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Russian investigation Russian investigation of the COof the CO
2 2 capture and capture and storage. storage.
Implementation of Implementation of CFB for CO2 capture CFB for CO2 capture
and and polygenerationpolygeneration systemssystems
G. A. Ryabov
AllAll--Russian Thermal Engineering Institute (VTI)Russian Thermal Engineering Institute (VTI)
[email protected]@gmail.com
6262--th IEA FB Cth IEA FB Coonversion meetingnversion meetingAugust, 29, 2011August, 29, 2011
Technical University of Vienna, AustriaTechnical University of Vienna, Austria
COCO2 2 emissions of Russia in 1990 emissions of Russia in 1990 ––
2020 period2020 period
Russia Federation is responsible for the 8 % of world GHG emissions and is amongst the world’s five largest emitters. If the current trends continue Russian GHG emissions would totally amount to 2
-
2.4 billion tons of СО2 equivalents in the 2010-2020 periods. Thus, considering overall levels of GHG emissions, Russia is expected to easily remain within the established balance of GHG emissions and even could have a surplus.
Russia federation guaranteed that Kioto
obligations will be fulfil. Cumulative and not realizing votes on CO2
may be about 3000 mln. t.
•
Energy saving (up to 40 % of energy consumption)•
Increasing of power plants efficiency
•
Long term programme of CO2
capture and storage (IGCC, post combustion CO2
capture, chemical looping combustion, oxy-fuel combustion, underground CO2 storage in deep oil fields)
The schedule of Russian The schedule of Russian programmeprogramme
of COof CO22 reductionreduction
2015
г. 2020 г. 2030 г.
Wide implementation of gas turbine this net efficiency > 55 %
Start up new project of coal fired TPP on high supercritical parameters 28-30 МПа, 600-620 оС
Investigations of new technologies and processes of CO2
capture and storage
Start up operation of first units on ultra supercritical parameters 35 МПа, 700-720 оС
Implementation of gas turbine this net efficiency 63-65 %
Utility size IGCC plant
Demo plant of high temperature gas turbine and fuel cells
Demo plant of CO2
capture and storage
Utility size IGCC this H2
production
Utility size plant this high temperature gas turbine and fuel cells, net efficiency (gas) -
70-75 %, (coal) -
60-65 %
Utility size plant of CO2
capture and storage
The main trends of Russian programme in COThe main trends of Russian programme in CO2 2 reductionreduction
Since 2005 Russian programme
in field of capture and storage of CO2
startеd up. In view of some uncertainly in the forecasts about global warming and its consequences, it was decided not to aim at fastest implementation of the today available systems, but to elaborate advanced, economically attractive ideas: IGCC with precombustion
CO2
capture, oxyfuel
and chemical looping combustion (CLC).
The development of IGCC and experimental researches of processes
and equipments for them are caring out in VTI more then 25 years. Last time were consider the opportunities of integration in IGCC the systems, needed for water shift reaction
of CO to CO2
and H2
, the release of CO2
from synthetic gas before of its combustion in GT.Researches on CCS have begun in VTI a few years ago. They are financed by Ministry
of Science and Education. Also, VTI tooke
part in FP6 project “Calcium cycle for efficient and low cost CO2
capture using fluidized bed systems”.
CCS Russia programmeCCS Russia programme
CLC test rig (LCLC test rig (L--valve recirculation) valve recirculation)
The first in Russia laboratory CLC test rig was completed. The aims of investigations are combustion processes, heat realized and hydrodynamics in CLC operated as bubbling or circulated manner.
