Transcript Doosan Power Systems

Doosan Power Systems
Post Combustion Carbon Capture
Technology Development
Dr Saravanan Swaminathan
Nov 3, 2012
International Training Programme on Clean Coal Technologies and Carbon Capture
and Storage: Learning from the European CCT/CCS Experiences
Outline

Introduction

Background - CO2 emissions and electricity generation

CO2 reduction strategies

CO2 capture technologies

Development of PCC technology at DPS

PCC Challenges-Technical

PCC Challenges-Non technical

Concluding remarks

Q&A
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Products and Services
Doosan Heavy Industries
Doosan Power Systems
CEO JM Aubertin
Boiler & Air
Pollution Control
Doosan Babcock
Doosan Lentjes
Turbogenerators
Turnover 2011: £800m
Employees:
5,800
Plant
Skoda Power
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Service
Doosan Babcock
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Outline

Introduction

Background - CO2 emissions and electricity generation

CO2 reduction strategies

CO2 capture technologies

Development of PCC technology at DPS

PCC Challenges-Technical

PCC Challenges-Non technical

Concluding remarks

Q&A
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Background - CO2 Emissions, Global Primary Energy Demand
Use of coal will continue to grow and is necessary to meet the energy needs of developing countries and
to secure supplies of developed countries
200 years of proven reserves
Coal is sourced from many stable countries around the world and is key to security of supplies
(Source: IEA – World Energy Outlook 2011)
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Indian Power Sector Outlook Plan
Installed Capacity in MWe
REGION
THERMAL
Nuclear
R.E.S.@
(Renewable)
(MNRE)
TOTAL
COAL
GAS
DSL
TOTAL
Northern
29,923.50
4,671.26
12.99
34,607.75
1,620.00
15,423.75
4,437.65
56,089.15
Western
42,479.50
8,254.81
17.48
50,751.79
1,840.00
7,447.50
8,146.69
68,185.98
Southern
23,032.50
4,962.78
939.32
28,934.60
1,320.00
11,338.03
11,769.32
53,361.95
Eastern
22,337.88
190.00
17.20
22,545.08
0.00
3,882.12
410.71
26,837.91
N. Eastern
60.00
824.20
142.74
1,026.94
0.00
1,200.00
228.00
2,454.94
Islands
0.00
0.00
70.02
70.02
0.00
0.00
6.10
76.12
All India
117,833.38
18,903.05
1,199.75
137,936.18
4,780.00
39,291.40
24,998.46
207,006.04
Capacity Addition vis a vis GDP Growth
8% GDP growth
Capacity Addition Required (GW)
HYDRO
9% GDP growth
300
275
250
197
200
151
203
150
150
 Anticipated capacity addition at completion of 11th
plan – 71,644MWe
 Proposed capacity addition during 12th plan is
75,785MWe in line with 9% GDP growth
 Target capacity addition by 2030: 550 – 750 GW
from present Level of 207 GW
119
104
100
67
50
22
76
86
24
0
10th plan
'02-'07
11th plan
'07-'12
12th plan
'12-'17
13th plan
'17-'22
14th plan
'22-'27
15th plan
'27-'32
Source:
“All India region-wise generating installed capacity (mw) of power
utilities”, Central Electricity Authority (www.cea.gov.in) as of 31/08/2012
“Report of the working group on power for Twelfth Plan (2012-17)”,
Ministry of Power, Government of India, New Delhi, Jan 2012
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Growth of Power Generation in India (2011-2012)
Energy Generation (BU)
 Total annual power generation growth of
8.05% – highest during the decade.
 Remarkable growth in nuclear generation
of 22.86% – improved availability of
nuclear fuel to the nuclear plants.
 Improved hydro power generation of
14.15 % – good monsoon
 Total thermal generation growth of 6.53
% – growth rate of 9.20 % over last year
 Growth of thermal generation was mainly
restricted by:




coal shortages
receipt of poor quality/ wet coal
low schedule from beneficiaries
increased hydro generation
 increased nuclear generation
Note:
Generation excludes generation from plants up to 25 MW Capacity
1 BU = 1 Billion Units or 1 Billion kWh
Source:
“Operation performance of generating stations in the country during the
year 2011-12”, Central Electricity Authority, New Delhi, April 2012
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Background - CO2 Emissions
Fossil fuel power generation needs to be much cleaner to meet CO2 targets
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IEA 2011 Energy World Energy Outlook
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Outline

