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Hamburg University of Technology CO 2 Quality and Other Relevant Issues Oxyfuel Process (Post-Combustion Capture) (Pre-Combustion Capture) Introduction and Objectives of the Meeting 2 nd Working Group Meeting on CO 2 Quality and Other Relevant Issues 7 th September 2009, Cottbus A. Kather Institute of Energy Systems
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CO 2 purity Introduction ▸ What are the barriers for a successful deployment of the Oxyfuel Process? ▸ Why considering the impurities? General Boundary Conditions of the Oxyfuel Process ▸ Flue gas recycle demand; O 2 excess; O 2 concentration Impact of Impurities on the CO 2 Concentration ▸ Where do the impurities come from? R&D Project COORAL ▸ Definition of required CO 2 purity Possibilities to increase CO 2 Purity 2
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CO 2 purity Introduction ▸ What are the barriers for a successful deployment of the Oxyfuel Process? ▸ Why considering the impurities? General Boundary Conditions of the Oxyfuel Process ▸ Flue gas recycle demand; O 2 excess; O 2 concentration Impact of Impurities on the CO 2 Concentration ▸ Where do the impurities come from? R&D Project COORAL ▸ Definition of required CO 2 purity Possibilities to increase CO 2 Purity 3
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What are the barriers for a successful deployment of the Oxyfuel Process? Combustion: no problem ▸ higher oxygen content in comparison to air case ▸ enhanced NOx reduction in comparison to air case Efficiency of overall process: very important ▸ The Oxyfuel Process is competing with other Capture Processes ▸ Oxyfuel will only succeed if its efficiency is better than Post-Combustion Capture CO 2 Purity: very important ▸ Purities between 85% and 99.9% are achievable ▸ An increase in purity influences CAPEX, OPEX and capture rate and thus the economy of the process ▸ Oxyfuel will only succeed if its overall cost is lower than or equal as for the other capture technologies 4 ► Introduction
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CO 2 purity Introduction ▸ What are the barriers for a successful deployment of the Oxyfuel Process? ▸ Why considering the impurities? General Boundary Conditions of the Oxyfuel Process ▸ Flue gas recycle demand; O 2 excess; O 2 concentration Impact of Impurities on the CO 2 Concentration ▸ Where do the impurities come from? R&D Project COORAL ▸ Definition of required CO 2 purity Possibilities to increase CO 2 Purity 5
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Why considering the impurities? Directive 2009/31/EC ( 23 April 2009) Article 12 CO 2 stream acceptance criteria and procedure 1. A CO 2 stream shall consist overwhelmingly of carbon dioxide. To this end, no waste or other matter may be added for the purpose of disposing of that waste or other matter. However, a CO 2 stream may contain incidental associated substances from the source, capture or injection process and trace substances added to assist in monitoring and verifying CO 2 migration. Concentrations of all incidental and added substances shall be below levels that would: (a) adversely affect the integrity of the storage site or the relevant transport infrastructure; (b) pose a significant risk to the environment or human health; or (c) breach the requirements of applicable Community legislation. 6 ► Introduction
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Why considering the impurities? CO 2 Purity: very important ▸ Purities between 85% and 99.9% are achievable ▸ An increase in purity influences CAPEX, OPEX and capture rate and thus the economy of the process ▸ Oxyfuel will only succeed if its overall cost is lower than other capture technologies 7 ► Introduction
