Mr Nsakala Cebu-Advanced Clean Fossil Energy Technology.ppt

CFB Technology

1. Boiler Segment1
3
Advanced Clean Fossil
Energy Technologies
Nsakala ya Nsakala, Ph.D.
Presented at
APEC Clean Fossil Energy Technical Policy Seminar
Cebu, Philippines
January 26-29, 2005

2. Boiler Segment2
•Ultra-supercritical steam
conditions
Increase efficiency
•Circulating Fluid Bed (CFB) and
“advanced CFBs”
Low costs, low emissions, fuel flexibility
•Emissions controls
For new and existing, and integrated and post
•CO
2Capture
Oxygen firing
Chemical Looping/novel processes
Systems integration and ancillary components
Roadmap for Coal Combustion
Power
ALSTOM’s view includes four (4) legs to advance
coal combustion based power technology

3. Boiler Segment3
Why CFB
forPhilippines
CFB Technology

4. Boiler Segment4
Superheat and / or Reheat Surface
Economizer Surface
Air Out
Air Heater
Air In
Superheat /
Reheat
Surface
Evap.
Surface
Fluid Bed
Heat
Exchanger
Cyclone
Furnace
Cooling Water
Ash Cooler
Secondary Air In
Coal Storage
Coal
Crusher
Limestone Storage
Drum
Ash
Refractory Surface
Superheat or Reheat Surface
Evaporative Surface
Superheat and/or
Evaporative Surface
Limestone
Crusher
Limestone
Day Bin
Coal
Day Storage
Gravimetric
Feeder
Blower
Primary
Air In
Gravimetric
Feeder
I.D.
Fan
Stack
Fabric Filter
or
Electrostatic
Precipitator
Water
In
Mixer /
Hydrator
Fabric Filter
CFB Process Schematic with
Flash Dryer Absorber (FDA)
Primary
Air Fan
Secondary
Air Fan
Today’s CFB with state-of-the-art SO
2emissions control system
Ash
Silo
Seal Pot

5. Boiler Segment5
State-of-the-art CFBs:
Meeting customers’ needs for proven, reliable, economic, and
clean power
ALSTOM
CFBs
Low Risk
•Proven
technology
•Track record of
high availability
Economic
•Fuel flexible
•Waste fuels
Clean Power
•Low inherent
NOx and SOx
emissions
Steam Cycle Options
•Subcritical
•Supercritical

6. Boiler Segment6
ALSTOM Power CFBs
Clean Power
•Inherent Low NOx
•As a result of low combustion temperatures (815-980
o
C)
and staged combustion
•Amenable to secondary measures such as in-furnace
ammonia injection
•Typical NOx emissions of 100 -400 mg/m
3
stp(0.06 -0.25
lbs/MM Btu) -lower end of range for emission sensitive
areas, e.g. 0.1 lbs/MM Btu
•Inherent Low SOx
•As a result of limestone injection
•Typical removals of 90 -97%+
•Removals as high as 98% with secondary equipment

7. Boiler Segment7
QUEZON
MINDORO
SEMIRARA
NEGROS
ZAMBOANGA
BUKIDNON
SULTAN KUDARAT
SARANGANI
CAGAYAN VALLEY
BATAN-POLLILO
CATANDUANES
MASBATE
SAMAR
CEBU
SURIGAO
DAVAO
SOUTH COTABATO
Philippine Coals
CFB Technology