Introduction

Background - CO2 emissions and electricity generation

CO2 reduction strategies

CO2 capture technologies

Development of PCC technology at DPS

PCC Challenges-Technical

PCC Challenges-Non technical

Concluding remarks

Q&A
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CO2 Reduction Strategies
Two track approach
– Power plant efficiency
improvement
– Carbon dioxide Capture and
Storage (CCS)
CO2 Reduction
Track 2 :
Carbon Capture
& Storage (CCS)
- 95%
Approaches are fully complementary
Power plant efficiency improvement is
available now using supercritical
boiler/turbine technology
Track 1 :
Increased Efficiency,
Biomass co-firing, etc.
- 35%
-25%
CO2 Capture is under development
Baseline
CCS can be retrofitted to PF fired plant
Both approaches are necessary on the route
towards zero emissions
Possible
Now
2010
Medium
term
2020
Long
term
Time
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Abatement of CO2 by Efficiency Improvement of Pulverised Coal Plant
E.On 50+ project at
Wilhelmshaven
suspended
Best Available
Advanced
Supercritical
Technology being
supplied now
Plant efficiency
% NCV
55
50
45
Meri Pori
Hemweg
40
UK
38%
New Chinese
Orders
Chinese fleet
50 – 55%
(-29%)
Target
AD700
Doosan Power
Systems
ASC
Increasing
Efficiency
Lower CO2
emissions
46%
(-23%)
Supercritical
Boilers
42%
38%
fleet
35
Sub Critical
Boilers
32%
30
Older
Plants
Year
1960
1980
2000
2020
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Outline

Introduction

Background - CO2 emissions and electricity generation

CO2 reduction strategies

CO2 capture technologies

Development of PCC technology at DPS

PCC Challenges-Technical

PCC Challenges-Non technical

Concluding remarks

Q&A
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CO2 Capture Technologies
There are three main pathways to the capture of CO2 from coal-fired power generation
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CO2 Capture Options for Near Zero Emissions Coal Power Plant
Three options for commercialisation by 2020
Numerous studies have shown that these technologies are similar in terms of process efficiency achieved and
cost of electricity.
No clear winner, but Post Combustion Capture and/or Oxyfuel will need to be retrofitted to plants currently being
built around the world
All three capture technologies have been proven in pilot plants, but need scale-up and demonstration on full-size
plants
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Post Combustion Carbon Capture
Leading Edge Technology
Post Combustion Capture Technology – Solvent Scrubbing
 Solvent Scrubbing, also known as “sweetening” or acid gas removal, was originally
developed to remove H2S and CO2 from methane in natural gas processing plants and
other industries.
 Driven by the concerns of the impact of rising CO2 emissions from fixed sources, there has
been significant interest in the development of CO2 capture from Pulverised Coal Flue Gas.
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Post Combustion Capture Technology – Solvent Scrubbing (Amine)
R → Alkyl group
Amine Scrubbing:
N2
CO2
Offgas
CO2 to
Compression &
Dehydration
~45°C
Condenser
Reflux
Vessel
Demister
Make-up
Solvent
Water
Wash
~40°C
~120°C
Solvent
Cooling
REGENERATION
COLUMN
ABSORPTION
COLUMN
Lean/Rich
Exchanger
Flue Gas
~125°C
mixed
N2 / CO2
Blower Cooler
Reboiler
~50°C
LP Steam
LP Condensate
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PCC Technology: Summary
Advantages

Uses existing power plant technology

Can be retrofitted to existing plant or installed on
new build

Demonstrated at small-scale in other industry
sectors

Can be designed to fire a wide range of fuels

Robust to changes in fuel quality
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Outline

