CATs R+D- an Industrial Viewpoint
Mike Farley
Director of Technology Policy Liaison
APGTF 27 February 2008
Page 1
Contents
Doosan Babcock updateImportance of R+D + Demonstration to Best Available TechnologyCurrent activities in UK industryAmbitions of industryWhat is needed from
GovernmentUniversities and Research CouncilsTSB, ETI, ETF and the EU
Page 2
Company update
• Doosan Babcock Energy Limited is a subsidiary of Doosan Heavy Industries and Construction of South Korea, part of the Doosan Group – the oldest and one of the top 10 conglomerates in Korea
• Doosan Heavy is a market leader in gas, coal, nuclear power generation and desalination with orders in 2007 totalling 7 Bn USD
• Doosan Babcock Energy remains committed to all forms of power generation, including clean coal, nuclear, gas and renewables
• Doosan Babcock Energy will be the Doosan global Centre of Excellence and R+D Centre for Boilers (including Clean coal and Carbon dioxide capture)
• Doosan Babcock Energy’s territory is Europe, America, Southern Africa and China
Nuclear Thermal Turbine & Generator
Desalination Casting & Forging Construction
Page 3
Key resources maintained –Doosan Babcock
Changshu 3 x 600 MW supercritical boilers
Rebuild 800 MW supercritical Nikola Tesla
Trimble County B 750 MW supercritical boiler for EON USA
Doosan Changwonworks, Korea
Page 4
Recent contract successes–Doosan Babcock
• BOFA systems for Didcot, Ferrybridge, Cottam, Rugely, Drax, Longannet, Sines
• Major plant refurbishments Nikolai Tesla, Kosovo
• Advanced cofiring developments
• Feasibility / FEED studies for capture ready advanced supercritical retrofits– Ferrybridge, Longannet and Cockenzie, Brindisi North
• BOFA and SCR - EPC contract for 6 X 600MW Castle Peak B in Hong Kong, China and 2x 600MW at Wanqu in China
• Second Posiflow retrofit at Yaomeng in China
• £550M long term R+M and technical support contract for British Energy nuclear fleet
• Contract for 2 x 800MW Advanced Supercritical (600deg C) Boilers with Posiflowtm in Germany
Page 5
Contents
Doosan Babcock updateImportance of R+D + Demonstration to Best Available TechnologyCurrent activities in UK industryAmbitions of industryWhat is needed from
GovernmentUniversities and Research CouncilsTSB, ETI, ETF and the EU
Page 6
CO2 Abatement from Fossil Fuels – Twin Track Approach
Carbon Dioxide
Reduction
Increased Efficiency,Biomass
cofiring etc
CarbonCapture and
Storage (CCS)
- -
Possible Now
Long Term TimeMedium Term2012 2020
-23%
Baseline
- 60%
- 95% TRACK 2
TRACK 1
>>> concept of “Capture-ready plant”
Page 7
1960 1980 2000 2020
35
40
45
50
55
30
Supercritical Boilers
Sub Critical Boilers
Plant efficiency
% NCV
Year
Target AD700
50 – 55%
Doosan BabcockASC
46%
Meri PoriHemweg
New Chinese Orders
42%
Chinese fleet 38%
OlderPlants
Increasing Efficiency
Lower CO2
emissions
Best Available Advanced Supercritical Technology being supplied now
38%
32%
UK
fleet
Abatement of CO2 by efficiency improvement of Pulverised Coal Plant
(-23%)
(-29%)
Page 8
Main Steam 281bar 602.45°C
Reheat Steam 605 °C
International traded Bituminous Coal with 3 specified guarantee coals plus 100% oil firing
Boiler Efficiency (100% load LHV) 95%
O2 at economiser outlet 2.84%
Boiler HP steam flow 578.65 kg/s
Pressure drop (bar)HP 27RH 2.4
SCR inlet NOx (worst coal) <450mg/Nm3
SCR outlet NOx (all coals) 200mg/Nm3
CO at econ outlet <200mg/Nm3
Capture ready 2x 800MW 46 % efficiency two pass boiler
Ordered in Germany
Suitable for UK
Page 9
Advanced Supercritical Coal fired power plant with CO2 Capture
• DTI Project 407 Technoeconomic Study has shown:
– how to retrofit Advanced Supercritical boilers and turbines to existing plant, how to make the design “capture- ready”, and how to retrofit Amine scrubbing or Oxyfuel firing
– that these options can be economic in terms of the Cost of Electricity generated
• Partners: Doosan Babcock, Alstom, E.ON, Air Products, Imperial College• Sponsors: E.ON, DraxPower, EDF Energy, SSE, RWE, ScottishPower
FEED Studies on capture ready ASC (Ferrybridge and Longannet)
Capture ready design for EON Kingsnorth tender
and collaborative projects on Oxyfuel and Post-combustion capture, including Oxycoal2
Page 10
Contents
Doosan Babcock updateImportance of R+D + Demonstration to Best Available TechnologyCurrent activities in UK industryAmbitions of industryWhat is needed from
GovernmentUniversities and Research CouncilsTSB, ETI, ETF and the EU
Page 11
What are CATS?
