10 1 1 152

CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT
ENGINEERING FEASIBILITY AND ECONOMICS OF CO2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT FINAL REPORT VOLUME I AMERICAN ELECTRIC POWERS CONESVILLE POWER PLANT UNIT NO. 5 CO2 CAPTURE RETROFIT STUDY VOLUME II BENCH-SCALE TESTING AND COMPUTATIONAL FLUID DYNAMICS (CFD) EVALUATION SUBMITTED BY ALSTOM POWER INC. POWER PLANT LABORATORIES 2000 DAY HILL ROAD WINDSOR, CT 06095 (860) 688-1911 ABB LUMMUS GLOBAL INC. HOUSTON, TEXAS 77042 ALSTOM POWER ENVIRONMENTAL SYSTEMS KNOXVILLE, TENNESSEE 37932 AND AMERICAN ELECTRIC POWER COLUMBUS, OHIO 43215 PREPARED FOR OHIO DEPARTMENT OF DEVELOPMENT OHIO COAL DEVELOPMENT OFFICE COLUMBUS, OHIO 43266 (CONTRACT NO. CDO/D-98-8) AND US DEPARTMENT OF ENERGY NATIONAL ENERGY TECHNOLOGY LABORATORY PITTSBURGH, PENNSYLVANIA 15236 (CONTRACT NO. DE-FC26-99FT40576) REPORT SUBMITTAL DATE: JUNE 29, 2001 PROJECT PERFORMANCE PERIOD: NOVEMBER 11, 1999 JUNE 30, 2001 PPL REPORT NO. PPL-01-CT-09
VOLUME I
CONESVILLE POWER PLANT UNIT NO. 5 CO2 CAPTURE RETROFIT STUDY
ENGINEERING FEASIBILITY AND ECONOMICS OF CO2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT FINAL REPORT VOLUME I AMERICAN ELECTRIC POWERS CONESVILLE POWER PLANT UNIT NO. 5 CO2 CAPTURE RETROFIT STUDY SUBMITTED BY ALSTOM POWER INC. POWER PLANT LABORATORIES 2000 DAY HILL ROAD WINDSOR, CT 06095 (860) 688-1911 Carl R. Bozzuto, Project Manager Nsakala ya Nsakala, Project Engineer Gregory N. Liljedahl, Principal Investigator Mark Palkes John L. Marion David Vogel, Principal Investigator J. C. Gupta ABB LUMMUS GLOBAL INC. HOUSTON, TEXAS 77042 Michelle Fugate ALSTOM POWER ENVIRONMENTAL SYSTEMS KNOXVILLE, TENNESSEE 37932 Manoj K. Guha AMERICAN ELECTRIC POWER COLUMBUS, OHIO 43215 PREPARED FOR OHIO DEPARTMENT OF DEVELOPMENT OHIO COAL DEVELOPMENT OFFICE COLUMBUS, OHIO 43266 (CONTRACT NO. CDO/D-98-8) AND US DEPARTMENT OF ENERGY NATIONAL ENERGY TECHNOLOGY LABORATORY PITTSBURGH, PENNSYLVANIA 15236 (CONTRACT NO. DE-FC26-99FT40576) REPORT SUBMITTAL DATE: JUNE 29, 2001 PROJECT PERFORMANCE PERIOD: NOVEMBER 11, 1999 JUNE 30, 2001 PPL REPORT NO. PPL-01-CT-09
ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT
VOLUME I. AMERICAN ELECTRIC POWER'S CONESVILLE POWER PLANT UNIT NO. 5 CO2 CAPTURE RETROFIT STUDY
DISCLAIMER This report was prepared by ALSTOM Power Plant Laboratories with support in part by a grant from both the Ohio Coal Development Office/Ohio Department of Development and the United States Government. Neither the State of Ohio, the United States Government, nor any of their agencies, nor any person acting on their behalf: 1. Make any warranty or representation, express or implied, with respect to the accuracy, completeness, or usefulness of the information contained in this report, or that the use of any information, apparatus, method or process disclosed in this report may not infringe privately-owned rights; or 2. Assume any liabilities with respect to the use of, or damages resulting from the use of, any information, apparatus, method or process disclosed in this report. References herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring; nor do the view and opinions of authors expressed herein necessarily state or reflect those of the State of Ohio, the United States Government or their agencies.
ALSTOM Power Inc.
June 30, 2001
ACKNOWLEDGMENTS The authors appreciatively acknowledge the following people for their contributions to the successful performance of the work presented herein: Mark Borman and Tom Ross of AEP Conesville Plant for providing field unit information; Lorraine Miemiec, and Roland Tetreault of ALSTOM Powers Boiler Segment for providing boiler performance prediction, and design graphics, respectively; and Alan DelPaggio of CRI Catalyst Company for De-oxy catalyst process development. The financial support of this project by OCDO (Contract No CDO/D-98-8), DOE National Energy Technology Laboratory (Contract No DE-FC26-99FT40576), ALSTOM Power Inc. and ABB Lummus Global Inc. is also appreciated. The inkind financial support of the project by American Electric Power is greatly appreciated
ALSTOM Power Inc.
ii
June 30, 2001
PUBLIC ABSTRACT ALSTOM Power Inc.s Power Plant Laboratories (ALSTOM) has teamed with American Electric Power (AEP), ABB Lummus Global Inc. (ABB), the US Department of Energy National Energy Technology Laboratory (DOE NETL), and the Ohio Coal Development Office (OCDO) to conduct a comprehensive study evaluating the technical feasibility and economics of alternate CO2 capture and sequestration technologies applied to an existing US coal-fired electric generation power plant. The motivation for this study was to provide input to potential US electric utility actions concerning GHG emissions reduction. If the US decides to reduce CO2 emissions, action would need to be taken to address existing power plants. Although fuel switching from coal to natural gas may be one scenario, it will not necessarily be a sufficient measure and some form of CO2 capture for use or disposal may also be required. The output of this CO2 capture study will enhance the publics understanding of control options and influence decisions and actions by government, regulators, and power plant owners in considering the costs of reducing greenhouse gas CO2 emissions. The total work breakdown structure is encompassed within three major reports, namely: (1) Literature Survey, (2) AEPs Conesville Unit #5 Retrofit Study, and (3) Bench-Scale Testing and CFD Evaluation. The report on the literature survey results was issued earlier by Bozzuto, et al. (2000). Reports entitled AEPs Conesville Unit #5 Retrofit Study and Bench-Scale Testing and CFD Evaluation are provided as companion volumes, denoted Volumes I and II, respectively, of the final report. The work performed, results obtained, and conclusions and recommendations derived therefrom are summarized below. Volume I The Volume I report discusses three retrofit technology concepts, which were evaluated in conjunction with AEPs Conesville Unit #5, namely: Concept A: Coal combustion in air, followed by CO2 separation with Kerr-McGee/ABB Lummus Globals commercial MEA-based absorption/stripping process Concept B: Coal combustion with O2 firing and flue gas recycle (oxy-fuel firing) Concept C: Coal Combustion in air with oxygen removal and CO2 separation by a mixture of primary and tertiary amines, i.e., monoethanolamine (MEA)/methyldiethanolamine (MDEA).
Each of these technologies was evaluated against a baseline case, the existing design without CO2 capture, from the standpoints of performance, impacts on power generating cost, and CO2 emissions. AEPs 450 MW Conesville Unit No. 5, located in Conesville, Ohio, was used for the power plant case study. All technical performance and cost results associated with the available options were evaluated in a comparative manner. Major conclusions: No major technical barriers exist for retrofitting AEPs Conesville Unit #5 to capture CO2 for any of the three concepts considered under this study. Concept B (oxygen firing with flue gas recycle) appears clearly to be the best alternative of the three concepts studied from both an efficiency and incremental COE viewpoint for systems designed for very high CO2 capture (i.e. > 90%). If lower CO2 capture fractions are considered, it appears that Concept A would likely be the best alternative for capture fractions below some as yet undetermined value. Concept C would also improve considerably with lower capture fractions. This study has confirmed two important issues related to firing coal in a CO2-rich flue gas / O2 mixture: Modifications to the existing steam generator unit pressure arts are not required, and as such will also allow the unit to continue to operate in the conventional air- fired mode. CO2-rich flue gas can be cleaned and compressed with a relatively simple system to provide high purity CO2 for usage or sequestration.
ALSTOM Power Inc.
iii
June 30, 2001
Energy requirements and power consumption are high for all three concepts, resulting in significant decreases in overall power plant efficiencies (HHV basis), ranging from efficiencies of 20.5 to 22.5%, as compared to 35.0% for the Base case (air firing without CO2 capture), which is equivalent to an energy penalty ranging from 36% to 41%. That is, the net power plant output was reduced to 77% - 59%. The MEA/MDEA mixture of Concept C requires about 28% less energy per pound of CO2 captured to regenerate the solvent as compared to the MEA used in Concept A. Specific investment costs are high, ranging from about 800 to1800 $/kW and from 1000 to 2200 $/kW, corresponding to scenarios with and without replacement power, respectively. All cases studied indicate significant increases to the COE as a result of CO2 capture. The incremental COE as compared to the Base case (air firing without CO2 capture) ranges from 3.4 to 8.4 /kWh. Similarly CO2 mitigation costs range from about 42-98 $/ton of CO2 avoided for the range of cases studied. Specific carbon dioxide emissions were reduced from about 2 lbm/kWh for the Base case to 0.13 0.27 lbm/kWh for the study cases. Recovery or capture of CO2 ranged from 91 to 96%. Nominally, 5-8 acres of new equipment space is needed for Unit #5 alone on the existing 200-acre power plant site, which accommodates a total of 6 units with a total power generating capacity of 2,080 MW.
Major recommendations: A sensitivity study, for Concepts A and C, showing the impact of reducing CO2 capture percentage on plant efficiency, investment cost, emissions, and cost of electricity. The current work utilized 90% CO2 capture (nominal). The sensitivity study would investigate nominal CO2 capture percentages of 70% and 50%. Detailed analysis of the existing steam turbine for Concept A: In Concept A about 79% of the steam leaving the intermediate-pressure (IP) turbine is extracted from the IP/LP crossover pipe for solvent regeneration. The capability of the existing low-pressure (LP) turbine to operate under these conditions of very low steam flow o ver the load range should be investigated in detail, preferably by the original equipment manufacturer (OEM). Optimization of the amine system reboiler steam pressure for Concepts A and C. Concept B detailed boiler system analysis: A startup/shutdown procedure and system design, particularly the transition from air to oxygen firing (including transient conditions) should be developed. Detailed metal temperature analysis for all heat exchanger sections, including operation at part loads should be analyzed. This should also include furnace wall metal temperatures and analysis of the circulation system. The existing fans should be checked (preferably by the OEMs) for operation under the new conditions. The feasibility of operating the boiler under a slight positive pressure to eliminate air infiltration should also be investigated. Investigation of Improved oxygen production systems for Concept B, in line with the membrane-based air separation research being conducted by various research groups (e.g., Praxair, Air Products, Norsk Hydro). Also optimization of an integrated boiler and oxygen production system. Measurement of furnace heat transfer in CO2/O2 environments in a proof of concept boiler simulation facility. Improved solvents, which require lower regeneration energy requirements and/or can be regenerated at a lower temperature level, similar to MHIs KS1 system, but for coal-firing application. Hybrid process using oxygen-enriched combustion and amine based CO2 absorption, to accrue, simultaneously, both CO2 capture and drastic NOx emissions reduction. Investigation of a new novel high risk CO2 capture process that would reduce efficiency penalty and retrofit investment cost. This would likely not utilize the existing boiler.
ALSTOM Power Inc.
iv
June 30, 2001
Volume II The bench-scale testing consisted primarily of drop-tube (DTFS-1) and thermo-gravimetric analyses (TGA). Three cases were investigated: (1) an air-fired case (Base case); (2) a case in which the N2 was replaced by an equal mass of CO2 (Constant Mass case); and (3) a case in which the N2 volume was replaced by an equal volume of CO2 (Constant Volume case). The Constant Mass case represents the appropriate retrofit scenario in a commercial pulverized coal firing application, albeit without flue gas recycling. Major conclusions: (a) Based on TGA results Both the Conesville Unit #5 and Pittsburgh Seam #8 coals have, for air (Base case) and O2/CO2 environments (Constant Mass/Volume cases), similar burning characteristics, as they both go to completion within the same temperature range (550-575 oC). Burning either of the coals in air or any of the O2/CO2 mixture ratios used here would produce virtually identical results; and (2) both coals have similar reactivity characteristics. (b) Based on DTFS-1 results Residence time, as expected, has a significant impact on the overall coal combustion efficiency, and hence, on the unburned carbon emission in the fly ash for both coals under consideration. That is, while the combustion efficiency for both coals is only about 80% (dry-ash-free coal basis) at 0.2 sec., it is more than 98% at greater than 0.5 sec. Correspondingly, unburned carbon emissions range from about 65% to about 2% (dry fly ash basis). The impact of reaction medium is also significant. While the overall combustion efficiencies do not seem to exhibit significant differences between the baseline and Constant Mass firing, the more sensitive parameter, unburned carbon (UBC) in the fly ash, on the other hand, clearly shows better performance for the Constant Mass case. That is, the UBC at the furnace outlet was about a factor of 4.5 lower for the Constant Mass case (~2% vs. 9%). This is believed to be due to higher reactant gas temperature, and yet longer residence (0.77 sec. vs. 0.57 sec.). It appears, from the shape of the UBC profiles, that, if given enough residence time, these differences would narrow down considerably, implying that the ultimate performance in both mediums would be similar. The coal sample from Conesville Unit #5 appears to perform better than the sample from Pittsburgh seam #8 coal (e.g., 9% vs. 12.5% UBC for the air firing case). However, based on the shape of the UBC profiles, it can be seen that if given additional residence time, they would both be expected to perform similarly. NOx emission from oxy-fuel firing is about a factor of 3 (0.73 vs. 2.25 lb/MMBtu) lower than that of the Base Case. Correspondingly, sulfur dioxide is lower by about 19% (3.6 vs. 4.3 lb/MMBtu), and CO is significantly lower (0.09 lb/MMBtu vs. a negligible amount).
(c) Based on CFD results The baseline case exhibits higher carbon-in-ash (by 1.6 percentage points), higher outlet NOx emissions (by a factor of 2), and higher outlet CO (by a factor of 2) than the Concept-B case. These same computational trends are also qualitatively exhibited by the bench-scale testing. The baseline case exhibits a slightly higher peak gas temperature (maximum difference of about 200 F), and a correspondingly higher average (cross-sectional) gas temperature (difference of 90 F at the HFOT), than that of the Concept-B case. The net wall absorption in the furnace region for the baseline case is larger (by less than 1%) than that of the Concept-B case. However, A significant variation in both calculated and experimental irradiation to the wall between baseline and oxy-firing scenarios was also found in the literature (e.g., +6 to 18%). Differences may be partially attributed to the sensitivity of the irradiation and local emissivities to the aerodynamic and flame patterns, which are, in turn, a function of the furnace and firing system. It is suggested that radiatively absorbing gas species can either enhance or inhibit the irradiation in the vicinity of the wall, depending upon their local temperature and their relative spatial placement.
ALSTOM Power Inc.
June 30, 2001
Major recommendations: Carry out a systematic coal fundamentals study concerning this field of endeavor. This study should be geared toward the creation of a database of information depicting the impact of coal nature (using coals of various rank coming from both domestic and international sources) when fired in an oxy-fuel environment on: Coal devolatilization and char oxidation kinetics, and unburned carbon emissions in the fly ash Acid rain-related gaseous (NOx, SO2, and CO) emissions Air toxics, particularly, mercury (Hg), volatile organic compounds (VOCs), and particulate emissions. Derive furnace heat transfer data from natural gas and coal firing in an oxy-fired pilot-scale furnace, which simulates the temperature/time history of a boiler. Use first the data from natural gas firing to validate the CFD code, without the complication of burning particles transiting the boiler. Apply the experience learned from modeling a natural gas fired boiler to model the coal-fired boiler.
ALSTOM Power Inc.
vi
June 30, 2001
TABLE OF CONTENTS
Page 1.0 INTRODUCTION .................................................................................................................................................... 12 2.0 STUDY UNIT SELECTION, DESCRIPTION AND PERFORMANCE............................................................ 14 2.1 Study Unit Selection............................................................................................................................................. 14 2.2 Study Unit Description......................................................................................................................................... 16 2.3 Base Case Performance Analysis ........................................................................................................................ 19 2.3.1 Calibration of Boiler Computer Model....................................................................................................... 19 2.3.2 Overall System Description and Material and Energy Balance ................................................................ 19 2.3.3 Boiler Analysis Results................................................................................................................................ 22 2.3.4 Steam Cycle Performance ........................................................................................................................... 23 2.3.5 Flue Gas Desulfurization System Analysis ................................................................................................ 24 3.0 CO2 REMOVAL SYSTEMS ................................................................................................................................... 26 3.1 CO2 Removal Systems Design Basis .................................................................................................................. 26 3.1.1 Site Data........................................................................................................................................................ 26 3.1.2 Battery Limit Definition.............................................................................................................................. 27 3.1.3 CO2 Product Specification........................................................................................................................... 28 3.1.4 Chemicals ..................................................................................................................................................... 29 3.1.5 Utilities ......................................................................................................................................................... 30 3.1.6 Equipment Design........................................................................................................................................ 32 3.2 Concept A: CO2 Separation with Monoethanolamine Absorption ................................................................... 33 3.2.1 Overall System Description and Material and Energy Balance ................................................................ 33 3.2.2 Boiler Analysis............................................................................................................................................. 35 3.2.3 Steam Cycle Modifications and Performance............................................................................................ 35 3.2.4 Flue Gas Desulfurization System Analysis ................................................................................................ 37 3.2.5 Carbon Dioxide Separation and Compression System.............................................................................. 38 3.3 Concept B: CO2 Separation with Oxygen Firing and Flue Gas Recirculation................................................. 56 3.3.1 Overall System Description and Material and Energy Balance ................................................................ 56 3.3.2 Air Separation Unit ...................................................................................................................................... 59 3.3.3 Boiler Heat Transfer Analysis..................................................................................................................... 61 3.3.4 Boiler System Modifications....................................................................................................................... 69 3.3.5 Steam Cycle System .................................................................................................................................... 73 3.3.6 Flue Gas Desulfurization and Electrostatic Precipitator Systems Performance Issues ........................... 75 3.3.7 Carbon Dioxide Separation and Compression System.............................................................................. 79 3.4 Concept C: CO2 Separation by MEA/MDEA Absorption and De-Oxy Catalyst............................................. 91 3.4.1 Overall System Description and Material and Energy Balance ................................................................ 91 3.4.2 Boiler Analysis............................................................................................................................................. 93 3.4.3 Steam Cycle Modifications and Performance............................................................................................ 93 3.4.4 Flue Gas Desulfurization System Analysis ................................................................................................ 95 3.4.5 Carbon Dioxide Separation and Compression System.............................................................................. 96 4.0 SUMMARY OF SYSTEMS PERFORMANCE AND CARBON DIOXIDE EMISSIONS ............................ 111 Boiler Performance......................................................................................................................................................... 112 5.0 COST ANALYSIS.................................................................................................................................................. 116 5.1 Cost Estimation Basis ........................................................................................................................................ 116 5.2 Boiler Modification Costs.................................................................................................................................. 117 5.3 Carbon Dioxide Separation and Compression System Costs .......................................................................... 117 5.3.1 Concept A................................................................................................................................................... 117 5.3.2 Concept B ................................................................................................................................................... 120 5.3.3 Concept C ................................................................................................................................................... 122 5.4 Flue Gas Desulfurization System Modification Costs ..................................................................................... 123 5.5 Charges for Loss of Power during Construction and Operation of the Modified Power Plant System ....... 123 5.6 Summary of Total Plant Investment Costs ....................................................................................................... 124 6.0 ECONOMIC ANALYSIS...................................................................................................................................... 125 6.1 Concept A Results: CO2 Separation with Monoethanolamine (MEA) Absorption....................................... 127 6.1.1 Concept A Results without Replacement Power ..................................................................................... 127
ALSTOM Power Inc.
vii
June 30, 2001
6.1.2 Concept A Results with Replacement Power........................................................................................... 129 6.2 Concept B Results: CO2 Separation with Oxygen Firing and Flue Gas Re-circulation................................ 131 6.2.1 Concept B Results without Replacement Power...................................................................................... 131 6.2.2 Concept B Results with Replacement P ower........................................................................................... 133 6.3 Concept C Results: CO2 Separation with MEA / MDEA................................................................................ 135 6.3.1 Concept C Results without Replacement Power...................................................................................... 135 6.3.2 Concept C Results with Replacement Powe r........................................................................................... 137 6.4 Economic Study Summary and Conclusions.................................................................................................... 139 7.0 COMPARISONS WITH PRIOR WORK ............................................................................................................. 141 8.0 CONCLUSIONS AND RECOMMENDATIONS FOR FUTURE WORK ....................................................... 144 9.0 BIBLIOGRAPHY................................................................................................................................................... 146
ALSTOM Power Inc.
viii
June 30, 2001
LIST OF TABLES
Page Table 2.3. 1: Table 2.3. 2: Table 2.3. 3: Table 2.3. 4: Table 2.3. 5: Table 3.1. 1: Table 3.1. 2: Table 3.1. 3: Table 3.1. 4: Table 3.2. 1: Table 3.2. 2: Table 3.2. 3: Table 3.2. 4: Table 3.2. 5: Table 3.2. 6: Table 3.2. 7: Table 3.2. 8: Table 3.2. 9: Table 3.2. 10: Table 3.2. 11: Table 3.2. 12: Table 3.3. 1: Table 3.3. 2: Table 3.3. 3: Table 3.3. 4: Table 3.3. 5: Table 3.3. 6: Table 3.3. 7: Table 3.3. 8: Table 3.3. 9: Table 3.3. 10: Table 3.3. 11: Table 3.3. 12: Table 3.3. 13: Table 3.3. 14: Table 3.3. 15: Table 3.3. 16: Table 3.3. 17: Table 3.4. 1: Table 3.4. 2: Table 3.4. 3: Table 3.4. 4: Table 3.4. 5: Table 3.4. 6: Table 3.4. 7: Table 3.4. 8: Table 3.4. 9: Table 3.4. 10: Table 3.4. 11: Base Case Gas Side Material and Energy Balance................................................................................ 21 Overall Plant Performance Summary (Base Case)................................................................................ 22 Base Case Boiler/Turbine Steam Flows and Conditions....................................................................... 22 FGD Assumptions ................................................................................................................................... 24 FGD Performance.................................................................................................................................... 25 Flue Gas Analysis .................................................................................................................................... 28 Specification for Sequestration............................................................................................................... 29 Specification for EOR.............................................................................................................................. 29 Caustic (NaOH) ....................................................................................................................................... 29 Gas Side Material and Material Energy Balance (Concept A) ............................................................. 34 Overall Plant Performance Summary (Concept A) ............................................................................... 35 FGD Assumptions ................................................................................................................................... 37 FGD Performance.................................................................................................................................... 38 Material and Energy Balance for Concept A Amine System................................................................ 49 Material and Energy Balance for Concept A CO2 Compression and Liquifaction System................ 50 Concept A Utility Consumption ............................................................................................................. 51 Concept A Chemicals and Desiccants Consumption............................................................................. 52 Concept A Key Process Parameters Comparison.................................................................................. 53 Reclaimer Bottoms Composition............................................................................................................ 53 Filter Residue Composition..................................................................................................................... 54 Cooling Tower Blowdown Composition Limitations ........................................................................... 54 Gas Side Material and Energy Balance for Concept B ......................................................................... 58 Overall Plant Performance Summary for Concept B ............................................................................ 59 Apparent Combustor Gas Emissivities................................................................................................... 63 Gas Temperature Profiles ........................................................................................................................ 64 Boiler/Turbine Steam Flows and Conditions for Concept B ................................................................ 69 Booster Fan Specification ....................................................................................................................... 70 Oxygen Heater Performance Requirements and Gas Analysis............................................................. 71 Oxygen Heater Specifications................................................................................................................. 71 Parallel Feedwater Heater Performance Requirements......................................................................... 72 Parallel Feedwater Heater Specification ................................................................................................ 72 PFWH Header and Piping Specifications .............................................................................................. 73 FGD System Assumptions ...................................................................................................................... 75 FGD System Performance....................................................................................................................... 76 Composition of Flue Gases Entering the Electrostatic Precipitator (ESP) .......................................... 78 Material and Energy Balance for Flue Gas Cooling, CO2 Compression and Liquefaction................ 85 Concept B Utility Consumption.............................................................................................................. 86 Concept B Chemical and Desiccant Consumption................................................................................ 87 Gas Side Material and Energy Balance for Concept C ......................................................................... 92 Overall Plant Performance Summary for Concept C ............................................................................ 93 FGD Assumptions ................................................................................................................................... 95 FGD Performance.................................................................................................................................... 96 De-Oxy System Material and Energy Balance for Concept C............................................................ 103 Amine System Material and Energy Balance for Concept C.............................................................. 104 CO2 Compression and Liquefaction System Material and Energy balance for Concept C .............. 105 Utility Consumption for Concept C...................................................................................................... 106 Chemicals and Desiccants Consumption f or Concept C.................................................................... 107 Key Process Parameters Comparison................................................................................................... 108 Filter Residue Composition................................................................................................................... 108
ALSTOM Power Inc.
ix
June 30, 2001
LIST OF TABLES (CONT)

Page Table 3.4. 12: Table 4.0. 1: Table 5.3. 1: Table 5.3. 2: Table 5.3. 3: Table 5.3. 4: Table 5.3. 5: Table 5.3. 6: Table 5.5. 1: Table 5.6. 1: Table 6.0. 1: Table 6.0. 2: Table 6.1. 1: Table 6.1. 2: Table 6.2. 1: Table 6.2. 2: Table 6.3. 1: Table 6.3. 2: Table 7.0. 1: Filter Residue Composition................................................................................................................... 109 Overall Plant Performance and CO2 Emissions Comparison ............................................................. 111 Concept A CO2 Separation and Compression System Investment Costs .......................................... 118 Concept A CO2 Separation and Compression System Operating & Maintenance Costs ................. 119 Concept B CO2 Separation and Compression System Investment Costs........................................... 120 Concept B CO2 Separation and Compression System Operating & Maintenance Costs.................. 121 Concept C CO2 Separation and Compression System Investment Costs........................................... 122 Concept C CO2 Separation and Compression System Operating & Maintenance Costs.................. 123 NGCC Outputs and Costs for Replacement Power ............................................................................. 123 Total Retrofit Investment Capital Costs............................................................................................... 124 Economic Evaluation Study Assumptions ........................................................................................... 125 Economic Sensitivity Study Parameters............................................................................................... 126 Economic Sensitivity Results for Concept A without Replacement Power ...................................... 128 Economic Sensitivity Results for Concept A with Replacement Power............................................ 130 Economic Sensitivity Results for Concept B without Replacement Power....................................... 132 Economic Sensitivity Results for Concept B with Replacement Power ............................................ 134 Economic Sensitivity Results for Concept C without Replacement Power....................................... 136 Economic Sensitivity Results for Concept C with Replacement Power ............................................ 138 Summary of Performance for Original Plant and CO2 Capture Study Cases .................................... 141
ALSTOM Power Inc.
June 30, 2001
LIST OF FIGURES
Page Figure 2.1. 1: Figure 2.1. 2: Figure 2.3. 1: Figure 2.3. 2: Figure 2.3. 3: Figure 2.3. 4: Figure 3.1. 1: Plan View of AEPs Conesville, Ohio, Power Generating Station Site .............................................. 15 Study Unit (Existing Conesville Unit #5 Steam Genertor) .................................................................. 18 Simplified Gas Side Process Flow Diagram (Base Case) ..................................................................... 20 Base Case Steam Cycle Diagram and Performance .............................................................................. 23 Base Case Steam Cycle Mollier Diagram .............................................................................................. 23 Base Case Flue Gas Desulfurization System Process Flow Diagram................................................... 24 AEP Conesville, Ohio, Electric Power Generating Station Site ........................................................... 28
Figure 3.2. 1: Simplified Gas Side Process Flow Diagram for CO2 Separation by Monoethanolamine Absorption (Concept A) .................................................................................................................................................................. 33 Figure 3.2. 2: Modified Steam Cycle Diagram and Performance (Concept A) .......................................................... 36 Figure 3.2. 3: Modified Steam Cycle Mollier Diagram (Concept A) .......................................................................... 36 Figure 3.2. 4: Modified FGD System Process Flow Diagram (Concept A) ................................................................ 37 Figure 3.2. 5: Process Flow Diagram for Concept A: Flue Gas Cooling and CO2 Absorption................................ 45 Figure 3.2. 6: Process Flow Diagram for Concept A: Solvent Stripping.................................................................... 46 Figure 3.2. 7: Process Flow Diagram for Concept A: CO2 Compression and Liquefaction..................................... 47 Figure 3.3. 1: Simplified Gas Side Process Flow Diagram for CO2 Separation with Oxygen Firing........................ 56 Figure 3.3. 2: Boiler Flue Gas Cooling Curve ............................................................................................................... 57 Figure 3.3. 3: Process Flow Diagram of a BOC Improved Air Separation Unit......................................................... 60 Figure 3.3. 4: Variation of Radiative Heat Flux with Gas Temperature During Combustion in Air and O2/CO2 Mixtures (from Thambimuthu, 1998).......................................................................................................................... 62 Figure 3.3. 5: Apparent Combustor Gas Emissivities as a Function of Axial Distance............................................. 63 Figure 3.3. 6: Centerline Gas Temperature Shift as a Function of Axial Distance..................................................... 64 Figure 3.3. 7: Calculated Adiabatic Flame Temperature as a Function of CO2/O2 Mole Ratio for ......................... 65 Figure 3.3. 8: Specific Heats (Cp) of Nitrogen and Carbon Dioxide as a Function of Temperature......................... 65 Figure 3.3. 9: Furnace Region Heat Flux Comparison................................................................................................. 66 Figure 3.3. 10: Convective Heat Transfer Rate Comparison.......................................................................................... 68 Figure 3.3. 11: Non-luminous Heat Transfer Rate Comparison..................................................................................... 68 Figure 3.3. 12: Total Heat Transfer Rate Comparison................................................................................................... 68 Figure 3.3. 13: Duct and Damper Diagram for Concept B............................................................................................. 70 Figure 3.3. 14: Oxygen Heater Sketch............................................................................................................................. 71 Figure 3.3. 15: Parallel Feedwater Heater Arrangement ................................................................................................ 72 Figure 3.3. 16: Parallel Feedwater Heater Sketch.......................................................................................................... 72 Figure 3.3. 17: Modified Steam Cycle Diagram and Performance for Concept B ....................................................... 74 Figure 3.3. 18: Modified Steam Cycle Mollier Diagram for Concept B ....................................................................... 74 Figure 3.3. 19: Negative Corona Curves for Air-water Vapor Mixtures at 400F; Atmospheric Pressure; ................. 77 Figure 3.3. 20: Negative Corona Characteristics for Nitrogen-Oxygen Mixtures;....................................................... 77 Figure 3.3. 21: Negative Corona Curves for Nitrogen-Sulfur Dioxide Mixtures; ........................................................ 78 Figure 3.3. 22: Process Flow Diagram for Concept B: Flue Gas Cooling.................................................................... 83 Figure 3.3. 23: Process Flow Diagram for Concept B: CO2 Compression and Liquefaction ..................................... 84 Figure 3.3. 24: CO2 Recovery from Boiler Flue Gas ...................................................................................................... 88 Figure 3.3. 25: CO2 Recovery Boiler Flue Gas ............................................................................................................... 89 Figure 3.4. 1: Figure 3.4. 2: Figure 3.4. 3: Figure 3.4. 4: Figure 3.4. 5: Figure 3.4. 6: Figure 3.4. 7: Simplified Gas Side Process Flow Diagram for CO2 Separation by .................................................... 91 Modified Steam Cycle Diagram and Performance for Concept C ....................................................... 94 Modified Steam Cycle Mollier Diagram for Concept C ....................................................................... 95 De-Oxy System Process Flow Diagram for Concept C ........................................................................ 99 Flue Gas Cooling and Absorption System Process Flow Diagram for Concept C............................ 100 Solvent Stripping System Process Flow Diagram for Concept C ...................................................... 101 CO2 Compression and Liquefaction System Process Flow Diagram for Concept C ........................ 102
ALSTOM Power Inc.
xi
June 30, 2001
LIST OF FIGURES (Cont)

Page Figure 4.0. 1: Figure 4.0. 2: Figure 4.0. 3: Figure 4.0. 4: Figure 5.6. 1: Figure 5.6. 2: Figure 6.1. 1: Figure 6.1. 2: Figure 6.1. 3: Figure 6.1. 4: Figure 6.2. 1: Figure 6.2. 2: Figure 6.2. 3: Figure 6.2. 4: Figure 6.3. 1: Figure 6.3. 2: Figure 6.3. 3: Figure 6.3. 4: Figure 6.4. 1: Figure 6.4. 2: Figure 7.0. 1: Figure 7.0. 2: Net Plant Electrical Output (Mw) ......................................................................................................... 113 Plant Thermal Efficiency (HHV Basis)................................................................................................ 114 Carbon Dioxide Distribution................................................................................................................. 114 Specific Carbon Dioxide Emissions ..................................................................................................... 115 New Equipment Specific Investment Costs (Without Replacement Power)..................................... 124 New Equipment Specific Investment Costs (With Replacement Power) .......................................... 124 Concept A (MEA) Economic Results without Replacement Power .................................................. 127 Concept A (MEA) Economic Sensitivity Results without Replacement Power ............................... 128 Concept A (MEA) Economic Results wi th Replacement Power ....................................................... 129 Concept A (MEA) Economic Sensitivity Results with Replacement Power.................................... 130 Concept B (Oxygen Fired) Economic Results without Replacement Power..................................... 131 Concept B (Oxygen Firing) Economic Sensitivity Results without Replacement Power ................ 132 Concept B (Oxygen Firing) Economic Results with Replacement Power........................................ 133 Concept B (Oxygen Firing) Economic Sensitivity Results with Replacement Power...................... 134 Concept C (MEA/MDEA) Economic Results without Replacement Power..................................... 135 Concept C (MEA/MDEA) Economic Sensitivity Results without Replacement Power .................. 136 Concept C (MEA/MDEA) Economic Results with Replacement Power .......................................... 137 Concept C (MEA/MDEA) Economic Sensitivity Results with Replacement Power ....................... 138 Incremental Cost of Electricity (Using Base Parameter Values)........................................................ 139 Co 2 Mitigation Costs (Using Base Parameter Values) ........................................................................ 140 Comparative Net Plant Heat Rate Results for Coal Fired Power Plants ............................................ 142 Comparative CO2 Emissions for Coal Fired Power Plants ................................................................. 142
APENDICIES
Page APPENDIX I APPENDIX II - DRAWINGS ...................................................................................................................................... 148 - EQUIPMENT LISTS ......................................................................................................................... 173
ALSTOM Power Inc.
xii
June 30, 2001
EXECUTIVE SUMMARY
Background International discussions continue to debate the need for reductions in emission levels of greenhouse gases (GHG). Because fossil fuel fired power plants are among the largest and most concentrated producers of CO2 emissions, it stands to reason that recovery of CO2 from the flue gas of such plants has been identified as one of the primary means for reducing CO2 emissions. ALSTOM Power Inc.s Power Plant Laboratories (referred to herein as ALSTOM) teamed with American Electric Power (AEP), ABB Lummus Global Inc. (referred to herein as ABB), the US Department of Energy National Energy Technology Laboratory (DOE NETL), and the Ohio Coal Development Office (OCDO) to conduct a comprehensive study evaluating the technical and economic feasibility of three alternate CO2 capture technologies applied to an existing US coal-fired electric generation power plant. The steam generator analyzed in this study is the Conesville No. 5 unit, operated by American Electric Power (AEP) of Columbus, Ohio. This steam generator is a nominal 450 MW, coal-fired, subcritical pressure, controlled circulation unit. It has a single cell furnace that employs corner-fired, tilting, tangential burners and which fires bituminous coal from the state of Ohio. The flue gas leaving the boiler system is cleaned of particulate matter in an electrostatic precipitator (ESP) and of SO2 in a lime-based flue gas desulfurization (FGD) system before being discharged to the atmosphere. ALSTOM is managing and performing the subject study from its Power Plant Laboratories office in Windsor, CT. ABB, from its offices in Houston, Texas, is participating as a sub-contractor. AEP is participating by offering their Conesville Generating Station as the case study and cost sharing consultation, along with relevant technical and cost data. AEP is one of the largest US utilities, and as the largest consumer of Ohio coal, is bringing considerable value to the project. Similarly, ALSTOM and ABB are well established as global leaders in the design and manufacturing of steam generating equipment, petrochemical, and CO2 separation technology. The DOE National Energy Technology Laboratory and the Ohio Coal Development Office provided consultation and funding. All participants contributed to the cost share of this project. Objectives The motivation for this study was to provide input to potential US electric utility actions concerning GHG emissions reduction. If the US decides to reduce CO2 emissions, action would need to be taken to address existing power plants. Although fuel switching from coal to natural gas may be one scenario, it will not necessarily be a sufficient measure and some form of CO2 capture for use or disposal may also be required. The output of this CO2 capture study will enhance the publics understanding of control options and influence decisions and actions by government, regulators, and power plant owners in considering the costs of reducing greenhouse gas CO2 emissions. The key goals of the study were to evaluate the impacts on the plant output, efficiency, and CO2 emissions, resulting from the addition of the CO2-capture systems. Cost estimates were developed for the systems required to produce, extract, clean and compress the CO2, which could then be available for use in enhanced oil or gas recovery or sequestration. Additionally, the impact of CO2 capture on the cost of electricity (COE) and on the mitigation cost for CO2 ($/ton of CO2 avoided) was also evaluated. Work Scope The total work breakdown structure is encompassed within three major reports, namely: (1) Literature Survey, (2) AEPs Conesville Unit #5 Retrofit Study, and (3) Bench-Scale Testing and CFD Evaluation. The report on the literature survey results was issued earlier by Bozzuto, et al. (2000). The report entitled Bench-Scale Testing and CFD Evaluation constitutes Volume II of the final report. Work on AEPs Conesville Unit #5 Retrofit Study is presented here as Volume I report. The work performed, results obtained, and conclusions and recommendations derived therefrom are summarized below.
ALSTOM Power Inc.
June 30, 2001
System Descriptions The three retrofit CO2 capture technology concepts evaluated in this study are listed below: Concept A: Coal combustion in air, followed by CO2 separation with Kerr-McGee/ABB Lummus Globals commercial MEA-based absorption/stripping process Concept B: Coal combustion with O2 firing and flue gas recycle (oxy-fuel firing) Concept C: Coal combustion in air with oxygen removal and CO2 separation by a mixture of primary and tertiary amines
The results from each of these three evaluations were compared to the Base Case, which represents the business as usual operating scenario for the existing plant without CO2 capture. The CO2 capture systems were designed for a minimum of 90% CO2 capture. The Dakota Gasification Companys CO2 specification (DGC WebPages, 2001) for EOR, given in the following table, was used as the basis for the CO2 capture system design. A very low concentration of oxygen, in particular, is specified for meeting current pipeline operating practices, due to the corrosive nature of the oxygen. Hence, for Concept B, whereby the final CO2 liquid product was found to contain about 9300 vppm of O2, the design of the transport pipe to an EOR site for example would have to take this characteristic under consideration. Dakota Gasification Projects CO2 Specification for EOR
Component
CO 2 H2 S CH4 C2+HCs CO N2 H2 O O2
Unit
Vol.% Vol.% Vol.% Vol.% Vol.% vppm vppm vppm
Concentration
96.0 0.9 0.7 2.3 0.1 < 300 < 20 < 50
Concepts A and C are both low temperature CO2 absorption systems located downstream of the FGD system and as such do not impact the operation of the boiler. In Concept A Coal is burned conventionally in air as schematically depicted below. The flue gases leaving the modified FGD system (a secondary absorber is added to reduce the SO2 concentration for MEA system) are cooled with a direct contact cooler and ducted to the MEA system where more than 96% of the CO2 is removed, compressed, and liquefied for usage or sequestration. The remaining flue gases leaving the new MEA system, consisting of primarily oxygen, nitrogen, water vapor and a relatively small amount of sulfur dioxide and carbon dioxide, are discharged to the atmosphere.
CO2 for Sequestration or Use (in EOR or EGR) Air Coal
Boiler
CO2 Separation Unit using MEA
CO2 Compression & Liquifaction System
H 2O, N2, ...
Although boiler performance is identical to the Base Case in Concept A, there is a major impact to the steam cycle system where low-pressure steam is extracted to provide the energy for solvent regeneration. About 79% of the
ALSTOM Power Inc.
June 30, 2001
intermediate pressure (IP) turbine exhaust is extracted from the IP/LP crossover pipe. This steam is expanded from 200 psia to 65 psia through a new steam turbine. The exhaust from the new turbine provides the heat requirement for solvent regeneration in the reboilers of the MEA CO2 recovery system. Solvent regeneration requires about 4.7x10 6 Btu/Ton CO2. The condensate from the reboilers is pumped to the existing deaerator. The remaining 21% of the IP turbine exhaust is expanded in the existing low-pressure turbine before being exhausted to the existing condenser. The total output from both the existing and new generators is 331,422 kW. This represents a gross output reduction of 132,056 kW (about 28%) as compared to the Base Case. The basic concept of the overall system for Concept B is to replace air with oxygen for combustion in the furnace, thus directly producing a high CO2 content flue gas. In designing the Concept B system, emphasis was placed on utilizing as much as possible of the existing equipment, minimizing boiler modifications required, and providing operational flexibility to permit switching to the conventional mode of operation if desired. This process is depicted schematically below.
N2
Flue Gas Recycle
CO2 for Sequestration or Use (in EOR or EGR)
Air
Air Separation Unit (ASU)
O2
Boiler
Condenser
O2, N2 Air in-leakage
Coal
H 2O
The proposed combustion system uses a mixture of nearly pure oxygen with recycled flue gas. A conventional cryogenic Air Separation Unit (ASU) supplies the oxygen. The recycle flow rate is established by the need to maintain a thermal balance between the radiant and convective heat transfer surfaces of the existing steam generator. The quantity of the recirculated gas is approximately equal to the quantity of nitrogen contained in the combustion air that would have been supplied to the steam generator as part of the oxidant. Inherent in the flue gas recirculation process is the build-up of carbon dioxide and water vapor content in the flue gas. This increased concentration produces significant changes in the thermal and mechanical properties of the flue gas. These gas property differences cause significant differences in the heat transfer processes, which occur within the steam generator unit. Analyses were made to determine the impact of the heat transfer differences on boiler behavior. Heat transfer in the lower and upper furnace regions is compared in the figure to the left below. The figure on the left compares heat fluxes (Btu/hr-ft2) in the lower and upper furnace region between air firing and oxygen firing. Lower furnace results show firing zone heat flux to be about 11% higher with oxygen firing. Upper furnace region results show the reheat radiant wall is about 6% higher and the superheat panels are about 13% higher with oxygen firing. Similarly, the upper furnace waterwall region is about 10% higher. Convective heat transfer in utility steam generator units is dependent upon many of the transport properties of the flue gas (viscosity, thermal conductivity, density, specific heat and others). Additionally, convection depends strongly on gas velocity. With this system, there are significant changes in the flue gas analysis as compared with air firing. These gas analysis changes cause both transport property and gas velocity changes throughout the unit. Significant differences in non-luminous radiant heat transfer are also expected. Of the gases produced by the complete combustion of a fuel, only carbon dioxide, water vapor and sulfur dioxide emit radiation over a sufficiently wide band of wavelengths to warrant consideration. With this system the primary change in the flue gas as compared to air firing is the large increase in the CO2 content and decrease in N2 content. The total heat transfer rates (convective + nonluminous radiation) for the convection pass are shown in the figure on the right, below. Increases are calculated to be in the range of 1 to 8% for oxygen firing over the values with air firing.
ALSTOM Power Inc.
June 30, 2001
Steam Generator Heat Transfer Comparison (Oxygen and Air Firing)
1.14 1.12 1.10 1.08 1.06 1.04 1.02 1.00 LF Firing Zone UF Panel UF Rad Wall UF Waterwall
1.09 1.08 1.07 1.06 1.05 1.04 1.03 1.02 1.01 1.00 SH Platen RH Pendant Front RH Pendant Finish SH Finish SH Low Temp Horiz Economizer
Furnace Region Heat Flux Comparison
Convection Pass Total Heat Transfer Rate Comparison
Despite these heat transfer changes, boiler performance is achieved with the existing steam temperature control system that includes burner tilts and desuperheating sprays. Although more detailed analysis are needed, no boiler pressure parts modifications appear to be required. The products of combustion that exit the furnace are cooled in a series of heat exchangers. Two of these heat exchangers, located downstream of the existing air heater, are new. The first heat exchanger is provided to preheat the oxygen required for combustion. The second heat exchanger recovers additional heat from the flue gas in a low temperature economizer installed in parallel with the low-pressure extraction feedwater heaters. This heat exchanger was necessary as a result of reduced air heater performance with oxygen firing. The steam cycle system for Concept B is very similar to the Base Case. The only modification was the addition of a low-pressure feedwater heater arrangement in parallel with two low-pressure extraction feedwater heaters. The modified steam cycle system produces almost exactly the same output as the Base Case. In Concept C, coal is burned conventionally in air. A process comprising an optimized mixture of monoethanolamine (MEA) and methydiethanolamine (MDEA), installed downstream of the flue gas desulfurization unit, is integrated into the power plant to strip CO2 from the effluent gas stream. The mixture of MEA and MDEA cannot be made to be oxygen-resistant. Therefore, while this process potentially offers an improved system from the standpoint of solvent regeneration energy requirement, it is necessary that the excess oxygen in the flue gas be converted to CO2 by combustion with natural gas over a De-Oxy catalyst upstream of the solvent contactor. Solvent regeneration requires about 3.4x106 Btu/Ton CO2 (about 72% of that required for Concept A). High temperature heat recovery is provided in the De-Oxy system by the generation of high pressure superheated steam for power generation and solvent regeneration. Concept C is depicted schematically below.
Natural Gas Air Coal
CO2 for Sequestration or Use (in EOR or EGR)
Boiler
Oxygen Removal Unit
CO2 Separation Unit Using MEA/MDEA
H2O, N2, ...
Boiler performance for Concept C is again identical to the Base Case. There is a major impact to the steam cycle system, similar to Concept A, where low-pressure steam is extracted from the existing steam turbine to provide energy for solvent regeneration. In this case, about 45% of the IP turbine exhaust is extracted from the IP/LP crossover pipe. This steam is expanded from 200 psia to about 65 psia through a new low-pressure steam turbine. The exhaust from
ALSTOM Power Inc.
June 30, 2001
the new turbine provides most of the heat requirements for solvent regeneration in the reboilers of the MEA/MDEA CO2 capture system. The high-pressure steam generated in the De-Oxy heat recovery system is expanded through a new high-pressure steam turbine for additional power generation. The exhaust from this turbine provides about 20% of the energy requirement for the reboilers. Low temperature heat recovery is provided in the De-Oxy system with a low-pressure feedwater heater which is located in a feedwater stream which is in parallel with the three existing low pressure extraction feedwater heaters. The total output from the modified steam cycle is 431,290 kW. This represents a gross output reduction of 32,188 kW, which represents about 7% of the Base Case output. Performance Analysis Results The table shown below summarizes the performance differences between the cases. The primary design constraint among all cases was the supply of an equivalent main steam flow to the existing steam turbine.
Original Plant (Base) 4228.7 --4228.7 Concept A MEA 4228.7 17.7 4246.4 Concept B O2 Fired 4140.0 11.4 4151.5 Concept C MEA-MDEA 4228.7 885.9 5114.6
(units)
Fuel Paramaters
Coal Heat Input (HHV) Natural Gas Heat Input (HHV) Total Fuel Heat Input (HHV) (10 Btu/hr) (10 Btu/hr) (10 Btu/hr)
6 6 6
Steam Cycle Paramaters

Existing Steam Turbine Generator Output CO2 Removal System Turbine Generator Output De-Oxy System Turbine Generator Output (Concept C) Total Turbine Generator Output Total Auxiliary Power Net Plant Output (kW) (kW) (kW) (kW) (kW) (kW)
463478 0 0 463478 29700 433778
269341 62081 0 331422 76007 255414
463056 0 0 463056 189709 273347
357196 36343 37751 431290 95317 335973
Overall Plant Performance Paramaters

Net Plant Efficiency (HHV) Net Plant Efficiency (LHV) Normalized Efficiency (HHV; Relative to Base Case) Net Plant Heat Rate (HHV) Net Plant Heat Rate (LHV) (fraction) (fraction) (fraction) (Btu/kwhr) (Btu/kwhr)
0.3501 0.3666 1.0000 9749 9309
0.2053 0.2150 0.5864 16626 15872
0.2247 0.2354 0.6419 15188 14500
0.2242 0.2371 0.6404 15223 14395
As described above, significant reductions in Net Plant Output are incurred as a result of the CO2 capture systems (refer to the figure to the left below). Therefore, each case was also analyzed with replacement power to make up this difference. For cases with replacement power, it was assumed to be generated with a state-of-the-art natural gas fired combined cycle (NGCC) plant. The NGCC plant was analyzed without capturing the CO2 from its flue gas. The NGCC plant was assumed to generate power with an efficiency of 57.1 percent (LHV basis). The additional CO2 emitted from the NGCC was 0.762 lbm/kWh. Net plant efficiency is reduced from about 35% (HHV basis) for the Base Case to about 20.5% for Concept A and about 22.5% for Concepts B and C (without replacement power) as shown in the figure on the right below. These efficiencies represent energy penalties of 41% and 36%, respectively. The efficiency reductions for Concepts A and C are due to large reductions in the existing steam turbine output and significant auxiliary power requirement increases. Concept C additionally utilizes a large quantity of natural gas in the de-oxy system increasing the total fuel heat input by about 21%. The steam turbine output reductions for Concepts A and C result from solvent regeneration energy requirements, which are provided by low-pressure steam extraction. The auxiliary power increases are due to the CO2 compression and liquefaction system. Concept B, with a gross output essentially the same as the Base Case, suffers from high auxiliary power primarily from the ASU and the CO2 compression and liquefaction system. The efficiencies for these cases including replacement power are also shown on this figure and range from about 26% to 28% (HHV basis) with Concept B being the most efficient.
ALSTOM Power Inc.
June 30, 2001
Net Plant Output Comparison

500 450 400 350 300 250 200 150 100 50 0 255 273 336 434
Plant Thermal Efficiency Comparison (HHV Basis)

0.40
0.350 w/o Repl Pwr with Repl Pwr 0.273 0.205 0.284 0.257 0.225 0.224
0.35 0.30 0.25 0.20 0.15 0.10 0.05 0.00
Base Case
Base Case Concept A MEA Concept B O2 Fired Concept C MEA / MDEA
Concept A MEA
Concept B O2 Fired
Concept C MEA / MDEA
Plant CO2 Emissions Specific carbon dioxide emissions were reduced from about 2 lbm/kWh for the Base Case to between 0.13 0.27 lbm/kWh for the study cases as shown in the following table and figure (without replacement power). Recovery of CO2 ranged from 91 to 96%. The CO2 emissions with replacement power are also indicated on the figure below.
Original Concept A Plant (Base) MEA

(units)
Concept B O2 Fired
Concept C MEA-MDEA
Plant CO 2 Emissions
Carbon Dioxide Produced Carbon Dioxide Recovered Carbon Dioxide Emissions Fraction of Carbon Dioxide Recovered Specific Carbon Dioxide Emissions Normalized Specific CO2 Emissions (Relative to Base Case) Avoided Carbon Dioxide Emissions (as compared to Base) (lbm/hr) (lbm/hr) (lbm/hr) (fraction) (lbm/kwhr) (fraction) (lbm/kwhr)
866102 0 866102 0 1.997 1.00 ---
868137 835053 33084 0.962 0.130 0.065 1.867
849255 796238 53016 0.938 0.194 0.097 1.803
967806 875653 92153 0.905 0.274 0.137 1.722
Specific CO2 Emissions

2.5
1.997
2.0 1.5 1.0 0.5

0.130 0.390 0.194 0.404 0.274 0.384 w/o Repl Pwr with Repl Pwr
0.0
Base Case
Concept A MEA
Concept B O2 Concept C Fired MEA / MDEA
ALSTOM Power Inc.
June 30, 2001
Project Costs The project capital cost estimates, including construction, are shown in the following table and figure. These costs include all required equipment such as the amine based CO2 scrubbing systems of Concepts A and C, the modified FGD system of Concept A, the de-Oxy system of Concept C, the CO2 compression and liquefaction systems for all three concepts, steam cycle modifications for all concepts, the air separation unit and the boiler island modifications of Concept B. Boiler island modifications for Concept B are relatively small and include costs for such items as air and gas ducts and dampers, booster fans, parallel feedwater heaters and piping, O2 heater, and controls and instrumentation. All these CO2 capture options produce less net plant output than the original plant (Base Case). Therefore, each case was also analyzed with replacement power to make up this difference. For cases with replacement power, it was assumed to be generated with a state-of-the-art natural gas fired combined cycle (NGCC) plant. The NGCC plant was analyzed without capturing the CO2 from its flue gas. The NGCC plant was assumed to cost $450/kW, installed and its efficiency (LHV basis) was 57.1 percent. The additional CO2 emitted from the NGCC was 0.762 lbm/kWh. Two sets of costs are shown for each Concept in the table, one without replacement power and one including replacement power. The figure on the left shows new equipment specific investment costs ($/kW net) for the three concepts, without replacement power, based on both the original and modified net output. The figure on the right shows new equipment specific investment costs ($/kW net) for the three concepts, with replacement power, and therefore based on the original net output.
Total Retrofit Investment Capital Costs

CO2 Capture Concept Concept A Concept B Concept C Units 10 US$ $/kW 6 10 US$ $/kW 6 10 US$ $/kW
6
w/o Repl Pwr
with Repl Pwr
409 1602 285 1042 738 2197
489 1128 357 823 782 1803
Note:
The specific costs ($/kW) shown above for cases without replacement power are based on the new net kW output.
New Equipment Specific Investment Costs (Without Replacement Power)

2500 2000 1500 1000 500 0 Concept A Concept B Concept C
2500 2000 1500 1000 500 0
New Equipment Specific Investment Costs

(With Replacement Power)
Concept A
Concept B
Concept C
New kW basis
Original kW basis
Operating and maintenance (O&M) costs were calculated for all systems. The O&M costs for the Base Case were provided by AEP. The fixed O&M costs (FOM) for the existing plant were about $16/kW (0.27 Cents/kWh using the base parameter assumptions) and the variable O&M costs (VOM) were about 0.45 Cents/kWh. The VOM costs are
ALSTOM Power Inc.
June 30, 2001
comprised exclusively of the lime cost required for the FGD system and the costs for fly ash, bottom ash and FGD system waste disposal. For the retrofit CO2 capture system evaluations, additional O&M costs were calculated for the new equipment. The VOM costs for the new equipment included such categories as chemicals and desiccants, waste handling, maintenance material and labor, and contracted services. The FOM costs for the new equipment includes operating labor only. For the variable ranges considered in the economic sensitivity study, total FOM costs for the retrofit systems, including existing and new equipment, ranged from about 0.4 to 0.6 Cents/kWh and VOM costs ranged from about 0.9 to 2.3 Cents/kWh. Economic Evaluation A total of 66 CO2 capture cases were compared in the reported sensitivity studies. All cases studied indicate significant increases to the COE as a result of CO2 capture. The incremental COE as compared to the Base Case (air firing without CO2 capture) ranges from 1.5 to 9.8 Cents/kWh. Similarly CO2 mitigation costs range from about 17113 $/Ton of CO2 avoided for the range of cases studied. The following table and figures summarize the economic analysis results for the six primary cases using base parameter values (i.e.; Coal Cost = 1.32 $/106 Btu, Natural Gas Cost = 4.0 $/106 Btu, Capacity Factor = 67%, CO2 Byproduct Sell Price = 0.0 $/Ton, Investment Cost = As Estimated). Summary of Economic Analysis Results (Using base parameter values)
Parameter Incremental COE CO2 Mitigation Cost Units Cents/kWh
Concept A
w/o Repl Pwr with Repl Pwr
Concept B
Concept C
$/Ton
6.2 68
4.3 53
4.4 49
3.4 42
8.4 98
6.6 82
Incremental Cost of Electricity (Using base parameter values)

9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 w/o Repl Pwr Concept A (MEA) Concept B (O2 Fired) with Repl Pwr Concept C (MEA/MDEA)
ALSTOM Power Inc.
Incremental COE (Cents/kWh)
June 30, 2001
125
CO2 Mitigation Costs ($/Ton of CO 2 Avoided)
98
100
82
75
68 53 42
49
50
Without Replacement Power

25
With Replacement Power

0
O2 FIRED MEA MEA/MDEA O2 FIRED MEA MEA/MDEA
Concept B (oxygen firing with flue gas recycle) appears to clearly be the best alternative of the three concepts studied based on incremental COE or mitigation cost evaluation criteria. Using the base parameters of the sensitivity study for Concept B yields incremental COE values of 3.4 and 4.6 Cents/kWh for cases with and without replacement power respectively. The actual COE values for Concept B are 19% and 12% lower than the corresponding values for Concept A and 47% and 51% lower than the corresponding values for Concept C for cases with and without replacement power respectively. Similar results are also obtained when comparing mitigation costs. If CO2 byproduct were sold for $20/ton, incremental COE values would be reduced to 1.59 and 1.64 Cents/kWh respectively. Additional reductions would be possible with capacity factor increases, investment cost decreases or system efficiency increases as quantified in the sensitivity studies. Significant investment cost decreases and efficiency increases may be possible as oxygen transport membrane technology develops. Previous studies, Liljedahl, et al. (1999), have shown membrane technology to provide specific investment cost ($/kW) reductions of about 30% and net plant heat rate improvements greater than 20%. Conclusions and Recommendations No major technical barriers exist for retrofitting AEPs Conesville Unit #5 to capture CO2 with any of the three concepts considered under this study. Nominally, 5-8 acres of new equipment plan area is needed. For this site, new equipment is located approximately 1500 feet north of the Unit #5 stack on the existing ~200 acre power plant site which accommodates a total of 6 units with a total power generating capability of 2,080 MW. Energy requirements and power consumption are high, resulting in significant decreases in overall power plant efficiencies (HHV basis), ranging from about 21 to 23% as compared to 35% for the Base Case. The MEA/MDEA mixture of Concept C requires about 28% less energy per pound of CO2 captured to regenerate the solvent as compared to the MEA used for Concept A. Specific investment costs are also high ranging from about 1000 to 2200 $/kW without replacement power, and from about 800 to 1800 $/kW with replacement power. All cases studied indicate significant increases to the COE as a result of CO2 capture. The incremental COE as compared to the Base case (air firing without CO2 capture) ranges from 3.4 to 8.4 /kWh. Similarly CO2 mitigation costs range from about 42-98 $/ton of CO2 avoided for the range of cases studied. Specific carbon dioxide emissions were reduced from about 2.0 lbm/kWh for the Base Case to 0.13, 0.19, and 0.27 lbm/kWh for study cases A, B, and C, respectively. Recovery of CO2 ranged from 91 to 96%.
ALSTOM Power Inc.
June 30, 2001
Concept B (oxygen firing with flue gas recycle) appears to clearly be the best alternative of the three concepts studied from both an efficiency and incremental COE viewpoint for systems designed for very high CO2 capture (i.e. > 90%). If lower CO2 capture fractions are considered, it appears that Concept A would likely be the best alternative for capture fractions below some as yet undetermined value. Concept C would also improve considerably with lower capture fractions. This study has confirmed two important issues related to firing coal in a CO2 rich flue gas /O2 mixture: Modifications to the existing steam generator unit pressure parts may not be required, and as such will also allow the unit to continue to operate in the conventional air fired mode. This is an important consideration as it is unlikely that much new coal-fired capacity can be built in the short term. CO2 rich flue gas can be cleaned and compressed with a relatively simple system to provide high purity CO2 for usage or sequestration.
While overall plant performance penalty and costs are high, the integration of power generation, air separation, and CO2 separation, compression and liquifaction systems may significantly improve the overall system efficiency and economics. The major cost item in Concept B is in the air separation plant, both from a capital and an operating cost point of view. While in recent years advances have been made in air separation technology which have steadily improved the costs, new membrane based technologies are being researched which promise to provide greatly reduced auxiliary power requirements and investment costs which will significantly improve the overall system efficiency and economics. Previous studies, Liljedahl, et al. (1999), have shown membrane technology to provide specific investment cost ($/kW) reductions of about 30% and net plant heat rate improvements greater than 20%. Barring governmental mandates, it is clear that none of these three retrofit concepts will be acceptable to the electric utility industry from the standpoint of cost competitiveness. Recommendations for Future Work are listed below: A sensitivity study, for Concepts A and C, showing the impact of reducing CO2 capture percentage on plant efficiency, investment cost, emissions, and cost of electricity. The current work utilized 90% CO2 capture (nominal). The sensitivity study would investigate nominal CO2 capture percentages of 70% and 50%. Detailed analysis of the existing steam turbine for Concept A: In Concept A about 79% of the steam leaving the intermediate-pressure (IP) turbine is extracted from the IP/LP crossover pipe for solvent regeneration. The capability of the existing low-pressure (LP) turbine to operate under these conditions of very low steam flow should be investigated in detail, preferably by the original equipment manufacturer (OEM). Optimization of the amine system reboiler steam pressure for Concepts A and C. Concept B detailed boiler system analysis: A startup/shutdown procedure and system design, particularly the transition from air to oxygen firing (including transient conditions) should be developed. Detailed metal temperature analysis for all heat exchanger sections, including operation at part loads should be analyzed. This should also include furnace wall metal temperatures and analysis of the circulation system. The existing fans should be checked (preferably by the OEMs) for operation under the new conditions. The feasibility of operating the boiler under a slight positive pressure to eliminate air infiltration should also be investigated. Investigation of Improved oxygen production systems for Concept B, in line with the membrane-based air separation work being conducted by various research groups (e.g., Praxair, Air Products, Norsk Hydro). Also optimization of an integrated boiler and oxygen production system. Measurement of furnace heat transfer in CO2/O2 environments in a proof of concept boiler simulation facility.
ALSTOM Power Inc.
10
June 30, 2001
Improved solvents, which require lower regeneration energy requirements and/or can be regenerated at a lower temperature level, similar to MHIs KS-1 and KS-2 solvents (Iijima, et al., Feb. 1998), but for coal-firing application. Hybrid process using oxygen-enriched combustion and amine based CO2 absorption, to accrue, simultaneously, both CO2 capture and drastic NOx emissions reduction. Investigation of a new novel high risk CO2 capture process that would reduce efficiency penalty and retrofit investment cost. This would likely not utilize the existing boiler.
ALSTOM Power Inc.
11
June 30, 2001
1.0
INTRODUCTION
ALSTOM Power Inc. teamed with American Electric Power, ABB Lummus Global Inc., the US DOE NETL, and the Ohio Coal Development Office to conduct a comprehensive study evaluating the technical feasibility and economics of alternate CO2 capture and sequestration technologies applied to an existing US coal-fired electric generation power plant. The three retrofit technology concepts being evaluated are shown below. Concept A: Coal combustion in air, followed by CO2 separation from flue gas with Kerr-McGee/ABB Lummus Globals commercial MEA-based absorption/stripping process.
CO2 for Sequestration or Use (in EOR or EGR) Air Coal
Boiler
CO2 Separation Unit using MEA
H 2O, N2, ...
Concept B: Coal combustion with O2 firing and flue gas recycle.