Introduction

Background - CO2 emissions and electricity generation

CO2 reduction strategies

CO2 capture technologies

Development of PCC technology at DPS

PCC Challenges-Technical

PCC Challenges-Non technical

Concluding remarks

Q&A
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Doosan Carbon Capture Technologies
25 years of experience in carbon capture
Oxyfuel
40MWt
OxyCoalTM
Burner at
Doosan
CCTF
ERTF
Oxyfuel
Conversion
160KWt at
Doosan ERTF
1992
1996
2008
2009
Post Combustion Capture (PCC)
Boundary
Dam PCC
donated to
University for
research
University of
Regina
development
of PCC
1987
2000
UoR’s ITC
completed
2003
Doosan invest
into HTC
Purenergy
taking 15% &
exclusive
rights to PCC
technology
2008
Forecast
to be fully
commercialised
by 2020
2012/14
2020
 ERTF
converted to
PCC Test
Facility
 Antelope
Valley FEED
& Ferrybridge
Demo
2009/10
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Full Power
Plant Demo
Expected
100-250MW
Large Scale
Power Plant
with CCS
2012/16
Commercial
CCS Market
2016/2017
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Technology Leaders
Advanced solvent, advanced process and optimised integration provide
maximum customer value
 Global licensee of HTC Purenergy technology developed in conjunction with
the University of Regina (UoR)
– Over 20 years CCS experience
– Laboratories for development of solvent, material and process.
 Advanced designer solvent (RS family) providing:
– High efficiency system
– Low degradation rates
– Tailored to meet operating and flue gas conditions
 Patents in place for high efficiency advanced solvent and steam-side plant
integration
 Scale-up validated against actual operating data from several plants as large as
800 t/day (with +/- 3% accuracy)
 Scale-up only achievable through a complete and thorough understanding of:
– All physical and chemical properties (kinetics, diffusivity, etc.)
– Operating conditions
– Proper application of numerical modeling tools
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Optimised process
design (TKO™)
 Heat integration
 Reduction in steam
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Solvent Supply and Management
Most economic and flexible approach, but with infrastructure to support for the long-term
 Ability to optimise process to
match solvent specification
in-house ensures complete
system optimisation and
compatibility
 On-line monitoring and solvent
management
 Huntsman is our global strategic
partner and can provide long-term
aftermarket supply of optimised
solvents
 No mandatory long-term solvent
tie-in, Client has flexibility to meet
their own needs or go to market
Screen Shot of MCC Network control system
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Screen shot: online
plant monitoring
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Test Facilities and Demonstration Projects
Performance demonstrated on wide range of fuels and different plant configurations
Industry scale
20+ years of demo
Facilities and technology create a winning edge
ITC, 1 t/day
 Opened in 2003
 Flue gas from natural gas
combustion
 Includes equipment to
study corrosion, material
selection, solvent
degradation and kinetics
Boundary Dam, 4 t/day
 Commissioned in 1987
 Dedicated to post-combustion
capture since 2000
 Captures CO2 from flue gas
emitted from lignite-fired boiler
 Upgraded in 2007 to evaluate
advanced process with RS-2
ERTF, 1 t/day
 Commissioned in 2010
 Ability to test wide range
of coals and other fuels
 High degree of flexibility
and accuracy to test
wide range of solvents
and other modifications
Ferrybridge, 100 t/day
 Largest post carbon capture
demonstration plant in the UK
 Long-term testing and
validation of process and
solvent performance
 Evaluate transient conditions
and process control
 Extensive monitoring planned
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Emissions Reduction Test Facility
Emissions Reduction Test Facility (ERTF) for PCC Solvent Scrubbing – A 160kWt combustion
test facility
 Capable of firing a very wide range of coals
or natural gas.
 Originally constructed to test primary NOx
reduction measures, subsequently adapted
and upgraded to test secondary NOx
reduction measures.
 Upgraded for oxyfuel operation as part of
the OxyCoal-UK: Phase 1 project – a
collaborative project sponsored by the UK
Government with industrial and academic
participation.
 Post-Combustion CO2 Capture and Flue
Gas Desulphurisation (FGD) installation
completed in 2010.
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Emissions Reduction Test Facility
PCC Solvent Scrubbing Process - Equipment
Absorber column
 10” NB (DN250)
 4-off packed bed sections (with multiple
solvent feed inlet points)
Stripper column
 8” NB (DN200)
 4-off packed bed sections
Water Wash Column
 8” NB (DN200)
 1-off packed bed section
Heat exchangers
