Transcript Slide 1

Demonstration of oxy-fuel combustion in
once-through steam generators for CO2
capture
Carbon Capture & Storage Workshop 28 March, 2013
The High Commission of Canada, Canada House, London
Prepared by:
Mark Bohm (Suncor) Capture Team Member
Mark Crombie (BP): CCP3 Program Manager
Presented by:
Mark Crombie (BP): CCP3 Program Manager
CCP Project Overview
The CO2 Capture Project (CCP) is an award-winning partnership of several major
energy companies working to advance the technologies that will underpin the
deployment of industrial-scale CO2 capture and storage (CCS). The CCP is currently
in its third phase of activity:
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Phase 1 (CCP1, 2001-2004) technology screening/proof of concept – completed
Phase 2 (CCP2, 2004-2009) intensive development – completed
Phase 3 (CCP3, 2009-2013) demonstration – on going
The CCP is funded primarily by:
• Member contributions
• Government grants
• In-kind contributions
CCP Mission Statement
“To develop technologies that will reduce the risks of and
further advance CO2 capture and geological storage;
making CCS a practical reality for atmospheric carbon
mitigation”
How does CCP work?
Collaboration of leading oil & gas companies, government, NGOs, academic
institutions,
• Current members are BP, Chevron, ENI, Petrobras, Shell and Suncor
• Over 200 joint projects to date, broad scope ranging from policy to technology
development, R&D and knowledge sharing
• Incorporates oil & gas industry expertise + power industry experience
• CCP is now a leading authority on CCS, sharing research findings
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OTSG - Importance of Capture Solution
• 80-85% of oil sands are currently accessible only through in-situ
production methods; these are less invasive than mining and with
a smaller environmental footprint
• SAGD is the leading technology, but is more energy and GHG
intensive because of the large steam requirements
• Current carbon emissions from SAGD facilities exceed 25 Mt/yr,
and are expected to be the oil sand sector’s largest source of
future emission growth
• A cost-effective solution for CO2 capture from once-through steam
generators (OTSG) is needed for both greenfield and retrofit
applications
CCP and its Partners recognize the importance of an
economic, retrofitable CCS solution for OTSGs
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Unparalleled Project Team Expertise
Project Lead: Suncor
Funding Partners: Cenovus Energy
(host site), CO2 Capture Project,
Devon, Praxair, Statoil, MEG Energy
Technology Providers:
Praxair – industrial gas &
combustion technology
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Potential CCS Solutions for OTSGs
Amines
Oxy-fuel
• Requires solvents; potential
source of secondary emissions
• 90% Capture rate
• Large steam requirements
• Commercially available
• No solvents needed; near zero
emissions
• 99% Capture rate
• Requires power
• Need to demonstrate oxy-fuel
burners and CO2 purification
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Oxy-fuel Technology for OTSGs
Air
Air Separation
Unit (ASU)
Nitrogen
Flue Gas Recirculation
Vent of Non-Condensable Gases
( N2, Ar, excess O2)
Oxygen
Flue gas
(CO2 - rich)
Fuel
OTSG-Boiler
CO2 Processing
Unit (CPU)
CO2
Water
• Key Technologies
• ASU – Air Separation Technology
• CPU – CO2 Separation and Compression Technology
• Large Plant Engineering (Design, Construct, Operate, Maintain)
• Oxy-Fuel Combustion Technology
• Safety, System Integration and Optimization
Key to Success: Integration and Optimization of Existing Technologies
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Overview of Project
Three Phase Project:
• Phase I (completed): Develop design basis and cost estimates for
test and commercial scale OTSG
• Phase II (2013): Pilot oxy-fuel combustion on 50 mmbtu/hr test boiler
• Phase III (2014+): Pilot oxy-fuel combustion, compression and
purification on test boiler
Overall Objective:
To demonstrate that oxy-fuel combustion is a
safe, reliable and cost-effective technology for CO2 capture
from once-through steam generators
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Phase II - Oxy-fuel Boiler Test
• Existing commercial OTSG Boiler at Cenovus Energy - Christina Lake
• Retrofit with flue gas recirculation
• Installation of oxygen supply and control integration
OTSG-Boiler
Liquid
Oxygen
Natural
Gas
Oxygen
(gas)
Steam
Flue gas
~95% CO2 + H2O
Evaporator
FGR Damper
Eco
Feedwater
Flue Gas Recirculation
FD-Fan
Air Damper
Air
Project will demonstrate technical viability and safety of
oxy-fuel combustion at operating in-situ site
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Oxy-Fuel Technology Challenges
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Heat transfer changes in boiler versus air combustion
Burner design for desirable flame shape and stability
Material temperature limits, scale-up, emissions
Startup, operation, boiler performance and controls
Net Heat Flux on Boiler Tubes (W/m2)
Gas Temperature (oF)
Air Baseline
140,000
0
2,000
1,000
Oxy-fuel Mixture of FGR
and Oxygen
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Oxy-Fuel Burner Designs
Oxygen Mixer
• uses existing Coen burner →
• potential limitations on flame
stability and heat transfer
profile
Natural Gas
Oxygen
Oxygen Sparger
to mix oxygen
into FGR
Natural Gas
A-Burner
• very simple design
• need to prove
operation at
commercial scale
Flue Gas Recirculation
Existing Opening
Oxygen
• high degree of flame and
heat transfer adjustment
• water cooled
JL-Burner
Existing Air Burner
A-Burner
with new burner block
Flue Gas Recirculation
Oxygen
Natural Gas
Existing Opening
JL-Burner
with new burner block
Flue Gas Recirculation
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Technical Demonstration Goals
• Establish operating parameters for oxy-fuel combustion applied to
SAGD boilers (heat transfer, steam flow and quality)
• Confirm CFD model predictions with test results
• Identify and understand scale-up issues and retrofit risks
• Startup and control boiler to suit process needs
• Verify boiler NOx emissions with test measurements
Goal: Reliable Oxy-fuel Operation with known capture
costs
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Project Summary
Project addresses significant and growing source of GHG
emissions in Alberta
• CO2 capture is an option as large facilities exist (for retrofits or greenfield)
Strong Group of Committed Participants
• Consortium of energy companies working towards a common solution
• World leading technology providers
Compelling Technology Solution
• Oxy-fuel combustion with flue gas purification is expected to have a cost
advantage over amine systems
• Applicable to other combustion sources including upgrading and refining
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Thank You
Mark Bohm, P.Eng
Suncor Energy
Tel: 403 513-4613
Email: [email protected]
Mark Crombie, MBA
BP Alternative Energy
Tel: 0779 886 924
Email: [email protected]
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