alstom's chemical looping combustion prototype for co capture

Iqbal Abdulally - Alstom PowerHerb Andrus Jr., Carl Edberg, John Chiu - Alstom Power

Paul Thibeault - Alstom Power

Bruce Lani US DOE/NETL

2012 CO2 Capture Technology Meeting , July 9 – 12, 2012

ALSTOM’s Chemical Looping Combustion Prototype for CO2

Capture from Existing Pulverized Coal Fired Power Plants

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 2

Agenda

1st topic General Project & Technology Background

2nd topic Phase 0 to III Activities

3rd topic Phase IV Activities and Status

4th topic Next Steps


The Alstom Group: a Worldwide Leader in Power Generation

Full Power Systems Portfolio N 1 in air quality control systems

N 1 in services for electric utilities

N 1 in integrated power plants

N 1 in hydro power

N 1 in conventional nuclear power island

Recent acquisitions of solar & wind power

Over 41 GW under executionNuclearHydro

SteamGas

Chemical Looping Technology Development



Project OverviewProject Goals and Objectives

• Chemical Looping Program:

Develop and commercialize chemical looping process to meet the goals for new or existing coal-fired power plants.

• Prototype Project:

Design (BP1), build, and test (BP2) a 3 MWth Prototype to demonstrate Chemical Looping Systematic TestingExtended auto-thermal operation

Obtain engineering and operating information necessary to design and build a reliable follow-on demonstration plant.



Alstom’s Chemical Looping DevelopmentTargets:

• Over 90% CO2 capture from coal• Less than $20/ton avoided cost of CO2 capture• Capital cost 20% < conventional steam plant (w/o CO2

capture)• Applicable to retrofit and new coal-fired power plants• Retrofit < 20% increase in COE• Beat steam power and IGCC performance and

economics, world-wide• Medium-Btu syngas or hydrogen without oxygen plant• Economical H2 production at low cost



Chemical Looping Prototype Schedule As Planned

Phase IVA is on Schedule

4. Start Shakedown

5. Complete Phase IVA Testing

6. Deliver Interim Report

1. Complete Preliminary Engineering

2. Deliver Updated Technical and Cost Information to NETL (for BP1 Decision)

3. Start Installation

7. End of Phase IVA Program

Major Milestones:


Phase IVA DOE SchedulePhase IVA DOE Schedule.xls

October 2011

Task1.0 Project Management

and Reporting2.0 Prototype Engineering3.0 Prototype Procurement

and Installation4.0 Prototype Operation

ShakedownCold Flow Hot Flow, Non-ReactingHot Flow, Reacting

5.0 Solids Transport Testing6.0 Engineering Support7.0 Analytical Support8.0

Jul - Sep Oct - Dec Jan - Mar Apr - Jun Jul - Sep Oct - Dec Jan - Mar Apr - Jun Jul - Sep Oct - Dec Jan - Mar Apr - Jun Jul - Sep Oct - Dec Jan - Mar Apr - Jun Jul - Sep2008 2009 2010 2011 2012

Alstom FY 08-09 FY 09-10 FY 10-11 FY 11-12 FY 12-13DOE FY 08-09 DOE FY 09-10 DOE FY 10-11 DOE FY 11-12

Testing: - Systematic - Autothermal Optimization

Phase IVABP1 Phase IVA

Milestones:1.Complete Preliminary Engineering2.Deliver Updated Technical and Cost

Information to NETL (for BP1 Decision)3. Start Installation4. Start Shakedown5. Complete Phase IVA Testing6. Deliver Interim Report7. Deliver Final Report

4

5

1

32

6

BP2

Phase IVAExtension

7


Project Overview – Phase IVFunding

Participants:

Total Budget Period 1 & 2October 2008 to September 2011

DOE Funding $7,395,624 Alstom Funding $1,848,906 Total Budget $9,244,530

Total Budget Period 2 ExtensionOctober 2011 to Present

Alstom Funding $1,500,000

Total Budget 2008to Present $10,744,530



Air(O2/N2)

