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 * Thermofluid
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ArticlePDF Available


OPERATION EXPERIENCES OF OXYFUEL POWER PLANT IN CALLIDE OXYFUEL PROJECT

 * December 2014
 * Energy Procedia 63

DOI:10.1016/j.egypro.2014.11.053
 * License
 * CC BY-NC-ND 3.0

Authors:
Akihiro Komaki


Akihiro Komaki
 * This person is not on ResearchGate, or hasn't claimed this research yet.



Takahiro Gotou


Takahiro Gotou
 * This person is not on ResearchGate, or hasn't claimed this research yet.



Terutoshi Uchida


Terutoshi Uchida
 * This person is not on ResearchGate, or hasn't claimed this research yet.



Toshihiko Yamada


Toshihiko Yamada
 * This person is not on ResearchGate, or hasn't claimed this research yet.



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References (3)
Figures (1)





ABSTRACT AND FIGURES

Callide Oxyfuel Project is the only demonstration project for oxyfuel power
plant in the world and has been promoted at Callide-A power station in
Queensland, Australia. Callide-A power plant, which is a retrofit of an existing
power plant with a capacity of 30MWe, is now the largest operating oxyfuel power
plant all over the world. Two air separation units (ASU) of 330 TPD and CO2
compression and purification unit (CPU) of 75 TPD that is about 10% capacity of
total flue gas were newly installed. And the existing 30MWe boiler was modified
to apply both air and oxufuel combustion. This demonstration is the key and
important step for the large-scale oxyfuel power plant in the future and the
various tests regarding the oxyfuel boiler and CPU have been performed. Main
objectives of this project are to demonstrate the oxyfuel operation with CO2
capture and storage using the existing power plant and to obtain the design data
and operation know-how for the commercialization.
Main specifications of Oxyfuel power plant for CO 2 capture
… 




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Content available from CC BY-NC-ND 3.0:
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Operation Experiences of Oxyfuel Power Plant in Callide Oxyfuel Project.pdf
Available via license: CC BY-NC-ND 3.0
Content may be subject to copyright.
Energy Procedia 63 ( 2014 ) 490 – 496
Available online at www.sciencedirect.com
ScienceDirect
1876-6102 © 2014 The Authors. Published by Elsevier Ltd. This is an open access
article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Peer-review under responsibility of the Organizing Committee of GHGT-12
doi: 10.1016/j.egypro.2014.11.053
GHGT-12
Operation Experiences of Oxyfuel Power Plant
in Callide Oxyfuel Project
Akihiro Komaki
a
, Takahiro Gotou
a
, Terutoshi Uchida
a
, Toshihiko Yamada
a
,
Takashi Kiga
a
and Chris Spero
b
*
a
R&D Department, Energy & Plant Operations, IHI Corporation
b
CS Energy Ltd. / Callide Oxyfuel Services Pty Ltd.
Abstract
Callide Oxyfuel Project is the only demonstration project for oxyfuel power
plant in the world and has been promoted at
Callide-A power station in Queensland, Australia. Callide-A power plant, which
is a retrofit of an existing power plant with a
capacity of 30MWe, is now the largest operating oxyfuel power plant all over the
world. Two air separation units (ASU) of 330
TPD and CO
2
compression and purification unit (CPU) of 75 TPD that is about 10% capacity of
total flue gas were newly
installed. And the existing 30MWe boiler was modified to apply both air and
oxufuel combustion. This demonstration is the key
and important step for the large-scale oxyfuel power plant in the future and the
various tests regarding the oxyfuel boiler and
CPU have been performed. Main objectives of this project are to demonstrate the
oxyfuel operation with CO
2
capture and storage
using the existing power plant and to obtain the design data and operation
know-how for the commercialization.
Callide-A oxyfuel boiler with power generation and CO
2
purification unit from oxyfuel flue gas have been demonstrated and
have given us the various operation results with some test parameters in the
Project. Regarding the oxyfuel boiler, the heat
absorbed rate, combustion characteristics, trace elements behaviour and plant
operation flexibility have been confirmed at the
different coal type and the different boiler inlet O
2
concentration with the various power generation output through the
commissioning and demonstration stage.
In this paper, the operational experiences of the oxyfuel power plant in Callide
Oxyfuel Project are introduced.

© 2013 The Authors. Published by Elsevier Ltd.
Selection and peer-review under responsibility of GHGT.
Keywords: Oxyfuel; Coal; CO
2
capture; CCS; CCUS; Power plant


* Corresponding author. Tel.: +81-3-6204-7506; fax: +81-3-6204-8790.
E-mail address: toshihiko_yamada@ihi.co.jp
© 2014 The Authors. Published by Elsevier Ltd. This is an open access article
under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Peer-review under responsibility of the Organizing Committee of GHGT-12