 Gasketed (plate and frame)
Pumps
 Duties met by triplex diaphragm pumps
for high head – low flow duties
 Variable speed drives for efficiency and
ease of control
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Emission Reduction Test Facility PCC Plant - Coal Flue Gas Testing
Competitive CO2 capture efficiency and regeneration performance demonstrated on coal flue gas
100
1.6
90
1.4
1.2
70
1
60
50
0.8
40
0.6
30
0.4
Steam Duty (kg/kg)
80
Capture Rate (%)
RS-2TM solvent
< 1.2kg steam/ 1 kg CO2
captured, which equates
to less than 2.5 GJ/t CO2
captured
20
0.2
10
0
0
:5
04
0
0
:0
05
0
:1
05
0
:2
05
0
:3
05
0
:4
05
0
:5
05
Capture Rate (%)
Steam Duty (kg/kg)
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Emissions Reduction Test Facility PCC Plant - Simulated CCGT Flue Gas Testing
CO2 capture efficiency and regeneration performance demonstrated on simulated CCGT flue gas
100
2
90
1.8
80
1.6
70
1.4
60
1.2
50
1
40
0.8
30
0.6
20
0.4
10
0.2
:3
0
03
:2
0
03
:1
0
03
:0
0
03
:5
0
02
:4
0
02
:3
0
02
:2
0
02
:1
0
0
02
02
:0
0
0
Steam Duty (kg/kg)
Capture Rate (%)
RS-2TM solvent
< 1.4kg steam/ 1 kg CO2
captured, which equates
to less than 3.0 GJ/t CO2
captured
Capture Rate (%)
Steam Duty (kg/kg)
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Emissions Reduction Test Facility PCC Plant
Next steps:
 Carry out off-gas emissions measurement
and control trials
 Continue to optimise the process
 Reduce solvent regeneration energy
consumption
 Support for commercial bids:
– Capturing carbon dioxide from coal and natural
gas flue gas – diverse product offering
– Test materials and techniques to reduce capital
and operational expenditure on larger scale
plant
– Demonstrate plant functionality and flexibility to
clients
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CCPilot100+ Ferrybridge
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Ferrybridge CCPilot100+
 PCC demonstration plant using DPS’
technology
 100 t/day slip stream from a 500MWe unit
on SSE’s Ferrybridge Power Station,
making it the largest PCC demonstration in
the UK
 Two year test programme, fast-tracked
build, operating March 2012
 Funded by all the project partners
 Lessons learned to be incorporated into
future designs
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CCPilot100+ Project Location
Pictures courtesy Google Earth
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Complementary R&D Projects
1. Techno-Economic Optimisation
1. Amine Degradation Product Modelling
A steady-state HYSYS model (calibrated with real
data) combined with an economic model to be used
for design and cost optimisation.
2. Analysing Degraded solvent
Adapt an existing kinetic chemical reaction model
for atmospheric amine degradation product
emissions and calibrate it with actual plant
measurements to predict solvent degradation
products.
Use of various analytical techniques (GC-MS, LCMS, HPLC-RID) to characterise degraded solvent
and identify preferred techniques for analysis
1. Amine Waste Water Treatment
1. COMCAT
Build and site test a novel monitoring apparatus that
utilises a unique combination of well known
instruments to monitor solvent loading in real time
Characterisation of waste water streams from
CCPilot100+ and identification of alternative waste
water treatment methodologies
2. TRACTION
Use a dynamic model to investigate operation at
transient loads to suit market demand for flexibility.
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Wider Academic Involvement
 One-Month Secondments
( 24 Students )
– From Edinburgh, Leeds, Nottingham, Sheffield and Imperial College
– Aimed at MSc / PhD / Eng Docs who will complete an additional on-site project to further their
understanding of CCS and the as-built CCPilot100+ plant
 Industrial Awareness Module
( ~40 Students )
– From Edinburgh, Leeds, Nottingham and Sheffield
– 1 week split between Renfrew and Ferrybridge focused on process safety and deployment of
CCS.
 1 Day Visits
( >400 students, ~14 Visits)
– From Edinburgh, Leeds, Nottingham, Sheffield, Imperial College, York, Durham, Lancaster,
Manchester and Newcastle
– Lectures on the power station and electricity generation and the PCC process, its
commercialisation and economic drivers
 5 day short course on CCS via the Continuing Professional Development (CPD) Unit at
University of Leeds and as a 10-credit MSc course at University of Strathclyde
 Other industrial and research organizations are being invited (and requests being
considered) to visit the CCPilot100+ during operation.
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CCPilot100+ Project Execution
Simulation & modelling
Column fabrication & delivery
P&IDs & engineering
Construction
3D modelling
Testing program
Current stage
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CCPilot100+ Test Programme Key Parameters