Depleted air,

Ash, CaSO4

Option 1 – Chemical looping combustionExcess air (CaSO4) to fuelProduct gas is CO2Heat produces steam for power

Product Gas

Coal,

CO2H2O

CaS (s)

CaSO4 (s)

Calciner

CO2 (g)CaCO3 (s)

Syngas (CO, H2O

Hotsolids

Coldsolids

Steam toPower Cycle

CaO(s)

CaCO3(s)

H2 (g)

H2O

Option 2 – Chemical looping gasificationExcess fuel to air (CaSO4)Product gas is SyngasNo inherent CO2 capture

Option 3 – Hydrogen productionAdd CaO-CaCO3 to Option 2Add calcinerProduct gas is H2Calciner off-gas is CO2

Alstom’s LCL™ process is suited to coal

Air Reactor (Oxidizer)

CaS + 2O2 -> CaSO4 + Heat

Fuel Reactor (Reducer)

2 Cfuel + CaSO4 + Heat -> CaS + 2 CO2

8 Hfuel + CaSO4 + Heat -> CaS + 4H2O

Main Reactions:

Alstom’s Limestone Based Chemical Looping (LCL™) Concept & Process Options



Chemical Looping Process:Options and Applications

Re ducer Ox idize r

CaSO4 CaS

N2

AirCoal

CaCO3Steam

Ash, CaSO4to Disposal

CO2

Ste am

Option 1 – Combustion with CO2 Capture

Reducer Oxidizer

CaSO4 CaS

N2

AirCoal

CaCO3Steam


Calciner CO2

H2

Option 3 – Hydrogen with CO2 Capture

R e d u c e r O x id iz e r

C a S O 4 C a S

N 2

A irC o a l

C a C O 3S te a m

A s h , C a S O 4to D is p o s a l

S y n g a sC O ,H 2

Option 2 – Syngas with no CO2 Capture

• CO2 Capture – PC Retrofit• CO2 Capture – CFB Retrofit• CO2 Capture-Ready Power Plant• Advanced Steam Cycles with CO2 capture

• IGCC with Down-Stream CO2 Capture• Industrial Syngas production• Coal-to-Liquid Fuels

• CO2 Capture – PC Retrofit• CO2 Capture – CFB Retrofit• CO2 Capture-Ready PC/CFB Power Plant• Advanced Steam Cycles with CO2 capture• IGCC with CO2 Capture• Fuel Cell Cycles with CO2 Capture• Industrial Hydrogen with CO2 Capture

Applications – LCL™

Flexible technology with low cost2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 9


Chemical Looping Overview Retrofit Options

Existing Steam

TurbinePower Block

Steam

Feed WaterGenerator

Air

Fluegas

ExistingPC Boiler

ExistingCoal

Pulverizer

CoalLimestone

(CaCO3)

Reducer Oxidizer

CaSO4 CaS

N2 to Stack

AirAsh, CaSO4to DisposalCalcinerCO2

H2

CO2-freeBoiler fuel

(H2)

Steam

Concept 1 – Chemical Looping CO2 --free Fuel; Minimum Boiler Modification

Concept 2 – Chemical Looping Oxidizer Replaces/Modifies Boiler

Feed Water

ExistingSteam

TurbinePower Block

Steam

Generator

ExistingCoal

Pulverizer

CoalLimestone(CaCO3)

Reducer Oxidizer

CaSO4 CaS

N2 to Existing Stack

Air


CO2

Steam

Existing Steam

TurbinePower Block

Steam

Feed WaterGenerator

Air

Fluegas

ExistingPC Boiler

ExistingCoal

Pulverizer

CoalLimestone

(CaCO3)

Reducer Oxidizer

CaSO4 CaS

N2 to Stack

AirAsh, CaSO4to DisposalCalcinerCO2

H2

CO2-freeBoiler fuel

(H2)