N2 Flue Gas Recycle CO2 for Sequestration or Use (in EOR or EGR)
Air
Air Separation Unit (ASU)
O2
Boiler
Condenser
O2, N2 Air in-leakage
Coal
H 2O
Concept C: Coal combustion in air with oxygen removal and CO2 separation from flue gas by a mixture of primary and tertiary Amines
Natural Gas Air Coal CO2 for Sequestration or Use (in EOR or EGR)
Boiler
Oxygen Removal Unit
CO2 Separation Unit Using MEA/MDEA
H2O, N2, ...
Each of these technologies was evaluated against a Base Case from the standpoints of performance and impacts on power generating cost. The Base Case represents the business as usual operation scenario for the plant without CO2 capture. A typical existing US domestic pulverized coal-fired power plant is being used in this evaluation. Specifically, American Electric Powers (AEPs) 450 MW Conesville Unit No. 5, located in Conesville, Ohio is the power plant case study. All technical performance and cost results associated with these options are being evaluated in comparative manner. ALSTOM Power Inc. is managing and performing the subject study from its US Power Plant Laboratories office in Windsor, CT. ABB Lummus Global, from its offices in Houston, Texas, is participating as a sub-contractor. American Electric Power is participating by offering their Conesville Generating Station as the case study and cost sharing consultation, and relevant technical and cost data. AEP is one of the largest US utilities and is the largest consumer of Ohio coal, and as such, is bringing considerable value to the project. Similarly, ALSTOM Power and ABB Lummus Global are well established as global leaders in the design and manufacture of power generation equipment, petrochemical and CO2 separation technology. ALSTOM Power Performance Projects and Environmental Business Units are world leaders in providing equipment and services for boilers and power plant environmental control, respectively, and are providing their expertise to this project. The US Department of Energy (US DOE)
ALSTOM Power Inc.
12
June 30, 2001
National Energy Technology Laboratory (NETL) and the Ohio Coal Development Office (OCDO) provided consultation and funding. All participants provided cost share to this project. The motivation for this study was to provide input to potential US electric utility actions to meet Kyoto protocol targets. If the US decides to reduce CO2 emissions consistent with the Kyoto protocol, action would need to be taken to address existing power plants. Although fuel switching from coal to gas is a likely scenario, it will not be a sufficient measure and some form of CO2 capture for use or disposal may also be required. The output of this CO2 capture study will enhance the publics understanding of control options and influence decisions and actions by government, regulators, and power plant owners to reduce their greenhouse gas CO2 emissions. The key objectives of the study were to evaluate the impacts on the plant output, efficiency, CO2 emissions, investment costs, and the cost of generating electricity resulting from the addition of the CO2 capture systems. All technical performance and cost results associated with these options are being evaluated in comparative manner. Technical and economic issues being evaluated include: Boiler performance and plant efficiency Purity of O2 produced and flue gas recycled Heat transfer into the radiant and convective sections of the boiler NOX, SO2, CO and unburned carbon emissions Heat transfer surface materials Steam temperature control Boiler and Steam Cycle modifications Electrostatic Precipitator system performance Flue Gas Desulfurization system performance Plant systems integration and control Retrofit investment cost and cost of electricity (COE) CO2 Mitigation Costs
Each of the CO2 capture systems are designed for a minimum of 90% CO2 capture. Cost estimates were developed for all the systems required to produce, extract, clean, compress and liquefy the CO2, to a product quality acceptable for pipeline transport. The Dakota Gasification Companys CO2 specification (2) for EOR, given in the following table, was used as the basis for the CO2 capture system design. Dakota Gasification Projects CO2 Specification for EOR
Component
CO2 H2S CH4 C2+HCs CO N2 H2O O2
Unit
Vol.% Vol.% Vol.% Vol.% Vol.% vppm vppm vppm
Concentration
96.0 0.9 0.7 2.3 0.1 < 300 < 20 < 50
The CO2 product could then be available for usage in enhanced oil or gas recovery or sequestration. Additionally, an economic evaluation, showing the impact of CO2 capture on the cost of electricity (COE), was developed for each concept. Included in the economic evaluation was a sensitivity study showing the effects of coal cost, natural gas cost, plant capacity factor, CO2 byproduct sell price, investment cost, and replacement power, on the incremental cost of electricity and on the mitigation cost for the CO2 ($/ton of CO2 avoided).
ALSTOM Power Inc.
13
June 30, 2001
2.0
STUDY UNIT SELECTION, DESCRIPTION AND PERFORMANCE
This section includes the criteria used for selection of the study unit, and provides a brief description of the selected unit. Additionally, the Base Case is defined as the unmodified existing unit firing coal at full load, utilizing air as the oxidant, without capture of CO2 from the flue gas. This represents the business as usual operating scenario and is used as the basis of comparison for the three CO2 removal options investigated in this study. The overall performance of the Base Case is presented in Section 2.3. 2.1 Study Unit Selection
A decision was required at the end of Task 2 (Site Selection/Plant Evaluation) regarding the selection of either unit #5 or #6 of AEPs Conesville, Ohio, Power Generating Station, as the study unit for our retrofit evaluations. To provide the necessary background to facilitate this selection, a trip was made to the Conesville site on April 20, 2000. This visit provided the opportunity to gather operating data for unit #5, overall site information for both units #5 and 6, and additionally, to make arrangements for collecting a raw coal sample for Bench-Scale Testing (Task 4a). It was learned from the operators and plant maintenance personnel that both twin units #5 and #6 operate nearly identically, and that no renovations had been made to either unit aside from replacement in kind. AEP, OCDO and Alstom personnel conducted a walk down of both units. Site drawings were provided and photographs were taken to document the footprints of both units. This information was used to evaluate space availability for the various new equipment that would be required for the three CO2 capture systems being evaluated in this study. Figure 2.1.1 shows several potential areas for new equipment placement in the neighborhood of units #5 and #6. A large amount of additional land area (about 10 acres) is available in a location about 1,500 feet northeast of the common stack used for units #5 and #6 (upper right corner of Figure 2.1.1). The approximate size of the four areas in the immediate vicinity of units #5 and #6 for locating some of the new equipment on the ground are listed below: Area # 1 2 3 4 Approximate Size (square feet) 13,000 (Available) 29,000 (Partially available) 2,600 (Not available) 25,000 (Available)
Additionally, consideration was given for hanging some of the equipment, where appropriate, in the space between the far end of the ESP and the boiler: fifth floor and up. The major new equipment envisioned for the three retrofit concepts for this study include: An Air Separation Unit of about 9,000 tons of O2 per day (Concept B), An MEA system for removal of about 10,000 tons of CO2 per day from the flue gas (Concept A), An MEA/MDEA system for removal of about than 10,500 tons of CO2 per day from the flue gas (Concept C), A flue gas oxygen removal system upstream of the MEA/MDEA system (Concept C), A CO2 Compression and Liquefaction system (required for all 3 concepts), Various other ancillary equipment
ALSTOM Power Inc.
14
June 30, 2001
Partially not available
Not Available
Figure 2.1. 1: Plan View of AEPs Conesville, Ohio, Power Generating Station Site Showing Area Occupied by Units #5 and #6 The four areas identified previously and shown in Figure 2.1.1 indicate the following: These areas, even combined, are not large enough to locate all the equipment required for any one of these CO2 removal concepts. They may however be useful for location of various ancillary equipment. Areas 1 and 4, which are in the vicinity of unit #5 total to ~38,000 square feet Areas 2 and 3, which are in the vicinity of unit #6, total ~31,000 square feet, of which less than 28,000 square feet are available. Furthermore, conveniently we already had performance data from unit #5. Although we could have obtained data from unit #6, this step could be eliminated with the selection of unit #5. Hence, it made more sense to use unit #5 in this initial evaluation. If there is in the future a desire to evaluate unit #6, then a further re-examination of areas #2 and #3 would be warranted and performance data from unit #6 could be obtained.
In summary, the preceding information indicated that: Unit #5 offers more on-the-ground area near the unit for erecting new equipment than does unit #6.
ALSTOM Power Inc.
15
June 30, 2001
Both units #5 and #6 are equally accessible for erecting new equipment in the space between the boiler and the far end of the ESP, fifth floor and up. Both units #5 and #6 are equally accessible to the large area available about 1,500 feet northeast of the unit #5/#6 stack. Both units #5 and #6 perform similarly with respect to power generation.
Considering the totality of the information given above, we concluded that unit #5 offered a relatively more costeffective scenario for our retrofit evaluation. Cognizant personnel of the Conesville Power Generating Station were in complete agreement with these findings and Conesville Unit #5 was selected as the study unit. 2.2 Study Unit Description
The steam generator unit analyzed in this study was American Electric Powers Conesville Unit #5. A sectional side elevation drawing of the study unit is shown in Figure 2.2.1. This unit can be described as a nominal 450 MW-gross, tangentially coal fired, subcritical pressure, controlled circulation, radiant reheat wall unit. The furnace is a single cell design utilizing five elevations of tilting tangential coal burners. The unit fires mid-western bituminous coal. The coal is supplied to the five elevations with five RP-903 coal pulverizers. The unit is configured in a Conventional Arch type design and is representative in many ways of a large number of coal fired units in use today. The unit is designed to generate about 3.1 x 10 6 lbm/hr of steam at 2400 psi and 1005 F with reheat also to 1005 F. These represent the most common steam cycle operating conditions for existing utility scale power generation systems. Outlet steam temperature control is provided with de-superheating spray and burner tilt. The furnace is tangentially fired and is of the single cell design. It is about 51.67 ft wide, 44.33 ft deep and 171.67 ft high. The superheater is divided into four major sections. Saturated steam leaving the steam drum first cools the roof and rear pass walls before supplying the low temperature superheater section. The low temperature superheater section is located in the rear pass of the unit and is a horizontal section with the outlet tubes in a vertical orientation adjacent to the finishing superheater section. Steam leaving the low temperature superheater section first flows through the de-superheater spray stations and then to the radiant superheat division panel section. The division panels are located in the upper furnace directly above the combustion zone of the lower furnace. Steam leaving the panels flows to the superheater platen section, which is a more closely spaced vertical section located between the panels and the finishing pendant reheater. Steam leaving the platens flows into the finishing superheater section which is also a pendant section located downstream of the pendant reheater, just before the gas turns downward to enter the low temperature superheater section in the rear pass of the unit. Steam leaving the finishing superheater is piped to the high-pressure turbine where it is expanded to reheat pressure and then returned to the reheat de-superheating spray station. The reheater is divided into two sections, a low temperature radiant wall section followed by a spaced finishing pendent section. Steam is supplied to the reheater radiant wall from the de-superheating spray station, which is fed from the high-pressure turbine exhaust. The reheater radiant wall section is located in the upper furnace and covers the entire front wall and most of the two sidewalls of the upper furnace. The pendant finishing reheat section is located above the arch between the superheat platen and superheat finishing sections. Steam leaving the finishing reheater is returned to the intermediate pressure turbine where it continues its expansion through the intermediate and low-pressure turbines before being exhausted to the condenser. The gases leaving the low temperature superheater section are then further cooled in an economizer section. The economizer is comprised of four banks of spiral finned tubes (2 fins/inch) which heats high-pressure boiler feedwater before it is supplied to the steam drum. The feedwater supplying the economizer comes from the final extraction feedwater heater. Finally, a Lungstrom trisector regenerative air heater is used to heat both the primary and secondary air streams prior to combustion in the lower furnace. Particulate matter is removed from the cooled flue gas leaving the air heater in an electrostatic precipitator and sulfur dioxide is removed in a lime based flue gas de-sulfurization system. The flue gas
ALSTOM Power Inc.
16
June 30, 2001
is then exhausted to the atmosphere through the stack. The induced draft and forced draft fans are controlled to operate the unit in a balanced draft mode with the furnace maintained at a slightly negative pressure (typically 0.5 inwg). The high pressure superheated steam leaving the finishing superheater is expanded through the high pressure steam turbine, reheated in the two stage reheater and returned to the intermediate pressure turbine. The steam continues its expansion through the low-pressure turbine sections where it expands to condenser pressure. The generator produces about 463 MW of electric power at Maximum Continuous Rating (MCR). The steam cycle utilizes seven feedwater heaters (three low-pressure heaters, a deaerator, and three high-pressure heaters) where the feedwater is preheated to about 493 F before entering the economizer of the steam generator unit. The boiler feed pump is steam turbine driven with steam provided from the intermediate pressure turbine exhaust and expanded to condenser pressure.
ALSTOM Power Inc.
17
June 30, 2001
Superheater Outlet Line Reheater Outlet Line
Steam Drum Finishing Pendant Superheater Superheater Panels Superheater Platens Reheater Radiant Wall Finishing Pendant Reheater
Low Temperature Superheater
Reheater Inlet Header
Economizer Economizer Inlet Line
Downcomers
Tilting Tangential Fuel Nozzles Lungstrom Trisector Air Preheater Flue Gas to Emission Control Equipment and Induced Draft Fans
Boiler Circulating Pumps
Pulverized Coal Piping to Fuel Nozzles Bottom Ash Hopper
Forced Draft Fans
Coal Pulverizers
Figure 2.1. 2: Study Unit (Existing Conesville Unit #5 Steam Genertor)
ALSTOM Power Inc.
18
June 30, 2001
2.3
Base Case Performance Analysis
The Base Case can be described as the unmodified existing unit firing coal at full load and utilizing air as the oxidant without capture of CO2 from the flue gas. This represents the business as usual operating scenario and is used as the basis of comparison for the three the CO2 removal options investigated in this study. The first step in the development of a Base Case was to set up a computer model of the boiler. Using test data from the existing unit, the computer model was then calibrated. The calibrated boiler model was then used for analysis of the Base Case and the three CO2 removal concepts. 2.3.1 Calibration of Boiler Computer Model
The first step in the calculation of a Base Case was to set up a steady state performance computer model of the Conesville #5 steam generator unit. This involves calculating or obtaining all the geometric information for the unit as required by the proprietary Reheat Boiler Program (RHBP). The RHBP provides an integrated, steady state performance model of the Boiler Island including, in addition to the steam generator unit, pulverizers, air heater, and steam temperature control logic. The RHBP is used to size components and/or predict performance of existing components. In this study, since the boiler island component sizes are known, the RHBP was used exclusively for calculating unit performance. The next step in the heat transfer analysis of the Base Case was to calibrate the RHBP model of the unit. This involves obtaining test data (with air firing) for the existing unit and adjusting the performance model to match the test data. The required test data includes steam temperatures entering and leaving each major heat exchanger section in the unit, steam pressures, coal analysis, flue gas oxygen content, etc. The adjustments or calibration factors for the model are in the form of surface effectiveness factors and fouling factors for the various heat exchanger sections throughout the unit. Unfortunately, the test data used for calibration of this model was not totally complete and several assumptions were required in the calibration process. Although all the required data was not available, primarily due to existing instrumentation limitations, a satisfactory calibrated model was obtained. Using the calibrated boiler model and providing it with new steam side inputs (mass flows, temperatures, and pressures) from the agreed upon MCR steam turbine material and energy balance, the model was run and performance was calculated for the Base Case. The performance for the overall power plant system is described in Section 2.3.2 with the boiler performance shown in Section 2.3.3 and the steam turbine performance in Section 2.3.4. 2.3.2 Overall System Description and Material and Energy Balance
The simplified gas side process flow diagram for the Base Case is shown in Figure 2.3.1and the associated material and energy balance for this case is shown in Table 2.3.1. Overall plant performance is summarized in Table 2.3.2. This system is described previously in Section 2.2. Boiler efficiency is calculated to be 88.13 percent. The net plant heat rate is calculated to be 9,749 Btu/kwhr for this case as shown in Table 2.3.2. Auxiliary power is 29,700 kw and the net plant output is 433,778 kw. Carbon dioxide emissions are 866,156 lbm/hr or about 2.00 lbm/kwhr.
ALSTOM Power Inc.
19
June 30, 2001
5 ID Fan 4 ESP 21 Air Heater 19 18 1 Coal Mill System 16 13 PA Fan 17 15 SCAH 12 11 6 SCAH 20 7
Steam Generator Unit
3 22
Tri-Sector 14
FGD System
10 S t a c k
FD Fan
23
Material Flow Stream Identification

1 2 3 4 5 6 7 8 Raw Coal to Pulverizers Air Infiltration Stream Fluegas from Economizer to Air Heater Fluegas Leaving Air Heater to ESP Flyash Leaving ESP Fluegas Leaving ESP to Induced Draft Fan Fluegas to Fluegas De-Sulfurization System Lime feed to FGD System 9 10 11 12 13 14 15 16 FGD System Solids to Disposal Fluegas to Stack Air to Primary Air Fan Primary Air to Steam Coil Air Heater Primary Air to Air Heater Air Heater Leakage Air Stream Tempering Air to Pulverizers Hot Primary Air to Pulverizers 17 18 19 20 21 22 23 Mixed Primary Air to Pulverizers Pulverized Coal and Air to Furnace Secondary Air to Forced Draft Fan Secondary Air to Steam Coil Air Heater Secondary Air to Air Heater Heated Secondary Air to Furnace Bottom Ash from Furnace
Figure 2.3. 1:
Simplified Gas Side Process Flow Diagram (Base Case)
ALSTOM Power Inc.
20
June 30, 2001
Table 2.3. 1:
Constituent O2 N2 H2O CO2 SO2 H2 Carbon Sulfur Ca Mg MgO MgSO3 MgSO4 CaSO3 CaSO4 CaCO3 Ash / Inerts Total Gas Total Solids Total Flow (Units) (Lbm/hr) " " " " " " " " " " " " " " " " (Lbm/hr) " " 1 26586 4868 37820 2 42147 139626 2357
Base Case Gas Side Material and Energy Balance

5 6 7 144817 144817 2942220 2942220 231294 231294 867210 867210 20202 20202 8 5355 250709 9 10 144578 2942220 436024 866156 1063 11 203237 673283 11365 12 203237 673283 11365 13 112918 374075 6314
3 4 101097 144817 2797385 2942220 228849 231294 867210 867210 20202 20202
45979
16102 236655 10110 12452 584 484 1293 94 35179 2468 2398 968
FGD Disposal Fgas to CO2 Sep Pri Air to PA Fan PA from PA Fan Pri Air to AH
42313
Raw Coal Leakage Air
33851
Fluegas to AH
33851
Fluegas to ESP
33851
Flyash Fluegas to ID Fan Fluegas to FGD
968
Lime Slurry
184130 374455 374455 80 14.7 0.000 184130 80 14.7 0.000
4014743 4205743 33851 33851 4048594 4239594 706 14.6 161.831 311 14.3 57.924
4205743 4205743 33851 33851 311 14.7 57.750 4205743 4205743 311 14.2 57.924 325 15.0 61.384 14003 270067 80 14.7 0.000 42884 88863 136 14.7 14.116
4390042 4390042 136 14.7 14.543
887885 887885 80 14.7 0.000
887885 887885 92 15.6 2.899
493308 493308 92 15.6 2.899
Temperature (Deg F) Pressure (Psia) hsensible (Btu/lbm) Chemical (106 Sensible (106 Latent(106 Total Energy(1) (106
Btu/hr) 4228.715 Btu/hr) 0.000 Btu/hr) 0.000 Btu/hr) 4228.715
0.000 2.475 2.475
655.007 240.291 895.298
245.567 242.858 488.425
1.955 0.000 1.955
243.612 242.858 486.470
258.166 242.858 501.024
0.000 0.000 0.000
3.314 0.000 3.314
63.916 464.020 527.936
0.000 11.933 11.933
2.574 11.933 14.507
1.430 6.630 8.060
Constituent O2 N2 H2O CO2 SO2 H2 Carbon Sulfur Ca Mg MgO MgSO3 MgSO4 CaSO3 CaSO4 CaCO3 Ash / Inerts Total Gas Total Solids Total Flow
(Units) (Lbm/hr) " " " " " " " " " " " " " " " " (Lbm/hr) " "
14 43720 144835 2445
15 90319 299208 5051
16 66680 220899 3729
17 156999 520107 8779
18 19 183585 641283 524975 2124443 46599 35860
20 641283 2124443 35860
21 641283 2124443 35860
22 643801 2132785 36001
23
16102 236655 10110
42313
Air Htr Lkg Air Tempering Air Hot Pri Air Mixed Pri Air Coal-Pri Air Mix Sec Air to FD Sec Air to SCAH Sec Air to AH Hot Sec Air
8463
Bottom Ash
191000 191000 92 15.6 2.899
394577 394577 92 15.6 2.899
291308 291308 666 15.6 145.249
685885 685885 339 15.6 63.358
2801587 1060340 2801587 80 14.7 0.000
2801587 2801587 86.4 15.2 1.549
2801587 2801587 86.4 15.1 1.549
2812587 2812587 616 14.9 132.582 8463 8463 2000 14.7 480.000
Temperature (Deg F) Pressure (Psia) hsensible (Btu/lbm) Chemical (106 Sensible (106 Latent(106 Total Energy(1) (106 Btu/hr) Btu/hr) Btu/hr) Btu/hr)
15.0
0.554 2.567 3.121
1.144 5.303 6.447
42.312 3.915 46.227
4228.715 43.456 9.218 52.674 4281.389
0.000 37.653 37.653
4.341 37.653 41.994
4.341 37.653 41.994
372.898 37.801 410.699
4.062 0.000 4.062
ALSTOM Power Inc.
21
June 30, 2001
Table 2.3. 2:
Overall Plant Performance Summary (Base Case)

(units)
Original Plant (Base) 4228.7 --4228.7
Fuel Paramaters
6 6 6

Existing Steam Turbine Generator Output CO2 Removal System Turbine Generator Output Total Turbine Generator Output Total Auxiliary Power Net Plant Output (kW) (kW) (kW) (kW) (kW)
463478 0 463478 29700 433778

0.3501 0.3666 1.0000 9749 9309
Overall Plant CO 2 Emissions

Carbon Dioxide Emissions Specific Carbon Dioxide Emissions Normalized Specific CO2 Emissions (Relative to Base Case) Avoided Carbon Dioxide Emissions (as compared to Base) Specific Carbon Dioxide Emissions Avoided Carbon Dioxide Emissions (as compared to Base) (lbm/hr) (lbm/kwhr) (fraction) (lbm/kwhr) (kg/kwhr) (kg/kwhr)
866102 1.997 1.000 --0.906 ---
2.3.3
Boiler Analysis Results
The main steam flow for this case and all other cases in this study is 3,131,619 lbm/hr. The cold reheat flow leaving the high-pressure turbine for this case and all other cases in this study is 2,766,780 lbm/hr. The hot reheat flow (including de-superheating spray) returning to the intermediate pressure turbine for this case is 2,853,590 lbm/hr. The overall steam conditions produced by the existing Conesville #5 steam generator unit are shown in Table 2.3.3 below. To produce these conditions, the superheat circuit requires about 3.6 percent spray and the reheat circuit requires about 3.1 percent spray to maintain required steam outlet temperatures. The burner tilts are 10 degrees (the minimum value the customer uses). The boiler was fired with 15 percent excess air and the resulting boiler efficiency calculated for this case was 88.13 percent with an air heater exit gas temperature of 311 F. Table 2.3. 3: Base Case Boiler/Turbine Steam Flows and Conditions
SHO 3131619 2535 1005 1459.7 FWI ECO 3131619 3017507 3165 3070 492.6 630 479.2 652.8 RHO 2853590 590.8 1005 1520.4 RHI 2853590 656.5 607.7 1290.4
Mass Flow Pressure Temperature Enthalpy
(lbm/hr) (psia) (Deg F) (Btu/lbm)
Notes: SHO = Superheater Outlet; FWI = Feedwater Inlet; ECO = Economizer Outlet; RHO = Reheater Outlet; RHI = Reheater Inlet
ALSTOM Power Inc.
22
June 30, 2001
2.3.4
Steam Cycle Performance
The steam cycle for the Base Case is shown schematically in Figure 2.3.2. Figure 2.3.3 shows the associated Mollier diagram which illustrates the process on enthalpy - entropy coordinates. The high pressure turbine expands about 3.1 x 106 lbm/hr of steam at 2535 psia and 1005 F. Reheat steam is returned to the intermediate pressure turbine at 591 psia and 1005 F. These conditions (temperatures, pressures) represent the most common steam cycle operating conditions for existing utility scale power generation systems in use today. The condenser pressure used for the Base Case and all other cases in this study was 2.5 in Hga. The steam turbine performance analysis results show the generator produces 463,478 kw output and the steam turbine heat rate is about 7999 Btu/kwhr.
Existing Steam Turbine
2490802 195.2 lbm/hr psia
Existing IP Turbine Existing HP Turbine
2853607 lbm/hr From Boiler RHTR 3131619 lbm/hr From Boiler SHTR
Existing DFLP Turbine
Existing Generator
463,478 kw
To Boiler RHTR
COND
SCAH
DEA
To Boiler ECON
Boiler Feed Pump
To Boiler De-Sh Spray
Steam Cycle Energy Balance

Energy Outputs
(10 Btu/hr) 1606 0 2103 3709
Energy Inputs
(10 Btu/hr) 3707 2 3709 0
Turbine Heat Rate 7999 (Btu/kwhr)
Steam Turbine Power Output Steam Coil Air Heater Output Condenser Loss
Total Energy Output
Boiler Heat Input Condensate Pump

Total Energy Input In - Out
Figure 2.3. 2:
1600 1500 Enthalpy (Btu/lbm) 1400 1300 1200 1100 1000 900 800
Base Case Steam Cycle Diagram and Performance
1.2
1.4
1.6
1.8
2.2
Entropy (Btu/lbm-F)
10% Moisture Condenser Pressure
Saturation Line Steam Cycle
Figure 2.3. 3:
Base Case Steam Cycle Mollier Diagram
ALSTOM Power Inc.
23
June 30, 2001
2.3.5
Flue Gas Desulfurization System Analysis
Figure 2.3.4 shows the process flow diagram for the existing Flue Gas Desulfurization System. The stream numbers in Figure 2.3.4 also correspond to stream numbers shown in Figure 2.3.1 and Table 2.3.1. The flue gas leaving the ID fan (Stream 7) is delivered to the Absorber, which consists of a tray followed by a two-stage spray system. The incoming gas is saturated as it passes through the scrubbing slurry contained on the tray and through the two spray levels. The active component of the scrubbing slurry is calcium oxide (Stream 8a), which reacts with sulfur dioxide to form calcium bisulfite (Stream 9). The scrubbing slurry is circulated from the reagent feed tank that forms the base of the scrubber to the spray levels. The solids loading in the scrubbing slurry controls the blowdown from the reaction tank to byproduct disposal. The flue gas passes through chevron type mist eliminators that remove entrained liquid before exiting the scrubber (Stream 10). The water utilized in spray washing the mist eliminators also serves as makeup (Stream 8b). Table 2.3.4 identifies the assumptions that were made in predicting the FGD performance. Table 2.3.5 shows the gas constituents at the existing Absorber inlet and outlet locations. Results show a CO2/SO2 mole ratio of 63 and an SO2 removal efficiency of 94.8%, corresponding to a value of 104 vppm at the outlet of the absorber.
8a QUICKLIME
8b TO CO2 SEPARATION UNIT 10
FRESH WATER
ABSORBER
MAKE-UP WATER
WEIGH FEEDER SLAKER FROM ID FAN 7
REAGENT FEED TANK
DEWATERING SYSTEM
TO DISPOSAL
Figure 2.3. 4:
Base Case Flue Gas Desulfurization System Process Flow Diagram Table 2.3. 4: FGD Assumptions
Base Case Unit Mol Ratio Wt.% Wt.% Wt.% Wt.% Wt.% gpm/1000 acfm % %
Quantity Ca/S) Solids CaO MgO Inerts Bypass Leakage Liquid/Gas (L/G) Ratio SO2 Removal Efficiency APC Absorber
Existing Absorber 1.04 20 90 5 5 2.5 55 94.8 97.2
ALSTOM Power Inc.
24
June 30, 2001
Table 2.3. 5:
FGD Performance
Species O2 N2 H2O CO2 SO2 SO2 Removal Efficiency, % CO2/SO2 Mole Ratio
Base Case Existing Absorber Inlet Existing Absorber Outlet Mol/hr Vol.% Unit Mol/hr Vol.% Unit 4,469 105,018 12,863 19,743 315 3.14 73.74 9.03 13.86 2,212 Vol.% Vol.% Vol.% Vol.% vppm 4,461 105,018 24,228 19,720 16 2.91 68.44 15.79 12.85 104 94.9 63 Vol.% Vol.% Vol.% Vol.% vppm
ALSTOM Power Inc.
25
June 30, 2001
3.0
CO2 REMOVAL SYSTEMS
The following three basic process options were studied: Concept A: Coal combustion in air, followed by CO2 separation with Kerr-McGee/ABB Lummus Globals commercial MEA-based absorption/stripping process Concept B: Coal combustion with O2 firing and flue gas recycle (oxy-fuel firing) Concept C: Coal combustion in air with oxygen removal and CO2 separation
The Capture of CO2 from the flue gas for Concept A is accomplished using the Kerr-McGeee / ABB Lummus Global oxygen inhibited MEA technology. Only Kerr-McGee/ ABB Lummus oxygen inhibited amine was studied. It is the most commercially proven process evaluated in this study. Concept B utilizes oxygen firing with the recycle of flue gas to bring the firing and heat transfer characteristics of the boiler back close to original design. The oxygen firing is used to produce a flue gas stream with high enough CO2 content such that simple compression, refrigeration, and rectification can produce a suitable CO2 liquid product. Optimizations in various areas such as oxygen purity, air leakage into the boiler and associated equipment operating below atmospheric pressure, and flue gas recycle ratio have been made. On the liquefaction side, an optimization of the flow scheme to remove the inerts while maintaining CO2 recovery at the lowest energy consumption was made. For Concept C, CO2 recovery from the flue gas is accomplished by using generic amines (i.e. MEA, MDEA). However, if more efficient and cost effective, proprietary amines may be used. The difference between the amines used in this case and in Concept A is that the amines are not oxygen resistant. Hence, the oxygen is converted to CO2 by combustion with methane over a de-oxy catalyst upstream of the amine contactor. Although triethanolamine (TEA) was first proposed for use for Concept C, due to its relatively low energy requirement for solvent regeneration, the literature survey conducted earlier in the present study, Bozzuto, et al. (2000), revealed that the TEA had a very low recovery of CO2 when operating at near atmospheric pressure. Operating at higher pressures to improve recoveries is not economically feasible as the carbon dioxide concentration in the flue gas is less than 13% and compressing the entire flue gas stream to 200 psig would require approximately 250,000 hp. Therefore, only generic amines and proprietary amines that absorb efficiently at atmospheric pressure were evaluated for this case. Specifically, the amines evaluated were monoethanolamine/ methyldiethanolamime (MEA /MDEA) blend, BASF activated MDEA, and Mitsubishi Heavy Industries amines (Iijima, et al., 1998; Iijima, 1998). Since these amines are required to be oxygen resistant, de-oxygenation via catalytic combustion is required upstream of the amine unit. Neither the de-oxy catalyst nor any of these amines have been tested in coal fired power plant flue gas streams. 3.1 3.1.1 CO2 Removal Systems Design Basis Site Data
Listed below is the summary of the bases used for this design: Plant is located in Connesville, Ohio, elevation 744 feet. Atmospheric pressure is 29.92 inches of Hg. Ambient temperature for air cooler design is 80 F. Wet bulb temperature for cooling tower design is 75 F. Electric power may be available from the existing facilities. Auxiliary power, 7-8% of the gross, is provided through auxiliary transformers at 4160-volt bus and is reduced down to 480 volts.
ALSTOM Power Inc.
26
June 30, 2001
3.1.2
Flue gas is high in halides (chlorides and fluorides) as well as SO3 so that stainless steel 316L can be used as the material of construction for the flue gas cooling system. Pressure of liquid product CO2 is 2000 psig. Battery Limit Definition
The CO2 recovery and liquefaction sections are located approximately 1200 feet north of the Unit #5 stack (Figure 3.1.1). The new cooling tower is at a different location, which is about 1900 feet southwest of the CO2 recovery and liquefaction equipment. The CO2 recovery and liquefaction equipment, for Concepts A and C, actually receives cooling water from both the existing plants cooling system and the new cooling tower. This is due to the fact that the existing plant cooling water capacity will be partially available as a result of the amine system reboilers consumption of steam for solvent regeneration. This steam was previously exhausted from the existing low-pressure turbine and condensed in the existing power plant surface condensers. The new cooling tower section receives frequent deliveries of sodium hypochlorite. It is also periodically attended by cooling tower chemical service such as Betz or Nalco. They bring with them the required dispersant, pH control, and corrosion inhibitors. However, their visits do not totally relieve the power plant personnel from taking samples themselves at least once per shift. The blowdown from the cooling tower must be treated with sodium bisulfite to dechlorinate it. Sodium bisulfite will be unloaded from drums into the injection package. Concept A, which makes use of an existing cooling water make-up stream must have its blowdown filtered to reduce the suspended solids to within acceptable limits. Backwash from the sand filters will go back to the existing cooling tower blowdown disposal system. Concepts B and C require significant amounts of cooling tower make up water. Thus, river water taken from existing pumps will be sent to a new clarifier. It is expected that this clarifier will eliminate suspended solids to the extent that there will be no need for sand filters on the cooling tower blowdown. Blowdown from the clarifier will be sent to an existing clarifier blow down system. The new CO2 recovery and liquefaction section comprises another section of the power plant. It has its own control room and motor control center (MCC). In addition to the flue gas, which serves as the feed to the unit, it must also receive the required utilities and chemicals. Caustic, if available from existing facilities, can be used to maintain levels in this facilities day tanks. Otherwise it can be offloaded from trucks into the day tanks. Diatomaceous earth will be off loaded on skids. The spent diatomaceous earth leaves the plant in drums. Reclaimer effluent will be collected in a tank truck parked at one end of the unit. Potable water for eyewashes and cooling tower make-up water for hose down will be routed along side the feed gas duct and 180 psig steam. Corrosion inhibitor to provide oxygen resistance to the amine in Concept A will be directly from drums into an injection package.
ALSTOM Power Inc.
27
June 30, 2001
New Cooling Tower
New CO2 Separation Equipment
Unit #5
Figure 3.1. 1:
AEP Conesville, Ohio, Electric Power Generating Station Site
The design of the CO2 recovery and liquefaction sections has been based on the flue gas data leaving the Flue Gas Desulfurization System, shown in Table 3.1.1. Table 3.1. 1: Component O2 N2 H2O CO2 SO2 MW T (F) P (psig) Concept A Mole % 2.94 68.45 15.77 12.83 <10 ppmv 28.61 136 1 Flue Gas Analysis Concept B Mole % 2.91 5.03 19.01 73.04 0.01 37.92 144 0 Concept C Mole % 2.94 68.45 15.77 12.83 106 ppmv 28.61 136 1
3.1.3
CO2 Product Specification
The product specification for sequeststration (Orr, 2001) is shown in Table 3.1.2. This composition is what can be obtained from the liquefaction scheme for Concept B. Its hydrate locus was verified to be sufficiently close to that of pure CO2 which is the criterion used by one of the worlds foremost CO2 sequestration experts, Lynn Orr of Stanford University.
ALSTOM Power Inc.
28
June 30, 2001
Table 3.1. 2:
Specification for Sequestration Product Mole % 1.32 1.23 0 97.29 .16 43.68 82 2015
Component O2 N2 H2O CO2 SO2 MW T (F) P (psia)
Table 3.1.3 represents the specification required for Enhanced Oil Recovery (EOR). It was compiled by comparing the Dakota Gas specification supplied by AEP and contracts signed through Kinder Morgan CO2 company and taking the strictest specification of the two.
Table 3.1. 3: Component O2 N2 H2O CO2 H2S CO C2+ Hydrocarbons Methane T (F)
Specification for EOR Specification 10 weight ppm maximum of the CO2 300 ppmv maximum 20 ppmv maximum 96% minimum 20 weight ppm of the CO2 0.1% maximum 2.3 mole % max 0.7 % maximum 120 F max
A product pressure of 2000 psig was used in the designs that follow. 3.1.4 Chemicals
This section provides data for the chemicals available on site and used by the CO2 Recovery systems. Conditions for liquid chemicals are specified at grade level. Table 3.1. 4: Caustic (NaOH) Temperature F ambient 125
Pressure at B.L. psig Minimum Normal Maximum Mechanical Design 15 50
Available for reclaiming MEA (Concept A) The import and dilution facilities will be used to keep a day tank in the process area at desirable levels.
ALSTOM Power Inc.
29
June 30, 2001
3.1.5
Utilities
The data below applies to both Concepts A and C except where noted. For cooling water, new utility systems will have to be provided and are included in the cost estimate. For steam, obviously the export of 195 psia steam to an external process represents a change from the current operation. It was decided to use extraction steam from the turbine rather than build additional facilities. The reason for this decision comes from plant efficiency, investment cost, and plot considerations. Conditions for all liquid utilities are given at grade level. Steam: Low Pressure Steam (LP) (Concepts A and C) Used mainly for process heating Pressure at B.L. psig Minimum (for process design) Normal 180 Maximum 200 Mechanical Design 250 /FV Water: Cooling Water (Concepts A, B, and C) Source: New Cooling Tower CW Supply: Pressure at B.L. psig Minimum Normal 50 Maximum Mechanical Design 100 CW Return: Minimum Normal Maximum Mechanical Design Pressure at B.L. psig 30 100
Temperature F 700 716 775
Temperature F 85 150 Temperature F 103 175
Surface Condensate (Concept C process cooling, Concept A and C amine make-up) Pressure at B.L. Temperature psig F Minimum Normal 300 109 Maximum Mechanical Design 350 200 Raw Water (Fresh Water) Distributed for general use at hose stations (Concepts A and C). The source of this is a clarifier for cooling tower make-up. The capacity of this clarifier is sufficient for make up for Concept A, but not B or C. Its quality is as follows: Components Unit Specifications Si ppm. 22 Iron (as Fe) ppm. 0.18 Copper (as Cu) ppm 0.05
ALSTOM Power Inc.
30
June 30, 2001
Suspended Solids Chlorine Alkalinity Na
ppm ppm ppm ppm
15 100-180 100 100
For Concepts B and C water from the Muskingum River must be sent to a new clarifier. The specifications for this water are as follows: Unit Specification Suspended Solids ppm 10 to many hundreds Turbidity ppm 5 to 300 Potable Water (Concepts A and C) Pressure at B.L. Psig Minimum (for process design) Normal 100 Maximum Mechanical Design 150 Comes from public network For safety showers (Concepts A and C) Air: Plant Air (Concepts A, B, C) Pressure at B.L. psig Minimum (for process design) Normal 115 Maximum Mechanical Design 175 Dew point (at normal supply pressure - 40C) Instrument Air (Concepts A, B, C) Pressure at B.L. psig Minimum (for process design) Normal 115 Maximum Mechanical Design 175 Dew point (at normal supply pressure - 40C) Dust, oil and grease free Fuel Gas: LP Fuel Gas (Concepts A, B, C) Pressure at OSBL psig Minimum Normal 50 Maximum Mechanical Design 100 Temperature F 100 150 Temperature F 100 150 Temperature F ambient 150
Temperature F Ambient 150
ALSTOM Power Inc.
31
June 30, 2001
Power Supply: All of the required power (100%) for the CO2 Recovery Unit will be provided by AEP either from the local supply or from the Ohio Grid. (Concepts A, B, C) Service Voltage Phase Auxiliary plant power system 4160 3-phase Large Motors 4160 3-phase Small Motors 480 3-phase Instruments, Lighting etc 480 / 230 3/1-phase 3.1.6 Equipment Design
Equipment Numbering: Equipment numbering will be based on Lummus standards. Sparing Philosophy: A sparing philosophy was employed to reduce investment. Therefore, spares were spread out upon multiple trains or provide 50% or 33% sized spares when possible. Small pumps (e.g. metering pumps) and equipment related to protection of major equipment (e.g. lube oil pumps) may be spared. Mechanical Design Conditions: ABBLGI practices will be followed (page 24, T3.1.TP07.402 in Relief and Flare Systems manual).
ALSTOM Power Inc.
32
June 30, 2001
3.2
Concept A: CO2 Separation with Monoethanolamine Absorption
Concept A is defined as a system designed for the removal and recovery of CO2 from the boiler flue gas using an amine scrubbing system. The amine system selected was the Kerr-McGeee / ABB Lummus Global oxygen inhibited MEA technology. 3.2.1 Overall System Description and Material and Energy Balance
A simplified process flow diagram for the modified unit is shown in Figure 3.2.1. The operation and performance of the existing Boiler and ESP systems are identical to the Base Case and are not affected by the addition of the MEA based CO2 removal system. The FGD system is modified with the addition of a secondary absorber to reduce the SO2 content to about 10 ppmv (See Section 3.2.4). The overall material and energy balance for the system shown in Figure 3.2.1 is shown in Table 3.2.1. The flue gases leaving the modified FGD system are ducted to the new MEA system where ~94 percent of the CO2 is removed, compressed, and liquefied for usage or sequestration. The remaining flue gases leaving the new MEA system, consisting of primarily oxygen, nitrogen, water vapor and a relatively small amount of sulfur dioxide and carbon dioxide, is discharged to the atmosphere.
Note : Shading indicates new equipment ALSTOM Power Inc. Scope Tri-Sector 14 22 Air Heater 23 18 1 Coal Mill System 16 13 21
5
ALSTOM Environmental Scope
9 ABB LGI Scope
ID Fan 4 ESP 6 SCAH 20 7
Steam Generator Unit
Modified FGD System
CO 2 Compression & Liquefaction System 10
CO 2 Product for Usage or Sequestration
25
FD Fan 24 19 CO 2 Separation Unit using Monoethanolamine Absorption
S t a c k 26
PA Fan 17 15 SCAH 12 11

1 2 3 4 5 6 7 8 Raw Coal to Pulverizers Air Infiltration Stream Fluegas from Economizer to Air Heater Fluegas Leaving Air Heater to ESP Flyash Leaving ESP Fluegas Leaving ESP to Induced Draft Fan Fluegas to Fluegas De-Sulfurization System Lime feed to FGD System 9 10 11 12 13 14 15 16 17 FGD System Solids to Disposal Fluegas to MEA System Air to Primary Air Fan Primary Air to Steam Coil Air Heater Primary Air to Air Heater Air Heater Leakage Air Stream Tempering Air to Pulverizers Hot Primary Air to Pulverizers Mixed Primary Air to Pulverizers 18 19 20 21 22 23 24 25 26 Pulverized Coal and Air to Furnace Secondary Air to Forced Draft Fan Secondary Air to Steam Coil Air Heater Secondary Air to Air Heater Heated Secondary Air to Furnace Bottom Ash from Furnace Separated CO2 to Compressor Compressed CO2 Product CO2 Depleted Fluegas to Stack
Figure 3.2. 1:
Simplified Gas Side Process Flow Diagram for CO2 Separation by Monoethanolamine Absorption (Concept A)
ALSTOM Power Inc.
33
June 30, 2001
Table 3.2. 1:
Constituent O2 N2 H 2O CO2 SO2 H2 CH4 Carbon Sulfur Ca Mg MgO MgSO3 MgSO4 CaSO3 CaSO4 CaCO3 Ash / Inerts Total Gas Total Solids Total Flow Temperature Pressure hsensible (Units) (Lbm/hr) " " " " " " " " " " " " " " " " " (Lbm/hr) " " (Deg F) (Psia) (Btu/lbm)
6 6 6
Gas Side Material and Material Energy Balance (Concept A)

3 101097 2797385 228849 867210 20202 4 144817 2942220 231294 867210 20202 5 6 144817 2942220 231294 867210 20202 7 144817 2942220 231294 867210 20202 8 5628 258954 48324 9 10 144566 2942220 441924 866102 87 11 203237 673283 11365 12 203237 673283 11365 13 112918 374075 6314
1 26586 4868 37820
2 42147 139626 2357
16102 236655 10110 13087 613 509 1251 76 34395 2051 42313
33851
Fluegas to AH
33851
Fluegas to ESP
33851
1017
Lime Slurry
2520 1017
184130 374455 374455 80 14.7 0.000 184130 80 14.7 0.000
4014743 33851 4048594 706 14.6 161.831
4205743 33851 4239594 311 14.3 57.924
4205743 33851 33851 311 14.7 57.750 4205743 311 14.2 57.924
4205743 4205743 325 15.0 61.384 14717 279300 80 14.7 0.000 41819 90143 136 14.7 14.116
4394900 4394900 136 14.7 14.543
887885 887885 80 14.7 0.000
887885 887885 92 15.6 2.899
493308 493308 92 15.6 2.899
Chemical (10 Btu/hr) 4228.715 Sensible (10 Btu/hr)

(1)
0.000
0.000 2.475 2.475
655.007 240.291 895.298
245.567 242.858 488.425
1.955 0.000 1.955
243.612 242.858 486.470
258.166 242.858 501.024
0.000 0.000 0.000
3.314 0.000 3.314
63.916 464.020 527.936
0.000 11.933 11.933
2.574 11.933 14.507
1.430 6.630 8.060
Latent (10 Btu/hr) 0.000 6 Total Energy (10 Btu/hr) 4228.715
Constituent O2 N2 H 2O CO2 SO2 H2 CH4 Carbon Sulfur Ca Mg MgO MgSO3 MgSO4 CaSO3 CaSO4 CaCO3 Ash / Inerts Total Gas Total Solids Total Flow Temperature Pressure h sensible
(Units) (Lbm/hr) " " " " " " " " " " " " " " " " "
14 43720 144835 2445
15 90319 299208 5051
16 66680 220899 3729
17 156999 520107 8779
18 183585 524975 46599
19 641283 2124443 35860
20 641283 2124443 35860
21 641283 2124443 35860
22 643801 2132785 36001
23
24
25
26
16102 236655 10110
42313
8463
Bottom Ash CO2 to Comp CO2 Product Vent Stream
(Lbm/hr) " " (Deg F) (Psia) (Btu/lbm)

6 6
191000 191000 92 15.6 2.899
394577 394577 92 15.6 2.899
291308 291308 666 15.6 145.249
685885 685885 339 15.6 63.358 1060340
2801587 2801587 80 14.7 0.000
2801587 2801587 86.4 15.2 1.549
2801587 2801587 86.4 15.1 1.549
2812587 2812587 616 14.9 132.582 8463 8463 2000 14.7 480.000
15.0
Chemical (10 Btu/hr) Sensible (10 Btu/hr) 6 Latent (10 Btu/hr) (1) 6 Total Energy (10 Btu/hr) 0.554 2.567 3.121 1.144 5.303 6.447 42.312 3.915 46.227 43.456
4228.715 0.000 37.653 37.653 4.341 37.653 41.994 4.341 37.653 41.994 372.898 37.801 410.699 4.062 0.000 4.062 9.218 52.674 4281.389
Notes: (1) Energy Basis; Chemical based on Higher Heating Value (HHV); Sensible energy above 80F; Latent based on 1050 Btu/Lbm of water vapor
ALSTOM Power Inc.
34
June 30, 2001
Boiler efficiency is calculated to be 88.13 percent (HHV Basis), the same as for the Base Case. The net plant heat rate is increased significantly to 16,626 Btu/kwhr (HHV Basis) for this option as shown in Table 3.2.2 which also includes the Base Case for comparison. The plant thermal efficiency for Concept A (20.53%, HHV basis) is about 59 percent of the Base Case value (35.01%), indicating an energy penalty of ~41%. Auxiliary power is increased to 76,007 kw and the net plant output is reduced to 254,414 kw. Carbon dioxide emissions are 33,084 lbm/hr or about 0.13 lbm/kwhr. Table 3.2. 2: Overall Plant Performance Summary (Concept A)
Original Plant (Base) 4228.7 --4228.7 Concept A MEA 4228.7 17.7 4246.4
(units)
Fuel Paramaters
6 6 6

463478 0 463478 29700 433778
269341 62081 331422 76007 255414

0.3501 0.3666 1.0000 9749 9309
0.2053 0.2150 0.5864 16626 15872

Carbon Dioxide Emissions Specific Carbon Dioxide Emissions Normalized Specific CO2 Emissions (Relative to Base Case) Avoided Carbon Dioxide Emissions (as compared to Base) (lbm/hr) (lbm/kwhr) (fraction) (lbm/kwhr)
866102 1.997 1.000 ---
33084 0.130 0.065 1.867
3.2.2
Boiler Analysis
The boiler performance in Concept A is identical to that of the Base Case described previously in Section 2.3 and will not be repeated here. 3.2.3 Steam Cycle Modifications and Performance
The steam cycle system for Concept A is modified as shown in Figure 3.2.2 while Figure 3.2.3 shows the associated Mollier diagram. About 79 percent of the IP turbine exhaust is extracted from the IP/LP crossover pipe. This steam is expanded to about 65 psia through a new steam turbine generating 62,081 kw. The exhaust from the new turbine, at about 478 F, is de-superheated and then provides the energy requirement for the solvent regeneration done in the reboilers of the MEA CO2 removal system. The condensate from the reboilers is pumped to the Deaerator. The modified existing steam cycle system produces 269,341 kw. The total output from both generators is 331,422 kw. This represents a gross output reduction of 132,056 kw (about 28.5%) as compared to the Base Case. A yet unsolved uncertainty is whether the existing low-pressure turbine can be operated over the required load range with the such a small fraction of the original design steam mass flow rate. The answer to this question was beyond the scope of the current project.
ALSTOM Power Inc.
35
June 30, 2001
ABB LGI Scope 62,081 kw

New Generator
New Letdown Turbine
195.0 psia 716 Deg F
Modified 450 MW Steam Turbine
2853607 lbm/hr Reboiler Steam 65 psia 478 Deg F 514275 lbm/hr 41.7 psia
Existing DFLP Turbine Existing IP Turbine Existing HP Turbine
1935690 lbm/hr
New Flow Control Valve
From RHTR 3131619 lbm/hr From SHTR
De-Superheater
Existing Generator
269,341 kw
64.7 psia 298 Deg F
To RHTR
MEA System Reboiler
COND SCAH
DEA 640768 lbm/hr
To Boiler ECON
Condensate Return Pump
210.0 psia 293 Deg F Boiler Feed Pump To Boiler De-Sh Spray

Energy Outputs
(10 Btu/hr) 1151 0 1953 603

Total Energy Output
Energy Inputs
(10 Btu/hr) 3707 0 3708 0
Power Output (Existing and New Turbines) Steam Coil Air Heater Output MEA System Reboiler Duty Output Condenser Loss
Boiler Heat Input Condensate Pump

Total Energy Input
3708
In - Out
Figure 3.2. 2:
Modified Steam Cycle Diagram and Performance (Concept A)
1600.0 1500.0 Enthalpy (Btu/lbm) 1400.0 1300.0 1200.0 1100.0 1000.0 900.0 800.0 1.000
Reboiler New Letdown Turbine New Flow Control Valve
1.200
1.400
1.600 1.800
2.000
2.200
Entropy (Btu/lbm-F) 10% Moisture Condenser Pressure Saturation Line Steam Cycle
Figure 3.2. 3:
Modified Steam Cycle Mollier Diagram (Concept A)
ALSTOM Power Inc.
36
June 30, 2001
3.2.4
The FGD system for Concept A is modified with the addition of a secondary absorber to reduce the SO2 content to 10 vppm or less as required by the amine system downstream. The principle of operation is as briefly described previously in Section 2.3.5. In this case, however, the flue gas leaving the existing FGD systems absorber is supplied to the new secondary absorber and the flue gas leaving the secondary absorber provides the feed stream for the amine CO2 absorption system, as discussed later in Section 3.2.5. Additional piping and ductwork is required as is shown in Figure 3.2.4 process flow diagram. Table 3.2.3 identifies the assumptions that were made in predicting the FGD performance. Table 3.2.4 shows the gas constituents at the existing Absorber inlet and secondary Absorber outlet. Results show a CO2/SO2 mole ratio of 63 and an SO2 removal efficiency of 99.7%, corresponding to a value of 6.5 vppm at the outlet of the secondary absorber.
8a FLUE GAS OUT TO AMINE SYSTEM 10a 10 MAKE-UP WATER TANK WEIGH FEEDER SLAKER 7 REAGENT FEED TANK QUICKLIME
8b
FRESH WATER
NEW SECONDARY ABSORBER
EXISTING PRIMARY ABSORBERS
FLUE GAS IN FROM ID FAN
DEWATERING SYSTEM
TO DISPOSAL
Figure 3.2. 4:
Modified FGD System Process Flow Diagram (Concept A)
Table 3.2. 3:
FGD Assumptions
Quantity Ca/S) Solids CaO MgO Inerts By-pass Leakage Liquid/Gas (L/G) Ratio SO2 Removal Efficiency APC Absorber
Concept A (MEA) Unit Existing Absorber Secondary Absorber Mol Ratio Wt.% Wt.% Wt.% Wt.% Wt.% gpm/1000 acfm % % 1.04 20 90 5 5 2.5 75 94.8 97.2 1.04 20 90 5 5 0 45 93.0 93.0
ALSTOM Power Inc.
37
June 30, 2001
Table 3.2. 4:
FGD Performance
Concept A (MEA) Existing Absorber Inlet Secondary Absorber Outlet Mol/hr Vol.% Unit Mol/hr Vol.% Unit 4,469 105,018 12,863 19,743 315 3.14 73.74 9.03 13.86 2,212 Vol.% Vol.% Vol.% Vol.% vppm 4,461 105,018 24,555 19,718 1 2.90 68.30 15.97 12.82 6.50 99.7 63 Vol.% Vol.% Vol.% Vol.% vppm
3.2.5
Carbon Dioxide Separation and Compression System
The Kerr-McGee/ ABB Lummus amine technology is used for the Concept A CO2 removal system. This system is the most proven of the three processes analyzed in this study. An important feature of this CO2 recovery technology is its flexibility to operate with boilers or co-generation systems that fire fuels ranging from natural gas to high-sulfur coal and coke. The process tolerates oxygen in the flue gas as well as limited amount of sulfur dioxide. Low corrosion rates and minimal loss of the circulating solvent used to absorb CO2 ensure economical and reliable operation. Kerr-McGee started up their 800 TPD CO2 recovery unit in 1978. The Trona unit has been fed flue gases from boilers fired with natural gas, coal and coke. During its first several years of operation, the installation was improved in terms of reliability and cost effectiveness. As of January 1992, three units have been licensed using this technology. They are: 1.) Applied Energy Systems, Poteau, Oklahoma. This 300 MW coal-fired co-generation plant incorporates a 200 TPD food-grade liquid CO2 unit as the steam host. Startup was completed in January 1991. Lummus Crest was responsible for engineering, procurement, and construction of the entire facility, including the power plant. Lummus Crest made several design improvements to the AES facility. 2.) Soda Ash Botswana, Pty. Ltd., Sue Pan, Botswana. This soda ash facility, incorporating a 300 TPD CO2 unit, started up in March 1991. 3.) AES Corporation is building a second food grade CO2 plant in Warrior run, Pennsylvania using the Kerr-McGee / Lummus technology. This is a 150 short tons/day liquid CO2 plant, using flue gas from coal fired circulating fluidized bed (CFB) boilers, was commissioned in 1999. In late 1990, Kerr-McGee and Lummus Global concluded a joint licensing agreement whereby Lummus gained worldwide exclusive marketing rights to Kerr-McGees CO2 recovery technology and became responsible for marketing and basic engineering. Kerr-McGee maintains a continuing role in technology transfer, process improvement, quality control of new designs, operator training, and licensing. In addition to providing an experience list for the amine part of the process, these plants also contain CO2 compression and liquefaction facilities. These plants compress the CO2 to a slightly higher pressure and utilize ammonia refrigeration. Many of these plants make food grade CO2.
ALSTOM Power Inc.
38
June 30, 2001
3.2.5.1 Introduction The CO2 Recovery Unit for Concept A is comprised of the following sections: Flue Gas Pretreatment Absorption Stripping CO2 Compression and Liquefaction Drying
The flue gas pretreatment section cools and conditions the flue gas, which is then fed to the CO2 Absorber (or CO2 contactor as it is often called). In the Absorber, CO2 is removed from the gas by contacting it, in countercurrent fashion, with monoethanolamine (MEA). The recovered CO2 is then stripped off in the Stripper (or Regenerator) from where the lean solvent is recycled back to the Absorber. Solvent regeneration for Concept A requires about 4.7x106 Btu/Ton CO2. The overhead vapor from the Stripper is cooled to condense most of the water vapor. The condensate is used as reflux in the Stripper and the wet CO2 stream is fed forward to the CO2 Compression and Liquefaction System. Here the CO2 product is compressed and dried so it can be pumped to its final destination. No specific destination has been chosen for the product pipeline. It has been assumed to end at the battery limit for costing purposes. A brief description of the processing scheme for Concept A is given in the following paragraphs. Description of the package units is indicative only and may vary for the chosen supplier of the package unit 3.2.5.2 Process Description This section refers to the following process flow diagrams, which are shown in Section 3.2.5.3: PROCESS FLOW DIAGRAMS - CONCEPT A: Figure 3.2.5:Drawing D 09484-01001R-0: Flue Gas Cooling and CO2 Absorption Figure 3.2.6:Drawing D 09484-01002R-0: Solvent Stripping Figure 3.2.7:Drawing D 09484-01003R-0: CO2 Compression and Liquefaction The designs include several process trains. Only one train is shown. The note section of the PFD tells how many trains are included in the complete system. To avoid confusion, suffixes have been used to indicate parallel equipment. These are mainly for spared pumps and drier vessels in parallel. Even if there are several trains, only one drawing (typical) has been prepared to represent all of the trains. On these drawings, flow splits to the other parallel trains have been shown. Similarly, flows coming from other parallel trains and converging to a single common stream have also been shown. A note about stream numbering convention is also necessary. The stream numbers have not been tagged with A, B, etc. to indicate which train they belong to. Instead, the flow rate given in the material balance for each stream is the actual flow rate for the stream within the train. The combined flow from all of the trains leaving a process step shows the total flow going to the next process step. As an example, stream 8 (Drawing D 09484-01001R-0) is the Rich Amine stream leaving one train of the absorber process step, and comprises 1/5 of the total rich amine. Stream 9A is the total rich amine going to the Solvent Stripping process step. Stream 9A appears on both the absorber and solvent stripper PFDs. After the rich amine flow sheet continuation block, the stream splits 9 ways for the 9 stripping trains. Then stream 9 continues for processing on the solvent stripper PFD (Drawing D 09484-01002R-0), with 1/9 of the flow entering the rich-lean solvent exchanger (EA-2205). The numbering practice for Concept C is the same as for Concept A. Flue Gas Pretreatment: The pressure profile of the CO2 capture equipment is contained in the material balance. Since the flue gas pretreatment equipment flow scheme includes a blower, the pressure profile of the existing power generation equipment does not change from todays operation. To force the flue gas from the secondary FGD through the CO2
ALSTOM Power Inc.
39
June 30, 2001
Absorber, the pressure of the flue gas after sulfur removal is boosted to 1.5 psig by a motor driven fan. As the power consumption of the fan is considerable, the duct size must be chosen not to add excessive pressure drop for the 1200 feet it takes to get to the absorbers. The blower will run at constant speed. Each blower, provided as part of the boiler flue gas conditioning equipment, is equipped with its own suction and a discharge damper operated pneumatically. The suction damper controls the suction pressure to adjust for the flow variation resulting from the power plant performance. The suction pressure control will avoid any surges to blower. The discharge damper is an isolation damper. Direct Contact Cooling (Refer to Drawing No. D 09484-01001R-0): The Direct Contact flue gas Cooler (DCC) is a packed column where the hot flue gas flowing up is brought into an intimate contact with cold water which is fed to the top of the bed and flows down the tower. Physically, DA-2101 and DA-2102 have been combined into a single, albeit compartmentalized tower. DA-2101 is the lower one and is designed to support DA-2102 so that the top head of DA-2101 is the bottom head of DA-102. Effectively, this dividing head acts as a chimney tray with a number of upward extending chimneys which provide passages for the flue gas to flow directly from the DCC into the Absorber. Theoretically, a direct contact cooler is capable of cooling the gas to a very close approach in a short bed. When the hot gas enters the DCC, the gas contains water but is highly superheated. At the bottom end of the bed, the gas is quickly cooled to a temperature known as the Adiabatic Saturation Temperature (AST). This is the temperature the gas reaches when some of its own heat content has been used to vaporize just the exact amount of water to saturate the gas. Up to the point when the AST is reached, the mass flow of the gas stream increases due to evaporation of water. At the AST, water vapor contained in the gas begins to condense. And, as the gas travels up the column and cools further, more and more water is condensed. This internal refluxing increases the V/L traffic at the bottom end of the bed significantly beyond the external flows and must be considered in the hydraulic design. The water stream that leaves the bottom of the DCC contains the water fed to the top as well as any water that has condensed out of the flue gas. The condensed water may be somewhat corrosive due to sulfur and nitrogen oxides that may be present in the flue gas. Therefore, instead of using the condensate in the process, it will be blown down from the system. For the DCC to be effective, the temperature of the leaving water must always be lower than the AST. Most of the water leaving the bottom of the DCC is circulated back to the top of the direct contact cooler by DCC Water Pump GA-2102 A/B. However, before sending it back to the column the water stream is first filtered in DCC Water Filter FD-2101 and then cooled in DCC Water Cooler EA-2101 against the water from the new cooling tower. Temperature of the cooled water is controlled by a cascade loop which maintains a constant flue gas exit temperature (Absorber feed temperature). Because of the relatively low cooling water temperature at the plant, the circulating water is cooled down to 95 oF which, in turn, easily cools the gas down to 115 oF. Filtration is necessary to remove any particulate matter that may enter the DCC in the flue gas. The blowdown is taken out after the filter but before the cooler and mixed into the return water of cooler EA-2101. This way the cooler does not have to handle the extra duty that would otherwise be imposed by the blowdown stream. Absorption: CO2 Absorber DA-2102 (Refer to Drawing No. D 09484-01001R-0): From the DCC the cooled flue gas enters the bottom of the CO2 Absorber and flows up the tower countercurrent to a stream of 20-wt.% monoethanolamine (MEA) solution. The lean MEA solution (LAM) enters the top of the column and heats up gradually as more and more CO2 is absorbed. By the time the stream leaves the bottom of the tower it has gained approximately 28 oF. The tower has been designed to remove 94% of the CO2 in the incoming gas. The CO2 loading in LAM is 0.215 mol CO2 / mol MEA while the loading of the rich amine leaving the bottom is 0.44 mol CO2 / mol MEA. These values are consistent with the values reported by Rochelle (2000). To maintain water balance in the process, it is imperative that the temperature of the LAM feed be very close to that of the feed gas stream. Thus, with feed gas temperature fixed at 115 oF, the temperature of the LAM stream must also be
ALSTOM Power Inc.
40
June 30, 2001
close to 115 oF, preferably within 10 oF. If the feed gas comes in at a higher temperature than the LAM, it brings in excess moisture, which condenses in the Absorber and becomes excess water. Unless this water is purged from the system, the concentration of MEA will decrease and the performance of the system will suffer. If, on the other hand, the gas feed is colder than the LAM, it heats up in the tower and picks up extra moisture that is then carried out of the system by the vent gas. The result is a water deficiency situation because more water is removed than what comes into the system. For the reasons explained above, it is essential that both the temperature of the flue gas and that of the LAM be accurately controlled. In fact, it is best to control one temperature and adjust the temperature of the other to maintain a fixed temperature difference. The design difference is approximately 10 oF. The LAM temperature was chosen to be the master and the gas temperature to be the slave. The rich MEA solvent solution from the bottom of the absorber at 133 oF is heated to 204 oF by heat exchange with lean MEA solvent solution returning from the stripping column. The rich MEA solvent is then fed to the top of the stripping column. The lean MEA solvent solution thus partially cooled to 143 oF is further cooled to 105 oF by exchange with cooling water and fed back to the absorber to complete the circuit. CO2 Absorber DA-2102 is a packed tower which contains two beds of structured packing and a third bed, the so called Wash Zone, at the very top of the column. There is also a liquid distributor at the top of each of bed. The distributors for the main beds are of high-quality design. There are several reasons for selecting structured packing for this service: Very low pressure drop which minimizes fan horsepower High contact efficiency / low packing height Good tolerance for maldistribution in a large tower Smallest possible tower diameter Light weight
At the bottom of the tower, there is the equivalent of a chimney tray, which serves as the bottom sump for the Absorber. Instead of being flat like a typical chimney tray, it is a standard dished head with chimneys. The hold-up volume of the bottom sump is sufficient to accept all the liquid held up in the packing both in the CO2 Absorber and in the Wash Zone. Rich Solvent Pump GA-2103 A/D takes suction from the chimney tray. Absorber Wash Zone (Refer to Drawing. No. D 09484-01001R-0): The purpose of the Wash Zone at the top of the tower is to minimize MEA losses both due to mechanical entrainment and also due to evaporation. This is achieved by circulating wash water in this section to scrub most of the MEA from the lean gas exiting the Absorber. The key to minimizing MEA carryover is a mist separator pad between the wash section and the Absorber. But, the demister can not stop losses of gaseous MEA carried in the flue gas. This is accomplished by scrubbing the gas with countercurrent flow of water. Wash Water Pump GA-2101 takes water from the bottom of the wash zone and circulates it back to the top of the bed. Circulation rate has been chosen to irrigate the packing sufficiently for efficient operation. The key to successful scrubbing is to maintain a low concentration of MEA in the circulating water. The higher the concentration, the higher the vapor pressure of MEA and, consequently, the higher the MEA losses. Therefore, relatively clean water must be fed to the wash zone as make-up while an equal amount of MEA laden water is drawn out. A simple gooseneck seal accomplishes this and maintains a level on the chimney tray at the bottom of the wash section. Overflow goes to the main absorber. Make-up water comes from the overhead system of the Solvent Stripper. The lean flue gas leaving the wash zone is released to atmosphere. The top of the tower has been designed as stack which is made high enough to ensure proper dispersion of the exiting gas. Rich/Lean Solvent Exchanger EA-2205 (Refer to Drawing No. D 09484-01002R-0): The Rich/Lean Solvent Exchanger is a plate type exchanger with rich solution on one side and lean solution on the other. The purpose of the exchanger is to recover as much heat as possible from the hot lean solvent from the bottom
ALSTOM Power Inc.
41
June 30, 2001
of the Solvent Stripper by heating the rich solvent feeding the Solvent Stripper. This reduces the duty of the Solvent Stripper Reboiler. This exchanger is the single most important item in the energy economy of the entire CO2 Recovery Unit. For this study, 10 oF approach was chosen to maximize the heat recovery. An air cooler (EC-2201) was added on the lean amine stream leaving the Solvent Stripper. This was to reduce the plot space requirement (compared to placing the air cooler downstream of the rich/ lean exchanger) and overall cost of the project. A study was performed to determine that heat transfer via the plate frame type lean/ rich exchanger is relatively cheap which justifies tight temperature approaches with this type of exchanger. Stripping: Solvent Stripper DA-2201 (Refer to Drawing No. D 09484-01002R-0): The solvent Stripper is a packed tower which contains two beds of structured packing and a third bed, so called the wash zone at the very top of the column. The purpose of the Solvent Stripper is to separate the CO2 (contained in the rich solvent) from the bottom stream of the CO2 Absorber that is feeding the stripper. As the solvent flows down, the bottom hot vapor from the reboiler continues to strip the CO2 from the solution. The final stripping action occurs in the reboiler. The hot wet vapors from the top of the stripper contain the CO2, along with water vapor, and solvent vapor. The overhead vapors are cooled by Solvent Stripper CW Condenser (EA-2206) where most of the water and solvent vapors condense. The CO2 does not condense. The condensed overhead liquid and gaseous CO2 are separated in a reflux drum (FA-2201). CO2 flows to the CO2 purification section on pressure control and the liquid (called reflux) is returned via Solvent Stripper Reflux Pump (GA-2202A/B) to the top bed in the stripper. The top bed of the stripper is a water wash zone designed to limit the amount of solvent (MEA) vapors entering the stripper overhead system. Solvent Stripper Reboiler EA-2201 (Refer to Drawing No. D 09484-01002R-0): The steam-heated reboiler is a vertical shell and tube thermosyphon type exchanger using inside coated high flux tubing proprietary of UOP. Circulation of the solvent solution through the reboiler is natural and is driven by gravity and density differences. The reboiler tube side handles the solvent solution and the shell side handles the steam. The energy requirement for the removal of CO2 is about 2.6 tons of steam per ton of CO2 for Concept A. Solvent Reclaimer EA-2203 (Refer to Drawing No. D 09484-01002R-0): The Solvent Stripper Reclaimer is a horizontal heat exchanger. Certain acidic gases, present in the flue gas feeding the CO2 absorber, form compounds with the MEA in the solvent solution that cannot be regenerated by application of heat in the solvent stripper reboiler. These materials are referred to as Heat Stable Salts (HSS). A small slipstream of the lean solvent from the discharge of the Solvent Stripper Bottoms Pump (GA-2201A/B/C) is fed to the Solvent Reclaimer. The reclaimer restores the MEA usefulness by removing the high boiling and nonvolatile impurities, such as HSS, suspended solids, acids and iron products from the circulating solvent solution. Caustic is added into the reclaimer to free MEA up from its bond with sulfur oxides by its stronger basic attribute. This allows the MEA to be vaporized back into the circulating mixture, minimizing MEA loss. This process is important in reducing corrosion, and fouling in the solvent system. The reclaimer bottoms are cooled (EA-2204) and are supplied to a tank truck without any interim storage. Solvent Stripper Condenser EA-2206 (Refer to Drawing No. D 09484-01002R-0): EA-2206 is a water-cooled shell and tube exchanger. The purpose of the condenser is to completely condense all components contained in the overhead vapor stream that can condense under the operating conditions, with the use of cooling water as the condensing medium. Components that do not condense include nitrogen, carbon dioxide, oxygen, nitrogen oxides and carbon monoxide. The water vapor and MEA solvent vapor will condense and the condensed water will dissolve some carbon dioxide. This exchanger uses cooling water capacity freed up due to the reduced load on the existing surface condensers of the power plant. The same is true for the lean solvent cooler (EA2202). Solvent Stripper Reflux Drum, FA-2201 (Refer to Drawing No. D 09484-01002R-0): The purpose of the reflux drum is to provide space and time for the separation of liquid and gases and also provide liquid hold-up volume for suction to the reflux pumps and also provides surge for pre-coat filter. The separation is not perfect, as a small amount of carbon dioxide is left in the liquid being returned to the stripper and the CO2, saturated with water, is routed to the CO2 compression and liquefaction system.
ALSTOM Power Inc.
42
June 30, 2001
Solvent Stripper Reflux Pump, GA-2202 (Refer to Drawing No. D 09484-01002R-0): This pump takes suction from the reflux drum and discharges on flow control to the stripper top tray as reflux. Solvent Filtration Package, PA-2251 (Refer to Drawing No. D 09484-01002R-0): Precoat Filter PA-2251 is no ordinary filter; it is a small system. The main component is a pressure vessel that has a number of so called leaves through which MEA flows. The leaves have a thin (1/8 inch) coating of silica powder which acts to filter off any solids. For the purposes of such application the powder is called filter aid. To cover the leaves with the filter aid, the filter must be precoated before putting it into service. This is accomplished by mixing filter aid in water in a predetermined ratio (typically 10-wt %) to prepare a slurry. This takes place in an agitated tank. A pump, which takes its suction from this tank, is then operated to pump the slurry into the filter. Provided the flow rate is high enough, the filter aid is deposited on the leaves while water passes through and can be recycled back to the tank. This is continued until the water in the tank becomes clear indicating that all the filter aid has been transferred. The volume of a single batch in the tank is typically 125% of the filter volume because there must be enough to fill the vessel and have some excess left over so level in the tank is maintained and circulation can continue. In this design, water from the Stripper overhead will be used as make-up water to fill the tank. This way the water balance of the plant is not affected. During normal operation, it is often beneficial to add so-called body which is the same material as the precoat but may be of different particle size. The body is also slurried in water but is continually added to the filter during operation. This keeps the filter coating porous and prevents rapid plugging and loss of capacity. As the description suggests, an agitated tank is needed to prepare the batch. A metering pump is then used to add the body at preset rate to the filter. When the filter is exhausted (as indicated by pressure drop), it is taken off line so the dirty filter aid can be removed and replaced with fresh material. To accomplish this, the filter must be drained. This is accomplished by pressurizing the filter vessel with nitrogen and pushing the MEA solution out of the filter. After this step, the filter is depressurized. Then, a motor is started to rotate the leaves so a set of scrapers will wipe the filter cake off the leaves. The loosened cake then falls off into a conveyor trough in the bottom of the vessel. This motor operated conveyor then pushes the used cake out of the vessel and into a disposal container (oil drum or similar). The rejected cake has the consistency of toothpaste. This design is called dry cake filter and minimizes the amount of waste produced. For this application, some 2% of the circulating MEA will be forced to flow through the filter. In fact, Filter Circulating Pump GA-2203 draws the liquid through the filter as it has been installed downstream of the filter. The advantage of placing the pump on the outlet side of the filter is reduced design pressure of the filter vessel and associated piping. In spite of the restriction on its suction side, ample NPSH is still available for the pump. Flow is controlled on the downstream side of the pump. Corrosion Inhibitor (Refer to Drawing No. D 09484-01002R-0): Corrosion inhibitor chemical is injected into the process constantly to help control the rate of corrosion throughout the CO2 recovery plant system. Since rates of corrosion increase with high MEA concentrations and elevated temperatures, the inhibitor is injected at appropriate points to minimize the corrosion potential. The inhibitor is stored in a tank (Part of the Package, not shown) and is injected into the system via injection pump (Part of the Package, not shown). The pump is a diaphragm-metering pump. The selection of metallurgy in different parts of the plant is based on the performance feedback obtained from our similar commercial units in operation over a long period of time. CO2 Compression and Liquefaction: (Refer to Drawing. No. D 09484-01003R-0): CO2 from the solvent stripper reflux drum, GA-2201, saturated with water, is compressed in a three stage centrifugal compressor using the air and cooling water from the new cooling tower for interstage and after compression cooling.
ALSTOM Power Inc.
43
June 30, 2001
The interstage coolers for first and second stage are designed to supply 95 F CO2 to the compressor to minimize the compression power requirements. Most of the water in the wet CO2 stream is knocked out during compression and is removed from intermediate suction drums. A CO2 drier is located after the third stage to meet the water specifications for the CO2 product. The waterfree CO2 is liquefied after the third stage of compression at about 194 psig pressure and is further pumped with a CO2 pump (GA-2301) to the required battery limit pressure of 2000 psig. Drying: CO2 DRIER, FF-2351 (Refer to Drawing No. D 09484-01003R-0): The purpose of the CO2 drier is to reduce the moisture content of the CO2 product to less than 20 vppm to meet pipeline transport specifications. The drier package, FF-2351, includes four drier vessels, three of which are in service while one is being regenerated or is on standby. The package also includes a natural gas fired regeneration heater and a cooled regeneration cooler. The exchanger will have a knock out cooler downstream for separating the condensed water. The drier size used as a basis for cost estimate is good for 10 hour run length based on 3A molecular sieve. The drier is located on the discharge side of the 3rd Stage of the CO2 Compressor. Considering the cost of the vessel and the performance of the desiccant, this is the location favored by vendors. The temperature of the CO2 stream entering the drier is 90 oF. Once a bed is exhausted, it is taken off line and a slipstream of effluent from the on line beds is directed into this drier after being boosted in pressure by a compressor. Before the slipstream enters the bed that is to be regenerated, it is heated to a high temperature. Under this high temperature, moisture is released from the bed and carried away in the CO2 stream. The regeneration gas is then cooled to the feed gas temperature to condense any excess moisture. After this, the regeneration gas stream is mixed with the feed gas upstream of the third stage knockout drum. All the regeneration operations are controlled by a PLC that switches the position of several valves to direct the flow to the proper drier. It also controls the regeneration compressor, heater, and cooler. Because the regeneration gas has the same composition as the feed gas, it also contains some moisture. Thus, it is primarily the heat (temperature swing) that regenerates the bed. 3.2.5.3 Process Flow Diagrams The processes described above are illustrated in the following process flow diagrams: Figure 3.2.5: Drawing D 09484-01001R-0: Flue Gas Cooling and CO2 Absorption Figure 3.2.6: Drawing D 09484-01002R-0: Solvent Stripping Figure 3.2.7: Drawing D 09484-01003R-0: CO2 Compression and Liquefaction
ALSTOM Power Inc.
44
June 30, 2001
Figure 3.2. 5:
Process Flow Diagram for Concept A: Flue Gas Cooling and CO2 Absorption
ALSTOM Power Inc.
45
June 30, 2001
Figure 3.2. 6:
Process Flow Diagram for Concept A: Solvent Stripping
ALSTOM Power Inc.
46
June 30, 2001
Figure 3.2. 7:
Process Flow Diagram for Concept A: CO2 Compression and Liquefaction
ALSTOM Power Inc.
47
June 30, 2001
3.2.5.4 Overall Material and Energy Balance The material balances (Tables 3.2.5 and 3.2.6) were run on two process simulators: Hysim and Amsim. Amsim was used for the Absorption/Stripping systems while Hysim was used for the conventional systems as follows: Flue Gas feed SO2 scrubber Absorber and Stripper Compression Heat Pumps Hysim ALSTOM Power Program Amsim Hysim Hysim
The two simulators use a different reference enthalpy. They also use slightly different calculation methods for determining water saturation quantities. There is no simple way to normalize the enthalpies to the same reference. Thus, the enthalpies given in the balance are the values copied directly from the simulation. This creates a discontinuity at the interface between Hysim and Amsim simulations. Take for example the wet CO2 flow to the CO2 compressor. The stream comes from the Stripper overhead system, which was simulated with Amsim and enters the CO2 compressor, which was simulated using Hysim. For this particular stream, the enthalpy value given in the balance comes from Hysim. Lastly, convergence algorithms allow the programs to slightly alter input streams. Thus some leniency and care should be exercised when using such interface streams for heat balance checks. This section contains heat and material balances for Concept A. See the comments under Process Flow Diagrams (Section 3.2.5.3) for comments about stream numbering philosophies.
ALSTOM Power Inc.
48
June 30, 2001
Table 3.2. 5:
STREAM NAME STREAM NO. LIQUID FRACTION TEMPERATURE PRESSURE COMPONENTS CO2 (Carbon Dioxide) MEA H2O (Water) C1 (Methane) N2 (Nitrogen) O2 (Oxygen) Total Molar Flow Rate VAPOR MASS FLOW RATE STD. VOL. FLOW RATE ACTUAL VOL. FLOW RATE MOLECULAR WEIGHT STD. DENSITY GAS COMPRESSIBILITY VISCOSITY HEAT CAPACITY THERMAL CONDUCTIVITY LIQUID MASS FLOW RATE STD. VOL. FLOW RATE ACTUAL VOL. FLOW RATE MOLECULAR WEIGHT STD. DENSITY VISCOSITY HEAT CAPACITY THERMAL CONDUCTIVITY Lb/Hr GPM GPM MW Lb/Ft
3
Material and Energy Balance for Concept A Amine System