Akihiro Komaki et al. / Energy Procedia 63 ( 2014 ) 490 – 496
491
1. Introduction
Interest in global warming is still increasing, and the world is focusing on
countermeasures, due to soaring
atmospheric CO
2
concentrations accelerating global warming. “Energy Technology Perspectives
2014”(IEA) [1]
describe “Continued increase in coal use counteracts emissions reduction from
recent progress in the deployment of
renewables, underlining the need to improve coal plant efficiency and scale up
carbon capture and storage(CCS).”
This means that CCS plant itself using coal is very important and is now
required to scale up in the near future.
Recently, many CO
2
capturing processes from coal-fired power plants have been under development,
such as,
post-combustion capture, pre-combustion capture, and chemical looping
combustion. Oxyfiring is also a potential
candidate for capturing CO
2
from coal-fired power plants.
Oxyfuel technology has been developed within IHI since 1989 [2], and a
feasibility study on the demonstration
proj
ect between Australia and Japan was started in 2004, followed by the Callide
Oxyfuel Project which was
commenced in 2008.
In this paper, the operation experiences of oxyfuel power plant in Callide
Oxyfuel Project and the feasibility study
results of future oxyfuel power plant as one of the solution for matching with
the regulation of CO
2
emission are
introduced.

2. Outline of oxyfuel power plant
Fig.1 shows the overall process
of oxyfuel power plant. In
oxyfiring, O
2
is separated from the
air by ASU (Air Separation Unit)
and supplied to the boiler for coal
combustion. Accordingly, the flue
gas mainly comprises of CO
2
and
H
2
O, and will theoretically
enhance the CO
2
concentration in
flue gas up to more than 90 dry%.
The method for capturing almost
pure CO
2
involves removing H
2
O
and non-condensable gases from
the oxyfuel flue gas via a CO
2

processing unit (CPU).
When applying oxyfiring technology to power generation, in
order to use conventional technology for airfiring,
the flue gas from the boiler is recirculated and mixed with O
2.

The characteristics of oxyfiring technology are as follows:
¾ The system can be applied, to existing as
well as new construction boiler plants.
¾ Because N
2
is removed before combustion, highly-concentrated CO
2
can be captured easily from flue gas.
Moreover, removed N
2
can be utilized.
¾ Enriched O
2
is expected to improve combustion efficiency.
¾ Because the amount of flue gas is decreased (by approximately one-fifth), the
efficiency of oxyfuel boiler is far
higher
than that of an airfired boiler under the same conditions.
¾ NOx emissions are reduced because recirculation gas is supplied to a furnace
and the NOx in the recirculation
gas is
decomposed. Moreover, NOx can be removed at the CPU.
¾ Desulfurization equipment can be downsized due
to the reduced amount of flue gas.
¾ The system can be applied, to existing as well as new boiler plants.
The oxyfiri
ng system plays a significant role as an optional technology for capturing CO
2
from coal-fired power
plants. This technology is focused by many countries and they have conducted
research and demonstration
development [3] [4].
Recently, using oxyfiring systems, large-scale demonstration projects applied to
more than 250MW power plants
with CO
2
capturing ability exceeding 1Mt/yr., are proceeding [4]. They are expected to
start operation between 2015
and 2020.
Fig.1 Concept of the oxyfiring system
)


492 Akihiro Komaki et al. / Energy Procedia 63 ( 2014 ) 490 – 496
3. Callide Oxyfuel Project
At this moment, Callide Oxyfuel Project in central Queensland, Australia, is the
only operating project in
oxyfiring and the first and only commercial oxyfiring power plant in the world.
This was achieved with funding
from the Australian and Japanese governments, and the Queensland state
Government, and follows research results
from 1989 in Japan [2][5].
3.1. Project Summary
This
project is composed of three stages. In stage 1, an existing boiler was modified
to oxyfuel boiler, while the
ASU and CPU were newly installed. In stage 2, the CO
2
captured by oxyfiring system will be transported by truck
and injected underground. In stage 3, the project outcomes will be summarized
including the data acquired through
the operation. As of the end of August 2014, the cumulative oxyfuel operating of
over 7,700 hours and the
cumulative CPU operating of over 3,900 hours were achieved. Our target of
operation hours are 10,000 hours and
4,000 hours for each.
3.2. Oxyfiring Process in Callide-A
Callide A power station has four
30MWe unit and unit No.4 was
modified to oxyfuel one. Fig.2
shows the oxyfiring process applied
to the existing process, while Table
1 shows the specification of the
boiler. The oxyfiring process is
characterized as follows:
¾ Coal is fed to mill and
recirculation
gas is used for
drying and transporting the
coal.
¾ Three (3) mills and six (6)
burn
ers are installed. Namely,
each mill has two (2) burners,
two (2) mills (four (4) burners)
are in service in normal
operation. The boiler performances can be
confirmed by using different burner
patterns.
¾ The feed-water system is integrated
with
a flue gas system for heat recovery,
which facilitates efficient plant operation
in oxyfiring.
¾ A dehydration system is installed in the
prim
ary line to prevent low-temperature
corrosion of the mill outlet. It is also
possible to operate oxyfuel plants by
increasing mill outlet temperature
without a dehydration system.
¾ Air is introduced by the FDF in airfiring.
Conversely, gas is recirc
ulated by the
same FDF in oxyfiring.
¾ O
2
from the ASU is mainly mixed with
recirculation flue gas. O
2
can also be
directly injected into the flame via O
2

lances.
¾ A part of the flue gas is introduced to the
CPU process and
purified, compressed
Table 1 Major specifications of the Callide A boiler
Item Description
Name Callide-A power station unit No.4 (30MWe)
Coal Callide coal
Boiler type 2 drum type without re-heater
Main Steam
condition
Flow rate:136 ton/h
Pressure:4.1 MPa
Temperature:460 degC
Combustion
Device and
other facility
Mill:3 units
Burner arrangement: Wall (front) firing
Burner type: Original 4 units,
IHI-DF burners 2 units (Total 6 units)
Incidental facility: Direct O
2
nozzle
Draft system
Balance draft with 1 forced draft fan and 1
induced draft fan
CPU