The table presentsThe table presents main characteristics of VTI CLC test main characteristics of VTI CLC test rig in comparison of Chalmers University installation rig in comparison of Chalmers University installation
(A. (A. LungfeltLungfelt, 2005), 2005)Item Unit VTI
Power (fuel) kWt 10 10 -
20Stoichiometric
ratio - 1,2 –
2,6 2Temperature in reactors
0С 950 850 -
950
Apparent density kg/m3 2500 –
5400 near
4000Particle size mm 0,1 –
0,2 0,15Gas velocity/transport velocity in oxidiser
- 1,2 –
3 2 -
4
Gas velocity/minimal fluidization velocity in reducer
- 5 –
15 5 -
18
Gas velocity//minimal fluidization velocity in valves
- 1,2 –
4 2 -
5
Oxidizer diameter m 0,072 0,068Oxidizer height m 1,85 2,0Reducer diameter m 0,25 0,142Bed height in reducer m 0,13 0,15Reducer height m 0,34 1Full height of the installation
m 2,2 3,0
Oxygen carriersOxygen carriers
The feasibility study of preparing iron and nickel oxide as an oxygen carrier (NiO- Fe2
O3
/AL2
O3
, in size of 0,05 –
0,15 mm) carried out by Karpov
Institute of Physical Chemistry. The metal oxides, used as an oxygen carriers in CLC, should have sufficient rates of reduction and oxidation, at the same time as
it possesses enough
strength to limit particle breakage and attrition. It is also an
advantage if oxides are cheap. As active materials were chosen NiO
and Fe2
O3
and support material – Al2
O3
. The probe (5 and 7 kg) of composites was prepared in order of method investigated by Karpov
Institute of Physical Chemistry.
The fractional composition of the materialsThe fractional composition of the materialsNiO
+ Al2
O3 NiO
+ Fe2
O3
+ Al2
O3
The photo of the compositesThe photo of the composites
Common algorithm of the CLC unit calculation Common algorithm of the CLC unit calculation
Xoк
– preset of the conversion in oxidizer; Хок1 – current conversion in oxidizer; ∆
xoк
– carrier conversion calculation accuracy in oxidizer; ∆X - conversion difference; γвос
– fuel conversion in reducer; mтв
– quantity of materials carry away from oxidizer; Сок
– oxygen carrier capacity; m0 - necessary oxygen quantity for fuel combustion; Твос
– preset temperature in reducer; Т1 – current temperature in reducer; ∆т
- reducer temperature calculation accuracy; ∆X1- conversion difference updated valueу; ∆
- conversion difference calculation accuracy
Demo plant schemeDemo plant schemeVTI carried out the capital costs evaluation of the plant construction of 10 and about of 100MW
(thermal).
Industrial plant schemeIndustrial plant scheme
1 – compressor, 2 – air preheater, 3 – gas preheater, 4 – reducer, 5 – oxidizer, 6 – gas turbine, 7 – economizer II, 8 – economizer I, 9 – heat exchanger, 10 – feeding pump, 11 – evaporator + superheater, 12 – steam turbine, 13 – condenser, 14 – circulating pump,
15 – condensing pump, 16 – condenser, 17 – deaerator
Capital cost estimationsCapital cost estimations
• The CLC plants differ from traditional facilities with boiler units or combustion chambers and heat-recovery boilers. They include additionally the metal oxide reducer (fuel reactor) and reactant recirculation system. In fact, they are quite similar to the units with CFB boilers, as long as heat, in such installations, is withdrawn in the oxidizer, which operates with CFB.
• The convection pass is divided into two flows of flue gases. This fact does not change the construction substantially, but increases the fencing
and construction
expenditures. The construction includes heat exchanger for СО2 flow dehumidification, where the low potential heat of water evaporation is used (for heat supply or as heat exchanger for warming up the condensate –
LP Water
Heater).
• Thus, it is needed to evaluate the metal capacity of the whole installation and especially of its auxiliary details, and after that, on the basis of the similar projects, to determine the price of the whole work
price.
Capital cost and COCapital cost and CO22 capture costcapture cost
• Total capital costs of the installation with power output of 10 MW is about 150 million RUR. This installation produces about 510 kg/h of СО2
. Auxiliary capital expenditures for separation of СО2
do not exceed 50 million RUR.