Gas Feed to Absorber A Absorber A Inlet Separator Liquid Primary LeanAmine Feed to Absorber A Rich Amine from Absorber A Absorber A Total Treated Gas Total Rich Amine Rich Amine Feed to Flash Tank Rich Amine to Lean/Rich Heat Exchanger Rich Amine from Lean/Rich Heat Exchanger
Total Sour Gas Feed
Sour Gas Feedto PrecontactorGas Precontactor Outlet
1 0.000 F PSIA LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr 150 16.5 19,684.00 0.00 24,551.0 0.00 105,079.00 4,518.00 153,832.0
3 0.000 115 16.5 3,936.80 0.00 4,910.2 0.00 21,015.80 903.60 30,766.4 3,572,805 280.22 275.6 57.1642 0.153 0 0 0 25.5916 0.000 115 16.5 3,936.80 0.00 4,910.2 0.00 21,015.80 903.60 30,766.4 3,572,805 280.22 275.6 57.1642 0.153 0 0 0 25.5916 0.000 115 16.5 3,936.23 0.00 2,544.8 0.00 21,016.14 903.61 28,400.8 3,397,068 258.66 254.5 58.9234 0.1576 0 0 0 27.7192 85,263 85.26 86.02 18.02 62.34 0.6383 0.9948 0.3979 1.000 115 16.5 0.14 0.00 2,365.5 0.00 0.02 0.00 2,365.6
5 1.000 105 14.9 3,585.44 16,765.89 227,379.0 0.00 0.00 0.00 247,730.4
8 1.000 133 16.5 7,380.58 16,763.07 228,257.6 0.00 1.75 0.14 252,403.2
12 0.000 106 14.9 141.10 2.82 1,666.3 0.00 21,014.40 903.47 23,728.1 2,438,328 216.1 231.72 55.1246 0.1354 0 0 0 1.1892
9a 1.000 133 16.5 36,902.89 83,815.36 1,141,288.0 0.00 8.76 0.70 1,262,016.0
9 1.000 133 16.5 4,100.32 9,312.82 126,809.8 0.00 0.97 0.08 140,224.0
9 1.000 133 16.5 4,100.32 9,312.82 126,809.8 0.00 0.97 0.08 140,224.0
12 0.995 204 16.5 4,100.32 9,312.82 126,809.8 0.00 0.97 0.08 140,224.0
Lb/Hr 446,600,625 MMSCFD MMACFD MW Lb/Ft

3
1401.1 1378 285.821 0.765 0 0 0 127.9580
cP Btu/Lb-F Btu/Hr-ft-F
10,557,848 10252.78 10308.54 21.31 64.19 0.8608 0.9357 0.3557
10,923,302 10352.54 10467.22 21.64 65.77 0.6868 0.9221 0.3557
273,082,551 51762.70 52336.10 21.64 65.77 0.6868 0.9221 0.3557
3,371,390 5751.41 5815.12 21.64 65.77 0.6868 0.9221 0.3557
3,371,390 5751.41 5815.12 21.64 65.77 0.6868 0.9221 0.3557
3,371,390 5751.41 5940.30 21.64 65.77 0.3544 0.9325 0.3557
STREAM NAME STREAM NO. LIQUID FRACTION TEMPERATURE PRESSURE COMPONENTS CO2 (Carbon Dioxide) MEA H2O (Water) C1 (Methane) N2 (Nitrogen) O2 (Oxygen) Total Molar Flow Rate VAPOR MASS FLOW RATE STD. VOL. FLOW RATE ACTUAL VOL. FLOW RATE MOLECULAR WEIGHT STD. DENSITY GAS COMPRESSIBILITY VISCOSITY HEAT CAPACITY THERMAL CONDUCTIVITY LIQUID MASS FLOW RATE STD. VOL. FLOW RATE ACTUAL VOL. FLOW RATE MOLECULAR WEIGHT STD. DENSITY VISCOSITY HEAT CAPACITY THERMAL CONDUCTIVITY Lb/Hr GPM GPM MW Lb/Ft
3
Rich Amine Feed RegeneratorOverh RegeneratorConde to Regenerator ead Vapor nser Outlet
Acid Gas
RegeneratorReflux Liquid
Liquid to Regenerator Reboiler
Lean Amine from Lean Amine from RegeneratorReboil RegeneratorReboil Lean/Rich Heat er Vapor Exchanger er
Lean Amine to Cooler
Amine and Water Make-up
Total Acid Gas
35 1.000 F PSIA LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr Lb/Hr MMSCFD MMACFD MW Lb/Ft
3
36 0.000 209 26.0 2,081.06 9.92 2,128.7 0.00 0.97 0.08 4,220.7 221,688 38.44 27.73 34.37 0.12 0.00 0.00 0.00 54.78
37 1.000 105 23.0 2,081.06 9.92 2,128.7 0.00 0.97 0.08 4,220.7
38 0.000 105 23.0 2,079.81 0.01 105.7 0.00 0.97 0.08 2,186.6 166,131 19.91 13.72 47.50 0.18 0.00 0.00 0.00 105.69
39 1.000 105 23.0 1.27 9.90 2,023.0 0.00 0.00 0.00 2,034.1
41 1.000 248 29.8 2,701.12 9,381.40 137,717.9 0.00 0.00 0.00 149,800.3
42 0.000 250 30.0 680.61 68.60 11,013.8 0.00 0.00 0.00 11,763.0 429,305 107.13 70.62 21.97 0.09 0.00 0.00 0.00 6.43
43 1.000 250 30.0 2,020.51 9,312.81 126,704.0 0.00 0.00 0.00 138,037.3
21 1.000 173 30.0 2,020.51 9,312.81 126,704.0 0.00 0.00 0.00 138,037.3
21 1.000 173 30.0 2,020.51 9,314.38 126,321.8 0.00 0.00 0.00 137,656.7
47 1.000 68 30.0 0.00 1.58 (382.3) 0.00 0.00 0.00 (380.7)
24 0.000 105 23.0 18,718.28 0.11 951.3 0.00 8.76 0.70 19,679.2 121,109,333 179.20 123.50 427.46 1.62 0.00 0.00 0.00 951.17
209 28.0 4,100.32 9,312.82 126,809.8 0.00 0.97 0.08 140,224.0
cP Btu/Lb-F Btu/Hr-ft-F 3,371,390 5751.41 5951.79 21.64 65.77 0.3401 0.9324 0.3557
145,088 247.18 248.73 30.94 65.86 0.6888 0.4962 0.3945
41,234 73.13 73.61 18.24 63.27 0.6655 0.9902 0.3944
3,525,978 6116.13 6434.23 21.18 64.69 0.2592 0.9481 0.3583
3,267,542 5709.78 6011.14 21.30 64.21 0.2564 0.9491 0.3557
3,267,542 5709.78 5839.38 21.30 64.21 0.4548 0.9513 0.3557
3,259,998 5696.53 5825.79 21.31 64.21 0.4549 0.9513 0.3557
-7,547 -13.59 -13.6 17.84 62.31 1.2839 0.9454 0.3664
ALSTOM Power Inc.
49
June 30, 2001
Table 3.2. 6:
STREAM NAME STREAM NO. VAPOR FRACTION TEMPERATURE PRESSURE MOLAR FLOW RATE MASS FLOW RATE ENERGY COMPOSITON CO2 H2O Nitrogen Ammonia Propane Oxygen VAPOR MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW MOLECULAR WEIGHT DENSITY VISCOSITY HYDROCARBON LIQUID MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW DENSITY MOLECULAR WEIGHT VISCOSITY SURFACE TENSION
Material and Energy Balance for Concept A CO2 Compression and Liquifaction System
Total Acid gas from strippers To train A liquefaction First stage discharge To second stage First stage water KO 2nd stage discharge To 3rd stage 2nd stage water KO From 3rd stage To drier 3rd stage water KO
300 Molar F PSIG LbMol/Hr Lb/Hr Btu/Hr Mol % 95.12% 4.83% 0.04% 0.00% 0.00% 0.00% LbMol/Hr Lb/Hr MMSCFD MW Lb/Ft
3
300 1.000 105 4 2,811.30 120,170 1.26E+07 95.12% 4.83% 0.04% 0.00% 0.00% 0.00% 2,811.3 120,170 25.60 14,843.95 42.75 0.13 0.0149 -
301 1.000 230 25 2,811.30 120,170 1.58E+07 95.12% 4.83% 0.04% 0.00% 0.00% 0.00% 2,811.3 120,170 25.60 8,749.53 42.75 0.23 0.0187 -
302 1.000 95 19 2,743.70 118,951 1.19E+07 97.46% 2.49% 0.05% 0.00% 0.00% 0.00% 2,743.7 118,951 24.99 8,063.83 43.35 0.25 0.0149 -
310 0.000 95 19 67.60 1,219 -9.79E+05 0.09% 99.91% 0.00% 0.00% 0.00% 0.00% -
303 1.000 236 62 2,743.70 118,951 1.56E+07 97.46% 2.49% 0.05% 0.00% 0.00% 0.00% 2,743.7 118,951 24.99 4,417.63 43.35 0.45 0.0193 -
304 1.000 95 56 2,708.50 118,315 1.17E+07 98.72% 1.23% 0.05% 0.00% 0.00% 0.00% 2,708.5 118,315 24.67 3,728.32 43.68 0.53 0.0152 -
309 0.000 95 56 35.19 636 -5.09E+05 0.18% 99.82% 0.00% 0.00% 0.00% 0.00% -
306 1.000 282 191 2,708.50 118,315 1.64E+07 98.72% 1.23% 0.05% 0.00% 0.00% 0.00% 2,708.5 118,315 24.67 1,698.44 43.68 1.16 0.0212 -
305 1.000 90 185 2,686.56 117,917 1.10E+07 99.52% 0.42% 0.05% 0.00% 0.00% 0.00% 2,686.6 117,917 24.47 1,224.03 43.89 1.61 0.0154 -
314 0.000 90 185 21.94 398 -3.18E+05 0.54% 99.46% 0.00% 0.00% 0.00% 0.00% -
1.000 105 4 19,679.08 841,192 8.79E+07
19,679.1 841,192 179.23 42.75 0.13 0.0149 -
A C F M 103,907.68
cP LbMol/Hr Lb/Hr BPD GPM Lb/Ft

3
MW cP Dyne/Cm
STREAM NAME STREAM NO. VAPOR FRACTION TEMPERATURE PRESSURE MOLAR FLOW RATE MASS FLOW RATE ENERGY COMPOSITON CO2 H2O Nitrogen Ammonia Propane Oxygen Molar F PSIG LbMol/Hr Lb/Hr Btu/Hr Mol %
From drier/ To condenser
Water from drier
From condenser
From product pump
From Train A liquefaction
To pipeline
Refrig compressor discharge
From refrig condenser
From subcooler
Refrig to CO2 condenser
Refrig from CO2 condenser
307 1.000 90 180 2,675.15 117,711 1.10E+07 99.95% 0.00% 0.05% 0.00% 0.00% 0.00%
311 0.726 380 180 11.41 206 2.51E+04 0.00% 100.00% 0.00% 0.00% 0.00% 0.00%
312 0.000 -26 2,003 2,675.15 117,711 -8.07E+06 99.95% 0.00% 0.05% 0.00% 0.00% 0.00%
308 0.000 -12 2,000 2,675.15 117,711 -7.29E+06 99.95% 0.00% 0.05% 0.00% 0.00% 0.00%
309 0.000 82 2,000 2,675.15 117,711 -1.36E+06 99.95% 0.00% 0.05% 0.00% 0.00% 0.00%
313 0.000 82 2,000 18,726.05 823,979 -9.50E+06 99.95% 0.00% 0.05% 0.00% 0.00% 0.00%
400 1.000 65 55 2,928.57 129,141 1.81E+07 0.00% 0.00% 0.00% 0.00% 100.00% 0.00%
401 0.000 95 162 2,928.57 129,141 7.63E+05 0.00% 0.00% 0.00% 0.00% 100.00% 0.00%
402 0.000 24 159 2,928.57 129,141 -5.17E+06 0.00% 0.00% 0.00% 0.00% 100.00% 0.00%
403 0.173 -31 5 2,928.57 129,141 -5.17E+06 0.00% 0.00% 0.00% 0.00% 100.00% 0.00%
404 0.996 -31 5 2,928.57 129,141 1.39E+07 0.00% 0.00% 0.00% 0.00% 100.00% 0.00%
VAPOR MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW MOLECULAR WEIGHT DENSITY VISCOSITY HYDROCARBON LIQUID MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW DENSITY MOLECULAR WEIGHT VISCOSITY SURFACE TENSION LbMol/Hr Lb/Hr BPD GPM Lb/Ft
3
LbMol/Hr Lb/Hr MMSCFD ACFM MW Lb/Ft

3
2,675.2 117,711 24.36 1,253.44 44.00 1.57 0.0155 -
8.3 149 0.08 5.96 18.02 0.42 0.0154 -
2,675.15 117,711.33 9,766 217.05 67.61 44.00 0.1752 16.07
2,675.15 117,711.33 9,766 213.53 68.73 44.00 0.1607 14.07
2,675.15 117,711.33 9,766 289.79 50.64 44.00 0.0620 0.86
18,726.05 823,979.29 68,360 2,028.56 50.64 44.00 0.0620 0.86
2,928.6 129,141 26.67 3,573.03 44.10 0.60 0.0082 -
2,928.57 129,141.22 17,452 541.52 29.73 44.10 0.0906 5.74
2,928.57 129,141.22 17,452 480.49 33.51 44.10 0.1332 10.51
506.5 22,334 4.61 1,860.34 44.10 0.20 0.0065 2,422.10 106,807.22 14,434 372.27 35.77 44.10 0.1823 14.49
2,915.8 128,577 26.56 10,709.92 44.10 0.20 0.0065 12.79 563.95 76 1.97 35.77 44.10 0.1823 14.49
cP
MW cP Dyne/Cm
ALSTOM Power Inc.
50
June 30, 2001
3.2.5.5 Equipment List with Data Equipment data for Concept A, provided in Appendix II, has been presented in the so-called short spec format which provides adequate data for a factored cost estimate. 3.2.5.6 Consumption of Utilities The following utilities from outside boundary limits (OSBL) are required in the CO2 Recovery Unit. Steam High Pressure (HP) Steam Low Pressure (LP) Steam Water Demineralized Water Raw Water (Fresh Water) (Cooling tower make-up) Potable Water (hoses, etc.) Air Plant Air (maintenance, etc.) Instrument Air Electric Power Natural Gas
Note: The CO2 Recovery Plant includes cooling water pumps that supply all the cooling water required by this unit. Concept A utility consumption is presented in Table 3.2.7. Table 3.2. 7: Utility Natural Gas Steam (180 psig) Cooling water Concept A Utility Consumption Amount Consumed .42 1,950,000 22,000 Units MMSCFD Lb/hr Gpm Power (ea) including Number 0.95 Total Operating motor eff all trains per train (kW) (kW) 1 1 3 2 1 1 1 1 1 19 32 146 117 3 12 184 74 0 95 162 729 1,053 28 107 1,288 667 0
Number of Trains 5 5 5 9 9 9 7 9 3
Tag no. GA-2101 A/B GA-2102 A/B GA-2103 A/B/C/D GA-2201A/B/C GA-2202 A/B GA-2203 A/B GA-2301 A/B GA-2204 A/B GA-2501
Description Wash Water Pump Direct Contact Cooler Water Pump Rich Solvent Pump Lean Solvent Pump Solvent Stripper Reflux Pump Filter Circ. Pump CO2 Pipeline Pump LP condensate booster pump Caustic metering pump
ALSTOM Power Inc.
51
June 30, 2001
7 7 1 7 7 7 9 7 1
GB-2301 GB-2401 GB-2500 EC-2301 EC-2302 EC-2303 EC-2201 PA-2351 PA-2551
CO2 Compressor (Motor driven) Propane Refrig Compressor LP steam turbine/ generator CO2 compressor 1st stage air cooler CO2 compressor 2nd stage air cooler CO2 compressor 3rd stage air cooler Solvent stripper bottoms cooler CO2 Drier Package Cooling Tower Total
1 1 NA 1 1 1 1 1 1
3,557 2,395 NA 9 10 15 256 151 962
24,901 16,765 NA 66 69 103 2,305 1054 962 50,355
3.2.5.7 Consumption of Chemicals and Desiccants The consumption of chemicals and desiccants for Concept A are identified in Table 3.2.8 shown below. Table 3.2. 8: Concept A Chemical s and Desiccants Consumption Consumption per day (lbs.) 3600 14000 1140 916 257 3590 13.8
Chemical Caustic (100%) MEA Corrosion inhibitor Diatomaceous earth Molecular sieve Sodium hypochlorite Sodium bisulfite
This total does not include chemicals provided by the cooling tower service people nor disposal of waste. These are handled as a component of operating costs referred to as contracted services and waste handling, respectively. 3.2.5.8 Design Considerations The following parameters were optimized for Concept A with the objective of reducing the overall unit cost and energy requirements. Solvent Concentration Lean Amine Loading Rich Amine Loading Absorber Temperature Rich /Lean Exchanger approach CO2 Compressor inter-stage temperatures CO2 Refrigeration Pressure and Temperature
A minimum of 90% CO2 recovery was targeted. The above parameters were adjusted to increase the recovery until a significant increase in equipment size and/ or energy consumption was observed. AES Corporation owns and operates a 200 STPD food grade CO2 production plant in Oklahoma. This plant was designed and built by ABB Lummus
ALSTOM Power Inc.
52
June 30, 2001
Global as a part of the larger power station complex using coal fired boilers. This plant was started up in 1990 and has been operating satisfactorily with lower than designed MEA losses. The key process parameters from the present design for Concept A are compared with those from the AES plant (Barchas and Davis, 1992) in Table 3.2.9. Table 3.2. 9: PROCESS PARAMETER PLANT CAPACITY TPD CO2 in Feed, % mol O2 in Feed, % mol SO2 in Feed, % mol SOLVENT SOLVENT CONC. %WT LEAN LOADING RICH LOADING STRIPPER FEED TEMP , F STRIPPER BOTTOM TEMP F FEED TEMP TO ABSORBER, F CO2 RECOVERY % ABSORBER PRESSURE DROP psi STRIPPER PRESSURE DROP psi R/L EXCHANGER APPROACH,F CO2 COMPRESSOR I/STG TEMP F LIQUID CO2 TEMP F STEM CONSUMPTION (T steam/ T CO2) LIQUID CO2 PRESSURE psi (A) 3.2.5.9 OSBL Systems Reclaimer Bottoms (Concept A): The reclaimer bottoms are generated during the process of recovering MEA from heat stable salts (HSS), which are produced from the reaction of MEA with SO2 and NO2. The HSS accumulate in the reclaimer during the lean amine feed portion of the reclaiming cycle. The volume of reclaimer bottoms generated will depend on the quantity of SO2 and NO2 that is not removed in the Flue Gas Scrubber. A typical composition of the waste is presented in Table 3.2.10. Table 3.2. 10: Reclaimer Bottoms Composition MEA NH3 NaCl Na2SO4 Na2CO3 Insolubles Total Nitrogen Total Organic Carbon PH Specific Gravity 9.5 wt.% 0.02 wt.% 0.6 wt.% 6.6 wt.% 1.7 wt.% 1.3 wt.% 5.6 wt.% 15.6 wt.% 10.7 1.14 Concept A Key Process Parameters Comparison AEP DESIGN (Concept A) 9888 13.9 3.2 100 ppm MEA 20 0.21 0.44 210 250 105 95 1 0.6 10 105 82 2.6 2015 AES DESIGN 200 14.7 3.4 10 PPMV (Max) MEA 15 (Actual 17-18%Wt) 0.10 0.41 194 245 108 90 (ACTUAL 96-97%) 1.4 4.35 50 115 -13 3.45 247
ALSTOM Power Inc.
53
June 30, 2001
Filter Residues: A pressure leaf filter filters a slipstream of lean amine. Diatomaceous earth is used as a filter-aid for pre-coating the leaves and as a body feed. Filter cycles depend on the rate of flow through the filter, the amount of filter aid applied, and the quantity of contaminants in the solvent. A typical composition of the filter residue is provided in Table 3.2.11 below. These will be disposed of by a contracted service hauling away the drums of spent cake. Table 3.2. 11: MEA Total Organic Carbon SiO2 Insolubles PH Specific Gravity Filter Residue Composition 2.6 wt.% 1.5 wt.% 0.03 wt.% 0.03 wt.% 10.0 1.0
Excess Solvent Stripper Reflux Water: The CO2 Recovery Facility has been designed to operate in a manner to avoid accumulation of water in the Absorber / Stripper system. Conversely, no continuous make-up stream of water is required, either. By controlling the temperature of the scrubbed flue gas to the absorber, water balance of the MEA system can be kept in check. Excess water can accumulate in the Stripper Reflux Drum and can be reused once the system is corrected to operate in a balanced manner. Should water need to be discarded, contaminants will include CO2 and MEA. Secondary FGD Absorber Effluent: The existing plant uses lime in its flue gas desulfurizer. In the cost estimate of this plant, it has been assumed that the existing plant disposal facilities can include the relatively small additional load of the secondary regenerator. Cooling Tower Blowdown: The composition limits on cooling tower blowdown are shown in Table 3.2.12. Table 3.2. 12: Component Suspended Solids PH Oil and Grease Free Chlorine Cooling Tower Blowdown Composition Limitations Specification 30 ppm monthly, 100 ppm daily 6.5 to 9 15 ppm maximum monthly, 20 ppm maximum daily 0.035 ppm
There is a thermal limit specification for the entire river. However, the blowdown volume is too small to affect it significantly. Relief Requirements: The relief valve discharges from the CO2 Recovery Unit are discharged to atmosphere. No tie-ins to any flare header are necessary. 3.2.5.10 Plant Layout The new equipment required for Concept A covers about 7 acres of plot area. Plant layout drawings prepared for the Concept A CO2 Recovery System are as follows:
ALSTOM Power Inc.
54
June 30, 2001
These drawings are shown in Appendix I. Plot Plan Overall Site before CO2 Unit Addition U01-D-0208 Plot Plan Concept A: Flue Gas Cooling & CO2 Absorption U01-D-0214 Plot Plan Concept A: Solvent Stripping U01-D-0204 Plot Plan Concept A: CO2 Compression & Liquefaction U01-D-0211 Plot Plan Concept A: Overall Layout Conceptual Plan U01-D-0200R Plot Plan Concept A: Modified Overall Site Plan Plant layout has been designed in accordance with a spacing chart called Oil and Chemical Plant Layout and Spacing Section IM.2.5.2 issued by Industrial Risk Insurers (IRI). When reviewing the layout, the first thing to observe is that no highly flammable materials are handled within the CO2 Recovery Unit. The open cup flash point of MEA is 200 oF and, therefore, will not easily ignite. In addition to MEA, the corrosion inhibitor is the only other hydrocarbon liquid within the battery limits. The flash point of this material is higher than that of MEA and is handled in small quantities. As the chemicals used in the process present no fire hazard, there is an opportunity to reduce the minimum spacing between equipment from that normally considered acceptable in hydrocarbon handling plants. Regardless, for the drawings that follow, standard spacing requirements, as imposed by IRI have been followed. The plot area available for the installation of the desired equipment is small. Some equipment items are placed on structures to allow other pieces of equipment to be placed underneath them. This way pumps and other equipment associated with the Absorber can be located under the structure. Locating the pumps under the structure has been considered acceptable because the fluids being pumped are not flammable. Noise is an issue with the flue gas fan as much as it is with compressors. Discussions with vendors suggest that it will be possible to provide insulation on the fan casing to limit noise to acceptable levels. Therefore, it has been assumed that no building needs to be provided for noise reasons. Having economized on the required plot space as noted above, it was judged not to be practical to divide up the absorbers and strippers that are required into the relatively small plot areas initially offered for this purpose (refer to Section 2.1 and Figure 2.1.1). Eventually it was agreed that the units would be placed in an area about 1200 feet north of the Unit #5 stack (refer to Figure 3.1.1). By locating the units on a single site, the flue gas duct length and MEA piping between the absorber and stripper could be minimized, although the latter impact is not nearly as important as the flue gas routing. The corrosion inhibitor must be protected against freezing during winter. The caustic solution will not freeze but will become very viscous when it gets cold. Therefore, a heated shed has been provided for housing the Corrosion Inhibitor and the Caustic injection packages. The plot plan shows a substation in the Stripper area but none for the Absorber area. The assumption is that because the electrical consumption of the Absorber equipment is small (0.23 MW) compared to the Stripper equipment, the equipment can be run directly from the auxiliary power 480 volt power system. For the Rich/Lean Solvent Exchanger which is a plate and frame type exchanger, area estimates received from vendors based on similar conditions suggest that five units/ train would be sufficient for the specified service.
ALSTOM Power Inc.
55
June 30, 2001
3.3
Concept B: CO2 Separation with Oxygen Firing and Flue Gas Recirculation
The basic idea of the overall system for Concept B is to replace air with oxygen for combustion in the furnace in order to produces a high carbon dioxide content flue gas stream leaving the boiler island. A stream of re-circulated flue gas to the furnace is required to maintain thermal balance in the existing boiler between the lower furnace region where evaporation takes place and the convective heat transfer surfaces where steam is superheated and reheated to the required temperature level. This arrangement produces a high carbon dioxide content flue gas that after leaving the boiler system, is processed to provide high-pressure carbon dioxide liquid product for sequestration, enhanced oil recovery (EOR) or other uses. 3.3.1 Overall System Description and Material and Energy Balance
A simplified system diagram for the modified unit is shown in Figure 3.3.1. The system was designed to provide maximum flexibility of operation and to facilitate combustion of coal in either air or oxygen and recirculated flue gas mixture environment.
CO2 Product
Note : Shading indicates new equipment ALSTOM Power Inc. Scope
Air Air Separation Unit
Nitrogen ABB LGI Scope S t a c k 18
for Usage or Sequestration
17 CO 2 Compression & Liquefaction System 16 Booster Fan
33
3 O2 Htr 4 2 Steam Generator Unit 31 Air Heater 32 27 1 Coal Mill System 25 22 Tri-Sector 23 30 SCAH 5 6 7 ESP 8 ALSTOM Environmental Scope Parallel FW Heater 29 FD Fan 28 11 12 Direct Contact Gas Cooler 14
9 ID Fan
10
FGD System
13
15
19
20 PA Fan SCAH 21
26
24

1 2 3 4 5 6 7 8 9 10 11 Raw Coal to Pulverizers Air Infiltration Stream Heated Oxygen Stream to Furnace Fluegas from Economizer to Air Heater Fluegas Leaving Air Heater to Oxygen Heater Fluegas Leaving Oxygen Heater to ESP Flyash Leaving ESP Fluegas Leaving ESP to ID Fan Fluegas to Parallel FW Heater Fluegas Leaving Parallel FW Heater to FGD Lime Feed to FGD System 12 13 14 15 16 17 18 19 20 21 22 FGD System Solids to Disposal Fluegas Leaving FGD to Gas Cooler Condensed Water Stream Cooled Fluegas Stream to Booster Fan Fluegas to CO2 Compression System Compressed CO2 Product Fluegas Vent to Stack Cooled Recirculated Fluegas Stream Primary Fluegas to PA Fan Pressurized Primary Fluegas Primary Fluegas to Air Heater 23 24 25 26 27 28 29 30 31 32 33 Air Heater Leakage Gas Stream Tempering Fluegas to Pulverizers Hot Primary Fluegas to Pulverizers Mixed Primary Fluegas to Pulverizers Pulverized Coal and Fluegas to Furnace Secondary Fluegas to FD Fan Secondary Fluegas to Steam Coil Air Heater Secondary Fluegas to Air Heater Heated Secondary Fluegas to Furnace Bottom Ash from Furnace Oxygen Stream from Air Separation Unit
Figure 3.3. 1:
Simplified Gas Side Process Flow Diagram for CO2 Separation with Oxygen Firing
Raw coal (Stream 1) from the coal bunkers is supplied to the existing coal mills where it is pulverized and transported with recycled flue gas (Stream 27) to the furnace. The air separation unit (ASU) supplies the oxidant for the existing boiler. There is no air supply to the boiler except for air infiltration (Stream 2). The oxygen produced, about 8,924 tons per day, (Stream 33) flows through a heat exchanger where it is preheated by cooling the flue gas leaving the existing air heater (Stream 5). The pulverized coal is combusted in the furnace with a mixture of preheated oxygen (Stream 3) and preheated recycled flue gas (Stream 31). The products of combustion leave the furnace and are cooled in a series of heat exchangers. The gas leaving the furnace first enters the existing convection pass of the unit where steam generated in the existing furnace walls is superheated and reheated in the existing convection pass heat exchangers. The flue gas leaves the convection pass (Stream 4) and is further cooled in the existing air heater of the unit. The air heater, however, is now used to heat recycled flue gas since air is no longer supplied to the unit in this mode of operation. The flue gas stream leaving the air heater (Stream 5) flows through the oxygen heater, electrostatic precipitator, induced draft fan, parallel feedwater
ALSTOM Power Inc.
56
June 30, 2001
heater, flue gas de-sulfurization unit, gas cooler and booster fan, in series, before it is split into two streams. One stream (Stream 16) represents the exhaust gas stream leaving the boiler island. This stream provides the feed stream for the Carbon Dioxide Separation and Compression System (described in detail in Section 3.3.7). The remaining flue gas (Stream 19), which is roughly twice as large as Stream 16, is recycled back to the unit with the forced draft and primary air fans. Figure 3.3.2 shows the cooling curve for the flue gas leaving the existing boiler.
800 Temperature (Deg F) 700 600 500 400 300 200 100 0 0 100 200 300
6
400
500
Heat Transfered (10 Btu/hr) Flue Gas Air Heater Oxygen Heater Feedwater Heater
Figure 3.3. 2:
Boiler Flue Gas Cooling Curve
The primary reason for the large recycle stream is to maintain the thermal balance between heat transferred in the radiant furnace and the convective heat transfer surfaces, and to generate required boiler performance. In addition, gas temperatures throughout the unit must be low enough to assure the ash, which is contained within the fuel, is maintained in a state where cleanability of the unit is not compromised. Additionally, the integrity of the existing metallurgy in the furnace walls and convective pass heat exchangers must be ensured. The recycled flue gas is supplied to the unit through a combination of new ducts and the existing air ducts. These recycle streams (Streams 29, 30, 31, 21, 22, 24, 25, and 26) provide the primary and secondary "air" streams for the air heater as well as the tempering air stream for outlet temperature control of the pulverizers. The modified system was designed to generate approximately 3.1 x 10 6 lbm/hr of steam, which represents the Maximum Continuous Rating (MCR) for the unit. Table 3.3.1, below, shows constituent mass flows, temperatures, pressures, enthalpies, and energy values (chemical, sensible, latent, and total) for all the points shown in the system diagram of Figure 3.3.1 This table therefore provides the gas side energy and material balance for the system. Two of the key assumptions used in the development of this material and energy balance were an oxygen stream purity of 99 percent by weight, and an air infiltration rate equivalent to one percent of the total oxygen required for the process. For the definition of state points 17 and 18, (not defined in Table 3.3.1) refer to Section 3.3.7.4, which provides the complete material and energy balance for the CO2 Compression and Liquifaction System.
ALSTOM Power Inc.
57
June 30, 2001
Table 3.3. 1:
Gas Side Material and Energy Balance for Concept B
Boiler efficiency for the modified system is calculated to be 90.47 percent (HHV basis). This is increased significantly as compared to the Base Case (88.13 percent) due to Oxygen firing and the addition of the Oxygen Heater and Parallel Feedwater Heaters. The net plant heat rate (HHV basis) is increased significantly to 15,188 Btu/kwhr for this option as shown in Table 3.3.2, which also includes the Base Case for comparison. The plant thermal efficiency (HHV basis) for Concept B (22.47%) is about 64 percent of the Base Case value of 35.01%. This case represents the highest efficiency of the three CO2 removal cases studied in this project. Auxiliary power is increased to 189,709 kW as a result of the added Air Separation Unit and the CO2 Compression and Liquefaction System. Net plant output is reduced to 273,347 kW. Carbon dioxide emissions are 53,016 lbm/hr or about 0.194 lbm/kWh which is about 9.7% of the Base Case value of 1.997 lbm/kWh.
ALSTOM Power Inc.
58
June 30, 2001
Table 3.3. 2:
Overall Plant Performance Summary for Concept B

Original Plant (Base) 4228.7 --4228.7 Concept B O2 Fired 4140.0 11.4 4151.5
(units)
Fuel Paramaters
6 6 6

463478 0 463478 29700 433778
463056 0 463056 189709 273347

0.3501 0.3666 1.0000 9749 9309
0.2247 0.2354 0.6419 15188 14500

866102 1.997 1.000 --0.906 ---
53016 0.194 0.097 1.803 0.088 0.818
3.3.2
Air Separation Unit
Concept B uses nearly pure oxygen instead of air for combustion of coal and therefore requires an Air Separation Unit (ASU) to provide the supply of oxygen to the furnace. The ASU selected is a cryogenic type design because of the large capacity required. 3.3.2.1 Background As stated above in Section 3.3.1, AEPs Conesville Unit #5 requires 8,924 standard tons of 99% purity O2 per day (T/D) when fired at 100% of the maximum continuous rating (MCR). Hence it was necessary to design an Air Separation Unit (ASU) that would be capable of producing at least this amount of oxygen. Initial discussions between ABB and air separation plant vendors were about using two 3685 T/D of oxygen trains and one 1600 T/D train for a total of 8950 T/D. This is due to the fact that a 3685 T/D is the largest plant, which could be comfortably offered at this time. After factoring in capital cost considerations, it was decided to design an overall plant comprised of two3930 T/D trains and two-550 T/D trains, for a total capacity of 8,960 T/D. A variety of practical and technical issues are discussed below. A process flow diagram of a typical cryogenic air separation unit (BOC Webpage) showing all its major components is shown in Figure 3.3.3.
ALSTOM Power Inc.
59
June 30, 2001
Figure 3.3. 3:
Process Flow Diagram of a BOC Improved Air Separation Unit
3.3.2.2 Oxygen Purity Considerations Oxygen purities above 98% have significant impacts on the cryogenic portion of the process. O2 purities below 95% do not benefit in a cost reduction due to reduction in main air compressor discharge pressure requirements. The purities below 95% often require a frame size increase due to higher inlet volumetric flow rates. It also increases the size of the air adsorber system. The reduced discharge pressure requirements do save on energy of the main air compressor, but other process duties increase due to the higher flow rate of oxygen product. The overall energy consumption could increase if the product is gaseous oxygen with a significant battery limit pressure requirement. 3.3.2.3 Bottlenecks for building plants larger than 3685 ST/D The current largest single ASU in operation is 3500 ST/D at Rozenburg, The Netherlands. However, sizes up to 4950 ST/D have been designed on paper. Usually, larger size plants are cheaper than smaller plants due to economy of scale. However, it is believed that a break point somewhere near 3685 T/D is where increased plant size will actually cost more for the following reasons: The compressor size, driver size, motor sizes, and line voltage drop at start-up are potential hurdles. The largest compressor sizes that ASU manufacturers have experience with are in the 40000-hp range. There may not be any significant aspects of the larger compressors that would create problems over the voltage drop to the compressor if it is motor driven, however, there is no actual experience among the major manufacturers with compressors and drivers exceeding this size. Columns larger than 20 feet in diameter create transportation problems for the part of the trip, which is over land. Plants located adjacent to navigable bodies of water would not have any limitation like this. The impact could translate to the need to field fabricate the column. Large size pipe and valves become more job specific which create the loss of pricing economies of scale which can be attained when pipe and valve sizes fit many units being built at the same time.
3.3.2.4 Major Vendors Experience A plant size of 3685 ST/D O2 production is larger than any vendor had operating as of May 2000. The following list represents the largest operating plant size that the three vendors had running at that time: Vendor Air Liquide Air Products BOC Largest size operating plant (ST/D O2) 3190 3500 2640
ALSTOM Power Inc.
60
June 30, 2001
3.3.2.5 Power Consumption The Air Separation unit (ASU) includes a cryogenic plant for air separation. Economic considerations for this application favored the selection of oxygen stream purity of 99 percent by weight. As stated above, four trains were required to produce the required oxygen mass flow rate of about 8924 tons per day. This system consumes 95,822 kW of electric power or about 21 percent of the generator output. This energy consumption is equivalent to about 260 kWh/ton of O2 produced. By contrast, Kobayashi and Prasad (Kobayashi and Prasad, 1999) state that the thermodynamic minimum energy requirement is about 40 kWh/ton of O2 produced. If this limit could be approached, it would represent a breakthrough technology that would enable Concept B to become nearly cost competitive with business as usual (coal-fired in air without CO2 capture) electricity generation. 3.3.2.6 Plot Plan Requirements The required plot plan areas, supplied by Air Products, are 185 feet by 250 feet and 125 feet by 150 feet for the 3930 T/D and 550 T/D plants, respectively. When the areas for storage and oxygen compressions are included, the required total plot plan amounts to 555 feet by 620 feet. Refer to Appendix I for the plant layout drawings for Concept B. 3.3.2.7 Investment and Operation and Maintenance Costs The investment, and operation and maintenance costs of the Air Separation Unit are presented in Section 5.3.2. 3.3.3 Boiler Heat Transfer Analysis
The primary objective of the systems analysis task for Concept B was to develop a system, which would produce high carbon dioxide content flue gas from an existing coal, fired boiler without requiring major pressure part modifications to the boiler. In order to access whether pressure part modifications would be necessary an accurate heat transfer analysis of the existing boiler was required. The first step was to set up a steady state performance model of the Conesville #5 steam generator unit. This involved calculating or obtaining all the geometric information for the unit as required by the proprietary Reheat Boiler Program (RHBP). The RHBP provides an integrated performance model of the boiler island including, in addition to the steam generator unit, pulverizers, air heater, and steam temperature control logic. The RHBP is used to size components and/or predict performance of existing components. In this study, since the boiler island component sizes are known, the RHBP was used exclusively for calculating unit performance. The next step in the heat transfer analysis of the system was to calibrate the RHBP model of the unit. This involved obtaining a set of test data (with air firing) for the existing unit and adjusting the performance model to match the test data. The required test data includes steam temperatures entering and leaving each major heat exchanger section in the unit, steam pressures, coal analysis, flue gas oxygen content, etc. The adjustments to the model are in the form of surface effectiveness factors and fouling factors. After the model was calibrated, additional adjustments were required in order to obtain an accurate heat transfer analysis with the high carbon dioxide content flue gas of the Concept B system. The combustion process occurs in a non-conventional environment, which produces gases of different physical and thermal properties. These gas property differences cause significant differences in the heat transfer processes, which occur within the steam generator unit. Analyses were made to determine the impact of the heat transfer differences on boiler behavior. The RHBP accounts for three modes of heat transfer in the upper furnace and convective pass of the unit (direct radiation, non-luminous radiation and convection). The direct radiation is emitted from the furnace fire-ball and is absorbed in various areas of the unit depending on the geometry of the tube banks and the proximity to the fire-ball. Since the distribution of direct radiation is only a function of geometry, no formulation modifications were necessary for this component of the heat transfer analysis. Investigation of the non-luminous radiation formulations within the RHBP indicated that current equations (based on the Hottel curves, 1957) would be accurate and formulation modifications would not be required. The convection formulations, however, were not set up with the capability of
ALSTOM Power Inc.
61
June 30, 2001
accurately analyzing convective heat transfer for flue gases which were this much different than the typical range of boiler flue gases. The appropriate corrections were made to properly model the convection process in the RHBP with oxygen firing. 3.3.3.1 Furnace Analysis Initially, it was expected that heat fluxes to the furnace walls might be increased or decreased somewhat for Concept B (oxygen firing) due to the higher CO2 and H2O content of the flue gas relative to the air fired Base Case for the following reasons: Higher gas emissivity and absorptivity of CO2 and H2O relative to N2. For an equivalent local gas temperature, the higher emissivity of CO2 and H2O, relative to the optically transparent N2, should serve to increase the absorption coefficient and hence, the radiation to the walls in the recycled flue gas case (Concept-B) relative to the Base Case. Higher specific heat of CO2 and H2O relative to N2. For an equivalent local heat release and heat transfer, the higher specific heat of carbon dioxide will serve to decrease the overall flame temperatures of the recycled flue gas mixture in the Concept-B case, relative to the baseline case. This would tend to compensate for the higher gas emissivity.
In preparation for the Concept B furnace performance analysis, a review of pertinent literature and CFD furnace analysis results developed for this project (Bozzuto, et al., 2000) were completed. Explanations for the observed trends must rely on physical property differences between nitrogen, which dominates in the Base Case, and carbon dioxide, which largely supplants nitrogen in Concept-B. Literature review: The first step in the furnace analysis was to review applicable results obtained from the literature regarding combustion of coal in an environment where CO2 displaces the N2 in the combustion air. Several investigators (Thambimuthu, 1998; Kiga, et al., 1997; and Weller, at al., 1985) have found from pilot-scale testing that when coal is burned in O2/CO2 environment whereby CO2 displaces the N2 in the combustion air (i.e., in ~30% O2/70% CO2 mixture, by volume), the heat absorption in the lower furnace is not significantly impacted. To illustrate this point, the results of re-analyses of Thambimuthus (Thambimuthu, 1998) data concerning the combustion of a subbituminous coal sample from Western Canada are presented in Figure 3.3.4. As can be seen in this figure, the radiative heat fluxes into the lower furnace were, for the three cases studied (air, 28% O2/72% CO2, and 35%O2/65% CO2), roughly similar at gas temperatures greater than 1275 oC.
130,000
110,000
90,000
70,000
50,000
30,000
Air 28%O2/72%CO2 35%O2/65%CO2

1100 1200 1300 1400 1500
10,000 1000
Gas Temperature, C
Figure 3.3. 4:
Variation of Radiative Heat Flux with Gas Temperature During Combustion in Air and O2/CO2 Mixtures (from Thambimuthu, 1998)
ALSTOM Power Inc.
62
June 30, 2001
Results from a similar experiment, Chui, et al., (2001), were also investigated, in somewhat more detail, in order to assess the apparent overall change in gas emissive power that would occur in a furnace when switching from air-firing to a high CO2-O2 environment. The test facility, the same one used previously by Thambimuthu et.al.(1998), is a pilot-scale, 0.3 MW facility and consists of a cylindrical, down-fired vertical combustor (0.61 m I.D. and 6.7 m in length). The most relevant tests from the literature source are designated as Case-1 (baseline condition with air firing and a burner swirl setting of 11) and Case-2 (dry recycle with burner swirl setting of 10). The dry recycle case is representative of an oxygen fired case similar to Concept B with 28% O2 / 72% CO2 by volume. The principal conclusion of the work by Chui, et al., based on both experimental and simulated results, was that the dry recycle case demonstrated a distinct decrease in the incident radiant heat flux to the wall (by about 18%) relative to the baseline case (Case-1). The intent of the present re-analysis of this data was to utilize the incident heat flux measurements and measured centerline gas temperatures for the cases reported by Chui, et al., and then back-calculate the apparent gas emissivity for the furnace as a function of the longitudinal position. The desire was to verify whether the apparent emissivity differences between the baseline and dry recycle cases mirrored the known physical differences in radiative absorption properties between N2 and CO2 (corresponding to the baseline and dry recycle cases, respectively). The comparison of Case-1 and Case-2, which have similar swirl settings (and thus similar flow patterns), should isolate the effects of gas emissive properties without introducing the strong effects of flow pattern changes as observed by Chui and reconfirmed by our analysis. Based on the incident heat flux measurements and the measured centerline gas temperatures, apparent gas emissivities for the furnace were calculated. These values are tabulated in Table 3.3.3 and plotted in Figure 3.3.5. Table 3.3. 3: Axial Distance (m) 0.95 1.55 2.15 2.77 3.40 Apparent Combustor Gas Emissivities Case-1 (Air Firing) Gas Emissivity 0.685 0.657 0.611 0.562 0.532 Case-2 (Oxy-Firing) Gas Emissivity 0.782 0.737 0.796 0.829 0.766
Apparent Combustor Gas Emissisivities

0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 0
Case 1 Case 2
2 Axial Distance (m)
Figure 3.3. 5:
Apparent Combustor Gas Emissivities as a Function of Axial Distance
ALSTOM Power Inc.
63
June 30, 2001
As shown in Figure 3.3.5, the apparent emissivity of the dry recycle case (Case-2) is higher than that of the baseline case (Case-1). Based on the substitution of the radiating gas CO2 for non-radiating nitrogen in the dry recycle case, the observed shift is what would be expected. It should be understood, however, that these results are only to be expected for cases with identical or similar flow patterns. The other test cases reported in Chui, et al. (2001) with swirl settings and corresponding aerodynamic and flame patterns that were different from those of Case-1 and Case-2, showed that such flow patterns have a dominant influence on the apparent gas radiative properties. Another interesting aspect of the combustor results are the measured centerline gas temperatures. Table 3.3.4 tabulates the corresponding temperatures measured in the Chui, et al. combustor, along with the Case-1 to Case-2 shift. The temperature shifts are plotted in Figure 3.3.6. The mean gas temperature shift, averaged over all measurement locations, is -214 F. Table 3.3. 4: Axial Distance (m) 0.95 1.55 2.15 2.77 3.40 Case-1 Centerline Gas Temperature, F 2664 2552 2421 2284 2143 Gas Temperature Profiles Case-2 Centerline Gas Temperature, F 2419 2367 2215 2041 1953 Temperature Shift, F (Case 2 - Case 1) -245 -185 -205 -243 -191
Centerline Gas Temperature Shift (Case 2 - Case 1)

0 -50 -100 -150 -200 -250 -300 0 1 2 Axial Distance (m) 3 4
Figure 3.3. 6:
Centerline Gas Temperature Shift as a Function of Axial Distance
Calculations of adiabatic flame temperature (Tad) were performed for coal firing in AEP's Conesville Unit #5 at maximum continuous rating (MCR). A number of scenarios were considered, namely: (1) Base Case (i.e., coal firing in air); (2) Constant Mass Case (i.e., the mass of nitrogen in air was replaced by the mass of CO2 in the flue gas recycle (FGR); and (3) Various CO2/O2 Mole Ratio Cases. Results (Figure 3.3.7) indicated that the Tad for air firing was approximately 180 oF higher than for the Constant Mass Case. This difference is due to differences in specific heat (Cp) between N2 and CO2 (i.e., CO2 Cp > N2 Cp at elevated temperatures, Figure 3.3.8). One implication is that the ultimate combustion efficiency difference between air firing and O2/FGR firing could be governed by opposing phenomena, i.e., potentially lower reaction rate, but longer residence time in O2/FGR than in air. Thermo-gravimetric analysis (TGA) and Drop Tube Furnace System-1 (DTFS-1) results -- obtained from combustion firing of both Conesville Unit #5 and Pittsburgh Seam #8 coals other (See Volume II Report of this work, Bozzuto, et al., 2001) -indicate that these two phenomena indeed virtually cancel each other.
ALSTOM Power Inc.
64
June 30, 2001
3550 3500 3450 3400 3350 3300 3250 3200 0.0 0.5 1.0 1.5 CO2/O2 Mole Ratio 2.0 2.5 3.0
Air (Baseline) 44.5%CO2/45%O2 49.5%CO2/40.0%O2 54.5%CO2/35%O2 59.52/30.0%O2 61.9%CO2/27.5%O2 (Option B) 64.5%CO2/2.05%O2
Figure 3.3. 7:
Calculated Adiabatic Flame Temperature as a Function of CO2/O2 Mole Ratio for Conevsville Unit #5
0.360 0.340 0.320 0.300 0.280 0.260 0.240 0.220 0.200 500 1000 1500 2000 2500 3000 3500 CO2 N2
Gas Temperature, oF
Figure 3.3. 8:
Specific Heats (Cp) of Nitrogen and Carbon Dioxide as a Function of Temperature
CFD Furnace Model Results and Conclusions: Review of the CFD analysis results (Bozzuto, et al., 2001) which were developed for this project indicated the following with respect to furnace heat transfer: The baseline case (or Base Case) exhibits a slightly higher peak gas temperature (maximum difference of about 200 F), and a correspondingly higher average (cross-sectional) gas temperature (difference of 90 F at the HFOT), than that of the Concept-B case. This result compares favorably with the approximate -214 F shift found by Chui et.al.
ALSTOM Power Inc.
65
June 30, 2001
Note, however, that this close correspondence may be somewhat fortuitous, particularly since the two furnaces are so different. Nevertheless, the correspondence may indicate that the baseline air case may be expected to exhibit consistently higher peak and averaged post-flame temperatures than an oxy-fired case (with similar flow and flame patterns). The net wall absorption in the furnace region for the baseline case is larger (by less than 1%) than that of the ConceptB case. Conversely, the net wall absorption for the baseline calculation with the proprietary in house Reheat Boiler Program (RHBP), as described below, was found to be about 6% lower than the Concept-B case calculated by the RHBP. The higher specific heat of the carbon dioxide, and the associated lower gas temperatures in the Concept-B case, will tend to offset somewhat or compensate for the expected increase in the wall absorption (i.e., anticipated due to the enhanced emissivity of the CO2.) Furthermore, the spatial distribution of the carbon dioxide across the crosssection may be important; it is hypothesized that high concentrations of CO2 in the cooler gas mixtures between the wall and the flame may actually act to inhibit the net radiative flux to the walls. Performance Model (RHBP) Results: The present study for Concept B involves coal combustion in a medium with ~31%O2/69% CO2 volume ratio. Heat transfer in the lower and upper furnace regions as calculated by the RHBP is compared in Figure 3.3.9. This figure compares heat fluxes (Btu/hr-ft2) in selected lower and upper furnace regions for air firing and oxygen firing. Lower furnace region results show firing zone heat flux to be about 11 percent higher with oxygen firing. Upper furnace region results show the reheat radiant wall is about 6 percent higher and the superheat division panels are about 13 percent higher with oxygen firing. Similarly, the upper furnace waterwall area is about 10 percent higher. The overall lower furnace heat absorption for Concept B was about 6% higher than for the air fired Base Case. The horizontal furnace outlet temperature (HFOT) for Concept B was calculated to be 123 oF lower than for the Base Case.
1.14
Q/A Ratio (Oxygen / Air)
1.12 1.10 1.08 1.06 1.04 1.02 1.00 LF Firing Zone UF Panel UF Rad Wall UF Waterwall
Figure 3.3. 9:
Furnace Region Heat Flux Comparison
The trend calculated by the CFD code, with respect to the furnace temperature at the HFOP, appears to be qualitatively aligned with the trend calculated by the in-house RHBP code. However, the difference in wall absorption for the Concept-B case relative to the baseline case, calculated by FLUENT (change of 1%), does not fully agree with the results of the RHBP (change of +6%). Computed and/or experimental trends that indicate that oxy-firing may induce either an increase in wall absorption or a decrease in wall absorption, relative to the baseline case, are supported in the literature. It is suggested that the absorptive properties of a local CO2-containing gas mixture in the vicinity of the wall may either act to enhance or inhibit the incident radiative flux to the wall, depending upon its relative spatial location and mixture temperature. For example, a low-temperature, CO2-rich mixture near the wall would absorb the radiative flux from the interior fireball region; a portion of the energy would be re-emitted at the lower gas temperature, and the remainder of the energy would be used to heat up the gas. The result would be a net reduction in the incident radiative flux to the wall. Conversely, a high-temperature, CO2-rich mixture near the wall would emit at its local gas temperature, thus enhancing the incident radiative flux to the wall. Therefore, it is suggested that the relative spatial relationships of the cool and hot gas mixtures, the relative composition of the absorbing media, and the proximity of that media to the wall (as induced by the furnace and firing
ALSTOM Power Inc.
66
June 30, 2001
system aerodynamics), may significantly impact the gas-phase irradiation to the wall. Indeed, the aerodynamic and flame patterns that prevail in a given air-fired or oxy-fired furnace may conceivably have as strong an impact on the net wall absorption as the physical property differences themselves (gas-phase emissivity, specific heat, etc.) The results of computational tools (such as CFD and the RHBP) should be viewed with some skepticism, particularly when they are asked to produce calculations outside of the experience base for which they have been validated. Certainly, the gas-phase and particle-phase radiation property sub-models could be enhanced in both codes, and the impact of spatial gradients (caused by the interleaving of hot and cool regions of varying CO2 composition) on radiative wall flux needs to be investigated more fully. CFD computations have been utilized to gain a more in-depth qualitative understanding of aerodynamic and flame patterns in combustion systems, but have not yet been integrated into routine boiler design procedures. At the present time, the ALSTOM design standards are based upon the experience and expertise built into the RHBP and other design protocols, and those standards must be adhered to in any new design project in order to mitigate risk. Therefore, the results of the RHBP, as reported in this work, must be regarded as the current standard, both from an engineering experience viewpoint and from a rules-based design viewpoint. However, additional validation work needs to be done in order to confirm the trends for oxy-firing scenarios. Although differences in physical properties of the transport gases (e.g., air-firing versus oxy-firing) may initially induce undesirable deviations from the performance goals of an existing field unit, the designer and engineer views such alterations as challenges rather than insurmountable obstacles. Much can be done in the way of operating condition optimization (e.g., spray, nozzle tilt, and amount of gas recirculation), without major modifications to the unit, to realign steam temperatures and wall absorption with their desired, target values. Design parameters are often in conflict, and the intelligent designer must work to balance various parameters and operating conditions to achieve the desired outcome. The CFD work performed here was based on certain constraints to maintain equivalency for comparison purposes, which would not necessarily be the case in the field. For example, a potential decrease in furnace wall absorption of several percentage points could be nullified through manipulation of the various operating parameters available. 3.3.3.2 Convection Pass Analysis Figures 3.3.10, 3.3.11 and 3.3.12 show the comparison of convective, non-luminous, and total heat transfer rates between air firing and oxygen firing for all the major sections contained in the existing convection pass of the unit at full load operating conditions as calculated by the RHBP. Convective heat transfer in utility steam generator units is dependent upon many of the transport properties of the flue gas (viscosity, thermal conductivity, density, specific heat and others). Additionally, convection depends strongly on gas velocity. With the Concept B system there are significant changes in the flue gas analysis as compared with air firing. These gas analysis changes cause both transport property and gas velocity changes throughout the unit. The resulting convective heat transfer rates, as shown in Figure 3.3.10, ranged from about 80 to 105 percent as compared to air firing. Significant differences in non-luminous radiant heat transfer are also expected. Of the gases produced by the complete combustion of a fuel, only carbon dioxide, water vapor and sulfur dioxide emit radiation over a sufficiently wide band of wave lengths to warrant consideration. With this system the primary change in the flue gas as compared to air firing is the large increase in the CO2 content and decrease in N2 content. The resulting enhancement in nonluminous heat transfer rates range from about 26 to 28 percent greater than air firing as shown in Figure 3.3.11. Ultimately the convection pass total heat transfer rates, shown in Figure 3.3.12, were increased in the range of 1 to 8 percent over the values with air firing.
ALSTOM Power Inc.
67
June 30, 2001
1.10 1.05
(Rc oxygen / Rc air)
1.00 0.95 0.90 0.85 0.80 0.75 0.70 SH Platen RH Pendant Front RH Pendant Finish SH Finish SH Low Temp Horiz
Figure 3.3. 10: Convective Heat Transfer Rate Comparison
1.30
(Rn oxygen / Rn air)
1.25 1.20 1.15 1.10 1.05 1.00 SH Platen RH Pendant RH Pendant SH Finish SH Low Front Finish Temp Horiz
Figure 3.3. 11: Non-luminous Heat Transfer Rate Comparison
1.09 1.08
(Rt oxygen / Rt air)
1.07 1.06 1.05 1.04 1.03 1.02 1.01 1.00 SH Platen RH Pendant Front RH Pendant Finish SH Finish SH Low Temp Horiz Economizer
Figure 3.3. 12: Total Heat Transfer Rate Comparison
ALSTOM Power Inc.
68
June 30, 2001
Steam temperature control was achieved through the use of burner tilt and reheat spray. The performance analysis results indicated the reheater circuit required about 1.45 percent spray to maintain the reheat outlet temperature at the design value. The superheater circuit required about 0.34 percent spray to maintain the superheat outlet temperature at the design value. The burner tilt was set at 10 degrees, the minimum value the customer uses. The overall steam conditions produced are shown in Table 3.3.5 below. Furthermore, with this recycle gas system, flue gas recirculation is also available as an additional steam temperature control variable. In this study however, we did not utilize this as an additional steam temperature control variable. We decided, as a first approximation, to set the flue gas recirculation rate at a value such that the flue gas flow to coal flow ratio was the same as with air firing. As it turned out, this was an acceptable setting for the gas recirculation rate. Table 3.3. 5: Boiler/Turbine Steam Flows and Conditions for Concept B
SHO 3131619 2535 1000 1456.3 FWI 3131619 3165 493 479.2 ECO 3131619 3070 622 640.8 RHO 2808511 590.8 1000 1517.6
6
Flow (lbm/hr) Pressure (psia) Temperature (F) Enthalpy (Btu/lbm)
RHI 2808511 656.5 631 1305.6 3059.9 595.4 3655.3
Qmain steam (10 Btu/hr) 6 Qreheat (10 Btu/hr) Q Total s/w (10 Btu/hr)
6
Notes: SHO = Superheater Outlet; FWI = Feedwater Inlet; ECO = Economizer Outlet; RHO = Reheater Outlet; RHI = Reheater Inlet With the increased heat transfer rates with oxygen firing and similar steam temperature profiles, there was concern regarding metal temperatures throughout the unit. A detailed analysis using the Metal Temperature Program (MTP) was however, beyond the scope of this study. The MTP, using thermal inputs from the RHBP, calculates steam and metal temperatures at any selected point along the length of the tube. All tubes of each heat exchanger bank are modeled. A very brief review of metal temperatures at only a few selected points was done in this study. In general, for the points investigated, the metal temperatures were found to be the same or slightly lower than with air firing. The primary reason for this result was that although the heat transfer rates were slightly higher and the steam temperature profile was similar, the gas temperatures were lower. This combination yields similar heat flux conditions and ultimately similar metal temperatures. 3.3.4 Boiler System Modifications
Listed below are the basic modifications required for the Conesville No.5 unit to support firing with oxygen as required in Concept B. 3.3.4.1 Boiler The Boiler Island should be inspected for potential air leaks into the system and should be sealed to minimize any infiltration. Special attention should be given to all penetrations including seal boxes for convective surfaces, sootblowers, wallblowers, expansion joints, ductwork, fuel piping, fans and windbox. 3.3.4.2 Ducts and Dampers and Fans Refer to the Duct and Damper Diagram (Figure 3.3.13) shown below for the required duct arrangement and associated cross-sectional areas for this system. New flue gas ductwork is required for the Oxygen Heater. Part of the existing ductwork from the Air Heater flue gas exit to the Electrostatic Precipitator inlet must be removed and replaced with new ductwork that accommodates the new Oxygen Heater. Additionally, oxygen supply ductwork from the ASU to
ALSTOM Power Inc.
69
June 30, 2001
the Oxygen Heater is required and hot oxygen supply ductwork from the Oxygen Heater to the existing secondary air duct must be provided. Similarly, New flue gas ductwork is required for the Parallel Feedwater Heater. Part of the existing ductwork from the Induced Draft fan outlet to the Scrubber inlet must be removed and replaced with new ductwork that accommodates the new Parallel Feedwater Heater. New ductwork and dampers are also required for the recycle flue gas streams that feed the existing Forced Draft and Primary Air fans.
Fluegas To Stack During Air Firing Existing ID Fan ESP 5 6 16 9 Air Seperation Unit Oxygen Heater 33 3 Parallel FW Heater 10 13 30 Gas Cooler 15 New Booster Fan CO 2 Compression System 31 8 Remove Existing Duct FGD System Air Inlet During Air Firing
Fluegas From Air Heater
Remove Existing Duct
Air Inlet During Air Firing 19
28
20
Existing FD Fan
29
21 22
Existing PA Fan Tempering Air Stream Bypassing Air Heater 24
Air Heater
Oxygen To Furnace
25
Duct Area Calculations

Stream Number Gas Flow (lbm/hr) Temp. (deg F) Pressure (psia) Rgas Density (lbm/ft3) Vol Flow (Ft3/min) Velocity (Ft/min) Area (ft2) 26 Secondary Air To Furnace Primary Air Stream To Coal Mills
5 6 8 9 10 13 15 16 19 20 28 33 3
4067554 4067591 4067591 4067591 4067591 4159135 3895233 936822 2958410 784502 2173908 751151 751151
371 339 339 355 265 144 100 102 102 102 102 100 296
14.3 14.0 13.9 15.0 14.9 14.6 14.6 14.7 14.7 14.7 14.7 20.1 19.6
39.43 39.43 39.43 39.43 39.43 40.75 37.70 37.70 37.70 37.70 37.70 48.36 48.36
0.063 0.064 0.064 0.067 0.075 0.086 0.099 0.100 0.100 0.100 0.100 0.107 0.077
1080107 1056967 1065190 1012143 904391 809763 653985 156181 493210 130787 362419 117050 162090
4000 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000
270 264 266 253 226 202 163 39 123 33 91 29 41
Key
New Duct Existing Duct Damper
Figure 3.3. 13: Duct and Damper Diagram for Concept B A new booster fan will be required as a minimum. The booster fan is required to overcome the added draft loss of the various new heat exchanger components shown in Figure 3.3.1 previously. Specifications for the booster fan are shown in Table 3.3.6 below. The existing Induced Draft, Forced Draft and Primary Air fans should eventually be checked with the suppliers to see if they can handle the new conditions (Note: The molecular weight is now 37.7 for the FD and PA fans and 39.4 for the ID fan). For this study we have assumed that both fans are acceptable. Table 3.3. 6: Booster Fan Specification
Booster Fan Specification Gas Analysis Oxygen Nitrogen Water Vapor Carbon Dioxide Sulfur Dioxide Total Mass Flow Rate Gas Inlet Temperature Inlet Pressure Outlet Pressure Pressure Rise
(wt percent) " " " " " (lbm/hr) (Deg F) (psia) (psia) (in wg)
2.63 3.97 2.87 90.51 0.03 100.00 3895233 100.0 14.56 14.70 4.00
3.3.4.3 Oxygen Heater The flue gas exiting the Air Heater is at 371 oF. A large quantity of sensible heat is still available in this gas stream. The Oxygen heater is used to recover additional sensible heat in the flue gas as a result of reduced air heater performance with oxygen firing. This heat is partially recovered in the Oxygen Heater where cold O2 from the Air
ALSTOM Power Inc.
70
June 30, 2001
Separation Unit is preheated before being mixed with the gas recirculation stream prior to furnace injection. Part of the existing ductwork connecting the existing Air Heater flue gas exit stream to the Precipitator inlet is removed. New ductwork, which accommodates the addition of the new Oxygen Heater, is installed. Performance requirements and gas analyses for the Oxygen Heater are shown in Table 3.3.7. Table 3.3.8 shows the Oxygen Heater specifications. It should be noted that the flue gas stream, which provides the heat source for this heat exchanger, contains flyash, as the Oxygen Heater is located between the Air Heater and the Electrostatic Precipitator (ESP). A simple sketch of the oxygen heater, which is similar in design to a tubular air heater, is shown in Figure 3.3.14. Refer to Appendix I Concept B Boiler modification drawings for the proposed arrangement of this equipment. Table 3.3. 7: Oxygen Heater Performance Requirements and Gas Analysis
Oxygen Stream Fluegas Stream
Oxygen Heater Performance Requirements Gas Analysis (units) Value Constituant (units) Flue Gas Mass Flow (lbm/hr) 4067591 O 2 (Wt Frac) Flue Gas Inlet Temperature (deg F) 371 N 2 " Flue Gas Outlet Temperature Oxygen Mass Flow Oxygen Oxygen Oxygen Oxygen Inlet Temperature Outlet Temperature Heater Heat Transfer Pressure (deg F) (lbm/hr) (deg F) (deg F) (10 6 Btu/hr) (psia) (psia) 339 H 2 O 751151 CO 2 100 SO 2 296 Total 33.062 20 14.281 " " "
0.9900 0.0100
0.0252 0.0380 0.0647 0.8670 0.0051 1.0000
1.0000
Flue Gas Pressure
Table 3.3. 8:
Oxygen Heater Specification
Duct Height Duct Width Tube Outside Diameter Tube Spacings St and Sl Tubing Thickness Number of tubes wide Number of tubes deep Height of tubes Total Number of Tubes ft (ft) (Inches) (Inches) (inches) (no.) (no.) (ft) (no.) 20 44.33 2 3 0.083 177 19 20 3363 67260 35217 61.0 Bare tubes SA-178
Oxygen Heater Specifications