8. Boiler Segment8
Average Coal Qualitylocation Moisture Ash
Volatile
Matters
Fixed
Carbon
Sulfur
content Rank
% (ar) % (ar) % (ar) % (ar)BTU/Lbs kCal/kg % (ar) (ASTM)
Western Mindanao 5,6 12,1 19,7 62,7 11 100 6 200 0,8 hvBb
Eastern Mindanao 22,4 17,8 34,3 25,3 7 100 3 900 2,0 sub B
Eastern seaboard
Samar-Bagacay 25,6 10,0 36,7 27,7 7 600 4 200 3,2 sub C
Samar-Giporlos 17,3 24,6 30,6 27,7 7 000 3 900 1,8 sub B
Catanduanes 3,6 16,5 24,0 55,9 12 100 6 700 2,0 mv B
West Batan 10,4 9,6 37,9 41,6 10 500 5 800 1,6 hv Cb
East Batan 23,3 9,5 34,6 32,4 8 000 4 400 2,1 sub C
Polillos 12,1 6,9 37,0 44,5 10 700 5 900 0,5 hv Cb
Visayas Block
Danao/compostela 13,6 14,6 36,2 35,6 9 300 5 200 1,1 hv Cb
Toledo/Balamban 7,7 19,9 34,9 37,4 9 800 5 400 3,3 hv Cb
Uling/Alpaco 15,3 14,4 36,9 33,3 9 000 5 000 1,9 sub A
Argao/Dalaguete 9,5 9,9 37,7 42,8 11 500 6 400 1,2 hv Bb
Negros 14,5 16,4 33,2 34,9 8 100 4 500 2,9 sub B
Bohol 13,4 19,5 38,2 28,9 8 700 4 800 2,8 hv Cb
Masbate 8,7 15,7 35,1 40,7 9 800 5 400 2,0 hv Cb
Western Seaboard
Mindoro 23,4 5,3 40,6 30,7 8 500 4 700 3,6 sub B
Semirara 22,8 19,0 32,7 25,6 7 000 3 900 1,0 sub C
Luzon Block
Cagayan Basin 50,0 13,8 25,1 14,8 4 600 2 600 0,9 lig A
Lagmac 5,4 7,8 43,6 42,3 12 000 6 700 0,4 hv Bb
HHV
Philippine Coals
CFB Technology

9. Boiler Segment9
CFB Technology
All Philippines coals are well within ALSTOM’s
CFB experience
Fuels within CFB Experience vs. Philippines CoalsHIGH LOW HIGH LOW
HIGHER HEATING VALUE (HHV), Btu/lb 14000 1050 12100 4600
HIGHER HEATING VALUE (HHV), Kcal/kg 7880 570 6700 2600
MOISTURE, Wt. %, AS RECEIVED 62 3 50 5
ASH, Wt. %, AS RECEIVED 76 4 25 5
CARBON, Wt. %, AS RECEIVED 71 19 63 15
SULFUR, Wt. %, MAF 13 0.3 5 0.5
ALSTOM EXPERIENCE PHILIPPINES COALS
CONSTITUENT

10. Boiler Segment10
•Ultra-supercritical steam
conditions
Increase efficiency
•Circulating Fluid Bed (CFB) and
“advanced CFBs”
Low costs, low emissions, fuel flexibility
•Emissions controls
For new and existing, and integrated and post
•CO
2Capture
Oxygen firing
Chemical Looping/novel processes
Systems integration and ancillary components
Roadmap for Coal Combustion
Power
ALSTOM’s view includes four (4) legs to advance
coal combustion based power technology

11. Boiler Segment11
Power Plant Efficiency Evolution
1.Plant efficiency has improved steadily over the years
2.Efficiency increase from Subcritical to USC can, for
example, yield up to 30% CO
2emissions reduction