Carbon Dioxide
Reduction
, Increased Efficiency,
Biomasscofiring etc
CarbonCapture and
Storage (CCS)
- -
Possible Now
Long Term TimeMedium Term2012 2020
-23%
Baseline
- 60%
- 95% TRACK 2
TRACK 1
CO2 Abatement from Fossil Fuels – Twin Track Approach
Page 12
What’s happening in the CATs field in UK industry?
UK companies are participating in EU, UK govt and international R+D projects on High Efficiency Boiler/Steam Turbine , biomass cofiring and CO2 Capture, Transport and Storage
• EU Research projects on Efficiency ( COST 536 Materials for Advanced Plant, COMTES 700 ), Capture (ENCAP, CASTOR, CESAR, ASSOCOGS) and Storage
• DTI Projects (largely complete)– Retrofit of Gasifier to CCGT, DTI 407- Retrofits of Boiler/Turbines with CO2 Capture, DTI 366 Future
CO2 Capture Technology Options for the Canadian Market, High pressure coal gasification, DTI 410 -Materials and Fabrication for 700degC power plant,
• BERR/TSB projects underway:– Post-combustion capture (CASSCAP), Oxyfuel combustion (Oxycoal1,Oxycoal2), High efficiency
hydrogen gas turbines, Integrated Gasification Steam Cycle (IGSC), CO2 Aquifer Storage (CASSEM), Improved Modelling of Material Properties for Higher Efficiency Power Plant (TSB - IMMP3), Modelling Fireside Corrosion of Heat Exchanger Materials in Advanced Energy Systems
• International R+D– Vattenfall Oxyfuel demonstration- (via ENCAP)– E.ON Collaborative Pilot R&D activities( University of Texas, ITC Canada) and Bilateral Development
of pilot plants (up to 5MW scale) with Alstom, Siemens– Involvement in Futuregen 275MWe Project Development– RWE npower is an industrial sponsor of the pilot amine scrubbing research facility of University of
Texas at Austin
Page 13
What’s happening in the CATs field in UK industry?
UK companies are participating in EU, UK govt and international R+D projects on High Efficiency Boiler/Steam Turbine , biomass cofiring and CO2 Capture, Transport and Storage
• EU Research projects on Efficiency ( COST 536 Materials for Advanced Plant, COMTES 700 ), Capture (ENCAP, CASTOR, CESAR ASSOCOGS) and Storage
• DTI Projects (largely complete)– Retrofit of Gasifier to CCGT,DTI Project 407- Retrofits of Boiler/Turbines with CO2 capture, DTI - 366
‘Future CO2 Capture Technology Options for the Canadian Market’, High pressure coal gasification, DTI Project 410 - Materials and fabrication for 700degC power plant,
• BERR/TSB projects underway:– Post-combustion capture (CASSCAP), Oxyfuel combustion (Oxycoal1,Oxycoal2), High efficiency
hydrogen gas turbines, Integrated Gasification Steam Cycle (IGSC), CO2 Aquifer Storage (CASSEM), Improved Modelling of Material Properties for Higher Efficiency Power Plant (TSB - IMMP3), DTI/BERR: Modelling Fireside Corrosion of Heat Exchanger Materials in Advanced Energy Systems
• International R+D– Vattenfall Oxyfuel demonstration– E.ON Collaborative Pilot R&D activities( University of Texas, ITC Canada) and Bilateral Development
of pilot plants (up to 5MW scale) with Alstom, Siemens– Involvement in Futuregen 275MWe Project Development– RWE npower is an industrial sponsor of the pilot amine scrubbing research facility of University of
Texas at Austin
More detail of each of these
projects is given in the appended
slides
Page 14
Oxycoal2 - Demonstration of Oxycoal combustion system for coal fired power plants
• Convert Doosan Babcock’s full-scale burner test facility tooxyfuel firing
• Oxygen supply• Flue gas recycle system (fans, ducts, cooler, heater, etc.) • Instrumentation
• Design and build full-scale utility Oxycoal burner (40MW)• Derived from air-firing experience, CFD modelling and
Oxyfuel R+D
• Demonstrate a full-scale utility Oxycoal burner• Flame stability, combustion efficiency, emissions, flame
shape, and heat transfer characteristics as function of %CO2 recycle and excess oxygen
• Start-up, shut down, transition from air to oxyfuel, load change
Page 15
What’s happening in the CATs field in UK industry?