Air
Stack
Coal
b
anke
r
ASU
Boiler
N
2

Sec.Heater

Pri. Heate
r
Boiler
Feed Water

Fabric Filter





Forced Draft
Fan
O
2

Mill
Dehydration
system
Induced Draft
Fan
Flue gas
cooler
Fig.2 Oxyfiring
p
rocess in the Callide A boile
r

Boile
r
Fabric filte
r



Akihiro Komaki et al. / Energy Procedia 63 ( 2014 ) 490 – 496
493
and cooled to capture almost pure CO
2
.
3.3. Operation experiences of the oxyfuel boiler
Oxyfiring was started since March 2012 when O
2
was
supplied to the boiler and the various basic characteristics of
the oxyfuel boiler have been confirmed.
The oxyfiring operation starts after the combustion mode
transition from airfiring is completed. Testing has been
completed to confirm the characteristics of the various loads
and boiler inlet O
2
concentrations and also matters including
the influence of the variation in mill patterns to date. The test
results achieved from the demonstration operation of the
oxyfuel boiler are described as follows.
¾ When airfiring is compared to oxyfiri
ng, the amount of
flue gas out of the boiler process is decreased by around
a quarter under oxyfiring. From the result of operation.
Heat absorbed in furnace at oxyfiring with 30MWe and
the boiler inlet-O2 of 27% is 2 to 3 MW lower than that
at airifiring of 30MWe, because heat of flue gas in flue
gas cooler is recovered by boiler feed water and this
result suggest that plant efficiency in oxyfiring is
enhanced. And then, the rate of heat absorbed of the
furnace is almost same with airfiring.
¾ Fig.3 shows the stack inlet NO and NO
2
with correction
value to 12% CO
2
in order to compare on the basis of
emission amount. The NOcorr, with a 12% CO
2
corrective value, declines around 60% with oxyfiring
due to the effect of NO reduction by a large amount of
recirculation gas. On the other hand, there is not so
much different between airfiring and oxyfiring of NO
2

corr
¾ The CO
2
concentration in flue gas shows virtually
identical characteristics as deigned. Over 70 dry% CO
2

is obtained at 30MW operation as shown in
Fig.4.
¾ Fig.5 shows carbon-in-ash at both conditions. Carbon-
in-as
h in oxyfiring is almost half of carbon-in-ash in
airfiring. Because the residence time in furnace is
longer due to the smaller gas volume, and combustion
is improved due to the local higher O
2
concentration.
¾ The various operations at boiler inlet O
2
concentration
range between 24 - 30% were tried and confirmed. The
operation results with various boiler inlet O
2
are as
follows:
z The boiler performance was m
aintained during the
oxyfiring operation as well as the airfiring operation.
z NO is slightly higher when the boiler inlet
O
2
is 30%.
z Flame is more stable and plant operation is more
flexible
when inlet O
2
is less than 27%, due to higher
gas volume to the boiler.
z Brightness of the flame from viewed through the
obs
ervation window near the burner throat is different
depending on the boiler inlet O
2
as shown in Fig.6.
Flame location is closer to burner throat due to the
Fig.4 CO
2
concentration at stack inlet
Fig.5 Carbon-in-ash
Fig.3 Stack inlet NO and NO
2



494 Akihiro Komaki et al. / Energy Procedia 63 ( 2014 ) 490 – 496
reduction of gas volume and higher O
2
concentration in combustion gas, when boiler inlet O
2
is 30%.










¾ SO
3
and mercury contents were measured at boiler
outlet, secondary heater outlet, flue gas cooler outlet
and IDF outlet in Fig.7. Fig.7 shows SO
3
concentration
in the boiler process. At the boiler outet, SO
3
in
oxyfiring is almost 2 to 4 times concentration of SO
3
in
airfiring, however at IDF outlet after fabric filter
passed, SO
3
concentration in both airfiring and
oxyfiring was less than detection level that was 0.1
ppm. Fig.8 shows the Hg measurement results by
Ontario hydro method at boiler outlet, secondary heater
outlet and IDF outlet in oxyfiring. Hg measurement by
the continuous monitor was also performed at IDF
outlet and the average value of Hg
0
and Hg
2+
is also
shown in Fig.8. Hg concentration was decreased from
boiler outlet to IDF outlet, especially Hg
0
. This tendency is
almost same behaviour with the results at pilot-test
facilities. And Hg concentration at IDF outlet by the
continuous monitor is the same level with the results by
Ontario hydro method.
¾ At the design stage, the existing airfiring burners were
reused,
30MWe operation was required at both airfiring
and oxyfiring condition and the minimum load in
oxyfiring was set to be 24MWe with inlet O
2
of
between 24 and 30%, because flame stability and heat
balance of flue gas and recirculation gas were
concerned. However, it had been found that the flame
was stable at 24MWe and there was a possibility to
reduce the load at the demonstration stage. Therefore, it is
very important to enlarge the operation load range and the
confirmation of the turn-down of the oxyfuel boiler is tried with the
appropriate operation condition. Test was
conducted monitoring the flame shape and stability in visual and the level of
flame detection.
As the results, operation range down to 15MW is achieved that is equivalent with
airfiring operation. Test
results are summarized as follows.
z Minimum load is 21MW (70%L)
while the boiler inlet O
2
is controlled at 27%.
z Minimum load is 15MW (50%L)
while the boiler inlet O
2
is controlled at 24%.
z Burner flames look stable and the
boiler performance is also stable during the test.
3.4. Future works
To comm
ercialize and realize this technology in the future, further various
examinations must be performed in
24.5% 27% 30%
Fig.6 Photos of flame in oxyfiring with various inlet-O
2
, 24.5%, 27% and 30%
Fig.7 SO3 in boiler process
Fig.8 Hg behaviour in oxyfiring