CO2 capture rate and product compositions
Steam consumption at re-boiler
Amine and degradation product atmospheric emissions
Absorber column efficiency
– Column CO2 composition and temperature profiling
Power and water consumption under differing operating regimes
Use different process configurations to optimise thermal
integration
Solvent testing and formulation for efficiency and durability
Performance of construction materials including polymers
Comparison of performance with other pilot plant for scale-up
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Process Measurement & Control - CCPilot100+
Process conditions and gas analysis
 Gas and solvent flow rates, temperatures and pressures
 On-Line Gas Analysis
– FTIR – Extractive multi-point heated sampling system
– Ammonia Tuneable Diode Laser – Cross-duct, nonextractive
– ppm Oxygen Micro-Fuel Cell – Extractive cold sampling
system
 Manual Gas Analysis
– FGD Polisher Performance
– PCC – Based Emissions
– Solvent Carryover
– Degradation Products
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Process Measurement & Control - CCPilot100+
Solvent analysis – Major Parameters
 On-Line Solvent Analysis
– Solvent Concentration – On-Line Titration
– CO2 Loading – On-Line Titration
 Off-Line Solvent Analysis
– Solvent Composition – Ion Chromatography
– Solvent Concentration - Titration
– CO2 Loading – Titration and Gas/Liquid
Displacement
 PCC Chemistry Lab in Renfrew – Lab-Based
Degradation Trials
– Jacketed reactor used to run long-term
degradation trials simulating both coal and gas
firing via control of CO2 and O2
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CCPilot100+ Current Status
 Commissioned to run on MEA
 Plant handed over to SSE Operations Group on 22nd
March 2012
 1000 hours of running time recorded to date on 30%
MEA with water. Plant optimisation on-going.
 UK Environment Agency and SSE interface
– positive dialogue
– supportive of emissions measurement & control to
develop standards during the test programme
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CCPilot100+ MEA Test Results
MEA preliminary results show good agreement with publically available test data
– typical quoted values of 3.6 to 3.9 GJ/t CO2
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CCPilot100+ Operating Experience
 Good working relationships developed with
–
–
–
–
–
SSE Ferrybridge Station and CCPilot100+ staff
Environment Agency
Main process plant item suppliers
C&I equipment suppliers
Analytical instrument suppliers
 Commissioning
– Development of analytical techniques
– On-line solvent analysis instrumentation
 Testing
– Selection of manual gas analysis contractor
– Liaison with Environment Agency
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Cost Reduction - PCC Materials
 Installation Cost (i.e. raw material cost + fabrication cost)
– must be competitive in relation to ‘standard’ construction materials (e.g. carbon steel, concrete)
– must be site-friendly and not too labour-intensive
 Operating Cost (i.e. degree of process interaction)
– minimize material losses due to corrosion/degradation (repair outages)
– minimize contamination of PCC solvent (solvent make-up reagent and/or outages)
– minimize fouling of surface (cleaning outages)
 Track Record (i.e. perceived level of commercial risk)
– preferably in PCC or in amine-based natural gas purification
– composite track record from several related industries may be acceptable
– demonstration may be required (difficult due to the risk to the project)
In theory, cost reduction is the single biggest driver
In practice, track record has historically dominated pilot-stage materials selection
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PCC materials testing
Materials Selected
 Stainless steels
 Duplex alloys
 Solid polymers
 Structured polymer
composites
 Polymer-based coatings
 All on test at CCPilot100+ in
the harshest survivable
environments on the plant
 Full suite of
construction/application
procedures
 Further industrial-scale
trialling
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2nd Generation PCC Technologies
Technology
Solid sorbents
Brief Description
Potential Benefits vs 1st Gen
Perceived Cons
Monolithic structures using low temperature
swing adsorbents
< CAPEX/OPEX, and < energy penalty
Potentially limited to gas-fired plants due to
poisoning by contaminants in coal flue gas
High temperature swing adsorbents – Calcium
looping
< CAPEX and < energy penalty
High attrition, poisoning of the sorbent, > OPEX
Electrical swing adsorption
< CAPEX
> OPEX, > Energy penalty, unclear regeneration
process
Ionic liquids (IL) (incl. amino acid salt
solutions)
Non-toxic solvent, low solvent
carryover due to low vapour pressure
and environmentally safe
Expensive, > OPEX due to multi-step regeneration,
And scale-up difficulties
Amine-based solvents
Well developed technology and many
demonstrations underway
> CAPEX/OPEX, environmental concerns, limit on
minimizing energy penalty
Aminosiloxanes-based solvents
Low solvent carryover due to low
vapor pressure
Non-aqueous solvent – problems with condensed
moisture
Enzyme-promoted K2CO3
solvents
Non-toxic solvent, Low temperature
regeneration
Low temperature stripping (ultrasonic stripping
being developed)
Hollow fibre membranes
Nanocomposite/ Nanostructured polymeric
membranes
No moving parts,
no reagent usage and
low footprint (for Metal organic
frameworks)
Membrane integrity, > OPEX,
mechanical stability through use of support
structures, particulate blocking/poisoning
Chill flue gas to condense and separate CO2
< CAPEX
Higher parasitic power, > OPEX
Immobilized amines
Immobilized amines – looping technology
Advanced Liquid Solvents
Membranes
Cryogenics
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Monolithic Structures Using Low Temperature Swing Solid Sorbents
Project Partners: InvenTyS, Howden, Rolls Royce, MAST Carbon and Doosan Power Systems
Objectives:
Development of InvenTyS’ VeloxoTherm™ technology (based on a Temperature Swing adsorption
process) using a proprietary structured sorbent in a rotating frame (similar to regenerative air heaters
used in power plants) for NGCC PCC applications
Potential Benefits: A proven technology with a demonstrated reliability and simplicity
Environmental: Low levels of waste water generated
OPEX : (i) Lower regeneration energy (< 50% of the conventional amine process) and (ii) High sorbent
lifecycle (reducing replenishment costs)
CAPEX: (i) Low footprint due to integrated design of the adsorber and stripper into a Rotary Adsorption
Machine (RAM)
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Enzyme Activated K2CO3 Process with Ultrasonic Regeneration
Project Partners: Novozymes North America, Pacific Northwest National Laboratory,
University of Kentucky and Doosan Power Systems
Objectives:
An integrated bench-scale PCC system that combines the attributes of a bio-renewable enzyme
catalyst with low-enthalpy absorption solvent and novel ultrasonically-enhanced regeneration system
Potential Benefits:
Environmental: Benign solvent leads to low emissions and degradation products
OPEX : Low, (i) Enzyme is not susceptible to degradation by other flue gas components such as SO 2,
O2 etc and (ii) Lower regeneration energy (< 50% of the conventional amine process)
CAPEX : Low, (i) Lower operating temperatures and relatively non-corrosive solvent allows the use of
less expensive materials (ii) No FGD polisher needed due to enzyme’s resistance to SOx in the flue
gas, however a suitable HSS removal methodology will be adopted
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Next Steps
 Pursue large demonstration projects
 CCPilot100+
– Run RS-2™ testing – Q4 2012
– Advanced solvent testing - through 2013
– Advanced PCC materials testing through
2012 and 2013
– On-line liquid & gas analyses throughout
test programme
 ERTF
– Off-gas emissions measurement and
control
– Continued process optimisation
– Support commercial bids
 Solvent Development
– Performance assessment
– Degradation characterisation
 Feasibility studies & pilot-plant scale
demonstration of 2nd generation PCC
technologies
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Front End Engineering Design (FEED) Studies
NGCC
Coal-Fired Boilers
Application of the process technology to real projects
Basin Electric, AVS, 3,000 t/day
 CO2 from the adjacent
Dakota Gasification
Company (~3.0 MTPY) is
sold for enhanced oil
recovery
 FEED completed November
2010
Statoil Karsto, 3,000 t/day
 Flue gas type: NGCC
exhaust
 Configuration: two
absorbers and one
stripper
 FEED completed 2009
ENEL, Porto Tolle, 4,200 t/day
 Flue gas type: coal-fired flue gas
 Four oil-fired gas boilers being
converted to bituminous coalfiring
 Competing for NER 300 funding
 FEED completed Q2 2011
SSE, Peterhead, 3,300 t/day
 Flue gas type: NGCC exhaust
 Full flue gas processing of a
single 230MWe gas turbine
 Ultra low pressure drop
design
 Feasibility study completed
2011
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Doosan Power Systems Post Combustion Roadmap
Commercialisation
full-scale plant
10,000 t/day CO2 ≈ 500MWe
Large demonstration 15,000 t/day CO ≈ 800MWe
2
project(s)
slipstream
~3000 t/day CO2 ≈ 150MWe
Emissions reduction
test facilities
1 t/day to 4 t/day CO2
Slipstream
100 t/day CO2 ≈ 5MWe
Ferrybridge
2012
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Outline

