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

CIUDEN CO2 Capture TDPCommissioning

Commissioning: November 2010 (PC)

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 CompostillaSchedule

PHASE I PHASE II

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

OXY-CFB-300 CompostillaFuture Capture Plant 3D Model

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.

www.oxygenie.com

Thank You!