Akihiro Komaki et al. / Energy Procedia 63 ( 2014 ) 490 – 496
495
this project. The main contents are shown as follows:
¾ Various coal combustion tests and load ramp tests to confirm
the operation flexibility.
¾ O
2
injection test to the flame directly to confirm the boiler performance
¾ Mode transition tests to optimize and confirm the shorter
period of mode transition.
¾ A durable (long term) test to confirm the proper operation of each facility.
¾ A corrosion probe test to confirm the corrosion of
boiler tube materials under oxyfiring atmosphere.

4. Feasibility study in Australia
On the other hand, feasibility study of 500MW oxyfuel power plant in Australia
was performed on the basis of the
outcome from Callide Oxyfuel Project. From this study results, the utilization
of by-products such as N
2
as well as
CO
2
from the oxyfuel power plant is very important in order to achieve the lower
cost of electricity. If CO
2
and N
2

can be utilized effectively, the cost of electricity for oxyf
uel plants can be lower than that for conventional plants
and the oxyfuel power plant will be easy to be applied for the market of power
plant.
Feasibility study of 500MW oxyfuel
powe
r plant in Queensland, Australia
was performed in 2012 & 2013 [7] on
the basis of outcome from Callide
Oxyfuel Project. Table 2 shows the
main specifications of oxyfuel power
plant including ASU and CPU. Dry
cooling system for the condenser and
the compressors in ASU and CPU was
selected due to dry area in Australia.
The boiler process was considered to
minimize the air ingress amount to the
process and also 600 degree C class
steam condition for the boiler was
applied in order to minimize the coal
and O
2
consumption in this study. Each
two (2) trains for ASU and CPU would
be necessary for 500MW oxyfuel
power plant.
Fig.9 shows the layout of 500MW
oxyfuel power plant in the power
station and Fig.10 shows the study
results of LCOE (Levelized Cost Of Electricity)
based on the plant lifetime of 30 years after starting
the commercial operation and plant availability of
85% and so on. Total LCOE is approximately
AUD127 per a MWh, and CAPEX occupy over 60%
of total LCOE including CCS facility of ASU, CPU
and so on that occupy almost 20% (AUD26 per a
MWh) of total LCOE.
On the other hand, the utilization of by-products
such as N
2
from ASU as well as CO
2
from the
oxyfuel power plant is very important in order to
improve the LCOE. If N
2
as well as CO
2
can be
utilized effectively, the LCOE for oxyfuel power
plant can be lower than market price and this means
that oxyfuel power plant would be easy to be applied
commercially as compared with conventional power
plant in Australia from Fig.10.
Table 2 Main specifications of Oxyfuel power plant for CO
2
capture
Area Queensland, Australia
Power Plant
Gross output
Coal
Cooling syste
m
Steam condition


500 MW at each condition of air and oxy
Bitu
minous coal
Dry cooling
Main steam pressure : 25.0 MPa
Main steam temperature : 600 degree C class
ASU
Type
Capacity
O
2
purity

Cryogenic
20
0 t-O
2
/h x Two (2) trains
96.5 % or more
CPU
Capacity
Main gas
composition
Main product
Capture rate

270 t-CO
2
/h x Two (2) trains
H
2
O 8.1 mol% / CO
2
72.8 mol% wet
CO
2
liquid at 16 MPa(abs) & 45 degree C
Purity 99.9% or more
98% or more
Fig.9 Layout of 500MW oxyfuel power plant
ASU
CPU
Dry cooling
Oxyfuel boiler
Turbine
FGD


