Russian investigation Russian investigation of the COof the CO

2 2 capture and capture and storage. storage.

Implementation of Implementation of CFB for CO2 capture CFB for CO2 capture

and and polygenerationpolygeneration systemssystems

G. A. Ryabov

AllAll--Russian Thermal Engineering Institute (VTI)Russian Thermal Engineering Institute (VTI)

vti@vti.rugeorgy.ryabov@gmail.com

6262--th IEA FB Cth IEA FB Coonversion meetingnversion meetingAugust, 29, 2011August, 29, 2011

Technical University of Vienna, AustriaTechnical University of Vienna, Austria

COCO2 2 emissions of Russia in 1990 emissions of Russia in 1990 ––

2020 period2020 period

Russia Federation is responsible for the 8 % of world GHG emissions and is amongst the world’s five largest emitters. If the current trends continue Russian GHG emissions would totally amount to 2

-

2.4 billion tons of СО2 equivalents in the 2010-2020 periods. Thus, considering overall levels of GHG emissions, Russia is expected to easily remain within the established balance of GHG emissions and even could have a surplus.

Russia federation guaranteed that Kioto

obligations will be fulfil. Cumulative and not realizing votes on CO2

may be about 3000 mln. t.

•

Energy saving (up to 40 % of energy consumption)•

Increasing of power plants efficiency

•

Long term programme of CO2

capture and storage (IGCC, post combustion CO2

capture, chemical looping combustion, oxy-fuel combustion, underground CO2 storage in deep oil fields)

The schedule of Russian The schedule of Russian programmeprogramme

of COof CO22 reductionreduction

2015

г. 2020 г. 2030 г.

Wide implementation of gas turbine this net efficiency > 55 %

Start up new project of coal fired TPP on high supercritical parameters 28-30 МПа, 600-620 оС

Investigations of new technologies and processes of CO2

capture and storage

Start up operation of first units on ultra supercritical parameters 35 МПа, 700-720 оС

Implementation of gas turbine this net efficiency 63-65 %

Utility size IGCC plant

Demo plant of high temperature gas turbine and fuel cells

Demo plant of CO2

capture and storage

Utility size IGCC this H2

production

Utility size plant this high temperature gas turbine and fuel cells, net efficiency (gas) -

70-75 %, (coal) -

60-65 %

Utility size plant of CO2

capture and storage

The main trends of Russian programme in COThe main trends of Russian programme in CO2 2 reductionreduction

Since 2005 Russian programme

in field of capture and storage of CO2

startеd up. In view of some uncertainly in the forecasts about global warming and its consequences, it was decided not to aim at fastest implementation of the today available systems, but to elaborate advanced, economically attractive ideas: IGCC with precombustion

CO2

capture, oxyfuel

and chemical looping combustion (CLC).

The development of IGCC and experimental researches of processes

and equipments for them are caring out in VTI more then 25 years. Last time were consider the opportunities of integration in IGCC the systems, needed for water shift reaction

of CO to CO2

and H2

, the release of CO2

from synthetic gas before of its combustion in GT.Researches on CCS have begun in VTI a few years ago. They are financed by Ministry

of Science and Education. Also, VTI tooke

part in FP6 project “Calcium cycle for efficient and low cost CO2

capture using fluidized bed systems”.

CCS Russia programmeCCS Russia programme

CLC test rig (LCLC test rig (L--valve recirculation) valve recirculation)

The first in Russia laboratory CLC test rig was completed. The aims of investigations are combustion processes, heat realized and hydrodynamics in CLC operated as bubbling or circulated manner.

