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CCS Project: Chilled Ammonia Process at the AEP Mountaineer
CCS Project: Chilled Ammonia Process at the AEP Mountaineer Plant Fred Kozak Alstom Power, USA Vauhini Telikapalli Alstom Power, Switzerland Rameshwar Hiwale Alstom Power, USA Rob Bollinger American Electric Power, USA August 17, 2011 © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Agenda • CCS Development Program • CAP Process in the Field • Mountaineer PVF Program • CAP Steam Evaluation • PVF Additional Findings • Conclusion © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. CCS Development Program Alstom CCS Technologies CO2 capture technologies pursued by Alstom Post-combustion (New + retrofit) Oxy-combustion (New + retrofit) • Chilled Ammonia • Oxy Combustion with Air Separation Unit • Advanced Amines • Chemical Looping Combustion CCS Technology must be applied to both new and existing units © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Alstom CCS Demonstrations 1st and 2nd Generation Operating Completed Under Construction 2 Gen AEP Mountaineer USA - 58 MWth Chilled Ammonia, Coal Vattenfall Schwarze Pumpe Germany - 30 MWth Oxy - Lignite Total Lacq France - 30 MWth Oxy - Gas RFCS EU - Darmstadt Germany - 1 MWth Chemical looping, Coal 2 Gen TCM Mongstad Norway - 40 MWth Chilled Ammonia - Gas Pre-commercial Projects NER300 EoN Karlshamn Sweden - 5 MWth Chilled Ammonia -Fuel Dow Chemical Co. DOE/Alstom Windsor USA, West Virginia US – 3 MWth Adv. Amines - Coal Chemical looping, Coal WE – Energie USA WI - 5 MWth Chilled Ammonia, Coal Alstom BSF Windsor Alstom Labs Växjö US - 15 MWth Sweden – 0.25 MWth Oxy - Coals Post C. – multi purpose NER300 ON HOLD Drax - Selby UK - 426 MWe Oxy – Hard Coal NER300 Vattenfall Jänschwalde Germany - 250 MWe Oxy - Lignite Transalta Canada - >200 MWe Post - Coal NER300 ON HOLD PGE Belchatow Poland – 260 MWe Adv. Amines - Lignite NER300: Applied for EU ETS Presentation Title - Presenters Initials - dd mmm yyyy - P 4 EDF – Le Havre France – 5 MWth Adv. Adv. Amines - Coal New Entrant Reserve funding AEP Mountaineer USA – 235MWe Chilled Ammonia - Coal Selected for receiving EEPR funding Getica - CET Turceni Romania – >250MWe Chilled Ammonia - Lignite Selected by Alberta and Federal Canadian funding © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. CCS Development Program CAP Development Road Map 2006 Test Test Rigs Rigs Industrial Industrial Pilots Pilots Prove Concept Alstom Vaxjö Sweden 0.25 MWth 2015 2009 2008 Validation Validation Pilots Pilots Commercial Commercial by by 2015 2015 Large-scale Large-scale demonstration demonstration Validate Technology We Energies Pleasant Prairie USA - 5 MWth, Coal AEP Mountaineer USA - 58 MWth, Coal EoN Karlshamn Sweden - 5 MWth, Oil TCM Mongstad Norway - 40 MWth, Gas Turceni GETICA Romania - >200 MWe, Lignite Tests completed Under construction In operation Targeted Roadmap to Commercialization © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. CAP Process in the Field Chilled Ammonia Process (CAP) Description Principal • Cooled flue gas is treated with ammonium carbonate in solution, which reacts with CO2 to form ammonium bicarbonate • Raising solution temperature, reverses the reaction – releasing pressurized CO2 Advantages • Energy-efficient capture of CO2 • High CO2 purity • Tolerant to oxygen and flue gas impurities • Stable reagent, no degradation possible, no emission of trace contaminants • Low-cost, globally available reagent • Potentially salable byproduct (ammonium sulfate). Source: Alstom A CCS technology with demonstrated high availability © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. CAP Process in the Field WE Energies Pilot • Proof of Concept Objectives met: 9 90% CO2 capture efficiency 9 CO2 Product Quality >99.5% 9 Sustained regeneration at high pressure 9 NH3 in residual flue gas < 10 ppm 9 No solvent degradation 9 Heat integration opportunities identified 9 Mechanical inspection confirmed materials selection 9 Sustained operation through power plant transients CO2 Field Pilot at Pleasant Prairie Basic Concept Proven © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. CAP Process in the Field Mountaineer Process Validation Facility (PVF) • Validation Objectives met: 9 75-85% CO2 capture efficiency 9 CO2 Product Quality > 99.9% 9 NH3 in residual flue gas < 10 ppm 9 Sustained operation through transients 9 Process Simulation Model 9 Underground storage feasability 9 Detailed inspection underway CO2 Field Pilot at AEP Mountaineer Design Methodology Validation © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Mountaineer PVF Program PVF Unit Operations Unit Operations • Direct Contact Cooler/Heater to remove flue gas moisture • Absorber to capture CO2 • Water Wash to capture residual ammonia • Regenerator to release CO2 from rich solution • Ammonia Stripper to release NH3 from wash water • Appendix Stripper for liquid inventory control • Compressor to inject CO2 in geologic formations Demonstrated the Integration of