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ENCAP Integrated Project
Five years development of CO2 enhanced capture technologies
CO2Neteast Workshop CO2 Capture and Storage – Response to Climate Change3-4 March 2009, Bratislava
Leif BrandelsVattenfall AB, ENCAP Coordinator
2
ENCAP development Target
• 90% CO2 capture rate and
• a cost of < 20 €/ton stored CO2
Develop and validate a number of pre-combustion technologiesthat in large Power Plants meets the target:
2010
3
A five year Integrated Project within the EC FP6Total budget 22.2 MEuroEC support 10.7 MEuro
Enhanced CO2 Capture - ENCAP
Project period:2004 March - 2009 February (Requested extension August 2009)
4
A five year Integrated Project within the EC FP6Total budget 22.2 MEuroEC support 10.7 MEuro
Enhanced CO2 Capture - ENCAP
In 2009 - Recommend technology for a 350 MWel Demo Plant
Project period:2004 March – 2009 February (August)
5
Development and validation of mainly three pre-combustion technologies:
Enhanced CO2 Capture - ENCAP
IGCC/IRCC
OxyFuel
Chemical Looping
6
Development of 3 High-temperature oxygen generation technologies• Oxygen separator membrane for power plant cycles
• High temperature oxygen adsorbent (CAR)
• Oxygen-transport membrane systems for power production
Oxygen-process integration into IGCC and OxyFuel Power Plants
Development of new air separation technologies
7
Investigate prospective emerging technologiesOxy-fuel combustion cycles
Natural gasPre-combustion capture cycles
Natural gasHard coal
Novel Capture Concepts
GT
Steam turbine
Generator
NG (14.67 kg/s) HRSG
Pressurized oxygen (95 %) Condenser
H2OCO2 to compression
≈ 88 % recycle (mass basis)
Condenser
8
ENCAP – a powerful consortium
The ENCAP Consortium gathers:5 large European energy companies + Total France11 leading European technology providers12 high ranked research providers
ALSTOM Power Boiler (Fr)(GE)ALSTOM Power CentralesALSTOM Power Ltd (UK)ALSTOM Ltd (CH)
LindeAir Liquide BOC
Siemens
LurgiDoosan Babcock
SINTEF Chalmers
University of PaderbornNTNU University of Stuttgart
University of Twente
University of Ulster
DONGPPCRWE PowerStatoilHydroVattenfall+Total France
DLRIFPISFTA
TNO
9
Pre-Combustion Decarbonisation Concept Development
H2-rich combustion
Development of overall
plant outline specification:
Optimising of CO-shift conversion
Capture unit integration with plant
•1000 MWel Bituminous coal and lignite• Natural gas-fired 400 MWel Combined Cycle Gas Turbine
10
Development of overall plant outline:
Pre-Combustion Decarbonisation Concept Development
11
Temperature(K)24002200200018001600140012001000800
Hydrogen
Temperature(K)24002200200018001600140012001000800
Natural gas
Simulations
High pressure test rig DLR
Lean-Premixed Combustion of H2-rich fuels :
New burners development
12
OxyFuel Concept Development• 600 MWe Bituminous coal OxyFuel PF plant
• 1000 MWe German lignite OxyFuel PF plant
• 380 MWe Greek lignite OxyFuel PF plant
13
OxyFuel Concept Development
450 MWe Bituminous coal OxyFuel CFB plant
14
OxyFuel experimental work and pilot testing
Experimental investigation of combustion fundamentals in -10 kW IVD Stuttgart-100 kW Chalmers Gothenburg- 500 kW IVD Stuttgart test rigs
Phase 2 pilot testing:- 30 MW PF OxyFuel pilot plantVattenfall Schwartze Pumpe
0 200 400 600 800 1000 1200 1400Axial distance from burner inlet [mm]
200
400
600
800
1000
1200
1400
1600
Gas
tem
pera
ture
[oC
]
Test caseAirOF 21OF 27
Centerline temperature profiles
O2
coal mill, primary gas/ O2