The table presentsThe table presents main characteristics of VTI CLC test main characteristics of VTI CLC test rig in comparison of Chalmers University installation rig in comparison of Chalmers University installation

(A. (A. LungfeltLungfelt, 2005), 2005)Item Unit VTI

Power (fuel) kWt 10 10 -

20Stoichiometric

ratio - 1,2 –

2,6 2Temperature in reactors

0С 950 850 -

950

Apparent density kg/m3 2500 –

5400 near

4000Particle size mm 0,1 –

0,2 0,15Gas velocity/transport velocity in oxidiser

- 1,2 –

3 2 -

4

Gas velocity/minimal fluidization velocity in reducer

- 5 –

15 5 -

18

Gas velocity//minimal fluidization velocity in valves

- 1,2 –

4 2 -

5

Oxidizer diameter m 0,072 0,068Oxidizer height m 1,85 2,0Reducer diameter m 0,25 0,142Bed height in reducer m 0,13 0,15Reducer height m 0,34 1Full height of the installation

m 2,2 3,0

Oxygen carriersOxygen carriers

The feasibility study of preparing iron and nickel oxide as an oxygen carrier (NiO- Fe2

O3

/AL2

O3

, in size of 0,05 –

0,15 mm) carried out by Karpov

Institute of Physical Chemistry. The metal oxides, used as an oxygen carriers in CLC, should have sufficient rates of reduction and oxidation, at the same time as

it possesses enough

strength to limit particle breakage and attrition. It is also an

advantage if oxides are cheap. As active materials were chosen NiO

and Fe2

O3

and support material – Al2

O3

. The probe (5 and 7 kg) of composites was prepared in order of method investigated by Karpov

Institute of Physical Chemistry.

The fractional composition of the materialsThe fractional composition of the materialsNiO

+ Al2

O3 NiO

+ Fe2

O3

+ Al2

O3

The photo of the compositesThe photo of the composites

Common algorithm of the CLC unit calculation Common algorithm of the CLC unit calculation

Xoк

– preset of the conversion in oxidizer; Хок1 – current conversion in oxidizer; ∆

xoк

– carrier conversion calculation accuracy in oxidizer; ∆X - conversion difference; γвос

– fuel conversion in reducer; mтв

– quantity of materials carry away from oxidizer; Сок

– oxygen carrier capacity; m0 - necessary oxygen quantity for fuel combustion; Твос

– preset temperature in reducer; Т1 – current temperature in reducer; ∆т

- reducer temperature calculation accuracy; ∆X1- conversion difference updated valueу; ∆

- conversion difference calculation accuracy

Demo plant schemeDemo plant schemeVTI carried out the capital costs evaluation of the plant construction of 10 and about of 100MW

(thermal).

Industrial plant schemeIndustrial plant scheme

1 – compressor, 2 – air preheater, 3 – gas preheater, 4 – reducer, 5 – oxidizer, 6 – gas turbine, 7 – economizer II, 8 – economizer I, 9 – heat exchanger, 10 – feeding pump, 11 – evaporator + superheater, 12 – steam turbine, 13 – condenser, 14 – circulating pump,

15 – condensing pump, 16 – condenser, 17 – deaerator

Capital cost estimationsCapital cost estimations

• The CLC plants differ from traditional facilities with boiler units or combustion chambers and heat-recovery boilers. They include additionally the metal oxide reducer (fuel reactor) and reactant recirculation system. In fact, they are quite similar to the units with CFB boilers, as long as heat, in such installations, is withdrawn in the oxidizer, which operates with CFB.

• The convection pass is divided into two flows of flue gases. This fact does not change the construction substantially, but increases the fencing

and construction

expenditures. The construction includes heat exchanger for СО2 flow dehumidification, where the low potential heat of water evaporation is used (for heat supply or as heat exchanger for warming up the condensate –

LP Water

Heater).

• Thus, it is needed to evaluate the metal capacity of the whole installation and especially of its auxiliary details, and after that, on the basis of the similar projects, to determine the price of the whole work

price.

Capital cost and COCapital cost and CO22 capture costcapture cost

• Total capital costs of the installation with power output of 10 MW is about 150 million RUR. This installation produces about 510 kg/h of СО2

. Auxiliary capital expenditures for separation of СО2

do not exceed 50 million RUR.