Introduction

Background - CO2 emissions and electricity generation

CO2 reduction strategies

CO2 capture technologies

Development of PCC technology at DPS

PCC Challenges-Technical

PCC Challenges-Non technical

Concluding remarks

Q&A
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Safety Issues - CO2
Can we be sure that we will never exceed safe levels of CO2?
Most of plant will operate under
suction
 But from FGR fan through to the
windbox / burners the system is
under pressure, and may leak
CO2 is denser than air and will collect
in low level confined spaces
 i.e. in the basement areas
 Buoyancy helps dispersion
Good ventilation is essential
 How do you ensure this?
 Would you trust your life to a CFD
model?
The Dangers of Carbon Dioxide
1000ppm
0.1%
Prolonged exposure can affect powers of concentration
5000 ppm
0.5%
10,000ppm
1%
The normal international Safety Limit (HSE, OSHA)
8 hours
Your rate of breathing increases very slightly but you
probably will not notice it.
15,000ppm
1.5%
The normal Short Term Exposure Limit (HSE,
OSHA)
15 minutes
20,000ppm
2%
You start to breathe at about 50% above your normal
rate. If you are exposed to this level over several hours
you may feel tired and get a headache.
30,000ppm
3%
You will be breathing at twice your normal rate. You may
feel a bit dizzy at times, your heart rate and blood
pressure increase and headaches are more frequent. Even
your hearing can be impaired.
40,000-50,000ppm
4-5%
Now the effects of CO2 really start to take over. Breathing
is much faster - about four times the normal rate and after
only 30 minutes exposure to this level you will show signs
of poisoning and feel a choking sensation.
50,000-100,000ppm
5-10%
You will start to smell carbon dioxide, a pungent but
stimulating smell like fresh, carbonated water. You will
become tired quickly with laboured breathing, headaches,
tinnitus as well as impaired vision. You are likely to
become confused in a few minutes, followed by
unconsciousness.
100,000ppm-1,000,000ppm 10-100%
Unconsciousness occurs more quickly, the higher the
concentration. The longer the exposure and the higher the
level of carbon dioxide, the quicker suffocation occurs.
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PCC Challenges
There is, at present, commercial risk associated with CO2 capture in general:
 Technical
– Process Design and Chemistry
– Scalability
– Materials Selection
 Environmental
– Emissions from the PCC plants, their characterisation, impact and mitigation
 Social
 Financial
 Legislative
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Technical Challenges – Process Design and Chemistry
PCC process design depends on the characteristics of the flue gas, solvent and the
required CO2 capture efficiency.
 The following are typical characteristics of flue gas from coal-fired power plants
– High volume flow rates
– Low CO2 concentration (~15% v/v for coal power plants, and ~4% v/v for gas plants)
– Low gas pressures
 The baseline design of CO2 capture plants above or equal to 90% carbon capture
efficiency represents the final objective. This, however, is to be achieved at very low
capital and operational costs for the technology to be competitive.
 Capital Costs: Represent the cost of the plant equipment & components: Absorber,
stripper, pumps, heat exchangers etc.
 Operation Costs: Solvent life, Parasitic losses including steam for solvent
regeneration
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Technical Challenges – Process Design and Chemistry
Because process design is an iterative process, advanced simulation capabilities need to be
developed. These can be a mixture of commercially available and in-house (proprietary)
process simulators
Commercial process design tools used by technology developers;