• Capital expenditures for power unit with thermal output of 114 MW and combined electricity net generation of 36.4 MW come up to 2010 million RUR. Specific costs for generation of 1 kW of electricity are at the level of 2200 –
2600 USD. Such
expenditures for the similar power units with combined cycle plants and without СО2
separation come up to the level of 1500 –
1700 USD, thereby, the increase of capital
expenditures reaches about 30 –
40 %.
• This plant generates 5.8 tons/h СО2
. This is equal to 1.4 million tons for the whole operation period. Hereby, specific capital costs for СО2
capturing are at 620 RUR or 17 Euro per ton of СО2
. Taking into account the possibility of costs of the huge power
units with optimized parameters decrease, the specific expenses could be decreased by 12 –
15 Euro per ton of СО2
. These values are one of the best exponents among the all СО2
capturing technologies.
The evaluations of capturing, transportation The evaluations of capturing, transportation and disposal costs of ton of and disposal costs of ton of СОСО22
Plants СО2
capturing costs, Euro/ton
СО2 transportation costs, Euro/ton
СО2
disposal costs, Euro/ton
Total costs, Euro/ton
Pilot plant 100 MW
20 5 -
7 3 -5 28 -
32
Industrial plant 12 -
15 3 -
5 0,7 -
3 15,7 -
23
It is possible to expect 20 –
30 % investment growth, 30 -
40 % electricity shop price growth and 4 –
8 % decrease of efficiency for industrial plants with CLC gas combustion. It
is also needed to take into account the expenditures for the whole plant appreciation, however, their values are going to be lower, than with application of another CO2 capturing methods. This fact allows optimistically sight to the development of CLC plants. It is considered in (T. Mattisson, 2004, M. Johansson, 2004), due to the application of CLC fuel combustion, it would be possible to achieve the specific costs at a level of 10 Euro per 1 ton of СО2
. This value is twice less, than for other ways of СО2 separation.
The designed scheme of The designed scheme of oxyfueloxyfuel test rigtest rig
VTI start up investigation in field of oxyfuel
combustion.
The scheme of laboratory test rig shows in figure. The test rig is under construction now.
COCO22 storage from Russian TPP storage from Russian TPP
An inventory of the candidate sources for CO2
removal in Russian Thermal Power Plants (TPP) was determined.
As candidate sources could be characterized the sources which have large emission volumes, high CO2
concentration, proximity to a suitable storage site so the implementation of CO2
sequestration will be viable.
For example, the main CO2
generation regions are Moscow region (10.2 % CO2 emission from TPP), Ural region (5/8 %); the largest emission of
CO2
has Surgutskay
(3.2 %), Permskay
(1,4 %), Novocherkasskay
(1.2 %) TPP.
Underground storageUnderground storage
Regional storage opportunities was investigated also in cooperation with JSK
“PODZEMGASPROM”
and Gubkin
State University of oil and gas.
Inventory of the geological formations such as depleted oil and gas reservoirs, active oil and gas reservoirs, deep saline aquifers (sub-terranean
or sub-seabed) that
can be used as CO2
storage sites and their geological and hydrogeological characterization was studied.
The main possibility of CO2
storage of large Russian TPP is onshore storage. We began a preliminary estimation for detecting the major factors affected the storage cost.
Russia has more than 50 years experience of underground storage with amount of 114 billions m3
of natural gas. There are more than 20 underground gas storage (16 in used gas fields) in Russia.
Other tasks of our investigations are:
•
monitoring and verification issues once CO2
is geologically stored;
•
determining potential risks to humans and environment and implementation of remediation methods to stop or control leakage of CO2
;
•
detailed assessment of technical issues such as volume, CO2
concentration, flow rate, integrity of storage sites;
•
proximity of the source and storage site, transportation routes;
•
existing infrastructure, injection rates etc as well as economic, safety and environmental issues.
Our investigation shows that CO2
injection in deep oil or difficult to extraction oil fields is very attractive method for Russian conditions.