• Studies on new / retrofit power plant (capture ready or with CCS):– Peterhead Miller project (gas)
– Ferrybridge retrofit (coal, supercritical)
– Longannet advanced supercritical coal power plant
– E.ON Kingsnorth capture ready advanced supercritical coal power plant
– Tilbury replacement (coal, supercritical)
– Hatfield , E.ON , Teesside and Conocco Philips IGCC with CCS
• Prequalification preparation underway for the BERR CCS Demonstration Competition
• Studies on CO2 transport infrastructure – North West
– Yorkshire and Humberside
– Thames
– Firth of Forth
Page 16
Contents
Doosan Babcock updateImportance of R+D + Demonstration to Best Available TechnologyCurrent activities in UK industryAmbitions of industryWhat is needed from
GovernmentUniversities and Research CouncilsTSB, ETI, ETF and the EU
Page 17
Pilot Plant Constructed
Product Considered “Commercially Proven” - 100’s of MW (equivalent) deployed
First Full-Scale Plant Operational
New Ideas
Basic R&D:speculative, science ledindustry needs led
Feedback of R&D needs
Demonstration DeploymentResearch & Development
underpinning R&D to mitigate perceived technical, market & financial risks
applied R&D to address technical issues
Pilot Plant Constructed
Product Considered “Commercially Proven” - 100’s of MW (equivalent) deployed
First Full-Scale Plant Operational
New Ideas
Basic R&D:speculative, science ledindustry needs led
Feedback of R&D needs
Demonstration DeploymentResearch & Development
underpinning R&D to mitigate perceived technical, market & financial risks
applied R&D to address technical issues
Energy Innovation Chain: where are CATs now ?
Page 18
Energy Innovation Chain Specific to Carbon Abatement Technologies for Fossil Fuels
Research Councils
Demonstration DeploymentResearch & Development
Future Incentives?
DTI Technology Programme, ITI Energy DTI CATs planned
demonstration programmes
Research Councils
Demonstration DeploymentResearch & Development Demonstration DeploymentResearch & Development
Future Incentives for CCS?
TSB Technology Programme
ETI
BERR HFCCATs(Demonstration
programmes (£35M))
- Peterhead/Miller field Hydrogen power plant- Capture-ready Advanced Supercritical projects- IGCCs-
BERR/DEFRA ETF(Environmental Transformation
Fund)
-BERR Post combustion CCS Demonstration project
Page 19
Timescales and ambitions
• Research and Development: now → 2020+
• Early Demonstration projects (incl. Capture ready) now → 2012/15
• 10 - 12 Demonstrations in Europe by 2015
• Full commercialisation by 2020
• Extensive implementation 2020 – 2030
- Industry view is that the technologies that will be fully commercialised by 2020 will be based on the technologies that are known now at lab/pilot scale
- A huge build up in industry capacity is needed as well as proving of technology
- Need to create OEM /EPC capability in UK based companies
- R&D and early stage demonstration will continue to be essential
IEA scenario presented to G8 in
Bali requires 22 coal (800MW) and 20 gas (500MW)
CCS power plants per year from 2013
to 2030
Page 20
Research Agenda for CATs – Industry Reference Documents
• APGTF Vision for Clean Fossil Power Generation, May 2004• DTI CAT Strategy, July 2005• European Power Plant Suppliers Association, R, D and D needs• Coal Research Forum CUSG report “Coal Research Needs in the UK”, 4th
Edition, Sept 2005• European Technology Platform ZEP (Zero emissions Fossil Fuel Power Plant)
Strategic Research Agenda. Recently updated to provide recommendations to FP7. Also WG1 report on website.
• OSI Science Review for Energy:– Carbon Capture and Storage – Sept 2006 Jon Gibbins– Clean Fossil Fuelled Power Generation – Sept 2006 - Tony Oliver
• APGTF R,D and Demo Priorities, 2008
» All have in common the same research areas
Page 21
Overview of CATs Research Agenda
• Efficiency improvement for power plant– boilers, turbines, IGCC
• Co-use of biomass– cofiring, co-gasification, …
• Carbon dioxide capture – post-combustion, pre-combustion, oxyfuel
• Carbon dioxide transport and storage– Pipelines, Ships,– EOR, depleted gas fields, saline acquifers, unmineable coal seams
» Improved performance, economics, safety, environment and public awareness
Page 22
Efficiency improvement for Power Plant
• Materials, fabrication, inspection, monitoring and life assessment technologies for progressive increases in steam temperature and pressure to 350 bar and 750°C
– Particular issues relating to high nickel alloys– Inspection of dissimilar metal welds , thick section castings in steam chests and valves – On-line, in situ structural health monitoring
• Utilisation of waste heat– Needs more techno- economic/societal studies
Ambition: a 700deg coal power plant (efficiency >50 % before CCS and >45 % with CCS), designed for CCS, integrated with a district heating scheme.
