vattenfall oxyfuel power plant development

Vattenfall Oxyfuel Power Plant DevelopmentE i i f l fi d l t ith O f l t h lEngineering of a coal fired power plant with Oxyfuel technologyCottbus, 2009-09-08Heike Meyer, Detlef Radunsky,Detlef Radunsky, Markus Glausch, Thomas Witter, Daniel Hultqvist

Vattenfall Europe PowerConsult GmbH, Power Plant Engineering Division

08.09.2009 | Vattenfall Oxyfuel Power Plant Development | Vattenfall Europe PowerConsult 1

HeadlinesHeadlinesOverhead basic conditions and requirementsTime schedule Flexibility Efficiency

Phases of the engineering processTechnology concept design Process developmentTechnology concept design Process developmentExecution –Detailled process engineering Approval planning processD t ill d Ci il i iDetailled Civil engineering Detailled General Layout running parallel

On SiteFollow up of ConstructionCommissioning


Commissioning

Overhead basic conditions and requirementsrequirements


Time scheduleTime schedule

Key task:

Gain experience mainly for Design and Commissioning of the wholeSystem including all Operation- and potential Emergency Cases.

Limited time all through the process from feasibility study toCommissioning,

but detailled Engineering even for all “New” Components has to bebut detailled Engineering even for all New Components has to beexecuted.


Overhead ScheduleOverhead Schedule

Concept Technology Construction and ti f

pdevelopments

gydevelopment, Engineering

operation of Demo plant

2003 2005 2007 20112003 2005 2007 2011


Engineering ScheduleEngineering Schedule


FlexibilityFlexibility

What do we want with a research plant??

Simulation of a variety of operational modesDifferent types of power plantsDifferent types of power plantsBurner is top fitted to enable future change of burner

Wid f t t t b i d th h t i t k thWide range of test programms to be carried through trying to keep the same level of flexibility for an Oxyfuel Plant as for a conventional PP


EfficiencyEfficiency

Maximum efficiency out of a schedule and budget point of view

The pilot plant shall be as small as possible but large enough toThe pilot plant shall be as small as possible, but large enough toenable a single step scale up to a Demo Plant!

Effi i f i l P h ll b i ti t dEfficiency of single Processes shall be investigated


Engineering and project execution


GeneralGeneral

In an R&D project, more resources are to be allocated into theconcept development and pre engineering, before the concept isconsidered mature enough to enter the execution phase

Some challenges:

E t i f t h l i l “ i i il”• Entering of technological “virgin soil”• Utilisation of experience gained in lab scale tests• Future wide ranged test operation to be considered – no standard

base load plant!


Technology Concept DesignTechnology Concept Design • A straight line flue gas path with “basically” known power plant

components: boiler, ESP, FGD + FGC.

• In addition FG recirculation under Oxyfuel Conditions to achieve the wished combustion atmosphere.

• CO2 processing unit at the end, ASU immediately at the boiler where the mixing of oxidant takes place. g p

• Start up on air – reach stable conditions - shifting to Oxyfuel modemode

• Flexibility – single burner on top of boiler enabling future shift to hard coal firing space left for SCR installation


hard coal firing, space left for SCR installation.

LayoutLayout


Aerial viewAerial view


Some Challenges – In-leakage of airSome Challenges In leakage of air

Cruicial for the CO2 Process is a concentration of CO2 as high asiblpossible

Dilution with Nitrogen (ambient air) to be avoided

SolutionsTwo ID fans:Maintain the under pressure in the flue gas path, but keep it low andMaintain the under pressure in the flue gas path, but keep it low andavoid points of too high underpressure

CO2 sealing system:CO2 sealing system:Critical points for air in-leakage to be sealed with a „mantle“ of CO2


Some Challenges – Air firing / Oxy firingSome Challenges Air firing / Oxy firing

The plant is started on air and taken to stable conditions

Shifting to Oxy firing, the air is gradually replaced by oxygen andrecirculated flue gasrecirculated flue gas.

Oxygen and recirculated flue gas is mixed in one mixing battery.Additi ll th i ibilit f i j ti di tl tAdditionally, there is a possibility of oxygen injection directly at separate burner stages.


Execution – Detailed EngineeringExecution Detailed Engineering• Entering the execution phase, the design is only “soft frozen”

– Further development and minor changes expected– More late changes expected

• Award of contracts for component suppliers to be “stretched” as far a p pppossible – catch all the late R&D related changes. Challenging act of balance with Long Lead Items

• Be aware of the LLI’s: new technology makes some components extra complex, also for the suppliers

• Successful Engineering of components and systems requires tight and trustful cooperation between all Parties involved more than in a conventional PP Project


conventional PP Project

Civil Engineering, Follow up of ConstructionCivil Engineering, Follow up of ConstructionAll engineering work: Civil-

Process-Permission planning

Following up of constructionFollowing up of construction,handled and coordinated in one direct involved Project Team. Keeping all the engineering within one house (V tt f ll E G ti V tt f ll E P C lt)(Vattenfall Europe Generation - Vattenfall Europe PowerConsult) gives short ways and a “hands on” work process ableto act very fast.

Finally only excellent Cooperation within the Vattenfall Group has assured Success of the Project


assured Success of the Project

CommissioningCommissioning

• Experience transfer from Engineering and R&D into the Commissioning phase necessary!

• Personnel from R&D and Engineering to have leading roles in g g gthe Commissioning team


Approval processApproval process

• “Virgin land” also for authorities and other stake holders – to be considered during engineering planning.

• Documents for approval process to be acquired as early as pp p q ypossible. Minor or also major changes along the way due to further development are likely.

• Continuous dialogue with responsible authorities important – they must be brought on the train early to be given a fair chance;– Engineering Contractor to supply Client with appropriateEngineering Contractor to supply Client with appropriate

documentation to enable mentioned dialogue


Approval process - ChangesApproval process Changes

A Research plant will, naturally, be subjected to reconstructions andchanges.

Since this will mean deviations from originally approved design theSince this will mean deviations from originally approved design, theapproval change process with its appropriate documentation are to be carried through.

The Project Team Oxyfuel research plant of Schwarze Pumpe is e.g about to hand over its 9th change application.


SummarySummary

• New Engineering Challenges have been mastered by all Parties involved

• Total Oxyfuel Process is clearly subject for Improvement in the y y j pDemo Plant Project

• A lot of detail Engineering Experiences have been gained like for• A lot of detail Engineering Experiences have been gained, like for Detail design of the Plant, Operational mode changes, Control of potential emergency cases as well as for „simple“ processes like loading of CO2 on to Trucksloading of CO2 on to Trucks


Thank you for your attention!
