CO2 ‘Capture Ready’ Plant for India

An Update
Mr R Padmanabhan
Chennai, India

Delhi – 21 January 2008

Company update

Nuclear Thermal Turbine & Desalination Casting & Forging Construction

Generator

• Our new name - Doosan Babcock Energy Limited,

Limited
• Subsidiary of Doosan Heavy Industries of South Korea, and part of the Doosan
Group – the oldest and one of the top 10 conglomerates in Korea
– US$13bn turnover company (2006)
• Market leader in gas, coal, nuclear power generation and desalination.
– e.g. SIPAT, 3 x 660MWe and Mundra, 5 x 800MWe
• Our commitment is to all forms of power generation, including clean coal, nuclear,
gas and renewables
• The Doosan Group’s ‘Centre of Excellence’ and global R&D base for Boilers and
CO2 capture – which includes our India organisation
Page 1
In one year - How things have changed for coal and gas

• 14th Sept 07, Hans Stehr, chairman of UN CDM Exec Board:

``Fossil fuel will remain a big part of the world's energy mix for decades to
come,... essential we burn that fuel as efficiently as possible.''

• World Wide Recognition: These plants will operate for 40- 50 years; So
they need to be built ‘Capture Ready’- ‘TODAY’ to avoid carbon lock-in

• EU Agrees: renewables and energy efficiency, whilst vital, are ‘not enough’
– Coal has a huge role in the new EU Energy Policy
– New Plant to be ‘capture ready’ from 2010,
– 10-12 demonstrations of CCS operational by 2015,
– CCS in operation from 2020, So coal projects
• Gas has its issues beginning to be
– Price instability. developed
– Security of supply.
– Gas is also a CO2 emitter, will need CCS
which are
for deep cuts ‘Capture
Ready’ Page 2
Comparison of Carbon Capture options for Coal power plant
Three options:
• Post Combustion Capture – Amine or Specific Investment costs (Euro/kw)
Ammonia scrubbing 2000

• Oxyfuel firing (Doosan Babcock Focus) 1800

Specific Investment Cost Euro/kW

• Precombustion – IGCC 1600
1400-1800
1400
Euro/kw
Net Cycle Efficiencies (%LHV) 1200
for New
1000
40
800
build, 800
35 600
Euro/kw
400 for Retrofit
Net Efficiency % (LHV)

30 200

0
25
Amine Oxyfuel IGCC
20

15

10
Cost of Electricity (Eurocents/kwh)
7

5 6

Cost of Electricity EuroCent /kWh

0
5 5 -6.2
Amine Oxy Combustion IGCC 4
Euro/kwh
for New
Many studies show these result in are broadly 3
build, <5
similar
From efficiency
joint paper with Jacobs atand cost
Powergen of electricity.
2006
2
Euro/kwh
1 for retrofit
No clear winner, but PCC and Oxyfuel will be 0
needed for retrofit plants currently being built
Amine Oxyfuel IGCC
around the world (incl. India)
Page 3
New Coal Fired Plants planned in the UK
Start up
Project Size/Technology Status
Date
IGCC
Section 36 consent.
Powerfuel Hatfield 2 x 430MW IGCC with Capture 2011
FEED study starting
Internal feasibility
E.ON Killingholme 450-500MW IGCC with CCS 2012
study underway
Centrica Teesside 800 MW IGCC with CCS 2011 FEED study started
PF - Post Combustion
New build ASC (Capture ready) Scoping Report
RWE npower Blythe 2014
3x800 MW submitted 11/05/07
New build ASC (Capture Ready) Section 36 applied for
E.ON Kingsnorth 2012
2 x 800MW 11/12/06
New build ASC (Capture Ready) Scoping Report
RWE npower Tilbury 2013/14
1600MW submitted 13/3/07
PF – Oxyfuel (All are retrofits at the moment)

1 or 2 x 500MW ASC Retrofit FEED study well

SSE Ferrybridge 2011
(Capture Ready) advanced
Longannet and ASC Retrofit (Capture ready), up 2012 Feasibility study
Scottish Power Page 4
Cockenzie to 3390MW onwards announced 17/05/07
Ferrybridge – ASR Retrofit – Oxyfuel Capture ready

A ‘future proofed’ Advanced Supercritical Retrofit to

Ferrybridge Power Station – Oxyfuel capture ready.

Page 5
Ferrybridge Retrofit Specifics Present Boiler

Subcritical boiler

4 x 500MWe units

Ordered 1961, commissioned mid/late 60’s

Steam Conditions:160 bar,565oC/ 565oC

Page 6
Ferrybridge - Supercritical Boiler Retrofit with Oxyfuel
‘Capture Ready’
• 507 MWe (gross) 476MWe (net) /unit,
• 290 bar/ 6000C / 6100C
• BMCR steam flow 1,380 Te/hr
• Bituminous coal with up to 25% Biomass
• BOFA system
• New boiler within existing boiler house
• Re-use of much BOP equipment,
new SCR and FGD
• POSIFLOWTM low mass flux furnace

Page 7
Ferrybridge ASR Capture Ready Application - Summary

• Currently sub-critical operation with cycle efficiency 36.7%

• With SCR and FGD, new cycle efficiency 44.7%
– 22% increase in overall efficiency, despite SCR/FGD penalty
• CO2 reduction (with load factor of 70%) is 483,500tes/yr
– 18% reduction in CO2 emissions

• Status of design :
– No technical showstoppers
– ASR boiler fits easily within existing structure
– Turbine layout compatible with existing foundations
– Anticipated costs within budget

Page 8
What does it take to be CCS ready?