Operating in the UK by 2016
Page 23
Cofiring of Biomass
- Advanced cofiring or co-gasification (up to 20% or more by heat input), including corrosion, slagging and fouling issues
- Efficient preparation and processing of sustainable biomass energy crops (e.g. pelletisation, torrefaction)
Ambition:
a biomass cofired 600deg coal power plant (efficiency >45 %)designed for CCS, integrated with a district heating scheme,with 20% cofiring of a wide range of biomass fuels
Operating in the UK by 2016
Page 24
Carbon Dioxide Capture Technologies
Post-combustion (scrubbing)- Process optimisation- New and less energy intensive solvents (e.g. amines)- Avoidance of solvent degradation
Ambition:
a 600deg coal power plant (efficiency >45 % before CCS and >36 % with CCS), with Post combustion capture, operating in the UK by 2014and Several smaller scale demonstrations of competing scrubbing technologies eg 25 MW slip stream on UK coals
Page 25
Pre-combustion Capture- Gasification : process integration/optimisation, improved availability- Gas cleaning : improved reliability- Gas conditioning : CO2 capture : integration and optimisation of shift
conversion and CO2 capture processes, conditioning of H2 fuelgas stream for GT
- Gas turbine : Premix burners for hydrogen requiring- Air separation unit : Process optimisation, improved absorbents
for contamination removal, high efficiency packings for distilling fluids close to supercritical conditions
Ambition:
a UK demonstration and UK OEM capability
Page 26
Carbon Dioxide Capture Technologies - Oxyfuel combustion
- Process optimisation – including start-up/shut-down- Combustion chemistry and kinetics- Heat transfer prediction- Materials for oxyfuel environment, corrosion issues- Ash properties- Flue gas cleaning to meet CO2 specifications- ASUs- Flue gas cleaning and conditioning
Ambitions:
a 100MWe Demonstration of a wall fired Oxyfuel power plant on UK coals by 2012
a 500 MW Demonstration CCS project by 2015
Page 27
Carbon Dioxide Transport and Storage
Transport- Corrosion behaviour of pipelines as a function of material, temperature,
etc- Alternative materials, joining technologies, sealing technologies- Crack formation and growth- Technologies for CO2 ships
Ambitions: early stages of a transport network linked to one or more storage sites and several capture sites by 2015/7
Page 28
Carbon Dioxide Transport and Storage
Storage
• Gather experimental data and develop proper modelling and measuring, monitoring and verification techniques, together with knowledge and methods on trapping, rock and fluid properties, stability/integrity and CO2 mobility
• Assess / develop cost-effective methods for managing impact of sub-surface uncertainty on performance prediction and risk.
• Develop database of equilibrium and kinetic data for use in coupled geochemical modelling of storage systems.
• Develop remote sensing techniques that give improved characterisation of stability of storage sites e.g. geomechanical properties for fault stability
• Assess potential for storage in saline aquifers e.g. develop atlas of seal and saline formation properties for North Sea
• ECBM /UCG – real absorption capacity of coal as function of depth and permeability
Ambitions: multiple storage demonstrations in UK by 2015, including EOR, depleted gas fields and saline acquifers
Page 29
Contents
Doosan Babcock updateImportance of R+D + Demonstration to Best Available TechnologyCurrent activities in UK industryAmbitions of industryWhat is needed from
GovernmentUniversities and Research CouncilsTSB, ETI, ETF and the EU
Page 30
Government Strategy for CATs
• Published July 2005, covers coal and gas, being updated now
• Objective: “To ensure the UK takes a leading role in the development and commercialisation of carbon abatement technologies that can make a significant and affordable reduction in CO2 emissions for fossil fuel use”
• Covers whole spectrum from research, development, demonstration to deployment, including requirements for regulation, incentives and public awareness
• Similar objectives to industry but needs to match the scale of the industry’s ambitions if the objectives are to be achieved
Page 31
Actions for Government, TSB, ETI, ETF and the Research Councils
• The government should include in its revision of the CAT strategy a vision for the progress and roll out of CCS, first to 10-12 demonstrations and then to full commercialisation by 2020 on the scale necessary to meet its global CO2reduction targets
• The BERR review of incentives for CCS should be accelerated and a commitment given as part of the planning of the CO2 Allowance Auction process to recycle auction revenues to support a number of early CCS projects, infrastructure development and an ambitious programme of R,D and early stage demonstration, sufficient to meet the objectives of the updated CAT Strategy
• The government’s ten year commitment to ETI should be matched by similar long term plans for TSB and ETF
• The government should give maximum weight to the potential economic benefits and employment prospects in UK companies in all its support schemes, including the CCS competition
Page 32
Thank you for your attention
Doosan Babcock are committed to development and global implementation of
cleaner power plants - clean coal, clean gas, nuclear and renewables as rapidly as
the market allows
Page 33