12. Boiler Segment12
ALSTOM CO
2Capture for
Power Studies:#Project Name Sponsors Years
1
Technical Feasibility of a CO
2/O
2 Combustion Retrofit to an Existing Coal-Fired
Boiler for CO
2 Extraction
ABB 1998
2
Preliminary Design and Costing of a CO
2/O
2 Combustion Retrofit to an Existing
Coal-Fired Boiler for CO
2 Extraction
TransAlta Corp. 1999
3
Integration of Ceramic Oxygen Transport Membrane Processes with Coal Fired
Power Plants
ABB 1999
4
CFB Boiler Integrated with 300 Tonnes per Day CO
2 Removal System for
Suncor Thermal Solvent Process Project
Suncor 2000
5
CO
2 Capture Project: An Integrated, Collaborative Technology Development
Project for Next Generation CO
2 Capture, Separation and Geologic
Sequestration
BP Amoco Corporation 2000
6
CO
2 Capture in a Coal-Fired Boiler: Economic and Performance Sensitivity to
CO
2 Capture Percentage for Amine-Based Processes
ALSTOM Power Inc. 2001
7
Engineering Feasibility and Economics of CO
2 Capture on an Existing Coal-
Fired Power Plant
OCDO/DOE NETL 1999-2001
8
Greenhouse Gas Emissions Control by Oxygen Firing in Circulating Fluidized
Bed Boilers
DOE NETL 2001-2004
9GRACE - Chemical Looping Combustion - Feasability study EU 2002 - 2003
10CO2 capture (cascade cryogenics) - ECS/BUB ADEME 2003 - 2004
11CO2 Capture - Calcium cycle ADEME 2003 - 2004
12EDF - 2015 ADEME 2003 - 2005
13ENCAP (Oxyfiring - Chemical Looping) EU / IPFP6 2004
14EnCap EU 2003 - 2006

13. Boiler Segment13
Example:
Summary of DOE GHG Project
DE-FC26-01NT41146 Results

14. Boiler Segment14
Cases Studied:All ~ 210 MWe Gross
CASE 1: Base Case,Air-Fired Circulating Fluidized Bed (CFB) Boiler
CASE 2: New Compact Cryogenic O
2-Fired CFB with CO
2Capture,
Purification, Compression and Liquefaction
CASE 3: New Compact Cryogenic O
2-Fired CFB with “Dry” Flue Gas
Compression and Liquefaction
CASE 4: O
2-Fired Circulating Moving Bed (CMB) with CO
2Purification,
Compression and Liquefaction
CASE 5: Air-Fired CMB with High Temp. Regenerative Carbonate
Process
CASE 6: Case 4, Integrated with Oxygen Transport Membrane (OTM)
CASE 7: Indirect Combustion of Coal and CO
2Capture via Chemical
Looping
Combustion Cases
Cryogenic
Oxygen

15. Boiler Segment15
Cases Studied: All ~ 300 MW Gross
Texaco-Based IGCC Cases
CASE 8: Base Case,Built & operating IGCC w/o CO
2capture
CASE 9: Built & operating IGCC w/ CO
2capture, purification,
compression and liquefaction
CASE 10: Base Case,Commercially offered IGCC w/o CO
2capture
CASE 11: Commercially offered IGCC w/ CO
2capture, purification,
compression and liquefaction
Advanced Chemical Looping
CASE 12: Base Case,Indirect gasification of coal via Chemical
Looping w/o CO
2capture
CASE 13: Indirect gasification of coal & CO
2capture via Chemical
Looping

16. Boiler Segment16
Net Plant Efficiencies, % HHV
COMBUSTION
CASES
IGCC
CASES
ADV. CHEM. LOOPING
CASES35.5
24.8
25.3
24.6
30.2 30.0
30.9
37.6
29.8
34.5
27.4
41.4
36.9
0
5
10
15
20
25
30
35
40
45
1. BASE CASE: AIR-
FIRED CFB
2. O2-FIRED CFB
w/ASU & CO2
CAPTURE
3. O2-FIRED CFB
w/ASU & FLUE GAS
SEQUESTRATION
4. O2-FIRED CMB
w/ASU & CO2
CAPTURE
5. AIR-FIRED CFB CFB w/CARBONATE REG.&
CO2 CAPTURE
6. O2-FIRED CMB
w/OTM & CO2
CAPTURE
7. CMB CHEM.
LOOPING
COMBUSTION w/CO2
CAPTURE
8. BASE CASE: BUILT &
OPERATING (B&O)
IGCC
9, B&O IGCC w/ASU &
CO2 CAPTURE 10. BASE CASE: COMMERCIALLY
OFFERED (CO) IGCC 11. CO IGCC w/ASU &
CO2 CAPTURE
12. BASE CASE: CHEM.
LOOPING
GASIFICATION (CLG)
13. CLG w/ CO2
CAPTURE
NET PLANT EFFICIECNY, %HHV
1 2 3 4 5 6 7 8 9 10 11 12 13