Aspen Plus ®

Aspen HYSYS®

ProTreat®

ProMax ®
Simulation software models need to be evaluated for their performance prediction before they
can be used for designing large-scale plants.
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Technical Challenges – Process Design and Chemistry
Accurate estimation of process parameters for Process Design is the key!

Equilibrium concentrations
– Thermodynamics

Enthalpies of formation of the components
– Standard databases
– Scarcity of data for alkanolamine ions

Estimated using equilibrium constants data
– Measured temperature ranges

Heat exchanger design fundamental parameters
– Fluid mechanics (geometry, fluid velocity)
– Fluid properties (density, viscosity, thermal conductivity, specific heat capacity)
– Heat transfer coefficients
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Technical Challenges – Scalability
 One of the major challenges is the ability to scale carbon capture plants to large power
plant capacity (>500 MWe) within reasonable cost and footprint.
 For sizing a full-scale power plant (>400 MWe), realistic assumptions on the size of
equipment, the foot-print and the technical complexity in terms of equipment integration
and construction required to achieve 90% capture should be considered.
ERTF
Plant Capacity (tpd)
CCPilot100+
Basin Electric
1 tpd
100 tpd
3000 tpd
160 kW t
5 MWe
125 MWe
PCC Design Gas Flow (kg/h)
230
28, 245
700,346
CO2 capture (%)
90%
90%
90%
CO2 Absorber Dimensions (dia x height: m)
0.25 x 9
2.3 x39
11.8 x 45.4
Stripper Column Dimensions (dia x height: m)
0.20 x 8
1.1 x 30.5
5.5 x 30.5
Plant Size
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Technical Challenges – Material Selection
 Commonly used SS grades have a high cost/tonne.
 Certain SS grades are also susceptible to Stress Corrosion Cracking (SCC) at higher
temperatures.
 Certain SS grades can also corrode in the presence of solvent degradation products.
 Lower cost CS materials are unsuitable because of lower corrosion resistance when
compared with SS grades.
Way forward
Develop cheaper materials and/or metal coatings (e.g., Concrete)
Utilise Corrosion inhibitors (can reduce solvent performance)
Develop environmentally friendly, non-corrosive solvents
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Environmental Challenges
Sources of Emissions from PCC Plant
Solvent/Degradation
products carry-over
Solvent/Degradation
products carry-over
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Environmental Challenges – Solvent Degradation
Amine Degradation Products
It is difficult to describe the degradation chemistry of amines in CO2 capture succinctly
due to;
 Different types of degradation mechanisms involved
 Different grades of amines used by different PCC vendors
Computational chemistry & modelling approaches have been used to predict the most
likely amine degradation products in PCC which do not necessarily exist in reality.
“Verified and publicly available PCC plant emission data is not only incomplete but, in
many cases, rely on tests which are not performed under representative conditions. Most
impact assessment studies have been carried out in dry atmosphere and do not address
reactions that develop in the water phase, during darkness and with other radicals
present (other than hydroxide) – all of which can remove degradation products. The
result is an overestimation of the level of degradation product concentrations and their
persistence in the atmosphere”.
Source: HSE Impact Assessment of Amine-based Solvents in CO2 Capture, ZEP report (2011)
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Environmental Challenges – Solvent Degradation
Health Risks: Literature studies have found that;
 Most amines are biodegradable and hence, have little adverse environmental impact
 The highest concentrations (if emitted) would be found in liquid phase within 1 km of the
emitting PCC plant
 Nitrosamines and nitramines are potential carcinogens, but have short lifetimes of 1h and
upto 3 days, respectively in the atmosphere.
Where these emissions occur, their concentrations range from parts per million (ppm) to parts
per billion (ppb).
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Environmental Challenges – Solvent Degradation
1. In-Plant Degradation
In the PCC Plant, solvent degradation can occur by thermal breakdown, oxidation and
reactions with acid gases (NOx and SOx). The PCC plant will be operated to minimise the
formation of any degradation products during the capture process.
 Thermal degradation in the presence of CO2 typically occurs due to reactions of
amines with CO2 at excessive localised reboiler surface temperatures (130 to 150 oC),
forming oxazolidones. To mitigate, reboiler temperatures are kept at about 120 oC.
 Oxidative degradation occurs in the absorber column due to the reaction of amines
with flue gas oxygen and sulphur dioxide.
 Heat Stable Salts (HSS) are also produced from the reaction of amines with acid gases
(NOx and SOx). Absorber inlet NOx and SOx concentrations are typically controlled to
less than 100 ppm and 10 to 20 ppm respectively.
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Environmental Challenges – Solvent Degradation
2. In-Plume Degradation
Amine emissions in the off-gas can degrade further in the plume if the concentration of
contaminants, particularly NOx, are high, to produce amides, nitrosamines and nitramines.
However, NOx concentration in the plume will be low due to the low NOx requirements at the
inlet of the PCC plant.
3. Environmental Degradation
Amines undergo atmospheric degradation through absorption, adsorption, & photolysis
processes. Generally, environmental degradation of amines is initiated by reaction with OHradicals and, in sunlight, by photolysis.
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Environmental Challenges – Control Measures
Current Control Measures
Gas borne emissions from the PCC absorber are controlled through dissolution in water wash
section(s) installed at the absorber off-gas exit.
Droplets of amine solution, which also contain degradation products in suspension and
solution, could be entrained in the absorber off-gas stream and potentially escape to the
atmosphere. Absorber/water wash column demisters are typically designed to minimise such
entrainment.
Degradation products in the solvent solution are typically controlled to a total concentration of
2% w/w through solvent reclamation methods (thermal, Ion exchange etc).
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Outline