496 Akihiro Komaki et al. / Energy Procedia 63 ( 2014 ) 490 – 496
Table 3 shows the plant performance of both oxyfiring
and airfiring in this oxyfuel power plant. Oxyfiring
condition needs to have the large amount of in-house
power consumption for ASU and CPU and net plant
efficiency decrease down to around 31.5% as compared
with 39.9% in airfiring. However, net CO
2
emission is
dramatically decreased down to 20 g/kWh. Regarding
the water and steam process, operation results of
Callide Oxyfuel Project were
reflected and fuel
consumption and gross plant efficiency in oxyfiring
were improved.
Lastly, in recent days, it is said that CO
2
emission
[kg/MWh] from coal fired power plant will be regulated
of less than some level, for example 420 g/kWh in
Canada. To cope with this kind of the regulation,
oxyfuel power plant can be expected to keep with more
economical manner than
other CO
2
capture process.
5. Summary
This paper introduced the
Callide Oxyfuel Project and
operation experiences of
boiler as of now. The
demonstration operation
will be continued until
March 2015 and the operation data will be continued to obtain towards the
commercialization of this technology.
And feasibility study results of 500MW oxyfuel power plant were also introduced.
It is highly possible for
oxyfiring to provide more economical CO
2
capture process as the solution of coal fired power plant to CO
2

regulation. To realize this oxyfiring system as a highly-efficient CCS system,
we push forward research,
devel
opment and demonstration further.
Acknowledgment
These
studies have been greatly supported by DRET (Department of Resources, Energy and
Tourism) of
Australian government, METI (Ministry of Economy, Trade and Industry) of
Japanese government, NEDO (New
Energy and Industrial Technology Development Organization), the Queensland state
Government, as well as by
ACALET, GLENCORE, Schlumberger, J-Power, Mitsui & CO., LTD. and many others in
Australia and Japan, to
which the authors would like to express gratitude for their help and support.

References
1. Energy Technology Perspectives 2014, IEA
2. K.Kimura et al., JSME-ASME Int. Conf. On Power Eng.-93, Sept. 1993, Tokyo
3.
Global CCS Institute, Feb., 2014, “The Global Status of CCS 2014”
4. Website, http://sequestration.mit.edu/index.html
5. Website, www.callideoxyfuel.com
6. T, Yamada et al., IHI Engineering Review vol.43 No.2 (2010) “Study Results in
Demonstration Operation of
Oxyfuel Combustion boiler for CO
2
Capture”
7. NEDO report “Project Finding Research of High-Efficient Coal-Fired Power
Plant with CCS in Australia
(FY2012)” March, 2013
Table 3 Performance of Power Plant
Combustion mode Oxyfiring Airfiring
Gross / Net output
Gross / Net plant efficiency
Auxiliary power consumption
CO
2
emission (net)
Fuel consumption
[MW]
[%]
[MW]
[g/kWh]
[t/h]
500 / 345
45.7 / 31.5
155
20
196
500 / 473
42.1 / 39.9
27
740
212
Fig.10 Cost study results of oxyfuel power plant



CITATIONS (22)


REFERENCES (3)




... The viability of oxy-combustion has been demonstrated by Vattenfall's pilot
plant (Strömberg et al., 2009;Anheden et al., 2011), Compostilla OXYCFB300
(Endesa et al., 2013), Callide oxyfuel project Komaki et al., 2014;Liu et al.,
2016), and Lacq pilot plant (Monne et al., 2015). These projects have identified
operational issues and design parameters that, coupled with computational fluid
dynamics (CFD) analysis, could pave the way for large-scale projects (Li et al.,
2017). ...
... The results obtained from this simulation must first be compared with the
literature as a validation step before further analysis. As can be seen by the
horizontal lines in Fig. 4, this model shows good agreement with the literature
(Rubin et al., 2016;IEAGHG, 2013;Skorek-Osikowska et al., 2013;Katzer et al.,
2007;Wall, 2007;Komaki et al., 2014;Hnydiuk-Stefan and Skladzien, 2017;Buhre et
al., 2005;Janusz-Szymanska and Dryjanska, 2015;Farzan et al., 2007;Endesa et
al., 2013;López et al., 2018). It can be observed that the results obtained from
this simulation fall within zones with high-density of data points. ...
... Validation of the oxy-combustion model against the main performance
indicators capital cost (CAPEX), operating cost (OPEX), fuel consumption, net
power generation efficiency and levelised cost of electricity (LCOE)(Rubin et
al., 2016; IEAGHG, 2013;Skorek- Osikowska et al., 2013;Katzer et al., 2007;Wall,
2007;Komaki et al., 2014;Buhre et al., 2005; Janusz-Szymanska and Dryjanska,
2015;Farzan et al., 2007;Endesa et al., 2013;López et al., 2018). The horizontal
lines represent this model's values. ...

A synergistic approach for the simultaneous decarbonisation of power and
industry via bioenergy with carbon capture and storage (BECCS)
Article
 * May 2019
 * INT J GREENH GAS CON

