Project objective
Aim : to develop and demonstrate FLEXI BURN CFB concept enabling to reach the target of near zero emission power plants
The FLEXI BURN CFB concept: High efficiency Circulating Fluidized Bed (CFB) power plant with CCS capable of air/oxy operation with a wide range of fuels including biomass
The FLEXI BURN CFB concept has a set of important advantages: 1. 2. 3. fuel flexibility in order to decrease dependency on imported coals and in order to improve power plant economics especially with CCS operation operational flexibility in order to apply air-firing and oxygen-firing with CO2 capture lower NOx production due to reduced and more uniform furnace temperature profiles, and lower SOx concentration in flue gases due to in-furnace capture, thus reducing the need for downstream flue gas cleaning overall concept for phased transition into CCS technology with minimised risks through high efficiency air-oxy flexible CFB combustion lower specific CO2 emissions from the reduced consumption of fuel due to the intrinsic high efficiency of the technology . In addition, by substituting e.g. 20% of coal input with renewable fuels, CO2 emissions can further be reduced by 15-20%. Provides utilities an attractive alternative to take into use the new technology and decommission old capacity with lower efficiency and poorer emission performance
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4. 5.
6.
FLEXI BURN CFB diagram allowing operation under normal air-firing as well as oxygen-firing with CCS
Fluegas (CO2-rich) Switch Flue gas cleaning Stack
The FLEXI BURN CFB concept: High efficiency Circulating Fluidized Bed (CFB) power plant with CCS capable of air/oxy operation with a wide range of fuels including biomass
Large scale high efficiency CFB boiler with FLEXI BURN design
Fuel Bituminous coal Lignite Biomass Pet coke etc. Switch Air
CO2 capture and storage (CCS) Condensation Compression Purification Transport Storage
95-97% O2
UAP
Utilities
1st Commercial scale FLEXI BURN CFB Power Plant
Development steps
Manufacturers
VTT, LUT, CzUT UNIZAR-LITEC, AICIA
Demonstration Pilot Plant 30 MWth , CIUDEN
Research institutes
Concept
WP2 Development of design tools WP1 Comparison of airand oxy-firing Supporting R&D work WP3 Demonstration tests at large pilot unit and commercial scale air fired unit WP4 Boiler design and performance Viable boiler design WP5 Power plant integration, optimization and economics Viable power plant
Technology demonstration and background for the commercial scale design process
Pilot scale
PILOT SCALE CFB COMBUSTOR
FTIR sampling port Gas analysator Bag filt er Gas cooling Observation port To stack Sampling port Secondary cyclone Deposit probe port
Boiler scale
A GIS ZA 460 MWe supercritical O TU CFB
C ooler
C yclo ne
To S tack
C ooler/heater
Zone 3
EXPERIMENTAL SCALES
Zone 2 Sampling port Fuel containers 1 and 2 Zone 1 Additive container Secondary gas O2, CO2, N2
Air
Air
1D-MO DEL
flu e g as to stack
n+ 1
n -1 n -2
Model analyses
rc
dmc dt
n kmc XO2
Seco n da ry air
2 1 Pr ima ry air
kW/m
k W /m 2
Scale up criteria
WP1
R&D support
WP2
Design tools
WP3
Demonstration
WP4
Boiler design
WP5
Power plant concept
WP6
Commercial Scale FLEXIBURN
Process scale-up
Reference plant for the project
800
800 MWe
100
Pilot Plant Oriental Chem
0 1970
1975
1980
1985
1990
Start-Up Year
1995
2000
2005
2010
CFB technology is scaling up with the latest high-efficiency SC-OTU-references Lagisza (460 MWe). The Lagisza power plant (460 MWe), located in the southern Poland, is the world's largest CFB boiler, which is also the world's first supercritical CFB once-through unit (OTU)
CFB800 Furnace - Width - Depth - Height m m m 40 12 50.0 agisza 27.6 10.6 48.0 Turow 4-6 22.0 10.1 42.0 JEA 26.0 6.7 35.1 Turow 1-3 21.2 9.9 43.5
EMISSION ( at 6% O2, dry flue gas) (follows EUs LCP directive), mg/Nm3 SO2 NOx (as NO2) CO Dust
400 350
Low Emissions
Concentration of SO 2 [mg/mn]
300
200
950
250
300
350
400
450
200
250
300
350
400
450
500
200
Measured
175
CO measuring data
calculated by model
Concentration of CO [mg/mn]
140 120 100 80 60 40 20 0 200 250 300 350 400 450 500 550
Temperature [C]
Height [m]
25
30
35
40
45
50
200
250
300
350
400
450
500
Demonstration scales
CANMET 1MW Aim : to develop and demonstrate FLEXI BURN CFB concept enabling to reach the target of near zero emission power plants Completed In progress Time 2012
Pr imary cyclone
C ooler
Cyclone
Sampling port
Zone 2
To Sta ck
Zone 1
Co oler/hea ter
M
Air
Sampling port
O 2, C O2 , CO, N2 , SO 2 , NO
A ir
2009
Small pilot scale CFB experiments (0.1MW) under air- and oxygen-firing conditions
Operational point of views: Combustion process dynamics Transition between air- and oxygen firing