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Why considering the impurities? CAPEX, OPEX and capture rate 15:30 – 17:15 Requirements for the storage site 13:15 – 15:15 ▸ Geologists must define the concentration limits ▸ Will there be different limits for different storage options? Requirements for the transport (mainly pipeline) 11:55 – 12:20 ▸ Will there be different limits for the different transport options? Requirements for the recycled flue gas ▸ Internal question of boiler design considerations, mainly related to corrosion Requirements for health, safety and environmental (HSE) reasons ▸ Not subject of today’s discussion 8 ► Introduction
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CO 2 purity Introduction ▸ What are the barriers for a successful deployment of the Oxyfuel Process? ▸ Why considering the impurities? General Boundary Conditions of the Oxyfuel Process ▸ Flue gas recycle demand; O 2 excess; O 2 concentration Impact of Impurities on the CO 2 Concentration ▸ Where do the impurities come from? R&D Project COORAL ▸ Definition of required CO 2 purity Possibilities to increase CO 2 Purity 9
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10 Air 15 %CO 2 6 %H 2 O 76 %N 2 3 %Ar, O 2, … 66 %CO 2 26 %H 2 O 8 %Ar, N 2, O 2, … Air Separation Unit N2N2 O 2 Oxyfuel Process – simplified process scheme Flue Gas Recycle H2OH2O 89 %CO 2 11 % N 2, Ar, O 2, … 2/3 1/3 Flue Gas Drying CO 2 Separation Unit 18 % 82 % 47 %CO 2 53 %Ar, N 2, O 2, … nearly pure CO 2 all percentages as molar percentage Coal exhaust gas 98 %CO 2 2 % N 2, Ar, O 2, NO x, SO 2 ► General Boundary Conditions of the Oxyfuel Process
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11 Factors influencing the recycle requirement (I) Main boundary conditions for the boiler: Steam temperature in the boiler wall is limited to 470 °C due to material reasons Flue gas temperature at the exit of the combustion chamber should not exceed the temperature in the air case (slagging) Both conditions can approximately be fulfilled (for t Recycle < 400°C) if the condition t adiabatic, Air = t adiabatic, O 2 +Recycle is used. t Recycle tO2tO2 t Coal t adiabatic 1250 °C ► General Boundary Conditions of the Oxyfuel Process
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12 Factors influencing the recycle requirement (II) Condition: t adiabatic, Air = t adiabatic, O 2 +Recycle Underlying assumptions: t Air = 320 °C t O 2 = 25 °C t Coal = 40 °C O 2 excess: 15 % O 2 purity:98 % t Recycle tO2tO2 t Coal t adiabatic recycle demand ► General Boundary Conditions of the Oxyfuel Process
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CO 2 purity Introduction ▸ What are the barriers for a successful deployment of the Oxyfuel Process? ▸ Why considering the impurities? General Boundary Conditions of the Oxyfuel Process ▸ Flue gas recycle demand; O 2 excess; O 2 concentration Impact of Impurities on the CO 2 Concentration ▸ Where do the impurities come from? R&D Project COORAL ▸ Definition of required CO 2 purity Possibilities to increase CO 2 Purity 13
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Durch konstruktive Maßnahmen zu erzielender Falschluftanteil ▸ Fuel’s nitrogen and sulfur SO x, NO x Where do the impurities come from? ► Impact of impurities on the CO 2 concentration 14
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0 1 2 3 4 5 6 00,20,40,60,81 standardized pollutant formation rate standardized concentration (dry) Air Oxyfuel (treated recycle) Oxyfuel (untreated recycle) 15 Pollutant formation Air NO x treated SO 2 treated NO x untreated SO 2 untreated Effects: - smaller specific flue gas mass flow - increase of flue gas density - increase of water content in the flue gas ► Impact of impurities on the CO 2 concentration
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16 ▸ Fuel’s nitrogen and sulfur SO x, NO x ▸ Nearly all recycled NOx is reduced ▸ No sense to install DeNOx plant before the flue gas recirculation ▸ Only a small part of SO 2 is reduced ► Impact of impurities on the CO 2 concentration Where do the impurities come from?
