co 2 ‘capture ready’ boilers- an update international workshop on carbon capture and storage in...

CO2 ‘Capture Ready’ Boilers- An Update

International Workshop On Carbon Capture And Storage In The Power Sector

R. PadmanabhanDoosan Babcock Energy, Chennai

Hotel Ashok, New Delhi – 22-23 January 2008

Company update

• Our new name - Doosan Babcock EnergyDoosan Babcock Energy

• Subsidiary of Doosan Heavy Industries of South Korea, and part of the Doosan Group – the oldest and one of the top 10 conglomerates in Korea

– US$13bn turnover company

• Market leader in gas, coal, nuclear power generation and desalination.

– e.g. SIPAT, 3 x 660MWe and Mundra, 5 x 800MWe

• Our commitment is to all forms of power generation, including clean coal, nuclear, gas and renewables

• The Doosan Group’s ‘Centre of Excellence’ and global R&D base for Boilers and CO2 capture – which includes our India organisation

Nuclear Thermal Turbine & Generator

Desalination Casting & Forging Construction

In one year - How things have changed for coal and gas

• 14th Sept 07, Hans Stehr, chairman of UN CDM Exec Board:

``Fossil fuel will remain a big part of the world's energy mix for decades to come,... essential we burn that fuel as efficiently as possible.''

• World Wide Recognition: The new plants will operate for 40- 50 years; So they need to be built ‘Capture Ready’- ‘TODAY’ to avoid carbon lock-in

• EU Agrees that renewables and energy efficiency, whilst vital, are ‘not enough’

– Coal has a huge role in the new EU Energy Policy– New Plant to be ‘capture ready’ from 2010, – 10-12 demonstrations of CCS operational by 2015, – CCS in operation from 2020,

• Gas has its issues– Price instability.– Security of supply.– Gas is also a CO2 emitter, will need CCS for deep cuts

So coal projects beginning to be

developed which are

‘Capture Ready’

Comparison of Carbon Capture options for Coal power plant

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Amine Oxy Combustion IGCC

Amine Oxyfuel IGCC

Amine Oxyfuel IGCC

Cost of Electricity (Eurocents/kwh)

Specific Investment costs (Euro/kw)

From joint paper with Jacobs at Powergen 2006

1400-1800 Euro/kw for New build, 800 Euro/kw for Retrofit

5 -6.2 Euro/kwh for New build, <5 Euro/kwh for retrofit

Three options: •Post Combustion Capture – Amine or Ammonia scrubbing•Oxyfuel firing (Doosan Babcock Focus)•Precombustion – IGCC

Many studies show these result in are broadly similar efficiency and cost of electricity.

No clear winner, but PCC and Oxyfuel will be needed for retrofit plants currently being built around the world (incl. India)

New Coal Fired Plants planned in the UK

Project Size/TechnologyStart up

DateStatus

IGCC

Powerfuel Hatfield 2 x 430MW IGCC with Capture 2011Section 36 consent. FEED study starting

E.ON Killingholme 450-500MW IGCC with CCS 2012Internal feasibility study underway

Centrica Teesside 800 MW IGCC with CCS 2011 FEED study started

PF - Post Combustion

RWE npower BlytheNew build ASC (Capture ready) 3x800 MW

2014Scoping Report submitted 11/05/07

E.ON KingsnorthNew build ASC (Capture Ready) 2 x 800MW

2012Section 36 applied for 11/12/06

RWE npower TilburyNew build ASC (Capture Ready) 1600MW

2013/14Scoping Report submitted 13/3/07

PF – Oxyfuel (All are retrofits at the moment)

SSE Ferrybridge1 or 2 x 500MW ASC Retrofit (Capture Ready)

2011FEED study well advanced

Scottish PowerLongannet and Cockenzie

ASC Retrofit (Capture ready), up to 3390MW

2012 onwards

Feasibility study announced 17/05/07

Ferrybridge – AS Retrofit – Oxyfuel Capture Ready

A ‘future proofed’ Advanced Supercritical Retrofit to Ferrybridge Power Station – Oxyfuel capture ready.

Ferrybridge Retrofit Specifics Present Boiler

Subcritical boiler

4 x 500MWe units

Ordered 1961, commissioned mid/late 60’s

Steam Conditions:160 bar,565oC/ 565oC

Ferrybridge - Supercritical Boiler Retrofit with Oxyfuel ‘Capture Ready’

• 507 MWe (gross) 476MWe (net) /unit,

• 290 bar/ 6000C / 6100C • BMCR steam flow 1,380 Te/hr• Bituminous coal with up to 25% Biomass• BOFA system• New boiler within existing boiler house• Re-use of much BOP equipment,

new SCR and FGD• POSIFLOWTM low mass flux furnace

Ferrybridge ASR Capture Ready Application - Summary

• Currently sub-critical operation with cycle efficiency 36.7%

• With SCR and FGD, new cycle efficiency 44.7%

– 22% increase in overall efficiency, despite SCR/FGD penalty

• CO2 reduction (with load factor of 70%) is 483,500tes/yr

– 18% reduction in CO2 emissions

• Status of design :

– No technical showstoppers

– ASR boiler fits easily within existing structure

– Turbine layout compatible with existing foundations

– Anticipated costs within budget

What will a Supercritical Retrofit involve at Longannet & Cockenzie?