APGTF 27 January 2008 “An Industry View of CATs R+D” - supporting slides
Supporting slides• The author acknowledges slides provided by the following
organisations which demonstrate both the breadth and depth of industrial R+D in Carbon Abatement Technologies in the UK
– Doosan Babcock– Edinburgh University– EON– Jacobs – RWE– Scottish Power
Page 34
Emissions Reduction by Improvements in Plant Efficiency
1960 1980 2000 2020
35
40
45
50
55
30
Supercritical Boilers
Sub Critical Boilers
Plant efficiency
% NCV
Year
Target AD700
50 – 55%
Doosan BabcockASC
46%
Meri PoriHemweg
New Chinese Orders
42%
Chinese fleet 38%
OldPlants 30%
Increasing Efficiency
Lower CO2
emissions
Best Available Advanced Supercritical Technology being offered
NOW
38%
32%
UK/US
fleet
(-23%)
(-29%)
1960 1980 2000 2020
35
40
45
50
55
30
Supercritical Boilers
Sub Critical Boilers
Plant efficiency
% NCV
Year
Target AD700
50 – 55%
Doosan BabcockASC
46%
Meri PoriHemweg
New Chinese Orders
42%
Chinese fleet 38%
OldPlants 30%
Increasing Efficiency
Lower CO2
emissions
Best Available Advanced Supercritical Technology being offered
NOW
38%
32%
UK/US
fleet
(-23%)
(-29%)
Page 35
Improved Modelling of Material Properties for Higher Efficiency Power Plant (TSB - IMMP3)
• Overall Objectives – The development, integration and validation of three complementary modelling techniques:-
• Nano-scale modelling – nucleation and growth of second-phase particles.• Meso-scale modelling – microstructure evolution prediction .• Macro-modelling – dislocation/particle interaction leading to cavity formation.
– Applied to three material groups:-• Low gamma prime nickel alloys – Inconel 625, Inconel 617, Nimonic 263, Inconel 740.• Creep resistant alloy steels – primarily T/P91, T/P92 and matching weld metal.• High gamma prime single crystal nickel turbine blade material.
• Partners• Doosan Babcock Energy Ltd – Project Leader• Alstom Power Ltd. – Industrial partner, Steam Turbine Manufacturer.• E.ON UK plc. – Industrial partner, Power Plant Operator.• University of Leicester – Academic partner, modelling expertise, microstructural
characterisation.• Loughborough University – Academic partner, modelling expertise, microstructural
characterisation.• QinetiQ – Research Organisation, modelling expertise.• National Physical Laboratory – Research Organisation, providing MTDATA thermodynamic
database, plus conducting a variety of physical tests including small punch test.
Page 36
DTI Project 410 - Materials and fabrication for 700degC power plant
• Extrusion One.– AD700 programme ; first ever thick section alloy 263 pipe.– Mechanical test results obtained under this programme.
• Extrusion Two.– Provided by the present Doosan Babcock programme.
• Extrusion Three.– Provided by the German COORETEC programme and produced by a different material
supplier.
Extrusions 2 & 3 tested jointly in Doosan Babcock Programme and COORETEC Project.
Alloy 263 Full Qualification Requirements to Satisfy E.U. Rules.
Page 37
Direct Co-firing Options for Power Plant
• Dedicated burners are an option but an unnecessary expense• Coal burner utilisation most cost effective for direct co-firing systems • Burner design and biomass type critical to direct co-firing design
versus
• Pf pipework design options allow higher levels of direct co-firing at lower risk (iesimilar to Drax system)
• Up to 50% co-firing possible on new supercritical plant, however,– Mill control, furnace design and sootblower configuration require modification to
accommodate higher co-firing rates.– Fuel composition and co-firing level needs careful specification and control
• 20% limit recommended for retrofit
Page 38
Doosan Babcock ….Clean Coal and Carbon Capture
UK Government funded project : DTI-407 : Coal-Fired Advanced Supercritical Boiler/Turbine Retrofit with CO2 Capture
Objectives
• Evaluation of the technical and economic feasibility of retrofitting UK coal-fired power plants with advanced supercritical boiler/turbine technology and carbon dioxide capture
• Carbon capture technologies considered• Amine scrubbing• Oxyfuel
Project structure
• Project Leader : Doosan Babcock • Equipment Suppliers : Doosan Babcock, Alstom Power, Air Products• UK Utilities : E.ON UK, Drax Power Ltd, EDF Energy plc, Scottish & Southern Energy,
RWEnpower, ScottishPower• Universities: Imperial College London• Subcontractors: Fluor Ltd
Final Report Issued September 2007
Page 39
Doosan Babcock ….Clean Coal and Carbon Capture
Project StructureDTI 366 project has been undertaken by a project consortium co-ordinated by DoosanBabcock comprising of the following members:• Doosan Babcock (UK)• Canadian Clean Power Coalition (CCPC) (Canada)• Alstom Power (UK)• Air Products (UK)• Imperial College (UK)• Neill & Gunter (Canada)• Mitsubishi Heavy Industries (MHI) (Japan)
UK Government funded Project : DTI - 366 ‘Future CO2 Capture Technology Options for the Canadian Market’
Objectives• Evaluation of the techno-economic feasibility of new-build coal-fired advanced supercritical power plant options utilising Oxyfuel and Amine CO2 capture technologies for both capture and capture retrofit solutions, with conceptual designs evaluated for three different Canadian coals/sites
Final Report issued June 2007
Page 40
Doosan Babcock ….Clean Coal and Carbon Capture