Oxygen Heater Sketch
(Not to scale) 4 ft 44.33 ft Upper Tube Sheet 4 ft O2 Outlet Plenum O2 Inlet Plenum 4 ft
19 Tubes Deep 20 ft Flue Gas In
Flue Gas Out
177 Tubes Wide
Total Lineal length of tubing(ft) Tubing Outside Surface Total Weight of tubing Tubing type Tubing Material (ft2) (tons)
4 ft Oxygen Return Plenum Lower Tube Sheet
Figure 3.3. 14: Oxygen Heater Sketch 3.3.4.4 Parallel Low Pressure Feedwater Heater A parallel low-pressure feedwater heater (PFWH) is facilitated to remove remaining useful sensible heat in the flue gas. This heater is installed in a parallel feedwater stream with the existing extraction low-pressure feedwater heaters number 52 and 53. The heat source for the PFWH is flue gas leaving the ID fan as shown on the system diagram (Figure 3.3.1). In actuality, there are two ID fans on this unit and therefore two PFWHs are used. The flue gas
ALSTOM Power Inc.
71
June 30, 2001
temperature leaving the induced draft fans is 355 F. The PFWH cools the flue gases down to 265 F by heating feedwater in a parallel stream with the feedwater being heated in the extraction feedwater heaters No. 52 and 53 as shown in Figure 3.3.15. About 29 percent of the total low-pressure feedwater flow leaving the No. 51 low-pressure feedwater heater is heated in the new PFWH. This heat exchanger is essentially a low temperature economizer section that is designed similar to Heat Recovery Steam Generator (HRSG) tube banks with finned tubing. The fin pitch can be quite high (6 fins/inch) since the flue gas at this point is particulate free. These new components recover about 26,458 kW [90.3 x 106 Btu/hr]. This causes the steam extractions to heaters No. 52 and No. 53 to be reduced proportionally and the steam flow through the low-pressure section of the existing steam turbine to be increased by approximately two percent. This increases the generator output proportionally. Performance requirements and specifications for the PFWH are shown in Tables 3.3.9 and 3.3.10. Figure 3.3.16 shows a simple sketch of the new component. Refer to Appendix I Concept B Boiler modification drawings for the proposed arrangement of this equipment.
Table 3.3. 9:
Parallel Feedwater Heater Performance Requirements

Parallel Feedwater Heater Perf. Requirements Flue Gas Mass Flow Turbine Extractions Existing Extraction Feedwater Heaters Flue Gas Inlet Temperature Flue Gas Outlet Temperature Feedwater Flow Rate Feedwater from Heater #51 Feedwater Inlet Temperature Feedwater Outlet Temperature PFWH Heat Transfer Feedwater Pressure Flue Gas Pressure (lbm/hr) (deg F) (deg F) (lbm/hr) (deg F) (deg F)
6
Modified Low Pressure Feedwater Heater Arrangement
Heater #53 Feedwater to Deaerator Isolation Valve #53 Drain
Heater #52
(10 Btu/hr) (psia) (psia)
Isolation Valve #52 Drain to Heater #51
2033795 355 265 369724 184.9 305.3 45.1 210 14.95
Check Valve
Flow Control Valve
Flue gas from induced draft fan
New Parallel Low Pressure Feedwater Heaters (2 required)
Key
New Pipe Existing Pipe Flue gas
Flue gas to FGD syst
Figure 3.3. 15: Parallel Feedwater Heater Arrangement
Table 3.3. 10:
Parallel Feedwater Heater Specification

Parallel Feedwater Heater Specification Duct Height Duct Width Inlet Header Tube Outside Diameter Tube Spacings St and Sl Tubing Thickness Number of tubes wide Number of tubes deep Height of tubes (ft) (ft) (Inches) (Inches) (inches) (no.) (no.) (ft) (no.) (ft2) (tons)
Parallel Low Pressure Feedwater Heater Diagram

(2 Required; Not to scale)
Outlet Header
18.25 ft
20 ft Flue Gas In
15 Tubes Deep Flue Gas Out
Total Number of Tubes Outside Surface Area Total Weight of tubing Tubing type Fins per inch 49 Tubes Wide Fin Height Fin Thickness Fin Material Tubing Material
Total Lineal length of tubing (ft)
(Inches) (Inches)
5.625 ft
20 18.25 1.5 4.5 0.095 49 15 20 735 14700 72177 40.0 finned 5.2 0.75 0.05
Carbon Steel
SA-178A
Figure 3.3. 16: Parallel Feedwater Heater Sketch
ALSTOM Power Inc.
72
June 30, 2001
Table 3.3.11 shows the specifications for the PFWH headers and piping. The piping runs from the feedwater pipe entering existing feedwater heater #52 to the two PFWH unit inlet headers and returns from the to PFWH outlet headers to the feedwater pipe leaving existing feedwater heater #53. Table 3.3. 11:
Outside Dia. (inches) Headers Piping 8.625 6.625
PFWH Header and Piping Specifications

Material SA-106C ASA B36.1 Weight (lbm/ft) 53.41 36.3 Length Connections (ft) 18.25
375 ea. 2 reqd
Nominal ID (inches) 6.251 SCH 120
(number)
49-1.5" ; 1-6.625"
3.3.4.5 Controls and Instrumentation: Additional controls and instrumentation will be required for the new components and systems described. The transition between air firing and oxygen firing needs careful consideration. 3.3.4.6 Modified Boiler Drawings Drawings of the modified boiler showing the existing and new equipment are listed below and contained in Appendix I. U00-E-0551R General Arrangement - Side Elevation for Concept B U00-E-0552R General Arrangement - Plan View "B-B" for Concept B U00-E-0585R General Arrangement - Plan View "A-A" for Concept B 3.3.5 Steam Cycle System
The steam cycle system for Concept B is modified slightly with the addition of a low-pressure feedwater heater arrangement in parallel with extraction feedwater heaters # 52 and 53 as described in Section 3.3.4.4. The parallel feedwater heaters are used to recover additional sensible heat in the flue gas as a result of reduced air heater performance with oxygen firing. The modified steam cycle is shown in Figure 3.3.17. The associated Mollier diagram showing the modified steam cycle on enthalpy vs entropy coordinates is shown in Figure 3.3.18. The modified steam cycle system produces 463,056 kw with a steam turbine heat rate of 8089 Btu/kwhr.
ALSTOM Power Inc.
73
June 30, 2001
2808628 lbm/hr From RHTR 3131619 lbm/hr
2463899 lbm/hr 194.5 psia

From SHTR
Existing Generator
463,056 kw
To RHTR
COND SCAH
1849266 lbm/hr
DEA
To Boiler ECON
PFWH 739449 lbm/hr Boiler Feed Pump Energy Inputs
To Boiler De-Sh Spray

Energy Outputs
(10 Btu/hr) 1605 0 2143

Total Energy Output
(10 Btu/hr) 3656 90 2 3748 0
Turbine Heat Rate 8089 (Btu/kwhr)
Power Output (Existing Turbine) Steam Coil Air Heater Output Condenser Loss
Boiler Heat Input PFWH Heat Input Condensate Pump

3748
Figure 3.3. 17: Modified Steam Cycle Diagram and Performance for Concept B
1600 1500 Enthalpy (Btu/lbm) 1400 1300 1200 1100 1000 900 800 1 1.2 1.4 1.6 1.8 2 2.2 Entropy (Btu/lbm-F) 10% Moisture Condenser Pressure Saturation Line Steam Cycle
Figure 3.3. 18: Modified Steam Cycle Mollier Diagram for Concept B
ALSTOM Power Inc.
74
June 30, 2001
3.3.6
Flue Gas Desulfurization and Electrostatic Precipitator Systems Performance Issues
Because the flue gas for Concept B was significantly different in composition from the Base Case due to combustion with oxygen as opposed to air, analysis of the Flue Gas Desulfurization System (FGD) system and the Electrostatic Precipitator (ESP) system performance with these new conditions was investigated. The most noticeable differences regarding the flue gas composition for this case is that it contains significantly more CO2 and less N2 than with air firing. The overall mass flow rates for both cases are nearly identical. The effects of operating the Flue Gas Desulfurization System and the ESP with the high CO2 content flue gas of Concept B are discussed in this section. 3.3.6.1 Flue Gas Desulfurization System Performance Issues Table 3.3.12 identifies the assumptions that were made in predicting the FGD system performance. Table 3.2.13 shows the gas constituents at the existing Absorber inlet and outlet locations. It should be noted that the CO2/SO2 mole ratio is 199, as opposed to the value of 63 encountered previously for the Base Case and Concept A (refer to Section 3.2.4). Hence, it was necessary to assess the impact of high CO2 content in the flue gas on the performance of FGD System. It is important to note that SO2 forms a much stronger acid than CO2 (with a dissociation constant of 7.8E-3 vs. 5.2E-7). Additionally, SO2 is about 35 times more soluble in water than CO2. The absorbed SO2 will drop the pH of the scrubbing solution to about 4.5. At this level, the CO2 is basically insoluble in water. ALSTOM Powers Environmental Systems group predicted that, under these circumstances, the flue gas desulfurization systems SO2 capture efficiency would decrease by approximately 2%. Table 3.3. 12: FGD System Assumptions
Quantity Ca/S) Solids CaO MgO Inerts
Concept B (O 2 Fired) Unit Mol Ratio Wt.% Wt.% Wt.% Wt.% Wt.% gpm/1000 acfm % %
Existing Absorber 1.04 20 90 5 5 2.5 55 94.9 97.3
By-pass Leakage Liquid/Gas (L/G) Ratio SO2 Removal Efficiency APC Absorber
ALSTOM Power Inc.
75
June 30, 2001
Table 3.3. 13:
FGD System Performance
Concept B (O2 Fired) Existing Absorber Inlet Existing Absorber Outlet Mol/hr Vol.% Unit Mol/hr Vol.% Unit 3,200 5,467 14,570 80,031 403 3.09 5.27 14.05 77.20 3,887 Vol.% Vol.% Vol.% Vol.% vppm 3,190 5,467 22,400 80,021 21 2.87 4.92 20.16 72.03 189 94.8 199 Vol.% Vol.% Vol.% Vol.% vppm
3.3.6.2 Electrostatic Precipitator (ESP) System Performance Issues The effects of operating the Electrostatic Precipitator (ESP) in the high CO2 content flue gas environment of Concept B are discussed in this section. The electrostatic precipitation process can be characterized as four stages. Corona generation and flue gas ionization Particle charging resulting from ionization Migration of particles under the influence of the electric field Removal of particle cake from collecting electrodes
Background From White, J. Industrial Electrostatic Precipitation (1962): Corona discharge is vital to the electrical separation of particles from the gas stream. The dominant ion production mechanism in the corona is ionization by electron impact, in which free electrons in the gas acquire energy from an applied electric field and collide violently with gas molecules, literally knocking electrons out of the molecules. The net result is free electrons and positively charged gas ions. The unipolar corona, used in electrical precipitation, is a stable, self-maintaining gas discharge between an emitting electrode and a receiving electrode. The ionization processes are confined to or near the glow region in the strong electric field adjacent to the emitting electrode. Most of the ionization is produced by free electrons that are accelerated to fairly high energies in this region and ionize by collision with molecules. With negative corona free electrons from the ionization zone, upon entering the low-field region of the corona, combine with molecules of the gas to form negative ions. The ability to form negative ions is a fundamental property of the molecular species. Some gases such as nitrogen, hydrogen, helium, neon and argon, if sufficiently pure, have no affinity for electrons and hence do not form negative ions. Negative corona does not occur in these gases. Instead, when the voltage is raised to a point that would correspond to the corona onset point, spark over occurs. On the other hand, oxygen, chlorine, sulfur dioxide, and many other gases do have strong electron affinities, and, as would be expected, they produce highly stable negative coronas. Negative corona is possible only in gases, or mixtures of gases, that exhibit appreciable electron attachment. Consequently negative corona characteristics are highly sensitive to gas composition and can range from no corona to highly stable corona. Fortunately practically all industrial furnaces, boilers and process gases as well as air contain electro-negative gases such as oxygen, water vapor, carbon dioxide and frequently sulfur dioxide. Electron attachment is the process by
ALSTOM Power Inc.
76
June 30, 2001
which electrons combine with neutral molecules to form negative ions. The probability of attachment varies greatly with the gas composition. It is zero for gases such as nitrogen and hydrogen, very small for ammonia, and relatively high for chlorine. Theory and experiment show that the molecular composition of the gas profoundly influences its negative-corona characteristics (Please refer to Figures 3.3.19, 3.3.20 and 3.3.21 below, extracted from White, 1962). The general conclusion is that gases such as nitrogen that in the pure state have zero electron affinity, are incapable of supporting negative corona, and gases of the CO2 type that have moderate electron affinity do have considerable negative corona, and gases of the SO2 type have a very wide range of negative corona.
Figure 3.3. 19: Negative Corona Curves for Ai r-water Vapor Mixtures at 400F; Atmospheric Pressure; 3-in. Tube; 0.010-in. Wire
Figure 3.3. 20: Negative Corona Characteristics for Nitrogen-Oxygen Mixtures; 6-in Tube; 0.109-in Wire
ALSTOM Power Inc.
77
June 30, 2001
Figure 3.3. 21: Negative Corona Curves for Nitrogen-Sulfur Dioxide Mixtures; 6-in. Tube; 0.019-in. Wire Conditions with recycled flue gas: Table 3.3.14 gives a comparison of the flue gas analysis for air firing and O2/Recycled flue gas firing. The high nitrogen content, 73.7%, found with the air firing is reduced to 5.3 % where as the CO2 increases from 13.9% to 77.2%. There is also a small increase in the moisture content from 9% to 14.1% and SO2 content from 2212 vppm to 3887 vppm. Table 3.3. 14: Species Unit Composition of Flue Gases Entering the Electrostatic Precipitator (ESP) O2/Recycled Flue Gas Firing: (ESP Inlet Gas Composition) 3.1 5.27 14.1 77.2 3887
Air Firing: (ESP Inlet Gas Composition) 3.1 73.7 9.0 13.9 2212
O2 N2 H2O CO2 SO2
Vol.% Vol.% Vol.% Vol.% vppm
If the gas was 100% Nitrogen, the negative corona precipitation process could not occur. Nitrogen has no affinity for electrons and hence cannot form negative ions. When the voltage is raised to a point that would correspond to the corona onset point, spark over occurs. Figure 3.3.20 shows that the introduction of O2 allows an increase in voltage to take place creating a stronger electrical field prior to spark over. Figure 3.3.21 shows again the 100% nitrogen gas and the effects of various levels of the electro-negative gas S0 2. Also a comparison curve is given for 100% CO2. It can be seen that CO2 has electron affinity resulting in a significant increase in voltage, beyond corona onset voltage, before spark break down occurs. The curve tends to the improved characteristic that is obtained with the presence of a small percentage of S0 2.
ALSTOM Power Inc.
78
June 30, 2001
Hence with all other gas components remaining constant the replacement of nitrogen by CO2 will result in a gas that is more beneficial for negative corona precipitation. In Conclusion, for the gas analysis of Concept B shown above in Table 3.3.14, no ESP performance degradation is expected as a result of firing coal in O2/Recycled flue gas environment. 3.3.7 Carbon Dioxide Separation and Compression System
This system processes the flue gas stream leaving the oxygen fired boiler system of Concept B to provide a liquid product CO2 stream with suitable conditions for sequestration or usage. 3.3.7.1 Introduction: Traditionally, amine scrubbing has been used on industrial scale to recover CO2 from boiler flue gases. Monoethanolamine (MEA) is one of the most effective absorbents but reclamation of the absorbed CO2 from MEA solution consumes large amounts of energy. Therefore, a search is on for more energy efficient methods for recovering CO2 from flue gas streams. One proposed method is to replace combustion air of a power plant with nearly pure oxygen. Theoretically, the flue gas from such a plant would consist of only CO2 and water vapor. Because water can be separated from this gas relatively easily (by condensation) this method seems to offer a promising way to recover CO2 by simply compressing it to a high enough pressure so it can be disposed of or recovered for some useful purpose. Practically however, the stream leaving the Boiler Island contains many other components other than just CO2 and water vapor, which must be fully considered in the system design for Concept B. 3.3.7.2 Process Description: Figure 3.3.22 (Refer to Section 3.3.7.3) shows the Flue Gas Cooling process flow diagram and Figure 3.3.23 shows the Flue Gas Compression and Liquefaction process flow diagram. The following describes a CO2 recovery system that cools and then compresses a CO2 rich flue gas stream from an oxygen-fired boiler to a pressure high enough so CO2 can be liquefied. The resulting liquid CO2 is passed through a CO2 Stripper to reduce the N2/O2 content to an acceptable level. Then the liquid CO2 is pumped to a high pressure so it can be economically transported for sequestration or usage. Pressure in the transport pipeline will be maintained above the critical pressure of CO2 to avoid 2-phase flow. The overhead gas from the CO2 Stripper is vented to atmosphere. The key process parameters (pressures, temperatures, duties etc.) are shown on the process schematics and will not be repeated here except in selected instances. Later in this report there is a section titled Design Considerations (Section 3.3.7.8). This section covers design issues that are not discussed in the Process Description below. Flue Gas Cooling: Please refer to Figure 3.3.22 (drawing D 09484-01005R-0). The feed to the CO2 Recovery System is the flue gas stream that leaves the FGD system of the Boiler Island. At this point, the flue gas is at the dew point of H2O. All of the flue gas leaving the boiler is cooled to 100 F in Gas Cooler DA-101 A/B/C which operates essentially under atmospheric pressure. A significant amount of water condenses out in this cooler. Approximately 2/3 of the gas is then recycled back to the boiler while 1/3 is fed forward to the CO2 compression area. The recycle stream is required to maintain thermal balance in the existing Conesville #5 steam generator unit in order to avoid major pressure part modifications to the boiler. The Gas Cooler minimizes the volumetric flow rate to, and the resulting power consumption of, the Flue Gas Compression equipment located downstream. Excess condensate is blown down to the cooling water system. Three vessels have been provided for these coolers because a single vessel would be too large. The Gas Cooler is configured in a packed tower arrangement where the flue gas is contacted with cold water in countercurrent fashion. Warm water from the bottom of the contactor is recycled back to the top of the contactor by
ALSTOM Power Inc.
79
June 30, 2001
Water Pump GA-101 A/B/C/D after first cooling it in an external water cooled heat exchanger, Water Cooler EB-101 (plate and frame exchanger). The cooling water for this exchanger comes from the new cooling tower. Because the flue gas may carry a small amount of fly ash, the circulating water is filtered in Water Filter FD-101 to prevent solids build-up in the circulating water. Condensate blowdown is filtered and is taken out downstream of the filter. However, the stream is not cooled and is split off before EB-101. Thus the heat load to the cooling tower is minimized. From the Gas Cooler, the flue gas stream enters a series of booster blowers that are located adjacent to the Gas Cooler. This design was developed to minimize the length of ducting operating at a slight vacuum and to minimize the temperature of the gas being recycled back to the boiler. This arrangement also minimizes energy consumption, as it does not needlessly over boost the pressure of the stream to be recycled back to the boiler. It is only necessary to boost the pressure of the fraction of the flue gas flow that proceeds to compression and liquefaction to overcome the pressure drop of the duct which is about 1200 feet long. Three-Stage Gas Compression System: Please refer to Figure 3.3.23 (drawing D 09484-01004R-0). The compression section, where CO2 is compressed to 365 psig by a three-stage centrifugal compressor, includes Flue Gas Compressor GB-101. After the aftercoolers, the stream is then chilled in a propane chiller to a temperature of 21 F. Note that both the trim cooling water and water for the propane condenser come from the new cooling tower. At this pressure and temperature, about 80 mole % of the stream can be condensed. The flash vapors contain approximately 80 weight % of the inlet oxygen and nitrogen, but also 12 weight % of the CO2. Therefore, a rectifier tower has been provided to reduce the loss of CO2 to an acceptable level (about 6 weight %). Then the pressure of the liquid is boosted to 2000 psig by CO2 Pipeline Pump GA-103. This stream is now available for sequestration or usage. The volumetric flow to the compressor inlet is about 80,000 ACFM to each of the two trains and only a single frame is required in each train. The discharge pressures of the stages have been balanced to give reasonable power distribution and discharge temperatures across the various stages. They are: 1st Stage 2nd Stage 3rd Stage 28 psig 108 psig 365 psig
Power consumption for this large compressor has been estimated assuming adiabatic efficiency of 75%. The hot gas from each stage is first cooled in an air cooler to 120 oF (Flue Gas Compressor 1st/ 2nd / 3rd Stage Aftercooler EC-101/2/3) and then further cooled by a water-cooled heat exchanger to 95 oF (Flue Gas Compressor 1st/ 2nd Stage Trim Cooler EA-101/2). The flue gas compressor 3rd stage cooler (EA-103) cools the gas down to 90 oF to reduce the size of the dryers. Due to their large size, many of these heat exchangers consist of multiple shells. Because of highly corrosive conditions, the process side of the coolers must be stainless steel. Because the flue gas stream leaving DA-101 is wet, some water condenses out in the three aftercoolers. The sour condensate is separated in knockout drums (FA-101/2/3) equipped with mist eliminator pads. Condensate from these drums is drained to the cooling tower or to waste water treatment. To prevent corrosion, these drums have a stainless steel liner. Flue gas leaving the 3rd stage discharge knockout drum (FA-103) is fed to Flue Gas Drier FF-101 A/G where additional moisture is removed. Gas Drying: Please refer to Figure 3.3.23 (drawing D 09484-01004R-0). It is necessary to dry the CO2 stream to meet the product specification. A mole sieve drier has been selected.
ALSTOM Power Inc.
80
June 30, 2001
The performance of a fixed-bed drier improves as pressure increases. This favors locating the drier at the discharge of the compressor. However, as the operating pressure of the drier increases, so does the design pressure of the equipment. This favors low-pressure operation. But, at low pressure the diameter or number of the drier vessels grows, increasing the cost of the vessel. Having to process the recycle gas from the rectifier condenser cooling would also increase the diameter of the vessel. However, this is less than 10% of the forward flow. For this design the drier has been optimally located downstream of the 3rd stage compressor. The CO2 Drier system consists of six vessels; FF-101 A/G. One vessel is on line while the others are being regenerated. Flow direction is down during operation and up during regeneration. The drier is regenerated with the non-condensable vent gas from the rectifier after it exits the third stage discharge trim cooler in a simple once through scheme. During regeneration, the gas is heated in Regeneration Heater FH-101 before passing it through the exhausted drier. After regeneration, heating is stopped while the gas flow continues. This cools the bed down to the normal operating range. The regeneration gas and the impurities contained in it are vented to the atmosphere. Regeneration of a mole sieve bed requires relatively high temperature and, because HP steam pressure may fluctuate, a gas-fired heater has been specified for this service. Flue Gas Filter FD-102 has been provided at the drier outlet to remove any fines that the gas stream may pick up from the desiccant bed. CO2 Condensation and Stripping: Please refer to Figure 3.3.23 (drawing D 09484-01004R-0). From the CO2 Drier, the gas stream is cooled down further to -21 F with propane refrigeration in CO2 Condenser EA104. From EA-104 the partially condensed flue gas stream continues on to CO2 Rectifier DA-102. At this pressure and temperature 80 mole % of the stream can be condensed. The flash vapors contain approximately 80 weight % of the inlet oxygen and nitrogen, but also 12 weight % of the CO2. Therefore, as mentioned, a rectifier tower has been provided to reduced the loss of CO2 to an acceptable level. The pressure of the liquid is boosted to 2000 psig by CO2 Pipeline Pump GA-103 for delivery to a sequestration or usage location. The vapors in the feed to the rectifier contain the nitrogen and the oxygen that flashed from the liquid CO2. To keep the CO2 loss to the minimum, the rectifier also has an overhead condenser, CO2 Rectifier Condenser EA-107. This is a floodback type condenser installed on top of the Rectifier. It cools the overhead vapor from the tower down to 48 o F. The condensed CO2 acts as cold reflux in the CO2 Rectifier. Taking a slipstream from the inert-free liquid CO2 from the Rectifier bottoms and letting it down to the Flue Gas Compressor 3rd stage suction pressure cools EA-107. At this pressure, CO2 liquid boils at 55 oF thus providing the refrigeration necessary to condense some of the CO2 from the Stripper overhead gas. The process has been designed to achieve at least 94% CO2 recovery. The vaporized CO2 from the cold side of EA-107 is fed to the suction of the Flue Gas Compressor 3rd stage. Any system containing liquefied gas such as CO2 is potentially subject to very low temperatures if the system is depressurized to atmospheric pressure while the system contains cryogenic liquid. If the CO2 Rectifier (and all other associated equipment that may contain liquid CO2) were to be designed for such a contingency, it would have to be made of stainless steel. However, through proper operating procedures and instrumentation such a scenario can be avoided and low temperature carbon steel (LTCS) can be used instead. Our choice here is LTCS. However, the condenser section will be made from stainless steel. CO2 Pumping and CO2 Pipeline: Please refer to Figure 3.3.23 (drawing D 09484-01004R-0). The CO2 product must be increased in pressure to 2000 psig. A multistage heavy-duty pump (GA-103A/B) is required for this service. This is a highly reliable derivative of an API-class boiler feed-water pump.
ALSTOM Power Inc.
81
June 30, 2001
It is important that the pipeline pressure be always maintained above the critical pressure of CO2 such that singlephase (dense-phase) flow is guaranteed. Therefore, pressure in the line should be controlled with a pressure controller and the associated control valve located at the destination end of the line. Offgas: Please refer to Figure 3.3.23 (drawing D 09484-01004R-0). The vent gas from the CO2 Rectifier overhead is at high pressure and there is an opportunity for power recovery using turbo-expanders. Because the gas cools down in the expansion process, there is also an opportunity for cold recovery. Heat recovery from the stream after let down via an expander was examined and it was determined that the amount of duty that could be recovered without the carbon dioxide in the stream freezing was small. Thus heat recovery could not be justified. The offgas leaves the Rectifier at 48 oF approximately. The refrigeration recovery to condense CO2 was the best use for this cold since it also produces a reasonable temperature regeneration gas for the dryers. 3.3.7.3 Process Flow Diagrams Two process flow diagrams are shown below for these systems: Figure 3.3.22 (drawing D 09484-01005R-0) Flue Gas Cooling PFD Figure 3.3.23 (drawing D 09484-01004R-0) CO2 Compression and Liquefaction PFD
ALSTOM Power Inc.
82
June 30, 2001
Figure 3.3. 22: Process Flow Diagram for Concept B: Flue Gas Cooling
ALSTOM Power Inc.
83
June 30, 2001
Figure 3.3. 23: Process Flow Diagram for Concept B: CO2 Compression and Liquefaction
ALSTOM Power Inc.
84
June 30, 2001
3.3.7.4 Overall Material and Energy Balance Table 3.3.15 contains the overall material balance for the Flue Gas Cooling System and the CO2 Compression and Liquefaction System. It is based on 94% recovery of CO2. Table 3.3. 15:
STREAM NAME STREAM NO. VAPOR FRACTION TEMPERATURE PRESSURE MOLAR FLOW RATE MASS FLOW RATE ENERGY COMPOSITON CO2 H2O Nitrogen Ammonia Propane Oxygen SO2 VAPOR MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW MOLECULAR WEIGHT DENSITY VISCOSITY HYDROCARBON LIQUID MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW DENSITY MOLECULAR WEIGHT VISCOSITY SURFACE TENSION LbMol/Hr Lb/Hr BPD GPM Lb/Ft
3
Material and Energy Balance for Flue Gas Cooling, CO2 Compression and Liquefaction
To quench columns From Quench columns Excess water From Large blowers Quench water out Quench water in To liquefaction trains To boiler To Train A liquefaction First water KO To 2nd stage 2nd water KO To 3rd stage Recycle from condenser
1 Molar F PSIG LbMol/Hr Lb/Hr Btu/Hr Mol % 73.04% 19.01% 5.03% 0.00% 0.00% 2.91% 0.01% 1.000 144 0 109,760.00 4,162,006 5.24E+08
3a 1.000 100 0 95,103.76 3,897,793 4.16E+08 84.29% 6.53% 5.80% 0.00% 0.00% 3.36% 0.02%
6 0.000 100 0 14,659.53 264,213 -2.11E+08 0.03% 99.97% 0.00% 0.00% 0.00% 0.00% 0.00%
3b 1.000 108 1 95,103.76 3,897,793 4.23E+08 84.29% 6.53% 5.80% 0.00% 0.00% 3.36% 0.02%
2 1.000 #N/A 1 #N/A #N/A 0.03% 99.97% 0.00% 0.00% 0.00% 0.00% 0.00%
5 1.000 91 1
3c 1.000 114 0 22,857.50 936,806 1.03E+08
3d 1.000 108 1 72,246.26 2,960,987 3.21E+08 84.29% 6.53% 5.80% 0.00% 0.00% 3.36% 0.02%
4 1.000 114 0 11,428.75 468,403 5.15E+07 84.29% 6.53% 5.80% 0.00% 0.00% 3.36% 0.02%
7 0.000 95 22 499.76 9,015 -7.24E+06 0.09% 99.91% 0.00% 0.00% 0.00% 0.00% 0.00%
8 1.000 95 22 10,928.99 459,389 4.70E+07 88.14% 2.26% 6.07% 0.00% 0.00% 3.52% 0.02%
9 0.000 86 102 15.06 273 -2.20E+05 0.30% 99.69% 0.00% 0.00% 0.00% 0.00% 0.00%
10 1.000 86 102 11,675.19 496,582 4.83E+07 90.26% 0.59% 5.78% 0.00% 0.00% 3.37% 0.02%
25 1.000 -50 102 925.00 40,427 2.66E+06 97.82% 0.00% 1.24% 0.00% 0.00% 0.92% 0.02%
0.03% 99.97% 0.00% 0.00% 0.00% 0.00% 0.00%
84.29% 6.53% 5.80% 0.00% 0.00% 3.36% 0.02%

3
109,760.0 4,162,006 999.67 806,220.00 37.92 0.09 0.0147 -
95,103.8 3,897,793 866.16 650,850.00 40.98 0.10 0.0150 -
0.10 0.0150 -
95,103.8 3,897,793 866.16 632,520.00 40.98 0.10 0.0152 -
0.1 0.0 -
0.1 0.0 -
22,857.5 936,806 208.18 158,940.00 40.98 0.10 0.0154 -
72,246.3 2,960,987 657.99 480,500.00 40.98 0.10 0.0152 -
11,428.8 468,403 104.09 79,470.00 40.98 0.10 0.0154 -
10,929.0 459,389 99.54 29,015.79 42.03 0.26 0.0154 -
11,675.2 496,582 106.33 9,406.50 42.53 0.88 0.0155 -
925.0 40,427 8.42 521.00 43.71 1.29 0.0113 -
cP
MW cP Dyne/Cm
STREAM NAME
To drier
3rd water ko
From drier/ Condenser outlet Condenser inlet
Non-condensable vent
Rectifier bottoms to condenser
Train A CO2 to pipeline
Refrig condenser out
Refrig subcooler out
Refrig to CO2 condenser
Refrig from CO2 condenser
Warm non condensable
STREAM NO. VAPOR FRACTION TEMPERATURE PRESSURE MOLAR FLOW RATE MASS FLOW RATE ENERGY COMPOSITON CO2 H2O Nitrogen Ammonia Propane Oxygen SO2 VAPOR MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW MOLECULAR WEIGHT DENSITY VISCOSITY HYDROCARBON LIQUID MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW DENSITY MOLECULAR WEIGHT VISCOSITY SURFACE TENSION LbMol/Hr Lb/Hr BPD GPM Lb/Ft
3
12 Molar F PSIG LbMol/Hr Lb/Hr Btu/Hr Mol % 90.54% 0.28% 5.79% 0.00% 0.00% 3.38% 0.02% 1.000 90 359 11,638.57 495,913 4.50E+07
11 0.000 90 359 36.62 668 -5.28E+05 0.88% 99.11% 0.00% 0.00% 0.00% 0.00% 0.01%
14 1.000 90 354 11,606.46 495,335 4.50E+07 90.79% 0.00% 5.81% 0.00% 0.00% 3.39% 0.02%
15 0.200 -21 349 11,318.96 483,065 -1.86E+07 90.79% 0.00% 5.81% 0.00% 0.00% 3.39% 0.02%
24 1.000 -46 346 1,421.61 50,218 3.76E+06 40.47% 0.00% 38.53% 0.00% 0.00% 20.99% 0.00%
22 0.134 -56 105 925.00 40,427 -2.55E+06 97.82% 0.00% 1.24% 0.00% 0.00% 0.92% 0.02%
21 0.000 82 2,000 9,247.50 404,163 -3.13E+06 97.82% 0.00% 1.24% 0.00% 0.00% 0.92% 0.02%
100 1.000 144 169 9,750.00 429,946 7.13E+07 0.00% 0.00% 0.00% 0.00% 100.00% 0.00% 0.00%
101 0.000 95 162 9,750.00 429,946 2.54E+06 0.00% 0.00% 0.00% 0.00% 100.00% 0.00% 0.00%
102 0.000 24 159 9,750.00 429,946 -1.73E+07 0.00% 0.00% 0.00% 0.00% 100.00% 0.00% 0.00%
103 0.158 -26 8 9,750.00 429,946 -1.73E+07 0.00% 0.00% 0.00% 0.00% 100.00% 0.00% 0.00%
104 0.993 -26 8 9,750.00 429,946 4.67E+07 0.00% 0.00% 0.00% 0.00% 100.00% 0.00% 0.00%
26 1.000 81 341 1,421.61 50,218 5.35E+06 40.47% 0.00% 38.53% 0.00% 0.00% 20.99% 0.00%
LbMol/Hr Lb/Hr MMSCFD ACFM MW Lb/Ft3 cP
11,638.6 495,913 106.00 2,686.04 42.61 3.08 0.0164 -
11,606.5 495,335 105.71 2,718.77 42.68 3.04 0.0164 -
2,263.8 87,306 20.62 407.73 38.57 3.57 0.0145 9,055.12 395,757.44 32,774 748.51 65.92 43.71 0.1610 15.05
1,421.6 50,218 12.95 253.59 35.32 3.30 0.0146 -
124.2 5,207 1.13 67.90 41.94 1.28 0.0116 800.84 35,219.85 2,921 61.47 71.43 43.98 0.2221 20.06
9,247.50 404,163.41 33,471 1,008.54 49.96 43.71 0.0558 0.85
9,750.0 429,946 88.80 4,762.22 44.10 1.50 0.0098 -
9,750.00 429,945.75 58,100 1,802.87 29.73 44.10 0.0906 5.74
9,750.00 429946 58,100 1,598.64 33.53 44.10 0.1336 10.54
1,539.9 67,905 14.02 5,111.32 44.10 0.22 0.0066 8,210.14 362042 48,927 1,268.98 35.57 44.10 0.1771 14.13
9,681.4 426,923 88.17 32,135.98 44.10 0.22 0.0066 68.56 3,023.15 409 10.60 35.57 44.10 0.1771 14.13
1,421.6 50,218 12.95 366.87 35.32 2.28 0.0185 -
MW cP Dyne/Cm
3.3.7.5 Equipment List with Data Equipment data for Concept B, summarized in Appendix II, has been tabulated in the so-called short spec format which provides adequate data for a factored cost estimate.
ALSTOM Power Inc.
85
June 30, 2001
3.3.7.6 Consumption of Utilities In addition to the primary utilities listed below (Table 3.3.16), the plant will also need a supply of other utilities such as instrument air, plant air, process water, nitrogen etc. However, these needs are minor and in many cases are for maintenance purposes only. Consumption of these utilities has not been estimated. Table 3.3. 16: Utility Natural Gas Steam Cooling water Concept B Utility Consumption Amount Consumed 0.26 0 93,200 Units MMSCFD Lb/hr Gpm
Number of Trains 2 2 2
Item Number EC-101 EC-102 EC-103
Service Flue Gas Compressor 1st Stage Aftercooler Flue Gas Compressor 2nd Stage Aftercooler Flue Gas Compressor 3rd Stage Aftercooler Large Air Separation Unit Small Air Separation Unit Cooling Tower
Power (ea) Number including Operating 0.95 per train motor eff (kW) 1 81 1 1 69 68
Total all trains (kW) 163 138 137
1 1 1
PA-101A/B PA-102 PA-103
2 1 1
40255 15311 4074
80511 15311 4074
2 2 2 2 2 1 1
GB-101
GB-102
1 Stage 2 Stage 3 Stage 1 stage 2 stage Flue Gas Blower Flue Gas Booster
1 1 1 1 1 1 1
6416 6675 6718 2362 5204 2173 396
12831 13349 13436 4724 10408 2173 396
GB-100 GB-103
1 2
GA-101 A/B/C/D GA-103A/B
Water pump CO2 Pipeline pump Total
3 1
104 1045
311 2089 160051
ALSTOM Power Inc.
86
June 30, 2001
3.3.7.7 Consumption of Chemical and Desiccants The CO2 compression system does not need any chemicals for its operation. Naturally, there will be a minor demand of lube oil and similar supplies. These have not been estimated. It has been assumed that the mole sieve desiccant in the CO2 Drier must be replaced once every 3 years. The estimated consumption of mole sieve and other chemicals can be found Table 3.3.17. Table 3.3. 17: Chemical Sodium Hypochlorite Sodium Bisulfite Mole Sieves Concept B Chemical and Desiccant Consumption Consumption per day (lbs.) 15300 86 136
The totals shown in Table 3.3.17 do not include chemicals provided by the cooling tower service personnel. This is handled as a component of operating costs referred to as contracted services. It also does not include air separation plant chemicals and lubricants that were presented as monetary value only. They will appear in the operating expense break down. 3.3.7.8 Design Considerations The process and equipment specifications presented for Concept B were the result of a number of optimizations. The areas of optimizations in the CO2 Compression and Liquifaction System were: O2 purity CO2 purity CO2 condensation pressure and temperature
O2 Purity: Initial analysis included an Air Separation Unit (ASU) producing oxygen of 95% purity. Additionally, 5% of the total oxygen demand was assumed to be from infiltration of ambient air into the boiler which is typical for a boiler of this type and age. These operating conditions combined with the need for nominally 15% excess oxygen for combustion, resulted in almost 15-wt% of nitrogen and oxygen in the flue gas. This concentration is much higher than typically accepted for EOR applications. The conclusion then was that the bulk of the inerts must be separated from CO2 before it can be used for EOR. Thus, direct compression to the pipeline is not an option. Instead, CO2 would have to be condensed so the inerts could be separated. It soon became obvious that it is impossible to condense CO2 from such a mixture at pressures below the critical pressure of CO2 and temperatures achievable with cooling water. This is illustrated by Figure 3.3.24 which shows the achievable CO2 recovery (the ratio of pure CO2 product recovered to the CO2 in the flue gas entering the system) as a function of pressure and temperature. Pressure was limited to 1000 psig, which is just slightly below the critical pressure of CO2 (1070 psia).
ALSTOM Power Inc.
87
June 30, 2001
CO2 Recovery - Original Basis (14.69wt% N2 - Dry Basis)

100.00
50.00
0% Recovery 10% Recovery Temperature (F) 0.00 20% Recovery 40% Recovery 60% Recovery 80% Recovery -50.00 85% Recovery 90% Recovery 95% Recovery Pure CO2
-100.00
-150.00 0 100 200 300 400 500 Pressure (psig) 600 700 800 900 1000
Figure 3.3. 24: CO2 Recovery from Boiler Flue Gas (Combustion with 95% Pure O2 and 5% Air Infiltration) Because the combustion process requires excess oxygen (typically 15-20% with coal firing), the flue gas will always contain at least some oxygen. Furthermore, it is not easy to completely eliminate nitrogen. Some infiltration of air will always occur as long as the combustion chamber of the boiler operates under slight vacuum, as is the current practice with coal firing, thus some N2 will also be present. Additionally, increasing oxygen purity from the ASU beyond 99% is expensive because the remaining 1% is mainly argon and the separation becomes more difficult. Because the inert gases have a strong effect on the dew point of the flue gas, the only way to condense a substantial fraction of the CO2 is by refrigeration. One should keep in mind that the critical temperature of CO2 is approximately 88 F and condensation of CO2 without some form of refrigeration may not be feasible in the warmer regions of the world even when inerts are not present in the CO2 stream. Figure 3.3.25 shows the achievable CO2 recovery as a function of pressure and temperature using 99% pure O2 and 1% air infiltration as combustion process assumptions. One comparison which emphasizes the impact of flue gas purity is that with 95% O2 purity, the temperature for 95% recovery at 1000 psig is -60F (Figure 3.3.24) whereas it is 30 F (Figure 3.3.25) with 99% pure oxygen.
ALSTOM Power Inc.
88
June 30, 2001
CO2 Recovery - Revised Basis (3.56 wt% N2 - Dry Basis)

100.00
80.00
60.00
40.00
0% Recovery 10% Recovery 20% Recovery 40% Recovery 60% Recovery 80% Recovery 85% Recovery 90% Recovery 95% Recovery Pure CO2
Temperature (F)
20.00
0.00
-20.00
-40.00
-60.00
-80.00
-100.00 0 100 200 300 400 500 Pressure (psig) 600 700 800 900 1000
Figure 3.3. 25: CO2 Recovery Boiler Flue Gas (Combustion with 99% Pure O2 and 1% Air Infiltration) CO2 purity: Simulations were made to evaluate modifications to the liquefaction flow scheme presented in Sections 3.3.7.2 & 3.3.7.3 for this concept. The alternate schemes evaluated included total product condensation and having a reboiler on the rectifier (turning it into a complete distillation column). The result was that total condensation, even with the use of 99% pure oxygen, left the product with approximately 11% inerts, which cast doubt according to experts that it could be sequestered in a body of water. The result of having a reboiler on the bottom of the rectifier showed that it improved the CO2 product purity, but could never be feasibly made to produce a product which contained less than 10 ppm O2 which would be required for EOR applications. The reason that a reboiler was not presented in the final design was that all of the heat of reboiling was added to the condenser, which required refrigeration at a much lower temperature than the refrigeration which was recovered in the reboiler. The result was a significant work of liquefaction increase. CO2 condensation pressure and temperature: The range of condensation pressures evaluated ranged from 995 psia to 70 psia. The range of condensation temperatures evaluated ranged from 41 F to 69 F. The optimum was found to be 350 psig and 22 F. 3.3.7.9 OSBL Systems Concept B has equipment associated with the liquefaction of CO2 in four different areas. The areas include the cooling tower, flue gas cooling section, air separation plant, and the compression and liquefaction equipment. For this Concept, all of the cooling water must come from a new cooling tower since there is no diversion of steam to supply process heat. The clarifier producing make-up water for the cooling tower produces a blowdown sludge that must be sent to the existing clarifier blowdown handling system. The blowdown from the cooling tower itself can be discharged to the river after the free chlorine is removed by injection of sodium bisulfite. The air separation plant utilizes the bulk of the cooling water. It also consumes electric power. The original design of the air separation plant involved the consumption of steam for molecular sieve drier regeneration. This duty was converted to an electric load to get the CO2 recovery process isolated from swings in steam pressures that can occur with changes in throughput. The only other utility it takes in is instrument air.
ALSTOM Power Inc.
89
June 30, 2001
The CO2 compression and liquefaction section requires less supplemental utilities and chemicals than its amine counterparts. Only cooling water and electric power are required. Once every three years the molecular sieve in the dryers may need to be replaced. 3.3.7.10 Plant Layout The gas from the flue gas desulfurizer arrives at the nozzles of the flue gas coolers at atmospheric pressure. In order to avoid any additional inflow of oxygen, the flue gas coolers must be placed as close to the power boilers as possible. The coolers are located just west of the existing FGD system. Initially there were concerns about the piping between the air separation plant and the power boiler. The oxygen is produced at the air separation plant at 5 psig. Therefore it should not be subject to more than 3 psi of frictional pressure loss in the duct connecting it to the power boiler. Calculations reveal that two 36-inch supply lines can carry the oxygen from the ASU to the Boiler, a distance of about 1500 feet. The wall thickness of standard pipe should provide more than enough protection from most incidents that could be envisioned for a pipe spanning this distance. There may be even scope to reduce the wall thickness to less than standard wall if calculations permit. Air Products also had concerns about putting the Air Separation plant too close to the power plant where the inlet air may be high in CO2. This CO2 could affect the drier operation. Due to the fact that this CO2 liquefaction unit reduces gases going up the stack, there should be no problem. The layout of the compression and liquefaction unit offers few areas to comment on. At the low-pressure section of the plant, elbows are quite large making spacing allowances on the plot plan difficult without a rigorous design being made. Plant layout drawings for Concept B (listed below) are included in Appendix I. This new equipment requires about 5.5 acres of plot area. U01-D-0203 Plot Plan Concept B: Air Separation Plants U01-D-0209 Plot Plan Concept B: Flue Gas Cooling U01-D-0205 Plot Plan Concept B: CO2 Compression & Liquefaction U01-D-0212 Plot Plan Concept B: Overall Layout Conceptual Plan U01-D-0201R Plot Plan Concept B: Modified Overall Site Plan
ALSTOM Power Inc.
90
June 30, 2001
3.4
Concept C: CO2 Separation by MEA/MDEA Absorption and De-Oxy Catalyst
Concept C is defined as a system designed for the removal and recovery of CO2 from the boiler flue gas using MEA/MDEA blended amine technology. The difference between the amines used in this case and in Case A is that the mixture of amines are not oxygen resistant. Therefore, the oxygen in the flue gas is converted to CO2 by combustion with methane over a de-oxy catalyst upstream of the amine contactor. 3.4.1 Overall System Description and Material and Energy Balance
A simplified process flow diagram for the modified unit is shown in Figure 3.4.1. The operation and performance of the existing Boiler, ESP, and FGD systems are identical to the Base Case and are not affected by the addition of the MEA/MDEA based CO2 removal system. The gas side material and energy balance for the Boiler Island system is shown in Table 3.4.1 below. The flue gases leaving the existing FGD system are ducted to the new de-oxy system. The de-oxy system converts the remaining oxygen contained in the flue gas to CO2 using two stages of catalytic combustion with natural gas as the fuel source. High temperature heat recovery is provided in the de-oxy system by generation of high pressure superheated steam, which is expanded through a new steam turbine for additional power generation. The exhaust from this turbine provides part of the feed for solvent regeneration in the re-boilers of the MEA/MDEA system. The de-oxygenated flue gas leaving the de-oxy system is supplied to the MEA/MDEA system where about 91 percent of the CO2 is removed, compressed, and is available for usage or sequestration. The remaining flue gases leaving the new MEA/MDEA system absorber, consisting of primarily, nitrogen, water vapor, carbon dioxide, and relatively small amounts of sulfur dioxide and methane, is discharged to the atmosphere through stacks above the absorbers.
Note : Shading indicates new equipment ALSTOM Power Inc. Scope Tri-Sector 14 22 23 18 1 Coal Mill System 16 Air Heater 13 PA Fan 17 15 SCAH 12 11 21 SCAH 20 5
ALSTOM Environmental Scope
9
CO 2 Compression & Liquefaction System
27
CO 2 Product for Usage or Sequestration
ABB LGI Scope
ID Fan Steam Generator Unit 3 4 ESP 6 7
FGD System
26 FD Fan 19 10
CO 2 Separation Unit using MEA / MDEA Absorption
S t a c k
28
25
Catalytic O 2 Removal System
24

1 2 3 4 5 6 7 8 9 10 Raw Coal to Pulverizers Air Infiltration Stream Fluegas from Economizer to Air Heater Fluegas Leaving Air Heater to ESP Flyash Leaving ESP Fluegas Leaving ESP to Induced Draft Fan Fluegas to Fluegas De-Sulfurization System Lime feed to FGD System FGD System Solids to Disposal Fluegas to O 2 Removal System 11 12 13 14 15 16 17 18 19 20 Air to Primary Air Fan Primary Air to Steam Coil Air Heater Primary Air to Air Heater Air Heater Leakage Air Stream Tempering Air to Pulverizers Hot Primary Air to Pulverizers Mixed Primary Air to Pulverizers Pulverized Coal and Air to Furnace Air to Forced Draft Fan Secondary Air to Steam Coil Air Heater 21 22 23 24 25 26 27 28 Secondary Air to Air Heater Heated Secondary Air to Furnace Bottom Ash from Furnace Methane for Oxygen Consumption Oxygen Free Gas to CO 2 Removal Separated CO2 to Compressor Compressed CO 2 Product CO 2 Depleted Fluegas to Stack
Figure 3.4. 1:
Simplified Gas Side Process Flow Diagram for CO2 Separation by MEA/MDEA Absorption for Concept C
ALSTOM Power Inc.
91
June 30, 2001
Table 3.4. 1:
Constituent O2 N2 H2O CO2 SO2 H2 Carbon Sulfur Ca Mg MgO MgSO3 MgSO4 CaSO3 CaSO4 CaCO3 Ash / Inerts Total Gas Total Solids Total Flow (Units) (Lbm/hr) " " " " " " " " " " " " " " " " (Lbm/hr) " " 1 26586 4868 37820 2 42147 139626 2357
Gas Side Material and Energy Balance for Concept C

5 6 7 144817 144817 2942220 2942220 231294 231294 867210 867210 20202 20202 8 5355 250709 9 10 144578 2942220 436024 866156 1063 11 203237 673283 11365 12 203237 673283 11365 13 112918 374075 6314
3 4 101097 144817 2797385 2942220 228849 231294 867210 867210 20202 20202
45979
16102 236655 10110 12452 584 484 1293 94 35179 2468 2398 968
42313
33851
Fluegas to AH
33851
Fluegas to ESP
33851
968
Lime Slurry
184130 374455 374455 80 14.7 0.000 184130 80 14.7 0.000
4014743 4205743 33851 33851 4048594 4239594 706 14.6 161.831 311 14.3 57.924
4205743 4205743 33851 33851 311 14.7 57.750 4205743 4205743 311 14.2 57.924 325 15.0 61.384 14003 270067 80 14.7 0.000 42884 88863 136 14.7 14.116
4390042 4390042 136 14.7 14.543
887885 887885 80 14.7 0.000
887885 887885 92 15.6 2.899
493308 493308 92 15.6 2.899
Temperature (Deg F) Pressure (Psia) hsensible (Btu/lbm) Chemical (106 Sensible (106 Latent(106 Total Energy(1) (106
Btu/hr) 4228.715 Btu/hr) 0.000 Btu/hr) 0.000 Btu/hr) 4228.715
0.000 2.475 2.475
655.007 240.291 895.298
245.567 242.858 488.425
1.955 0.000 1.955
243.612 242.858 486.470
258.166 242.858 501.024
0.000 0.000 0.000
3.314 0.000 3.314
63.916 464.020 527.936
0.000 11.933 11.933
2.574 11.933 14.507
1.430 6.630 8.060
Constituent O2 N2 H2O CO2 SO2 H2 Carbon Sulfur Ca Mg MgO MgSO3 MgSO4 CaSO3 CaSO4 CaCO3 Ash / Inerts Total Gas Total Solids Total Flow
(Units) (Lbm/hr) " " " " " " " " " " " " " " " " (Lbm/hr) " "
14 43720 144835 2445
15 90319 299208 5051
16 66680 220899 3729
17 156999 520107 8779
18 183585 524975 46599
19 20 641283 641283 2124443 2124443 35860 35860
21 641283 2124443 35860
22 643801 2132785 36001
23
24
25
26
16102 236655 10110
42313
8463
Bottom Ash CO2 to Comp CO2 Product Vent Stream
191000 191000 92 15.6 2.899
394577 394577 92 15.6 2.899
291308 291308 666 15.6 145.249
685885 685885 339 15.6 63.358 1060340
2801587 2801587 2801587 2801587 80 14.7 0.000 86.4 15.2 1.549
2801587 2801587 86.4 15.1 1.549
2812587 2812587 616 14.9 132.582 8463 8463 2000 14.7 480.000
Temperature (Deg F) Pressure (Psia) hsensible (Btu/lbm) Chemical (106 Sensible (106 Latent(106 Total Energy(1) (106 Btu/hr) Btu/hr) Btu/hr) Btu/hr)
15.0
0.554 2.567 3.121
1.144 5.303 6.447
42.312 3.915 46.227
4228.715 43.456 9.218 52.674 4281.389
0.000 37.653 37.653
4.341 37.653 41.994
4.341 37.653 41.994
372.898 37.801 410.699
4.062 0.000 4.062
ALSTOM Power Inc.
92
June 30, 2001
Boiler efficiency is calculated to be 88.13 percent, the same as for the Base Case and Case A. The net plant heat rate is increased significantly to 15,223 Btu/kwhr for this case as shown in Table 3.4.2 which also includes the Base Case for comparison. The plant thermal efficiency for Case C (22.42%) is about 64 percent of the Base Case value (35.01%). Auxiliary power is increased to 95,317 kW and the net plant output is reduced to 335,973 kw. Fuel heat input to the overall system is increased by about 21 percent as compared to the Base Case due to the natural gas consumption of the de-oxy system. The fuel heat input to the boiler is the same as in the Base Case and Concept A. Carbon dioxide emissions are 92,153 lbm/hr or about 0.274 lbm/kWh which is about 13.7% of the Base Case value. Table 3.4. 2: Overall Plant Performance Summary for Concept C
Original Concept C Plant (Base) MEA-MDEA 4228.7 --4228.7 4228.7 885.9 5114.6
(units)
Fuel Paramaters
6 6 6

463478 0 463478 29700 433778
357196 36343 431290 95317 335973

0.3501 0.3666 1.0000 9749 9309
0.2242 0.2371 0.6404 15223 14395

866102 1.997 1.000 --0.906 ---
92153 0.274 0.137 1.722 0.125 0.782
3.4.2
Boiler Analysis
The existing boiler system performance in Case C is identical to that of the Base Case described previously in Section 2.3 and will not be repeated here. 3.4.3 Steam Cycle Modifications and Performance
The steam cycle system for Concept C is modified as shown in Figure 3.4.2. Figure 3.4.3 shows the associated Mollier diagram for this system. About 45 percent of the IP turbine exhaust is extracted from the IP/LP crossover pipe. This steam is expanded to about 65 psia through a new letdown steam turbine generating 36,343 kw. The exhaust from the letdown turbine, at about 478 oF, is de-superheated and then provides most of the heat requirement for solvent regeneration in the re-boilers of the MEA/MDEA CO2 removal system. The condensate leaving the reboilers is split. About 20 percent of the condensate provides feedwater for the de-oxy system heat recovery steam generator system. The remainder is pumped to the Deaerator of the existing steam cycle. High temperature heat
ALSTOM Power Inc
93
June 30, 2001
recovery is provided in the de-oxy by the generation of high pressure superheated steam. This steam is then expanded through a second new steam turbine for additional power generation. This turbine generates 37,751 kw. The exhaust from this turbine provides about 20 percent of the feed for the re-boilers of the MEA/MDEA system. Low temperature heat recovery is provided in the de-oxy system with a low pressure feedwater heater which is located in a feedwater stream which is in parallel with the three existing low pressure extraction feedwater heaters. This heat exchanger is located in the gas stream leaving the gas to gas heat exchanger. About 92 percent of the low-pressure feedwater leaving the main condenser flows through this new heat exchanger with the remainder flowing through the existing extraction feedwater heaters. The modified existing steam cycle system produces 357,196 kw. The total output from the modified steam cycle is 431,290 kw. This represents a gross output reduction of 32,188 kW (about 7%) as compared to the Base Case.
1209 Deg F Hot Fluegas from De-oxy System Catalytic Burner (DA-301) New HRSG
1800 psia 1100 Deg F 383590 lbm/hr

New HP Turbine
74,094 kw
New Generator
New Letdown Turbine
1133173 lbm/hr 195.0 psia 716 Deg F
Superheater (EA-303)
2853607 lbm/hr 338 Reboiler Steam 478 Deg F New Flow Control Valve From RHTR 3131619 lbm/hr 1396431 lbm/hr De-Superheater Cooled Fluegas to De-oxy System Gas/Gas Hx (EA-301) 840 Deg F MEA /MDEA System Reboiler (EA-2201) COND SCAH 1133173 lbm/hr 64.7 psia 293 Deg F Condensate Return Pump To Boiler De-Sh Spray DEA To Boiler ECON To RHTR 65 psia 298 Deg F 111.9 psia
Evaporator (EA-304)
Deg F
From SHTR
Existing Generator
357,196 kw
Boiler Feed Pump (GA-2204)
840504 lbm/hr 108.9 Deg F 198 Deg F 358 Deg F
Boiler Feed Pump Cooled Fluegas from De-oxy System Feedgas Preheater (EA-301)
ABB LGI Scope Steam Cycle Energy Balance

Energy Outputs
Cooled Fluegas to De-oxy System Cooler (DA-2101) and Amine System
De-oxy System LT-ECON (EA-305)
378 Deg F
(10 Btu/hr) 1496 0 1503 1412

Total Energy Output
Energy Inputs
(10 Btu/hr) 3707 703 1 4412 0
Steam Turbine Power Output (Existing and New Turbines) Steam Coil Air Heater Heat Output MEA / MDEA System Reboiler Heat Output Condenser Heat Loss
Boiler Heat Input De-Oxy System Heat Recovery Condensate Pump

4411
Figure 3.4. 2:
Modified Steam Cycle Diagram and Performance for Concept C
ALSTOM Power Inc.
94
June 30, 2001
1600.0 1500.0 1400.0 1300.0 1200.0 1100.0
New De-Oxy Ststem Turbine New Letdown Turbine
New Flow Control Valve
Reboiler
1000.0 900.0 800.0 1.000 1.500 2.000 2.500 Entropy (Btu/lbm-F)
10% Moisture Condenser Pressure De-Oxy Steam Cycle
Saturation Line Steam Cycle
Figure 3.4. 3: 3.4.4
Modified Steam Cycle Mollier Diagram for Concept C
The Flue Gas Desulfurization System performance in Case C is identical to that of the Base Case described previously in Section 2.3.5 and will not be repeated here. Table 3.4.3 identifies the assumptions that were made in predicting the FGD performance. Table 3.4.4 shows the gas constituents at the existing Absorber inlet and outlet locations. Results show a CO2/SO2 mole ratio of 63 and an SO2 removal efficiency of 94.8%, corresponding to a value of 104 vppm at the outlet of the absorber. Table 3.4. 3: FGD Assumptions
Quantity Ca/S) Solids CaO MgO Inerts
Concept C (MEA/MDEA) Unit Existing Absorber Mol Ratio Wt.% Wt.% Wt.% Wt.% Wt.% gpm/1000 acfm % % 1.04 20 90 5 5 2.5 55 94.8 97.2
Bypass Leakage Liquid/Gas (L/G) Ratio SO2 Removal Efficiency APC Absorber
ALSTOM Power Inc.
95
June 30, 2001
Table 3.4. 4:
FGD Performance
Concept C (MEA/MDEA) Existing Absorber Inlet Existing Absorber Outlet Mol/hr Vol.% Unit Mol/hr Vol.% Unit 4,469 105,018 12,863 19,743 315 3.14 73.74 9.03 13.86 2,212 Vol.% Vol.% Vol.% Vol.% vppm 4,461 105,018 24,228 19,720 16 2.91 68.44 15.79 12.85 104 94.9 63 Vol.% Vol.% Vol.% Vol.% vppm
3.4.5
Carbon Dioxide Separation and Compression System
One important aspect of this project was to evaluate a new technology to separate the CO2 with the intent of finding a more cost-effective process. Initially triethanolamine (TEA) was proposed for the solvent due to its low energy requirement to remove the absorbed CO2. Preliminary calculations made on TEA showed that it had poor performance removing CO2 at atmospheric pressure. Calculations made on compressing the flue gas stream in order to use TEA showed that energy requirements were excessive and that a different solvent should be found. The result was that a 10/25-weight % mixture of monoethanolamine (MEA) and methyldiethanolamine (MDEA) was to be employed. This combination has the benefit of the low energy requirement for CO2 stripping of a tertiary amine with the aggressiveness to capture CO2 at atmospheric pressure of MEA. The energy requirement for the removal of CO2 (about 3.4x106 Btu per ton of CO2) is about 72% of what was required for Concept A with MEA. However, MDEA lacked both oxygen resistance and SO2 resistance. Thus a process had to be developed to reduce both of these components to very low levels. Burner manufacturers, Corporate Development Labs, and Catalyst Vendors were contacted. In the end only one catalyst vendor was willing to put forth the resources to demonstrate that they could meet our process requirements. CRI Catalyst, affiliated with the Shell Oil Company, modified their NOx reduction catalyst to create a low-pressure drop surface to promote the reaction between the excess oxygen present in the flue gas and natural gas added to the mixture. In reality the bench tests were done with ethylene instead of natural gas due to availability at the testing facility. However, identical results for oxygen removal (to below 100 ppmv) with natural gas were promised by CRI. The resulting process, reflected in the following pages, shows the most thermally efficient process to get the flue gas heated above its minimum inlet temperature, 550 oF, by the use of a feed/effluent exchanger. 3.4.5.1 Process Description The numbering practice for Concept C is the same as for Concept A. The process description for the amine absorption and stripping in Concept C is essentially the same as of Concept A except that Concept C uses a less energy intensive amine than Concept A. Thus the reboiler duty will be less per unit of CO2 absorption. Also prior to selecting which amine was to be used for Concept C, it was decided to remove essentially all of the oxygen in the flue gas stream. Tertiary amines cannot tolerate oxygen and form oxalic, acetic, propionic, glycolic, and formic acids, which are corrosive. Thus, there will be no chemical injection package for Concept C. Besides the process differences, the oxygen removal steps have an impact on the material balance. The de-oxy catalyst reactor enables the injection of methane to combine with the 2.94% of the flue gas stream that is oxygen. The process of combusting methane creates 11 % more CO2 than in Concept A and also requires the addition of additional heat recovery equipment. The hydraulics of the equipment sized in Concept A were such that this volume of gas can be tolerated in the same size
ALSTOM Power Inc.
96
June 30, 2001
equipment. The hydraulics in this Concept are also helped by the fact that there is less liquid circulation required due to the higher amine concentration. Thus the process flow for Concept C proceeds as follows: Flue Gas De-Oxygenation and Cooling Systems: Please refer to Figures 3.4.4 and 3.4.5 (drawings D 09484-01006R-0; D 09484-01007R-0) Flue gas supplied from the existing Flue Gas Desulfurizer (FGD) is at 14.7 psia and 136 F. It goes through the Flue Gas Blower, GB-301 where it is boosted by 2.4 psi which increases its temperature to 173 F. The flue gas is then delivered to the Bottom Direct Contact Cooler DA-2103 to be cooled to 140 F. The heat from this process stream goes to the new cooling tower. This is done because the flow to one train is at the maximum capacity of the largest skid built by the Flue Gas Scrubber manufacturer with which there is the most experience. The gas then proceeds to Flue Gas Scrubber, D-301X, a two stage scrubbing system. The active component of the scrubbing solution is sodium sulfite, which reacts with sulfur dioxide to form sodium bisulfite. The resulting bisulfite is converted sodium sulfite with make-up caustic prior to recirculation to the scrubber. It is also equipped with a pressure control damper that maintains a constant inlet pressure to the scrubber. The scrubbing liquid used in this stage is fed to a common manifold that feeds the quench and the first stage of scrubbing. Flue gas traverses through the two-stage scrubber. The first stage includes three baffles and a Chevron type mist eliminator. In the second stage, three more baffles are encountered and scrubbing with sodium sulfite is introduced at a constant pH. The liquid level controller is used to control blowdown from the second stage to the first stage. Each section has separate pH controllers for caustic addition. The water spray in spray washing the mist eliminators also serves as make-up. The purpose of this equipment is to reduce the inlet SO2 level from 108 ppmv down to 1 ppmv. The gas then flows to a feed/ effluent exchanger, EA-301, where it exchanges heat with the de-oxy catalyst reactor effluent. Next the gas proceeds to a mixing chamber where the stochiometric quantity of natural gas required for the complete combustion of the oxygen is flow ratio controlled into the flue gas stream. A temperature of 628 F is sufficient to start the reaction with the natural gas. The heat from the exothermic reaction is not available until the reaction has been established, so a start-up heater is also required. This heater, FH-302 is placed in series with the feed/ effluent exchanger, but it is normally turned off. It has 33 % of the duty of the feed/ effluent exchanger and is designed to initially heat the reactors using 33% of the design flow rate. The other 67 % of the flow continues to flow up the stack until the reactors reach operating temperature. However, as the gas leaving the de-oxy catalyst reactor increases in temperature as the reactors absorb the heat from the start-up heater, a larger gas flow can be put through the heater. Note that during the start-up mode natural gas is not mixed in with the flue gas. All of the piping downstream of the feed/effluent exchanger through the start-up heater and reactor loop back to the other side of the feed effluent exchanger is refractory lined. The De-oxy Catalyst Reactor, DA-301, is refractory lined also. It is actually two reactors in parallel. This reactor is in a vertical orientation and contains two catalyst beds, each 5 feet deep, which create a pressure drop of 0.5 psi for each reactor vessel. The flow goes into the middle of each reactor and is split into to 50% streams by having symmetrical external piping and identical internals in the reactors. Half of the flow goes through the upper bed and half of the flow goes through the lower bed. The catalyst is a hollow cylinder 6-mm OD x 2.5-mm ID x 6-mm long. The de-oxygenated flue gas exits the reactor at 1209 F. The outlet of the exchanger is cooled back to 840F in the EA-303 and EA-304, Reactor Effluent/ Steam Superheater & Steam Generator, respectively. These heat exchangers are similar to a Heat Recovery Steam Generator (HRSG) type heat exchanger and only have about 6 inches of water pressure drop. The pressure of the steam generated is 1800 psia due to the desire to generate power. The effluent from the steam turbine, which drives the generator, provides part of the reboiler steam for solvent regeneration in the amine stripper. The flow passes from the steam generating heat exchangers to the Feed/ Effluent Exchanger, EA-301, where it cools by exchanging heat with the flue gas coming from the Flue Gas Scrubber. The effluent outlet temperature from EA-301supplies 42.4 MM-Btu/h heat to preheat the boiler feed water in each of the five trains. This heat is used to preheat low-pressure feedwater before supplying the power plant deaerator. The heat exchange takes place in the Dry Flue Gas Cooler EA-305. The gas is further cooled in Direct Contact Cooler (DCC) Flue Gas Cooler DA-2101. From the DCC cooler the gas then continues on to the CO2 Absorber. The DCC Flue Gas Cooler DA-2101 is a packed column where the hot flue gas flowing up is brought into an intimate contact with cold water which is fed to the top of the bed and flows down the tower. Physically, DA-2101, DA-2102,
ALSTOM Power Inc.
97
June 30, 2001
and DA-2103 have been combined into a single, albeit compartmentalized tower. DA-2103 is the bottom one and will be designed to support the top portion of this column. However, since there is intervening equipment between this equipment and the DCC Flue Gas cooler, DA-2101, the top head must have an outlet nozzle added to it so that the outlet pipe can exist through the section of skirt between these two vessel sections. The top of the DCC Flue Gas Cooler is configured differently. Since the flow from it proceeds directly to the amine absorption section above it, the top head of this section serves as the bottom head for the CO2 Absorber. Effectively, this dividing head acts as a chimney tray with a number of upward extending chimneys which provide passages so the flue gas may flow directly from the DCC into the Absorber. Theoretically, a direct contact cooler is capable of cooling the gas to a very close approach in a short bed. When the hot gas enters the DCC, it contains water but is highly superheated. At the bottom end of the bed, the gas quickly cools down to a temperature called the Adiabatic Saturation Temperature (AST). The AST is the temperature the gas reaches when some of its own heat content has been used to vaporize just the exact amount of water to saturate the gas. Up to the point when the AST is reached, the mass flow of the gas stream increases due to evaporation of water. At the AST, water begins to condense. And, as the gas travels up the column and cools down further, more and more water is condensed. This internal refluxing increases the V/L traffic at the bottom end of the bed significantly beyond the external flows and must be considered in the hydraulic design. The water stream which leaves the bottom of the DCC contains the water fed to the top as well as any water which has condensed out of the flue gas. The condensed water may be somewhat corrosive due to sulfur and nitrogen oxides that may be present in the flue gas. Therefore, instead of using the condensate in the process, it will be blown down from the system. For the DCC to be effective, the temperature of the leaving water must always be lower than the AST. DCC Water Pump GA-2102A/B circulates most of the water leaving the bottom of the DCC back to the top of the direct contact cooler. However, before sending it back to the column the water stream is first filtered in DCC Water Filter FD-2101 and then cooled in DCC Water Cooler EA-2101. The source of this cooling water is the new cooling tower. Temperature of the cooled water is controlled by a cascade loop which maintains a constant flue gas exit temperature (Absorber feed temperature). The circulating water is cooled to 95 oF, which in turn, easily cools the gas to 115 oF. Filtration is necessary to remove any particulate matter that may enter the DCC in the flue gas. The blowdown is taken out after the filter but before the cooler and mixed into the return water of cooler EA-2101. This way the cooler does not have to handle the extra duty that would otherwise be imposed by the blowdown. The process description of all other equipment (CO2 absorption, solvent stripping, and CO2 compression and liquefaction) is essentially the same as in Concept A and will not be repeated here. Refer to Section 3.2.5.2 for the process description of this equipment. One small exception to note is a difference in the lean amine cooling. In Concept C the lean amine is cooled in two steps against cooling water downstream of the lean-rich exchanger. The warmest cooling water exchanger (EA-2208) is fed from the new cooling tower. The final cooler (EA-2202) is fed from the existing plant cooling tower. The solvent stripper CW condenser (EA-2206) also gets water from the existing plant cooling tower. Another exception for Concept C is the lean and rich amine loading. For Concept C the loadings are 0.148 mole CO2/mole of amine and 0.445 mole CO2/mole of amine for the lean and rich streams respectively. Please refer to Figures 3.4.6 and 3.4.7 (drawings D 09484-01008R-0; D 09484-01009R-0) for process flow diagrams of these systems for Concept C. 3.4.5.2 Process Flow Diagrams: The processes described above for Concept C are illustrated in the following Process Flow Diagrams. Figure 3.4.4: Drawing D 09484-01006R-0: De-Oxy System Figure 3.4.5: Drawing D 09484-01007R-0: Flue Gas Cooling and Absorption Figure 3.4.6: Drawing D 09484-01008R-0: Solvent Stripping Figure 3.4.7: Drawing D 09484-01009R-0: CO2 Compression and Liquefaction
ALSTOM Power Inc.
98
June 30, 2001
Figure 3.4. 4:
De-Oxy System Process Flow Diagram for Concept C
ALSTOM Power Inc.
99
June 30, 2001
Figure 3.4. 5:
Flue Gas Cooling and Absorption System Process Flow Diagram for Concept C
ALSTOM Power Inc
100
June 30, 2001
Figure 3.4. 6:
Solvent Stripping System Process Flow Diagram for Concept C
ALSTOM Power Inc
101
June 30, 2001
Figure 3.4. 7:
CO2 Compression and Liquefaction System Process Flow Diagram for Concept C
ALSTOM Power Inc.
102
June 30, 2001
3.4.5.3 Overall Material and Energy Balance This section contains energy and material balances for the CO2 capture system for Concept C. Table 3.4. 5:
STREAM NAME STREAM NO. VAPOR FRACTION TEMPERATURE PRESSURE MOLAR FLOW RATE MASS FLOW RATE ENERGY COMPOSITON Methane Oxygen Nitrogen H2O CO2 SO2 SO3 VAPOR MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW MOLECULAR WEIGHT DENSITY VISCOSITY LbMol/Hr Lb/Hr MMSCFD ACFM MW 3 Lb/Ft cP 153,440.0 4,390,041 1,397.55 1,109,800.0 28.61 0.07 0.0173 30,688.0 878,008 279.51 221,960.00 28.61 0.07 0.0173 30,688.0 878,008 279.51 203,080.00 28.61 0.07 0.0184 30,688.0 878,008 279.51 193,174.00 28.61 0.08 0.0175 30,686.0 877,796 279.48 196,044.00 28.61 0.07 0.0175 30,686.0 877,796 279.48 359,640.00 28.61 0.04 0.0281 451.8 7,248 4.11 2,620.60 16.04 0.05 0.0113 31,138.0 885,044 283.59 361,460.00 28.42 0.04 0.0277 31,138.0 885,042 283.59 577,460.00 28.42 0.03 0.0379 #N/A #N/A #N/A #N/A #N/A #N/A #N/A Molar F PSIG LbMol/Hr Lb/Hr Btu/Hr Mol %
Flue gas from power plant
De-Oxy System Material and Energy Balance for Concept C