 * Renato Pereira Cabral
 * Mai Bui
 * Niall Mac Dowell

There is a need for a rapid and large scale decarbonisation to reduce CO2
emissions by 45% within 12 years. Thus, we propose a method that accelerates
decarbonisation across multiple sectors via a synergistic approach with
bioenergy with CCS (BECCS), which is able to remove 740 kg CO2 from air per MWh
electricity generated. Industry is a hard-to-decarbonise sector which presents a
unique set of challenges where, unlike the power sector, there are no obvious
alternatives to CCS. One of these challenges is the significant variation of CO2
concentration, which directly influences CO2 capture costs, ranging from $10/t
CO2 to over $170/t CO2 for high (95-99% CO2) and low CO2 concentration (4% CO 2)
applications, respectively. Re-purposing the existing coal-fired power plant
fleet into BECCS displaces CO2 emissions from coal-use and enables a just
transition, i.e., avoiding job loss, providing a supportive economic framework
that does not rely on government subsidies. Negative emissions generated from
capturing and storing atmospheric CO2 can be converted into negative emission
credits (NECs) and auctioned to hard-to-decarbonise sectors, thus providing
another revenue stream to the power plant. A levelised cost of electricity
(LCOE) between $70 and $100 per MWh can be achieved through auctioning NECs at
$90-$135 per t CO2. Offsetting the global industrial CO 2 emissions of 9 Gt CO2
would require 3000 BECCS plants under this framework. This approach could
jumpstart industrial decarbonisation whilst giving this sector more time to
develop new CCS technologies.
View
Show abstract
... In addition, oxy-coal combustion has several advantages over air-coal
combustion such as (i) higher combustion efficiency of the boiler due to higher
concentration of O 2 [41]; (ii) higher CO 2 concentration, easy to separate;
(iii) reduced volume of flue gas, which reduces the flue gas treatment cost;
(iv) low NOx emission per unit of fuel consumption due to reduced thermal NOx
and flue gas recycling. Callide-A power plant in Queensland, Australia, is a
retrofit of an existing power plant with a capacity of 30MWe and is the largest
operating oxy-fuel power plant in the world [42]. ...

Coal: Past, present, and future sustainable use
Chapter
 * Jan 2020

 * Deepak Pudasainee
 * Vinoj Kurian
 * Rajender Gupta

View
... Oxyfuel-betriebene Kraftwerke mit nachgeschalteter CO 2 -Abtrennung
erfolgreich getestet worden. So zum Beispiel im brandenburgischen
Braunkohlekraftwerk "Schwarze Pumpe" [13] oder im australischen Queensland mit
dem "Callide Oxyfuel Project" [14]. ...

Reaktive Cu-Fe-Al-Mn-Oxidkeramiken für die Sauerstoffseparation aus der Luft
Thesis
Full-text available
 * Dec 2019

 * Alexander Tasch

Die Gase Sauerstoff und Stickstoff werden für eine Vielzahl an technischen,
industriellen, biologischen und medizinischen Einsatzzwecken benötigt. So liegen
Anwendungsgebiete dieser Gase neben der klassischen metallverarbeitenden und der
chemischen Industrie bei Sauerstoff vor allem in der Medizin, Verbrennungs- und
Kläranlagenoptimierung sowie der Fischzucht und bei Stickstoff als Schutz-
beziehungsweise Inertgas in der Kunststoffindustrie, der Luft- und Raumfahrt
sowie dem Brandschutz. Die Bereitstellung der Gase Sauerstoff und Stickstoff
wird nahezu ausschließlich durch die Abtrennung aus der Umgebungsluft
realisiert, welche aus ca. 78 Vol.-% Stickstoff, 21 Vol.-% Sauerstoff und 1
Vol.-% Spurengasen (Ar, CO2, Ne, He, ...) besteht. Am Markt etablierte Verfahren
der Luftzerlegung sind das Linde-, das PSA- (pressure swing
adsorption/Druckwechseladsorption) oder verschiedene Membran-Verfahren.
Hierdurch werden die benötigten Gase entweder direkt vor Ort beim Verbraucher
erzeugt (PSA- und Polymer-Membranverfahren: geringe Reinheiten) oder zentral in
großen Anlagen hergestellt (Linde-Verfahren: hohe Reinheiten) und anschließend
zum Verbraucher in Form von Flaschen- oder Tankgasen geliefert (Tansportkosten).
Für kleinere Verbraucher mit hohen Ansprüchen an die Reinheit des benötigten
Sauerstoffs beziehungsweise Stickstoffs ergibt sich nur die Möglichkeit, die
Gase als kostenintensive Transportgase zentraler Gaseversorger zu beziehen und
sich somit in eine Abhängigkeit (Lieferverträge, Flaschen-/Tankmieten, ...) zu
diesen zu begeben sowie eine eigene Lagerhaltung für die benötigten Gase
(Mehraufwand, Lagerkosten, Platzbedarf) zu betreiben. Ziel dieser Arbeit ist es,
keramische Material-Systeme auf Basis chemischer Hochtemperatur-Reaktionen als
Reaktive Oxidkeramiken zu entwickeln und diese hinsichtlich eines möglichen
Einsatzes für die Sauerstoffseparation in neuartigen Luftzerlegungsanlagen zu
untersuchen. Derartige Anlagen sollen in ihrem Prinzip an die regenerative
Sauerstoffseparation angelehnt sein und in ihren Reaktoren die Reaktiven
Oxidkeramiken als Festbett-Material abwechselnd mit Luft be- und Vakuum oder
O2-armen Atmosphären entladen. Die Verwendung Reaktiver Oxidkeramiken, welche im
Vergleich zu den bisherigen Materialien höhere Sauerstoffaustauschmengen und
-raten bei gleichzeitig hoher Lebensdauer und Korrosionsbeständigkeit sowie
relativ einfacher Handhabe aufweisen würden, soll ein Schritt in Richtung einer
effizienten alternativen Luftzerlegungstechnologie sein. Mit den Reaktiven
Oxidkeramiken in einer Luftzerlegungsanlage sollte es im besten Fall möglich
sein, in kleinen Anlagen sehr reinen Sauerstoff und zugleich sauerstofffreies
Inertgas zu erzeugen sowie eine Sauerstoffan- oder -abreicherung von Luft,
Prozess- oder Abgasen zu generieren. Somit besäße eine solche, auf Reaktiven
Oxidkeramiken basierende Technologie sehr weit gefächerte Einsatzgebiete und
demzufolge ein enormes wirtschaftliches Potential.
View
Show abstract
Technical and economic prospects of CCUS projects in Russia
Article
 * Jun 2022