Air-firing
Oxygen-firing
Oxygen-firing
Air-firing
Small pilot scale CFB experiments (0.1MW) under air- and oxygen-firing conditions
Small pilot scale CFB experiments (0.1MW) under air- and oxygen-firing conditions have been completed with totally 33 experiments Transition between air- and oxygen firing conditions could be carried out smoothly and safely with the renovated automation system which included an automated transition mode between air- and oxygen-firing Combustion process could be operated in the both modes without any major drawbacks Based on the dynamic tests the reliable control of oxidant oxygen concentration is very important from the safety operation and process controllability point of view If the inlet gas (oxidant) oxygen concentration is controlled effectively the combustion process stability seems to be comparable to corresponding air-firing conditions If flue gas emissions are expressed in milligrams per megajoules the emission levels between air- and oxygenfiring have not remarkable differences
Bottom ash Air-firng (Test 19)
Detailed analysis of solids mass balance Furnace vertical temperature profile Combustion and energy release profile Solids density profile Heat flux profile Furnace heat transfer
1000 950 900 850
Temperature
800 750 700 650 600 550 500 0 2 High load OXY High load AIR
Furnace height
4
DCS
CFB BOILER
PC BOILER
FUEL PREPARATION
LIMESTONE
FUEL FEED
SAND
CB1
FAN
MIXER
CB2
NATURAL GAS
OXYGEN
BOTTOM ASH
NEXT STEPS
PLANNING OF TEST MATRIX FLEXI BURN TEST PERIOD FLEXI BURN PROJECT DEADLINE
01
02
03
04
05
06
07
08
09
10
11
12
01
02
03
04
05
06
07
08
09
10
11
12
2011
2012
COMPILATION OF RESULTS
17
Plant size: Two cases considered: Flexi Burn CFB demonstration plant: 300-350 MWe gross. (Detailed technical scope, main focus) Full Commercial plant - post-2020: 800 MWe gross (techno-economical feasibility study)
Steam parameters:
Main steam temperature Main steam pressure Reheated steam pressure Reheated steam temperature 598 C 270 bar 57 bar 600 C
Operating parameters:
Dynamic requirements for the power plant Operational Mode Load change rate Minimum load Start-up time (cold) Start-up time (ASU cold) Base Load Max ramping 4%/min 40% <24h <8h
Oxy mode Air mode TOTAL Annual equivalent operating hours 6500 h 500 h 7000 h
Large scale high efficiency CFB boiler with FLEXI BURN design Fuel Bituminous coal Lignite Biomass Pet coke etc. Switch Air
CO2 capture and storage (CCS) Condensation Compression Purification Transport Storage
95-97% O2
The initial conceptual design of the FLEXI BURN CFB boiler has been developed The first conceptual design for the FLEXI BURN has been implemented including a preliminary integration with the Air Separation Unit (ASU) and the Compression and Purification Unit (CPU)
Boiler
Oxidant Flue gas
ASU
CPU
Steam Cycle
Next steps
The second test campaign at Lagisza Power Plant is carried out during the first half of 2011 Demonstration tests at CIUDEN in the beginning of 2012 Concept optimisation for the boiler island and the integrated power plant unit including dynamic simulation of the plant Health and safety assessment related to oxygen-firing conditions Estimate economics for the new concept and evaluate their feasibility on a commercial scale range Identification of the key success factors of the FLEXI BURN CFB technology covering the process efficiency, operability, maintainability, environmental impact and responsiveness to the market requirements, all leading to the economic performance of this new approach for power generation
2) What is NOT yet achieved? 3) What are the next logical steps, i.e.: what do we still need to do within the subject of the presentation towards the implementation and commercialisation of CCS? Next logical steps: demonstration tests at CIUDEN (30MW) and development of final concept for 300MWe Development of 2nd generation oxyfuel concept with significantly higher overall plant efficiency Transportation and storage part is not in the scope of the project but it will be the key issue in the implementation and commercialisation of CCS Emission limits for CCS plants must be reconsider (concentration based limits are not valid) Demonstration of FLEXI BURN CFB concept: FLEXI BURN CFB consortium and OXYCFB300 consortium Development of 2nd generation oxyfuel concept: Organizations who have been involved in the development of the 1st generation oxyfuel concepts Transportation and storage: all together, public acceptance and political decisions are very important Emission limits for CCS: European Commission is working on the issue
4) Who do you think is best placed to take these next steps forward?