Flue gas to train A deoxygenation Flue gas from Flue gas from Flue gas to Flue gas from feed/ effluent booster blower desulfurization desulfurization exchanger Methane for first deoxo reactor First de-oxo reactor inlet First de-oxo reactor outlet
201A 1.000 136 0 153,440.00 4,390,041 6.60E+08 0.00% 2.94% 68.45% 15.77% 12.83% 0.01% 0.00%
201 1.000 136 0 30,688.00 878,008 1.32E+08 0.00% 2.94% 68.45% 15.77% 12.83% 0.01% 0.00%
202 1.000 173 2 30,688.00 878,008 1.41E+08 0.00% 2.94% 68.45% 15.77% 12.83% 0.01% 0.00%
203 1.000 140 2 30,688.00 878,008 1.33E+08 0.00% 2.94% 68.45% 15.77% 12.83% 0.01% 0.00%
204 1.000 140 2 30,686.00 877,796 1.33E+08 0.00% 2.94% 68.45% 15.77% 12.83% 0.00% 0.00%
205 1.000 628 2 30,686.00 877,796 2.48E+08 0.00% 2.94% 68.45% 15.77% 12.83% 0.00% 0.00%
214 1.000 80 2 451.80 7,248 1.96E+06 100.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
206 1.000 618 2 31,138.00 885,044 2.50E+08 1.45% 2.90% 67.46% 15.55% 12.64% 0.00% 0.00%
207 1.000 1,209 1 31,138.00 885,042 4.06E+08 0.00% 0.01% 67.46% 18.44% 14.09% 0.00% 0.00%
215 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
STREAM NAME STREAM NO. VAPOR FRACTION TEMPERATURE PRESSURE MOLAR FLOW RATE MASS FLOW RATE ENERGY COMPOSITON Methane Oxygen Nitrogen H2O CO2 SO2 SO3 VAPOR MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW MOLECULAR WEIGHT DENSITY VISCOSITY LbMol/Hr Lb/Hr MMSCFD ACFM MW Lb/Ft
3
From reactor effluent cooling
Effluent from De-oxygenated High pressure feed/ effluent flue gas to BFW to steam exchanger amine generator
Superheated steam from steam superheater
Condensate to Dry Gas Cooler
Hot condensate from dry gas cooler
208 Molar F PSIG LbMol/Hr Lb/Hr Btu/Hr Mol % #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
210 1.000 840 1 31,138.00 885,046 3.08E+08 0.01% 0.01% 67.46% 18.44% 14.09% 0.00% 0.00% 31,138.0 885,046 283.60 455,320.00 28.42 0.03 0.0314
211 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
212 1.000 378 1 31,138.00 885,046 1.92E+08 0.00% 0.01% 67.46% 18.44% 14.09% 0.00% 0.00% 31,138.0 885,046 283.60 299,000.00 28.42 0.05 0.0229
213 1.000 200 1 31,138.00 885,046 1.50E+08 0.00% 0.01% 67.46% 18.44% 14.09% 0.00% 0.00% 31,138.0 885,046 283.60 236,160.00 28.42 0.06 0.0186
216 0.000 297 1,785 4,300.00 77,465 -4.56E+07 0.00% 0.00% 0.00% 100.00% 0.00% 0.00% 0.00% -
218 1.000 1,102 1,785 4,300.00 77,465 5.25E+07 0.00% 0.00% 0.00% 100.00% 0.00% 0.00% 0.00% 4,300.0 77,465 39.16 620.17 18.02 2.08 0.0335
219 0.000 109 195 9,224.09 166,173 -1.31E+08 0.00% 0.00% 0.00% 100.00% 0.00% 0.00% 0.00% -
220 0.000 350 192 9,224.09 166,173 -8.87E+07 0.00% 0.00% 0.00% 100.00% 0.00% 0.00% 0.00% -
cP
ALSTOM Power Inc
103
June 30, 2001
Table 3.4. 6:
STREAM NAME STREAM NO. LIQUID FRACTION TEMPERATURE PRESSURE COMPONENTS CO2 (Carbon Dioxi MEA MDEA H2O (Water) C1 (Methane) N2 (Nitrogen) O2 (Oxygen) Total Molar Flow VAPOR MASS FLOW RATE STD. VOL. FLOW RATE ACTUAL VOL. FLOW RATE MOLECULAR WEIGHT STD. DENSITY GAS COMPRESSIBILITY VISCOSITY HEAT CAPACITY THERMAL CONDUCTIVITY LIQUID MASS FLOW RATE STD. VOL. FLOW RATE ACTUAL VOL. FLOW MOLECULAR WEIGHT STD. DENSITY VISCOSITY HEAT CAPACITY THERMAL CONDUCTIVITY Lb/Hr GPM GPM MW Lb/Ft
3
Amine System Material and Energy Balance for Concept C

Lean Amine from Stripping Section Primary Rich Amines from Rich Amine from Absorber A Total LeanAmines Feed Absorber A Absorption Section Treated Gas toAbsorber A Rich Aminesto Lean/Rich Heat Exchanger Rich Aminesfrom RegeneratorOverh RegeneratorCond Lean/RichHeat ead Vapor enser Outlet Exchanger
Gas Feed to Absorber A
213 0.000 F PSIA LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr Lb/Hr MMSCFD MMACFD MW Lb/Ft
3
6 1.000 105 14.9 9,889.26 29,344.65 37,607.29 646,705 0.00 0.00 0.00 723,546
5 1.000 105 14.9 1,977.85 5,868.93 7,521.46 129,341 0 0 0 144,709
8 1.000 137 15.8 5,953.08 5,867.05 7,521.38 130082 0 1 0 149424
9A 1.000 137 15.8 29,765.42 29,335.26 37,606.91 650,410 0.00 4.81 0.00 747,122
12 0.000 109 14.9 408.61 1.88 0.08 1,738.26 1.54 21,004.70 3.09 23,158.16 2,365,819 210.92 227.42 55.0962 0.1346 1.999 0.0356 0.5038 0.0298
9 1.000 137 15.6 3,307.27 3,259.47 4,178.54 72,267.71 0.00 0.58 0.00 83,013.58
35 0.989 201 15.6 3,307.27 3,259.47 4,178.54 72,267.71 0.00 0.58 0.00 83,013.58
36 0.000 211 26.0 2,207.25 6.71 0.41 2,345.92 0.00 0.58 0.00 4,560.86 236,573 41.5444444 30.0666667 34.0783333 0.123 1.10211111 0.01822222 0.29622222 0.0157
37 1.000 105 23.0 2,207.25 6.71 0.41 2,345.92 0.00 0.58 0.00 4,560.86
115 15.5 4,383.84 0.00 0.00 2,479.20 1.54 21,005.66 3.09 27,873.34 3,152,095 253.86 265.88 59.28 0.149 1.9978 0.035 0.4922 0.0284
183,618,326 35184.1 35498.9 25.3776 65.0654 1443.164 1.3621 0.8545
7,344,733 7036.82 7099.78 25.3776 65.0654 1443.164 1.3621 0.8545
7721129 7169.36 7296.84 25.8363 67.1353 4263.43 0.9361 0.838
193,028,218 35846.8 36484.2 25.8363 67.1353 4263.43 0.9361 0.838
2,383,064 4053.8 25.8363 67.1353 4263.431 0.9361 0.838
2,383,064 4152.81111 25.8363 67.1353 4263.431 0.5233 0.8554
155,429 279.655556 281.522222 30.6705 62.3637 40525.96 0.6489 0.4488
3982.97778 3982.97778
STREAM NO. LIQUID FRACTION TEMPERATURE PRESSURE COMPONENTS CO2 (Carbon Dioxi MEA MDEA H2O (Water) C1 (Methane) N2 (Nitrogen) O2 (Oxygen) Total Molar Flow VAPOR MASS FLOW RATE STD. VOL. FLOW RATE ACTUAL VOL. FLOW RATE MOLECULAR WEIGHT STD. DENSITY GAS COMPRESSIBILITY VISCOSITY HEAT CAPACITY THERMAL CONDUCTIVITY LIQUID MASS FLOW RATE STD. VOL. FLOW RATE ACTUAL VOL. FLOW MOLECULAR WEIGHT STD. DENSITY VISCOSITY HEAT CAPACITY THERMAL CONDUCTIVITY Lb/Hr GPM GPM MW Lb/Ft
3
38 0.000 F PSIA LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr LbMol/Hr Lb/Hr MMSCFD MMACFD MW Lb/Ft
3
50 0.000 105 23.0 19,853.09 0.07 0.00 1,010.61 0.00 5.23 0.00 20,868.99 128475917 190.10 130.90 427.47 1.6220 9.9230 0.1570 2.1450 0.1030
39 1.000 105 23.0 1.40 6.70 0.41 2,233.58 0.00 0.00 0.00 2,242.09
41 1.000 248 29.8 1,852.30 3,291.65 4,180.89 80,554.30 0.00 0.00 0.00 89,879.13
42 0.000 250 30.0 750.93 32.18 2.35 8,398.87 0.00 0.00 0.00 9,184.33 344216 83.64 55.18 22.58 0.0889 1.0958 0.0162 0.3553 0.0171
43 1.000 250 30.0 1,101.37 3,259.46 4,178.54 72,155.42 0.00 0.00 0.00 80,694.80
21 1.000 177 30.0 1,101.37 3,259.46 4,178.54 72,155.42 0.00 0.00 0.00 80,694.80
47 1.000 68 30.0 0.00 1.05 0.04 (299.34) 0.00 0.00 0.00 (298.25)
47 1.000 105 14.9 1,098.81 3,260.52 4,178.59 71,856.12 0.00 0.00 0.00 80,394.03
105 23.0 2,205.90 0.01 0.00 112.29 0.00 0.58 0.00 2,318.78 176236 21.12 14.54 47.50 0.1802 1.1026 0.0174 0.2383 0.0114
45295 79.73 80.26 18.18 63.7434 90.1959 0.6638 0.9903
2480296 4239.72 4521.07 24.84 65.6431 2243.225 0.3745 0.8891
2272931 3919.88 4189.88 25.35 65.0634 1442.643 0.3776 0.8918
2272931 3919.88 4050.54 25.35 65.0634 1442.643 0.613 0.8799
-5917 -10.66 -10.66 17.85 62.3123 0 0.9817 0.9826
2266893 3909.34 3944.32 25.38 65.0654 1443.164 1.3621 0.8545
ALSTOM Power Inc.
104
June 30, 2001
Table 3.4. 7:
STREAM NAME STREAM NO. VAPOR FRACTION TEMPERATURE PRESSURE MOLAR FLOW RATE MASS FLOW RATE ENERGY COMPOSITON CO2 H2O Nitrogen Ammonia Propane VAPOR MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW MOLECULAR WEIGHT DENSITY VISCOSITY HYDROCARBON LIQUID MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW DENSITY MOLECULAR WEIGHT VISCOSITY SURFACE TENSION
CO2 Compression and Liquefaction System Material and Energy Balance for Concept C
Total acid gas from strippers To train A liquefaction First stage discharge To second stage First stage water KO 2nd stage discharge To 3rd stage 2nd stage water KO From 3rd stage To drier 3rd stage water KO
50 Molar F PSIG LbMol/Hr Lb/Hr Btu/Hr Mol % 95.13% 4.84% 0.03% 0.00% 0.00% 1.000 105 4 20,642.53 882,394 9.22E+07
300 1.000 105 4 2,948.93 126,056 1.32E+07 95.13% 4.84% 0.03% 0.00% 0.00%
301 1.000 230 25 2,948.93 126,056 1.66E+07 95.13% 4.84% 0.03% 0.00% 0.00%
302 1.000 95 19 2,877.78 124,773 1.25E+07 97.48% 2.49% 0.03% 0.00% 0.00%
310 0.000 95 19 71.16 1,283 -1.03E+06 0.09% 99.91% 0.00% 0.00% 0.00%
303 1.000 236 62 2,877.78 124,773 1.63E+07 97.48% 2.49% 0.03% 0.00% 0.00%
304 1.000 95 56 2,840.86 124,106 1.22E+07 98.74% 1.23% 0.03% 0.00% 0.00%
309 0.000 95 56 36.92 667 -5.34E+05 0.18% 99.82% 0.00% 0.00% 0.00%
306 1.000 282 191 2,840.86 124,106 1.72E+07 98.74% 1.23% 0.03% 0.00% 0.00%
305 1.000 90 185 2,817.85 123,688 1.16E+07 99.55% 0.42% 0.03% 0.00% 0.00%
314 0.000 90 185 23.01 418 -3.33E+05 0.54% 99.46% 0.00% 0.00% 0.00%
LbMol/Hr Lb/Hr MMSCFD MW Lb/Ft

3
20,642.5 882,394 188.00 42.75 0.13 0.0149 -
2,948.9 126,056 26.86 15,570.65 42.75 0.13 0.0149 -
2,948.9 126,056 26.86 9,177.60 42.75 0.23 0.0187 -
2,877.8 124,773 26.21 8,457.57 43.36 0.25 0.0149 -
2,877.8 124,773 26.21 4,633.12 43.36 0.45 0.0193 -
2,840.9 124,106 25.87 3,910.14 43.69 0.53 0.0152 -
2,840.9 124,106 25.87 1,781.35 43.69 1.16 0.0212 -
2,817.8 123,688 25.66 1,283.82 43.89 1.61 0.0154 -
ACFM 108,994.53
cP LbMol/Hr Lb/Hr BPD GPM Lb/Ft

3
MW cP Dyne/Cm
STREAM NAME STREAM NO. VAPOR FRACTION TEMPERATURE PRESSURE MOLAR FLOW RATE MASS FLOW RATE ENERGY COMPOSITON CO2 H2O Nitrogen Ammonia Propane VAPOR MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW MOLECULAR WEIGHT DENSITY VISCOSITY HYDROCARBON LIQUID MOLAR FLOW RATE MASS FLOW RATE STD VOL. FLOW ACTUAL VOL. FLOW DENSITY MOLECULAR WEIGHT VISCOSITY SURFACE TENSION LbMol/Hr Lb/Hr BPD GPM Lb/Ft
3
From drier/ To condenser
Water from drier
From condenser
From product pump
From Train A liquefaction
To pipeline
From refrig condenser
From subcooler
To chiller
From chiller
307 Molar F PSIG LbMol/Hr Lb/Hr Btu/Hr Mol % 99.97% 0.00% 0.03% 0.00% 0.00% 1.000 90 180 2,805.88 123,473 1.15E+07
311 0.726 380 180 11.97 216 2.63E+04 0.00% 100.00% 0.00% 0.00% 0.00%
312 0.000 -26 175 2,805.88 123,473 -8.44E+06 99.97% 0.00% 0.03% 0.00% 0.00%
308 0.000 -11 2,003 2,805.88 123,473 -7.62E+06 99.97% 0.00% 0.03% 0.00% 0.00%
309 0.000 82 2,000 2,805.88 123,473 -1.43E+06 99.97% 0.00% 0.03% 0.00% 0.00%
313 0.000 82 2,000 19,641.16 864,308 -9.99E+06 99.97% 0.00% 0.03% 0.00% 0.00%
400 1.000 149 169 3,071.43 135,441 2.28E+07 0.00% 0.00% 0.00% 0.00% 100.00%
401 0.000 95 162 3,071.43 135,441 8.00E+05 0.00% 0.00% 0.00% 0.00% 100.00%
402 0.000 24 159 3,071.43 135,441 -5.39E+06 0.00% 0.00% 0.00% 0.00% 100.00%
403 0.174 -31 5 3,071.43 135,441 -5.39E+06 0.00% 0.00% 0.00% 0.00% 100.00%
404 0.996 -31 5 3,071.43 135,441 1.46E+07 0.00% 0.00% 0.00% 0.00% 100.00%

3
2,805.9 123,473 25.55 1,314.67 44.01 1.57 0.0155 -
8.7 156 0.08 6.25 18.02 0.42 0.0154 -
2,805.88 123,472.59 10,244 227.86 67.56 44.01 0.1746 16.01
2,805.88 123,472.59 10,244 224.14 68.68 44.01 0.1602 14.00
2,805.88 123,472.59 10,244 303.64 50.70 44.01 0.0621 0.86
19,641.16 864,308.12 71,706 2,125.46 50.70 44.01 0.0621 0.86
3,071.4 135,441 27.97 1,522.13 44.10 1.48 0.0099 -
3,071.43 135,440.78 18,304 567.94 29.73 44.10 0.0906 5.74
3,071.43 135,440.78 18,304 504.18 33.49 44.10 0.1330 10.48
534.9 23,589 4.87 1,964.87 44.10 0.20 0.0065 2,536.49 111,851.67 15,116 389.85 35.77 44.10 0.1823 14.49
3,058.8 134,886 27.86 11,235.55 44.10 0.20 0.0065 12.59 555.16 75 1.94 35.77 44.10 0.1823 14.49
cP
MW cP Dyne/Cm
ALSTOM Power Inc.
105
June 30, 2001
3.4.5.4 Equipment List with Data Equipment data has been presented in the so-called short spec format as shown in Appendix II, which provides adequate data for a factored cost estimate. 3.4.5.5 Consumption of Utilities Consumption of utilities for Concept C is defined in Table 3.4.8. Table 3.4. 8: Utility Natural Gas Steam (180 psig) Cooling water Utility Consumption for Concept C Amount Consumed 21.0 1,130,000 67800 Units MMSCFD Lb/hr Gpm Power (ea) including Number 0.95 Total Operating motor eff all trains per train (kW) (kW) 1 1 1 1 1 3 1 2 1 1 1 1 1 1 1 1 1 NA NA 1 1 10 10 16 19 55 103 10 82 3 12 184 0 148 57 2628 3730 2532 NA NA 166 2972 71 73 109 95 274 1542 48 1473 28 107 1288 0 742 514 13142 26110 17727 NA NA 1160 2972 67477
Number Of Trains 7 7 7 5 5 5 5 9 9 9 7 3 5 9 5 7 7 1 1 7 1
Tag no. EC-2301 EC-2302 EC-2303 GA-2101 A/B GA-2102 A/B GA-2103 A/B/C/D GA-2104 A/B GA-2201A/B/C GA-2202 A/B GA-2203 A/B GA-2301 A/B GA-2501 GA-301 A/B GA-2204 A/B GB-301 GB-2301 GB-2401 GB-2500 GB-2501 PA-2351 PA-2551
Description CO2 compressor 1st stage air cooler CO2 compressor 2nd stage air cooler CO2 compressor 3rd stage air cooler Wash Water Pump Direct Contact Cooler Water Pump Rich Solvent Pump Bottom Direct Contact Cooler Water Pump Lean Solvent Pump Solvent Stripper Reflux Pump Filter Circ. Pump CO2 Pipeline Pump Caustic metering pump HP condensate booster pumps LP condensate booster pump Flue Gas Blower CO2 Compressor (Motor driven) Propane Refrig Compressor LP steam turbine/ generator HP steam turbine/ generator CO2 Drier Package Cooling Tower Total
ALSTOM Power Inc.
106
June 30, 2001
3.4.5.6 Consumption of Chemicals and Desiccants Consumption of Chemicals and Desiccants for Concept C is defined in Table 3.4.9.
Table 3.4. 9:
Chemicals and Desiccants Consumption f or Concept C Consumption per day (lbs.) 25200 700 0 916 282 10300 30
Chemical Caustic (100%) MEA Corrosion inhibitor Diatomaceous earth Molecular sieve Sodium hypochlorite Sodium bisulfite
This total does not include chemicals provided by the cooling tower service people nor disposal of waste. These are handled as a component of operating costs referred to as contracted services and waste handling, respectively. 3.4.5.7 Design Considerations The following parameters were optimized for Concept C with the objective of reducing the overall unit cost and energy requirements. Solvent Concentration Lean Amine Loading Rich Amine Loading Stripper Feed Temperature Absorber Temperature Rich /Lean Exchanger approach CO2 Compressor interstage temperatures CO2 Refrigeration Pressure and Temperature
A minimum of 90% recovery was targeted. The above parameters were adjusted to increase the recovery until a significant increase in equipment size and/ or energy consumption was observed. AES Corporation owns and operates a 200 STPD food grade CO2 production plant in Oklahoma. This plant was designed and built by ABB Lummus Global as a part of the larger power station complex using coal fired boilers. This plant was started up in 1990 and has been operating satisfactorily with lower than designed MEA losses. Table 3.4.10 compares key process parameters for the Concept C design with the AES design.
ALSTOM Power Inc.
107
June 30, 2001
Table 3.4. 10: PROCESS PARAMETER
Key Process Parameters Comparison AEP DESIGN (Concept C) 10372 15.7 100 ppm 1 ppm MEA/ MDEA 10/25 0.15 0.44 201 250 105 90.5 1 0.6 10 105 82 2015 AES DESIGN
PLANT CAPACITY TPD CO2 in Feed, % mol O2 in Feed, % mol SO2 in Feed, % mol SOLVENT SOLVENT CONC. %WT LEAN LOADING RICH LOADING STRIPPER FEED TEMP , F STRIPPER BOTTOM TEMP F FEED TEMP TO ABSORBER, F CO2 RECOVERY % ABSORBER PRESSURE DROP psi STRIPPER PRESSURE DROP psi R/L EXCHANGER APPROACH,F CO2 COMPRESSOR I/STG TEMP F LIQUID CO2 TEMP F LIQUID CO2 PRESSURE psi (A)
200 14.7 3.4 10 PPMV (Max) MEA 15 (Actual 17-18%Wt) 0.10 0.41 194 245 108 90 (ACTUAL 96-97%) 1.4 4.35 50 115 -13 247
3.4.5.8 OSBL Systems Filter Residues: A pressure leaf filter filters a slipstream of lean amine. Diatomaceous earth is used as a filter-aid for pre-coating the leaves and as a body feed. Filter cycles depend on the rate of flow through the filter, the amount of filter aid applied, and the quantity of contaminants in the solvent. A typical composition of the filter residue is provided in Table 3.4.11 below. These will be disposed of by a contracted service hauling away the drums of spent cake.
Table 3.4. 11: MEA
Filter Residue Composition 2.6 wt.% 1.5 wt.% 0.03 wt.% 0.03 wt.% 10.0 1.0
Total Organic Carbon SiO2 Insolubles PH Specific Gravity
Excess Solvent Stripper Reflux Water: The CO2 Recovery Facility has been designed to operate in a manner to avoid accumulation of water in the Absorber / Stripper system. Conversely, a continuous make-up stream of water is not required either. By controlling the temperature of the scrubbed flue gas to the absorber, water balance of the MEA/MDEA system can be kept in check. Excess water can accumulate in the Stripper Reflux Drum and can be reused once the system is corrected to operate in a balanced manner. Should water need to be discarded, contaminants will include CO2 and MEA/MDEA.
ALSTOM Power Inc.
108
June 30, 2001
Secondary Absorber Effluent: The existing plant uses lime in its flue gas desulfurizer. In the cost estimate of this plant, it has been assumed that the existing plant disposal facilities can include the additional load of the secondary absorber (D-301X). Cooling Tower Blowdown: The composition limits on cooling tower blowdown are shown in Table 3.4.12: Table 3.4. 12: Component Suspended Solids pH Oil and Grease Free Chlorine Filter Residue Composition
Specification 30 ppm monthly, 100 ppm daily 6.5 to 9 15 ppm maximum monthly, 20 ppm maximum daily 0.035 ppm
There is a thermal limit specification for the entire river. However, the blowdown volume is too small to affect it significantly. The relief valve discharges from the CO2 Recovery Unit are discharged to atmosphere. No tie-ins to any flare header are necessary. 3.4.5.9 Plant Layout The Concept C Plant Layout Drawings listed below are shown in Appendix I. This equipment requires about 8 acres of plot area. U01-D-0207 Plot Plan Concept C: De-Oxy Catalyst & Cooling U01-D-0210 Plot Plan Concept C: Flue Gas Cooling & CO2 Absorption U01-D-0215 Plot Plan Concept C: Solvent Stripping U01-D-0206 Plot Plan Concept C: CO2 Compression & Liquefaction U01-D-0213 Plot Plan Concept C: Overall Layout Conceptual Plan U01-D-0202R Plot Plan Concept C: Modified Overall Site Plan Plant layout has been designed in accordance with a spacing chart called Oil and Chemical Plant Layout and Spacing Section IM.2.5.2 issued by Industrial Risk Insurers. When discussing layout, the first thing to observe is that no highly flammable materials are handled within the CO2 Recovery Unit. The open cup flash point of MEA is 200 oF and, therefore, will not easily ignite. In addition to MEA, the corrosion inhibitor is the only hydrocarbon liquid within the battery limits. The flash point of this material is higher than that of MEA and is handled in small quantities. As the chemicals used in the process present no fire hazard, there is an opportunity to reduce the minimum spacing between equipment from that normally considered acceptable in hydrocarbon handling plants. Regardless, for the drawings that follow, standard spacing requirements, as imposed by IRI have been followed. The plot area available for the installation of the desired equipment is small. Some equipment items are placed on structures to allow other pieces of equipment to be placed underneath them. This way pumps and other equipment associated with the Absorber can be located under the structure. Locating the pumps under the structure has been considered acceptable because the fluids being pumped are not flammable. Noise is an issue with the flue gas fan as much as it is with compressors. Discussions with vendors suggest that it will be possible to provide insulation on the fan casing to limit noise to acceptable level. Therefore, it has been assumed that no building needs to be provided for noise reasons.
ALSTOM Power Inc.
109
June 30, 2001
Having economized on the required plot space as noted above, it was judged not to be practical to divide up the absorbers and strippers that are required into the plot areas initially offered for this purpose (refer to Section 2.1, Figure 2.1.1). Eventually it was agreed that the units would be placed in the northeast corner of the site, about 1200-ft from the Unit 5/6 stack. By having the units all together, the flue gas duct length and MEA piping between the absorber and stripper could be minimized, although the latter impact is not nearly as important as the flue gas routing. The caustic solution will not freeze but will become very viscous when it gets cold. It will be electric traced. The plot plan shows a substation in the Stripper area but none for the Absorber area. The assumption is that because the electrical consumption of the Absorber equipment is small (0.23 MW) compared to the Stripper equipment, the equipment can be run directly from the auxiliary power 480 volt power system. For the Rich/Lean Solvent Exchanger which is a plate and frame type exchanger, area estimates received from vendors based on similar conditions suggest that five units/ train be sufficient for the specified service.
ALSTOM Power Inc.
110
June 30, 2001
4.0
SUMMARY OF SYSTEMS PERFORMANCE AND CARBON DIOXIDE EMISSIONS
This section summarizes overall system performance and CO2 emissions. Table 4.0.1 shows a comparison of plant performance and emissions for the three CO2 recovery concepts and the Base Case that has no CO2 recovery system. Table 4.0. 1: Overall Plant Performance and CO2 Emissions Comparison
Original Plant (Base)
(units)
Concept A MEA
Concept B O2 Fired
Concept C MEA-MDEA
Boiler Parameters
Main Steam Flow Reheat Steam Flow (to IP turbine) Main Steam Pressure Main Steam Temp Reheat Steam Temp 1 Boiler Efficiency Flue Gas Flow leaving Economizer Flue Gas Temperature leaving Air Heater Coal Heat Input (HHV)
1
(lbm/hr) (lbm/hr) (psia) (Deg F) (Deg F) (percent) (lbm/hr) (Deg F) (10 Btu/hr) (LHV ) (10 Btu/hr)
6 6
(Includes New Oxygen Heater and Parallel FW Heater for Case B)
3131619 2853607 2535 1000 1000 88.13 4014743 311 4228.7 4037.9
3131651 2853607 2535 1000 1000 88.13 4014743 311 4228.7 4037.9
3131651 2808612 2535 1000 1000 90.47 3930554 371 4140.0 3953.2
3131651 2853607 2535 1000 1000 88.13 4014743 311 4228.7 4037.9
CO 2 Removal Steam System Parameters

CO2 Removal System Steam Pressure CO2 Removal System Steam Temp CO2 Removal System Steam Extraction Flow CO2 Removal System Condensate Pressure (from reboilers) CO2 Removal System Condensate Temperature 2 Natural Gas Heat Input (HHV)
2
(psia) (Deg F) (lbm/hr) (psia) (Deg F) 6 (10 Btu/hr) (LHV ) (10 Btu/hr)
6
(Includes Desicant Regeneration Case A,B,C and De-Oxy system for Case C)
---------------
65 478 1935690 64.7 292.7 17.7 16.0
----0 ----11.4 10.3
65 478 1133173 64.7 292.7 885.9 798.4
Steam Cycle Parameters

Total Heat Input to Steam Cycle Existing Condenser Pressure
(10 Btu/hr) (10 Btu/hr) (psia) (lbm/hr) 6 (10 Btu/hr) (kW) (kW) (kW) (kW)
6
Heat Output to CO 2 Removal System Reboilers Existing Condenser Condensate Flow Existing Condenser Heat Loss Existing Steam Turbine Generator Output CO2 Removal System Turbine Generator Output De-Oxy System Turbine Generator Output (Concept C) Total Turbine Generator Output
3
3707.4 --1.23 2617295 2102.8 463478 0 0 463478
3707.4 1953.0 1.23 640768 603.3 269341 62081 0 331422
3745.8 --1.23 2588715 2142.6 463056 0 0 463056
4410.4 1503.0 1.23 1522923 1412.1 357196 36343 37751 431290
(Includes Boiler Heat Output for the Base Case and Case A, Boiler + PFWH for Case B, and Boiler + De-Oxy System Heat Recovery for Case C)
Auxiliary Power Requirements

Condensate Pump Power Condenser Cooling Water Pump Power Boiler Island Auxiliary Power (Fans & Pulverizers) Coal & Ash Handling System FGD & ESP System Auxiliary Power Misc. Auxiliary Power (Lighting, HVAC, Trans, etc) Air Separation Unit Power Reqirement (Case B) CO2 Removal System Auxiliary Power Total Auxiliary Power (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW)
563 5562 7753 1020 8157 6645 0 0 29700
481 1596 7753 1020 8157 6645 0 50355 76007
557 5667 7804 998 7986 6645 95822 64229 189709
530 3735 7753 1020 8157 6645 0 67477 95317
Plant Performance Parameters

Net Plant Output Normalized Net Plant Output (Relative to Base Case) Net Plant Efficiency (HHV) Net Plant Efficiency (LHV) Normalized Efficiency (HHV; Relative to Base Case) Net Plant Heat Rate (HHV) Net Plant Heat Rate (LHV) (kW) (fraction) (fraction) (fraction) (fraction) (Btu/kwhr) (Btu/kwhr)
433778 1.00 0.3501 0.3666 1.00 9749 9309
255414 0.59 0.2053 0.2150 0.59 16626 15872
273347 0.63 0.2247 0.2354 0.64 15188 14500
335973 0.77 0.2242 0.2371 0.64 15223 14395
Plant CO 2 Emissions
Carbon Dioxide Produced Carbon Dioxide Recovered Carbon Dioxide Emissions Fraction of Carbon Dioxide Recovered Specific Carbon Dioxide Emissions Normalized Specific CO 2 Emissions (Relative to Base Case) Avoided Carbon Dioxide Emissions (as compared to Base) (lbm/hr) (lbm/hr) (lbm/hr) (fraction) (lbm/kwhr) (fraction) (lbm/kwhr)
866102 0 866102 0 1.997 1.00 ---
868137 835053 33084 0.962 0.130 0.065 1.867
849255 796238 53016 0.938 0.194 0.097 1.803
967806 875653 92153 0.905 0.274 0.137 1.722
ALSTOM Power Inc.
111
June 30, 2001
Several comparisons have been made in this table and throughout the report. Some of the more important comparisons are summarized in this section. Boiler Performance All four cases were analyzed and designed based on the boiler producing a main steam flow of 3,131,619 lbm/hr at conditions of 1000 F and 2535 psia at the turbine. This main steam flow represents the maximum continuous rating (MCR) for the unit. All four cases also provided reheat steam to the turbine at conditions of 1000 oF and 590.8 psia. The boiler performance for the Base Case, Case A, and Case C was identical. Case B, while producing the same main steam flow as the other cases had a slightly lower reheat steam flow because there was less reheat spray required for this case. Boiler efficiency for Case B (90.47%) was somewhat higher than the other cases (88.13%) due primarily to the oxygen firing and the addition of the new oxygen heater and parallel feedwater heater. Steam Cycles The steam cycles for the four cases were all very different. The Base Case steam cycle is a typical steam cycle with nominal conditions of 2535 psia / 1000 oF / 1000 oF. Six extraction feedwater heaters are used. The generator in this case produces 463,478 kW. Case A differs from the Base Case in that it extracts a large portion of steam from the IP/LP crossover pipe. The extracted steam, at about 200 psia is expanded through a new turbine generating power before exhausting into the reboilers of the CO2 recovery plant at 65 psia. The modified existing steam turbine generator produces 269,341 kW and the new turbine produces 62,081 kW for a total of 331,422 kW. The gross output is reduced by 132,056 kW, about 28 percent, for this case. The steam cycle for Case B is quite similar to the Base Case. The system is modified slightly with the addition of a new low-pressure feedwater heater in parallel with existing extraction feedwater heaters # 52 and #53 as described in Section 3.1.2. The parallel feedwater heater (PFWH) was used to recover additional sensible heat in the flue gas as a result of reduced air heater performance with oxygen firing. The modified steam cycle system of Case B produces 463,056 kW. This is 422 kW lower than for the Base Case. The gross output for Case B is slightly lower than the Base Case due to less reheat spray being required. Nearly offsetting this is the increased output resulting from the addition of the PFWH. Case C differs from the Base Case in that a large portion of steam is extracted from the IP/LP crossover pipe that is ultimately used for the solvent regeneration in the reboilers similar to Case A. The amount of steam extracted is however, less for Case C due to two reasons. First, less steam is required per unit of CO2 recovered and secondly, additional steam is being provided to the reboilers from the de-oxy system. The steam extracted from the existing steam turbine is expanded through a new turbine generating 36,343 kW before exhausting into the reboilers of the CO2 recovery plant at 65 psia. The high-pressure steam generated in the de-oxy system is expanded through a new turbine providing 37,751 kW of output. A parallel low-pressure feedwater heater, arranged similar to the one used in Case B, is used for low level heat recovery in the de-oxy system. The modified existing steam turbine generator produces 357,196 kW for a total gross output of 431,290 kW. The gross output is reduced by 32,188 kW, about 7 percent, for Case C as compared to the Base Case. Auxiliary Power and Net Plant Output The auxiliary power required for the Base Case is 29,700 kW or about 6.4 percent of the gross output. Net plant output is 433,778 kW. All three CO2 capture options require large amounts of additional auxiliary power. For Concept A (MEA) auxiliary power is increased to 76,007 kW due primarily to the addition of the CO2 compression and liquefaction system which delivers the CO2 as a liquid at 2000 psig. This system consumes 50,355 kW. The total amount of auxiliary power represents about 23 percent of the gross output. Net plant output is reduced to 255,414 kW or about 59 percent of the Base Case output. For Concept B (oxygen fired) auxiliary power is increased to 189,709 kW due primarily to the addition of the air separation unit, which consumes 95,822 kW, and the CO2 compression and liquefaction system which consumes 64,229 kW. The total amount of auxiliary power represents about 41 percent of the gross output. Net plant output is reduced to 273,347 kW or about 64 percent of the Base Case output. For Concept C (MEA/MDEA) auxiliary power is increased to 95,317 kW due primarily to the addition of the CO2 compression and liquefaction system which consumes 67,477 kW. The total amount of auxiliary power for Concept C
ALSTOM Power Inc.
112
June 30, 2001
represents about 22 percent of the gross output. Net plant output is reduced to 335,973 kW or about 77 percent of the Base Case output. Net Plant Output values are compared below in Figure 4.0.1.
500 450 400 350 300 250 200 150 100 50 0 255 273 336 434
Base Case
Concept A MEA
Concept B O2 Fired
Figure 4.0. 1:
Net Plant Electrical Output (Mw)
Net Plant Heat Rate and Thermal Efficiency Because of the large energy requirements and/or auxiliary power demands for the new equipment required for the CO2 capture systems, net plant heat rate and thermal efficiency are degraded substantially relative to the Base Case as shown in Figure 4.0.2. The Base Case plant thermal efficiency (HHV Basis) is about 35.0%, which equates to a net plant heat rate of 9,749 Btu/kwhr. Concept A, with large amounts of steam extracted for solvent regeneration and increased auxiliary power for the CO2 compression and liquefaction system, has plant thermal efficiency degraded to about 20.5% (16,626 Btu/kwhr). Concept B, with large amounts of auxiliary power for the air separation unit and the CO2 compression and liquefaction system, has plant thermal efficiency degraded to about 22.5% (15,187 Btu/kwhr). Concept C, with less steam extracted than Concept A for solvent regeneration and increased auxiliary power for the CO2 compression and liquefaction system, has plant thermal efficiency degraded to about 22.4% (15,223 Btu/kwhr). These results correspond to energy penalties of 41%, 36%, and 36% for Concepts A, B, and C, respectively. As shown in figure 4.0.1 plant output is reduced significantly with the addition of the CO2 capture systems. Therefore replacement power is required to restore the original capacity of the unit. For cases with replacement power, it was assumed to be generated with a state-of-the-art natural gas fired combined cycle (NGCC) plant. The NGCC plant was analyzed without capturing the CO2 from its flue gas. The NGCC plant was assumed to generate power with an efficiency of 57.1 percent (LHV basis). The additional CO2 emitted from the NGCC was 0.762 lbm/kWh. The thermal efficiency of the three concepts including the replacement power systems is also shown in Figure 4.0.2. The efficiencies (HHV basis) range from about 26% to 28% with Concept B being the highest at 28.4%.
ALSTOM Power Inc.
113
June 30, 2001
0.40
0.350 w/o Repl Pwr with Repl Pwr 0.273 0.205 0.284 0.257 0.225 0.224
0.35 0.30 0.25 0.20 0.15 0.10 0.05 0.00
Base Case
Concept A MEA
Concept B Concept C O2 Fired MEA / MDEA
Figure 4.0. 2:
Plant Thermal Efficiency (HHV Basis)
CO2 Emissions CO2 emissions are summarized in Table 4.0.1 for the cases without replacement power. Specific carbon dioxide emissions were reduced from 1.997 lbm/kWh for the Base Case to 0.130, 0.194, and 0.274 lbm/kWh for Concepts A, B, and C, respectively. Figure 4.0.3 illustrates this comparison while also showing the CO2 captured and the avoided emissions. Figure 4.0.4 compares specific CO2 emissions both with and without replacement power. Recovery of CO2 ranged from 91 to 96%. Normalized specific CO2 emissions for Concepts A, B, and C respectively (without Replacement Power), were 6.5, 9.7, and 13.7 percent of the Base Case value.
Carbon Dioxide
(Produced, Captured, Emitted and Avoided)
3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0

Concept A CO2 Avoided
Captured Emitted
Base Case
Concept A MEA
Concept B O2 Fired
Figure 4.0. 3:
Carbon Dioxide Distribution (without replacement power)
ALSTOM Power Inc.
114
June 30, 2001
2.5
1.997
2.0 1.5 1.0 0.5 0.0

0.390 0.130 0.404 0.194 0.384 0.274 w/o Repl Pwr with Repl Pwr
Base Case
Concept A MEA
Concept B O2 Concept C Fired MEA / MDEA
Figure 4.0. 4:
Specific Carbon Dioxide Emissions
ALSTOM Power Inc.
115
June 30, 2001
5.0
COST ANALYSIS
The project capital cost estimates, including engineering, procurement and construction (EPC basis), are shown in this section. These costs include all required equipment such as the amine-based CO2 scrubbing systems of Concepts A and C, the modified FGD system of Concept A, the De-Oxy system of Concept C, the CO2 compression and liquefaction systems for all three concepts, steam cycle modifications for all concepts, and the air separation unit and the boiler island modifications of Concept B. Boiler island modifications for Concept B are relatively small and include costs for such items as oxygen and gas ducts and dampers, booster fans, parallel feedwater heaters and piping, oxygen heater, and controls and instrumentation. All these CO2 capture options produce less net plant power output than the original plant (Base Case). Therefore, costs for replacement power to make up this difference were also calculated. Economic analyses discussed in Section 6 were done both with and without replacement power. For cases with replacement power, it was assumed to be generated with a state-of-the-art natural gas fired combined cycle (NGCC) plant. The NGCC plant cost and performance were developed without capturing the CO2 from its flue gas. Operating and maintenance (O&M) costs were calculated for all systems. The O&M costs for the Base Case were provided by American Electric Power (AEP). For the retrofit CO2 capture system evaluations, additional O&M costs were calculated for the new equipment. The variable operating and maintenance (VOM) costs for the new equipment included such categories as chemicals and desiccants, waste handling, maintenance material and labor, and contracted services. The fixed operating and maintenance (FOM) costs for the new equipment includes operating labor only. 5.1 Cost Estimation Basis
The following assumptions were made in developing these cost estimates for each concept evaluated: Outdoor installation Investment in new utility systems is outside the scope CO2 pipeline is outside the scope No special limitations for transportation of large equipment No protection against unusual airborne contaminants (dust, salt, etc.) No unusual wind storms No earthquakes No piling required All releases can go to atmosphere no flare provided CO2 Pump designed to API standards, all other pumps conform to ANSI All heat exchangers designed to TEMA C All vessels are designed to ASME Section VIII, Div 1. Annual operating time is 5870 h/yr. The investment cost estimate was developed as a factored estimate based on in-house data for the major equipment. Such an estimate can be expected to have accuracy of +/-30%. No purchases of utilities or charges for shutdown time have been charged against the project.
Other exclusions from the cost estimate are as follows: Soil investigation Environmental Permits Disposal of hazardous or toxic waste Disposal of existing materials Custom's and Import duties Sales/ Use tax. Forward Escalation Capital spare parts Chemical loading facilities
ALSTOM Power Inc.
116
June 30, 2001
5.2
Buildings except for Compressor building and electrical substation. Financing cost Owners cost Guards during construction Site Medical and Ambulance service Cost & Fees of Authorities Overhead High voltage feed lines Cost to run a natural gas pipeline to the plant (Concept 3C) Excessive piling Contingency and risk Boiler Modification Costs
Boiler modification costs for these three CO2 capture options are relatively minor as compared to the other new equipment required. For this project the Boiler Scope is defined as everything on the gas side upstream of the FGD System. Therefore it includes equipment such as fans, ductwork, ESP, air heater, steam generator, pulverizers, coal and ash handling systems, etc. Not included in the boiler scope is the FGD system. The FGD system modification costs are shown separately in Section 5.4. For Concepts A and C, the Boiler Scope is not modified from the Base Case configuration and as such there are no costs in this category. Concept B Boiler Scope modifications were described in Section 3.3.4 and include such items as sealing the boiler for air leaks, new ductwork dampers and fans for the recirculated flue gas, oxygen heater, parallel low-pressure feedwater heater, and modified controls and instrumentation. The total cost required for the boiler scope modifications of Concept B is $7,000,000. This estimate includes material, engineering and construction. The expected level of accuracy for this budget level cost estimate is +/- 30%. 5.3 5.3.1 Carbon Dioxide Separation and Compression System Costs Concept A
Investment Cost Table 5.3.1 shows investment costs for the Concept A CO2 Separation and Compression System. Included in this table (Acct. Code - 14200) are the steam cycle modification costs as well as the new letdown turbine and associated electric generator. The steam cycle modifications were described in Section 3.2.3. The Total Installed Cost (TIC) of this equipment is $393,325,000. The expected level of accuracy for this budget level cost estimate is +/- 30%.
ALSTOM Power Inc.
117
June 30, 2001
Table 5.3. 1:
Acc't Code 11000 11200 12000 12100 12200 13000 14100 14200 18000 21000 21100 22000 23000 30000 40000 50000 61100 61200 61300 70000 71000 80000 80000 95000 19400 19300 80000 80000 19200 97000 96000 91400 93000 93000 Description Heaters Exchangers & Aircoolers Vessels / Filters Towers / Internals Reactors Tanks Pumps Compressors Special Equipment Sub-Total Equipment Civil Site Preparation Structures Buildings Piping Electrical Instruments Insulation Fireproofing Painting Sub-Total Commodities Construction Indirects Sub-Total Direct Cost Constr. Management Home Office Engineering Basic Engineering License fee Vendor Reps Spare parts Training cost Commissioning Catalyst & Chemicals Freight CGL / BAR Insurance Sub-Total Escalation Contingency Risk Total Base Cost Contracters Fee Grand Total
Concept A CO2 Separation and Compression System Investment Costs

Pieces Direct Manhours 44,970 5,776 43,200 10,078 100,925 10,991 215,939 287,919 75,579 39,589 593,833 305,914 251,929 215,939 107,970 53,985 1,932,656 2,148,595 Labor ($,000) 697 90 670 156 1,564 170 3,347 4,463 1,171 614 9,204 4,742 3,905 3,347 1,674 837 29,956 33,303 Material ($,000) 28,481 3,658 27,360 Subcontract ($,000) Total ($,000) 29,178 3,748 28,030 6,539 65,483 7,131 140,109 14,036 6,779 2,255 33,821 15,683 21,000 10,459 3,725 1,794 109,551 48,343 298,003 2,000 44,472 5,000 2,500 4,000 Excluded Excluded 1,100 6,500 363,575 10,000 Excluded Excluded 373,575 19,750 393,325 % 0.0% 7.4% 1.0% 7.1% 0.0% 0.0% 1.7% 16.6% 1.8% 35.6% 3.6% 0.0% 1.7% 0.6% 8.6% 4.0% 5.3% 2.7% 0.9% 0.5% 27.9% 12.3% 75.8% 0.5% 11.3% 1.3% 0.0% 0.6% 1.0% 0.0% 0.0% 0.3% 1.7% 0.0% 92.4% 2.5% 0.0% 0.0% 95.0% 5.0% 100.0%
436
6,383 63,919 6,961 136,762 9,573 5,607 1,641 24,617 10,941 17,095 7,112 2,051 957 79,595 216,357
Excluded
Exclusions : Bonds,Taxes,Import duties , Hazerdous material handling & disposal, Capital spare parts, Catalyst & Chemicals , Commissioning and Initial operations, Buildings other than Control room & MCC.
ALSTOM Power Inc.
118
June 30, 2001
Additional Operating Cost Table 5.3.2 shows O&M costs for the Concept A CO2 Separation and Compression System. They amount to $12,700,000/yr. Table 5.3. 2: Operating Cost Chemical and Desiccant Waste Handling Utility Costs* Maintenance (Material and Labor) Operating Labor** Contracted Services Column Total Grand Total (Fixed + Variable) Concept A CO2 Separation and Compression System Operating & Maintenance Costs Variable Costs Amount ($/ yr) 2,958,000 120,000 0* 7,845,000 1,380,000 392,000 11,320,000 1,380,000 12,700,000 Fixed Costs Amount ($/ yr)
*Included with heat rate reduction, operating expense included with power plant modifications operating cost. ** Operating labor is 365 days/ year, all other numbers are variable costs and are based on 245 days/ yr.
ALSTOM Power Inc.
119
June 30, 2001
5.3.2
Concept B
Investment Cost Table 5.3.3 shows investment costs for the Concept B CO2 Separation and Compression System. Also included in this table is the cost of the Air Separation Unit ($138,544,000). The ASU System represents about 50% of the total cost for this concept whose Total Installed Cost (TIC) is $277,905,000. The expected level of accuracy for this budget level cost estimate is +/- 30%. Table 5.3. 3:
Acc't Code 11000 11200 12000 12100 12200 13000 14100 14200 18000 21000 21100 22000 23000 30000 40000 50000 61100 61200 61300 70000 Description
Concept B CO2 Separation and Compression System Investment Costs

Pieces Direct Manhours Labor ($,000) Material Subcontract ($,000) ($,000) Total ($,000) 9,771 3,713 4,134 1,844 21,475 3,289 44,226 5,470 2,312 1,459 11,539 4,950 7,276 2,087 1,176 807 37,077 15,720 97,022 138,544 1,500 10,914 1,500 %
71000 80000 80000 95000 19400 19300 80000 80000 19200 97000 96000 91400 93000 93000
Heaters 0.0% Exchangers & Aircoolers 15,060 233 9,538 3.5% Vessels / Filters 5,722 89 3,624 1.3% Towers / Internals 6,371 99 4,035 1.5% Reactors 0.0% Tanks 0.0% Pumps 2,842 44 1,800 0.7% Compressors 33,098 513 20,962 7.7% Special Equipment 5,068 79 3,210 1.2% Sub-Total Equipment 107 68,162 1,057 43,169 15.9% Civil 102,242 1,585 3,885 2.0% Site Preparation 0.0% Structures 23,857 370 1,943 0.8% Buildings 27,265 423 1,036 0.5% Piping 187,444 2,905 8,634 4.2% Electrical 96,562 1,497 3,454 1.8% Instruments 79,522 1,233 6,044 2.6% Insulation 51,121 792 1,295 0.8% Fireproofing 34,081 528 648 0.4% Painting 28,401 440 367 0.3% Sub-Total Commodities 630,495 9,773 27,304 13.3% Construction Indirects 5.7% Sub-Total Direct Cost 698,656 10,829 70,473 34.9% ASU TIC plant cost 49.9% Constr. Management 0.5% Home Office Engineering 3.9% Basic Engineering 0.5% License fee Excluded 0.0% Vendor Reps 1,750 0.6% Spare parts 2,900 1.0% Training cost Excluded 0.0% Commissioning Excluded 0.0% Catalyst & Chemicals 161 0.1% Freight 2,114 0.8% CGL / BAR Insurance 0.0% Sub-Total 256,405 92.3% Escalation 7,500 2.7% Contingency Excluded 0.0% Risk Excluded 0.0% Total Base Cost 263,905 95.0% Contracters Fee 14,000 5.0% Grand Total 277,905 100.0% Exclusions : Bonds,Taxes,Import duties , Hazerdous material handling & disposal, Capital spare parts, Catalyst & Chemicals , Commissioning and Initial operations, Buildings other than Control room & MCC.
ALSTOM Power Inc.
120
June 30, 2001
Additional Operating Cost Table 5.3.4 shows O&M costs for the Concept B CO2 Separation and Compression System. They amount to $10,643,000/yr. Table 5.3. 4: Operating Cost Concept B CO2 Separation and Compression System Operating & Maintenance Costs Variable Costs Amount ($/ yr)** Fixed Costs Amount ($/ yr)
Chemical and Desiccant 376,000 Waste Handling 0 Utility Costs* 0* Maintenance (Material and Labor) 5,700,000 Operating Labor** 0 261,000** Contracted Services 1,660,000 ASU Operating Labor** 0 902,000** ASU Chemicals and Lubricants 237,400 ASU Maintenance 1,506,200 Column Totals 9,480,000 1,163,000 Grand Total (Fixed + Variable) 10,643,000 *Included with heat rate reduction, operating expense included with power plant modifications operating cost. ** Operating labor is 365 days/ year, all other numbers are variable costs and are based on 245 days/ yr.
ALSTOM Power Inc.
121
June 30, 2001
5.3.3
Concept C
Investment Cost Table 5.3.5 shows investment costs for the Concept C CO2 Separation and Compression System. Included in this table (Acct. Code - 14200) are the steam cycle modification costs as well as the new letdown turbine and De-Oxy system turbine and associated electric generators. The steam cycle modifications were described in Section 3.4.3. The Total Installed Cost (TIC) of this equipment is $738,041,000. The expected level of accuracy for this budget level cost estimate is +/- 30%. Table 5.3. 5:
Acc't Code 11000 11200 12000 12100 12200 13000 14100 14200 18000 21000 21100 22000 23000 30000 40000 50000 61100 61200 61300 70000 71000 80000 80000 95000 19400 19300 80000 80000 19200 97000 96000 91400 93000 93000 Description
Concept C CO2 Separation and Compression System Investment Costs

Pieces Direct Manhours 3,947 70,071 6,611 81,947 14 15,320 98,073 11,424 485 287,407 383,209 100,592 52,691 958,024 407,160 335,308 287,407 143,704 71,852 2,739,948 Labor ($,000) 61 1,086 102 1,270 0 237 1,520 177 4,455 5,940 1,559 817 14,849 6,311 5,197 4,455 2,227 1,114 42,469 Material Subcontract ($,000) ($,000) 2,500 44,378 4,187 51,900 Total ($,000) 2,561 45,464 4,289 53,170 9 9,940 63,633 7,412 186,479 18,681 9,022 3,001 47,614 20,873 27,950 13,920 4,958 2,388 148,407 68,115 403,002 2,500 49,470 5,000 %
Heaters 0.3% Exchangers & Aircoolers 6.2% Vessels / Filters 0.6% Towers / Internals 7.2% Reactors 0.0% Tanks 9 0.0% Pumps 9,703 1.3% Compressors 62,113 8.6% Special Equipment 7,235 1.0% Sub-Total Equipment 182,025 25.3% Civil 12,742 2.5% Site Preparation 0.0% Structures 7,463 1.2% Buildings 2,184 0.4% Piping 32,764 6.5% Electrical 14,562 2.8% Instruments 22,753 3.8% Insulation 9,465 1.9% Fireproofing 2,730 0.7% Painting 1,274 0.3% Sub-Total Commodities 105,938 20.1% Construction Indirects 9.2% Sub-Total Direct Cost 3,027,355 46,924 287,963 54.6% Constr. Management 0.3% Home Office Engineering 6.7% Basic Engineering 0.7% License fee Excluded 0.0% Vendor Reps 2,500 0.3% Spare parts 5,000 0.7% Training cost Excluded 0.0% Commissioning Excluded 0.0% Catalyst & Chemicals Catalyst Excluded 222,430 30.1% Freight 8,639 1.2% CGL / BAR Insurance 0.0% Sub-Total 698,541 94.6% Escalation 13,500 1.8% Contingency Excluded 0.0% Risk Excluded 0.0% Total Base Cost 712,041 96.5% Contracters Fee 26,000 3.5% Grand Total 738,041 100.0% Exclusions : Bonds,Taxes,Import duties , Hazerdous material handling & disposal, Capital spare parts, Reactor Catalyst & Chemicals , Commissioning and Initial operations, Buildings other than Control room & MCC.
ALSTOM Power Inc.
122
June 30, 2001
Additional Operating Cost Table 5.3.6 shows O&M costs for the Concept C CO2 Separation and Compression System. They amount to $26,535,920/yr.
Table 5.3. 6: Operating Cost
Concept C CO2 Separation and Compression System Operating & Maintenance Costs Variable Costs Amount ($/ yr)** 1,797,000 15,600 0* 22,141,320 0 1,202,000 25,155,920 Fixed Costs Amount ($/ yr)
Chemical and Desiccant Waste Handling Utility Costs* Maintenance (Material and Labor) Operating Labor** Contracted Services Column Totals Total (Fixed + Variable)
1,380,000** 1,380,000 26,535,920
*Included with heat rate reduction, operating expense included with power plant modifications operating cost. ** Operating labor is 365 days/ year, all other numbers are variable costs and are based on 245 days/ yr. 5.4 Flue Gas Desulfurization System Modification Costs
Flue Gas Desulfurization System modification costs for these three CO2 capture options are relatively minor as compared to the other new equipment required. For Concepts B and C, the existing Flue Gas Desulfurization System is not modified from the Base Case configuration and as such there are no costs in this category. The Concept A Flue Gas Desulfurization System modifications, which include the addition of a secondary absorber island, building, booster fan, and ductwork, are described in Section 3.2.4. The total cost required for the Flue Gas Desulfurization System scope modifications of Concept A is $15,800,000. This estimate includes material, engineering and construction. The expected level of accuracy for this cost estimate is +/- 10%. 5.5 Charges for Loss of Power during Construction and Operation of the Modified Power Plant System
During the construction period it is assumed the existing Unit No. 5 power plant will be operated in its normal way. The new CO2 capture equipment is being located some 1500 feet from the Unit No. 5/6 stack (see Appendix I for plant layout drawings) and as such will not impede operation of Unit No. 5 or any of the other units on site. Once construction is completed it has been assumed the final connections between the CO2 capture systems and the existing power plant can be completed during the annual outage for the unit. Final shake down testing will be completed after the outage. During plant operation, all these CO2 capture options produce less net plant output at full load than the original plant (Base Case). Therefore, each concept was analyzed with replacement power to make up for this difference. For cases with replacement power, it was assumed to be generated with a state-of-the-art natural gas fired combined cycle (NGCC) plant. The NGCC plant performance and cost was calculated assuming the CO2 from its flue gas was not captured. The NGCC plant was assumed to cost $450/kW, installed. Table 5.5.1 shows the NGCC outputs and costs for the three CO2 capture concepts. Table 5.5. 1: NGCC Outputs and Costs for Replacement Power Concept A 178,363 80,264 Concept B 160,430 72,194 Concept C 97,805 44,012
NGCC Power Output (kW) NGCC Installed Cost ($ x 1000)
ALSTOM Power Inc.
123
June 30, 2001
5.6
Summary of Total Plant Investment Costs
Table 5.6.1 summarizes the total retrofit investment costs required for each of the three Concepts. Two costs are shown for each concept, one with and one without replacement power. Figure 5.6.1 shows the specific investment costs ($/kW) for the three concepts without replacement power. Two costs are given for each of the three concepts in this figure. The bars on the left are relative to the new plant output and the bars on the right are relative to the original plant output. Figure 5.6.2 shows the specific investment costs ($/kW) for the three concepts with replacement power These costs were used in the economic evaluation (Section 6) to develop incremental Cost of Electricity values and comparisons. Table 5.6. 1: Total Retrofit Investment Capital Costs
CO2 Capture Concept Concept A Concept B Concept C Units 10 US$ $/kW 6 10 US$ $/kW 6 10 US$ $/kW
6
w/o Repl Pwr
with Repl Pwr
409 1602 285 1042 738 2197
489 1128 357 823 782 1803
2500 2000 1500 1000 500 0 Concept A Concept B New kW basis Concept C
Original kW basis
Figure 5.6. 1:
New Equipment Specific Investment Costs (Without Replacement Power)

2500 2000 1500 1000 500 0 Concept A Concept B Concept C
Figure 5.6. 2:
New Equipment Specific Investment Costs (With Replacement Power)
ALSTOM Power Inc.
124
June 30, 2001
6.0
ECONOMIC ANALYSIS
A comprehensive economic evaluation comparing the Base Case study unit and the three retrofit CO2 capture concepts (A MEA absorption, B - O2 Fired with flue gas recycle, and C - MEA/MDEA absorption) was performed. The purpose of the evaluation was to quantify the impact of CO2 capture on the Cost of Electricity (COE) of this existing coal fired unit. CO2 mitigation costs were also determined in this analysis. The economic evaluation results are presented as incremental Costs of Electricity (first full year of operation basis). The first year basis is quite representative (at least for the input assumptions used in this study) as the post modification COE for year 10 is only about 7% greater than for year 1. The incremental costs of electricity are incremental relative to the Base Case (air fired without CO2 capture, i.e., business as usual). Each CO2 capture option was evaluated both with and without replacement power. Since all these CO2 capture options produce less net plant output than the original plant (Base Case), the replacement power exactly represents this difference. For cases with replacement power, it was assumed to be generated with a state-of-the-art natural gas fired combined cycle (NGCC) plant. The NGCC plant was analyzed without CO2 capture from its flue gases. Additionally, economic sensitivity studies were developed for the six primary cases (each of the CO2 capture options with and without replacement power) to highlight which parameters affected the COE to the greatest extent. A total of 66 economic evaluation cases are reported. The model used to perform the economic evaluations was the proprietary ALSTOM Power Plant Laboratories Project Economic Evaluation Pro-Forma. This cash flow model, developed by the Companys Project & Trade Finance group, has the capability to analyze the economic effects of different technologies based on differing capital costs, operating and maintenance costs, fuel costs, and cost of capital assumptions. Various categories of results are available from the model. In addition to cost of electricity, net present value, project internal rate of return, payback period, and other evaluation parameters are available. In performing the economic evaluations, numerous assumptions were required. Table 6.0.1 lists the primary assumptions used in this analysis. Table 6.0. 1:
Economic Assumptions
NPV Cash Discount Rate Depreciable Life
Economic Evaluation Study Assumptions

Financing Terms
percent years
12.0 15
Project Schedule
Project Start Construction Period Evaluation Period
date months years
9/1/01 30 15
Equity Debt Interest on Loan (APR) Term of Loan Return on Equity
percent percent percent years percent
50.0 50.0 9.0 15 12.0
Fuel Information
Coal Cost
$/10 Btu $/10 Btu

6
1.32 4.00
Variable Operating Costs (Non-Fuel) $/Ton Lime Cost (Delivered) $/Ton Ash Disposal Cost Revenue Information
Electricity Price CO2 Market Price $/MWhr $/Ton
Natural Gas Cost 60 14
Plant Information
32.00 0.0 Capacity Factor Remaining Operating Life Fixed O&M Costs
percent years $/kw
67.0 20 16.0
ALSTOM Power Inc.
125
June 30, 2001
The following list defines additional assumptions used in all Replacement Power Cases. Power Generation Technology: Natural Gas fired Combined Cycle (NGCC) without CO2 capture NGCC Net Plant Heat Rate (HHV basis): 6640 Btu/kWh (GTW, 1998-1999) NGCC Net Plant Efficiency (LHV basis): 57.1 percent NGCC Investment Cost; Engineered, Procured, Constructed basis (EPC): 450 $/kW NGCC Fixed O&M Cost: 16.92 $/kW-yr NGCC Variable O&M Cost: 0.01 Cents/kWh
As is evident from the above list, the NGCC replacement power calculations were identical for all cases with the only difference between cases being the scaling of various items required for the economic evaluation as a function of output requirement. In other words a rubber NGCC was assumed with performance, O&M costs, and specific investment costs assumed constant and not a function of output. This was done such that all economic differences between the cases would be completely attributable to the CO2 capture technology employed and not influenced by changes in NGCC specific costs, or performance, resulting from economy of scale. The Economic Sensitivity Study was performed for each of six primary cases. The six primary cases include two cases each for Concepts A, B, and C (one case with and one case without replacement power). The sensitivity study shows the effect on incremental COE and on CO2 mitigation cost of variations in five parameters of interest. CO2 mitigation costs were calculated according to Equation (6.1) below. The five parameters varied in this study were investment cost (which included the new CO2 capture equipment, replacement power equipment, and the book value of the existing plant), coal cost, natural gas cost, capacity factor, and CO2 byproduct sell price. Eleven evaluations were done for each of the six cases providing a total of 66 economic evaluations from the overall sensitivity study. Table 6.0.2 shows the ranges for each of the five parameters varied in the sensitivity study. Three points were calculated for each parameter (Base Value, Minimum, and Maximum). Mitigation Cost = (COE Cp COE Ref) / (CO2 Ref CO2 Cp ) Where: Mitigation Cost = $/Ton of CO2 Avoided COE = Cost of Electricity ($/kWh) CO2 = Carbon Dioxide Emitted (Ton/kWh) Cp = Capture Plant Ref = Reference Plant Table 6.0. 2:
Parameter
(6.1)
Economic Sensitivity Study Parameters

Units
Investment Cost Fuel Cost (Coal) Fuel Cost (Natural Gas) Capacity Factor CO2 Byproduct Sell Price
$ $/MMBtu $/MMBtu Fraction $/ton
Minimum Maximum as estimated Base - 25% Base + 25% 1.32 1.00 1.60 4.00 3.00 5.00 0.67 0.60 0.75 0.00 10.00 20.00
Base Value
ALSTOM Power Inc.
126
June 30, 2001
6.1
Concept A Results: CO2 Separation with Monoethanolamine (MEA) Absorption
This section shows the economic analysis results for Concept A, CO2 separation with Monoethanolamine Absorption. Results both with and without replacement power are reported including sensitivity results. 6.1.1 Concept A Results without Replacement Power
Figure 6.1.1 shows the economic analysis results using the base parameter values for Concept A (MEA) as compared with the Base Case (air fired without CO2 capture). This analysis was done without replacement power. The first year incremental cost of electricity for this case was about 6.17 Cents/kWh greater than the Base Case COE.
Incremental Cost of Electricity

(First Full Year of Operation)
7.00 6.00 5.00 4.00 3.00 2.00 1.00 0.00 Concept A (MEA) Incremental Cost of Electricity Distribution (Cents/ kWh) Fixed O&M Variable O&M Fuel Capital Investment
Capital Investment Fixed O&M Variable O&M Fuel

Total Incremental Cost of Electricity
3.86 0.28 1.10 0.93 6.17
Figure 6.1. 1:
Concept A (MEA) Economic Results without Replacement Power
Results for the Concept A sensitivity study, without replacement power, are shown in Table 6.1.1 and Figure 6.1.2. This table and the associated figure show the sensitivity of incremental COE to coal cost, natural gas cost, capacity factor, CO2 byproduct sell price, and new equipment installed capital cost. Results for the Base parameter values (i.e., Coal Cost = 1.32 $/106 Btu, Natural Gas Cost = 4.0 $/106 Btu, Capacity Factor = 67%, CO2 Byproduct Sell Price = 0.0 $/Ton, Investment Cost = As Estimated) are shown above in Figure 6.1.1. The base parameter values also represent the point in Figure 6.1.2 where all the sensitivity curves intersect (point 0.0, 0.0). Incremental COE ranges from a low of 2.90 to a high of 7.25 cents/kWh. The most sensitive parameters are CO2 byproduct sell price, capital cost and capacity factor, in that order, with coal cost and natural gas cost showing significantly less impact on incremental COE. CO2 mitigation costs ranged from 31-73 $/Ton of CO2 avoided with the baseline value at 66 $/Ton of CO2 avoided.
ALSTOM Power Inc.
127
June 30, 2001
Table 6.1. 1:
Parameter Power Output Net Power Output Replacement Power Total Power Output Plant Performance Net Plant heat Rate Net Plant Efficiency CO2 Emitted CO2 Emitted Total Capital Cost Capital Cost Economic Analysis Basis Capital Charge Rate Fuel Cost (Coal) Fuel Cost (Natural Gas) Capacity Factor CO2 Price Economic Analysis Results coe: Incremental CO2 Mitigation Cost Unit kW kW kW
Economic Sensitivity Results for Concept A without Replacement Power

CO 2 Capture with MEA, Without Replacement Power 255414 0 255414 255414 0 255414 255414 0 255414 255414 0 255414 255414 0 255414 255414 0 255414 255414 0 255414 255414 0 255414 255414 0 255414 255414 0 255414 255414 0 255414
Btu/kWh Fraction lbm/h lbm/kWh $ (1000's) $/kW
16,626 0.2053 33084 0.130 495881 1941
16,626 0.2053 33084 0.130 495881 1941
16,626 0.2053 33084 0.130 495881 1941
16,626 0.2053 33084 0.130 495881 1941
16,626 0.2053 33084 0.130 495881 1941
16,626 0.2053 33084 0.130 495881 1941
16,626 0.2053 33084 0.130 495881 1941
16,626 0.2053 33084 0.130 495881 1941
16,626 0.2053 33084 0.130 495881 1941
16,626 0.2053 33084
16,626 0.2053 33084
371911 1456
619851 2427
% $/MMBtu $/MMBtu Fraction $/ton
0.1302 1.32
4.00
0.1302 1.00
4.00
0.1302 1.60
4.00
0.1302 1.32
3.00
0.1302 1.32
5.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.67 0.00
0.67 0.00
0.67 0.00
0.67 0.00
0.67 0.00
0.60 0.00
0.75 0.00
0.67 10.00
0.67 20.00
0.67 0.00
0.67 0.00
cents/kWh $/ton
6.17
66
5.96
64
6.36
68
6.17
66
6.18
66
6.66
71
5.73
61
4.54
49
2.90
31
5.10
51
7.25
73
Incremental COE Sensitivity Analysis Concept A - MEA

(without replacement power)

20.0 15.0
7.5
0 6.0
7.0 10.0 5.0 0.0 -5.0 -10.0 5.5 -15.0 -20.0 -30.0 -20.0 -10.0 0.0 10.0 20.0 Percent Change in Variable 5.0 30.0 6.0 6.5
-10
5.5 5.0 4.5 4.0
-20
-30
-40 3.5 -50 3.0 2.5 0 5 10 15 20 25 CO2 Byproduct Sell Price ($/Ton)
-60
Coal Cost Investment Cost
Capacity Factor
Natural Gas Cost
Figure 6.1. 2:
Concept A (MEA) Economic Sensitivity Results without Replacement Power
ALSTOM Power Inc.
128
June 30, 2001
6.1.2
Concept A Results with Replacement Power
Figure 6.1.3 shows the economic analysis results using the base parameter values for Concept A (MEA) with replacement power as compared with the Base Case. The first year incremental cost of electricity for this case was about 4.25 Cents/kWh greater than the Base Case COE.

