide Oxyfuel ProjectView of Callide Oxyfuel Boiler Equipment

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Source: OTPL, GCCSI

A – boiler house

B – fabric filter

C – flue gas exit duct

D – recycled flue gas (RFG) duct

On completion of the operational phase in March 2015 the project had successfully achieved virtually all of its objectives, including: 10,200 hours of actual oxy-firing operation (target 10,000 hours)

5,600 hours of CO2 capture plant operation (target 4,000 hours)

Demonstrated boiler turn-down to 50% Load Factor

Demonstrated ramp-rate capabilities equivalent to air-fired operation

Demonstrated high purity of CO2 product (> 99.9%)

Demonstrated near complete capture of SOx, NOx, particulates and trace metals

Excellent safety and environmental performance

Callide Oxyfuel ProjectObjectives Achieved

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Source: OTPL

The project has provided a great deal of knowledge and experience to inform future oxy-fuel technology development

A range of valuable lessons have been learned, covering: Project establishment (structure, business systems, contract management) Communications with Project Partners and other stakeholders, including the

public Identification and control of technical risks associated with the technology Managing workplace health and safety and the environment Operating and maintenance strategies and experience Developing the skills of plant operators, maintenance staff and engineers Enhancements that would be applied to the next scale up of oxy-fuel and CO2

capture technology

Callide Oxyfuel ProjectLessons Learned

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More detailed coverage can be found in a report titled “Callide Oxyfuel Project - Lessons Learned”, published by the Global CCS Institute in May 2014. http://www.globalccsinstitute.com/publications/callide-oxyfuel-project-lessons-learned

Source: OTPL

Scale-up

A large scale demonstration project is essential to prove Oxy technology at the required scale

Capital Cost Reduction

ASU and CPU equipment is key part of capital cost reduction challenge; improved ASU and CPU technology are required for significant capital cost reduction outcomes

Operating Cost Reduction (Parasitic Energy)

The addition of capture with current low pressure oxy technology (auxiliary power associated with air compression in a cryogenic air separation unit and CO2 compression in the CO2

purification unit) results in a loss of net power output of about 25% and a reduction of about 9 percentage points in efficiency; in the case of retrofit this would imply the need for replacement power to make up for the power loss

ASU and CPU Plant Physical Footprint

Plot space requirements are significant; the back-end at existing plants is often already crowded by other emission control equipment

Extra costs may be required to accommodate ASU and CPU at some more remote location

Oxy Challenges – 1 First Generation Technology – Low Pressure Process

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Sub-scale Demonstration Restrictions (all-or-nothing)

It is not possible to develop sub-scale oxy-combustion technology at existing power plants

An oxy-combustion power unit is an integrated plant and oxy-combustion technology development will require commitment of the whole power unit to the technology

Thus, the technology development path for oxy-combustion may be more costly than that for either pre-combustion or post-combustion capture which can be developed on slip streams of existing plants

Start-up Requirements Air-fired combustion is commonly anticipated for start-up of oxy-combustion power plants

The very low emissions achieved by oxy-combustion with CO2 purification cannot be achieved during air-fired start-up operations without specific flue gas quality controls for air-fired operations that are redundant during steady state oxy-fired operations

If a significant number of annual restarts are specified, either these added flue gas quality controls will be required (at additional capital cost) or provisions must be made to start up and shut down the unit only with oxy-firing and without venting significant amounts of flue gas

Oxy Challenges – 2 First Generation Technology – Low Pressure Process

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Technologies StatusTechnology Readiness Levels (TRL)

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These steps are

individually very

expensive

Source: US DoE

Technology StatusCommercial Readiness Levels (CRL)

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These steps are

individually very

expensive

The Callide Oxyfuel Project has allowed first generation Oxy-combustion technology to achieve TRL-7 maturity

It is proving difficult to get a first generation Oxy demonstration project at TRL-8+ scale financed, constructed and into operation

Large scale demonstration projects that have or will complete FEED, but have either been put on hold or are experiencing significant barriers to progressing further Vattenfall’s Jaenschwalde Project (Germany) CIUDEN/Endessa’s Compostilla OxyCFB300 Project (Spain) KEPCO’s Young Dong Project (South Korea) FutureGen 2.0 Project (USA) White Rose Project (UK)

Oxy-combustion CaptureFirst Generation Technology – Getting Beyond TRL-7

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With the addition of currently available carbon capture technology, the Levelised Cost Of Electricity (LCOE) produced is impacted in the following way:

For coal-fired electricity, LCOE increases by 140%*

A key focus for oxy-combustion carbon capture technology development is to reduce the impact on LCOE of adding carbon capture

This provides the opportunity to consider improved and alternative Oxy – Next Generation technology

Challenge – Cost of ElectricityLessons from First Generation Technology

* Basis – Australian Energy Technology Assessment 2012 – BREE; carbon price effect removed

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Currently available Oxy technology at significant scale (first generation technology) is based on low pressure processes