• Capital expenditures for power unit with thermal output of 114 MW and combined electricity net generation of 36.4 MW come up to 2010 million RUR. Specific costs for generation of 1 kW of electricity are at the level of 2200 –

2600 USD. Such

expenditures for the similar power units with combined cycle plants and without СО2

separation come up to the level of 1500 –

1700 USD, thereby, the increase of capital

expenditures reaches about 30 –

40 %.

• This plant generates 5.8 tons/h СО2

. This is equal to 1.4 million tons for the whole operation period. Hereby, specific capital costs for СО2

capturing are at 620 RUR or 17 Euro per ton of СО2

. Taking into account the possibility of costs of the huge power

units with optimized parameters decrease, the specific expenses could be decreased by 12 –

15 Euro per ton of СО2

. These values are one of the best exponents among the all СО2

capturing technologies.

The evaluations of capturing, transportation The evaluations of capturing, transportation and disposal costs of ton of and disposal costs of ton of СОСО22

Plants СО2

capturing costs, Euro/ton

СО2 transportation costs, Euro/ton

СО2

disposal costs, Euro/ton

Total costs, Euro/ton

Pilot plant 100 MW

20 5 -

7 3 -5 28 -

32

Industrial plant 12 -

15 3 -

5 0,7 -

3 15,7 -

23

It is possible to expect 20 –

30 % investment growth, 30 -

40 % electricity shop price growth and 4 –

8 % decrease of efficiency for industrial plants with CLC gas combustion. It

is also needed to take into account the expenditures for the whole plant appreciation, however, their values are going to be lower, than with application of another CO2 capturing methods. This fact allows optimistically sight to the development of CLC plants. It is considered in (T. Mattisson, 2004, M. Johansson, 2004), due to the application of CLC fuel combustion, it would be possible to achieve the specific costs at a level of 10 Euro per 1 ton of СО2

. This value is twice less, than for other ways of СО2 separation.

The designed scheme of The designed scheme of oxyfueloxyfuel test rigtest rig

VTI start up investigation in field of oxyfuel

combustion.

The scheme of laboratory test rig shows in figure. The test rig is under construction now.

COCO22 storage from Russian TPP storage from Russian TPP

An inventory of the candidate sources for CO2

removal in Russian Thermal Power Plants (TPP) was determined.

As candidate sources could be characterized the sources which have large emission volumes, high CO2

concentration, proximity to a suitable storage site so the implementation of CO2

sequestration will be viable.

For example, the main CO2

generation regions are Moscow region (10.2 % CO2 emission from TPP), Ural region (5/8 %); the largest emission of

CO2

has Surgutskay

(3.2 %), Permskay

(1,4 %), Novocherkasskay

(1.2 %) TPP.

Underground storageUnderground storage

Regional storage opportunities was investigated also in cooperation with JSK

“PODZEMGASPROM”

and Gubkin

State University of oil and gas.

Inventory of the geological formations such as depleted oil and gas reservoirs, active oil and gas reservoirs, deep saline aquifers (sub-terranean

or sub-seabed) that

can be used as CO2

storage sites and their geological and hydrogeological characterization was studied.

The main possibility of CO2

storage of large Russian TPP is onshore storage. We began a preliminary estimation for detecting the major factors affected the storage cost.

Russia has more than 50 years experience of underground storage with amount of 114 billions m3

of natural gas. There are more than 20 underground gas storage (16 in used gas fields) in Russia.

Other tasks of our investigations are:

•

monitoring and verification issues once CO2

is geologically stored;

•

determining potential risks to humans and environment and implementation of remediation methods to stop or control leakage of CO2

;

•

detailed assessment of technical issues such as volume, CO2

concentration, flow rate, integrity of storage sites;

•

proximity of the source and storage site, transportation routes;

•

existing infrastructure, injection rates etc as well as economic, safety and environmental issues.

Our investigation shows that CO2

injection in deep oil or difficult to extraction oil fields is very attractive method for Russian conditions.

Multi-generation systems based on pyrolysis

of coal include many of configurations. Two high-capacity units of this type (UTT –

3000, 139 tons of

shale per hour each) were erected at Estonian thermal power plants (TPP). And they with still show good performance.