Multi-generation systems based on pyrolysis
of coal include many of configurations. Two high-capacity units of this type (UTT –
3000, 139 tons of
shale per hour each) were erected at Estonian thermal power plants (TPP). And they with still show good performance.
VTI has an agreement on scientific cooperation with the Institute for Thermal Power Engineering, Zhejiang University in this field. In studies
carried out by
Zhejiang University data were received from their tests on a 1 MW pilot plant. Our investigation was financed by the Russian Ministry of Science and Education as a part of a China –
Russia scientific cooperation project.
Another aim of the investigation of the interconnected FB and CFB reactors is the chemical looping process hydrodynamics (double metal oxides or carbonate oxides reactors) and the three reactor chemical looping gasification processes.
DCFB concept for DCFB concept for polygenerationpolygeneration systems and CLCsystems and CLC
Scheme VTI cold model of interconnected reactors General arrangement of Cold model
1
-
furnace model; 2 -
cyclone; 3
-
riser; 4
-
pneumatic valve; 5
-
heat exchanger
model
1 –
transportation reactor; 2 –
FB reactor; 3 –
CFB
reactor
TEST RIGSTEST RIGS
Our studies were basically directed to calculate the circulating
mass flow rate in the external circuit (Gr), as it is the critical operational parameter for the interconnected reactors. The solid flow rate increases with gas velocity in the CFB unit and unit inventory.
Typical solid circulation rate as function of velocity and
RESULTS. BED MATERIAL RECIRCULATIONRESULTS. BED MATERIAL RECIRCULATION
Pressure profile in the Cold modelSand, 0, 21 mm, gas velocity -
4 m/s,
particle flow rate –
1kg/s
Typical pressure profile
in the cold model of interconnected reactors
RESULTS. PRESSURE PROFILERESULTS. PRESSURE PROFILE
The
studies
on
circulation
and
the
return
systems
of
interconnected
reactors found:
•pressure
profile
and
vertical
solids
concentrations
in
interconnected
FB
and
CFB reactors are typical for corresponding reactors of this type, and depended on gas velocity and bed level (bed inventory);
•pressure
change
at
corresponding
points
depend
on
the
fluidization
and
the design features of unit`s
structure and return system;
•solids
flow
rate
in
interconnected
FB
and
CFB
reactors
depends
on
gas
velocity and
solids
inventory
in
CFB
reactor,
on
condition
of
high‐efficient
separation
and
sufficient capacity of return system with fixed diameter of particles;
•bed
return
system
(standpipe
and
pneumatic
valve)
must
have
reserve
capacity and
regulation
ability
by
air
injection
to
standpipe
and
upflow
part
of
the
valve.
Otherwise
the
recirculation
solids
flow
rate
is
determined
by
the
operational mode of the valve.
Financial support of this work by the Federal Agency of Science and Innovation is gratefully acknowledged.
CONCLUSIONS (cold models DCFB)CONCLUSIONS (cold models DCFB)
CONCLUSIONSCONCLUSIONS
• Russian federation is interested in progress of CO2 capture and storage investigations. The main trends of Russian programme in CO2 reduction are:
o energy saving (up to 40 % of energy consumption);o increasing of power plants efficiency;o long term programme of CO2 capture and storage (IGCC, post combustion CO2 capture,
chemical looping combustion, oxy-fuel combustion, underground CO2 storage in deep oil fields).
• Since 2005 Russian program in field of capture and storage of CO2 startеd up. In view of some uncertainly in the forecasts about global warming and its consequences, it was decided not to aim at fastest implementation of the today available systems, but to elaborate advanced, economically attractive ideas: IGCC with precombustion CO2 capture, oxyfuel and chemical looping combustion (CLC).
• Chemical looping combustion (CLC) is a promising technique for the separation CO2 with small losses in energy. The laboratory CLC test rig (10 – 20 kW) was completed for natural gas and singas firing.
• Other task of our investigation is to determine optimal storage methods for Russian conditions.
Thank you for attention!Thank you for attention!Thank you for attention!