4.50 4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 0.00 Concept A (MEA-rp) Incremental Cost of Electricity Distribution Capital Investment Fixed O&M Variable O&M Fuel (Cents/ kWh) Fixed O&M Variable O&M Fuel Capital Investment
2.50 0.17 0.47 1.11 4.25
Figure 6.1. 3:
Concept A (MEA) Economic Results with Replacement Power
Results for the Concept A sensitivity study, with replacement power, are shown in Table 6.1.2 and Figure 6.1.4. Incremental COE ranges from a low of 2.33 to a high of 4.99 cents/kWh. The most sensitive parameters again are CO2 byproduct sell price, investment cost and capacity factor, in that order. Natural gas cost shows significantly more impact on incremental COE when replacement power is included as would be expected with the NGCC being used to generate the replacement power. Coal cost, on the other hand, has no impact on incremental COE with replacement power since both the Base Case and Concept A use the same amount of coal and the net electrical output is also the same. CO2 mitigation costs ranged from 29-73 $/Ton of CO2 avoided with the baseline value at 53 $/Ton of CO2 avoided.
ALSTOM Power Inc.
129
June 30, 2001
Table 6.1. 2:
Economic Sensitivity Results for Concept A with Replacement Power

CO 2 Capture with MEA, Including Replacement Power 255414 178363 433778 255414 178363 433778 255414 178363 433778 255414 178363 433778 255414 178363 433778 255414 178363 433778 255414 178363 433778 255414 178363 433778 255414 178363 433778 255414 178363 433778 255414 178363 433778
Btu/kWh % lbm/h lbm/kWh $ (1000's) $/kW
12,520 0.2726 169053 0.390 576144 1328
12,520 0.2726 169053 0.390 576144 1328
12,520 0.2726 169053 0.390 576144 1328
12,520 0.2726 169053 0.390 576144 1328
12,520 0.2726 169053 0.390 576144 1328
12,520 0.2726 169053 0.390 576144 1328
12,520 0.2726 169053 0.390 576144 1328
12,520 0.2726 169053 0.390 576144 1328
12,520 0.2726 169053 0.390 576144 1328
12,520 0.2726 169053 0.390 432108 996
12,520 0.2726 169053 0.390 720180 1660
0.1302 1.32
4.00
0.1302 1.00
4.00
0.1302 1.60
4.00
0.1302 1.32
3.00
0.1302 1.32
5.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.67 0.00
0.67 0.00
0.67 0.00
0.67 0.00
0.67 0.00
0.60 0.00
0.75 0.00
0.67 10.00
0.67 20.00
0.67 0.00
0.67 0.00
cents/kWh $/ton
4.25
53
4.25
53
4.25
53
3.97
49
4.53
56
4.56
57
3.97
49
3.29
41
2.33
29
3.52
44
4.99
62

(with replacement power)

20.0 5.0 15.0 4.8 10.0 5.0 0.0 -5.0 -10.0 -15.0 -20.0 -30.0 4.6 4.4 4.2 4.0 3.8
-35 0 -5 -10 -15 -20 -25 -30 3.1 3.6 4.1
3.6 3.4 30.0
-40 -45 -50 0 5 10 15 20 25
2.6
-20.0
-10.0
0.0
10.0
20.0
2.1
Percent Change in Variable Capacity Factor Investment Cost Natural Gas Cost Coal Cost
CO 2 Byproduct Sell Price ($/Ton)
Figure 6.1. 4:
Concept A (MEA) Economic Sensitivity Results with Replacement Power
ALSTOM Power Inc.
130
June 30, 2001
6.2
Concept B Results: CO2 Separation with Oxygen Firing and Flue Gas Re-circulation
This section shows the economic analysis results for Concept B, CO2 Separation with Oxygen Firing and Flue Gas Re-circulation. Results both with and without replacement power are also reported along with sensitivity results. 6.2.1 Concept B Results without Replacement Power
Figure 6.2.1 shows the economic analysis results using the base parameter values for Concept B (Oxygen Fired) as compared with the Base Case (air fired without CO2 capture). This analysis was done without replacement power. The first year incremental cost of electricity for this case was about 4.45 Cents/kWh greater than the Base Case COE.
5.00 4.50 4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 0.00 Concept B (Oxy-Fired) Incremental Cost of Electricity Distribution (Cents/ kWh) Fixed O&M Variable O&M Fuel Capital Investment

2.57 0.24 0.91 0.73 4.45
Figure 6.2. 1:
Concept B (Oxygen Fired) Economic Results without Replacement Power
Results for the Concept B sensitivity study, without replacement power, are shown in Table 6.2.1 and Figure 6.2.2. Incremental COE ranges from a low of 1.53 to a high of 5.20 cents/kWh. The most sensitive parameters are, again, CO2 byproduct sell price, investment cost and capacity factor, in that order, with coal cost and natural gas cost showing significantly less impact on incremental COE. CO2 mitigation costs ranged from 17-58 $/Ton of CO2 avoided with the baseline value at 49 $/Ton of CO2 avoided.
ALSTOM Power Inc.
131
June 30, 2001
Table 6.2. 1:
Economic Sensitivity Results for Concept B without Replacement Power

CO2 Capture with O2 Firing, Without Replacement Power 273347 0 273347 273347 0 273347 273347 0 273347 273347 0 273347 273347 0 273347 273347 0 273347 273347 0 273347 273347 0 273347 273347 0 273347 273347 0 273347 273347 0 273347
15,188 0.2247 53016 0.194 371661 1360
15,188 0.2247 53016 0.194 371661 1360
15,188 0.2247 53016 0.194 371661 1360
15,188 0.2247 53016 0.194 371661 1360
15,188 0.2247 53016 0.194 371661 1360
15,188 0.2247 53016 0.194 371661 1360
15,188 0.2247 53016 0.194 371661 1360
15,188 0.2247 53016 0.194 371661 1360
15,188 0.2247 53016 0.194 371661 1360
15,188 0.2247 53016 0.194 278746 1020
15,188 0.2247 53016 0.194 464576 1700
0.1302 1.32
4.00
0.1302 1.00
4.00
0.1302 1.60
4.00
0.1302 1.32
3.00
0.1302 1.32
5.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.67 0.00
0.67 0.00
0.67 0.00
0.67 0.00
0.67 0.00
0.60 0.00
0.75 0.00
0.67 10.00
0.67 20.00
0.67 0.00
0.67 0.00
cents/kWh $/ton
4.45
49
4.27
47
4.60
51
4.44
49
4.45
49
4.77
53
4.15
46
2.99
33
1.53
17
3.69
41
5.20
58
Incremental COE Sensitivity Analysis Concept B - O2 Firing


20.0 15.0 10.0 5.0 0.0 -5.0 -10.0 -15.0 -20.0 -30.0 5.2 5.0 4.8 4.6 4.4 4.2 4.0 3.8 3.6 30.0
0 -10
4.3 3.8
-20 3.3 -30 2.8 -40 -50 -60 -70 0 5 10 15 20 25 2.3 1.8 1.3
-20.0
-10.0
0.0
10.0
20.0
Percent Change in Variable
CO 2 Byproduct Sell Price ($/Ton) Natural Gas Cost
Capacity Factor
Figure 6.2. 2:
Concept B (Oxygen Firing) Economic Sensitivity Results without Replacement Power
ALSTOM Power Inc.
132
June 30, 2001
6.2.2
Concept B Results with Replacement Power
Figure 6.2.3 shows the economic analysis results using the base parameter values for Concept B (Oxygen Firing) with replacement power as compared with the Base Case. The first year incremental cost of electricity for this case was about 3.35 Cents/kWh greater than the Base Case COE.

4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 0.00 Concept B-rp (Oxy-Fired) Incremental Cost of Electricity Distribution (Cents/ kWh) Fixed O&M Variable O&M Fuel Capital Investment

1.83 0.15 0.41 0.97 3.35
Figure 6.2. 3:
Concept B (Oxygen Firing) Economic Results with Replacement Power
Results for the Concept B sensitivity study, with replacement power, are shown in Table 6.2.2 and Figure 6.2.4. Incremental COE ranges from a low of 1.52 to a high of 3.92 cents/kWh. The most sensitive parameters, again, are CO2 byproduct sell price, investment cost and capacity factor, in that order. Natural gas cost shows significantly more impact on incremental COE when replacement power is included as would be expected with the NGCC being used to generate the replacement power. Coal cost, on the other hand, shows minimal impact on incremental COE with replacement power since both the Base Case and Case A use nearly the same amount of coal and the net electrical output is exactly the same. CO2 mitigation costs ranged from 19-49 $/Ton of CO2 avoided with the baseline value at 42 $/Ton of CO2 avoided.
ALSTOM Power Inc.
133
June 30, 2001
Table 6.2. 2:
Economic Sensitivity Results for Concept B with Replacement Power

CO 2 Capture with O2 Firing, Including Replacement Power 273347 160430 433778 273347 160430 433778 273347 160430 433778 273347 160430 433778 273347 160430 433778 273347 160430 433778 273347 160430 433778 273347 160430 433778 273347 160430 433778 273347 160430 433778 273347 160430 433778
12,026 0.2838 175315 0.404 443855 1023
12,026 0.2838 175315 0.404 443855 1023
12,026 0.2838 175315 0.404 443855 1023
12,026 0.2838 175315 0.404 443855 1023
12,026 0.2838 175315 0.404 443855 1023
12,026 0.2838 175315 0.404 443855 1023
12,026 0.2838 175315 0.404 443855 1023
12,026 0.2838 175315 0.404 443855 1023
12,026 0.2838 175315 0.404 443855 1023
12,026 0.2838 175315 0.404 332891 767
12,026 0.2838 175315 0.404 554818 1279
0.1302 1.32
4.00
0.1302 1.00
4.00
0.1302 1.60
4.00
0.1302 1.32
3.00
0.1302 1.32
5.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.67 0.00
0.67 0.00
0.67 0.00
0.67 0.00
0.67 0.00
0.60 0.00
0.75 0.00
0.67 10.00
0.67 20.00
0.67 0.00
0.67 0.00
cents/kWh $/ton
3.35
42
3.36
42
3.35
42
3.10
39
3.60
45
3.58
45
3.14
39
2.44
31
1.52
19
2.79
35
3.92
49


20.0 15.0 10.0 5.0 0.0 -5.0 -10.0 -15.0 -20.0 -30.0 -20.0 -10.0 0.0 10.0 20.0 3.1 2.9 2.7 30.0 3.9 3.7 3.5 3.3
0 -10 -20 -30 -40 -50 -60 0 5 10 15 20 25
3.4 3.2 3.0 2.8 2.6 2.4 2.2 2.0 1.8 1.6 1.4
CO 2 Byproduct Sell Price ($/Ton) Coal Cost Investment Cost Capacity Factor Natural Gas Cost
Figure 6.2. 4:
Concept B (Oxygen Firing) Economic Sensitivity Results with Replacement Power
ALSTOM Power Inc.
134
June 30, 2001
6.3
Concept C Results: CO2 Separation with MEA / MDEA
This section shows the economic analysis results for Concept C, CO2 Separation with MEA / MDEA absorption. Results both with and without replacement power are reported along with sensitivity results. 6.3.1 Concept C Results without Replacement Power Figure 6.3.1 shows the economic results using the base parameter values for Concept C (MEA /MDEA) as compared with the Base Case (air fired without CO2 capture). This analysis was done without replacement power. The first year incremental cost of electricity for this case was about 8.41 Cents/kWh greater than the Base Case COE.

9.00 8.00 7.00 6.00 5.00 4.00 3.00 2.00 1.00 0.00 Concept C (MEA/MDEA) Incremental Cost of Electricity Distribution (Cents/ kWh) Fixed O&M Variable O&M Fuel Capital Investment

5.00 0.17 1.81 1.43 8.41
Figure 6.3. 1:
Concept C (MEA/MDEA) Economic Results without Replacement Power
Results for the Concept C sensitivity study, without replacement power, are shown in Table 6.3.1 and Figure 6.3.2. Incremental COE ranges from a low of 5.93 to a high of 9.77 cents/kWh. The most sensitive parameters are CO2 byproduct sell price, investment cost and capacity factor with coal cost and natural gas cost showing significantly less impact on incremental COE. CO2 mitigation costs ranged from 69-113 $/Ton of CO2 avoided with the baseline value at 98 $/Ton of CO2 avoided.
ALSTOM Power Inc.
135
June 30, 2001
Table 6.3. 1:
Parameter Power Output Net Power Output Replacement Power Total Power Output Plant Performance Net Plant heat Rate Net Plant Efficiency CO2 Emitted CO2 Emitted Total Capital Cost Capital Cost Economic Analysis Basis Capital Charge Rate Fuel Cost (Coal) Fuel Cost (Natural Gas) Capacity Factor CO2 Price Economic Analysis Results coe: Incremental CO2 Mitigation Cost
Economic Sensitivity Results for Concept C without Replacement Power

Unit kW kW kW 335973 0 335973 335973 0 335973 335973 0 335973 CO2 Capture with MEA / MDEA, Without Replacement Power 335973 0 335973 335973 0 335973 335973 0 335973 335973 0 335973 335973 0 335973 335973 0 335973 335973 0 335973 335973 0 335973
15,223 0.2242 92153 0.274 824797 2455
15,223 0.2242 92153 0.274 824797 2455
15,223 0.2242 92153 0.274 824797 2455
15,223 0.2242 92153 0.274 824797 2455
15,223 0.2242 92153 0.274 824797 2455
15,223 0.2242 92153 0.274 824797 2455
15,223 0.2242 92153 0.274 824797 2455
15,223 0.2242 92153 0.274 824797 2455
15,223 0.2242 92153 0.274 824797 2455
15,223 0.2242 92153 0.274 618598 1841
15,223 0.2242 92153 0.274 1030996 3069
0.1302 1.32
4.00
0.1302 1.00
4.00
0.1302 1.60
4.00
0.1302 1.32
3.00
0.1302 1.32
5.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.67 0.00
0.67 0.00
0.67 0.00
0.67 0.00
0.67 0.00
0.60 0.00
0.75 0.00
0.67 10.00
0.67 20.00
0.67 0.00
0.67 0.00
cents/kWh $/ton
8.41
98
8.32
97
8.49
99
8.15
95
8.67
101
9.01
105
7.86
91
7.17
83
5.93
69
7.05
82
9.77
113
Incremental COE Sensitivity Analysis Concept C - MEA / MDEA

Incremental COE Sensitivity Analysis Concept C - MEA /MDEA

20.0 15.0 10.0 5.0 0.0 8.2 -5.0 -10.0 -15.0 -20.0 -30.0 7.7 9.7 9.2 8.7
0 -5 -10 -15 7.0 -20 6.5 -25 7.2 -30 -20.0 -10.0 0.0 10.0 20.0 6.7 30.0 -35 0 5 10 15 20 25 6.0 8.0
7.5
5.5
Capacity Factor
Natural Gas Cost
CO2 Byproduct Sell Price ($/Ton)
Figure 6.3. 2:
Concept C (MEA/MDEA) Economic Sensitivity Results without Replacement Power
ALSTOM Power Inc.
136
June 30, 2001
6.3.2
Concept C Results with Replacement Power
Figure 6.3.3 shows the economic analysis results using the base parameter values for Concept C (MEA / MDEA) with replacement power as compared with the Base Case. The first year incremental cost of electricity for this case was about 6.61 Cents/kWh greater than the Base Case COE.

7.00 6.00 5.00 4.00 3.00 2.00 1.00 0.00 Concept C-rp (MEA/MDEA) Incremental Cost of Electricity Distribution (Cents/ kWh) Fixed O&M Variable O&M Fuel Capital Investment

3.77 0.12 1.30 1.42 6.61
Figure 6.3. 3:
Concept C (MEA/MDEA) Economic Results with Replacement Power
Results for the Concept C sensitivity study with replacement power are shown in Table 6.3.2 and Figure 6.3.4. Incremental COE ranges from a low of 4.69 to a high of 7.66 cents/kWh. The most sensitive parameters again are CO2 byproduct sell price, investment cost and capacity factor. Natural gas cost shows significantly more impact on incremental COE when replacement power is included as would be expected with the NGCC being used to generate the replacement power. Coal cost, on the other hand, shows minimal impact on incremental COE with replacement power since both the Base Case and Case A use the same amount of coal and the net electrical output is exactly the same. CO2 mitigation costs ranged from 58-95 $/Ton of CO2 avoided with the baseline value at 82 $/Ton of CO2 avoided.
ALSTOM Power Inc.
137
June 30, 2001
Table 6.3. 2:
Economic Sensitivity Results for Concept C with Replacement Power

C O2 Capture with MEA / MDEA, Without Replacement Power 335973 97805 433778 335973 97805 433778 335973 97805 433778 335973 97805 433778 335973 97805 433778 335973 97805 433778 335973 97805 433778 335973 97805 433778 335973 97805 433778 335973 97805 433778 335973 97805 433778
13,288 0.2568
13,288 0.2568
13,288 0.2568
13,288 0.2568
13,288 0.2568
13,288 0.2568
13,288 0.2568
13,288 0.2568
13,288 0.2568
13,288 0.2568
13,288 0.2568
166711.546 166711.546 166711.546 166711.546 166711.546 166711.546 166711.546 166711.546 166711.546 166711.546 166711.546 0.384 0.384 0.384 0.384 0.384 0.384 0.384 0.384 0.384 0.384 0.384 824797 1901 824797 1901 824797 1901 824797 1901 824797 1901 824797 1901 824797 1901 824797 1901 824797 1901 618598 1426 1030996 2377
0.1302 1.32
4.00
0.1302 1.00
4.00
0.1302 1.60
4.00
0.1302 1.32
3.00
0.1302 1.32
5.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.1302 1.32
4.00
0.67 0.00
0.67 0.00
0.67 0.00
0.67 0.00
0.67 0.00
0.60 0.00
0.75 0.00
0.67 10.00
0.67 20.00
0.67 0.00
0.67 0.00
cents/kWh $/ton
6.61
82
6.61
82
6.61
82
6.26
78
6.96
86
7.06
88
6.20
77
5.65
70
4.69
58
5.56
69
7.66
95


20.0 7.8 15.0 10.0 5.0 6.8 0.0 -5.0 -10.0 5.8 -15.0 -20.0 -30.0 -20.0 Coal Cost -10.0 0.0 10.0 20.0 5.3 30.0 6.3 -15 -20 -25 4.8 -30 -35 0 Natural Gas Cost 5 10 15 20 25 4.3 5.3 7.3 0 -5 -10 5.8 6.3
Percent Change in Variable Capacity Factor
CO2 Byproduct Sell Price ($/Ton)
Investment Cost
Figure 6.3. 4:
Concept C (MEA/MDEA) Economic Sensitivity Results with Replacement Power
ALSTOM Power Inc.
138
June 30, 2001
6.4
Economic Study Summary and Conclusions
A total of 66 CO2 capture cases were compared in the reported sensitivity studies. All cases studied indicate significant increases to the COE as a result of CO2 capture. The incremental COE as compared to the Base Case (air firing without CO2 capture) ranges from 1.52 to 9.77 Cents/kWh. Similarly CO2 mitigation costs range from about 17-113 $/Ton of CO2 avoided for the range of cases studied. Table 6.4.1 summarizes the economic analysis results for the six primary cases using base parameter values (i.e.; Coal Cost = 1.32 $/106 Btu, Natural Gas Cost = 4.0 $/106 Btu, Capacity Factor = 67%, CO2 Byproduct Sell Price = 0.0 $/Ton, Investment Cost = As Estimated). Figure 6.4.1 shows the incremental COE values for these cases and similarly, Figure 6.4.2 shows the associated CO2 mitigation costs. Table 6.4. 1:
Parameter Incremental COE CO2 Mitigation Cost Units Cents/kWh
Summary of Economic Analysis Results (for 6 primary cases)

Concept A
Concept B
Concept C
$/Ton
6.2 68
4.3 53
4.4 49
3.4 42
8.4 98
6.6 82
Incremental COE (Cents/kWh)
9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 w/o Repl Pwr Concept A (MEA) Concept B (O2 Fired) with Repl Pwr Concept C (MEA/MDEA)
Figure 6.4. 1:
Incremental Cost of Electricity (Using Base Parameter Values)
ALSTOM Power Inc.
139
June 30, 2001
125
98
100
82
75
68 53 42
49
50
Without Replacement Power

25
With Replacement Power

0
O2 FIRED MEA MEA/MDEA O2 FIRED MEA MEA/MDEA
Figure 6.4. 2:
Co 2 Mitigation Costs (Using Base Parameter Values)
Concept B (oxygen firing with flue gas recycle) appears to clearly be the best alternative of the three concepts studied based on incremental COE evaluation criteria. Using the base parameters of the sensitivity study for Concept B yields incremental COE values of 3.35 and 4.45 Cents/kWh for cases with and without replacement power, respectively. The actual COE values for Concept B are 20% and 13% lower than the corresponding values for Concept A and 47% and 51% lower than the corresponding values for Concept C for cases with and without replacement power respectively. If CO2 byproduct can be sold at $20/ton, incremental COE values are reduced to 1.53 and 1.52 Cents/kWh, respectively. Additional reductions would be possible with capacity factor increases, investment cost decreases or system efficiency increases. Significant investment cost decreases and efficiency increases may be possible as oxygen transport membrane technology develops. Previous internal studies (Liljedahl, et al., 1999) have shown membrane technology to provide specific investment cost ($/kW) reductions of about 30% and net plant heat rate improvements greater than 20%. Barring governmental mandates, it is clear that none of these three retrofit concepts will be acceptable to the electric utility industry from the standpoint of cost competitiveness.
ALSTOM Power Inc.
140
June 30, 2001
7.0
COMPARISONS WITH PRIOR WORK
This section provides a comparison of the basic performance, CO2 emissions, investment costs, and cost of electricity results of this study with selected results from the literature (David and Herzog, 2000; Palkes, et al., 1999; and Liljedahl, et al., 1999). Table 7.0.1 summarizes the pertinent technical results determined in this study (Marion, et al., 2001; Griffin, et al., 2001; and Liljedahl, et al., 2001). Figures 7.0.1 and 7.0.2 compare net plant heat rates and CO2 emissions for this study with selected results from the literature (David and Herzog, 2000; Palkes, et al., 1999; and Liljedahl, et al., 1999). This study shows a significantly greater impact on net plant heat rate, for the MEA process, than David and Herzog show. David and Herzog show about a 33% increase in net plant heat rate (e.g. 8,277 vs. 11,037 Btu/kWh; LHV basis) corresponding to an energy penalty of about 25%. This study shows about a 70% increase in net plant heat rate for the MEA system (e.g. 9,309 vs. 15,872 Btu/kWh; LHV basis) corresponding to an energy penalty of about 41%. A partial explanation for this difference can be seen in Figure 7.0.2, which shows specific CO2 emissions. The present work shows significantly higher CO2 removal (e.g., 0.906 to 0.059 kg/kWh) than David and Herzog show (e.g. 0.789 to 0.105 kg/kWh). Using the CO2 emission and heat rate values from these figures, it can be determined that the CO2 captured for the David and Herzog study is about 0.71 kg per original kWh, and for this study it is 0.87 kg per original kWh (e.g. this study is capturing about 23% more CO2 per unit of original net electrical output). Additionally, this study produced a liquid CO2 product stream at 2000 psig with product purity meeting the Dakota Gasification Project specification for EOR (Dakota Gasification WebPages). The David and Herzog product stream was reported at 1470 psia and the details regarding purity are not given although purity is probably similar in both cases. Both these differences would help explain at least partially, the efficiency penalty deviation between the two studies.
Table 7.0. 1:
Summary of Performance for Original Plant and CO2 Capture Study Cases
(units)
Original Plant (Base) 4228.7 --4228.7
Concept A MEA 4228.7 17.7 4246.4
Concept B O2 Fired 4140.0 11.4 4151.5
Concept C MEA-MDEA 4228.7 885.9 5114.6
Fuel Paramaters
Coal Heat Input (HHV) Natural Gas Heat Input (HHV) Total Fuel Heat Input (HHV)
(10 Btu/hr) (10 Btu/hr) (10 Btu/hr)

6 6

463478 0 463478 29700 433778
269341 62081 331422 76007 255414
463056 0 463056 189709 273347
357196 36343 431290 95317 335973

0.3501 0.3666 1.0000 9749 9309
0.2053 0.2150 0.5864 16626 15872
0.2247 0.2354 0.6419 15188 14500
0.2242 0.2371 0.6404 15223 14395

866102 1.997 1.000 --0.906 ---
33084 0.130 0.065 1.867 0.059 0.848
53016 0.194 0.097 1.803 0.088 0.818
92153 0.274 0.137 1.722 0.125 0.782
ALSTOM Power Inc.
141
June 30, 2001
17000 15000 13000 11000

9309
15872 14500 14395 13796
10501 9184 8277
11037
9000 7000 5000 3000
Figure 7.0. 1:
Comparative Net Plant Heat Rate Results for Coal Fired Power Plants
10
0.906
1
0.953 0.206
0.789
0.1
0.059
0.088
0.125
0.146
0.105
0.01
Figure 7.0. 2:
Comparative CO2 Emissions for Coal Fired Power Plants
ALSTOM Power Inc.
142
June 30, 2001
Investment costs are also significantly different between the studies. David and Herzog (2000) show the cost of the CO2 processing plant to be about 529 $/kg/hr of CO2. This study shows 1,037 $/kg/hr of CO2 for this equipment. The differences in the CO2 product conditions and purity, discussed above, may represent part of this deviation. Additionally, for this retrofit study, the steam extracted from the existing steam turbine at the IP/LP crossover pipe had to be further expanded in a new letdown turbine before being exhausted to the reboilers for solvent regeneration. The David and Herzog study was for a new plant and therefore may not have required this letdown turbine/generator and the investment cost associated with it. Not enough information is given in their paper to determine if a letdown turbine is used in their particular system. Other savings may also possible for a new plant designed specifically for CO2 removal. The steam turbine and generator may be significantly less expensive than for a reference plant designed for the same steam flow as a result of the large quantity of extracted low-pressure steam. The low-pressure feedwater heaters and condenser would also be significantly smaller and less expensive. David and Herzog show the incremental capital cost for a new plant, as compared to the reference plant without CO2 capture, to be about 940 $/kW as compared to this study, for a retrofit situation, which shows about 1,600 $/kW. Ultimately David and Herzog show the incremental cost of electricity to be about 3.3 Cents/kWh as compared to Concept A (MEA) of this study, which shows about 6.2 Cents/kWh. Financial assumptions, while probably not identical for both cases, would likely not cause a large impact on this difference. With respect to oxy-fuel firing (Palkes, et al., 1999; Liljedahl, et al., 1999), it is seen that producing the oxygen in a ceramic membrane system leads to an improvement in net plant heat rate of more than 20% over the cases whereby the cryogenic method is used to produce oxygen (e.g., 10,501 vs. 13,796 Btu/kWh). CO2 emissions are somewhat higher with the membrane system (e.g. 0.206 vs. 0.146 kg/kWh) due to natural gas firing in the membrane system air heater. Investment costs were shown to be more than 30% lower. Cost of electricity was not reported in this study.
ALSTOM Power Inc.
143
June 30, 2001
8.0
CONCLUSIONS AND RECOMMENDATIONS FOR FUTURE WORK
Conclusions: No major technical barriers exist for retrofitting AEPs Conesville Unit #5 to capture CO2 for any of the three concepts considered under this study. Nominally, 5-8 acres of new equipment space is needed and is located approximately 1500 feet north of the Unit #5 stack on the existing 200-acre power plant site which accommodates a total of 6 units. If all 6 units on this site were converted to CO2 capture, it would be difficult if not impossible to accommodate all the new CO2 capture equipment on the existing site. Energy requirements and power consumption are high, resulting in significant decrease in overall power plant efficiencies, ranging from about 20.5 to 23% as compared to 35% (all HHV basis) for the Base Case. Specific carbon dioxide emissions were reduced from about 2 lbm/kWh for the Base Case to 0.12 0.26 lbm/kWh for the study cases. Recovery of CO2 ranged from 91 to 96%. Specific investment costs are also high ranging from about 1000 to 2200 $/kW without replacement power, and from about 800 to 1800 $/kW with replacement power. All cases studied indicate significant increases to the COE as a result of CO2 capture. The incremental COE as compared to the Base case (air firing without CO2 capture) ranges from 3.4 to 8.4 /kWh. Similarly CO2 mitigation costs range from about 42-98 $/ton of CO2 avoided for the range of cases studied. Concept B (oxygen firing with flue gas recycle) appears to clearly be the best alternative of the three concepts studied from both an efficiency and incremental COE viewpoint for systems designed for very high CO2 capture (i.e. > 90%). If lower CO2 capture fractions are considered, it appears that Concept A would likely be the best alternative with capture fractions below some as yet undetermined value. Concept C would also improve considerably with lower capture fractions. This study has confirmed two important issues related to firing coal in a CO2 -rich flue gas /O2 mixture: Modifications to the existing steam generator unit pressure parts are not required, and as such will also allow the unit to continue to operate in the conventional air fired mode. This is an important consideration as it is unlikely that much new coal-fired capacity can be built in the short term. CO2-rich flue gas can be cleaned and compressed with a relatively simple system to provide high purity CO2 for usage or sequestration.
While overall plant performance penalty and investment costs are high, an optimum integration of power generation, air separation, and CO2 separation and compression systems may significantly improve the overall system efficiency and economics. The major cost item for Concept B is the air separation plant, both from a capital and an operating cost point of view. While in recent years advances have been made in air separation technology which have steadily improved the costs, new membrane based technologies are being researched which promise to provide greatly reduced auxiliary power requirements and investment costs which will significantly improve the overall system efficiency and economics. Previous studies (Liljedahl, et al., 1999) have shown membrane technology, applied to coal-fired boilers, to provide specific investment cost ($/kW) reductions of about 30% and net plant heat rate improvements greater than 20% as compared to cryogenic based air separation. Recommendations for Future Work: A sensitivity study, for Concepts A and C, showing the impact of reducing CO2 capture percentage on plant efficiency, investment cost, emissions, and cost of electricity. The current work utilized 90% CO2 capture (nominal). The sensitivity study would investigate nominal CO2 capture percentages of 70% and 50%. Detailed analysis of the existing steam turbine for Concept A: In Concept A about 79% of the steam leaving the intermediate-pressure (IP) turbine is extracted from the IP/LP crossover pipe for solvent regeneration. The capability of the existing low-pressure (LP) turbine to operate under these conditions of very low steam flow should be investigated in detail, preferably by the original equipment manufacturer (OEM).
ALSTOM Power Inc.
144
June 30, 2001
Optimization of the amine system reboiler steam pressure for Concepts A and C. Concept B detailed boiler system analysis: A startup/shutdown procedure and system design, particularly the transition from air to oxygen firing (including transient conditions) should be developed. Detailed metal temperature analysis for all heat exchanger sections, including operation at part loads should be analyzed. This should also include furnace wall metal temperatures and analysis of the circulation system. The existing fans should be checked (preferably by the OEMs) for operation under the new conditions. The feasibility of operating the boiler under a slight positive pressure to eliminate air infiltration should also be investigated. Investigation of Improved oxygen production systems for Concept B, in line with the membrane-based air separation research being conducted by various research groups (e.g., Praxair, Air Products, Norsk Hydro). Also optimization of an integrated boiler and oxygen production system. Measurement of furnace heat transfer in CO2/O2 environments in a proof of concept boiler simulation facility. Improved solvents, which require lower regeneration energy requirements and/or can be regenerated at a lower temperature level. Hybrid process using oxygen-enriched combustion and amine based CO2 absorption, to accrue, simultaneously, both CO2 capture and drastic NOx emissions reduction. Investigation of a new novel high risk CO2 capture process that would reduce efficiency penalty and retrofit investment cost. This would likely not utilize the existing boiler.
ALSTOM Power Inc.
145
June 30, 2001
9.0
BIBLIOGRAPHY
Barchas, R. and Davis, R., The Kerr-McGee/Lummus Crest Technology for the Recovery of CO2 from Stack Gases, Presented at the First International Conference on Carbon Dioxide Removal, Amsterdam, The Netherlands, March 46, 1992 BOC Webpage: http://www.boc.com/gases/air/cryo/icoscheme.htm Bozzuto, C., Nsakala, N., McGowan, J, and Borio, R., Engineering Feasibility and Economics of CO2 Sequestration/Use on an Existing Coal-Fired Power Plant: A Literature Survey (Task 1 Report), Prepared for OCDO under Contract NO. CDO/D-98-8 and DOE NETL under Contract NO. DE-FC26-99FT40576. Prepared by ALSTOM Power Inc., Windsor, CT, January 2000 Bozzuto, C., Nsakala, N., Sloan, D., and MacWhinnie, R., Engineering Feasibility and Economics of CO2 Capture on an Existing Coal-Fired Power Plant: A Draft Final Report, Prepared for OCDO under Contract NO. CDO/D-98-8 and DOE NETL under Contract NO. DE-FC26-99FT40576. Prepared by ALSTOM Power Inc., Windsor, CT, June 30, 2000 Chui, E.H, Croiset, E., and Thambimuthu, K.V., Simulation of Coal Combustion in High CO2 and O2 Environment, CANMET Energy Technology Centre, Natural Resources Canada, Ottawa, Canada, K1A 1M1, Private Communication, 2001 Dakota Gasification Company, Carbon Dioxide Specifications, http://www.dakotagas.com/specs/co2spec.htm David, J. and Herzog, H., The Cost of Carbon Capture, Presented at the MIT Sequestration Forum, Cambridge, MA, October 31 November 1, 2000 Gas Turbine World, Combined Cycle Specs, 1998-1999, p. 32 Griffin, T., Bill, A., Marion, J., and Nsakala, N., Controlling Power Plant CO2 Emissions: A Long Range View, for Presentation at the 2001 Power-Gen Europe, Brussels, Belgium, 29-31 May 2001 Hottel, H.C., and Cohen, E.S., Radiant Heat Exchange in a Gas-Filled Enclosure, ASME Paper No. 57-HT-23. New York: American Society of Mechanical Engineers, 1957 Iijima, M., A Feasible New Flue Gas CO2 Recovery Technology for Enhanced Oil Recovery Mitsubishi Heavy Industries, Ltd., Society of Petroleum Engineers, SPE 39686, 1998 Iijima, M., Iwaki, T., Mitsuoka, S., Tanaka, H., Flue Gas CO2 Recovery and its Application Mitsubishi Heavy Industries, Ltd., Technical Review Vol.35 No.1, Feb. 1998 Kobayashi, H., and Prasad, R., A Review of Oxygen Combustion and Oxygen Production Systems, Copyright 1999 Praxair Technology, Inc. Kiga, T., Takano, S., Kimura, N., Omata, K., Okawa, M., Mori, T., and Kato, M., Characteristics of Pulverized-Coal Combustion in the system of Oxygen/Recycled Flue Gas Combustion, energy Convers. Mgmt. 38, (S129), 1997 Liljedahl, G., Marion, J., Nsakala, N., Bozzuto, C., Palkes, Vogel, D., Gupta, J.C., Guha, M., Johnson, H., and Plasynski, S., Technical and Economic Feasibility of CO2 Capture on an Existing Coal-Fired Power Plant, for Presentation at the 2001 International Joint Power Generation Conference, New Orleans, LA, June 4-7, 2001 Liljedahl, G., Nsakala, N., Palkes, M., Integration of Ceramic Oxygen Transport Membrane Processes with Coal Fired Power Plants, Alstom Power Proprietary Internal Publication, August 2, 1999
ALSTOM Power Inc.
146
June 30, 2001
Marion, J., Nsakala, N., Bozzuto, C., Liljedahl, G., Palkes, Vogel, D., Gupta, J.C., Guha, M., Johnson, H., and Plasynski, S., Engineering Feasibility of CO2 Capture on an Existing Coal-Fired Power Plant, Presented at the 26th International Conference on Coal Utilization & Fuel Systems, Clearwater, FL, March 5-8, 2001 Orr, F., Stanford University, Private Communication, 2001 Palkes, M., Liljedahl, G., Nsakala, N., McDonald, M., and Gupta, J.C., Preliminary Design of a CO2/O2 Combustion Retrofit To an Existing Coal-Fired Boiler for CO2 Extraction, Presented at Electric Power Gen 99 Conference, Baltimore, MD, April 20-22, 1999 Rochelle, G., Research Needs for CO2 Capture from Flue Gas by Aqueous Absorption/Stripping, Draft of Final Report for DOE P.O. NO. DE-AF26-FT01029, University of Texas at Austin, Texas, September 2000 Thambimuthu, K., Private Communication, 1998 Weller, B., Boiarski, T., and Barrett, R., An Experimental Evaluation of Firing Pulverized Coal in and CO2-O2 Atmosphere, Battelle Columbus Laboratories Presentation to Argonne National Laboratory, 1985 White H.J., Industrial Electrostatic Precipitation, Reading, Mass, Addison-Wesley Publishing Co., 1962, Library of Congress Card No. 62-18240
ALSTOM Power Inc.
147
June 30, 2001
APPENDIX I
- DRAWINGS
This appendix contains all drawings developed for this project for Concepts A, B, and C and also includes a plot plan of the existing site. Existing Plant: 66-530.00 Plot Plan Existing Overall Site before CO2 Unit Addition Concept A: U01-D-0208 Plot Plan Concept A: Flue Gas Cooling & CO2 Absorption U01-D-0214 Plot Plan Concept A: Solvent Stripping U01-D-0204 Plot Plan Concept A: CO2 Compression & Liquefaction U01-D-0211 Plot Plan Concept A: Overall Layout Conceptual Plan U01-D-0200R Plot Plan Concept A: Modified Overall Site Plan Concept B: U01-D-0203 Plot Plan Concept B: Air Separation Plants U01-D-0209 Plot Plan Concept B: Flue Gas Cooling U01-D-0205 Plot Plan Concept B: CO2 Compression & Liquefaction U01-D-0212 Plot Plan Concept B: Overall Layout Conceptual Plan U01-D-0201R Plot Plan Concept B: Modified Overall Site Plan Boiler Modifications: U00-E-0551R General Arrangement - Side Elevation for Concept B U00-E-0552R General Arrangement - Plan View "B-B" for Concept B U00-E-0585R General Arrangement - Plan View "A-A" for Concept B Concept C: U01-D-0207 Plot Plan Concept C: De-Oxy Catalyst & Cooling U01-D-0210 Plot Plan Concept C: Flue Gas Cooling & CO2 Absorption U01-D-0215 Plot Plan Concept C: Solvent Stripping U01-D-0206 Plot Plan Concept C: CO2 Compression & Liquefaction U01-D-0213 Plot Plan Concept C: Overall Layout Conceptual Plan U01-D-0202R Plot Plan Concept C: Modified Overall Site Plan
ALSTOM Power Inc.
148
June 30, 2001
Existing Plant: The existing plant site drawing is shown below: 66-530.00 Plot Plan Existing Overall Site before CO2 Unit Addition
ALSTOM Power Inc.
149
June 30, 2001
ALSTOM Power Inc
150
June 30, 2001
Concept A: The plant layout drawings prepared for the Concept A CO2 Recovery System are as follows: U01-D-0208 Plot Plan Concept A: Flue Gas Cooling & CO2 Absorption U01-D-0214 Plot Plan Concept A: Solvent Stripping U01-D-0204 Plot Plan Concept A: CO2 Compression & Liquefaction U01-D-0211 Plot Plan Concept A: Overall Layout Conceptual Plan U01-D-0200 Plot Plan Concept A: Modified Overall Site Plan
ALSTOM Power Inc
151
June 30, 2001
ALSTOM Power Inc
152
June 30, 2001
ALSTOM Power Inc.
153
June 30, 2001
ALSTOM Power Inc.
154
June 30, 2001
ALSTOM Power Inc.
155
June 30, 2001
ALSTOM Power Inc.
156
June 30, 2001
Concept B: The plant layout drawings prepared for the Concept B Air Separation Unit & CO2 Recovery System are as follows: U01-D-0203 Plot Plan Concept B: Air Separation Plants U01-D-0209 Plot Plan Concept B: Flue Gas Cooling U01-D-0205 Plot Plan Concept B: CO2 Compression & Liquefaction U01-D-0212 Plot Plan Concept B: Overall Layout Conceptual Plan U01-D-0201 Plot Plan Concept B: Modified Overall Site Plan The boiler modification drawings prepared for the Concept B are as follows: U00-E-0551- General Arrangement - Side Elevation for "Concept B" U00-E-0552 - General Arrangement - Plan View "B-B" for "Concept B" U00-E-0585 - General Arrangement - Plan View "A-A" for "Concept
ALSTOM Power Inc
157
June 30, 2001
ALSTOM Power Inc
158
June 30, 2001
ALSTOM Power Inc.
159
June 30, 2001
ALSTOM Power Inc.
160
June 30, 2001
ALSTOM Power Inc
161
June 30, 2001
ALSTOM Power Inc.
162
June 30, 2001
ALSTOM Power Inc.
163
June 30, 2001
ALSTOM Power Inc.
164
June 30, 2001
ALSTOM Power Inc.
165
June 30, 2001
Concept C: The plant layout drawings prepared for the Concept C CO2 Recovery System are as follows: U01-D-0207 Plot Plan Concept C: De-Oxy Catalyst & Cooling U01-D-0210 Plot Plan Concept C: Flue Gas Cooling & CO2 Absorption U01-D-0215 Plot Plan Concept C: Solvent Stripping U01-D-0206 Plot Plan Concept C: CO2 Compression & Liquefaction U01-D-0213 Plot Plan Concept C: Overall Layout Conceptual Plan U01-D-0202 Plot Plan Concept C: Modified Overall Site Plan
ALSTOM Power Inc
166
June 30, 2001
ALSTOM Power Inc
167
June 30, 2001
ALSTOM Power Inc.
168
June 30, 2001
ALSTOM Power Inc.
169
June 30, 2001
ALSTOM Power Inc.
170
June 30, 2001
ALSTOM Power Inc.
171
June 30, 2001
ALSTOM Power Inc.
172
June 30, 2001
APPENDIX II
- EQUIPMENT LISTS
This appendix contains equipment lists for the CO2 Capture Systems of Concepts A, B, and C. Concept A Equipment List and Data:
Number of Trains 5 5 9 9 9 9 9 7 7 7 7 5 9 9 7 7 7 7 7 9
Tag no.
Description
Size Parameters
Material
DA-2101 DA-2102 DA-2201 EA-2201 EA-2203 EA-2204 EA-2206 EA-2301 EA-2302 EA-2303 EA-2304 EA-2101 EA-2205 EA-2202 EA-2401 EA-2402 EC-2301
Direct Contact Flue Gas Cooler CO2 Absorber Solvent Stripper Solvent Stripper Reboiler
27' ID x 34' S/S, DP 2.5 psig/ 0.7 psi vac 27' ID x 92' S/S, DP 2.5 psig/ 0.7 psi vac 16' ID x 100' S/S, DP 35 psig/ FV
CS/SS CS/SS CS/SS
217 MMBTU/HR DP S/T, 50 psig/ 60 CS/SS psig Solvent Stripper Reclaimer 5.6 MMBTU/HR, DP S/T, 120 psig/ 190 CS/TI psig Solvent Reclaimer Effluent 5 MMBTU/HR, DP S/T, 125 psig, 100 CS/TI Cooler psig Solvent Stripper CW 41.6 MMBTU/HR, DP S/T, 35 psig/ 100 SS/TI Condenser psig CO2 Compr. 1st Stage 1.9 MMBTU/HR, DP S/T, 75 psig/ 100 SS/TI Aftercooler psig CO2 Compr. 2nd Stage 1.3 MMBTU/HR, DP S/T, 125 psig/ 100 SS/TI Aftercooler psig CO2 Compr. 3rd Stage 1 MMBTU/HR, DP S/T, 235 psig/ 100 CS/TI Aftercooler psig CO2 Condenser 19 MMBTU/hr DP S/T, 235 psig/ 300 CS/TI psig Direct Contact Flue Gas Water 4.8 MMBTU/HR, DP P/U, 50 psig/ 100 TI Clr psig Rich / Lean Solvent Exchanger 210 MMBTU/HR, DP P/P, 135 psig/ SS316 155 psig Lean Solvent Cooler 101.8 MMBTU/HR, DP P/U 135 psig/ TI 100 psig Propane Refrig Condenser 20.45 MMBTU/HR, DP S/T, 300 psig/ CS/CS 100 psig Propane Refrig Subcooler 5.9 MMBTU/HR, DP S/T, 300 psig/ CS/LTCS 2500 psig 2.94 MMBTU/HR, DP 75 psig 3.1 MMBTU/HR, DP 125 psig 4.6 MMBTU/HR, DP 235 psig 80.3 MMBTU/HR, DP 135 psig SS SS SS SS
CO2 compressor 1st stage air cooler EC-2302 CO2 compressor 2nd stage air cooler EC-2303 CO2 compressor 3rd stage air cooler EC-2201 Solvent stripper bottoms cooler FA-2201 Solvent Stripper Reflux Drum FA-2301 CO2 Compressor 2st Stage Suction Drum FA-2302 CO2 Compressor 3rd Stage
9 7 7
5' ID x 16' S/S, DP 35 psig/ FV 7'- 6" ID x 10' S/S, DP 75 psig 6' ID x 10' S/S, DP 125 psig
304L CS/SS CS/SS
ALSTOM Power Inc
173
June 30, 2001
7 7 7 7 3 5 5 5 5 9
FA-2303 FA-2304 FA-2401 FA-2402 FB-2503 FD-2101
Suction Drum Liquid CO2 Surge Drum CO2 Compressor 3rd stage Discharge KO Drum Propane Refrig Surge Drum Propane Refrig Suction Scubber Caustic day tank DCC Water Filter
4'- 6" ID x 14' S/S, DP 235 psig 4' 6" ID x 10' S/S, DP 235 psig 10' ID x 30' S/S, DP 300 psig 8' 6" ID x 12' S/S, DP 300 psig 2' ID x 4' S/S, DP atm 205 gpm, DP 35 psig 1425 gpm, DP 29 psi 205 gpm, DP 36 psi 3450 gpm, DP 92 psi 3000 gpm, DP 85 psi
KCS CS/SS CS LTCS CS SS DI/SS SS/SS SS/SS SS/SS
9 9 9 7 3 7 7 1 9 9 7 1 1 1
GA-2101 Wash Water Pump A/B GA-2102 Direct Contact Cooler Water A/B Pump GA-2103 Rich Solvent Pump A/B/C/D Lean Solvent Pump GA2201A/B/ C GA-2202 Solvent Stripper Reflux Pump A/B GA-2203 Filter Circ. Pump A/B GA-2204 LP Condensate Booster Pump A/B GA-2301 CO2 Pipeline Pump A/B GA-2501 Caustic metering pump GB-2301 GB-2401 GB-2500 PA-2551 PA-2251 PA-2351 CO2 Compressor (Motor driven) Propane Refrig Compressor LP steam turbine/ generator Corrosion Inhibitor Package Solvent Filter Package CO2 Dryer Package Crane for Compr. Bldg. Flue gas ducting Cooling Tower Cooling tower blowdown treatment package
310 gpm, DP 75 psi 290 gpm, DP 91 psi 512 gpm, DP 237 psi 217 gpm, DP 1815 psi .45 gpm, DP 50 psi 4480 hp 3075 hp 83365 hp
DI/SS SS/SS CI/ SS CS/CS SS SS wheels LTCS
Metering, 25 lb/ hr 140 gpm 4 driers, 200 hp compressor, elec heater, cooler
PA-2551 PA-2552
22000 gpm, includes basin, pumps, chlorine injection 100 gpm sand filters and dechlorinator, hypochlorite storage tank
ALSTOM Power Inc.
174
June 30, 2001
Concept B Equipment List and Data: Number of Trains 1 2
Tag No. DA DA-101 A/B/C DA-102
Service
Sizing Parameters
MOC
Columns and Towers Direct Contact Flue Gas Cooler 27' ID x 30' S/S, DP 10 psig, 3 psi CS w/ SS vacuum liner CO2 Rectifier 6'/ 13' ID x 30'/ 10' S/S, DP 425 LTCS psig Heat Transfer Equipment Shell & Tube Exchangers Flue Gas Compressor 1 Stage Trim Cooler Flue Gas Compressor 2 Stage Trim Cooler Flue Gas Compressor 3 Stage Trim Cooler CO2 Condenser Refrig condenser Refrig Subcooler CO2 Rectifier Condenser Rectifier Ovhd Interchanger 7.25 MMBTU/h, DP S/T, 85 psig/ CS/SS 85 psig 4.2 MMBTU/HR, DP S/T, 175 CS/SS psig/ 125 psig 4.1 MMBTU/HR, DP S/T, 425 CS/SS psgi/ 300 psig 64.3 MMBTU/HR, DP S/T, 300 LTCS/ psig/ 425 psig LTCS 68.8 MMBTU/HR, DP S/T, 300 CS/CS psig/ 200 psig 20 MMBTU/HR, DP S/T, 300 CS/ LTCS psig/ 2500 psig 5.2 MMBTU/HR, DP S/T, 425 SS/SS psig/ 425 psig 1.6 MMBTU/HR, DP S/T, 425 LTCS/ SS psig/ 425 psig Total 313 MMBTU/HR, DP P/U, 65 psig/ 100 psig CS
E 2 2 2 2 2 2 2 EA EA-101 EA-102 EA-103 EA-104 EA-201 EA-202 EA-107 EA -108
EB EB-101
Plate Exchangers Water Cooler
2 2 2
EC EC-101 EC-102 EC-103
Air Coolers Flue Gas Compressor 1 Stage Aftercooler Flue Gas Compressor 2 Stage Aftercooler Flue Gas Compressor 3 Stage Aftercooler Heaters Dryer Regeneration Gas Heater Drums and Vessels Flue Gas Compressor 2nd Stage Suction Drum Flue Gas Compressor 3rd Stage Suction Drum Flue Gas Compressor Third Stage Discharge K/O Drum Refrig Surge Drum Refrig Suction Srubber
25.5 MMBTU/HR, DP 85 psig 21.6 MMBTU/HR, DP 175 psig 21.4 MMBTU/HR, DP 425 psig
SS SS SS
FH FH-101 FA FA-101 FA-102 FA-103 FA-201 FA-202
Gas fired, 8.5 MBTU/HR
2 2 2 2 2
10' ID x 26' S/S, DP 85 psig 8' ID x 20' S/S DP 175 psig 8' ID x 12' S/S, DP 425 psig 16' ID x 34' S/S DP 300 psig 16' ID x 16' S/S, DP 300 psig
CS w/ SS liner CS w/ SS liner CS w/ SS liner CS ITCS
ALSTOM Power Inc.
175
June 30, 2001
1 2
FD FD-101 FD-102 FF FF-101 A/H GA GA-101 A/B/C/D GA-103A/B GB GB-101 GB-102 GB-100 GB-103 PA PA-101A/B PA-102 A/B PA-103
Filters and Dryers Water Filter Flue Gas Filter Dryers (Desiccant Type) Flue Gas Dryer Pumps Centrifugal Water Pump CO2 Pipeline pump Compressors & Blowers Flue Gas Compressor Propane Refrig Compressor Flue Gas Blower Flue Gas Booster Packaged Equipment Large Air Separation Unit Small Air Separation Unit Cooling Tower
6 units, 2422 gpm each, DP 50 psig 2718 ACFM, DP 425 psig
SS CS
Six Vessels, 5 drying, 1 regeneration
CS
1 2 2 2 1 1
4900 gpm, DP 35 psi 800 gpm, DP 1655 psi 3 stages Includes Lube/Seal Oil Systems, 18818 kW 2 Stage, Includes lube oil/ seal oil system, 7188 kW 2750 HP 500 HP
CI w/ SS impeller ITCS SS ITCS SS SS
1 1 1
3925 tons/ day 99% pure O2 550 tons/ day 99% pure O2 93200 gpm Includes pumps, basin, and chlorine injection, hypochlorite storage tank
PA-104
Cooling Tower Make-up water Purification unit Ducting
ALSTOM Power Inc.
176
June 30, 2001
Concept C Equipment List and Data: Number of Trains 5 5 5 5 5 5 5 9 5 5 5 5 9 9 9 9 9 7 7 7 7 5 9 9 7 7
Tag no. D-301X DA-301
Description Flue gas scrubber De-oxy Catalyst Reactor
Size Parameters 192500 ACFM, 213 lb/hr SO2 2 shells 32 dia x 50 S/S DP 14 psig
Material 316L CS w/ refractory CS CS/SS CS/SS CS/SS CS/SS CS CS CS
DA-302 Reactor Effluent/ Steam Drum 8' 6" ID x 16' S/S, DP 2000 psig DA-303 De-oxy Catalyst Reactor 2 DA-2101 Direct Contact Flue Gas Cooler 27' ID x 34' S/S, DP 2.5 psig/ 0.7 psi vac DA-2102 CO2 Absorber 27' ID x 92' S/S, DP 2.5 psig/ 0.7 psi vac DA-2103 Bottom Direct Contact Flue Gas 27' ID x 20' S/S, DP 2.5 psig/ 0.7 psi Cooler vac DA-2201 Solvent Stripper 16' ID x 100' S/S, DP 35 psig/ FV EA-301 EA-303 EA-304 EA-305 EA-2201 EA-2203 EA-2204 Feed/ Effluent Exchanger Reactor effluent/ steam superheater Reactor effluent/ steam generator Dry Flue Gas Cooler Solvent Stripper Reboiler Solvent Stripper Reclaimer 167.8 MMBTU/HR, DP 5 psig, 5 psig 24 MMBTU/HR, DP 2100 psig 70 MMBTU/HR, DP 2100 psig
Solvent Reclaimer Effluent Cooler EA-2206 Solvent Stripper CW Condenser EA-2208 EA-2301 EA-2302 EA-2303 EA-2304 EA-2101 EA-2205 EA-2202 EA-2401 EA-2402 Solvent stripper bottoms cooler CO2 Compr. 1st Stage Aftercooler CO2 Compr. 2nd Stage Aftercooler CO2 Compr. 3rd Stage Aftercooler CO2 Condenser Direct Contact Flue Gas Water Clr Rich / Lean Solvent Exchanger Lean Solvent Cooler Propane Refrig Condenser Propane Refrig Subcooler
42.5 MMBTU/HR, DP 350 psig CS 167 MMBTU/HR DP S/T, 50 psig/ CS/SS 60 psig 5.6 MMBTU/HR, DP S/T, 120 psig/ CS/TI 190 psig 5 MMBTU/HR, DP S/T, 125 psig, CS/TI 100 psig 45.7 MMBTU/HR, DP S/T, 35 psig/ SS/TI 100 psig 66.7 MMBTU/HR, DP P/U 135 psig/ SS/TI 100 psig 2 MMBTU/HR, DP S/T, 75 psig/ 100 SS/TI psig 1.35 MMBTU/HR, DP S/T, 125 psig/ SS/TI 100 psig 1.1 MMBTU/HR, DP S/T, 235 psig/ CS/TI 100 psig 20 MMBTU/hr DP S/T, 235 psig/ CS/TI 300 psig 77.3 MMBTU/HR, DP P/U, 50 psig/ TI 100 psig 133 MMBTU/HR, DP P/P, 135 psig/ SS316 155 psig 60 MMBTU/HR, DP P/U 135 psig/ TI 100 psig 22 MMBTU/HR, DP S/T, 300 psig/ CS/CS 100 psig 6.2 MMBTU/HR, DP S/T, 300 psig/ CS/LTCS 2500 psig
ALSTOM Power Inc.
177
June 30, 2001
7 7 7
EC-2301 EC-2302 EC-2303
CO2 compressor 1st stage air cooler CO2 compressor 2nd stage air cooler CO2 compressor 3rd stage air cooler Solvent Stripper Reflux Drum CO2 Compressor 2st Stage Suction Drum CO2 Compressor 3rd Stage Suction Drum Liquid CO2 Surge Drum CO2 Compressor 3rd stage Discharge KO Drum Propane Refrig Surge Drum Propane Refrig Suction Scubber Caustic day tank DCC Water Filter Start-up heater HP Condensate Booster pumps Wash Water Pump Direct Contact Cooler Water Pump Rich Solvent Pump Bottom Direct Contact Cooler Water Pump Lean Solvent Pump Solvent Stripper Reflux Pump Filter Circ. Pump LP Condensate Booster Pump CO2 Pipeline Pump Caustic metering pump Flue Gas Blower CO2 Compressor (Motor driven) Propane Refrig Compressor LP steam turbine/ generator HP steam turbine/ generator
3.2 MMBTU/HR, DP 75 psig 3.3 MMBTU/HR, DP 125 psig 4.9 MMBTU/HR, DP 235 psig
SS SS SS
9 7 7 7 7 7 7 3 5 5 5 5 5 5 5 9 9 9 9 7 3 5 7 7 1 1
FA-2201 FA-2301 FA-2302 FA-2303 FA-2304 FA-2401 FA-2402 FB-2503 FD2101A/B FH- 302 GA-301 A/B GA-2101 A/B GA-2102 A/B GA-2103 A/B/C/D GA-2104 A/B GA2201A/B/C GA-2202 A/B GA-2203 A/B GA-2204 A/B GA-2301 A/B GA-2501 GB-301 GB-2301 GB-2401 GB-2500 GB-2501
5' ID x 16' S/S, DP 35 psig/ FV 7'- 6" ID x 10' S/S, DP 75 psig 6' ID x 10' S/S, DP 125 psig 4'- 6" ID x 14' S/S, DP 235 psig 4' 6" ID x 10' S/S, DP 235 psig 10' ID x 30' S/S, DP 300 psig 8' 6" ID x 12' S/S, DP 300 psig 2' ID x 4' S/S, DP atm 1645 gpm each, DP 35 psig 54.6 MMBTU/HR 163 gpm, DP 1500 psi 1425 gpm, DP 29 psi 3289 gpm, DP 36 psi 2435 gpm, DP 92 psi 325 gpm, DP 36 psi 2095 gpm, DP 85 psi 310 gpm, DP 75 psi 290 gpm, DP 91 psi 395 gpm, DP 237 psi 228 gpm, DP 1815 psi .45 gpm, DP 50 psi 3350 hp 4750 hp 3225 hp 48809 hp 52421 hp
304L CS/SS CS/SS KCS CS/SS CS LTCS CS SS CS DI/SS DI/SS SS/SS SS/SS SS/SS SS/SS DI/SS SS/SS DI/SS CS/CS SS SS SS wheels LTCS
ALSTOM Power Inc.
178
June 30, 2001
9 7 1 1 1
PA-2251 PA-2351
Solvent Filter Package CO2 Dryer Package Crane for Compr. Flue gas ducting Cooling Tower Make-up water purification package
140 gpm 4 dryers, 200 hp compressor, fired heater, cooler
PA-2551 PA-2552
67500 gpm, includes basin, pumps, chlorine injection 1570 gpm clarifier w/ b/d sump and pump, and CT b/d dechlorinator, hypochlorite storage tank
ALSTOM Power Inc.
179
June 30, 2001
ALSTOM Power Inc
180
June 30, 2001
VOLUME II
ALSTOM Power Inc
181
June 30, 2001
ENGINEERING FEASIBILITY AND ECONOMICS OF CO2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT FINAL REPORT VOLUME II BENCH-SCALE TESTING AND COMPUTATIONAL FLUID DYNAMICS (CFD) EVALUATION SUBMITTED BY ALSTOM POWER INC. POWER PLANT LABORATORIES 2000 DAY HILL ROAD WINDSOR, CT 06095 (860) 688-1911 Carl R. Bozzuto, Project Manager Nsakala ya Nsakala, Project Engineer David G. Sloan, Principal Investigator Raymond MacWhinnie John L. Marion PREPARED FOR OHIO DEPARTMENT OF DEVELOPMENT OHIO COAL DEVELOPMENT OFFICE COLUMBUS, OHIO 43266 (CONTRACT NO. CDO/D-98-8) AND US DEPARTMENT OF ENERGY NATIONAL ENERGY TECHNOLOGY LABORATORY PITTSBURGH, PENNSYLVANIA 15236 (CONTRACT NO. DE-FC26-99FT40576) REPORT SUBMITTAL DATE: JUNE 29, 2001 PROJECT PERFORMANCE PERIOD: NOVEMBER 11, 1999 JUNE 30, 2001 PPL REPORT NO. PPL-01-CT-10
ALSTOM Power Inc
182
June 30, 2001
ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 ON AN EXISTING COAL-FIRED POWER PLANT
VOLUME II: BENCH SCALE TESTING AND CFD EVALUATION
Disclamer This report was prepared by ALSTOM Power Plant Laboratories with support in part by a grant from both the Ohio Coal Development Office/Ohio Department of Development and the United States Government. Neither the State of Ohio, the United States Government, nor any of their agencies, nor any person acting on their behalf: 1. Make any warranty or representation, express or implied, with respect to the accuracy, completeness, or usefulness of the information contained in this report, or that the use of any information, apparatus, method or process disclosed in this report may not infringe privately-owned rights; or 2. Assume any liabilities with respect to the use of, or damages resulting from the use of, any information, apparatus, method or process disclosed in this report. References herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring; nor do the view and opinions of authors expressed herein necessarily state or reflect those of the State of Ohio, the United States Government or their agencies.
ALSTOM Power Inc.
June 30, 2001
Acknowledgements The authors appreciatively acknowledge the following people for their contributions to the successful performance of the work presented herein: Gregory A. Burns for setting up and running all the Drop Tube Furnace System-1 (DTFS1) tests; Kurt W. Johnson and the Chemical Analytical Services Laboratory personnel for providing all fuel analyses; John Holmes and all the Electrical and Controls Services personnel for providing computer and instrumentation support; and Woodrow A. Fiveland for his leadership and counsel on the CFD computations. The financial support of this project by OCDO (Contract NO. CDO/D-98-8), DOE National Energy Technology Laboratory (Contract NO. DE-FC26-99FT40576), ALSTOM Power Inc. and ABB Lummus Global Inc. is also appreciated. The in-kind financial support of the project by American Electric Power is greatly appreciated.
ALSTOM Power Inc.
June 30, 2001
Public Abstract ALSTOM Power Inc.s Power Plant Laboratories (ALSTOM) has teamed with American Electric Power (AEP), ABB Lummus Global Inc. (ABB), the US Department of Energy National Energy Technology Laboratory (DOE NETL), and the Ohio Coal Development Office (OCDO) to conduct a comprehensive study evaluating the technical feasibility and economics of alternate CO2 capture and sequestration technologies applied to an existing US coal-fired electric generation power plant. The motivation for this study was to provide input to potential US electric utility actions concerning GHG emissions reduction. If the US decides to reduce CO2 emissions, action would need to be taken to address existing power plants. Although fuel switching from coal to natural gas may be one scenario, it will not necessarily be a sufficient measure and some form of CO2 capture for use or disposal may also be required. The output of this CO2 capture study will enhance the publics understanding of control options and influence decisions and actions by government, regulators, and power plant owners in considering the costs of reducing greenhouse gas CO2 emissions. The total work breakdown structure is encompassed within three major reports, namely: (1) Literature Survey, (2) AEPs Conesville Unit #5 Retrofit Study, and (3) Bench-Scale Testing and CFD Evaluation. The report on the literature survey results was issued earlier by Bozzuto, et al. (2000). Reports entitled AEPs Conesville Unit #5 Retrofit Study and Bench-Scale Testing and CFD Evaluation are provided as companion volumes, denoted Volumes I and II, respectively, of the final report. The work performed, results obtained, and conclusions and recommendations derived therefrom are summarized below. Volume I The Volume I report discusses three retrofit technology concepts, which were evaluated in conjunction with AEPs Conesville Unit #5, namely: Concept A: Coal combustion in air, followed by CO2 separation with Kerr-McGee/ABB Lummus Globals commercial MEA-based absorption/stripping process Concept B: Coal combustion with O2 firing and flue gas recycle (oxy-fuel firing) Concept C: Coal combustion in air with oxygen removal and CO2 separation by a mixture of primary and tertiary amines, i.e., monoethanolamine (MEA)/methyldiethanolamine (MDEA).
Each of these technologies was evaluated against a baseline case, without CO2 capture, from the standpoints of performance, impacts on power generating cost, and CO2 emissions. AEPs 450 MW Conesville Unit No. 5, located in Conesville, Ohio, was used for the power plant case study. All technical performance and cost results associated with the available options were evaluated in a comparative manner. Major conclusions: No major technical barriers exist for retrofitting AEPs Conesville Unit #5 to capture CO2 for any of the three concepts considered under this study. Concept B (oxygen firing with flue gas recycle) appears clearly to be the best alternative of the three concepts studied from both an efficiency and incremental COE viewpoint. This study has confirmed two important issues related to firing coal in a CO2-rich flue gas / O2 mixture: Modifications to the existing steam generator unit pressure arts are not required, and as such will also allow the unit to continue to operate in the conventional air- fired mode. CO2-rich flue gas can be cleaned and compressed with a relatively simple system to provide high purity CO2 for usage or sequestration. Energy requirements and power consumption are high, resulting in significant decreases in overall power plant efficiencies (HHV basis), ranging from efficiencies of 20.5 to 22.5%, as compared to 35.0% for the Base case (air
ALSTOM Power Inc.
June 30, 2001
firing without CO2 capture), which is equivalent to an energy penalty ranging from 36% to 41%. That is, the net power plant output was reduced to 77% - 59%. Specific investment costs are high, ranging from about 800 to1800 $/kW and from 1000 to 2200 $/kW, corresponding to scenarios with and without replacement power, respectively. All cases studied indicate significant increases to the COE as a result of CO2 capture. The incremental COE as compared to the Base case (air firing without CO2 capture) ranges from 3.4 to 8.4 /kWh. Similarly CO2 mitigation costs range from about 42-98 $/ton of CO2 avoided for the range of cases studied. Specific carbon dioxide emissions were reduced from about 2 lbm/kWh for the Base case to 0.13 0.27 lbm/kWh for the study cases. Recovery or capture of CO2 ranged from 91 to 96%. Nominally, 5-8 acres of new equipment space is needed for Unit #5 alone on the existing 200-acre power plant site, which accommodates a total of 6 units with a total power generating capacity of 2,080 MW.
Major recommendations: A sensitivity study, for Concepts A and C, showing the impact of reducing CO2 capture percentage on plant efficiency, investment cost, emissions, and cost of electricity. The current work utilized 90% CO2 capture (nominal). The sensitivity study would investigate nominal CO2 capture percentages of 70% and 50%. Detailed analysis of the existing steam turbine for Concept A: In Concept A about 79% of the steam leaving the intermediate-pressure (IP) turbine is extracted from the IP/LP crossover pipe for solvent regeneration. The capability of the existing low-pressure (LP) turbine to operate under these conditions of very low steam flow over the load range should be investigated in detail, preferably by the original equipment manufacturer (OEM). Optimization of the amine system reboiler steam pressure for Concepts A and C. Concept B detailed boiler system analysis: A startup/shutdown procedure and system design, particularly the transition from air to oxygen firing (including transient conditions) should be developed. Detailed metal temperature analysis for all heat exchanger sections, including operation at part loads should be analyzed. This should also include furnace wall metal temperatures and analysis of the circulation system. The existing fans should be checked (preferably by the OEMs) for operation under the new conditions. The feasibility of operating the boiler under a slight positive pressure to eliminate air infiltration should also be investigated. Investigation of Improved oxygen production systems for Concept B, in line with the membrane-based air separation research being conducted by various research groups (e.g., Praxair, Air Products, Norsk Hydro). Also optimization of an integrated boiler and oxygen production system. Measurement of furnace heat transfer in CO2/O2 environments in a proof of concept boiler simulation facility. Improved solvents, which require lower regeneration energy requirements and/or can be regenerated at a lower temperature level, similar to MHIs KS1 system, but for coal-firing application. Hybrid process using oxygen-enriched combustion and amine based CO2 absorption, to accrue, simultaneously, both CO2 capture and drastic NOx emissions reduction. Investigation of a new novel high risk CO2 capture process that would reduce efficiency penalty and retrofit investment cost. This would likely not utilize the existing boiler.
Volume II
ALSTOM Power Inc. June 30, 2001
The bench-scale testing consisted primarily of drop-tube (DTFS-1) and thermo-gravimetric analyses (TGA). Three cases were investigated: (1) an air-fired case (Base case); (2) a case in which the N2 was replaced by an equal mass of CO2 (Constant Mass case); and (3) a case in which the N2 volume was replaced by an equal volume of CO2 (Constant Volume case). The Constant Mass case represents the appropriate retrofit scenario in a commercial pulverized coal firing application, albeit without flue gas recycling. Major conclusions: (a) Based on TGA results Both the Conesville Unit #5 and Pittsburgh Seam #8 coals have, for air (Base case) and O2/CO2 environments (Constant Mass/Volume cases), similar burning characteristics, as they both go to completion within the same temperature range (550-575 oC). Burning either of the coals in air or any of the O2/CO2 mixture ratios used here would produce virtually identical results; and (2) both coals have similar reactivity characteristics. (b) Based on DTFS-1 results Residence time, as expected, has a significant impact on the overall coal combustion efficiency, and hence, on the unburned carbon emission in the fly ash for both coals under consideration. That is, while the combustion efficiency for both coals is only about 80% (dry-ash-free coal basis) at 0.2 sec., it is more than 98% at greater than 0.5 sec. Correspondingly, unburned carbon emissions range from about 65% to about 2% (dry fly ash basis). The impact of reaction medium is also significant. While the overall combustion efficiencies do not seem to exhibit significant differences between the baseline and Constant Mass firing, the more sensitive parameter, unburned carbon (UBC) in the fly ash, on the other hand, clearly shows better performance for the Constant Mass case. That is, the UBC at the furnace outlet was about a factor of 4.5 lower for the Constant Mass case (~2% vs. 9%). This is believed to be due to higher reactant gas temperature, and yet longer residence (0.77 sec. vs. 0.57 sec.). It appears, from the shape of the UBC profiles, that, if given enough residence time, these differences would narrow down considerably, implying that the ultimate performance in both mediums would be similar. The coal sample from Conesville Unit #5 appears to perform better than the sample from Pittsburgh seam #8 coal (e.g., 9% vs. 12.5% UBC for the air firing case). However, based on the shape of the UBC profiles, it can be seen that if given additional residence time, they would both be expected to perform similarly. NOx emission from oxy-fuel firing is about a factor of 3 (0.73 vs. 2.25 lb/MMBtu) lower than that of the Base case. Correspondingly, sulfur dioxide is lower by about 19% (3.6 vs. 4.3 lb/MMBtu), and CO is significantly lower (0.09 lb/MMBtu vs. a negligible amount).
(c) Based on CFD results The baseline case exhibits higher carbon-in-ash (by 1.6 percentage points), higher outlet NOx emissions (by a factor of 2), and higher outlet CO (by a factor of 2) than the Concept-B case. These same computational trends are also qualitatively exhibited by the bench-scale testing. The baseline case exhibits a slightly higher peak gas temperature (maximum difference of about 200 F), and a correspondingly higher average (cross-sectional) gas temperature (difference of 90 F at the HFOT), than that of the Concept-B case. The net wall absorption in the furnace region for the baseline case is larger (by less than 1%) than that of the Concept-B case. However, a significant variation in both calculated and experimental irradiation to the wall between baseline and oxy-firing scenarios was also found in the literature (e.g., +6 to 18%). Differences may be partially attributed to the sensitivity of the irradiation and local emissivities to the aerodynamic and flame patterns, which are, in turn, a function of the furnace and firing system. It is suggested that radiatively absorbing gas species can either enhance or inhibit the irradiation in the vicinity of the wall, depending upon their local temperature and their relative spatial placement.
ALSTOM Power Inc.
June 30, 2001
Major recommendations: Carry out a systematic coal fundamentals study concerning this field of endeavor. This study should be geared toward the creation of a database of information depicting the impact of coal nature (using coals of various rank coming from both domestic and international sources) when fired in an oxy-fuel environment on: Coal devolatilization and char oxidation kinetics, and unburned carbon emissions in the fly ash Acid rain-related gaseous (NOx, SO2, and CO) emissions Air toxics, particularly, mercury (Hg), volatile organic compounds (VOCs), and particulate emissions. Derive furnace heat transfer data from natural gas and coal firing in an oxy-fired pilot-scale furnace, which simulates the temperature/time history of a boiler. Use first the data from natural gas firing to validate the CFD code, without the complication of burning particles transiting the boiler. Apply the experience learned from modeling a natural gas fired boiler to model the coal-fired boiler.
ALSTOM Power Inc.
June 30, 2001
TABLE OF CONTENTS Page Executive Summary 1 1.0 BACKGROUND/OBJECTIVES 7 2.0 BENCH-SCALE TESTING 8 2.1 Introductory Remarks 8 2.2 Analysis of Test Coals 8 2.3 Combustion Evaluation of Size-Graded Coal Samples11 2.3.1 Thermo-Gravimetric Analysis (TGA) ......................................................................................................... 11 2.3.1.1 TGA Description and Procedure .............................................................................................................. 11 2.3.3.2 TGA Results ............................................................................................................................................... 13 2.3.2 Drop Tube Furnace System-1 (DTFS-1) Testing....................................................................................... 17 2.3.2.1 DTFS-1 Description and Testing Procedure .......................................................................................... 17 2.3.2.2 Reactant Gas Temperature Measurements ............................................................................................... 19 2.3.2.3 Unburned Carbon and Gaseous Emission Results ................................................................................... 21 2.3.3 Conclusions and Recommendations for Future Work............................................................................... 28 2.3.3.1 Conclusions ............................................................................................................................................... 28 2.3.3.2 Recommendations for Future Work......................................................................................................... 28 3.0 CFD Evaluation Of Conesville Boiler No. 5 30 3.1 Introduction 30 3.2 Grid Preparation 30 3.3 Baseline Calibration Procedure and Strategy 36 3.4 CFD Test Matrix 37 3.5 Input and Boundary Conditions 38 3.6 Submodel Parameters and Case Preparation 47 3.7 Calculation Results 49 3.8 Contour Plots 56 3.9 Conclusions 62 4.0 Bibliography 65
LIST OF TABLES Table 2. 1: Standard ASTM Analysis of Test Coals...........................................................................................................9 Table 2. 2: Characteristics of Test Coal Ash Samples .................................................................................................... 10 Table 2. 3: Proximate and Ultimate Analyses of Size Graded Coal Samples.............................................................. 11 Table 2. 4: Thermo-Gravimetric Analysis Test Matrix................................................................................................. 12 Table 2. 5: DTFS-1 Test Matrix.......................................................................................................................................... 19 Table 2. 6: Summary of DTFS-1 Test Results on Coal Combustion Efficiencies and Unburned Carbon in Fly Ashes ................................................................................................................................................................................ 22 Table 2. 7: Summary of DTFS-1 Test Results on Gaseous emissions from Conesville Unit #5 Coal Combustion27 Table 3. 1: Matrix of CFD Cases ........................................................................................................................................ 37 Table 3. 2: Overall Mass Flow Rate Parameters ............................................................................................................. 39 Table 3. 3: Overall Gas Property and Input Parameters ............................................................................................... 40 Table 3. 4: Coal Composition and Heating Value ............................................................................................................ 41 Table 3. 5: Mass Flow Rates for the Secondary Gas Feed Streams .............................................................................. 42 Table 3. 6: Mass Flow Rates for the Primary Gas and Coal Feed Streams ................................................................. 43 Table 3. 7: Wall Heat Transfer Parameters in the CFD Cases ..................................................................................... 46 Table 3. 8: Energy Extracted from Tube Banks .............................................................................................................. 47 Table 3. 9: Comparison of Predicted Residual Carbon and Emissions for Cases 1 and 2 ........................................ 49 Table 3. 10: Comparison of Predicted Gas Temperature and Sectional Wall Absorption Values for Cases 1 and 2 ........................................................................................................................................................................................... 51
ALSTOM Power Inc. June 30, 2001
LIST OF FIGURES Page Figure 2. 1: Thermo-Gravimetric Analyzer (TGA) ......................................................................................................... 12 Figure 2. 2: TGA Coal Combustion Efficiency Profiles.................................................................................................. 14 Figure 2. 3: Differential Thermo-Gravimetric Analysis Profiles .................................................................................. 15 Figure 2. 4: TGA Reaction Rates of Coal Samples .......................................................................................................... 16 Figure 2. 5: ALSTOM Powers Drop-Tube Furnace System-1 (DTFS-1)................................................................... 18 Figure 2. 6: Measured and Predicted Gas Temperatures in the DTFS-1 .................................................................... 20 Figure 2. 7: Specific Heats of Nitrogen and Carbon Dioxide as a Function of Temperature ................................... 21 Figure 2. 8: DTFS-1 Generated Coal Combustion Efficiency Profiles......................................................................... 23 Figure 2. 9: DTFS-1 Generated Unburned Carbon in Fly Ash Samples ..................................................................... 24 Figure 2. 10: DTFS-1 Generated NOx, CO and SO2 Emissions .................................................................................... 26 Figure 3. 1: Sectional Side View of the Conesville Unit #5 Steam Generator ............................................................. 31 Figure 3. 2: Isometric Views of the Conesville Unit #5 Computational Domain........................................................ 32 Figure 3. 3: Side Views of the Conesville Unit #5 Exterior Grid................................................................................... 33 Figure 3. 4: Detailed Drawing of Windbox and Corresponding Side View of Grid Depicting Nozzle Openings. 34 Figure 3. 5: Cross-Sectional View of Normal Firing Angles for Conesville Unit 5 .................................................... 35 Figure 3. 6: Cross-Sectional View of Grid, in the Vicinity of the Windbox, for Conesville Unit 5.......................... 36 Figure 3. 7: Furnace and Backpass Sections Specific to the RHBP .............................................................................. 44 Figure 3. 8: Depictions of Specific Planes for Comparisons of Averaged Temperatures.......................................... 50 Figure 3. 9: Vertical Profiles of the Local Peak and Area-Weighted Net Wall Heat Flux for the Base Case........ 54 Figure 3. 10: Vertical Profiles of the Local Peak and Area-Weighted Net Wall Heat Flux for the Concept-B Case ........................................................................................................................................................................................... 54 Figure 3. 11: Vertical Profiles of the Local Peak and Mass-Averaged Gas Temperatures for the Base Case....... 55 Figure 3. 12: Vertical Profiles of the Local Peak and Mass Averaged Gas Temperatures for the Concept B Case ........................................................................................................................................................................................... 56 Figure 3. 13: Planar Contour Plots of Temperature at Various Elevations for the Base Case and Concept-B Case ........................................................................................................................................................................................... 57 Figure 3. 14: Planar Contour Plots of Temperature at two Elevations for the Base Case and Concept-B Case .. 58 Figure 3. 15: Planar Contour Plots of Temperature at the X-Mid-Plane for the Base Case and Concept-B Case59 Figure 3. 16: Contour Plots of O2 Mass Fraction (Wet) at the X-Mid-Plane for the Base Case and Concept-B Case .................................................................................................................................................................................. 60 Figure 3. 17: Contour Plots of the (Upward) Z-Velocity at the X-Mid-Plane for the Base Case and Concept-B Case .................................................................................................................................................................................. 61 Figure 3. 18: Net Wall Heat Flux for the Base Case and Concept-B Case .................................................................. 62
ALSTOM Power Inc.
June 30, 2001
Executive Summary
Background International discussions continue to debate the need for reductions in emission levels of green house gases (GHG). Because fossil fuel fired power plants are among the largest and most concentrated producers of CO2 emissions, it stands to reason that recovery of CO2 from the flue gas of such plants has been identified as one of the primary means for reducing CO2 emissions. ALSTOM Power Inc.s Power Plant Laboratories (ALSTOM) teamed with American Electric Power (AEP), ABB Lummus Global Inc. (ABB), the US Department of Energy National Energy Technology Laboratory (DOE NETL), and the Ohio Coal Development Office (OCDO) to conduct a comprehensive study evaluating the technical and economic feasibility of three alternate CO2 capture technologies applied to an existing US coal-fired electric generation power plant. The steam generator analyzed in this study is the Conesville No. 5 unit, operated by American Electric Power (AEP) of Columbus, Ohio. This steam generator is a nominal 450 MW, coal-fired, subcritical pressure, controlled circulation unit. It has a single cell furnace that employs corner-fired, tilting, tangential burners and which fires bituminous coal from the state of Ohio. The flue gas leaving the boiler system is cleaned of particulate matter in an electrostatic precipitator (ESP) and of SO2 in a lime-based flue gas desulfurization (FGD) system before being discharged to the atmosphere. ALSTOM is managing and performing the subject study from its US Power Plant Laboratories office in Windsor, CT. ABB, from its offices in Houston, Texas, is participating as a sub-contractor. AEP is participating by offering their Conesville Generating Station as the case study and cost sharing consultation, along with relevant technical and cost data. AEP is one of the largest US utilities, and as the largest consumer of Ohio coal, is bringing considerable value to the project. Similarly, ALSTOM and ABB are well established as global leaders in the design and manufacturing of steam generating equipment, petrochemical, and CO2 separation technology. The DOE National Energy Technology Laboratory and the Ohio Coal Development Office provided consultation and funding. All participants contributed to the cost share of this project. Objectives The motivation for this study was to provide input to potential US electric utility actions concerning GHG emissions reduction. If the US decides to reduce CO2 emissions, action would need to be taken to address existing power plants. Although fuel switching from coal to natural gas may be one scenario, it will not necessarily be a sufficient measure and some form of CO2 capture for use or disposal may also be required. The output of this CO2 capture study will enhance the publics understanding of control options and influence decisions and actions by government, regulators, and power plant owners in considering the costs of reducing greenhouse gas CO2 emissions. The key goals of the study were to evaluate the impacts on the plant output, efficiency, and CO2 emissions, resulting from the addition of the CO2-capture systems. Cost estimates were developed for the systems required to produce, extract, clean and compress the CO2, which could then be available for use in enhanced oil or gas recovery or sequestration. Additionally, the impact of CO2 capture on the cost of electricity (COE) and on the mitigation cost for CO2 ($/ton of CO2 avoided) was also evaluated. Work Scope The total work breakdown structure is encompassed within three major reports, namely: (1) Literature Survey, (2) AEPs Conesville Unit #5 Retrofit Study, and (3) Bench-Scale Testing and CFD Evaluation. The report on the literature survey results was issued earlier by Bozzuto, et al. (2000). The report entitled AEPs Conesville Unit #5 Retrofit Study constitutes Volume I of the final report. Bench-Scale Testing and CFD Evaluation is presented herein as the Volume II report. The work performed, results obtained, and conclusions and recommendations derived therefrom are summarized in the sections that follow.
ALSTOM Power Inc.
1
June 30, 2001
Bench-Scale Testing The overall objective of the (Volume II) work segment was to provide critical technical information for evaluating a single option, selected from the three retrofit technology options available, which had the highest probability of realizability. The final option selected was that denoted as: Coal Combustion in an O2/CO2 Environment with CO2 Recycle. Specific objectives were two-fold: (1) bench-scale testing was to provide experimental combustion and emissions performance data on a specific Ohio coal under conditions where the fuel was to be burned in mixtures of CO2 and O2; and (2) a computational fluid dynamics (CFD) modeling effort was to utilize design and operating information from a commercial boiler burning Ohio coal in order to establish a calculation for the conventional burning of coal (in air), and then to evaluate performance in the same commercial unit for the burning of the same coal in mixtures of CO2 and O2. Bench-scale results provided surrogate combustion kinetics, NOx, CO, SO2 and unburned carbon results on the coal that is presently burned in the Conesville Boilers Units #5 and 6 under conditions that represent conventional combustion (in air) and in various mixtures of CO2 and O2. A knowledge of the actual combustion and emissions data from Conesville Unit #5 provided a means whereby the baseline bench-scale results in air were referenced and interpreted; in a sense, it allowed calibration of the bench-scale experimental facility to a given point of reference. Referencing the baseline bench-scale results to the actual furnace emissions data allowed a more accurate interpretation of the bench-scale results of the CO2-O2 mixtures and permitted a more reliable/extrapolation of how an actual retrofitted boiler would respond to the same CO2-O2 mixtures. The completed literature survey, performed under an initial task of this project (Bozzuto, et al., 2000), indicated that no fundamental combustion performance had been carried out on any coal in CO2/O2 media. Hence, the work scope provided first-of-a-kind information to the project. Information derivation and application was carried out as follows: First, bench-scale testing of the Conesville coal was carried out in both air (to provide baseline information) and in two mixtures of CO2 and O2. A comparison of the information on combustion performance in air with information from ALSTOMs proprietary database permitted ALSTOM to select char oxidation kinetic parameters to be used on a surrogate basis during the calibration of the CFD cases.
Coal Characteristics ASTM standard analyses and ash chemistry analyses were performed for coal samples from AEPs Conesville Unit #5 and Pittsburgh #8 seam. Both of these coal samples are typical of good Eastern US bituminous steaming coals, with fuel values (i.e., FC/VM ratios) of 1.4 and 1.3, respectively. Both coals have high sulfur contents and exhibit medium potentials for slagging the boiler waterwall and convective pass. TGA Results The coal samples were size graded to 200x400 mesh. These size-graded materials were subsequently tested in the thermo-gravimetric analyzer (TGA) and the drop-tube furnace system (DTFS-1) equipment to determine their reactivities and unburned carbon emission propensities. Three cases were evaluated for each coal. The Base case consisted of burning the coal in air. The Constant Mass case consisted of burning the coal in an O2/CO2 mixture, such that the mass of O2 used in the Base case was maintained and the mass of N2 used in the Base case was replaced with an equal mass of CO2. The Constant Volume case consisted burning the coal in O2/CO2 mixture, such that the mass of O2 used in the Base case was again maintained and the volume of N2 used in the Base case was replaced with an equal volume of CO2.
ALSTOM Power Inc.