Unit Operations to meet Process Objectives under changing flue gas conditions © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Mountaineer PVF Program PVF Unit Operation Summary CO2 Stored Total Metric tones 40,000 YTD Total 11,563 27,177 8,668 10,227 20,230 37,404 30,000 20,000 10,000 CAP Act Jun-11 May-11 Apr-11 Mar-11 Jan-11 Feb-11 Nov-10 Dec-10 Oct-10 Sep-10 Jul-10 Aug-10 Jun-10 May-10 Apr-10 Mar-10 0 Jan-10 Metric tones 7,901 Feb-10 CO2 Stored AEP-2 2,672 Nov-09 CO2 Stored AEP-1 Metric tones 50,000 Dec-09 Storage System 51,173 Oct-09 Operational time (hr) 23,736 60,000 Sep-09 Metric tones Total Aug-09 CO2 Captured YTD metric tones CO2 Capture System STOR Act Data through May 28, 2011 Increased Operating Reliability and Capacity with Improvements in Place © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Mountaineer PVF Program Model Development • Aspen Plus® was selected as the design platform for CAP technology • Recognized issues with resident thermodynamic and thermo-physical property data - • Regressed laboratory data to adjust the standard platform Obtained field results from stable operations Compared the field results with the regressed model results Used the model as an optimization tool to predict field conditions Adjusted operations to compare against the model benchmark Established validation program to test the mathematical model Validated Model Available for Economic Optimization © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Mountaineer PVF Program Model Development Ammonia Solution Molarity :Higher Molarity Regressed model Experimental PCO2 Aspen with Regressed Parameters Aspen with Default Parameters 1.10 1.00 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 Unregressed model Mole Fraction of CO2 Regressed VLE Model matches experimental data © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Mountaineer PVF Program Model Validation Test Program Test Description Flue Gas Flow Rate Tests DCC/DCH Tests Overall Optimization Test Campaign Regenerator Tests Rich/Lean Heat Exchanger Network Tests Reduced Pressure Regenerator Test High Pressure Appendix Stripper Tests Low Pressure Appendix Stripper Tests Absorber Tests Campaign WW-Stripper Tests Transient Behavior Tests Total Field Test Conducted 5 14 1 9 9 1 6 3 8 8 1 65 Test program designed to validate process adequacy © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Mountaineer PVF Program Model Validation MTN-PVF:Regenerator Testing: Regenerator Duty 23 22 Predicted Duty 21 20 19 18 17 Error Bar -7% 16 15 15 16 17 18 19 20 21 22 23 Measured Duty Model Variance within Design Margin © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Mountaineer PVF Program Steam Demand Evaluation Steam Users • Regenerator • Main Stripper •Appendix Stripper Steam Utilization • Measured at PVF – 2.8 GJ/MT CO2 • Corrected at PVF – 2.2 GJ/MT CO2 Improvement Opportunities • Rich/Lean Heat Integration • LP Stripping • Appendix Stripper Heat Integration Operating Data Validates Process Model • System Optimization Studies Underway • Further reductions in steam demand expected Validated Model allows Optimized Design for Demonstration Projects © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Mountaineer PVF Program Additional Findings Materials of Construction • General satisfaction with PVF materials selection as indicated by initial coupon tests • Localized incidents of chemical attack under evaluation • Detailed PVF inspection sponsored by EPRI underway Steam Quality for CAP • No solvent limitations for high regeneration temperature/pressure • Energy requirement (GJ/ton CO2) decreases with higher regeneration pressure • Optimization studies initiated to select regeneration pressure • Objective is to minimize CoE for Power Plant with CCS on a project specific basis Solvent Management • No solvent degradation experienced through 15000 CAP operating hours • Ammonia losses below design PVF Operation Validates Initial Design Decisions © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Mountaineer PVF Program Additional Findings Water Management • PVF was net water producer • Beneficial uses for water identified Solids Accumulation • Susceptable areas identified • Mitigation strategies in place for demonstration projects PVF Operation Highlights Paths to Improvement © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Conclusions • PVF is the world’s first post combustion facility to both capture and store CO2 • Objectives achieved during the operating program included: – Capture rates from 75% (design value) to as high as 90% – CO2 purity of greater than 99.9% – Steady-state operation during all modes of power plant operation including load changes – Availability of the CCS system greater than 90% • Formal testing program validated the process simulation model • Optimization studies underway to reduce energy penalty and reduce ammonia losses © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Thank You www.alstom.com © ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