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17 0,001 0,01 0,1 p H 2 SO 4 in mbar 10 Air Oxyfuel SO x higher SO x concentration due to missing nitrogen (factor 4 - 5) SO 3 formation promoted by higher concentrations of oxygen and water +20....40 K higher acid dew point temperature of the flue gas temperature vapour pressure curve of sulphuric acid Low temperature corrosion ► Impact of impurities on the CO 2 concentration
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18 76°C Untreated recycle H2OH2O to CO 2 capture O2O2 Coal 14% 347°C 100°Cfeed water preheating FGD 160°C Elevated classifier exit temperature of 160 °C necessary (above acid dew point) No full load operation in air case due to SCR and FGD restrictions 76°C 320°C 80°C 350°C 55% degree of dust removal in recycle P primary fan MW P secondary fan MW P FGD MW P FGD fan MW ΣP MW η gross % completely2.01.83.51.58.850.2 ► Impact of impurities on the CO 2 concentration
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19 Treated recycle H2OH2O coal 260°C 15% 53% 350°C 320°C Classifier exit temperature can be maintained at 100 °C No full load operation in air case due to SCR restrictions (not FGD) 100°C 76°C P primary fan MW P secondary fan MW P FGD MW P FGD fan MW ΣP MW η gross % 1.10.33.55.09.949.4 feed water preheating to CO 2 capture 100°C FGD 73°C O2O2 80°C ► Impact of impurities on the CO 2 concentration
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20 Residual oxygen in flue gas In the Oxyfuel process the following applies for the residual oxygen in the flue gas: ▸ The smaller the recycle rate the larger the concentration of residual oxygen ▸ The concentration of residual oxygen is always significantly higher than in the air case (4.8 vs. 2.8 vol.-%, dry) 10 50556065%75 2 3 4 5 6 7 8 vol. % (dry) recycle rate 11 % 12 % 13 % 14 % 15 % 16 % 17 % 18 % 19 % 20 % oxygen excess for combustion residual oxygen ≈ 4,8 air case ► Impact of impurities on the CO 2 concentration
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Durch konstruktive Maßnahmen zu erzielender Falschluftanteil ▸ Fuel’s nitrogen and sulfur SO x, NO x ▸ Oxygen excess 3 – 3.5% / 4.5 – 5% O 2 -residue 21 ► Impact of impurities on the CO 2 concentration Where do the impurities come from?
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Durch konstruktive Maßnahmen zu erzielender Falschluftanteil 22 ▸ Fuel’s nitrogen and sulfur SO x, NO x ▸ Oxygen excess 3 – 3.5% / 4.5 – 5% O 2 -residue ▸ Air separation unit 98% O 2 -purity:2%Ar 95% O 2 -purity:3.8%Ar + 1.2% N 2 ► Impact of impurities on the CO 2 concentration Where do the impurities come from?
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23 Energy demand for ASU and CO 2 separation Boundary conditions: capture rate = 90 %, CO 2 -purity > 96%, 87 % of oxygen delivered by ASU, South African hard coal, 2 % leakage air Overall net efficiency increase by decreased O 2 purity by approx. 2.3 %-points ► Impact of impurities on the CO 2 concentration O 2 purity - ASU technology
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Durch konstruktive Maßnahmen zu erzielender Falschluftanteil 24 ▸ Fuel’s nitrogen and sulfur SO x, NO x ▸ Oxygen excess 3 – 3.5% / 4.5 – 5% O 2 -residue ▸ Air separation unit 98% O 2 -purity:2%Ar 95% O 2 -purity:3.8%Ar + 1.2% N 2 ► Impact of impurities on the CO 2 concentration Where do the impurities come from?
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25 ▸ Fuel’s nitrogen and sulfur SO x, NO x ▸ Oxygen excess 3 – 3.5% / 4.5 – 5% O 2 -residue ▸ Air separation unit 98% O 2 -purity:2%Ar 95% O 2 -purity:3.8%Ar + 1.2% N 2 ▸ Air leakage approx. 3 % of flue gas flow for a new conventional power plant up to 10 % over the years for power plants in use Air leakage is a major source of impurities and needs to be reduced by appropriate design Air Leakage ► Impact of impurities on the CO 2 concentration Where do the impurities come from?