17. Boiler Segment17
CO
2Emissions2.00
0.19
0.03
0.21
0.01
0.16
0.01
1.81
0.23
1.98
0.25
1.71
0.02
0.00
0.01
0.10
1.00
10.00
1. BASE CASE: AIR-FIRED CFB
2. O2-FIRED CFB w/ASU & CO2 CAPTURE
3. O2-FIRED CFB w/ASU & FLUE GAS
SEQUESTRATION
4. O2-FIRED CMB w/ASU & CO2
CAPTURE
5. AIR-FIRED CFB CFB w/CARBONATE
REG.& CO2 CAPTURE
6. O2-FIRED CMB w/OTM & CO2
CAPTURE
7. CMB CHEM. LOOPING COMBUSTION
w/CO2 CAPTURE
8. BASE CASE: BUILT & OPERATING
(B&O) IGCC
9, B&O IGCC w/ASU & CO2 CAPTURE
10. BASE CASE: COMMERCIALLY
OFFERED (CO) IGCC
11. CO IGCC w/ASU & CO2 CAPTURE
12. BASE CASE: CHEM. LOOPING
GASIFICATION (CLG)
13. CLG w/ CO2 CAPTURE
CO2 Emissions, lbm/kWh
1 2 3 4 5 6 7 8 9 10 11 12 13

18. Boiler Segment18
Total EPC Investment Costs,
July 2003, $/kW, Gulf Coast Site
COMBUSTION
CASES
IGCC
CASES1,304
2,481
2,369
2,553
1,677
2,375
1,663
1,565
2,179
1,451
2,052
1,120
1,383
-
500
1,000
1,500
2,000
2,500
3,000
1. BASE CASE: AIR-
FIRED CFB
2. O2-FIRED CFB
w/ASU & CO2
CAPTURE
3. O2-FIRED CFB
w/ASU & FLUE GAS
SEQUESTRATION
4. O2-FIRED CMB
w/ASU & CO2
CAPTURE
5. AIR-FIRED CFB CFB w/CARBONATE REG.&
CO2 CAPTURE
6. O2-FIRED CMB
w/OTM & CO2
CAPTURE
7. CMB CHEM.
LOOPING
COMBUSTION w/CO2
CAPTURE
8. BASE CASE: BUILT & OPERATING (B&O)
IGCC
9, B&O IGCC w/ASU &
CO2 CAPTURE 10. BASE CASE: COMMERCIALLY
OFFERED (CO) IGCC
11. CO IGCC w/ASU &
CO2 CAPTURE 12. BASE CASE: CHEM. LOOPING
GASIFICATION (CLG)
13. CLG w/ CO2
CAPTURE
TOTAL EPC INVESTMENT COSTS, $/kW
1 2 3 4 5 6 7 8 9 10 11 12 13
ADV. CHEM. LOOPING
CASES

19. Boiler Segment19
Levelized Costs of Electricity, Cents/kWh
COMBUSTION
CASES
IGCC
CASES4.53
8.25
7.98
8.41
5.95
7.05
5.84
5.30
7.15
5.22
7.18
4.28
5.22
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
1. BASE CASE: AIR-
FIRED CFB
2. O2-FIRED CFB
w/ASU & CO2
CAPTURE
3. O2-FIRED CFB
w/ASU & FLUE GAS
SEQUESTRATION
4. O2-FIRED CMB
w/ASU & CO2
CAPTURE
5. AIR-FIRED CFB CFB w/CARBONATE REG.&
CO2 CAPTURE
6. O2-FIRED CMB
w/OTM & CO2
CAPTURE
7. CMB CHEM.
LOOPING
COMBUSTION w/CO2
CAPTURE
8. BASE CASE: BUILT & OPERATING (B&O)
IGCC
9, B&O IGCC w/ASU &
CO2 CAPTURE 10. BASE CASE: COMMERCIALLY
OFFERED (CO) IGCC 11. CO IGCC w/ASU &
CO2 CAPTURE 12. BASE CASE: CHEM. LOOPING
GASIFICATION (CLG)
13. CLG w/ CO2
CAPTURE
LEVELIZED COST OF ELECTRICITY, Cents/kWh
1 2 3 4 5 6 7 8 9 10 11 12 13
ADV. CHEM. LOOPING
CASES