Project Structure• Project Leader : Doosan Babcock • Equipment Suppliers : Doosan Babcock, Air Products• UK Utilities : E.ON UK, RWEnpower• Universities : University of Nottingham, Imperial College London• Other Partners : BP• Sponsored by SP, SSE, Drax, EDF and DONG Energy
UK Government funded Project : DTI - 404 ‘Development of Oxyfuel Combustion as a potential Carbon Capture Technology’ – Oxycoal1
Objectives
• Evaluation of the techno-economic feasibility of oxyfuel combustion as a carbon capture technology , via
• Laboratory and pilot scale (up to 1 MWth) testing running from 2007 to 2009• Full-scale single burner testing (70MWth), commencing 2008 and running to 2010• Development and test of CO2purification and compression system
Work in Progress
Page 41
Purification of Oxyfuel derived CO2
• Oxycoal 1 project – Air Products led Work Package with Imperial College and Doosan Babcock participation
• CO2 compression and purification system – inerts removal and compression to 110 bar
• Design and experimental design complete• Modelling underway• Batch reactor tests at Imperial College starting• NRTF tests (160KW) at Doosan Babcock to follow in Spring 2008
Page 42
Advanced Supercritical Boiler Technology with Oxyfuel
750MW ASC DoosanBabcock boiler – Trimble County EON USA
Burners, typically 50 x 40MW
Air firing:
Coal +O2 +4N2
Air firing:
CO2 +4N2 FGD
Flue
CO2 Recycle line
Oxy firing:
Coal +O2 + xCO2
Oxy firing:
CO2
CO2Clean and compression
FGD
from ASU
The burners are critical to the combustion, emissions and thermal performance of utility boilers
Page 43
BERR HFCCATS Oxycoal2 - Demonstration of Oxycoal combustion system for coal fired power plants
• Convert Doosan Babcock’s full-scale burner test facility tooxyfuel firing
• Oxygen supply• Flue gas recycle system (fans, ducts, cooler, heater, etc.) • Instrumentation
• Design and build full-scale utility Oxycoal burner• Derived from air-firing experience, CFD modelling and
Oxyfuel R+D
• Demonstrate a full-scale utility Oxycoal burner• Flame stability, combustion efficiency, emissions, flame
shape, and heat transfer characteristics as function of %CO2 recycle and excess oxygen
• Start-up, shut down, transition from air to oxyfuel, load change
Page 44
Oxycoal2 - Project delivers
• Key knowledge to potential users :
– the combustion performance of a full-scale (40MWt) oxyfuel coal burner– the operational envelope of the burner with respect to flame stability, turndown,
start-up, shutdown – the transition between air- and oxyfuel-firing – the safe operation of an oxyfuel combustion process
• Important feedback to R+D (internal and external): – materials, corrosion– slagging and fouling under oxyfuel conditions
• Feed-forward into commercial product design and optimisation for use in a full power plant demonstration (either retrofit, new build or both)
• Complements other R+D on Oxyfuel (UK and International)
• Accelerates the implementation of the technology in the UK
• Fits the strategies of Doosan Babcock and it’s partners for Oxyfuel for both New Build and Retrofit
Page 45
Oxycoal2
The substantial contributions of:
• the Prime Sponsor
• Sponsors
• University participants
are acknowledged by Doosan Babcock
Page 46
APGTF 27 January 2008 “An Industry View of CATs R+D” - supporting slides
• The author acknowledges the slides provided by the following organisations which demonstrate both the breadth and depth of industrial R+D in Carbon Abatement Technologies in the UK
– Doosan Babcock– Edinburgh University– E.ON– Jacobs – RWE– ScottishPower
47
Scottish Centre for Carbon Storage
NINE FUNDERS, from along the CCS chain
BP, Shell, EoN, Scottish Power, Scottish and Southern,
BG, Schlumberger, Arup, Scottish Enterprise £ 480 k
University of Edinburgh
Heriot-Watt University
British Geological Survey
24 academic and research staff 15 PhD research 5/yrMSc
New Carbon Management MSc 2008 New CCS MSc 2009
MAJOR PROJECTS
PVT, EOR, Hydrates
Aquifer exploration,evaluation
Scotland Regional Transport and storage site
Natural analogues: UK, USA, Italy
China, India
CPD courses: Geology, Reservoir Engineering
Carbon Capture Centre: (2008)Chemical and Process
Engineering Biochar and pyrolysis
Project funding: £ 10M
www.geos.ed.ac.uk/sccs
48
UK aquifers• “CASSEM” £2.3 M • Aquifer methodology •Two UK settings• Integrated Exploration Combustion, Transport, Geology, Geophysics, Storage volumesReservoir engineering, Risk, Public acceptance
Page 49
APGTF 27 January 2008 “An Industry View of CATs R+D” - supporting slides
• The author acknowledges slides provided by the following organisations which demonstrate both the breadth and depth of industrial R+D in Carbon Abatement Technologies in the UK
– Doosan Babcock– Edinburgh University– E.ON– Jacobs – RWE– ScottishPower
Page 50
E.ON’s CCS Activities - A Brief Overview
GOALCombine experience from our businesses in the UK, Europe and the USA to support fundamental and applied research; undertake pilot scale testing and develop projects suitable for large scale demonstration, given the right economic drivers. DELIVERYMajor funder of Energy Technologies Institute and University ResearchParticipate in UK and international collaborative R&D programmes (BERR, TSB, RFCS, FP5, 6 and 7 ...).Acceleration of technology development through strategic partnerships and project development.TECHNOLOGY CHOICEPursue parallel tracks to accelerate development of higher plant efficiency, post-combustion capture, IGCC and oxyfuel.
