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Seminar on Carbon Capture and Storage, 11 November 2010, Espoo, Finland
DEVELOPMENT AND DEMONSTRATION OF
FLEXI-BURN® CFB TECHNOLOGY
Timo Eriksson,
Foster Wheeler Energia Oy
Contents of Presentation
• Introduction
• Flexi-Burn® CFB power plant
• Framework for research and technology development
• Ongoing testing activities
• CIUDEN TDP - Oxyfuel demonstration in 30 MWth scale
• OXY-CFB-300 Compostilla demonstration project
• Summary
"Flexi-Burn" is a trademark of Foster Wheeler AG, registered in the U.S., EU, Finland
IntroductionFW CFB Technology: Experience and Scale-Up
Foster Wheeler´s CFB Experience• Foster Wheeler Fluidized Bed Technology Basis: Over 1700
years of operating experience
• Foster Wheeler Energia Oy in Finland is the Technology
Center for Fluidized Bed Boilers in Foster Wheeler Global
Power Group
• 370 CIRCULATING FLUID BED (CFB) BOILERS SOLD
• Variety of fuels: coal, lignite, petroleum coke, biomass,
RDF, etc.
The world’s largest and first SC OTU CFB
with the capacity of 460 MWe at PKE’s Lagisza
plant in Poland is in operation.
FW has developed and is offering the CFB
technology in 600-800 MWe scale with 600 °C
steam temperature.
Flexi-Burn CFB Power Plant
Steam
turbine
Flue gas recycle
Flexi-Burn
CFB boilerFlue gas
cleaning
CO2
AirAir
separation
N2, (Ar)
G
Fuels
CO2/H2O
H2O
Condensation
Compression
Purification
Transport
Storage
Vent gas
95-97% O2, (Ar, N2)
Flexi-Burn CFB• CFB design capable for both
oxy and air firing
• 1st generation oxy-fuel
technology with flue gas
recycling
Oxy-readiness• A plant design with certain
Flexi-Burn features and
space reservation for the
ASU and CPU systems
• Later upgrading for CCS
Framework for Reseach and Technology DevelopmentIntegrated Experimental and Modeling Work for Scale-Up
Air firing:
• Vast experimental and modeling
experience from air combustion (bench-
scale Pilots 300+ operating units;
max. 460 MWe)
• Validated design models and engineering
tools
Oxy-fuel combustion:
• Bench-scale and 30-100 kWth pilot scale
at VTT during 2004-2010
• 1 MWth pilot scale at CanmetENERGY in
2010
• Max. 30 MWth CFB demonstration unit at
the CIUDEN TDP 2011-2012
• OXY-CFB-300 Compostilla Project: 300
MWe Flexi-Burn CFB demonstration
project 2016-2020
Flexi-Burn CFB Boiler DevelopmentActivities
• R&D support - EU FP7 project "FLEXI BURN CFB" 2009 – 2012• Design tool development toward oxy & air compatibility (combustion,
heat transfer, fluid dynamics, emissions)
• Experiments in small and large scale pilots → scale-up information
• Performance of materials
• Dynamic simulations
• Concept optimization, etc.
• Boiler design - Oxy-CFB-300 Compostilla project 2009 – 2012• Engineering of Flexi-Burn CFB boiler
• Performance and cost estimates
• Design verification at CIUDEN TDP
• Support of FEED study by ENDESA → plant level estimates
Conclusions from Pilot TestingCanmetENERGY
• Test program completed in August
2010, analysis of results in progress →
validation of design tools and process
models.
• Spanish anthracite, petroleum coke,
bituminous coal, lignite and mixtures
tested.
• The CFB process performs very well in
oxycombustion. Differences compared
to air combustion are small and in line
with initial expectations.
• Emissions are typically lower during
oxycombustion. 500
550
600
650
700
750
800
850
900
950
1000
0 2 4 6
Tem
pera
ture
Furnace height
High load OXY
High load AIR
Temperature profile at high and low firing
rate (An example of results)
CIUDEN´s Technological Development Plant (TDP)
• Fundación Ciudad de la Energía
(CIUDEN) is a non-profit,
collaborative research organization
for technological development
established by three ministries of
the Spanish government.