Steam

Concept 1 – Chemical Looping CO2 --free Fuel; Minimum Boiler Modification

Concept 2 – Chemical Looping Oxidizer Replaces/Modifies Boiler

Feed Water

ExistingSteam

TurbinePower Block

Steam

Generator

ExistingCoal

Pulverizer


Feed Water

ExistingSteam

TurbinePower Block

Steam

Generator

ExistingCoal

Pulverizer


Feed Water

ExistingSteam

TurbinePower Block

Steam

Generator

ExistingCoal

Pulverizer


Reducer Oxidizer

CaSO4 CaS


Air


CO2

Steam

Reducer Oxidizer

CaSO4 CaS


Air


CO2

Steam

Retrofit Options at < 20% Increase in COE with CO2 Capture2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 10

Concept 1 –Chemical Looping CO2 Free Fuel; Minimum Boiler Modifications (Option 3)

Concept 2 –Chemical Looping Oxidize Replaces/Modifies Boiler (Option 1)


Agenda







Limestone CLC Development Timeline

• Earlier Program: Hot Solids Gasification: 1996-2001 Process and Sorbent Investigation Economic Evaluation Lead to Chemical Looping Program

• Chemical Looping Development Phase 0 (2001) - Alstom's Internal Development Project,

Construction of the Process Development Unit (PDU) Phase I (2003) - DOE Program Started, Verified Sorbent

Chemistry and Solids Transport Phase II (2005) -Verified Gasification Chemistry and

Process Control Strategy Phase Ill (2006) - Developed Automatic Control System Phase IVA (2008) - Built 3 MW Prototype, Shakedown and

Initial testing2012 CO2 Capture Technology Meeting , July 9 – 12, 2012P 12


Agenda







• Main objectives:

Design, engineering, construction, commissioning and operation of a 3 MWth CaS prototype,

Autothermal operation of Limestone-based prototype,

Proof of concept – deliver data required to scale up to Demo and commercial size

• 50 month program Shakedown completed First coal fire completed June 2011 Autothermal operation Scheduled for August/Sept. 2012

• Total approved budget: 9.25 M$, cost share by US-DOE and Alstom

• Partners: US-DOE/NETL & Alstom

Prototype Constrauction and OperationChemical looping – 3 MWth Limestone based Prototype Coal

Rear View of Prototype Building

3 MWth Prototype Model

70 ft



Chemical Looping PrototypeComponent Construction

The Prototype was integrated into the existing Multi-use Test Facility (MTF)

70 ft



Barracuda Simulation of the Chemical Loop reducer column(color range 0 – 25m/s)

Mixing of solids streams in Cactus above the fluidizing gas grid 0-25 m/s

Prototype Validation: Computational Fluid Dynamics

Improving LCL™Process

Reducer

Oxidizer

Coal Feed

Coal Feed

Reducer

Fluidizing Grid

Fluidizing Grid

Reducer Bottom Outlet

Oxidizer return

Reducer RecycleOxidizer

return

Study and improve:

Fluidization

Solids transport

Mixing in “Cactus”

Residence times

Fixed carbon retention

in reducer

Cactus



Prototype Validation: Cold Flow Model Testing

L o o p P re s s u re fo r 4 H o u rs S te a d y R u n (1 7 J A N 2 0 1 1 1 0 :0 0 to 1 4 :5 5 )

P 1 0R x c y c i

P 1 3R x d ip le g

P 2R x r is e r

5 6

P 1c a c tu s

P 5 0X O to R x

P 5 1 X O to O x

P 4 3 P re s s c o lu m n

P 4 0O x s p o

P 3 2 O x r is e r

P 3 8O x d ip i

-2 0

0

2 0

4 0

6 0

8 0

1 0 0

1 2 0

1 4 0

1 6 0

1 8 0

2 0 0

P re ss ure a lo ng L oo p ["wg ]