20. Boiler Segment20
CO
2Mitigation Cost, $/ton Of CO
2Avoided41
35
43
14
27
13
23
23
11
0
5
10
15
20
25
30
35
40
45
50
2. O2-FIRED CFB
w/ASU & CO2
CAPTURE
3. O2-FIRED CFB
w/ASU & FLUE GAS
SEQUESTRATION
4. O2-FIRED CMB
w/ASU & CO2
CAPTURE
5. AIR-FIRED CFB
CFB w/CARBONATE
REG.& CO2
CAPTURE
6. O2-FIRED CMB
w/OTM & CO2
CAPTURE
7. CMB CHEM.
LOOPING
COMBUSTION w/CO2
CAPTURE
9, B&O IGCC w/ASU
& CO2 CAPTURE
11. CO IGCC w/ASU &
CO2 CAPTURE
13. CLG w/ CO2
CAPTURE
CO2 Mitigation Cost, $/Ton of CO2
2 3 4 5 6 7 9 11 13

21. Boiler Segment21
Oxygen Fired CFB
ASU or other
O
2Source
Circulating Fluidized Bed Boiler1,550
o
F
(850
o
C)
1,550
o
F
(850
o
C)
O
2
EOR
CO
2
N
2
Air
Fuel
•PET Coke
•Coal
•Biomass
Recirculation
Steam
Steam
Emissions
Control
Steam
Recycled cooled
solids in CFB
help control
combustor
temperature
Future -O
2
Membranes
Fuel Flexible

22. Boiler Segment22
Preliminary Economics of Oxy-Fuel CFB for
EOR Application
3.95
3.95
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
9
Air-Fired CFB w/ Petcoke O2-Fired CFB Retrofit w/ Petcoke and CO2
& N2 Credits
Levelized COE (Cents per kWh)
Fuel
Variable O&M
Fixed O&M
Financial
N2 Credit
CO2 Credit
17 $ / ton CO2
Credit

Credits:
1. 17 $/ton of CO
2
2. 4 $/ton of N
2

23. Boiler Segment23
Commercialization Development
Timeframe for Oxy-Fuel CFB PlantPHASE I: DESIGN & TECHNO-ECONOMIC ANALYSIS OF
VARIOUS POWER PLANT CONCEPTS WITH AND WITHOUT
CO
2 CAPTURE
PHASE II: PILOT-SCALE TESTING OF O
2-FIRED CFB
CONCEPT, REFINE DESIGN & ECONOMIC MODELS
PHASE III: COMMERCIALIZATION OF DEVELOPMENT OF
O
2-FIRED CFB FOR GREENHOUSE GAS CONTROL
COMMERCIALIZATION DEMONSTRATION
COMMERCIALIZATION
YEAR
0102030405 06 10070809
Short range development, because this technology uses commercially available enabling
Technologies, such as Cryogenic Air Separation & Gas Processing

24. Boiler Segment24
SUMMARY
•ALSTOM STATE-OF-ART CFB TECHNOLOGY:
Offers environmentally friendly use of all grades
of coals, petcoke, biomass, low grade fuels….
•ALSTOM ADVACED TECHNOLOY DEVELOPMENTS
FOR GREENHOUSE GAS CONTROL:
CO
2Capture-Ready Plants with Super Critical/
Ultra-super Critical Steam Conditions
Oxygen-Fired Commercial CFB Plant Demonstration
for Enhanced Oil RecoveryApplication or Carbon
Sequestration
Chemical Looping Process Development Unit (PDU)
---Hydrogen production
---Syngas production

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