• The TDP located in El Bierzo in
North Western Spain will allow
collaborative research for
international cooperation with
industry, universities and research
institutions
• Location of the TDP is adjacent to
the Compostilla II Power Plant
CIUDEN CO2 Capture TDP
Fuels: anthracites, bituminous, subbituminous coals, pet coke, sustainable
biomass
Oxycombustion
Pulverized
Coal
20 MWth
Circulating
Fluidized
Bed
30 MWth
DeNOX
Dedust
DeSOX
CO2 purification and compression
Biomass Gasifier 3 MWth
+
The Oxyfuel Carbon Capture TDP
TECHNICAL
BUILDINGS
CONTROL
SYSTEM
PC BOILER
CFB BOILERCO2
PURIFICATIO
N
FLUEGAS
CLEANING
FUEL
PREPARATI
ON
FLUEGAS
RECIRCULATIO
N AND
MIXING
GASIFIER
The main systems at the TDP:
• Coal and limestone preparation
and feeding
• Pulverized coal and circulating
fluidized bed boilers
• Flue gas recirculation, preheating
and oxygen mixing devices
• Flue gas cleaning
• Test unit for CO2 purification and
compression
• DCS system
FW designs and supplies the
CFB boiler for the TDP →
commissioning in 2011
The Main CFB Boiler Systems and Components
Furnace Dimensions (m) 20x2.9x1.7
MWth maxoxycombustion
30
O2 consumption (kg/h) 8775
Flue gas recycle (kg/h) 25532
Flue gas (kg/h) 28800
Coal consumption (kg/h) 5469
Limestone feed (kg/h) 720
Steam (t/h) 47.5
P(bar) / T (°C) 30 / 250
European Energy Program for Recovery
• The origin of the European Energy
Programme for Recovery (EEPR) is
the global €200 billion European
Economic Recovery Plan presented
by the Commission on 26 November
2008. Investment in energy projects
was considered an important tool to
support the economic recovery.
• On 9 December 2009, the European
Commission announced details of the
six CO2 capture and storage (CCS)
projects which will receive funding (€1
billion in total) under the EEPR.
• Each project will receive 180 M€
funding (except Porto Tolle 100 M€)
OXY-CFB-300 Compostilla Project
• The OXY-CFB-300 Project is devoted to demonstrate the CCS value chain
(Capture + Transport + Storage) as one of the 12 commercial size demo
projects to be finally within the EU SET (Strategic Energy Technolgy) Plan.
• The Project has been selected in the EEPR Program to complete, during the
2009-2012 period, all the studies, pilot size test, and engineering (FEED) to
allow by mid-2012 the Investment Decision (FID) for the final construction
phase.
• As beneficiaries of the EEPR a consortium between ENDESA GENERACIÓN,
CIUDEN and FWEOy has been created to develop the initial phase.
OXY-CFB-300 Compostilla ProjectEEPR – Organization & Roles
ENDESA GENERACION
• Utility promoter, Phase I (capture, transport and storage)
• General coordination and project management
• Engineering (FEED, studies, etc)
• Permitting
• Knowledge sharing
CIUDEN
• CCS Technology Development Plants (TDP) promoter
• Capture (OXY-CFB and OXY-PC)
• Transport (Test Ring)
• Storage
• Public perception
FOSTER WHEELER ENERGIA Oy
• Flexi-Burn CFB Technology developer and provider
OXY-CFB-300 Compostilla ProjectCCS Value Chain
CAPTURE TECHNOLOGY
• OXY-CFB supercritical boiler; wide
design fuel range (domestic and
imported), including biomass.
CO2 TRANSPORT
• 12” / 16” underground pipeline; 135
km.
• 5,500 ton/day; ~ 120 bar
CO2 STORAGE
• Deep saline formation
• Duero basin (optional: Ebro basin)
Consortium
of the FLEXI
BURN CFB
FP7
Research institutes
Industrial applicability
Laboratory and small
pilot scale test
(0.1-1MWth)Concept
FLEXI BURN CFB
2009 -
2012
Manufacturers
Demonstration
Pilot Plant
30 MWth, CIUDEN
Utilities
1st Commercial scale
FLEXI BURN CFB Power Plant
OXY-CFB-300 CompostillaPower Plant Performance (Preliminary)
Oxy Mode
Net power (MWe) 235
Boiler efficiency (%, LHV) 94.3
CO2 emission (g/kWh-net) 97
CO2 capture ratio (%) 91
CO2 captured for the first 5 years of
operation (Mt)
~ 5
OXY-CFB-300 CompostillaChallenges
TECHNICAL
• Oxy-CFB design: Technology validation program, CCS integration.
• Performance: Capacity, efficiency, Capture rate, CO2 purity.
• Operational: Availability, reliability, load-following capability.
• Storage feasibility.
ECONOMICAL / FUNDING (NER-300; etc.)
PERMITTING / REGULATORY
PUBLIC PERCEPTION
These challenges are related to all CCS activities, as new technology
development.
OXY-CFB-300 CompostillaOpportunities
EU SUPPORT (Parliament, EC, Council)
CO2 STORAGE DIRECTIVE
• Spanish transposition in process
MEMBER STATE SUPPORT
• Future domestic coal use
• Maintain the generation mix balance
OXY-CFB TECHNOLOGY FUTURE OPTIMIZATION
Summary
• Foster Wheeler’s Flexi-Burn technology has been succesfully
demonstrated for carbon capture in small pilot scale
• The piloting of Flexi-Burn technology in 30 MWth scale will start in
2011 in the CIUDEN Technology Development Plant
• EEPR funding has accelerated the commercialization of CCS by
funding the development of six CCS demonstration projects in Europe.
• ENDESA GENERACIÓN, CIUDEN and Foster Wheeler have signed a
contract for a Oxy-CFB-300 Project to develop the 300 MWe Flexi-Burn
CFB power plant for a complete chain of CCS by end 2012.