• Furnace thermal performance to suit oxyfuel/air coal combustion

• Boiler performance considerations
• Oxy-fuel burners would fit in the same space as regular burner without
need for major pressure part modification
• Flue gas recycle consideration in boiler design
• Boiler Layout consideration for interfacing equipment
• Boiler sealing against tramp air ingress

Page 9
What will a Supercritical Retrofit involve at Longannet &
Cockenzie?

• Replacement of boiler pressure

parts, within boilerhouse envelope
• Lighter boiler weight means re-use
of existing primary structure
• Replacement of HP and IP turbine,
modified LP turbine
• Replacement of all steam and feed
water piping
• New feed pumps and feed heating
system
• New DCS system (if not already
installed)
• Re use of bulk of ancillary
equipment
• New SCR plant
• New FGD plant (if not already
installed)

600 MWe units similar to Ferrybridge ASR & CCS ready

Page 10
Advanced Supercritical Retrofit (ASR)

• POSIFLOWTM Boiler Retrofit Process demonstrated at Yaomeng, China

in 2002
– Retrofit of Chinese designed sub-critical 300MWe boiler.
– Flaws in its design meant it had a low availability due to overheating
– Retrofitted with Doosan Babcock POSIFLOWTM boiler
– Order received Dec 07 for similar conversion of a 2nd boiler

• Technology could be applied to existing 200/210/250 MWe Indian boilers

subject to full technical evaluation
– There is a minimum size of unit below which the technology cannot be
applied
– Indian 200/210/250MWe boilers are borderline
– requires a feasibility study to fully evaluate

Page 11
Carbon Capture by Oxyfuel firing on Pulverised Coal Plant

Figure courtesy of Vattenfall

Page 12
Carbon Capture by Oxyfuel firing on Pulverised Coal Plant

- Pilot scale tests by Doosan Babcock Energy 1996

- IEA studies completed

- EU project ENCAP underway

- EON 1MW rig now operational, confirmed DBE results

- DTI funded collaborative R&D projects in progress (Doosan Babcock

Energy, EON, RWE, Air Products …)

- Vattenfall 30MW demonstration plant being built , and similar projects at

Lacq and Callide

- Full scale 40 MW burner test planned by Doosan Babcock in 2008/9

Page 13
Doosan Babcock Oxyfuel Burner development program

Three Stage Development Programme

• To develop a competitive Oxyfuel technology suitable for full scale
application 2010.

• A staged approach through the development and demonstration of Oxyfuel

technology:-

- Stage 1 : Fundamentals and System Design

- Stage 2 : Modified Design Tools and Component Testing

- Stage 3 : Reference Designs

2005 2006 2007 2008 2009 2010

Stage 1
Stage 2
Stage 3

Page 14
Doosan Babcock burner test facility to be converted to
Oxycoal firing
Stage 2 will involve conversion of the test facility to OXYCOAL firing

Multi Fuel Burner Test Facility (MBTF)

• commissioned in Renfrew in 1999

• conversion to Oxyfuel under the UK

OXYCOAL collaborative project.

• £7m ($14m) funding now in place.

Demonstration of a full utility sized Oxyfuel

PF combustion,

The first full-scale test of Oxyfuel firing

in the world

Page 15
Carbon Capture Ready - Oxyfuel

Main Considerations:

• Space for Air Separation Unit

• Space for CO2 cleaning and compression

• Space for CO2 recycle ducts

• FGD may be needed for some coals

• Feasible CO2 pipeline route to a storage area

Page 16
Site Layout - Capture Plant Space Requirements

1 x ASC BT Amine Unit:

CW Tower Pond Dia ~90m
CW Tower Height ~110m
- 2 x DCC
- 2 x Fans / Blowers
- 2 x CO2 Absorber Towers (12.5m Dia x
45m Height)
- 1 x CO2 Stripper Tower (10m Dia.)
- CO2 Compression : 40 m x 15m approx

DCC &

STRIPPER
ABORBER 1

100m
DCC &
CO2
ABSORBER 2
230m 15m

1 x ASC BT Oxyfuel Unit:

- 2 x ASU trains : 80 m x 140 m
- CO2 Compression : 80 m x 15 m
- Maximum Height : 68 m

80m
ASU 1 ASU 2 CO2

70m 70m 15m

Page 17
Key Messages

• Work to date has demonstrated that ASC Retrofits, designed to be

“Capture Ready” are available options today – subject to initial
feasibility study of each plant.

• Indian coals, with high ash and low reactivity, are well suited to
Oxyfuel firing than either Amine scrubbing or IGCC.

• A CCS Indian-based demonstration, involving oxyfuel firing, should

be a high priority

• Feasibility study of Indian 200/210/250MWe units urgently needed

EU expertise and capital, combined with Indian skills and availability

of utility plant in desperate need of renovation provides an
‘Ideal Opportunity for EU-Indo Co-operation &
International Leadership’

Page 18
Our Commitment to the Industry

Doosan Babcock is committed to

development and global implementation of
cleaner power plants - clean coal, clean
gas, nuclear and renewables as rapidly as
the market allows

Thank you for your attention

rpadmanabhan.mas@doosanbabcock.co.in

Page 19
Carbon Dioxide Capture Technologies

Page 20
Post-combustion Carbon Capture - Amine Scrubbing on Pulverised Coal Plant

Large Scale CO2 Capture Plant

- IEA, EU projects underway

- Requires scale up ( factor of 10)
- 300 MW planned by MHI
- Collaborative DTI project in negotiation
- Technology likely to be available for 2010 / 12
implementation

Page 21