T R ,T O /F 1 ,T 2 /F 3 8 ,T 3 9 /F 4 0 ,T 4 1 /F 3 1 ,T 3 2 /G5 2 0 8 , 2 9 5 5 / 4 1 .9 ,5 5 .1 / 2 1 .4 ,1 4 .0 /0 ,0 / 6 5 .3

Stable coupled operation with smooth solids transport

P9

P4

P5

INJ2

P7

P10

Reducer Riser

INJ1

P6

Fuel/LS Feed

P8

480 in

P5 P58

G43 Oxider

P37 P36

P38

P4

P47 P46

P43

P54

P55 P56

P41

P48

P31

P33

P35

P32

P3 4

P42

P50 P49

P40

P3

Butterfly Valve

P45

G33 G34

G35 G36

G3 7

P0

F38 T3 9

F31 T32

F40 T41

P21 P23

P17

P1

P14

P2

P13

P15

P16

Butterfly Valve

Laser Probe

load cell

F1 T2

G1

TO

load

BH

P53 G42

P51 P52 TR

P11

BH

P12 P39

P2

37th International Technical Conference on Clean Coal & Fuel Systems June 3-7, 2012 Clearwater, FL, USA P 17

Pre

ssur

e –I

ns W

G


Hot Coupled Loop Operation Achieved with Coal & Charcoal

Main Milestones:

• June 2011 - First coupled run with Pitts #8 Coal• Sept. – Oct. 2011 - Series of short runs with

Pitt.#8 coal• May 2012 - Reducer tests decoupled, nitrogen

blown runs with Adaro coal and charcoal – All reducer reactions observed

• June 2012 – Extended reducer tests with Adaro Coal – All reducer reactions observed

Prototype Testing Status


Research Operators in Control Room During Hot Coupled Testing

Major Achievements:• Controlled solids recirculation in CFM & prototype.• Coal firing at low reactor temps with low tar formation.• Coal firing at design temperature with no evidence of

tar formation.• SAHE operation.• Hot restart after main fuel trip.• Production of CO2 (Option 1) and Syngas (Option 2).• Combustion reactions with chemical looping

reactions.


Prototype Validation: “Decoupled” Tests Towards Autothermal


Decoupled Reducer Test Decoupled Oxidizer Test

Integrated Autothermal Test


Hot Coupled Loop Operation Achieved with Coal & Charcoal

Prototype Reducer tests: Preliminary Testing Results


Significant Observations:• All LCL™ reactions realized• High carbon burnup efficiency > 98%• Negligible carbon carryover to oxidizer • Oxygen demand - 15 to 20%• SO2 release can be minimized by varying excess

air (CaSO4) to fuel ratio


Agenda







Limestone Based Chemical Looping Path Forward

• Oxidizer Testing: July – August 2012• Coupled Autothermal Operation: August -September

2012



LCL™ Process Development StepsManaged Development and Scale-up

Pilot PlantPilot Plant

PrototypePrototype

Demonstration Demonstration

2015-2020

2000-2004

2008-2012

Commercial Scale

Commercial Scale

2020-2025

Bench TestsBench Tests

1996

10-100 kWth

1& 3MWth

10 50 MWe

>100 MWe

Reference Design Studies

Drop-Tube/TGA

Small & Large Cold-Flow-ModelSmall & Large Cold-Flow-Model

CFD Modeling, Controls and Tool Development



Acknowledgments

• Funding Partners:− US-DOE/NETL, Alstom

• Key Team Members:− Herbert E. Andrus, John Chiu, Jr., Paul Thibeault, Carl

Edberg, Jim Kenney, Michael Clark

Significant Progress Thanks to These Contributions37th International Technical Conference on Clean Coal & Fuel Systems June 3-7, 2012 Clearwater, FL, USA - P 24

www.alstom.com

Thank You!

Any Questions?

alstom's chemical looping combustion prototype for co capture

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