 * Stepan Bazhenov
 * V. Chuboksarov
 * A. L. Maksimov
 * Oleg Zhdaneev

Carbon dioxide is one of the main contributors to global climate change. The
Russian Federation plays an essential role as one of the primary fossil fuel
producers and CO2 emitters globally. Therefore, introducing novel carbon
capture, utilization, and storage (CCUS) technologies will inevitably contribute
to further Russia's economic and industrial development. Moreover, CCUS should
be intensified due to the cross-border tax under Carbon Border Adjustment
Mechanism (CBAM) introduced by European Union. This paper presents a brief
review of the CO2 capture strategies and their comparison. A short overview of
different CCUS technologies with a partial focus on the studies by the Russian
researchers is presented. CO2 transportation, utilization, and storage aspects
are highlighted, considering Russia's potential. The model scheme of the CCUS
plant based on existing technologies is given, and the economic estimations and
consequences relative to Russian policy under the CBAM tax are discussed. The
markable financial losses are shown; thus, the commercial success of CCUS can
only bring a radical reduction in cost, which is only expected by 2040.
View
Show abstract
Techno-economic optimization and off-design analysis of CO2 purification units
for cement plants with oxyfuel-based CO2 capture
Article
 * Mar 2022
 * INT J GREENH GAS CON

 * Francesco Magli
 * Maurizio Spinelli
 * Martina Fantini
 * Manuele Gatti

This paper evaluates the technical and economic performance, as well as the
direct/indirect CO2 emissions of the CO2 Purification Unit (CPU) for cement
plants equipped with oxyfuel-based CO2 capture. Two configurations, targeting
two different outlet CO2 specifications (‘moderate’ 95% purity and ‘high’ 99.9%
purity) are designed, modelled and optimized in order to minimize the
incremental clinker production cost for different values of the carbon tax. Mass
and energy balances are simulated with Aspen Plus, while the operating
conditions are numerically optimized with Matlab. Results show that moderate
purity can be achieved with an increased cost of clinker of 16.3 €/tclk (CO2
recovery 99.3%), while the base high purity configuration leads to a 19.3 €/tclk
increase (CO2 recovery 96.1%). Sensitivity analyses are carried out on design
parameters (fuel and air infiltrations in the oxyfuel calciner line) and
exogenous factors (carbon tax, CO2 intensity of electricity). Air infiltration
rate has the highest impact on the incremental cost of clinker (increased by 25%
when air leakage grows from 0 to 10%) and on the selection of optimal
operational conditions. Off-design analyses aimed at assessing the impact of air
infiltration changing over time highlight the relevance of designing the CPU for
the scenario with air infiltrations, while selecting reasonable temperature
differences (e.g. 5K) to avoid operability issues in the cold box heat
exchanger. For the base case CPU, the cost of clinker increases by 3 €/tclk when
moving from zero to 10% air infiltration.
View
Show abstract
Review on principles, recent progress, and future challenges for oxy-fuel
combustion CO2 capture using compression and purification unit
Article
 * Jun 2021

 * Esmaeil Koohestanian
 * Farhad Shahraki

The emission of anthropogenic carbon dioxide (CO2) as a result of fossil fuel
burning is regarded as a leading cause of global warming and environmental
problems. An efficient method to capture CO2 from flue gases is oxy-fuel
combustion. CO2 compression and purification unit (CO2CPU) is a promising
process to capture CO2 from oxy-fuel combustion flue gases. However, the
widespread implementation of this method is encountered with different
techno-economical and legal challenges. The present study aims to review the
principles and latest advances of CO2CPU process as well as the challenges this
process may encounter in the future. The CO2CPU system is introduced and the
latest research on the optimization and dynamic investigation of this process
are reviewed. In addition, relevant standards and specifications of CO2 product
as well as the effect of impurity are collected. Finally, a summary of the
future challenges and research directions is presented.
View
Show abstract
Design and evaluation of a novel system for the flue gas compression and
purification from the oxy-fuel combustion process
Article
 * Mar 2021
 * APPL ENERG