secondary, main combustion gas
staging gas
re-circulated part-stream offlue-gas
oxygensupply
O2
coal mill, primary gas/ O2
secondary, main combustion gas
staging gas
re-circulated part-stream offlue-gas
O2O2
coal mill, primary gas/ O2
secondary, main combustion gas
staging gas
re-circulated part-stream offlue-gas
oxygensupply
additional fuel +conveyor air
coal + primary air
secondary air, flue gas recirculation
ESP
bagfilter
verticalfurnace
burner
reburning fuel
burnout air
reductionzone
burnoutzone
= 200°Cfly ash samples :
- particle size- burnout- ash analysis- trace element analysis- melting behaviour
= 150°C
in-flame measurement :O2, CO2, CO, NOX, CmHn, temperature
slag and ash
> 100 µm
flue gas emissions :O2, CO2, CO, NOX, CmHn, temperature
SCR Catalyst
= 400°C
video control
`
to stack
15
Chemical Looping Combustion DevelopmentCombustion with a solid ”oxygen carrier”
avoids energy penalty of air separation
Ni + O2 => NiO
Air reactor
Cyclone
CH4 + 4NiO => 4Ni + CO2 + 2H2O
Courtesy Jens Wolf, Vattenfall Utveckling AB
16
Chemical Looping Combustion DevelopmentDevelopments within the ENCAP project
Chemical looping combustion for solid fuelsEvaluation of oxygen carrier materialsNovel reactor conceptsProcess design, integration optimisation and economics
Ni + O2 => NiO
Air reactor
Cyclone
CH4 + 4NiO => 4Ni + CO2 + 2H2O
Courtesy Jens Wolf, Vattenfall R&D AB
17
Chemical Looping Combustion Development
Concept design:Testing:
Coal tests in CLC CFB 10 kW Prototype at Chalmers
18
Air separation: Development within the ENCAP project
High temperature oxygen separation with ceramic materials
oxygen transfer membranes high temperature oxygen adsorbent (CAR)
Development of materials, cost, integration into power plant
19
Air separation: Development within the ENCAP project
Concept design:
Material development
and testing:
20
A large number concepts have been classified and evaluatedAround 20 have been further developed including:Oxy-fuel combustion cycles
Natural gasPre-combustion cycles
Natural gasHard coal
Novel Capture Concepts
GT
Steam turbine
Generator
NG (14.67 kg/s)
HRSG
Pressurized oxygen (95 %) Condenser
H2OCO2 to compression
≈ 88 % recycle (mass basis)
Condenser
Location of S-Graz C1 compressor stages on the flow coefficient / loading coefficient diagram
0 .1
0. 15
0 .2
0. 25
0 .3
0. 35
0 .4
0. 45
0 .5
0. 55
0 .6
0.45 0.5 0.5 5 0.6 0. 65 0.7 0.75 0.8
Flow coefficient (Vz/U)
Load
ing
coef
ficie
nt (d
el(V
th)/U
)
Del _p/D =0.3
D el_p/D=0.4
Del_p/D=0.5D el_p/D=0.6
INDUSTRIALSAERO-CIVIL
AERO-M ILITARY
STAGE 1
STAGE 14
21
Pre-combustion Technologies for Development and validation
SP2 Pre-Combustion Decarbonisation Concept DevelopmentSP3 OxyFuel Concept DevelopmentSP4 Chemical Looping Combustion Development
SP5 High Temperature oxygen separation technology developmentSP6 Novel Concepts
Benchmarking of ENCAP developped concepts and recommendation of technology for 350 MW Demo Plant
SP1 Power System evaluation
ENCAP Sub Projects
22
A common framework is established to define:• State of the art reference power plants without CO2 capture
• Boundaries for economic analysis• Procedure to evaluate power plants with CO2 capture• Design scenarios for CO2 purity
- Natural gas-fired 400 MWe Combined Cycle Gas Turbine (Statoil / Siemens) - Hard coal / pet coke-fired 445 MWe Circulating Fluidised Bed (Alstom) - Hard coal-fired 600 MWe PF (Mitsui Babcock) - Lignite-fired 1000 MWe IGCC/PF (RWE / Vattenfall) - Lignite fired 380 MWe PF (PPC).