• Replacement of boiler pressure parts, within boilerhouse envelope

• Lighter boiler weight means re-use of existing primary structure

• Replacement of HP and IP turbine, modified LP turbine

• Replacement of all steam and feed water piping

• New feed pumps and feed heating system

• New DCS system • Re use of bulk of ancillary

equipment• New SCR plant• New FGD plant

600 MWe units similar to Ferrybridge ASR & CCS ready

Advanced Supercritical Retrofit (ASR) - Demonstrated

• POSIFLOWTM Boiler Retrofit Process demonstrated at Yaomeng, China in 2002

– Retrofit of Chinese designed sub-critical 300MWe boiler.

– Flaws in its design meant it had a low availability due to overheating

– Retrofitted with Doosan Babcock POSIFLOWTM boiler

– Order received in Dec 07 for similar conversion of a 2nd boiler

• Technology could be applied to existing 200/210/250 MWe Indian boilers subject to full technical evaluation

– There is a minimum size of unit below which the technology cannot be applied

– Indian 200/210/250MWe boilers are borderline

– requires a feasibility study to fully evaluate

Carbon Capture by Oxyfuel firing on Pulverised Coal Plant

Figure courtesy of Vattenfall

- Pilot scale tests by Doosan Babcock Energy 1996

- IEA studies completed

- EU project ENCAP underway

- EON 1MW rig now operational, confirmed DBE results

- DTI funded collaborative R&D projects in progress (Doosan Babcock Energy, EON, RWE, Air Products …)

- Vattenfall 30MW demonstration plant being built , and similar projects at Lacq and Callide

- Full scale 40 MW burner test planned by Doosan Babcock in 2008/9

Carbon Capture by Oxyfuel firing on Pulverised Coal Plant

• The Plan: To develop a competitive Oxyfuel technology suitable for full scale application 2010.

• Three Stage Development Programme approach through the development and demonstration of Oxyfuel technology:-

- Stage 1 : Fundamentals and System Design

- Stage 2 : Modified Design Tools and Component Testing

- Stage 3 : Reference Designs

Doosan Babcock Oxyfuel Burner development program

2005 2006 2007 2008 2009 2010

Stage 1

Stage 2

Stage 3

Multi Fuel Burner Test Facility (MBTF)

• commissioned in Renfrew in 1999

• conversion to Oxyfuel under the UK OXYCOAL collaborative project.

• £7m ($14m) funding now in place.

Stage 2 will involve conversion of the test facility to OXYCOAL firing

Demonstration of a full utility sized Oxyfuel PF combustion,

The first full-scale test of Oxyfuel firing in the world

Doosan Babcock burner test facility to be converted to Oxycoal firing

What does it take for boiler to be (Oxyfuel) CCS ready

• Space for Air Separation Unit

• Space for CO2 cleaning and compression

• Space for CO2 recycle ducts

• FGD may be needed for some coals

• Feasible CO2 pipeline route to a storage area

• Furnace & Boiler performance to suit oxyfuel/air coal combustion

• Oxy-fuel burners would fit in the same space as regular burner without need for major pressure part modification

• Boiler sealing against tramp air ingress

• Planning extra space for piping/cabling & racks.

Main Considerations:

Site Layout - Capture Plant Space Requirements

80m

ASU 1 ASU 2 CO2

70m 70m

1 x ASC BT Oxyfuel Unit: - 2 x ASU trains : 80 m x

140 m

- CO2 Compression : 80 m x 15 m

- Maximum Height : 68 m

CW Tower Pond Dia ~90mCW Tower Height ~110m

100m

230m

1 x ASC BT Amine Unit: - 2 x DCC - 2 x Fans / Blowers - 2 x CO2 Absorber Towers (12.5m Dia x

45m Height) - 1 x CO2 Stripper Tower (10m Dia.)

- CO2 Compression : 40 m x 15m approx

15m

DCC &ABSORBER 2

DCC & ABORBER 1

CO2

ST

RIP

PE

R

15m

Key Messages

• Work to date has demonstrated that ASC Retrofits, designed to be “Capture Ready” are available options today – subject to initial feasibility study of each plant.

• Oxyfuel firing is best suited to Indian coals due to their high ash and low reactivity.

• An Indian-based CCS demonstration, involving oxyfuel firing, should be a high priority.

• Feasibility study of Indian 200/210/250MWe units for ASC Retrofit with CCS urgently needed.

• UK expertise and capital, combined with Indian skills and availability of utility plant in desperate need of renovation provides ‘Ideal Opportunity for UK-Indo Co-operation & International Leadership’.

Doosan Babcock is committed to Development and Global Implementation of Cleaner power plants - Clean coal, Clean

gas, nuclear and renewables as rapidly as the market allows

Our Commitment to the Industry

Thank you for your attention

[email protected]

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