Oxyfuel
CASTOR Capture Pilot
Page 51
Selected Project Involvement
Higher EfficiencyDTI/BERR: Modelling Fireside Corrosion of Heat Exchanger Materials in Advanced Energy Systems, COST 536 Materials for Advanced PlantRFCS - COMTES 700 - Demonstration of advanced materials at very high steam conditions
OxyfuelRFCS ASSOCOGS - Conversion of 1MW Test Facility to Oxyfuel CapabilityDTI/BERR Oxycoal UK I and II
Post-Combustion CaptureInvolvement with Collaborative Pilot R&D activities, University of Texas,
ITC Canada, CASTOR, CESARBilateral Development of pilot plants (up to 5MW scale) with Alstom, SiemensEntry in UK Govt. Competition
IGCCProject Development of 400MWe IGCC plant with capture atKillingholmeE t i i l t i F t 275MW P j t
Accelerated Corrosion
Chilled Ammonia pilot - Karlshamn
Killingholme IGCC
Page 52
Kingsnorth Units 5 & 6 ─ Figures
Fuel: Hard - CoalOutput: 2 x 800 MWSteam Conditions: 280 – 300 bar
600°C Superheat
620°C ReheatEfficency: > 45 %Cooling: Direct Cooled Environmental Control:FGD & SCR
CO2 capture readyInvestment: £1 Billion Commissioning: 2012
Page 53
Kingsnorth Units 5 & 6
Page 54
APGTF 27 January 2008 “An Industry View of CATs R+D” - supporting slides
• The author acknowledges slides provided by the following organisations which demonstrate both the breadth and depth of industrial R+D in Carbon Abatement Technologies in the UK
– Doosan Babcock– Edinburgh University– E.ON– Jacobs– RWE– ScottishPower
55
HATFIELD IGCC (WITH COHATFIELD IGCC (WITH CO22 CAPTURE)CAPTURE)
• PRELIMINARY PROCESS DESIGN COMPLETED
• GRID CONNECTION SECURED
• GASIFICATION PACKAGE LICENCE TAKEN OUT WITH SHELL GLOBAL
• FRONT END ENGINEERING DESIGN AWARDED TO JACOBS
• CURRENTLY IN NEGOTIATIONS WITH CCU SUPPLIERS
• OPERATION ON NATURAL GAS PLANNED 2011
• FULL IGCC OPERATION BY 2013
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Integrated Gasification Steam Cycle Integrated Gasification Steam Cycle –– 1200 MW 1200 MW Utility DesignUtility Design
Electricity
Clean Condensate
BFW
Electricity
CO2LP Steam Generator
QuenchGasifier
Coal
Oxygen
Water
24 CES Burners around Circumference
Slag
Fired Expander
Surplus Water
LPIP
HRSG
HP
Retrofit or New Steam
Turbine
Expander From V94.3A Gas
Turbine
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200 200 MWMWthth CES BURNERCES BURNER
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IGSC CYCLE ADVANTAGESIGSC CYCLE ADVANTAGES
• ALL COMMERCIALLY PROVEN EQUIMENT WITH THE EXCEPTION OF THE FIRED EXPANDER
• SUITABLE FOR RETROFITING EXISTING SINGLE CYCLE POWER STATIONS
• ROBUST AND STABLE OPERATION
• NO MAINSTREAM SULPHUR REMOVAL (SO2 CAN BE REMOVED FROM PRODUCT CO2)
• EASY START-UP AND SHUT-DOWN USING NATURAL GAS
• SIGNIFICANT PRODUCTION OF SURPLUS WATER
• BURNER LICENSOR CES PLANNING TO BUILD DEMONSTRATION UNIT AT HATFIELD
Page 59
APGTF 27 January 2008 “An Industry View of CATs R+D” - supporting slides
• The author acknowledges slides provided by the following organisations which demonstrate both the breadth and depth of industrial R+D in Carbon Abatement Technologies in the UK
– Doosan Babcock– Edinburgh University– E.ON– Jacobs – RWE– ScottishPower
60
RWE Group’s CO2 reduction strategy for fossil-fired power generation
Horizon 1 Horizon 2 Horizon 3
Efficiency increases
CO2 capture & storage
Exploitation of existing efficiency potential
(Further) development of new supercritical power plant
Virtually zero-CO2 electricity generation
Horizon 1 (2013)Efficiency upgrade programmes
Steam turbine replacementRenewal of existing coal plant
Efficiency up to 47%Steam cycles up to 620ºC
Horizon 2 (2016)Efficiency target >50%Efficiency measures e.g. lignitedrying in WTA plantHigh temperature materials(700ºC)
Horizon 3 (2020)Low CO2 electricity productionBased on coal with carboncapture and storage
This strategy is consistent with the UK Government’s current position on reduction of carbon emissions