2
June 30, 2001
The combustion efficiency profiles from the TGA indicate that both the Conesville and Pittsburgh #8 coals, for both the air (Base case) and O2/CO2 environments (Constant Mass/Volume cases), have similar burning characteristics, as they both go to completion within the same temperature range (550-575oC). Additional analysis of the weight loss as a function of time, as well as the temperature at which the maximum reaction rate occurs, confirms that: (1) burning either of the coals in air or any of the O2/CO2 mixture ratios used will produce virtually identical results; and (2) both coals have similar reactivity characteristics. Drop-Tube Combustion Furnace System-1 Results The DTFS-1 testing was used to derive quantitative information on the impact of various operating parameters such as particle size, stoichiometry and temperature/time history on unburned carbon loss and gaseous (NOx, CO and SO2) emissions. The coal feed rate was adjusted for each coal such that the overall stoichiometry () was ~2.50, which is the stoichiometry required to achieve reasonably low unburned carbon emissions in the drop tube. The DTFS-1 was operated in a laminar flow regime, with a Reynolds number in the 150-225 range; the maximum residence time for the conditions evaluated was about 0.8 seconds. DTFS-1 results showed the following: Residence time has, as expected, a significant impact on the overall coal combustion efficiency, and hence, on the unburned carbon emission in the fly ash for both coals under consideration. That is, while the combustion efficiency for both coals is only about 80% (dry-ash-free coal basis) at 0.2 sec residence time, it is more than 98% at greater than 0.5 sec. residence times. Correspondingly, unburned carbon emissions range from about 65% to less about 2% (dry fly ash basis) for the same residence times. The impact of reaction medium is also significant. While the overall combustion efficiencies do not seem to exhibit significant differences between the baseline and Constant Mass firing, the more sensitive parameter, unburned carbon (UBC) in the fly ash, on the other hand, clearly shows better performance for the Constant Mass case. That is, the UBC at the furnace outlet was more than a factor of 4.5 lower for the Constant Mass case (~2% vs. 9%). This is believed to be due to higher reaction temperature, and yet longer residence time (0.77 sec. vs. 0.57 sec.). It appears, from the shape of the UBC profiles, that, if given enough residence time, these differences would considerably narrow down, implying that the performance in both mediums would be similar. The coal sample from Conesville Unit #5 appears to perform better than the sample from Pittsburgh seam #8 coal (e.g., 9% vs. 12.5% UBC for the air firing case). However, based on the shape of the UBC profiles, it can be seen that if given additional residence times, they would both be expected to perform similarly. NOx emission from oxy-fuel firing is about a factor of 3 (0.73 vs. 2.25 lb/MMBtu) lower than that of the Base case. Correspondingly, sulfur dioxide is lower by about 19% (3.6 vs. 4.3 lb/MMBtu), and CO is significantly lower (0.09 lb/MMBtu vs. a negligible amount). The gaseous emission trends are consistent with results reported by others (Thambimuthu, et al.; 1998; Weller, et al., 1985) and by the CFD results of the present study (Section 3.0, below).
CFD Analysis ALSTOM Power uses a commercial CFD code (denoted FLUENT) from Fluent Inc. for its simulations of furnaces and auxiliary equipment. Case preparation of a boiler for the Fluent code was initiated with the collection of the geometry data (from blueprints and schematics), the free areas of the nozzles, and the operating conditions. A CFD grid or mesh was prepared using a combination of EXCEL spreadsheets and a grid-generation package (denoted GAMBIT) supplied by Fluent Inc. The total number of cells in the grid was approximately 315,000. Two cases have been compared using the FLUENT CFD code a baseline, nominal 15% excess air case (Case 1 or Base case), and a recirculated flue gas, oxy-fired case (Case 2 or Concept-B case). In the Concept-B case, the nitrogen was largely replaced by carbon dioxide. The cases have been compared on the basis of equivalent nozzle/inlet areas, as well as an equivalent coal-to-oxygen feed ratio (by mass).
ALSTOM Power Inc.
3
June 30, 2001
The baseline case was calibrated to known furnace performance and operating conditions. Calibration is required because of the uncertainty associated with wall fouling factors, particle reactivities, etc. Implicit boundary conditions that were matched during the baseline calibration included: the unburned carbon (UBC) in the fly ash (i.e., carbon-in-ash value) at the outlet of the computational domain the outlet NOx emissions value at the outlet of the computational domain the horizontal furnace outlet temperature (HFOT), which is the mass-weighted average temperature across the plane at the apex of the arch (i.e. the horizontal furnace outlet plane or HFOP).
Both the UBC and NOx emissions values were derived from experimental measurements (usually taken downstream of the air preheater). The HFOT value was calculated by an in-house, proprietary design package denoted the Reheat Boiler Program (RHBP). An iterative trial-and-error method was used to calibrate the baseline case by changing the input parameters for char oxidation, NOx, and waterwall conduction resistance, until (after a number of runs) the code calculations matched the desired UBC, the NOx value, and the HFOT, respectively. Lateral and vertical waterwall heat flux or absorption distributions, as well as the overall heat transfer in the lower and upper furnace, were extracted from the CFD calculations. Total and sectional (area-weighted) waterwall heat absorption rates, in addition to peak heat absorption values, were used to quantify the heat absorption rates that constitute one of the metrics used as a basis of comparison between the cases. Metrics utilized to compare the cases include: the unburned carbon (UBC) in the fly ash at the outlet of the computational domain the outlet NOx emissions value at the outlet of the computational domain the horizontal (and/or vertical) furnace outlet temperature(s) (FOT) the outlet CO emissions value at the outlet of the computational domain total, sectional, and peak waterwall heat flux or absorption rates
Some of the metrics for the two cases, such as NOx, were compared on a basis that is scaled or referenced to the baseline value, since relative trends may be a more reliable indicator of the expected performance than the absolute magnitudes of the metrics. Line and contour plots for variables of interest were prepared at selected horizontal or vertical planes, as appropriate. The predictions provided a relative indication of the changes that occurred in the oxy-firing case as a result of deviation from the baseline operating conditions. The difference in inlet nozzle velocities, mixture specific heats, and radiative properties between CO2 and N2 had a visible impact on the performance criteria and metrics of interest, e.g., HFOT, waterwall heat flux distributions, NOx emissions, and unburned carbon in the fly ash. Overall, the CFD runs served to provide insight into the flow and reaction patterns of the lower furnace, as well as to provide relative changes in emissions and residual carbon values at the exit plane as a result of changes in operating conditions. CFD Results and Conclusions The following computational results have been highlighted: The baseline case exhibits higher carbon-in-ash (by 1.6 percentage points), higher outlet NOx emissions (by a factor of 2), and higher outlet CO (by a factor of 2) than the Concept-B case. These same computational trends are also qualitatively exhibited by the bench-scale testing. The baseline case exhibits a slightly higher peak gas temperature (maximum difference of about 200 F), and a correspondingly higher average (cross-sectional) gas temperature (difference of 90 F at the HFOT), than that of the Concept-B case. The net wall absorption in the furnace region for the baseline case is larger (by less than 1%) than that of the Concept-B case. (Conversely, the net wall absorption for the baseline calculation with the RHBP was found to be about 6% lower than the Concept-B case calculated by the RHBP.)
June 30, 2001
4
ALSTOM Power Inc.
Explanations for the observed trends must rely on physical property differences between the nitrogen, which dominates in the baseline case, and carbon dioxide, which largely supplants the nitrogen in the Concept-B case. The physical species properties and the anticipated consequences are itemized below: 1. Higher molecular weight of CO2 relative to N2. For equivalent inlet areas, and as a result of the molecular weight and associated density differences, the baseline case will exhibit larger inlet velocities and a higher penetration capability than the Concept-B case. The inlet velocity differences will further serve to impact the aerodynamic, particle trajectory, mixing, and flame patterns. 2. Higher specific heat of CO2 relative to N2. For an equivalent local heat release and heat transfer, the higher specific heat of carbon dioxide will serve to decrease the overall flame temperatures of the recycled flue gas mixture in the Concept-B case, relative to the baseline case. 3. Higher gas emissivity and absorptance of CO2 relative to N2. For an equivalent local gas temperature, the higher emissivity of CO2, relative to the optically transparent N2, should serve to increase the absorption coefficient (and the irradiation to the wall) in the recycled flue gas case (Concept-B) relative to the baseline case. The three physical properties listed above may have compensatory rather than cumulative effects. In the present CFD calculations, the resultant, local gas temperatures are not equivalent in the two cases. The higher specific heat of the carbon dioxide, and the associated lower gas temperatures in the Concept-B case, will tend to offset somewhat or compensate for the expected increase in the wall absorption (i.e., anticipated due to the enhanced emissivity of the CO2.) Furthermore, the spatial distribution of the carbon dioxide across the cross-section may be important; it is hypothesized that high concentrations of CO2 in the cooler gas mixtures between the wall and the flame may actually act to inhibit the net radiative flux to the walls. The trend calculated by the CFD code, with respect to the furnace temperature at the HFOP, appears to be qualitatively aligned with the trend calculated by the in-house RHBP code. However, the difference in wall absorption for the Concept-B case relative to the baseline case, calculated by FLUENT (change of 1%), does not fully agree with the results of the RHBP (change of +6%). Computed and/or experimental trends that indicate that oxy-firing may induce either an increase in wall absorption (+6%) or a decrease in wall absorption (-18%), relative to the baseline case, are supported in the literature. It is suggested that the absorptive properties of a local CO2-containing gas mixture in the vicinity of the wall may either act to enhance or inhibit the incident radiative flux to the wall, depending upon its relative spatial placement and mixture temperature. For example, a low-temperature, CO2-rich mixture near the wall would absorb the radiative flux from the interior fireball region; a portion of the energy would be re-emitted at the lower gas temperature, and the remainder of the energy would be used to heat up the gas. The result would be a net reduction in the incident radiative flux to the wall. Conversely, a high-temperature, CO2-rich mixture near the wall would emit at its local gas temperature, thus enhancing the incident radiative flux to the wall. Therefore, it is suggested that the relative spatial relationships of the cool and hot gas mixtures, the relative composition of the absorbing media, and the proximity of that media to the wall (as induced by the furnace and firing system aerodynamics), may significantly impact the gas-phase irradiation to the wall. Indeed, the aerodynamic and flame patterns that prevail in a given air-fired or oxy-fired furnace may conceivably have as strong an impact on the net wall absorption as the physical property differences themselves (gas-phase emissivity, specific heat, etc.) The results of computational tools (such as CFD and the RHBP) should be viewed as being qualitative in nature, particularly when they are asked to produce calculations outside of the experience base for which they have been validated. Certainly, the gas-phase and particle-phase radiation property submodels could be enhanced in both codes, and the impact of spatial gradients (caused by the interleaving of hot and cool regions of varying CO2 composition) on radiative wall flux needs to be investigated more fully. CFD computations have been utilized to gain a more in-depth qualitative understanding of aerodynamic and flame patterns in combustion systems, but have not yet been integrated into routine boiler design procedures. At the present time, the ALSTOM design standards are based upon the experience and expertise built into the RHBP and other design protocols, and those standards must be adhered to in any new design project in order to mitigate risk. Therefore, the results of the RHBP must be regarded as the default standard, both from an engineering experience viewpoint and from a rules-based design viewpoint. However, additional validation work needs to be done in order to confirm the trends for oxy-firing scenarios.
ALSTOM Power Inc.

5
June 30, 2001
Although differences in physical properties of the transport gases (e.g., air-firing versus oxy-firing) may initially induce undesirable deviations from the performance goals of a field unit, the designer and engineer views such alterations as challenges rather than insurmountable obstacles. Much can be done in the way of operating condition optimization (e.g., spray and nozzle tilt), without major retrofits, to realign steam temperatures and wall absorptions with their desired, target values. Design parameters are often in conflict, and the intelligent designer must work to balance various parameters and operating conditions to achieve the desired outcome. The CFD work performed here was based on certain constraints to maintain equivalency for comparison purposes, which would not necessarily be the case in the field. For example, a potential decrease in furnace wall absorption of several percentage points could be nullified through manipulation of various operating parameters. If required, firing system retrofits and surface modifications could be performed to handle more severe decreases in absorption; certainly new unit design could easily accommodate any necessary alterations in design philosophy. Recommendations for Future Work There is, to the authors knowledge, no fundamental coal combustion work being carried out elsewhere to determine the impact of coal nature in an oxy-fuel environment on unburned carbon and gaseous and particulate emissions. Hence, the following is recommended: Carry out a systematic coal fundamentals study concerning this field of endeavor. This study should be geared toward the creation of a database of information depicting the impact of coal nature (using coals of various rank coming from both domestic and international sources) when fired in an oxy-fuel environment on: Coal devolatilization and char oxidation kinetics, and unburned carbon emissions in the fly ash Acid rain-related gaseous (NOx, SO2, and CO) emissions Air toxics, particularly mercury (Hg), volatile organic compounds (VOCs), and particulate emissions. Derive furnace heat transfer data from natural gas and coal firing in an oxy-fired pilot-scale furnace, which simulates the temperature/time history of a boiler. Use first the data from natural gas firing to validate the CFD code, without the complication of burning particles transiting the boiler. Apply the experience learned from modeling a natural gas-fired boiler to model the coal-fired boiler.
ALSTOM Power Inc.

6
June 30, 2001
1.0
BACKGROUND/OBJECTIVES
ALSTOM Power Inc.s Power Plant Laboratories led a team, which performed a study titled Engineering Feasibility and Economics of CO2 Capture on an Existing Coal-Fired Power Plant, under the auspices of the OCDO and DOE NETL. The other team members were ABB Lummus Global Inc. and American Electric Power (AEP). The overall objective of this project was to evaluate the technical feasibility and the economics of alternate CO2 capture and sequestration/use technologies for retrofitting an existing coal-fired power plant. Three alternate CO2 capture systems (see Section 3 of Volume I) were evaluated, with attention being given to the impact of such systems on an existing boiler, the auxiliary components of the boiler, the boiler and overall plant performance, and the power plant costs, including the cost of electricity. The overall objective of this work segment was to provide critical technical information for evaluating one of the three retrofit technology options, namely Coal Combustion in an O2/CO2 Environment with CO2 Recycle. Specific objectives were two-fold: (1) bench-scale testing was to provide experimental combustion and emissions performance data on a specific Ohio coal under conditions where the fuel was to be burned in mixtures of CO2 and O2; and (2) a computational fluid dynamics (CFD) modeling effort was to utilize design and operating information from a commercial boiler burning Ohio coal in order to establish a calculation for the conventional burning of coal (in air), and then to evaluate performance in the same commercial unit for the burning of the same coal in mixtures of CO2 and O2. Bench-scale results provided surrogate combustion kinetics, NOx, CO, SO2 and unburned carbon results on the coal that is presently burned in the Conesville Boilers Units #5 and 6 under conditions that represent conventional combustion (in air) and in various mixtures of CO2 and O2. A knowledge of the actual combustion and emissions data from Conesville Unit #5 provided a means whereby the baseline bench-scale results in air were referenced and interpreted; in a sense, it allowed calibration of the bench-scale experimental facility to a given point of reference. Referencing the baseline bench-scale results to the actual furnace emissions data allowed a more accurate interpretation of the bench-scale results of the CO2-O2 mixtures and permitted a more reliable/extrapolation of how an actual retrofitted boiler would respond to the same CO2-O2 mixtures. The completed literature survey, performed under an initial task of this project (Bozzuto, et al., 2000), indicated that no fundamental combustion performance had been carried out on any coal in CO2/O2 media. Hence, the work scope provided first-of-a-kind information to the project. Information derivation and application was carried out as follows: First, bench-scale testing of the Conesville coal was carried out in both air (to provide baseline information) and in various mixtures of CO2 and O2. A comparison of the information on combustion performance in air with information from ALSTOMs proprietary database permitted ALSTOM to select char oxidation kinetic parameters to be used on a surrogate basis during the calibration of the CFD cases.
ALSTOM Power Inc.

7
June 30, 2001
2.0
2.1
BENCH-SCALE TESTING
Introductory Remarks
ALSTOM Powers DTFS-1 has been used extensively over the years to derive, among other things, the following information (Nsakala, et al., 1986; Nsakala, et al., 1991; Thornock, et al., 1993): High temperature volatile matter yields from coals over the whole ASTM rank spectrum and from various synthetic solid fuels (petroleum cokes, refused-derived fuels, process coal gasification chars, beneficiated coal-based fuels, etc.). Fuel nitrogen conversion from coals over the whole ASTM rank spectrum and from the same various synthetic solid fuels given above. Gasification and devolatilization kinetic parameters for coals over the whole ASTM rank spectrum and for the same various synthetic solid fuels given above. Oxidation kinetic parameters of chars prepared from coals over the whole ASTM rank spectrum and from the same various synthetic solid fuels given above.
This information is used, where appropriate, in conjunction with coal combustion modeling with CFD and other proprietary in-house codes for the purpose of predicting (principally) unburned carbon loss and NOx emissions in pulverized fuel fired utility power boilers. 2.2 Analysis of Test Coals
Tables 2.1 and 2.2 present the ASTM standard analyses and ash chemistries of coal samples from AEPs Conesville Unit #5 and Pittsburgh #8 seam. Both of these coal samples are typical of good Eastern US bituminous steaming coals, with fuel values (i.e., FC/VM ratios) of 1.4 and 1.3, respectively. Consistent with the majority of the coal samples from this geological province, they have high sulfur contents (2.4 and 3.5 lbm S/MMBtu, respectively). Their coal ashes are typical of Eastern coal ashes, in which the iron contents are greater than the sums of alkali and alkaline earth contents. Based on the commonly used ash slagging and fouling indices, in conjunction with ash contents and fusibility temperatures, these coal ashes have only medium potentials of slagging the boiler waterwall and convective pass. The plant personnel from Conesville Generating Station confirmed this behavior, with respect to their Unit #5. The coal samples in Table 2.1 were size graded to 200x400 mesh. These size-graded materials (Table 2.3) were subsequently tested in the TGA and DTFS-1 equipment to determine their reactivities and unburned carbon emission propensities. It is important to note that the chemical compositions of these size fractions are comparatively consistent with those of the parent coal samples they were prepared from.
ALSTOM Power Inc.

8
June 30, 2001
Table 2. 1: Standard ASTM Analysis of Test Coals
CONESVILLE #5 COAL QUANTITY As Rec'd Coal Properties Moisture Volatile Matter Fixed Carbon (Diff.) Ash 10.1 32.7 45.9 11.3 41.6 58.4 (hvAb) daf
PITTSBURGH #8 COAL (hvAb) As Rec'd daf
8.2 34.8 44.5 12.5 43.9 56.1
Hydrogen Carbon Sulfur Nitrogen Oxygen (Diff.)
4.3 63.2 2.7 1.3 7.1
5.5 80.4 3.4 1.7 9.0
3.9 64.3 4.1 1.2 5.8
4.9 81.1 5.2 1.5 7.3
FC/VM Sulfur loading, lb.S/MMBtu
1.40 2.39
---
1.28 3.50
---
HHV (Btu/lb.) lb. Ash/MMBtu HGI
11293 10.0 50
14368.
11726 10.7 63
14787.
Ash Properties Fusibility Temperatures, ( F) I.T. S.T. H.T. F.T. 2125 2140 2165 2180 2140 2185 2240 2290
o
Ash Comp., (Wt.%, Dry) SiO2 Al2 O3 Fe2 O3 CaO MgO Na 2O K2O TiO2 P2O5 SO3 MnO TOTAL 45.9 21.7 20.4 2.9 0.9 0.9 2.0 1.1 0.3 3.0 0.1 99.2 47.7 19.9 22.9 3.0 0.7 0.6 2.1 1.0 0.5 1.5 0.1 99.9
ALSTOM Power Inc.

9
June 30, 2001
Table 2. 2: Characteristics of Test Coal Ash Samples

PARAMETER
Conesville Unit #5 Coal Data 2125 2140 2165 2180 45.9 21.7 20.4 2.9 0.9 0.9 2.0 1.1 0.3 3.0 99.1 3.0
Pittsburgh #8 Coal Data 2140 2185 2240 2290 47.7 19.9 22.9 3.0 0.7 0.6 2.1 1.0 0.5 1.5 99.9 4.4
Fusibility Temperatures ( F) I.T. S.T. H.T. F.T. Composition, Wt.% (dry) SiO2 Al2O 3 Fe2 O3 CaO MgO Na2 O K 2O TiO 2 P 2O 5 SO3 Total Coal Sulfur Content, Wt.% (dry) Ash Type Slagging Index Definition Bituminous Ash: R S = B/A*S Lignitic Ash: R* S = [Max (H.T.)+4*Min(I.T.)]/5 Slagging Index & Potential Bituminous Ash: R S = B/A*S RS < 0.6 = low 0.6<R s<2.0 = medium 2.0<R s<2.6 = high Rs>2.6 = severe Lignitic Ash: R* S = [Max (H.T.)+4*Min(I.T.)]/5 Rs* > 2450 = low 2250<Rs*< 2450 = medium 2150<Rs*< 2250 = high Rs* < 2100 = severe Fouling Index Definition Bituminous Ash: R F = B/A*Na 2 O Lignitic Ash, Na2O, when CaO+MgO+Fe 2O 3 >20% (w/w) Lignitic Ash, Na2O, when CaO+MgO+Fe 2O 3 <20% (w/w) Fouling Index & Potential Bituminous Ash: R F = B/A*Na 2 O RF < 0.2 = low 0.2 < R F < 0.5= medium 0.5 < R F < 1.0= high RF>1.0 = severe Lignitic Ash, Na2O, when CaO+MgO+Fe 2O 3 >20% (w/w) Na 2O < 3 = low to medium 3 <Na2O < 6 = high Na 2O > 6 = severe Lignitic Ash, Na2O, when CaO+MgO+Fe 2O 3 <20% (w/w) Na 2O < 1.2 = low to medium 1.2 <Na2O < 3 = high Na 2O > 3 = severe Index 0.36 Index 1.18
Eastern Bit.
Eastern Bit.
Potential
Index 1.88
Potential
---
Medium
---
Medium
TRUE --Potential Index 0.26
TRUE --Potential
Medium
Medium
0.9 ---
0.6 ---
0.9 ---
0.6 ---
Ash Classification: Fe2O 3 > CaO+MgO ==> Bituminous ash; Fe O3 < CaO+MgO ==> Lignitic ash 2
ALSTOM Power Inc.

10
June 30, 2001
Table 2. 3: Proximate and Ultimate Analyses of Size Graded Coal Samples

CONESVILLE #5 COAL QUANTITY (400x400 Mesh) As Rec'd daf PITTSBURGH #8 COAL (200x400 Mesh) As Rec'd daf
Moisture Volatile Matter Fixed Carbon (Diff.) Ash
3.6 36 50.5 9.9 41.6 58.4
1.1 38.2 48.1 12.7 44.2 55.8
Hydrogen Carbon Sulfur Nitrogen Oxygen (Diff.)
4.5 69.1 3.1 1.4 8.4
5.2 79.9 3.6 1.6 9.7
4.4 70.6 5.2 1.3 4.8
5.1 81.8 6.1 1.5 5.5
2.3
Combustion Evaluation of Size-Graded Coal Samples
The coal samples, whose analyses are given in Table 2.3, were combustion tested in both a Thermo-Gravimetric Analysis (TGA) apparatus and a Drop Tube Furnace System-1 (DTFS-1). The equipment, experimental procedures, and conclusions are presented in the succeeding sections. 2.3.1 Thermo-Gravimetric Analysis (TGA)
The TGA apparatus, experimental procedure, and results are presented below.
2.3.1.1 TGA Description and Procedure
ALSTOM uses a Perkin-Elmer TGA Model 7 (Figure 2.1) to obtain specific reactivity parameters of fuels and limestones, among other things. The TGA is also used to derive the micro-proximate analyses of coals and coal chars, based on a test protocol developed in-house. Testing was conducted as follows. About 4-6 mg of sample was placed in the TGA sample pan. The sample amount was such that it distributed over the bottom of the pan almost as a monolayer, thus minimizing O2 mass transfer control phenomenon during combustion. Equal amounts of nitrogen (which serves to protect the balance) and air is allowed to pass through the reaction tube containing the coal sample. The temperature control mechanism is actuated, such that the heating rate is maintained at 10 oC/min from room temperature to the completion of combustion. Both weight loss and rate of rate of weight loss are monitored and recorded throughout the combustion process. The information from this testing is used, as shown in the next section, to derive combustion efficiency curves, and pseudo surface reaction kinetic parameters of the test coals as a function of reaction medium. Three cases were evaluated for each coal. Fifty cc/min of N2 gas were admitted into the balance compartment to protect it from over-heating. The Base case consisted of burning the coal in 50 cc/min of air. The Constant Mass case consisted of burning the coal in an O2/CO2 mixture, such that the mass of O2 used in the Base case was maintained and the mass of N2 used in the Base case was replaced with an equal mass of CO2. The Constant
ALSTOM Power Inc.

11
June 30, 2001
Volume case consisted of burning the coal in O2/CO2 mixture, such that the mass of O2 used in the Base case was again maintained and the volume of N2 used in the Base case was replaced with an equal volume of CO2.
Gas Flow Control Assembly
Control & Data Acquisition System Control & Data Acquisition
Figure 2. 1: Thermo-Gravimetric Analyzer (TGA)
Table 2. 4: Thermo-Gravimetric Analysis Test Matrix

Balance Combustion Medium Case Cooling N2 (cc/min) (g/min) Total Air Combustion Air O2 N2 CO 2 Grand Total
N2 Comb.Med. Comp. (Vol. %) CO2 O2
(cc/min) (g/min) (cc/min)
(g/min) (cc/min) (g/min) (cc/min) (g/min) (cc/min) (g/min)
Air
Baseline
50
0.0573
50
0.0592
10.5
0.01373
39.5
0.04524
0.0
0.0
100.0
0.1162
89.5
---
10.5
O2/CO 2 Mixture Constant Mass
50
0.0573
0.0
0.0
10.5
0.01373
0.0
0.0
25.2
0.0452
85.7
0.1162
58.4
29.4
12.3
O2/CO 2 Mixture Constant Volume
50
0.0573
0.0
0.0
10.5
0.01373
0.0
0.0
39.5
0.071
100.0
0.1420
50.0
39.5
10.5
All flow rates @ 25 C & 1 atm.
ALSTOM Power Inc.

12
June 30, 2001
2.3.3.2 TGA Results
As stated in Section 2.2, the TGA evaluation was carried out on the 200x400-mesh samples identified in Table 2.3. Results from this evaluation are presented in Figures 2.2 to 2.4. The combustion efficiency profiles, shown in Figure 2.2, indicate that some subtle differences seem to exist between coal firing in air and O2/CO2 mediums. A close examination of the data, however, shows that these differences are within experimental error for this type of testing. The results further indicate that both coals have similar burning characteristics, as they both go to completion within the same temperature range (550-575 o C). The differential thermo-gravimetric analysis profiles, derived from the first derivative of weight loss with time (i.e., -dW/dt) are shown in Figure 2.3. One of the parameters traditionally used to interpret these curves is the Tkp. This parameter is, by definition, the temperature at which maximum heat evolution or reaction rate occurs. The values for the Conesville Unit #5 coal range from 472 to 479 oC; the corresponding values for Pittsburgh #8 coal fall in the 462 to 479 oC range. Clearly, these numbers are in such a narrow range that it can be concluded that: (1) burning either of the coals in air or any of the O2/CO2 mixture ratios used will produce virtually identical results; and (2) both coals have similar reactivity characteristics. These results are consistent with those reported in Figure 2.2. The combustion efficiency curves in Figure 2.2 were used to derive first-order reaction kinetic parameters, assuming that the effects of O2 mass transfer in the fixed-bed TGA were minimal and could be neglected. Results are plotted in Figure 2.4 as logKs versus 1000/, where Ks is the pseudo surface reactivity rate parameter (sec -1), and T ( oK) is the reaction temperature. These results are consistent with those reported in Figures 2.2 and 2.3.
ALSTOM Power Inc.

13
June 30, 2001
Conesville Coal
100 90 80 70 60 50 40 30 20 10 0 250 300 350 400 450
o
Combustion in Air (Base Case) Combustion in O2/CO2 (Constant Mass Case) Combustion in O2/CO2 (Constant Volume Case)
500
550
600
Temperature, C
Pittsburgh #8 Coal
100 90 80 70 60 50 40 30 20 10 0 250 300 350 400 450
o
500
550
600
Temperature, C
Figure 2. 2: TGA Coal Combustion Efficiency Profiles
ALSTOM Power Inc.

14
June 30, 2001
Conesville Coal 0.5 0.45 0.4 0.35 0.3 0.25 0.2 0.15 0.1 0.05 0 -0.05 250 300 350 400 450 500 550 600 Air (Base Case), Tkp=472 C O2/CO2 (Constant Mass Case), Tkp=476 C O2/CO2 (Constant Volume Case), Tkp=479 C
Temperature, oC
Pittsburgh #8 Coal 0.5 0.45 0.4 0.35 0.3 0.25 0.2 0.15 0.1 0.05 0 -0.05 250 300 350 400 450
o
Air (Base Case), Tpk=469 C O2/CO2 (Constant Mass Case), Tkp=462 C O2/CO2 (Constant Volume Case), Tkp=479 C
500
550
600
Temperature, C
Figure 2. 3: Differential Thermo-Gravimetric Analysis Profiles
ALSTOM Power Inc.

15
June 30, 2001
Conesville Coal 0.0 -0.2 -0.4 -0.6 -0.8 -1.0 -1.2 -1.4 -1.6 -1.8 -2.0 1.35 1.40 1.45 1000/T, oK -1 1.50 1.55 Combustion in Air (Base Case) Combustion in O2/CO2 (Constant Mass Case) Combustion in O2/CO2 (Constant Volume Case)
Pittsburgh #8 Coal 0.0 -0.2 -0.4 -0.6 -0.8 -1.0 -1.2 -1.4 -1.6 -1.8 -2.0 1.35 1.40 1.45 1000/T, oK-1 1.50 1.55 Combustion in Air (Base Case) Combustion in O2/CO2 (Constant Mass Case) Combustion in O2/CO2 (Constant Volume Case)
Figure 2. 4: TGA Reaction Rates of Coal Samples
ALSTOM Power Inc.

16
June 30, 2001
2.3.2
Drop Tube Furnace System-1 (DTFS-1) Testing
The test facility, testing procedures used, and results obtained therefrom are discussed in the following sections.
2.3.2.1 DTFS-1 Description and Testing Procedure
ALSTOMs Drop Tube Furnace System-1 (DTFS-1) (Figure 2.5) is comprised of a 1-inch inner diameter, horizontal tube, gas pre-heater and a 2-inch inner diameter, vertical tube, test furnace for providing controlled temperature conditions to study devolatilization, gasification and/or combustion phenomena. This entrained flow reactor, which is electrically heated with silicon carbide elements, is capable of heating reacting particles to temperatures of up to 2700 F and sustaining particle residence times of up to about one second to simulate the suspension firing conditions encountered in pulverized coal-fired boilers. The DTFS-1 testing procedure entails the following: (1) the fuel is fed at a precisely known rate through a water-cooled injector into the test furnace reaction zone; (2) the fuel and its carrier gas are allowed to rapidly mix with a pre-heated down-flowing secondary gas stream; (3) devolatilization, gasification, or combustion is allowed to occur for a specific time (dictated by the transit distance); (4) reactions are rapidly quenched by aspirating the mixture into a water-cooled sampling probe; (5) the solids are separated from gaseous products in a filter medium; and (6) an aliquot of the effluent gas stream is sent to a dedicated Gas Analysis System (GAS) for on-line determination of NOx, SO2, O2, CO2, CO, and THC (total hydrocarbons) concentrations. Minor gaseous components (HCN, NHI, CHI, VOCs, PAHs, etc.) can be measured, if required, with existing ancillary equipment (a gas chromatograph and / or a Fourier transform infrared spectrometer). A LabView-based data acquisition system records, on demand, all relevant test data for subsequent retrieval and processing. The LabView software package is also used to control the gas flow rates into the furnace. An ash tracer technique (Nsakala, et al., 1977; Nsakala, et. Al., 1986) is used in conjunction with the proximate analyses of feed samples and chars subsequently generated in the DTFS-1 to calculate the devolatilization, gasification or combustion efficiency as a function of operational parameters (particle temperature, particle residence time, fuel fineness, reaction medium, etc.). A proprietary software package can, alternatively, use the information on concentrations of CO2, CO, and THC (if available) in the effluent gas streams to calculate carbon conversion rates under prevailing conditions. The DTFS-1 testing is normally used to derive quantitative information on the impact of various operating parameters such as particle size, stoichiometry and temperature/time history on unburned carbon loss and gaseous (NOx, CO and SO2) emissions.
ALSTOM Power Inc.

17
June 30, 2001
Water-Cooled Injector Preheater
Syringe Pump Feeder
Gas Preheater Test Furnace
Figure 2. 5: ALSTOM Powers Drop-Tube Furnace System-1 (DTFS-1) Three cases were evaluated for each coal (Table 2.5). The Base case consisted of burning the coal in 15 l/min of air. The Constant Mass case consisted of burning the coal in an O2/CO2 mixture, such that the mass of O2 used in the Base case was maintained and the mass of N2 used in the Base case was replaced with an equal mass of CO2. The Constant Volume case consisted of burning the coal in an O2/CO2 mixture, such that the mass of O2 used in the Base case was again maintained and the volume of N2 used in the Base case was replaced with an equal volume of CO2. The rationale for selecting these three test cases is as follows. The Base case represents coal combustion in air, consistent with a business as usual scenario. The Constant Mass case represents a realistic scenario if coal were to be fired in an O2/recycled flue gas environment. The Constant Volume case also represents coal combustion in an O2/recycled flue gas environment, although in this case the CO2 volume is conserved vis--vis the N2 it would displace from the air. Table 2.5 shows that the total gas volumetric flow rates for the Constant Mass and Constant Volume cases are, respectively, lower than and equal to that of the Base case (10.7 l/min and 15.0 l/min versus 15.0 l/min, at 25 oC and 1 atm.). Hence, all other things being equal, the gas residence times in the furnace for the Constant Mass and Constant Volume cases would be, respectively, longer than and equal to the gas residence time for the Base case. The coal feed rate was adjusted for each coal such that the overall stoichiometry () was ~2.50. This value is more than a factor of 2 higher than the typical value encountered in pulverized coal firing applications. It was known, from previous experience, that in order to achieve reasonably low unburned carbon emissions in the drop tube, it was necessary to conduct these experiments in such oxygen-rich environments. This mode of operation is necessitated for two principal reasons, namely: (1) the DTFS-1 operates in a laminar flow regime,
ALSTOM Power Inc.

18
June 30, 2001
with a Reynolds number in the 150-225 range; and (2) the maximum residence time for the conditions evaluated was about 0.8 seconds.
Table 2. 5: DTFS-1 Test Matrix

Combustion Air Combustion Medium Case Total Air O2 N2 CO2 Grand Total (g/min) Overall Stoichiometry ()
N2 Comb.Med. Comp. (Vol. %) CO2 O2
(l/min) (g/min) (l/min) (g/min)
(l/min) (g/min) (l/min) (g/min) (l/min)
Air
Baseline
15.00
17.76
3.15
4.12
11.85
13.57
0.00
0.00
15.00
17.69
2.5
79.0
---
21.0
O2/CO2 Mixture
Constant Mass
0.00
0.00
3.15
4.12
0.00
0.00
7.55
13.57
10.70
17.69
2.5
---
70.5
29.5
O2/CO2 Mixture
Constant Volume
0.00
0.00
3.15
4.12
0.00
0.00
11.85
21.31
15.00
25.43
2.5
---
79.0
21.0
All flow rates @ 25 C & 1 atm.
2.3.2.2 Reactant Gas Temperature Measurements
A suction pyrometer was used to measure, for each of the three study cases, the gas temperature profile along the axis of the DTFS-1 reaction chamber. In addition to the in-furnace measurements, heat transfer calculations were performed for each case to predict the impact of the reactant gas characteristics on its temperature profile along the axis of the DTFS-1 reaction chamber. The predictions were based on the exact DTFS-1 operating conditions for the same three study cases. The measurements (Figure 2.6) indicate the following gas temperature profile trend: TBase case < TConstant Volume case < TConstant Mass case. The reason for this occurrence is that CO2 , unlike N2 , is capable of absorbing energy radiated from the furnace walls. CO2 has a greater specific heat than N2 (Figure 2.7), but as is evident from the Constant Mass case, the ability of the CO2 to absorb/emit radiation dominates and causes the CO2-rich gas to achieve higher temperatures than the N2-rich case. The trends exhibited by the theoretical heat transfer model, developed to predict gas temperatures, supported those found experimentally (Figure 2.6).
ALSTOM Power Inc.

19
June 30, 2001
DTFS-1 Experimental Results 3000 2900 2800 2700 2600 2500 2400 2300 2200 2100 2000 0 2 4 6 8 10 12 14 16 18 Air (Base Case) O2/CO2 (Constant Mass Case) O2/CO2 (Constant Volume Case)
Reaction Zone Distance, Inches
DTFS-1 Simulated Results 3000 2900 2800 2700 2600 2500 2400 2300 2200 2100 2000 0 2 4 6 8 10 12 14 16 18 Air (Base Case) O2/CO2 (Constant Mass Case) O2/CO2 (Constant Volume Case)
Reaction Zone Distance, Inches
Figure 2. 6: Measured and Predicted Gas Temperatures in the DTFS-1
ALSTOM Power Inc.

20
June 30, 2001
0.360 0.340 0.320 0.300 0.280 0.260 0.240 0.220 0.200 500 1000 1500 2000 2500 3000 3500 CO2 N2
Gas Temperature, oF
Figure 2. 7: Specific Heats of Nitrogen and Carbon Dioxide as a Function of Temperature It should be borne in mind that the heat transfer calculations were made only to validate the trends of the gas temperatures measured in the DTFS-1. No attempts were made to calibrate those calculations to the measurements. When gas mass flow rates, temperatures, and furnace geometry are taken into consideration together the corresponding gas residence times () indicated the following trend: Constant Volume case < Base case < Constant Mass case . The impacts of these trends or lack thereof, on unburned carbon and gaseous emissions, will be discussed in Section 2.3.2.3.
2.3.2.3 Unburned Carbon and Gaseous Emission Results
It is important to reiterate at the outset (See Section 2.3.2.1) that: (1) the DTFS-1 is operated in a laminar flow regime, with a Reynolds number in the 150-225 range; and (2) the maximum residence time for the conditions evaluated was about 0.8 sec. Hence, in order to achieve reasonably low unburned carbon emissions at the furnace outlet, the DTFS-1 was operated at a rather high overall oxygen/fuel stoichiometric ratio (i.e., ~2.5 versus the typical value of ~1.2 encountered in pulverized coal firing applications). Consequently, the unburned carbon and gaseous emission results reported here should be interpreted strictly on a relative basis only, as no attempt was made to correlate them with field (i.e., Conesville Unit #5) performance results. Table 2.6 summarizes the unburned carbon (UBC) results obtained from firing the coal samples from Conesville Unit #5 and Pittsburgh #8 seam under the three study cases discussed above. Figures 2.8 and 2.9 are plots of coal combustion efficiency and unburned carbon in fly ash as a function of gas residence time.
ALSTOM Power Inc.

21
June 30, 2001
Table 2. 6: Summary of DTFS-1 Test Results on Coal Combustion Efficiencies and Unburned Carbon in Fly Ashes
Combustion in Air Conesville Unit #5 Coal Reaction Zone Length (inches) Gas Residence Time (sec) UBC in Fly Ash (% dry) Coal Combustion Efficiency (%daf) Pittsburgh #8 Seam Coal UBC in Fly Ash (% dry) Coal Combustion Efficiency (%daf)
4 8 12 12 14 16 16 16
0.15 0.30 0.44 0.44 0.51 0.58 0.58 0.58
64.52 47.70 20.48 22.71 11.34 8.47 8.49 9.58
78.74 89.18 97.20 96.90 98.59 99.00 99.10 98.70 12.53 87.55
Combustion in O 2/CO2, Constant Mass Case Conesville Unit #5 Coal Reaction Zone Length (inches) Gas Residence Time (sec) UBC in Fly Ash (% dry) Coal Combustion Efficiency (%daf) Pittsburgh #8 Seam Coal UBC in Fly Ash (% dry) Coal Combustion Efficiency (%daf)
4 8 12 14 16 16
0.20 0.40 --0.68 0.78 0.78
51.07 39.13 --3.41 2.27 1.92
85.23 93.01 --99.63 99.75 99.81 6.16 7.23 93.56 92.90
Combustion in O 2/CO 2, Constant Volume Case Gas Reaction Zone Length (inches) Gas Residence Time (sec) Conesville Unit #5 Coal UBC in Fly Ash (% dry) Coal Combustion Efficiency (%daf) Pittsburgh #8 Seam Coal UBC in Fly Ash (% dry) Coal Combustion Efficiency (%daf)
4 8 12 14 16 16 16
0.15 0.29 0.43 --0.57 0.57 0.57
66.61 38.67 16.05 --1.23 3.00 5.29
75.32 93.14 98.00 --99.91 99.67 99.64 16.05 84.33
ALSTOM Power Inc.

22
June 30, 2001
Conesville Coal 100 90 80 70 60 50 40 30 20 10 0 0.0 0.2
Combustion in Air (Base Case) Combustion in O2/CO2 (Constant Mass Case) Combustion in O2/CO2 (Constant Volume Case) 0.4 0.6 Residence Time, Sec. Pittsburgh #8 Coal 0.8 1.0
100 90 80 70 60 50 40 30 20 10 0 0.0 0.2
Combustion In Air (Base Case) Combustion In O2/CO2 (Constant Mass Case) Combustion In O2/CO2 (Constant Volume Case) 0.4 0.6 Residence Time, Sec. 0.8 1.0
Conesville and Pittsburgh #8 Coals 100 90 80 70 60 50 40 30 20 10 0 0.0 0.2
Conesville Coal Pittsburgh #8 Coal Polynomial (Conesville Coal) Exponential (Pittsburgh #8 Coal) 0.4 0.6 Residence Time, Sec. 0.8 1.0
Figure 2. 8: DTFS-1 Generated Coal Combustion Efficiency Profiles

ALSTOM Power Inc.
23
June 30, 2001
Conesville Coal 100 90 80 70 60 50 40 30 20 10 0 0.0 0.2 Combustion in Air (Base Case) Combustion in O2/CO2 (Constant Mass Case) Combustion in O2/CO2 (Constant Volume Case)
0.4 0.6 Residence Time, Sec. Pittsburgh #8 Coal
0.8
1.0
18 16 14 12 10 8 6 4 2 0 0.0 0.2 0.4 0.6 Residence Time, Sec. 0.8 1.0 Combustion in Air (Base Case) Combustion in O2/CO2 (Constant Mass Case) Combustion in O2/CO2 (Constant Volume Case)
Conesville and Pittsburgh #8 Coals 100 90 80 70 60 50 40 30 20 10 0 0.0 0.2
Conesville Coal Pittsburgh #8 Coal Polynomial (Conesville Coal) Exponential (Pittsburgh #8 Coal)
0.4 0.6 Residence Time, Sec.
0.8
1.0
Figure 2. 9: DTFS-1 Generated Unburned Carbon in Fly Ash Samples

ALSTOM Power Inc.
24
June 30, 2001
Figures 2.8 and 2.9 indicate that residence time has, as expected, a significant impact on the overall coal combustion efficiency, and hence, on the unburned carbon emission in the fly ash for both coals under consideration. That is, while the combustion efficiency for both coals is only about 80% (dry-ash-free coal basis) at 0.2 sec residence time, it is more than 98% at 0.8 sec. residence time. Correspondingly, unburned carbon emissions range from about 65% to less about 2% (dry fly ash basis) for the same residence times. The second point that can be made is that for the given thermal regime in the DTFS-1, the impact of reaction medium is significant. While the overall combustion efficiencies do not seem to exhibit significant differences between the baseline and Constant Mass firing, the more sensitive parameter, unburned carbon (UBC) in the fly ash, on the other hand, clearly shows better performance for the Constant Mass case. That is, the UBC at the furnace outlet was more than a factor of 4.5 lower for the Constant Mass case (~2% vs. 9%). This is believed to be due to higher reaction temperature, and yet longer residence by 35% (0.77 sec. vs. 0.57 sec.). It appears, from the shape of the UBC profiles, that, if given enough residence times, these differences would considerably narrow down. Finally, it appears that the coal sample from Conesville Unit #5 performs better than the sample from Pittsburgh #8 coal seam (e.g., 9% vs. 12.5% UBC for the air firing case). However, if given additional residence times, they would both be expected to perform similarly. The ultimate conclusion is that unburned carbon emission for the Constant Mass case, which represents the appropriate retrofit scenario in a commercial pulverized coal firing application (i.e., the mass of CO2 in the O2/CO2 combustion medium displaces the same mass of N2 in the combustion air), provides a significant advantage over air firing. This is, presumably, because of the relatively higher temperature, and yet longer combustion process time that the Constant Mass case provides. Table 2.2.7 and Figure 2.10 show gaseous (NOx, CO, and SO2) emissions results obtained from burning the coal sample from Conesville Unit #5 in air and O2/CO2 combustion mediums. These results indicate significant increases in NOx, slight increases in SO2, and significant decreases in CO emissions as a function of increasing residence time. This is due to, as expected, correspondingly improved overall coal combustion efficiency with time. The NOx emission reduction from air firing (Base case) to oxy-fuel firing (i.e., O2/CO2 combustion mediums) is about a factor of 3 (0.73 vs. 2.25 lb/MMBtu). The trend is consistent with results reported by others (Thambimuthu, et al.; 1998; Weller, et al., 1985) and by the CFD results of the present study (Section 3.0, below). However, Thambimuthu, et al. and Weller, et al. reported reductions ranging up to only about 30%. Hence, it is not clear whether the superstoichiometry utilized in the present experiment ( ~2.5) exaggerates the difference. Sulfur dioxide for oxy-fuel firing is lower by about 19% than the corresponding value for air firing (3.6 vs. 4.3 lb/MMBtu). CO for oxy-fuel firing was lower than the corresponding values for air firing (0.09 lb/MMBtu vs. a negligible amount). The ultimate conclusion from gaseous emission findings is that the Constant Mass case does seem to provide (1) a significant advantage over air firing, with respect to NOx and CO emissions; and (2) a slight advantage over air firing, with respect to SO2 emission.
ALSTOM Power Inc.

25
June 30, 2001
NOx Emissions 2.5
2.0 Combustion in Air (Base Case) 1.5 Combustion in O2/CO2 (Constant Mass Case) Combustion in O2/CO2 (Constant Volume Case) 1.0
0.5
0.0 0.0 0.2 0.4 0.6 Residence Time, Sec. 0.8 1.0
SO2 Emissions
5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 0.0 0.2 0.4 0.6 Residence Time, Sec. 0.8 1.0
CO Emissions
0.7 0.6 0.5

Combustion in O2/CO2 (Constant Volume Case) Combustion in Air (Base Case) Combustion in O2/CO2 (Constant Mass Case)
0.4 0.3 0.2 0.1 0.0 0.0 0.2 0.4 0.6 Residence Time, Sec. 0.8 1.0
Figure 2. 10: DTFS-1 Generated NOx, CO and SO2 Emissions
ALSTOM Power Inc.

26
June 30, 2001
Table 2. 7: Summary of DTFS-1 Test Results on Gaseous emissions from Conesville Unit #5 Coal Combustion
Reaction Zone Length (inches) 4 8 12 12 14 16 16 16 Reaction Zone Length (inches) 4 8 12 14 16 16 Reaction Zone Length (inches) 4 8 12 14 16 16 16 Combustion in Air Gas Residence UBC Coal Time in Fly Ash Comb. Eff. NOx SO2 (sec) (% dry) (%daf) (lb/MMBtu) (lb/MMBtu) 0.15 0.30 0.44 0.44 0.51 0.58 0.58 0.58 Gas 64.52 47.70 20.48 22.71 11.34 8.47 8.49 9.58 78.74 89.18 97.20 96.90 98.59 99.00 99.10 98.70 1.72 1.93 2.27 2.22 2.36 2.11 4.56 4.22 4.11 4.08 4.57 4.04
CO (lb/MMBtu) 0.61 0.22
0.13 0.09
Combustion in O 2/CO2, Constant Mass Case CO (lb/MMBtu) 0.54 0.24 0.00 0.00
Residence UBC Coal SO2 Time in Fly Ash Comb. Eff. NOx (sec) (% dry) (%daf) (lb/MMBtu) (lb/MMBtu) 0.20 0.40 --0.68 0.78 0.78 Gas 51.07 39.13 --3.41 2.27 1.92 85.23 93.01 --99.63 99.75 99.81 0.43 0.74 0.72 0.73 2.17 3.67 3.56 3.63 3.74
Combustion in O 2/CO2, Constant Volume Case CO (lb/MMBtu) 0.50 0.10 0.00 0.04
Residence UBC Coal Time in Fly Ash Comb. Eff. NOx SO2 (sec) (% dry) (%daf) (lb/MMBtu) (lb/MMBtu) 0.15 0.29 0.43 --0.57 0.57 0.57 66.61 38.67 16.05 --1.23 3.00 5.29 75.32 93.14 98.00 --99.91 99.67 99.64 0.73 0.78 0.84 0.85 4.19 3.82 4.18 4.08 4.43
ALSTOM Power Inc.

