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