Introduction

Background - CO2 emissions and electricity generation

CO2 reduction strategies

CO2 capture technologies

Development of PCC technology at DPS

PCC Challenges-Technical

PCC Challenges-Non technical

Concluding remarks

Q&A
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Public perception - Introduction
 Positive public perception is critical to the success of CCS
- Direct impact on specific projects
- Influence on Government CCS policy
- Public acceptance can be difficult to win and easy to lose
 Academic studies have shown low levels of public knowledge of CCS, including in UK
-
How the public learns of CCS is key to what they think of it
Some evidence that greater public familiarity with CCS can correlate with greater
public concern
-
Source: Carbon capture & Storage association
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Public perception of CCS
Building public understanding, awareness and acceptance is key to CCS deployment.
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Source: Carbon capture & Storage association
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Other Challenges – Financial & Legislation
FINANCIAL
 Current Issues
How much is CCS going to cost?
How much energy will CCS require?
 CCS Government funding/subsidy insufficient/lack of clarity
- Impact of Recession ?
LEGISLATION
 Lack of adequate legal & regulatory framework
 Lack of commitment from major polluters (US, Canada, Brazil, Russia, India, China etc.)
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Concluding Remarks – The Way Forward
 The time is right for the full-scale demonstration of PCC technology
 Considerable progress has been made in the development of PCC technology
-The
process is technically viable
-The
process is reasonably well understood
-The
process has been demonstrated at pilot-scale
-The
process is being demonstrated at large-scale (100+ t/day)
-Most
of the individual components are in commercial operation at the required scale
 PCC technology is economically competitive with alternative carbon capture technologies
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In Summary
Low impact high efficiency integrated EPC carbon capture solutions
Doosan is a forward looking, technology driven organisation, positioned to
take advantage of future markets
 As such it is focussed on, and driving towards CCS commercialisation
 Underpinning its existing technology offering
 Improving the technology offering through capital and operational cost
reduction
 Working closely with utilities and environmental agencies to develop
measurement and control standards to bolster confidence in postcombustion capture
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Contact Details
Dr Saravanan Swaminathan
Senior Engineer, Product Development
E [email protected]
Mark Bryant
Director Carbon Capture
E [email protected]
Doosan Power Systems Limited
Porterfield Road
Renfrew
PA4 8DJ
United Kingdom
T +44 (0)141 886 4141
Matthew Hunt
Business Development Manager
E [email protected]
Indian Office Contact details to be added?
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Thank you
Disclaimer:
The contents in this presentation are for information purposes only
and are not intended to be used or relied upon by the reader and are
provided on the condition that you 'use it at your own risk'. Doosan
Power Systems Limited does not accept any responsibility for any
consequences of the use of such information.
All rights are reserved and you may not disseminate, quote or copy
this presentation—written by Doosan Power Systems Limited—without
its written consent.