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26 Impurities in the Flue Gas N 2, Ar ▸ Sources: oxygen, air ingress,… ▸ Inert components which have no significant impact underground ▸ Increase auxiliary power demand for liquefaction of the CO 2 (as shown above this is not very much) ▸ Removing them during air separation (to achieve purer O 2 ) increases the auxiliary power demand of the air separation unit (as shown above this is very much) Need for optimization between air separation and CO 2 liquefaction (considering also air leakage) ► Impact of impurities on the CO 2 concentration
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27 O 2, NO X, SO 2,CO, Hg, Cl ▸ May negatively influence the geological storage site by causing geochemical reactions or the transport in pipelines The maximum permissible concentrations for these impurities are still to be defined Impurities in the Flue Gas ► Impact of impurities on the CO 2 concentration
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CO 2 purity Introduction ▸ What are the barriers for a successful deployment of the Oxyfuel Process? ▸ Why considering the impurities? General Boundary Conditions of the Oxyfuel Process ▸ Flue gas recycle demand; O 2 excess; O 2 concentration Impact of Impurities on the CO 2 Concentration ▸ Where do the impurities come from? R&D Project COORAL ▸ Definition of required CO 2 purity Possibilities to increase CO 2 Purity 28
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29 COORAL CO 2- Reinheit für Abtrennung und Lagerung (CO 2 purity for capture and storage) Partners: ▸ BGR, BAM, DBI, MLU, TUHH ▸ Industry: Alstom, E.ON, Vattenfall, EnBW, VNG Includes the whole CO 2 chain from production to storage: Production Storage Transport Injektion I II III IV Project COORAL ► R&D project COORAL
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30 COORAL - Objectives Estimation of impurities in CO 2 (Post-Combustion, Oxyfuel, Pre-Combustion) Possibilities to influence the CO 2 impurities by ▸ operation of the power plant ▸ CO 2 separation processes (Post-Combustion, Oxyfuel, Pre-Combustion) ▸ CO 2 treatment (mainly Oxyfuel) Examination of the effects caused by impurities on ▸ the transport chain ▸ the injection chain ▸ the geological site (geochemical reactions) Optimisation between economic and plant-specific demands Definition of the required CO 2 purity for capture and storage ► R&D project COORAL
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Expected impurities in separated CO 2 Component Post-Combustion Oxyfuel Pre-Combustion N 2 Yes O 2 Yes (Yes) ArYes H 2 OYes NO X Yes No SO X Yes No NH 3 YesNo Hg,...NoYes H 2 No Yes H 2 SNo Yes HCNNo Yes CH 4 No Yes COYes COSNo Yes Residues from WashingYesNoYes 31 ► R&D project COORAL
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Scenarios of Expected Impurities - Post-Combustion Post I ▸ 99,93 Vol.-% CO 2 ▸ 150 ppm O 2 ▸ 450 ppm N 2 + Ar ▸ 20 ppm NO X ▸ 10 ppm SO 2 ▸ 100 ppm H 2 O ▸ 10 ppm CO Post II ▸ 99,92 Vol.-% CO 2 ▸ 150 ppm O 2 ▸ 450 ppm N 2 + Ar ▸ 20 ppm NO X ▸ 10 ppm SO X ▸ 100 ppm H 2 O ▸ 10 ppm CO ▸ 50 ppm NH 3 * Post III ▸ 99,81 Vol.-% CO 2 ▸ 300 ppm O 2 ▸ 900 ppm N 2 + Ar ▸ 40 ppm NO X ▸ 20 ppm SO X ▸ 600 ppm H 2 O ▸ 20 ppm CO 32 * approximation. ► R&D project COORAL
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Scenarios Expected Impurities - Pre-Combustion Selexol ▸ 97,95 Vol.-% CO 2 ▸ 1,0 Vol.-% H 2 ▸ 0,9 Vol.-% N 2 ▸ 300 ppm Ar ▸ 100 ppm H 2 S + COS ▸ 600 ppm H 2 O ▸ 400 ppm CO ▸ 100 ppm CH 4 Rectisol ▸ 99,7 Vol.-% CO 2 ▸ 20 ppm H 2 ▸ 0,21 Vol.-% N 2 ▸ 150 ppm Ar ▸ 20 ppm H 2 S + COS ▸ 10 ppm H 2 O ▸ 400 ppm CO ▸ 100 ppm CH 4 ▸ 200 ppm Methanol 33 ► R&D project COORAL