Reference cases and guidelines for ENCAP technology concepts
This has enable consistency in the benchmarking of CO2capture alternatives
23
Benchmarking in ENCAP
Net electricity reduced with capture:6-9 % for IGCC, OxyFuel PF , CFB hard coal15 % IRCC natural gas
Electricity cost with capture increased:30-60% for developed technologies
CO2 avoidance cost:18-24 €/t IGCC13-17 €/t OxyFuel6-8 €/t CLC
Electricity generation costs
100105110115120125130135140145150155160165170175180
600 MW Bit coal SP2 Pre-combustion
600 MW Bit coal SP3 Oxyfuel
% in
com
p. to
ref.
case
Electricity generation costs
100105110115120125130
135140145150155160
445 MW Bit coal CFB SP3 Oxyfuel 445 MW Bit coal CFB SP4 CLC
% in
com
p. to
ref.
case
PF 600 MWel gross reference case CFB 445 MWel gross reference case
Electricity generation costs
100105110115120125130135140145150155160165170175180
600 MW Bit coal SP2 Pre-combustion
600 MW Bit coal SP3 Oxyfuel
% in
com
p. to
ref.
case
Electricity generation costs
100105110115120125130
135140145150155160
445 MW Bit coal CFB SP3 Oxyfuel 445 MW Bit coal CFB SP4 CLC
% in
com
p. to
ref.
case
PF 600 MWel gross reference case CFB 445 MWel gross reference case
CO2 avoidance costs
0,0
5,0
10,0
15,0
20,0
25,0
30,0
35,0
40,0
600 MW Bit coal SP2 Pre-combustion
600 MW Bit coal SP3 Oxyfuel
EUR
O/t
PF 600 MWel gross reference case
CO2 avoidance costs
0,0
5,0
10,0
15,0
20,0
25,0
30,0
35,0
40,0
445 MW Bit coal CFB SP3 Oxyfuel 445 MW Bit coal CFB SP4 CLC
EUR
O/t
CFB 445 MWel gross reference case
CO2 avoidance costs
0,0
5,0
10,0
15,0
20,0
25,0
30,0
35,0
40,0
600 MW Bit coal SP2 Pre-combustion
600 MW Bit coal SP3 Oxyfuel
EUR
O/t
PF 600 MWel gross reference case
CO2 avoidance costs
0,0
5,0
10,0
15,0
20,0
25,0
30,0
35,0
40,0
445 MW Bit coal CFB SP3 Oxyfuel 445 MW Bit coal CFB SP4 CLC
EUR
O/t
CFB 445 MWel gross reference case
Net electric efficiency
05
10152025
303540
45505560
600 MW Bit coal SP2 Pre-combustion
600 MW Bit coal SP3 Oxyfuel
%
PF 600 MWel gross reference case
Net electric efficiency
05
10152025
303540
45505560
600 MW Bit coal SP2 Pre-combustion
600 MW Bit coal SP3 Oxyfuel
%
PF 600 MWel gross reference case
Net electric efficiency
05
10152025
303540
45505560
600 MW Bit coal SP2 Pre-combustion
600 MW Bit coal SP3 Oxyfuel
%
PF 600 MWel gross reference case
Net electric efficiency
05
10152025
303540
45505560
600 MW Bit coal SP2 Pre-combustion
600 MW Bit coal SP3 Oxyfuel
%
PF 600 MWel gross reference case
Cost base: Year 2005
24
ENCAP Integrated Project
A two phase approach in the development and validation of pre-combustion technologies of
capture of CO2
25
ENCAP 5 year project – Planned in two phases
2004 2005 2006 2007 2008 20092004 2005 2006 2007 20092004 2005 2006 2007 2009
Power System evaluation
Pre-combustion Decarbonisation
Phase I
OxyFuel
Phase II
Chemical Looping Combustion
High Temperature Oxygen generation
Novel Concepts
-validation tests included
Large Scale validation testCandidates
30 MW PF Pilot1 MW CFB
1 MW CFB
(Small pilot Scale CAR Concept)
Two Component experimental scale test
Selection of Large Scale Testing candidates 2006:
26
Vattenfall 30 MW PF OxyFuel Pilot in Germany
September 2008
First pilot including the whole chain/components:Air separationBoiler 30 MWthAsh treatmentElectrostatic precipitatorCO2 processing unit
Schwarze Pumpe Power Plant1000 MW
Pilot Plant
27
ENCAP 5 year project – Planned in two phases
2004 2005 2006 2007 2008 20092004 2005 2006 2007 20092004 2005 2006 2007 2009
Power System evaluation
Pre-combustion Decarbonisation
Phase I
OxyFuel
Phase II
Chemical Looping Combustion
High Temperature Oxygen generation
Novel Concepts
-validation tests included Selected for Large Scale testing30 MW PF Pilot
3 test campaigns planned
Extension of 6 month requested April 2008
28
ENCAP 5 year project – Planned in two phases
2004 2005 2006 2007 2008 20092004 2005 2006 2007 20092004 2005 2006 2007 2009
Power System evaluation
Pre-combustion Decarbonisation
Phase I
OxyFuel
Phase II
Chemical Looping Combustion
High Temperature Oxygen generation
Novel Concepts
-validation tests included Selected for Large Scale testing30 MW PF Pilot
Extension not finally approved by EC
( ) ??
