callide oxyfuel project update

Callide Oxyfuel Project Update

クリス・スペロ博士カライド酸素燃焼プロジェクト・ディレクター

19 June 2014

Global CCS Institute Japan Regional Members’ Meeting

Presentation Overview

• Purpose of the presentation is to provide an overview of the Callide Oxyfuel Project and considers:

• Historical background of PF and oxy-combustion

• Callide Oxyfuel technology description (Oxyfuel Boiler and CO2 Capture Plant)

• Results of Oxy-fuel boiler and CO2 Capture trials

• Results of Storage assessments

• Lessons learned

Historical development of PF and oxy-combustion

The project, as formally established in 2008 has two broad goals, namely to:

• Demonstrate a complete and integrated process of oxy-fuel combustion of pulverised coal within a National Electricity Market facility, incorporating oxygen production, oxy-fuel combustion, CO2 processing and liquefaction, and to assess CO2 transport and geological storage;

• Obtain detailed engineering design and costing data and operational experience to under-pin the commercial development and deployment of new and retrofit oxy-fuel boiler applications for electricity generation.

Configuration: 2 x 330 TPD ASUs, 30 MWe Oxyfuel boiler, 75 TPD CO2 Capture

Overall budget: CAPEX AU$180 million; OPEX $64 million

Operating Period: 2½ years

Project Goals, Cost and Operational Targets

Project Structure

Project Milestones

TECHNOLOGY DESCRIPTION

Oxyfuel boiler schematic

COP - Boiler works

ID Fan

H2O remover

PAH

SAHOutlet

FGLPH

Carbon dioxide capture plant

Courtesy of Air Liquide

LP Scrubber

DriersHP Scrubber

Compressor

Cold box/inerts separators

CO2 Capture: 75 t/day (net)CO2 Capture rate: > 85%

ASU & CO2 capture plant

Compressor

Coldbox

LP Scrubber

Quencher

HP Scrubber

Driers

Filters

OXYFUEL BOILERRESULTS AND LEARNINGS

Air-mode to Oxy-mode transition

1. Optimisation of mode transition Air → Oxy, Oxy → Air, stable Oxy-mode operation

2. Trials completed with a range of bituminous coals and semi-anthracite/Callide blend

3. Combustion Efficiency: 50 – 60% decrease in unburnt Carbon

4. NOx emissions: Air (90 mg/MJ fuel) → Oxy (40 mg/MJ fuel)

5. Particulates: Air (2 – 2.5 g/s) →Oxy (1.6 – 2.3 g/s)

Oxyfuel boiler performance

CO2 CAPTURE (CPU)RESULTS AND LEARNINGS

CPU – Environmental performance

•Low pressure scrubbers utilise a caustic soda wash to remove SO2 from the gas stream (< 10 ppm in gas phase).

•Nitrous Oxide (NO) passes through the LP scrubbers but is largely converted to NO2 during flue gas compression.

•Trace elements in the gas phase are also effectively extracted from the gas phase in the Low Pressure section of the CPU.

•The principal gaseous emissions from the CPU are CO2 and NO2. Considerable work has been done to characterise the behaviour of NOx in the CPU.

CPU – Process condensates

Test data indicates:

• LP area (caustic wet scrubbers and filters) remove particulates, SOX, NO2 and a major portion of trace elements

• NO is converted to NO2 in the compressor and a significant portion is removed with the intercooler and aftercooler condensates as Nitric Acid.

• Almost all the Hg that has passed through the LP sections (as Hgo) is removed with the compressor condensates.

CO2 STORAGE ASSESSMENTS

Surat Basin Storage Tenements (South East Queensland)

Surat Basin Storage Capacity

Courtesy: Coal Bed Energy Consultants

Overall Surat Basin storage capacity > 850 Mt CO2

• Establishment of the Project (structure, business systems, budgets, and schedules)

• Contract management

• Communications (with partners, Stakeholders and the Public)

• Identification and control of technical risks

• Operations and maintenance strategies and experience.

• Managing workplace health and safety, and the environment

• Transitioning of the power station culture and skill base from conventional coal-fired power plant to more complex and multi-purpose facilities designed to make electricity and capture CO2 and other emissions

• Enhancements that would be applied to the next scale up of the Oxyfuel and CO2 capture technology

• Efficacy of the technology in general

High-level learnings

1. The Callide Oxyfuel Project has been complex for 3 principal reasons:

• Large capital investment for a non-commercial demonstration, requiring a number of funding agreements and equity.

• Engineer Procure Construct Manage (EPCM) for capital works involving a large number of contracts.

• First-of-a-kind project, operating in an electricity market.

2. Supporting R&D and publications:

• ANLEC (University Newcastle, Macquarie University)

• ACALET

• Global CCS Institute (Lessons Learned Report; Appraisal of CO2 storage sites in Surat Basin)

• NEDO & METI (IHI R&D)

• Air Liquide R&D

3. The Project has demonstrated over 6500 hours of oxyfuel boiler operation, routine mode changes air-oxy mode, over 3200 hours of CO2 capture plant operation and capture rates exceeding 85%

4. Next step is to consolidate the learnings from Callide A and to apply these to new projects

Concluding comments

Thank you

for more information: www.callideoxyfuel.com

Callide Oxyfuel Project – Participants