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Scenarios of Expected Impurities - Oxyfuel Oxyfuel I (Zero Emission) ▸ 85,0 Vol.-% CO 2 ▸ 4,70 Vol.-% O 2 ▸ 5,80 Vol.-% N 2 ▸ 4,47 Vol.-% Ar ▸ 100 ppm NO X ▸ 50 ppm SO 2 ▸ 20 ppm SO 3 ▸ 100 ppm H 2 O ▸ 50 ppm CO Oxyfuel II Oxyfuel IV (Distillation) ▸ 99,94 Vol.-% CO 2 ▸ 100 ppm O 2 ▸ 100 ppm N 2 ▸ 100 ppm Ar ▸ 100 ppm NO X ▸ 50 ppm SO 2 ▸ 20 ppm SO 3 ▸ 100 ppm H 2 O ▸ 50 ppm CO 34 Oxyfuel III (Concentration) ▸ 98,0 % CO 2 ▸ 0,67 % O 2 ▸ 0,71 % N 2 ▸ 0,59 % Ar ▸ 100 ppm NO X ▸ 50 ppm SO 2 ▸ 20 ppm SO 3 ▸ 100 ppm H 2 O ▸ 50 ppm CO ► R&D project COORAL
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CO 2 purity Introduction ▸ What are the barriers for a successful deployment of the Oxyfuel Process? ▸ Why considering the impurities? General Boundary Conditions of the Oxyfuel Process ▸ Flue gas recycle demand; O 2 excess; O 2 concentration Impact of Impurities on the CO 2 Concentration ▸ Where do the impurities come from? R&D Project COORAL ▸ Definition of required CO 2 purity Possibilities to increase CO 2 Purity 35
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36 p-T-diagram for Single-Stage Cryogenic CO 2 Liquefaction ► Possibilities to increase CO 2 purity Conditions: Air leakage:2.0% O 2 -purity:99.5 % Range of interest
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Impact of distillation on overall power demand for CO 2 capture 37 ► Possibilities to increase CO 2 purity CO 2 capture rate Overall power demand for CO 2 capture in MW Consider a certain minimal temperature level (e. g. -40 °C): ▸ higher flue gas pressure necessary to achieve a similar CO 2 capture rate ▸ increase in power demand The additional distillation reduces the efficiency of the overall power plant process by 0.2 %-pts. for a capture rate of 90 %.
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CO 2 liquefaction plant photos 38 ► Possibilities to increase CO 2 purity
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39 Experiments with Oxyfuel flue gas ► Possibilities to increase CO 2 purity Oxyfuel Flue Gas: Combustion of hard coal in CO 2 mixture with 30 %vol O 2, residual oxygen ~4 %vol Experiments at different pressure and temperature conditions ▸ Composition of vapour and liquid phase ▸ Experimental experience ▸ Sulphur and nitrous components
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CO 2 purity Introduction ▸ What are the barriers for a successful deployment of the Oxyfuel Process? ▸ Why considering the impurities? General Boundary Conditions of the Oxyfuel Process ▸ Flue gas recycle demand; O 2 excess; O 2 concentration Impact of Impurities on the CO 2 Concentration ▸ Where do the impurities come from? R&D Project COORAL ▸ Definition of required CO 2 purity Possibilities to increase CO 2 Purity 40 Thank you for your attention!
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Hamburg University of Technology CO 2 Quality and Other Relevant Issues Oxyfuel Process (Post-Combustion Capture) (Pre-Combustion Capture) Introduction and Objectives of the Meeting Thank you for your attention! 2 nd Working Group Meeting on CO 2 Quality and Other Relevant Issues 7 th September 2009, Cottbus A. Kather Institute of Energy Systems
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