This technology requires further development to overcome challenges including reducing the impact on LCOE of adding carbon capture

There are a range of other technology options that have been identified as alternatives to currently available low pressure Oxy technology

These technologies are at various stages of development, and can be categorised into different technology generations

Oxy Technology GenerationsDefinitions Needed for Current (First) and Next Generation Technologies

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Second Generation Technologies

Technology components currently in research and development that: Will be validated and ready for demonstration in the 2020-2025

timeframe

Result in a captured cost of CO2 less than $40/tonne in the 2020-2025 timeframe

Third Generation Technologies

“Transformational” technologies include technology components in early development (including conceptual stages) that: Offer the potential for significant improvements in technology cost and

performance

Will be ready for scale-up in the 2016-2030 timeframe

Will be ready for demonstration in the 2030-2035 timeframe

Next Generation Oxy TechnologiesDefinitions – Next Generation Technologies *

29 * Source: CSLF (2015) and US DoE (2015)

Low cost oxygen Transport Membranes (ITM/OTM) Advanced cryogenic ASU

High pressure oxy-GT (gaseous fuel) SCOC-CC cycle Allam cycle CES cycle Graz cycle

Solid looping (solid and gaseous fuels) Chemical looping combustion (CLC) Limestone chemical looping (LCL) Chemical looping with oxygen uncoupling (CLOU) Coal direct chemical looping (CDLC)

Useful sources describing 2nd and 3rd generation PCC technologies IEA GHG have produced interim report 2014/TR4 “Emerging CO2 capture

technologies and their cost reduction potential”

Next Generation Oxy Technologies Examples of 2nd and 3rd Generation Technologies

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An issue with Oxy technology is that there is a range of technologies and technology variants that have potential application for Oxy: As improvements to first generation technologies

Directly as second and third generation technologies

With a number of technology options that potentially could be applied to Oxy, there is a risk of dilution of effort Too many choices and not enough money to drive the right

technology to required maturity

..and then there is the time needed to drive the right technology to required development maturity

Challenge – Time & Oxy Technology VarietyEnhancements for or Alternatives to First Generation Oxy

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Technology demonstration in the 2030-2035 timeframe will require technology to have developed sufficient technical and commercial maturity

In order to control development risk, there is a maximum realistic scale up (typically one order of magnitude) between successive demonstrations

There will likely be insufficient time available to take a standalone immature technology to technical and commercial maturity in the 2030-2035 timeframe To achieve CRL-2 by 2030-2035 technology has to be at

least at a TRL-6 level now

Challenge – Time To Achieve Required Technology Maturity, It Takes Time

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Challenge – Oxy Development TimeTime to Develop New Technologies

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Demonstrations – actual Burner test facilities (B&W,

Alstom, Doosan Babcock) 2007 – Lacq pilot 2008 – Schwarze Pumpe pilot 2008 to 2015 – Callide Oxyfuel

demonstration

8 years from first TRL-6 operations commencement to end of TRL-7 trial operations

Source: Alstom, IEA GHG, OTPL

Demonstration of technical and commercial readiness of Oxy technologies in full chain (e.g. capture, transport and storage) is crucial to confirm maturity to stakeholders before wide-scale deployment can occur

Difficult to conceive of full-scale Oxy projects able to be funded without inclusion of a sink for CO2 (saline storage or EOR); activities associated with CO2 sink often dominate overall schedule for project

Individual demonstration projects typically require approximately ten years from inception to operational proving, which includes approximately five elapsed years to undertake the works from FID to operation

Achieving Oxy Technology MaturityTo Achieve Required Maturity, Need Large Scale Integrated Projects

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Oxy-combustion CaptureIEA GHG Oxy Technology Roadmap

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Source: Stanger et al, IJGGC (40), p106; adapted from Santos, 2014

A technology roadmap has been developed for oxyfuel combustion for coal fired power plant with CO2capture

To be able to commercialise this technology by 2020, a full scale oxyfuelcombustion power plant should be deployed between 2016 and 2020

Retrofit options for the substantial fleet of recent and planned coal fired generators are required Oxy-combustion provides such an option

Current (first) generation Oxy-combustion technology for coal-fired generation is based on low pressure processes (Oxy-PF and Oxy-CFB)

Significant-scale demonstration of 1st Gen Oxy-PF has been successfully completed, with the Callide Oxyfuel Project achieving TRL-7 maturity

It is proving difficult to get a 1st Gen Oxy-PF demonstration project at TRL-8+ scale financed, constructed and into operation

A significant number of different “next generation” Oxy technologies are under some form of development

A technology roadmap has been developed for oxyfuel combustion for coal fired power plant with CO2 capture

Key challenges to allow achievement of technical and commercial maturity of Oxy technologies are a combination of: Time to achieve scale up Significant capex reduction of the technology, and Parasitic load reduction (increased efficiency)

Summary

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Questions welcomed

Thank You

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