29
Thanks for the attention
the ENCAP consortium
Energy providers
Main operating areas
Power & fossil fuel suppliers
E2
Vattenfall
RWE
Vattenfall
PPC
Statoil
Vattenfall
Energy prov
Main operating areas
Power & fossil fuel suppliers
E2
Vattenfall
RWE
Vattenfall
PPC
Statoil
Vattenfall
Energy providers
Main operating areas
Power & fossil fuel suppliers
E2
Vattenfall
RWE
Vattenfall
PPC
St atoil
Vattenfall
Energy providers
Main operating areas
Power & fossil fuel suppliers
E2
Vattenfall
RWE
Vattenfall
PPC
Statoil
Vattenfall
Energy prov
Main operating areas
Power & fossil fuel suppliers
E2
Vattenfall
RWE
Vattenfall
PPC
Statoil
Vattenfall
Energy providers
Main operating areas
Power & fossil fuel suppliers
E2
Vattenfall
RWE
Vattenfall
PPC
St atoil
Vattenfall
SINTEF Energy Research
Statoil Research Center
Vattenfall Laboratory
SINTEF
RTD Providers
proficient European research institutes and unive rsities
Universität Paderborn
ISFTA
Chalmers
CSIC
DLR
College
IFP
Lund University
TNO
NTNU
University of
Twente
University of Ulster
SINTEF Energy Research
Statoil Research Center
Vattenfall Labor atory
SINTEF
RTD Providers
proficient European research institutes and universities
University of Stttuttgart
Universität Paderborn
ISFTA
Chalmers
DLR
IFP
TNO
NTNU
University of
Twente
University of Ulster
SINTEF Energy Research
Statoil Research Center
Vattenfall Laboratory
SINTEF
RTD Providers
proficient European research institutes and unive rsities
Universität Paderborn
ISFTA
Chalmers
CSIC
DLR
College
IFP
Lund University
TNO
NTNU
University of
Twente
University of Ulster
SINTEF Energy Research
Statoil Research Center
Vattenfall Labor atory
SINTEF
RTD Providers
proficient European research institutes and universities
University of Stttuttgart
Universität Paderborn
ISFTA
Chalmers
DLR
IFP
TNO
NTNU
University of
Twente
University of Ulster
ALSTOM Power Boiler FR
Alstom Power CentralesAlstom Power CentralesAlstom Power Centrales
Technology providersleading European manufacturers
L´Air Liquide
ALSTOM Power Boiler DE
ALSTOM Power CH
BOC
LindeLurgi
Siemens
Technology providersleading European manufacturers
L´Air Liquide
ALSTOM Power Boiler DE
ALSTOM Power CH
BOC
LindeLurgi
Siemens
Technology providersleading European manufacturers
L´Air Liquide
ALSTOM Power Boiler DE
ALSTOM Power UK
ALSTOM Power CH
BOC
LindeLurgi
Siemens
Mitsui Babcock
ALSTOM Power Boiler FR
Alstom Power CentralesAlstom Power CentralesAlstom Power CentralesAlstom Power CentralesAlstom Power CentralesAlstom Power Centrales
Technology providersleading European manufacturers
L´Air Liquide
ALSTOM Power Boiler DE
ALSTOM Power CH
BOC
LindeLurgi
Siemens
Technology providersleading European manufacturers
L´Air Liquide
ALSTOM Power Boiler DE
ALSTOM Power CH
BOC
LindeLurgi
Siemens
Technology providersleading European manufacturers
L´Air Liquide
ALSTOM Power Boiler DE
ALSTOM Power UK
ALSTOM Power CH
BOC
LindeLurgi
Siemens
Mitsui Babcock