27
June 30, 2001
2.3.3
Conclusions and Recommendations for Future Work
The conclusions and recommendations that were derived from this bench-scale testing campaign are given below.
2.3.3.1
Conclusions
A series of conclusions can be drawn from the results from combustion testing of the coal samples from Conesville Unit #5 and Pittsburgh #8 seam in both TGA and DTFS-1 equipment, namely: TGA results indicate that subtle differences exist between: (1) coal firing in air and in O2/CO2 mediums; and (2) Conesville Unit #5 coal and Pittsburgh Seam #8 coal. A close examination of the data, however, indicates that these differences are within experimental errors. Hence, it can be concluded that both coals can be expected to perform similarly under the experimental constraints specified in this study. DTFS-1 results showed the following: Residence time has, as expected, a significant impact on the overall coal combustion efficiency, and hence, on the unburned carbon emission in the fly ash for both coals under consideration. That is, while the combustion efficiency for both coals is only about 80% (dry-ash-free coal basis) at 0.2 sec residence time, it is more than 98% at greater than 0.5 sec. residence times. Correspondingly, unburned carbon emissions range from about 65% to less about 2% (dry fly ash basis) for the same residence times. The impact of reaction medium is also significant. While the overall combustion efficiencies do not seem to exhibit significant differences between the baseline and Constant Mass firing, the more sensitive parameter, unburned carbon (UBC) in the fly ash, on the other hand, clearly shows better performance for the Constant Mass case. That is, the UBC at the furnace outlet was more than a factor of 4.5 lower for the Constant Mass case (~2% vs. 9%). This is believed to be due to higher reaction temperature, and yet longer residence (0.77 sec. vs. 0.57 sec.). It appears, from the shape of the UBC profiles, that, if given enough residence times, these differences would considerably narrow down, implying that the performance in both mediums would be similar. The coal sample from Conesville Unit #5 appears to perform better than the sample from Pittsburgh seam #8 coal (e.g., 9% vs. 12.5% UBC for the air firing case). However, base on the shape of the UBC profiles, it can be seen that if given additional residence times, they would both be expected to perform similarly. NOx emission from oxy-fuel firing is about a factor of ~3 (0.73 vs. 2.25 lb/MMBtu) lower than that of Base case. Correspondingly, sulfur dioxide is lower by about 19% (3.6 vs. 4.3 lb/MMBtu), and CO is significantly lower (0.09 lb/MMBtu vs. a negligible amount). The gaseous emission trends are consistent with results reported by others (Thambimuthu, et al.; 1998; Weller, et al., 1985) and by the CFD results of the present study (Section 3.0, below).
2.3.3.2
Recommendations for Future Work
There is, to the authors knowledge, no fundamental coal combustion work being carried out elsewhere to determine the impact of coal nature in an oxy-fuel environment on unburned carbon and gaseous and particulate emissions. Hence, the following is recommended: Carry out a systematic coal fundamentals study concerning this field of endeavor. This study should be geared toward the creation of a database of information depicting the impact of coal nature (using coals of various rank coming from both domestic and international sources) when fired in an oxy-fuel environment on: Coal devolatilization and char oxidation kinetics, and unburned carbon emissions in the fly ash
ALSTOM Power Inc.
28
June 30, 2001
Acid rain-related gaseous (NOx, SO2, and CO) emissions Air toxics, particularly mercury (Hg), volatile organic compounds (VOCs), and particulate emissions. Derive furnace heat transfer data from natural gas and coal firing in a pilot-scale furnace, which simulates the temperature/time history of a boiler. Use first the data from natural gas firing to validate the CFD code, without the complication of burning particles transiting the boiler. Apply the experience learned from modeling a natural gas flame to model the coal-fired flame.
ALSTOM Power Inc.

29
June 30, 2001
3.0
3.1
CFD Evaluation Of Conesville Boiler No. 5

Introduction
ALSTOM Power has made a strong commitment to computational fluid dynamics (CFD) and has effectively used CFD in many applications, e.g., design and optimization of coal-, oil-, and gas-fired boilers, pulverizers, air heaters, electrostatic precipitators, cyclones, and scrubbers. At any given time, there are 8 to 10 individuals performing CFD simulations on approximately 40 CPUs, including both workstations and multi-processor servers. With respect to boiler performance, significant CFD and combustion modeling research efforts have been conducted at ALSTOM Power to characterize and optimize the performance of tangentially-fired and wall-fired furnaces. These projects have demonstrated the impact of fluid dynamics, gas phase stoichiometry, and heat input on the combustion efficiency and boiler emissions for a variety of commercial boiler applications. Synopses of recent studies that have been permitted to enter the public domain include the prediction of furnace gas temperatures and species concentrations for NOx reduction with recirculated flue gas (Richards, et al., 1997), furnace waterwall species concentrations for improvement to deposition and slagging performance (Hart, et al., 1998), and design of a low NOx burner (Haynes, et al., 1996). (Overview papers on CFD at ALSTOM Power include Marion, et al., 1995 and Fiveland, 2000.) CFD modeling is considered to be the most cost-effective approach to assess flow and mixing related phenomena for reacting flow conditions, and was therefore proposed for this work. 3.2 Grid Preparation
American Electric Powers Conesville Unit #5 boiler has been described in detail in Volume I of this report (Bozzuto, et al., 2001); however, certain features will be reviewed below to introduce the grid and case preparation. In general, the Conesville unit can be described as a nominal 450 MW-gross, tangentially coal fired, subcritical pressure, controlled circulation, radiant reheat unit. The furnace is a single cell design utilizing five elevations of tilting tangential coal burners. The unit fires a mid-western bituminous coal. The coal is supplied to the five elevations with five RP-903 coal pulverizers. The unit is designed to generate about 3.1 x 10 6 lbm/hr of steam at 2400 psi and 1005 F with reheat also to 1005 F. The boiler is equipped with a number of superheater surfaces, including a low temperature superheater (horizontal), finishing superheater, a radiant superheat division panel section, and the superheater platen section. The reheater consists of a low temperature radiant wall section followed by a spaced finishing section. The economizer section consists of four banks of spiral finned tubes. Outlet steam temperature control is provided with desuperheating spray and burner tilt. The dimensions of the boiler unit are 51 8 in width, 44 3-15/16 in depth (to the rear wall), and 170 10-1/4 in height. A sectional side view of this boiler is shown in Figure 3.1.
ALSTOM Power Inc.

30
June 30, 2001
Superheater Outlet Line Reheater Outlet Line Steam Drum Finishing Pendant Superheater Finishing Pendant Reheater
Superheater Panels Superheater Platens
Reheater Radiant Wall Reheater Inlet Header
Low Temperature Superheater Economizer
Downcomers
Economizer Inlet Line
Tilting Tangential Fuel Nozzles Lungstrom Trisector Air Preheater Flue Gas to Emission Control Equipment and Induced Draft Fans
Boiler Circulating Pumps
Pulverized Coal Piping to Fuel Nozzles
Forced Draft Fans
Bottom Ash Hopper Coal Pulverizers
Figure 3. 1: Sectional Side View of the Conesville Unit #5 Steam Generator ALSTOM Power uses a commercial CFD code (denoted FLUENT) from Fluent Inc. (Lebanon, NH) for its simulations of furnaces and auxiliary equipment. Case preparation of a boiler for the Fluent code is initiated with the collection of the geometry data (from blueprints and schematics), the free areas of the nozzles, and the operating conditions. A CFD grid or mesh is prepared using a combination of EXCEL spreadsheets and a grid-generation package (denoted GAMBIT) supplied by Fluent Inc. Skeletal and external isometric views of the computational domain are shown in Figure 3.2.
ALSTOM Power Inc.
31
June 30, 2001
Corner Cutouts with Non-Conformal Interfaces
Figure 3. 2: Isometric Views of the Conesville Unit #5 Computational Domain The framework or skeletal view above shows square cutouts in the corners that encompass the windboxes. These square cutouts contain cells that are smaller (by a factor of 2 in each coordinate direction) than the cells in the interior of the domain, thus allowing the windbox region to receive a greater concentration of cells than in the interior. The enhanced cell concentration in the windbox region permits greater resolution of the relatively small nozzle openings and the high gradient regions associated with discrete jets. The interfaces between each of the corner cutouts and the domain interior are referred to (by Fluent Inc.) as non-conformal interfaces. Such interfaces permit grids of dissimilar type and size to seamlessly interact with each other along any given plane and preserve the conservation of all relevant quantities (e.g., mass, momentum, and energy). Close-ups of the grid from a side view of the boiler are shown in Figure 3.3. Besides the non-conformal interfaces around the windboxes, another non-conformal grid interface is utilized in the convective pass, permitting the grid to coarsen (by a factor of 2 in each coordinate direction) into the backpass. The grid in the computational domain is composed primarily of hexahedral elements. Tetrahedral elements are utilized only at the top and bottom of the windbox to assist in a geometric transition. Pyramidal elements are used at the interface between the tetrahedrons and the hexahedrons. The total number of cells in the grid is 314,176.
ALSTOM Power Inc.

32
June 30, 2001
Non-Conformal Interface
Tetrahedral Elements
Non-Conformal Interface
Figure 3. 3: Side Views of the Conesville Unit #5 Exterior Grid Conesville Unit No. 5 is equipped with a tangential firing system, consisting of 3 close-coupled overfire air (CCOFA) register elevations, and 5 coal nozzle elevations. The main and CCOFA windbox widths are equal to 26 inches and the coal nozzle ID is equal to 19.25 inches. The tip/nozzle free areas were extracted from the firing system windbox selection sheets and the nozzle elevations were calculated from the available blueprints. A computational representation of the windbox and nozzles, which is necessarily crude in comparison to the details of the actual hardware, is shown in Figure 3.4. The computational inlet designations (i.e., CCOFA-C, etc.) are also shown. The small inlets on the top and bottom of each computational coal nozzle represent the flow area associated with the fuel-air stream, which in actuality, flows into the furnace around the periphery of the primary coal pipe/tip.
ALSTOM Power Inc.

33
June 30, 2001
CCOFA-C CCOFA-B CCOFA-A Coal-E
Aux-DE
Coal-D
Aux-CD
Coal-C
Aux-BC
Coal-B
Aux-AB
Coal-A Bottom-End
Figure 3. 4: Detailed Drawing of Windbox and Corresponding Side View of Grid Depicting Nozzle Openings The direction of swirl rotation in Conesville Unit 5 (as viewed from the top of the boiler), is shown below in Figure 3.5. The direction of the fireball rotation is counter-clockwise. The normal firing angles are at 44 degrees and at 36 degrees for the pairs of opposed jets.
ALSTOM Power Inc.

34
June 30, 2001
51 8 Furnace Width 19-5/32 Furnace Rear Wall 19-5/32
44
36 23-9/32
44 3-15/16 Furnace Depth
36
44
Furnace Front Wall Figure 3. 5: Cross-Sectional View of Normal Firing Angles for Conesville Unit 5
The corresponding grid on the cross-section, in the vicinity of the windbox, is shown in Figure 3.6. As explained before, a 2:1 change in cell dimension occurs across the non-conformal interface in the windbox region, thus allowing a greater grid density to be concentrated in the immediate vicinity of the nozzle inlets. The grid in the windbox region consists of hexahedral cells, although they may be slightly skewed to accommodate the corner fillets (comprising the windbox).
ALSTOM Power Inc.

35
June 30, 2001
23-9/32
Non-Conformal Interface Paved Hexahedral Grid
Figure 3. 6: Cross-Sectional View of Grid, in the Vicinity of the Windbox, for Conesville Unit 5
3.3
Baseline Calibration Procedure and Strategy
Typically, in an applications project, as in the present study, the first CFD case that is prepared and run is used to evaluate the furnace performance under its baseline combustion conditions. Many of the boundary conditions, such as velocity and temperature, constitute explicit boundary conditions and are defined as part of the input. However, a few boundary conditions (or equality constraints) are implicitly defined and are derived either from experimental measurements or external calculations. While implicit boundary conditions are not explicitly defined as inputs, it is understood that such boundary conditions must nevertheless be matched by the post-run results. Such implicit boundary conditions include: the unburned carbon (UBC) in the fly ash (i.e., carbon-in-ash value) at the outlet of the computational domain the outlet NOx emissions value at the outlet of the computational domain the horizontal furnace outlet temperature (HFOT), which is the mass-weighted average temperature across the plane at the apex of the arch (i.e. the horizontal furnace outlet plane or HFOP).
Both the UBC and NOx emissions values originate from experimental measurements (usually taken downstream of the air preheater). The HFOT value is calculated by an in-house, proprietary design package denoted the Reheat Boiler Program (RHBP). The Reheat Boiler Program, running in its reverse/calibration mode, is fed the excess air, windbox nozzle tilts, all known steam-side parameters, the fuel flow rate, and other general and geometric parameters, and in turn, calculates the HFOT (as well as the wall heat transfer fouling factors, the tube bank surface effectiveness factors, the gas flow rates, and the amount of superheat/reheat spray, if applicable).
ALSTOM Power Inc.

36
June 30, 2001
In the CFD calculation, the char oxidation input parameters control the final amount of residual carbon in the fly ash, the NOx kinetic input parameters largely control the outlet NOx values, and the overall resistance to heat transfer through the waterwall and superheater surfaces and deposits controls the HFOT. An iterative trial-and-error method is used to calibrate the baseline case by changing the input parameters for char oxidation, NOx, and waterwall conduction resistance, until (after a number of runs) the code calculations match the desired UBC, the NOx value, and the HFOT, respectively. Such an iterative procedure for calibration is required since many of the input parameters and boundary conditions are not known with sufficient accuracy to be specified in an a priori manner, and calibration tends to compensate for the accrued uncertainty. In the present study, the above procedure was used to calibrate the baseline case to the desired UBC (as dictated by experimental field data) and to the desired HFOT (as dictated by the RHBP results). Since the CFD code (i.e., the FLUENT code) did not provide sufficient access to the NOx kinetic parameters, the calculated baseline NOx results were scaled to the baseline experimental values. 3.4 CFD Test Matrix
Two main cases were analyzed in this CFD modeling study. The scope of the modeling work consisted of the baseline case and one subsequent case entailing oxy-firing (i.e., firing the coal in O2- and CO2-rich recycled flue gas. A description of each of the cases is provided in Table 3.1. Table 3. 1: Matrix of CFD Cases Case 1 Case Description Base Case: Nominally 15% Excess Air Concept B Case: FGR / Oxy-Firing Nominal Inlet O2 Mole Percent (Dry) 21 Nominal Inlet CO2 Mole Percent (Dry) 0 Nominal Inlet N2 Mole Percent (Dry) 79
29
65
Case 1 is the Base case or baseline case, which corresponds to a nominal 15% excess air and maximum continuous rating (MCR) load conditions. As discussed above, specific input parameters have been iteratively modified until calibration with the selected implicit boundary conditions was achieved to a reasonable approximation. The FLUENT code, calibrated with the baseline combustion conditions, was subsequently used to evaluate the impact of oxy-firing the coal, with a prescribed CO2/O2 mole ratio. In comparison with the baseline run (Case 1), the ConceptB case (Case 2) displaces the mass of N2 by an equivalent mass of CO2 (approximately). Since the molecular weight of CO2 is greater than that of N2 by a factor of approximately 1.57, the density of CO2 will be correspondingly greater than that of N2, and the velocity of the recirculated flue gas streams through the windbox nozzles will therefore be smaller (by, e.g., 36% for pure streams) than that of the baseline case (for the same nozzle free area). Based on the presumption that windbox retrofits should not be required in any application of the proposed advanced FGR technology, a decision was made to preserve the same (computational) inlet nozzle area for both cases; therefore, both cases were compared on an equivalent inlet-area basis, rather than on an equivalent inlet-velocity basis. Lateral and vertical waterwall heat flux or absorption distributions, as well as the overall heat transfer in the lower and upper furnace, have been extracted from the CFD calculations. Total and sectional (area-weighted) waterwall heat absorption rates, in addition to peak heat absorption values, have been used to quantify the heat absorption rates that constitute one of the metrics used as a basis of comparison between the cases. Metrics utilized to compare the cases include: the unburned carbon (UBC) in the fly ash at the outlet of the computational domain the outlet NOx emissions value at the outlet of the computational domain the horizontal (and/or vertical) furnace outlet temperature(s) (FOT) the outlet CO emissions value at the outlet of the computational domain total, sectional, and peak waterwall heat flux or absorption rates
June 30, 2001
37
ALSTOM Power Inc.
Some of the metrics for the two cases, such as NOx, will be compared on a basis that is scaled or referenced to the baseline value, since relative trends may be a more reliable indicator of the expected performance than the absolute magnitudes of the metrics. Line and contour plots for variables of interest will be shown at selected horizontal or vertical planes, as appropriate. The predictions provide a relative indication of the changes that may occur as a result of deviation from the baseline operating conditions. The difference in inlet nozzle velocities, mixture specific heats, and radiative properties between CO2 and N2 have an impact on the performance criteria and metrics of interest, e.g., HFOT, waterwall heat flux distributions, NOx emissions, and unburned carbon in the fly ash. Overall, the CFD runs serve to provide insight into the flow and reaction patterns of the lower furnace, as well as to provide relative changes in emissions and residual carbon values at the exit plane as a result of changes in operating conditions. 3.5 Input and Boundary Conditions
The case selected as the Base case is not strictly a replication of the experimental test data at one operating condition of the Conesville Unit No. 5. Rather, the Base case is defined as being a composite case which is representative of the available control room or board data over multiple test days. The board data encompasses variations in excess air conditions (14.1% to 18.1%), tilts, and burners designated as being out of service (BOOS)). From the array of operating conditions available in the board data, specific operating parameters were selected, which collectively constituted the Base case operating conditions. A RHBP simulation of the selected Base case test conditions helped to further delineate and refine some of the operating condition parameters. Based on the project goals and requirements for flue gas recirculation and oxy-firing, the operating conditions of the Concept-B case were also subsequently defined. A RHBP run was conducted to study and evaluate the Concept-B case. The mass flow rates, excess air conditions, inlet temperatures, tilts, etc. calculated in the RHBP runs were utilized directly in the CFD runs. A summary of the overall input parameters applied to the two cases are shown in Table 3.2.
ALSTOM Power Inc.

38
June 30, 2001
Table 3. 2: Overall Mass Flow Rate Parameters
Parameters
Base Case (15% Excess Air)
Concept B Case (Oxy-Firing)
Total Secondary Gas (lbm/hr) = Total Primary Gas (lbm/hr) = Total Gas (lbm/hr) = Total (As Rec'd) Coal (lbm/hr) = Total (Moisture-Free) Coal (lbm/hr) = Total (DAF) Coal (lbm/hr) =
2,968,935 724,580 3,693,515 374,455 336,635 294,322
2,933,877 671,503 3,605,380 366,603 329,576 288,150
O2:Coal Feed Ratio (by Mass) = % Excess O2 (by Mass) =
2.253 13.75
2.251 13.64
For Complete Combustion: % Exit O2 (by Volume, Dry) = % Exit O2 (by Volume, Wet) = % Exit O2 (by Mass, Dry) = % Exit O2 (by Mass, Wet) =
2.594 2.351 2.687 2.534
3.599 3.083 2.698 2.520
As shown in the above table, the primary criterion used to put the two cases on an equivalent basis for comparison purposes was the oxygen-to-coal ratio (by mass), designated to be approximately 2.252. Additional input parameters, including the inlet gas composition, are provided in Table 3.3.
ALSTOM Power Inc.

39
June 30, 2001
Table 3. 3: Overall Gas Property and Input Parameters
Parameters
Primary Gas Mass Fraction: N2 O2 H2O CO2 SO2
75.872 22.845 1.283 0.000 0.000
3.967 2.627 2.867 90.513 0.026
Secondary Gas Mass Fraction: N2 O2 H2O CO2 SO2
75.872 22.845 1.283 0.000 0.000
4.011 27.528 2.115 66.327 0.019
Inlet Primary Gas Temperature ( F) = Inlet Secondary Gas Temperature (F) =
156 614
140 552
Nozzle Tilt (Degrees)=
-10
-10
The same coal composition for the mid-western bituminous fuel was utilized for both cases and is shown in Table 3.4.
ALSTOM Power Inc.

40
June 30, 2001
Table 3. 4: Coal Composition and Heating Value
Coal Ultimate Analysis As-Received Basis (Weight %) Carbon Hydrogen Nitrogen Sulfur Oxygen Moisture Ash Total 63.2 4.3 1.3 2.7 7.1 10.1 11.3 100.0
Coal Proximate Analysis As-Received Basis (Weight %)
Volatile Matter Fixed Carbon Moisture Ash Total
32.7 45.9 10.1 11.3 100.0
Higher Heating Value (Btu/lbm) =
11,293 (As-Rec'd Basis)
The mass flow rates for the secondary gas feed streams are shown in Table 3.5.
ALSTOM Power Inc.

41
June 30, 2001
Table 3. 5: Mass Flow Rates for the Secondary Gas Feed Streams
Compartment / Nozzle Name
Damper Position (% Open)
Mass Flow Rate (lbm/hr/elev)
Average Velocity (ft/s)
Mass Flow Rate (lbm/hr/elev)
Average Velocity (ft/s)
CCOFA-C CCOFA-B Top Air / CCOFA-A Coal-E (Fuel-Air) Aux Air DE Coal-D (Fuel-Air) Aux Air CD Coal-C (Fuel-Air) Aux Air BC Coal B (Fuel-Air) Aux Air AB Coal A (Fuel-Air) Bottom-End Air
0.0 49.7 20.0 60.0 33.0 60.0 33.0 60.0 33.0 60.0 33.0 0.0 70.0
74,671 286,760 121,270 108,016 412,925 108,016 412,925 108,016 412,925 108,016 397,744 23,874 393,774
48.1 184.8 72.2 217.7 115.0 217.7 115.0 217.7 115.0 217.7 115.0 48.1 234.6 % of Total Gas
73,789 283,374 119,838 106,741 408,049 106,741 408,049 106,741 408,049 106,741 393,048 23,593 389,124
33.8 130.0 50.8 153.1 80.9 153.1 80.9 153.1 80.9 153.1 80.9 33.8 165.0 % of Total Gas
Totals: Total Sec Through Windbox CCOFA Total Windbox - CCOFA Aux Air Fuel-Air/Gas Bottom-End Air/Gas 2,968,935 482,701 2,486,234 1,636,520 455,940 393,774
80.38 13.07 67.31 44.31 12.34 10.66
2,933,877 477,001 2,456,876 1,617,196 450,556 389,124
81.37 13.23 68.14 44.86 12.50 10.79
The damper positions for the top two CCOFAs were extracted from field board data. The other damper positions were estimated, based upon ALSTOM Powers experience. A proprietary EXCEL spreadsheet calculator, denoted the Firing Zone Stoichiometry Calculations (FZSC) spreadsheet, was used to modify the damper positions slightly until the desired windbox-to-furnace p of 6.4 inches-of-water-gauge and the desired excess air (XA) were achieved. (The desired windbox-to-furnace p of 6.4 inches-of-water-gauge corresponds to a field measurement from the Conesville Unit No. 5 board data at a relatively low excess air condition of 14.1%.) The mass flow rates for the primary gas and coal feed streams are shown in Table 3.6.
ALSTOM Power Inc.

42
June 30, 2001
Table 3. 6: Mass Flow Rates for the Primary Gas and Coal Feed Streams
1.1.1.1.1.1 Base Case (15% Excess Air)
1.1.1.1.1.2 Concept B Case (Oxy-Firing)
Nozzle
Primary Air Mass Flow Rate (lbm/hr/elev)
Average Air Velocity (ft/s)
Coal Mass Flow Rate (lbm/hr/elev)
Primary Gas Mass Flow Rate (lbm/hr/elev)
Average Gas Velocity (ft/s)
Coal Mass Flow Rate (lbm/hr/elev)
Coal E Coal D Coal C Coal B Coal A Total:
178,909 178,909 178,909 178,909 8,945 724,580
96.2 96.2 96.2 96.2 4.8
93,614 93,614 93,614 93,614 0 374,455
165,803 165,803 165,803 165,803 8,290 671,503
60.8 60.8 60.8 60.8 3.0
91,650.8 91,650.8 91,650.8 91,650.8 0.0 366,603.0
It should be noted that the bottom coal elevation (Coal A) has been designated as being out of service (OOS) for these two cases. For the Coal-A nozzle, the coal mass flow rate is completely turned off and only a small amount (e.g., 5% of the normal allocation) of air or gas is permitted to pass through the coal nozzle (i.e., to help purge and cool the nozzle). The inlet turbulence intensity was arbitrarily set at 10% of the mean velocity. The dissipation length scale for the turbulence was calculated using an effective hydraulic diameter for the inlet. As mentioned previously, the overall wall absorption and the HFOT constitute implicit boundary conditions. The RHBP is the external resource which is used to provide values for the tube bank heat extraction, the overall wall absorption, and the HFOT. The overall resistance to wall heat transfer in the CFD computation is iteratively changed until the calculated implicit boundary condition constraint (i.e., wall absorption and HFOT) matches the RHBP values to within acceptable accuracy. Since the wall absorption computed by the CFD must ultimately match the wall absorption calculated by the RHBP, a brief tutorial of the RHBP nomenclature is required. The RHBP arbitrarily divides the furnace and convective pass into the sections shown in Figure 3.7.
ALSTOM Power Inc.

43
June 30, 2001
Upper Furnace
Convective Pass
HFOP
Furnace
Lower Furnace
Firing Zone Region
Figure 3. 7: Furnace and Backpass Sections Specific to the RHBP The furnace volume (outlined in Figure 3.7) is defined within the RHBP to include most of the radiant wall sections and extends from the bottom of the coutant to the roof of the upper furnace; it does not include the convective pass section, nor the superheater platen tube bank. The furnace volume encompasses 3 partitioned sections. The first section is the firing zone region, which extends from the bottom of the coutant to several feet above the top coal elevation. The lower furnace section extends from the top of the firing zone section to the HFOT plane. The upper furnace section extends from the HFOT to the roof and encompasses the superheater division panels, but not the superheater pendant platens. For all surfaces in the furnace volume, the RHBP generates the appropriate fouling factors.
ALSTOM Power Inc.

44
June 30, 2001
The convective pass and backpass volume is defined by the RHBP to encompass all of the tube banks and their bounding surfaces, with the exception of the division panels. For convenience sake, the RHBP treats the convective pass volume differently than it does the furnace volume. For the convective section, the RHBP generates surface effectiveness factors, rather than fouling factors. The HFOP is at the apex of the arch. The VFOP (not shown) is defined by the RHBP as being at the inlet to the superheater platen (both along the top and along the bottom of the platen), but this definition will be modified later on. The nomenclature utilized by the RHBP (with the exception of the VFOP definition), will be adhered to in the ensuing discussion. The material properties and relative amounts of slag and fouling deposits found locally on the superheater division panels and the bounding tube walls are usually not known a priori. Consequently, the surface resistance to heat transfer in the CFD computation must be iteratively adjusted throughout the furnace volume in order to match the horizontal furnace outlet temperature (HFOT) calculated by the RHBP. For heat transfer to the computational waterwalls, radiant reheat surfaces, and superheat surfaces, the boundary conditions were prescribed using an effective overall surface resistance (or overall fouling factor) and a back-side (steam) temperature. It should be noted that the fouling factors calculated by the RHBP are not utilized directly in the CFD computation. Since the radiation and heat transfer submodels in the RHBP are significantly different than those found in a CFD code, it follows that the fouling factors and emissivities generated by the RHBP may also be quite different from those calculated by the CFD code. In the waterwalls, the backside (two-phase) steam-water temperature corresponds to saturated conditions and was assigned a temperature of 680 F. Since the fouling factor must be iteratively changed in the CFD calculation in order to calibrate the wall absorption and HFOT to the RHBP value, all of the backside steam temperatures were equated to the (constant) saturation steam temperature, including the radiant reheat and superheat surfaces. Although the superheat temperatures in the bounding surfaces will be higher than the saturation temperature, the goal of the calibration exercise was principally to match the overall absorption in the furnace proper, the convective pass being secondary, and the approximation was thought to be acceptable. The wall heat transfer parameters found to calibrate the Base case to the RHBP results are shown in Table 3.7.
ALSTOM Power Inc.

45
June 30, 2001
Table 3. 7: Wall Heat Transfer Parameters in the CFD Cases
Interior Wall Surface
Internal Wall Emissivity
Overall Fouling Factor (hr-ft 2-F/Btu)
Coutant and Wall Below Windbox Firing Zone Lower Furnace Waterwall (Above Windbox) Radiant Reheat Walls (Lower Furnace) Upper Furnace Waterwalls/Radiant Reheat Upper Furnace Roof Superheater Division Panels Convective Pass and Backpass Roof of Convective Pass and Backpass
0.80 0.80 0.75 0.75 0.65 0.65 0.65 0.75 0.75
0.0175 0.0232 0.0258 0.0247 0.0378 0.0258 0.0378 0.0232 0.0142
Backside Wall / Steam Temperature (F) =
680
One of the quantifiable metrics selected as a means of comparing the Base case and the Concept-B case is the overall wall absorption. In order to compare the two cases on an equivalent basis, it was deemed necessary to maintain the same fouling factors throughout the furnace volume in both cases. Therefore, the two corresponding RHBP runs were generated with the same fouling factors. However, convective section surface effectiveness factors and tube bank absorptions could not also be forced to be identical for the two cases in order to permit the RHBP to converge to a physical solution based on its solution constraints (i.e., prescribed superheat and reheat temperatures). The tube banks are approximated as porous media in the CFD cases; parameters describing the pressure drop through each tube bank are calculated from industry design standards. The RHBP is used to evaluate the steam side performance and to estimate the furnace outlet temperature and the heat duty of the various tube bank sections. The amount of heat extracted from each tube bank, as calculated from the RHBP, with the exception of the superheater division panels (which are calculated with the resistance and backside temperature approach), are shown in Table 3.8. The tube bank absorption quantities also include the absorption through any nearby screen tubes.
ALSTOM Power Inc.

46
June 30, 2001
Table 3. 8: Energy Extracted from Tube Banks
Tube Bank
Heat Transferred to Steam in Banks (Btu/hr)
Heat Transferred to Steam in Banks (Btu/hr)
Superheater Pendant Platen Reheater Pendant Platen (Front) Assemblies Reheater Finishing Section Superheater Finishing Section Superheater Low Temp (Vertical) Pendant Section Superheater Horizontal Spaced Rear Assemblies Economizer Assembly Totals:
2.930E+08 3.957E+08 1.424E+08 2.397E+08 1.298E+08 2.998E+08 5.118E+08 2.012E+09
2.942E+08 3.753E+08 1.286E+08 2.194E+08 1.253E+08 2.807E+08 4.594E+08 1.883E+09
Although the fouling factors in the furnace volume were forced to be identical in the two RHBP cases, the heat absorption through each tube bank in the convective pass was allowed to self-adjust to meet the RHBP solution and convergence criteria. Therefore, the tube bank heat extractions for the two cases are somewhat different. The tube bank absorption for the Concept-B case is generally lower than (but within 10% of) the tube bank absorption in the Base case. The above absorptions were specified in the CFD calculation for each tube bank in the form of a sink term to the energy transport equation. 3.6 Submodel Parameters and Case Preparation
Calculations of the two Conesville cases were run using FLUENT Version 5.4.8. FLUENT is a general purpose CFD code with a range of physical model capabilities. For these simulations, the important fluid flow, heat transfer, gas and solid phase combustion processes were represented in a steady-state calculation. Submodel selections and their parameter settings are described below. The SIMPLE pressure-correction algorithm was used with first-order upwind differencing. The turbulence model was the traditional or standard k- turbulence model. The turbulence-chemistry interaction was modeled using the composite Magnussen eddy-breakup (mixing-limited / fast-chemistry) and Arrhenius rates (kinetically-limited) combustion submodel, in which the smaller of the two rates (eddy-breakup or Arrhenius rates) takes local precedence. The gas-phase chemistry was based on two, irreversible, global steps: (1) volatile combining with oxygen to form carbon monoxide, water, nitrogen, and sulfur dioxide, and (2) carbon monoxide combining with oxygen to form carbon dioxide. The Discrete Ordinates radiation model was used to calculate the local radiative fluxes. The particle absorption and scattering efficiencies were specified via a proprietary user-defined function (UDF). An implementation inconsistency was found in the weighted-sum-grey-gas (WSGGM) model in the FLUENT code (which ultimately forced the CFD
ALSTOM Power Inc.
47
June 30, 2001
runs to be repeated and delayed the final report). To circumvent the use of the WSGGM submodel, a gas-phase absorption coefficient, calculated from the Edwards wide-band model, was calculated and utilized instead. Unfortunately, the polynomial prescriptions for the gas-phase absorption coefficient in the FLUENT input permitted the coefficient to be a function of local temperature only, whereas it should ideally be a dual function of both local concentration and temperature. Consequently, the gas-phase absorption coefficient was input as a linear function of temperature, calculated from a single CO2 and H2O partial pressure that prevailed in the computed upper furnace region. (While the complete wide-band model cannot be incorporated in the time frame required to impact the present CFD runs, a recommendation will subsequently be made to Fluent Inc. to upgrade their gas-phase radiative properties submodel to incorporate a full and reliable wide-band model.) The particles were modeled as discrete trajectories using the stochastic Lagrangian particle model. Particles were injected from 16 inlet surfaces (8 cells per injection surface), corresponding to each of the primary coal inlets (4 coal elevations), with 10 particle size bins per distribution and 6 stochastic tries, for a total of 7,680 discrete particles that were tracked through the domain. Conesville Unit No. 5 mill classifier or sieve analysis data was available, which were averaged to produce a composite analysis with 98.35% through 50 mesh and 88.55% through 100 mesh. A RosinRammler fit of the data produced a mean particle diameter of 66 microns and a slope/spread parameter of near unity. Maximum and minimum particle sizes were chosen as 200 microns and 1 micron, respectively. This information was utilized to calculate the particle size distribution through the Rosin-Rammler utility in FLUENT. Each of the particles followed a stochastic particle trajectory, progressing through the sequential stages of heating, devolatilization and char oxidation according to local flame conditions. The mill module, one of the modules within the company proprietary Reheat Boiler Program (RHBP), estimated that the amount of moisture in the as-fired coal would be approximately 4.5% (from an as-received moisture value of 10.1%). However, to simplify the CFD calculations, all of the coal moisture was presumed to have evaporated completely in the mill and was given to the primary transport air. Devolatilization was calculated from the Kobayashi-type two-competing-rates submodel. The high-temperature volatile yield parameter was estimated using the commercially available Niksa Energy Associates (NEA) PC COAL LAB software (i.e., FLASHCHAIN model). The high-temperature volatile yield was specified to be 67.6% on a DAF basis (as calculated for 55 micron particles at 25 C entrained in nitrogen at 1600 C in a furnace at 1700 C and atmospheric pressure). The same high-temperature volatile yield was specified for all particle sizes. Based on the results of an inhouse, proprietary study, the Kobayashi devolatilization parameters were modified somewhat to give accelerated devolatilization rates which more closely approximated the FLASHCHAIN rates. Parameters for the char oxidation kinetics of the mid-western bituminous coal fired in Conesville Unit No. 5 were set initially through comparison of the proximate and ultimate analyses of the coal with other coals tabulated in an inhouse, drop-tube, kinetics database. Based on a comparison with the database, a reasonable surrogate fuel was found to be Pittsburgh No. 8. Consequently the database kinetics for Pittsburgh No. 8 were used for the Conesville case. The activation energy was not subsequently changed, but the pre-exponential factor was iteratively adjusted as necessary to match the desired unburned carbon in the ash at the exit (of approximately 2%) for the baseline case. The char oxidation submodel in FLUENT is a composite kinetics/diffusion-limited char combustion model. In the char oxidation submodel, the char is oxidized via heterogeneous reaction to form CO, which is then oxidized further in the gas phase to form CO2. The species (gaseous) properties, such as thermal conductivity, viscosity, and specific heat, were calculated at each cell in the domain based on polynomial functions of temperature. The species specific heats did not account for dissociative effects. The gas mixture properties were based on composition dependent formulations of the properties of the pure species. The NOx model is run in a post-processor fashion. NOx predictions were performed for a combination of both thermal and fuel NOx submodels. Destruction through the reburn mechanism is permitted only for the presumed probablility distribution function (PDF) combustion model, which was not utilized in this case. For thermal NOx, the partial equilibrium assumption was activated for atomic oxygen, and a beta function PDF was utilized for the convolution over temperature. For the fuel NOx model, atomic nitrogen fractions in both the volatile and the char were specified. The char nitrogen was presumed to go to HCN, rather than directly to NO. NOx and CO emissions are typically more difficult to predict than gross flow features or overall heat release because they are more sensitive to accurate calculations of local temperature and require more detailed chemistry. Consequently the NOx predictions were ultimately scaled to the measured Base case value.
ALSTOM Power Inc.
48
June 30, 2001
Further grid refinement or adaption of the grid was not performed for the two cases. It is not known to what extent numerical diffusion, typically associated with coarse or skewed meshes, has impacted the quantitative accuracy in the present study. Since the focus of the present investigation was to discriminate between the two cases on a relative basis only, the present grid was presumed to be acceptable. 3.7 Calculation Results
The baseline case (Case 1) and the Concept-B case (Case 2) will be compared on the basis of the metrics discussed previously in Section 3.3. All of the gas-phase, planar integrated scalars, such as temperature and species, will be reported on a mass-averaged basis. The calculated residual carbon in the fly ash, as well as the NOx and CO emissions are shown in Table 3.9. Table 3. 9: Comparison of Predicted Residual Carbon and Emissions for Cases 1 and 2
Residual Carbon in Ash (%) NOx (ppmm, uncorrected, dry) [Note 1] CO (ppmv, dry)
2.4 190 141
0.8 104 82
Note 1: Baseline value was scaled to measurement
The carbon-in-ash measured in the field was between 2% and 3%; therefore for the baseline case, the pre-exponential factor for the char oxidation kinetics was adjusted until such a representative value was calculated. Relative to the baseline case, the carbon-in-ash value for the Concept-B case was calculated to be significantly lower. The same trend is also exhibited by the emissions calculations. If the calculated NOx value is scaled to the representative measured value of approximately 190 ppm, and assuming that the Concept-B calculated value can be proportionately scaled as well, then the Concept-B NOx value may be expected to decrease by about a factor of two relative to the baseline value. The calculated CO value for Concept-B is also much lower than its baseline counterpart. Since experimental CO values were reported as being under range, and are therefore not available, and since the inclusion of reliable CO kinetics within the CFD computation is not considered to be practical at present, the CO results, as well as the unburned carbon results, may be taken as an indication of the extent of mixing, the temperature history, and the residence time differences between the two cases.
ALSTOM Power Inc.

49
June 30, 2001
The planar temperatures at the HFOP, VFOP, and economizer outlet plane constitute implicit boundary conditions or target temperatures, provided by the RHBP, that the CFD calculations attempts to match through modification of its wall heat transfer boundary conditions. The aforementioned planes are depicted in Figure 3.8, to show their relative positioning.
VFOP
Convective Pass
HFOP Furnace Economizer Outlet
Figure 3. 8: Depictions of Specific Planes for Comparisons of Averaged Temperatures The temperatures at various cross-sections, as well as the integrated wall absorption over various furnace wall sections (largely in accordance with the RHBP partitioning and definitions in Figure 3.7), are shown in Table 3.10. The definition of the upper furnace section, prescribed by the RHBP to exclude the superheater platen, is inconvenient for CFD computations. Hence, the term has been modified in the table below, such that the heat extracted in the superheater platen (via a sink term to the energy equation), and its bounding surfaces, is now included in the definition of the upper furnace term.
ALSTOM Power Inc.

50
June 30, 2001
Table 3. 10: Comparison of Predicted Gas Temperature and Sectional Wall Absorption Values for Cases 1 and 2
RHBP
FLUENT
RHBP
FLUENT
Average Planar Temperature (F): HFOP VFOP [Note 1] Economizer / Domain Outlet 2,756 2,185 706 2,765 2,125 666 2,729 2,027 683 2,676 2,040 696
Furnace Absorption (Btu/hr): Firing Zone Region Lower Furnace Total Absorption Below HFOP Upper Furnace (Note 2) Total Furnace Percent Change of Absorption from Baseline 5.06E+08 5.28E+08 1.03E+09 8.95E+08 1.93E+09 4.37E+08 5.92E+08 1.03E+09 8.96E+08 1.93E+09 4.83E+08 5.85E+08 1.07E+09 9.74E+08 2.04E+09 +5.8 4.33E+08 5.88E+08 1.02E+09 8.88E+08 1.91E+09 -0.8
Note 1: Note 2:
Definition of "VFOP" modified to be at the platen outlet Definition of "upper furnace" modified to include platen
The wall absorption throughout the furnace dictates the resultant temperatures at the HFOP and VFOP. (The domain outlet temperature is a less reliable indicator, since the heat extracted from the tube banks is different for the two cases.) The FLUENT code does not presently permit the user to interrogate the net radiative flux through an arbitrary interior plane, so it is difficult to know to what extent radiation losses through each section, and through the porous media (representing the tube banks), are impacting the above results. Therefore, while it may not be possible to fully ascertain the energy entering and leaving each section in the CFD computation, and thus provide a more detailed explanation as to the magnitudes of the temperatures and fluxes, some general conclusions about the relative trends may be drawn. In the baseline case, the HFOT and wall absorptions were calibrated to the RHBP values (as shown above in Table 3.10). Although the individual absorptions in the firing zone region and the lower furnace region are not duplicated, the total absorption below the HFOP, as well as the total absorption in the upper furnace are matched to an acceptable degree. The reason that the individual absorptions in the firing zone and lower furnace regions are not matched is because the CFD computation is much more sensitive to the location of the burner-out-of-service (BOOS) than the RHBP (as will be apparent later when the absorption profiles are shown). Since the lowest coal elevation has been dictated to be out of service (OOS), a smaller number of burning particle trajectories traverse the coutant region than would occur if the lowest coal elevation were in service; hence the heat release and wall absorption in the region below the windbox is also commensurately less. Alternatively, the RHBP effectively treats all of the firing zone region (below
ALSTOM Power Inc.
51
June 30, 2001
the lower furnace) as a single, well-mixed, global volume (with an allowance for a radiation boundary layer). Since the RHBP has a long history of successful designs that encompass a wide variation in firing system configurations, it is suspected, although not proven, that the CFD computation may be overly sensitive to the location of the BOOS. When the RHBP run for Case 1 is compared with the RHBP run of Case 2, it is evident from the calculations that the HFOT for Concept-B decreases by 29 F and the VFOT decreases by 158 F (for an average decrease of about 94 F) from the corresponding baseline values. The overall furnace wall absorption for Concept-B is expected to increase over that of the baseline (by 5.8%). This result is in accordance with a literature source (Wilkinson, et al., 2001) for refinery gas fired into a wall-fired boiler, in which a one-dimensional, slice-type model (i.e., RHBP-type model) was used to perform the analysis. The authors found that the oxyfuel concept experienced an increase in the incident radiative heat flux of about 4% to 6%, and a corresponding increase in the furnace heat absorption of approximately 9%, relative to the baseline air concept. This increase was attributed by the authors to the increase in radiative power of the carbon dioxide and water-rich combustion gases. The CFD computations exhibited a similar temperature trend to that of the RHBP. Both the HFOT and VFOT for the Concept-B case decreased by 85 and 89 F, respectively, relative to the baseline results. On the other hand, the CFD cases exhibited a trend in wall absorption which was not as strong as the RHBP results. The wall absorption for the Concept-B case decreased by less than 1% relative to the furnace absorption of the baseline CFD case. Additional CFD runs, in which the fuel was changed from coal to an equivalent gas-only fuel (i.e., volatile), confirmed the trend (i.e., the Concept-B absorption was slightly lower than the baseline absorption). This same CFD trend is partially supported in the literature (Chui, et al., 2001) for coal burned in a cylindrical, down-fired vertical combustor, in which both CFD and experimental data were utilized to assess performance. The authors found that both the CFD calculation and the measured data showed that the oxygen-enriched, recycle-gas case exhibited a significant decrease of about 18% in the incident radiant flux, relative to the baseline case. Chui, et al. attributed this decrease to: (a) the change in aerodynamic and temperature patterns due to the lower inlet velocity and penetration of the recycled flue gas (i.e., due to the higher molecular weight of CO2 relative to N2), (b) a decrease in the overall flame temperatures of the recycled flue gas case due to the higher specific heat of CO2 relative to N2, and principally to (c) the increase in the absorption coefficient in the recycled flue gas case because of the higher concentrations of the optically absorbing CO2 and H2O, relative to the optically transparent N2. The analysts of both the (1) one-dimensional/slice or global mixing codes (like the RHBP) and the (2) CFD codes rely on the enhanced radiative absorption coefficient associated with CO2 to partially explain the furnace absorption results, although the calculated trends exhibit different apparent sensitivities for the two types of codes. Apart from differences in the gas-phase radiation properties themselves, a potential explanation for this apparent dichotomy is not readily available. However, in the CFD calculations, the high flame temperatures and patterns are a function of the local aerodynamics and may be effectively isolated from the wall by a significant presence of colder gases. Any CO2 (and H2O) in the near-wall gases will absorb radiative energy at the higher temperature of the fireball, but will re-emit at the lower near-wall temperature, thus acting to increase the temperature of the near-wall gases and decreasing the net wall heat absorption. Slice or global-mixing codes will try to mimic this same effect and may, for example, presume a uniform firing zone or slice temperature radiating through a (colder) radiation boundary layer adjacent to the wall. The quantitative impact of the near-wall or radiation boundary layer gases on the net radiative flux to the wall may be significantly different between the two types of codes. The CFD computations may simply exhibit a greater insulative effect to radiation in the near-wall regions than that provided in RHBP-type models due to aerodynamic (case-specific) and submodel differences. As discussed earlier, due to an implementation inconsistency in the FLUENT code, the gas-phase radiation absorption coefficient utilized in the CFD computational was a linear function of local temperature only, and not a function of concentration. While it is anticipated that the gas-phase absorption coefficient will be sensitive to the local concentrations of CO2 and H2O, it is not known at this juncture whether the difference in overall wall absorption between the two cases would increase or decrease relative to its present values, and what the difference in magnitude would be. The calculations should be repeated with a gas-phase radiation absorption coefficient submodel that uses the full wide-band model (and that is more reliable than the WSGGM model presently in FLUENT).
ALSTOM Power Inc.

52
June 30, 2001
Vertical profiles of the maximum and average net wall heat flux for the baseline case and the Concept-B case are shown in Figures 3.9 and 3.10, respectively. At any given elevation, the net wall heat flux value represents the area-weighted average of all the cells positioned circumferentially around the furnace (at that elevation). The maximum local net wall heat flux is simply the maximum value of all of the circumferential cells (at a given elevation). The radiative portion of the net wall heat flux, the portion of the net wall heat flux due to conduction, and the incident radiative flux are also shown. A geometry profile is also provided, showing the coutant bendline, the windbox, and the arch bendline. The recessed line in the geometry profile represents the windbox, while the slanted line with the positive slope represents the coutant, and the slanted line with the negative slope represents the arch bendline. The maximum and average values of the net wall heat flux calculated from idealized in-house design standards correspond to the base case conditions only (on both Figures 3.9 and 3.10) and are provided simply for comparative reference purposes.
ALSTOM Power Inc.

53
June 30, 2001
180,000 160,000 140,000
Area-Weighted Average of Circumferential Wall Heat Flux from FLUENT Calculation Scaled Net Wall Heat Flux from ALSTOM Performance Design Standards Local Maximum of Net Wall Heat Flux from FLUENT Calculation Local Maximum of Scaled Net Wall Heat Flux from ALSTOM Performance Design Standards Area-Weighted Average of the Net Wall Heat Flux due to Conduction from FLUENT Calculation Area-Weighted Average of the Net Wall Heat Flux due to Radiation from FLUENT Calculation Area-Weighted Average of the Incident Radiative Flux from FLUENT Calculation Geometry Contour
Baseline Case 120,000 100,000 80,000 60,000 40,000 20,000 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130
Furnace Elevation (ft)
Figure 3. 9: Vertical Profiles of the Local Peak and Area-Weighted Net Wall Heat Flux for the Base Case
Area-Weighted Average of Circumferential Wall Heat Flux from FLUENT Calculation Scaled Net Wall Heat Flux from ALSTOM Performance Design Standards Local Maximum of Net Wall Heat Flux from FLUENT Calculation Local Maximum of Scaled Net Wall Heat Fluxes from ALSTOM Performance Design Standards Area-Weighted Average of the Net Wall Heat Flux due to Conduction from FLUENT Calculation Area-Weighted Average of the Net Wall Heat Flux due to Radiation from FLUENT Calculation Area-Weighted Average of the Incident Radiative Flux from FLUENT Calculation Geometry Contour
180,000 160,000 140,000
Concept-B Case 120,000 100,000 80,000 60,000 40,000 20,000 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130
Figure 3. 10: Vertical Profiles of the Local Peak and Area-Weighted Net Wall Heat Flux for the Concept-B Case
ALSTOM Power Inc.

54
June 30, 2001
For the Base case (Figure 3.9), it can be seen that the CFD-calculated average net wall heat flux is less than the idealized design standard in the furnace volume below the windbox, and is above the design standard in the furnace volume above the windbox. This is due again to the fact that the lower coal is OOS, which means that fewer particles are carried down toward the bottom of the furnace, and the heat release generated in the coutant region is correspondingly smaller than it otherwise would be. (Computational runs with the lower coal in service show a heat release in the coutant region which is similar in magnitude to the design standard profile.) In a comparison of Figures 3.9 and 3.10, it can be seen that the Base case has a slightly higher peak and average wall heat flux, over most of the furnace elevation, than the Concept-B case, as has already been established. However, differences in the overall absorption between the two cases are rather small (i.e., less than 1%) and may perhaps be construed to be part of the noise in the CFD calculations. Vertical profiles of the peak, standard deviation, and mass-averaged, planar, gas temperatures are provided in Figures 3.11 and 3.12. The area-averaged interior wall temperature is also shown in both figures. The peak temperatures and standard deviations of the local gas temperature (i.e., a type of unmixedness) for the baseline case are somewhat higher than those of the Concept-B case. The peak temperature differences are higher in the windbox region, with a delta of approximately 200 F or more for the peak temperature in the mid-windbox region, which then diminishes slightly to about 150 F as the arch elevation is approached. The standard deviation of the local gas temperature for the baseline case is about 150 F higher than that of the Concept-B case in the windbox region, although the difference then diminishes and becomes negligibly small as the HFOP is approached. (It is difficult to say whether the difference in standard deviation between the two cases reflects a significant difference in mixing efficiencies or simply a difference in local peak temperature values.) Over most of the furnace height, except in the immediate vicinity of the CCOFA jets, the mean temperature and the interior wall temperature are generally higher in the baseline case than in the Concept-B case. (Table 3.10 shows that the baseline HFOT is approximately 90 F higher than that of Concept-B.)
3500 Baseline Case 3000
2500
2000 Mass-Averaged Gas Temperature Maximum Value of the Local Planar Gas Temperature Standard Deviation of the Local Planar Gas Temperature Area-Averaged Interior Wall Temperature Geometry Contour
1500
1000
500
0 0 10 20 30 40 50 60 70 80 90 100 110 120 130
Figure 3. 11: Vertical Profiles of the Local Peak and Mass-Averaged Gas Temperatures for the Base Case The specific heat of CO2 is about 6% to 7% greater than that of N2 over the range of 1340 F (1000 K) to 3140 F (2000 K). Therefore, for equivalent heat release and wall absorption, the Concept-B case would be expected to have a slightly
ALSTOM Power Inc.

55
June 30, 2001
lower mean gas temperature. The specific heat of H2O (gaseous) is a factor of 2 to 3 times that of CO2, but the mass fraction of H2O in the inlet mixtures of the Concept-B case is only about a percentage point higher than that in the baseline case; thus its impact on lowering the Concept-B HFOT is minimal. Consequently, it is expected that the specific heat consideration of CO2 (alone) should be a factor which would ordinarily cause the HFOT for the ConceptB case to decrease relative to that of the baseline case.
3500 Concept-B Case 3000
2500
2000
1500
1000
Mass-Averaged Gas Temperature Maximum Value of the Local Planar Gas Temperature Standard Deviation of the Local Planar Gas Temperature Area-Averaged Interior Wall Temperature Geometry Contour
500
0 0 10 20 30 40 50 60 70 80 90 100 110 120 130
Figure 3. 12: Vertical Profiles of the Local Peak and Mass Averaged Gas Temperatures for the Concept B Case 3.8 Contour Plots
Contour plots of temperature at selected elevations are given in Figure 3.13. The plots show reasonable symmetry of the flowfield, with a relatively cool inner core, surrounded by an annular, high-temperature region. In certain regions, cooler near-wall temperatures may separate the high-temperature annular ring from the walls.
ALSTOM Power Inc.

56
June 30, 2001
1.1.1.1.1.1.3 Figure 3. 13: Planar Contour Plots of Temperature at Various Elevations for the Base Case and Concept-B Case
ALSTOM Power Inc.

57
June 30, 2001
A cross-sectional view of the temperature contours at two planes is given in Figure 3.14.
TEMPERATURE (F)
1.1.1.1.1.1.8.2 CON
Figure 3. 14: Planar Contour Plots of Temperature at two Elevations for the Base Case and Concept-B Case As can be seen in Figure 3.14, the aerodynamics and flame regions are rather similar in shape and appearance, with minor differences in temperature magnitude. The higher inlet velocities and penetration of the baseline case (see Tables 3.5 and 3.6) are apparent, in that a longer traverse distance is required before the jet is either swept upward out of the plane or mixed out to equivalent temperatures. The swirl is sufficiently strong to prevent the jets from penetrating radially to the core; rather the jets are quickly bent over in the direction of the swirl crossflow vectors (in the crosssectional plane) and any residual jet penetration is in that same direction. It should be noted that although the difference in inlet velocities between the two jets is a factor in the resultant aerodynamic penetration, a perhaps equally influential factor is the velocity acceleration due to combustion. The coal jets, for example, enter the domain at 96.2 ft/s and 60.8 ft/s, for the baseline case and the Concept-B case respectively, but the jets are rapidly accelerated to approximately 170 ft/s (figure not shown) within a few nozzle diameters of the entrance. The peak temperatures in the annular high-temperature annular ring are higher in the baseline case than in the Concept-B case. By the time the CCOFA is reached, the core temperature of the baseline case also appears to be higher than that in the Concept-B case (contributing ultimately to a higher HFOT for the Base case). Temperature plots at the mid-plane of the x-coordinate direction are shown in Figure 3.15. The plots are again qualitatively very similar in appearance.
ALSTOM Power Inc.

58
June 30, 2001
BASE CASE TEMPERATURE (F)
CONCEPT-B CASE
Figure 3. 15: Planar Contour Plots of Temperature at the X-Mid-Plane for the Base Case and Concept-B Case
ALSTOM Power Inc.

59
June 30, 2001
The corresponding contour plots of the oxygen mass fraction (wet) at the x-mid-plane are shown in Figure 3.16.
BASE CASE 1.1.1.1.1.1.9 MASS FRACTION
CONCEPT-B CASE
Figure 3. 16: Contour Plots of O2 Mass Fraction (Wet) at the X-Mid-Plane for the Base Case and Concept-B Case The Concept-B case appears to have a slightly greater concentration of oxygen in the coutant region and in the furnace core than the Base case does. The amount of oxygen will be partially controlled by the relative local concentrations of the particles and the gas, as well as the particle burning rates and trajectory history. Assuming complete combustion, the exit O2 concentrations on a mass fraction basis are almost equivalent (see Table 3.2); on a molar basis, the ConceptB case will have a higher exit mole fraction (3.6%, dry) compared to that of the Base case (2.6%, dry). Since the composite kinetic/diffusion surface reaction rate model for char oxidation in FLUENT is a direct function of the partial pressure of oxygen, assuming an equivalent particle distribution, the higher oxygen mole fraction in the ConceptB case should help the particles to burn out more completely than the particles in the Base case (as shown in Table 3.9).
ALSTOM Power Inc.

60
June 30, 2001
Figure 3.17 shows the z-component (i.e., the upward component) of velocity on the mid-plane.
BASE CASE VELOCITY (ft/s)
CONCEPT-B CASE
Figure 3. 17: Contour Plots of the (Upward) Z-Velocity at the X-Mid-Plane for the Base Case and Concept-B Case In Figure 3.17, only the positive (upward) z-component velocity is shown. The upward velocity appears to be somewhat greater in the core of the furnace for the baseline case than for the Concept-B case. For an equivalent upward mass flow rate, at any cross-section, it would be expected that the baseline case velocity would be higher than that of the Concept-B case due simply to the difference in molecular weights (between CO2 and N2) and the associated densities. In addition, the baseline case has higher peak temperatures which would also accelerate the local velocity field. However, the presence of a higher velocity does not necessarily mean that the integrated planar flow rates are higher. The CFD results also show that between the bottom of the coutant and the top of the windbox, the planar integrals (not shown) of negative mass flow rate, positive mass flow rate, and absolute mass flow rate are on the order of 10% greater for the Concept-B case than for the baseline case. Above the windbox, the differences in integrated mass flow rate become small (since they simply reflect the nearly equivalent overall inlet flow rates). Both cases evidence the presence of an adverse pressure gradient (i.e., low velocity region) in the core between the arch-bendline elevation and the top-of-the-windbox elevation. However, the higher upward core velocities associated with the baseline case appear to almost overcome the low-velocity, adverse pressure gradient region. Planar integrals of the swirl number (not shown) indicate that the Concept-B case has a slightly higher swirl magnitude at all elevations except over the upper windbox region. As a result, the Concept-B case appears to be closer to incipient reverse flow zone formation than the baseline case in the upper core region below the arch bendline. The net wall heat flux is shown in Figure 3.18. (It should be noted that the wall absorption of greatest magnitude is represented by the blue color (i.e., value on the order of 70,000).)
ALSTOM Power Inc.
61
June 30, 2001
BASE CASE
CONCEPT-B CASE
NET WALL HEAT FLUX (Btu/hr-ft2)
Figure 3. 18: Net Wall Heat Flux for the Base Case and Concept-B Case As discussed earlier, the wall absorption is very similar for both cases. The peak net wall heat flux is between the top coal nozzle elevation and the arch bendline, in the mid-span region of the waterwall. 3.9 Conclusions
Two cases have been compared using the FLUENT CFD code -- a baseline, nominal 15% excess air case (Case 1 or Base case), and a recirculated flue gas, oxy-fired case (Case 2 or Concept-B case). In the Concept-B case, the nitrogen was largely replaced by carbon dioxide. The cases have been compared on the basis of equivalent nozzle/inlet areas, as well as an equivalent coal-to-oxygen feed ratio (by mass). The following computational results have been highlighted: The baseline case exhibits higher carbon-in-ash (by 1.6 percentage points), higher outlet NOx emissions (by a factor of 2), and higher outlet CO (by a factor of 2) than the Concept-B case. These same computational trends are also qualitatively exhibited by the bench-scale testing. The baseline case exhibits a slightly higher peak gas temperature (maximum difference of about 200 F), and a correspondingly higher average (cross-sectional) gas temperature (difference of 90 F at the HFOT), than that of the Concept-B case. The net wall absorption in the furnace region for the baseline case is larger (by less than 1%) than that of the Concept-B case. (Conversely, the net wall absorption for the baseline calculation with the RHBP was found to be about 6% lower than the Concept-B case calculated by the RHBP.)
Explanations for the observed trends must rely on physical property differences between the nitrogen, which dominates in the baseline case, and carbon dioxide, which largely supplants the nitrogen in the Concept-B case. The physical species properties and the anticipated consequences are itemized below:
ALSTOM Power Inc.

62
June 30, 2001
(1) Higher molecular weight of CO2 relative to N2. For equivalent inlet areas, and as a result of the molecular weight and associated density differences, the baseline case will exhibit larger inlet velocities and a higher penetration capability than the Concept-B case. The inlet velocity differences will further serve to impact the aerodynamic, particle trajectory, mixing, and flame patterns. (2) Higher specific heat of CO2 relative to N2. For an equivalent local heat release and heat transfer, the higher specific heat of carbon dioxide will serve to decrease the overall flame temperatures of the recycled flue gas mixture in the Concept-B case, relative to the baseline case. (3) Higher gas emissivity and absorptance of CO2 relative to N2. For an equivalent local gas temperature, the higher emissivity of CO2, relative to the optically transparent N2, should serve to increase the absorption coefficient (and the irradiation to the wall) in the recycled flue gas case (Concept-B) relative to the baseline case. The three physical properties listed above may have compensatory rather than cumulative effects. In the present CFD calculations, the resultant, local gas temperatures are not equivalent in the two cases. The higher specific heat of the carbon dioxide, and the associated lower gas temperatures in the Concept-B case, will tend to offset somewhat or compensate for the expected increase in the wall absorption (i.e., anticipated due to the enhanced emissivity of the CO2.) Furthermore, the spatial distribution of the carbon dioxide across the cross-section may be important; it is hypothesized that high concentrations of CO2 in the cooler gas mixtures between the wall and the flame may actually act to inhibit the net radiative flux to the walls. The trend calculated by the CFD code, with respect to the furnace temperature at the HFOP, appears to be qualitatively aligned with the trend calculated by the in-house RHBP code. However, the difference in wall absorption for the Concept-B case relative to the baseline case, calculated by FLUENT (change of 1%), does not fully agree with the results of the RHBP (change of +6%). Computed and/or experimental trends that indicate that oxy-firing may induce either an increase in wall absorption (+6%) or a decrease in wall absorption (-18%), relative to the baseline case, are supported in the literature. It is suggested that the absorptive properties of a local CO2-containing gas mixture in the vicinity of the wall may either act to enhance or inhibit the incident radiative flux to the wall, depending upon its relative spatial placement and mixture temperature. For example, a low-temperature, CO2-rich mixture near the wall would absorb the radiative flux from the interior fireball region; a portion of the energy would be re-emitted at the lower gas temperature, and the remainder of the energy would be used to heat up the gas. The result would be a net reduction in the incident radiative flux to the wall. Conversely, a high-temperature, CO2-rich mixture near the wall would emit at its local gas temperature, thus enhancing the incident radiative flux to the wall. Therefore, it is suggested that the relative spatial relationships of the cool and hot gas mixtures, the relative composition of the absorbing media, and the proximity of that media to the wall (as induced by the furnace and firing system aerodynamics), may significantly impact the gas-phase irradiation to the wall. Indeed, the aerodynamic and flame patterns that prevail in a given air-fired or oxy-fired furnace may conceivably have as strong an impact on the net wall absorption as the physical property differences themselves (gas-phase emissivity, specific heat, etc.) The results of computational tools (such as CFD and the RHBP) should be viewed as being qualitative in nature, particularly when they are asked to produce calculations outside of the experience base for which they have been validated. Certainly, the gas-phase and particle-phase radiation property submodels could be enhanced in both codes, and the impact of spatial gradients (caused by the interleaving of hot and cool regions of varying CO2 composition) on radiative wall flux needs to be investigated more fully. CFD computations have been utilized to gain a more in-depth qualitative understanding of aerodynamic and flame patterns in combustion systems, but have not yet been integrated into routine boiler design procedures. At the present time, the ALSTOM design standards are based upon the experience and expertise built into the RHBP and other design protocols, and those standards must be adhered to in any new design project in order to mitigate risk. Therefore, the results of the RHBP must be regarded as the default standard, both from an engineering experience viewpoint and from a rules-based design viewpoint. However, additional validation work needs to be done in order to confirm the trends for oxy-firing scenarios. Although differences in physical properties of the transport gases (e.g., air-firing versus oxy-firing) may initially induce undesirable deviations from the performance goals of a field unit, the designer and engineer views such alterations as challenges rather than insurmountable obstacles. Much can be done in the way of operating condition optimization (e.g., spray and nozzle tilt), without major retrofits, to realign steam temperatures and wall absorptions with their desired, target values. Design parameters are often in conflict, and the intelligent designer must work to balance various parameters and operating conditions to achieve the desired outcome. The CFD work performed here was based on
ALSTOM Power Inc.
63
June 30, 2001
certain constraints to maintain equivalency for comparison purposes, which would not necessarily be the case in the field. For example, a potential decrease in furnace wall absorption of several percentage points could be nullified through manipulation of various operating parameters. If required, firing system retrofits and surface modifications could be performed to handle more severe decreases in absorption; certainly new unit design could easily accommodate any necessary alterations in design philosophy.
ALSTOM Power Inc.

64
June 30, 2001
4.0
Bibliography
Bozzuto, C. R., Nsakala, N., Liljedahl, G., Palkes, M., Marion, J., Vogel, D., Fugate, M., Guha, M., Engineering Feasibility and Economics of CO2 Sequestration/Use on an Existing Coal-Fired Power Plant. Volume I: AEPs Conesville Power Plant Unit No. 5 Retrofit Study, Prepared for the Ohio Department of Development, Ohio Coal Development Office and US Department of Energy, National Energy Technology Laboratory (June 30, 2001). Bozzuto, C., Nsakala, N., McGowan, J., and Borio, R., Engineering Feasibility and Economics of CO2 Sequestration/Use on a Existing Coal-Fired Power Plant, Task 1 (Literature Survey) Report. OCDO Contract CDO/D98-8 (January 1, 2000). Chui, E. H., Croiset, E., and Thambimuthu, K. V., Simulation of Coal Combustion in High CO2 and O2 Environment, Personal Correspondence (2001). Fiveland, W. A., Invited Lecture on Multi-Dimensional Modeling of Reacting Flow in Stationary Combustors, Central States Section of the Combustion Institute, Indianapolis, IN (April 17-18, 2000). Hart, D., Lewis, R., Chen, W., Tobiasz, R., Firing System Modification to Alter Ash Properties for Reduction of Deposition and Slagging, IJPGC, Baltimore, MD (1998). Haynes, J. M., Beer, J. M., Toqan, M. A., Nicholson, J. A., Duby, T. G., Narula, R. N., Thornock, D. E., Borio, R. W., Sutton, J. P., LaFlesh, R. C., Aerodynamic Modeling and Scale-Up of a Low NOx Oil Burner, Proceedings of the 1996 International Joint Power Generation Conference, The 1996 International Joint Power Generation Conference, Houston, TX, EC-Vol. 4, FACT-Vol. 21, pp. 313-323 (October 13-17, 1996). Marion, J., Chapman, P. J., and von Hein, R. J., From Equations to Combustion System Equipment at the ABB Power Plant Laboratories, American Flame Research Committee, Fall International Symposium, Monterey, CA (October 1518, 1995). Nsakala, N., Essenhigh, R. H., and Walker, P. L., Jr "Studies on Coal Reactivity: Kinetics of Lignite Pyrolysis in Nitrogen at 808 C.; Combustion Science & Technology, 16, 153 (1977). Nsakala, N., Goetz, G. J., Patel, R. L., Lao, T.C., Hickerson, J. D., and Ritz, H. J., "Pyrolysis and Combustion Characterization of Pulverized Coals for Industrial Applications," Presented at the 189th American Chemical Society National Meeting, held at Miami, Florida (April 28 - May 3, 1985). Nsakala, N., Patel, R. L. and Borio, R. W., "An Advanced Methodology for Prediction of Carbon Loss in Commercial Pulverized Coal-Fired Boilers," Presented at the1986 ASME/IEEE Joint Power Generation Conference, Portland, Oregon (October 19-23, 1986). Paper No. 86-JPGC-FACT-L. CE Publication TIS-8211. Nsakala, N., Patel, R. L., and Lao, T. C., "Combustion and Gasification of Chars From Four Commercially Significant Coals of Different Rank," Goetz, G.J., EPRI Final Report AP -2601, September 1982. Work presented at the 1983 International Conference on Coal Science, held in Pittsburgh, PA (August 15-19, 1983). Nsakala, N., Patel, R., Raymond, D. and Hargrove, M., "Effects of Coal Nature and Cleaning Processes on the Physicochemical and Reactivity Characteristics of Beneficiated Coal-Based Products, Presented at the 16th Conference on Coal & Slurry Technologies Conference, Clearly Water, FL (April 22-25, 1991). Richards, G.H., Chen, W., Toqan, M. A., Horn, K., Blande, V., and Sirois, R. H., Reducing NOx Emissions in a Natural Gas-Fired Utility Boiler Using Computational Fluid Dynamics, EPRI-DOE-EPA Combined Utility Air Pollutant Control Symposium, Washington, DC (Aug 25-29, 1997). Wilkinson, M. B., Boden, J. C., Panesar, R. S., and Allam, R. J., A Study on the Capture of Carbon Dioxide from a Large Refinery Power Station Boiler by Conversion to Oxyfuel Operation, Personal Correspondence (2001).
ALSTOM Power Inc.

65
June 30, 2001

10 1 1 152

Uploaded by

Copyright:

Available Formats

10 1 1 152

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

10 1 1 152

Uploaded by

Copyright:

Available Formats

CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

CONESVILLE POWER PLANT UNIT NO. 5 CO2 CAPTURE RETROFIT STUDY

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

LIST OF TABLES (CONT)

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

LIST OF FIGURES (Cont)

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

CO2 Separation Unit using MEA

CO2 Compression & Liquifaction System

H 2O, N2, ...

ALSTOM Power Inc.

June 30, 2001

ENGINEERING FEASIBILITY AND ECONOMICS OF CO 2 CAPTURE ON AN EXISTING COAL-FIRED POWER PLANT

Flue Gas Recycle

CO2 for Sequestration or Use (in EOR or EGR)

Air Separation Unit (ASU)

CO2 Compression & Liquifaction System

O2, N2 Air in-leakage

ALSTOM Power Inc.