61
Tilbury artist’s impression with CCS
To make space for CCSclose currently operating units, demolish, rebuildmove the coal stockthen build capture plant
PCC optiontower boilersuse aminestechnology advances to reduce sizetwo absorbers plus onedesorber per 800 MWe
Alternative optionsland area for oxyfuel similarlook at alternatives to tower boilers
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CTF amine plant at DidcotSpecification
Treat 33% of 0.5 MW CTF flue gasCarbon dioxide removal using MEA of 1 tonne per day (>85%)SO2 and NOX pre-treatmentMultiple solvent sampling locationsProvision for corrosion and alternate material test sites
Pilot research facility of University of Texas at Austin (RWE npower is an industrial sponsor)
RWE npower
Test programmeMEA reference tests with heat and material balances and parametric studiesAlternative solvents e.g. MDEA, hindered aminesValidation of baseline process economics and assessment of plant flexibility
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Parallel oxyfuel studies
Conversion of CTF to oxyfuelStorage tanks for O2 and CO2 with mixing and safety systemsProvides the capability to investigate hybrid systems with oxygen enhanced post-combustion captureFull flue gas recirculation in future
Oxyfuel programme objectivesRAMO - reliability, availability, maintainability and operability plus understanding of safety issuesEnvironmental issues - NOX/SO2 and CO2 purification requirementsAssess oxyfuel materials choicesMonitor burner developmentsKeep options open for CCS
Page 64
APGTF 27 January 2008 “An Industry View of CATs R+D” - supporting slides
• The author acknowledges slides provided by the following organisations which demonstrate both the breadth and depth of industrial R+D in Carbon Abatement Technologies in the UK
– Doosan Babcock– Edinburgh University– E.ON– Jacobs – RWE– ScottishPower
65
CO2 Aquifer Storage Site Evaluation and
Monitoring (CASSEM)
• The project (£2.3M) aims to develop the techniques to evaluate the potential for saline aquifers to store CO2 and to also monitor and verify storage over the long term:
– Development of methodology to explore low cost aquifer storage for the UK, using sites where some data are already available
– Design of systems for monitoring the behaviour of CO2 stores over time.– Evaluation of two sites near to existing coal-fuelled plant, i.e.
Longannet/Cockenzie area and Ferrybridge.– A generic toolbox for assessing UK aquifer sites.
• Project is being lead by ScottishPower, in collaboration with the University of Edinburgh, Heriot-Watt University, SSE, British Geological Survey, Amec, Marathon Oil, Schlumberger and Tyndall Centre.
• Contributions being made by each of the industry partners are as follows:– ScottishPower - £170k– Scottish & Southern - £120k– Amec - £100k– Schlumberger - £170k– Marathon Oil - £100k
• Supported by TSB Low Carbon and EPSRC
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Enhanced Coal Bed Methane
• This Project (£350K) aims to determine the potential for unmineable coal seams deep under the Forth Basin to store CO2.
• To achieve this, a series of laboratory tests ( lab-scale absorption and diffusion) are being carried out by the University of Strathclyde and Imperial College London on coal samples taken from deep underground local to LongannetPower Station.
• Project being lead by Composite Energy and funded by ScottishPower, British Gas and Royal Bank of Scotland. These organisations are acting as project sponsors.
Page 67
APGTF 27 January 2008 “An Industry View of CATs R+D” - supporting slides
• The author acknowledges slides provided by the following organisations which demonstrate both the breadth and depth of industrial R+D in Carbon Abatement Technologies in the UK
• Doosan Babcock• Edinburgh University• E.ON• Jacobs • RWE• ScottishPower