VTI has an agreement on scientific cooperation with the Institute for Thermal Power Engineering, Zhejiang University in this field. In studies

carried out by

Zhejiang University data were received from their tests on a 1 MW pilot plant. Our investigation was financed by the Russian Ministry of Science and Education as a part of a China –

Russia scientific cooperation project.

Another aim of the investigation of the interconnected FB and CFB reactors is the chemical looping process hydrodynamics (double metal oxides or carbonate oxides reactors) and the three reactor chemical looping gasification processes.

DCFB concept for DCFB concept for polygenerationpolygeneration systems and CLCsystems and CLC

Scheme VTI cold model of interconnected reactors General arrangement of Cold model

1

-

furnace model; 2 -

cyclone; 3

-

riser; 4

-

pneumatic valve; 5

-

heat exchanger

model

1 –

transportation reactor; 2 –

FB reactor; 3 –

CFB

reactor

TEST RIGSTEST RIGS

Our studies were basically directed to calculate the circulating

mass flow rate in the external circuit (Gr), as it is the critical operational parameter for the interconnected reactors. The solid flow rate increases with gas velocity in the CFB unit and unit inventory.

Typical solid circulation rate as function of velocity and

RESULTS. BED MATERIAL RECIRCULATIONRESULTS. BED MATERIAL RECIRCULATION

Pressure profile in the Cold modelSand, 0, 21 mm, gas velocity -

4 m/s,

particle flow rate –

1kg/s

Typical pressure profile

in the cold model of interconnected reactors

RESULTS. PRESSURE PROFILERESULTS. PRESSURE PROFILE

The 

studies 

on 

circulation 

and 

the 

return 

systems 

of 

interconnected 

reactors  found:

•pressure 

profile 

and 

vertical 

solids 

concentrations 

in 

interconnected 

FB 

and 

CFB  reactors are typical for corresponding reactors of this type, and depended on gas  velocity and bed level (bed inventory); 

•pressure 

change 

at 

corresponding 

points 

depend 

on 

the 

fluidization 

and 

the  design features of unit`s

structure and return system; 

•solids 

flow 

rate 

in 

interconnected 

FB 

and 

CFB 

reactors 

depends 

on 

gas 

velocity  and 

solids 

inventory 

in 

CFB 

reactor, 

on 

condition 

of 

high‐efficient 

separation 

and 

sufficient capacity of return system with fixed diameter of particles;

•bed 

return 

system 

(standpipe 

and 

pneumatic 

valve) 

must 

have 

reserve 

capacity  and 

regulation 

ability 

by 

air 

injection 

to 

standpipe 

and 

upflow

part 

of 

the 

valve. 

Otherwise 

the 

recirculation 

solids 

flow 

rate 

is 

determined 

by 

the 

operational  mode of the valve.

Financial support of this work by the Federal Agency of Science and Innovation is gratefully acknowledged.

CONCLUSIONS (cold models DCFB)CONCLUSIONS (cold models DCFB)

CONCLUSIONSCONCLUSIONS

• Russian federation is interested in progress of CO2 capture and storage investigations. The main trends of Russian programme in CO2 reduction are:

o energy saving (up to 40 % of energy consumption);o increasing of power plants efficiency;o long term programme of CO2 capture and storage (IGCC, post combustion CO2 capture,

chemical looping combustion, oxy-fuel combustion, underground CO2 storage in deep oil fields).

• Since 2005 Russian program in field of capture and storage of CO2 startеd up. In view of some uncertainly in the forecasts about global warming and its consequences, it was decided not to aim at fastest implementation of the today available systems, but to elaborate advanced, economically attractive ideas: IGCC with precombustion CO2 capture, oxyfuel and chemical looping combustion (CLC).

• Chemical looping combustion (CLC) is a promising technique for the separation CO2 with small losses in energy. The laboratory CLC test rig (10 – 20 kW) was completed for natural gas and singas firing.

• Other task of our investigation is to determine optimal storage methods for Russian conditions.

Thank you for attention!Thank you for attention!Thank you for attention!