 * Ming-xin Xu
 * Hai-bo Wu
 * Ya-chang Wu
 * Qiang Lu

The process of flue gas compression and purification is essential for oxy-fuel
combustion, because of its significance in determining the quality of the CO2
product. Based on the difference of dew points between CO2 and acid
contaminants, a novel system, which integrated the partial CO2 recirculation
with the flue gas purification, was proposed and evaluated in this study. The
simulation results confirmed that a CO2 stream with a purity of 99.9% could be
achieved, and the distillate after treatment in SO2 and NO absorbers could be
directly recycled back to the boiler. The performance of CO2 recovery was
enhanced by elevating the condensing pressure to 3.0–4.0 MPa. Besides, there was
a critical ratio between the recycled CO2 liquid and the raw flue gas for the
abatement of contaminants, which was 11.0 L/m³. Furthermore, the performances of
SO2 and NO removal were investigated. The efficiencies of SO2 and NO abatement
could be more than 99% when the reaction pressures were 0.5 MPa and 1.5 MPa
separately. Besides, a critical molar ratio of SO2 to NO in the raw feeding flue
gas was determined, and the removal of SO2 was restrained when the SO2/NO molar
ratio increased over the critical point. As for the NO abatement, the continuous
re-oxidation of NO released from the dissociation of HNO2 was dominant in the NO
absorber, and the performance of NO removal was dramatically enhanced with the
presence of NO pre-oxidation at low reaction pressures.
View
Show abstract
CHAPTER 5. Application Status of Post-combustion CO2 Capture
Chapter
 * Oct 2018

 * Deepak Pudasainee
 * Vinoj Kurian
 * Rajender Gupta

Inorganic solid adsorbents/sorbents are attractive materials for capturing
carbon dioxide (CO2) from flue gases after fossil fuel combustion.
Post-combustion Carbon Dioxide Capture Materials introduces the key inorganic
materials used as adsorbents/sorbents with specific emphasis on their design,
synthesis, characterization, performance, and mechanism. Dedicated chapters
cover carbon-based adsorbents, zeolite- and silica-based adsorbents,
metal–organic framework (MOF)-based adsorbents, and alkali-metal-carbonate-based
adsorbents. The final chapter discusses the practical application aspects of
these adsorbents used in carbon dioxide capture from flue gases. Edited and
written by world-renowned scientists in each class of the specific material,
this book will provide a comprehensive introduction for advanced undergraduates,
postgraduates and researchers from both academic and industrial fields wishing
to learn about the topic.
View
Show abstract
Techno-economic evaluation of near-zero CO2 emission gas-fired power generation
technologies: A review
Article
 * Dec 2019

 * Navid Khallaghi
 * Dawid Hanak
 * Vasilije Manovic

Recently, natural gas-fired power generation has attracted more attention as
they have lower specific CO2 emissions and higher operational flexibility than
coal- and oil-fired power generation. In state-of-the-art gas-fired
oxy-combustion cycles, combustion takes place at elevated pressure, which
enables high efficiency and competitive economic performance. This review
presents a new insight by summarising the main challenges associated with these
types of cycles and covers: (i) O2 production methods and purity; (ii) types of
exhaust gas recirculation; and (iii) operating pressure. The techno-economic
evaluation of the state-of-the-art gas-fired power cycles showed that although
the Allam cycle is superior among other cycles with an efficiency of 55.1%, its
highly affected levelised cost of electricity by interest rate adds more
uncertainty to investment decisions. Importantly, the progress towards the next
generation of gas-fired oxy-combustion cycles will require the development of
less complex cycles with more efficient and less energy-intensive O2 production.
View
Show abstract
Chapter 6. Oxy-fuel Combustion Capture Technology
Chapter
 * Nov 2019

 * R. P. Cabral
 * Niall Mac Dowell

This chapter discusses oxy-fuel combustion for the capture and subsequent
sequestration of carbon dioxide. Technologies for oxygen production based on air
separation will be presented and the need to reduce energy consumption of these
units will be discussed along with some potential strategies. A pulverized
coal-fired power plant and a natural gas combined cycle will be analysed as case
studies for oxy-combustion and the benefits of using pure oxygen will be
discussed as well as how the changes in the thermodynamic properties affect
boiler operation. Purification of carbon dioxide in the resulting flue gas to
pipeline transport specifications will end the discussion of this chapter with
two examples of gas processing units. The parasitic power consumption of this
gas processing unit combined with the air separation unit reduces the net
efficiency of the plant even though the thermal efficiency is increased, which
emphasises the importance of developing new technologies, such as ion transport
membranes for oxygen production. The possibility to reduce the energy
consumption of both air separation unit and gas processing unit combined with
the increased combustion efficiency by using pure oxygen make this a promising
technology for carbon capture and storage.
View
Show abstract
Show more

The Global Status of CCS

 * Ccs Global
 * Institute

Global CCS Institute, Feb., 2014, "The Global Status of CCS 2014"

Study Results in Demonstration Operation of Oxyfuel Combustion boiler for CO 2
Capture
 * Jan 2010

T, Yamada et al., IHI Engineering Review vol.43 No.2 (2010) "Study Results in
Demonstration Operation of Oxyfuel Combustion boiler for CO 2 Capture"

Project Finding Research of High-Efficient Coal-Fired Power Plant with CCS in
Australia (FY2012

 * Nedo






RECOMMENDATIONS

Discover more about: Oxyfuel
Project


REACTIONS, TRANSFORMATIONS AND FATE OF SULFUR OXIDES DURING OXY-FUEL COMBUSTION.

 * Lawrence Phoa Belo
 * Kalpit Shah
 * Liza Elliott
 * [...]
 * Roman Giniyatullin

View project
Project


OXY-FUEL COMBUSTION TECHNOLOGY

 * Sameer Khare
 * Rajender Gupta
 * Renu Kumar Rathnam
 * [...]
 * Liza Elliott

Performance evaluation of coal combustion in a CO2 rich flue gas and
retrofitting to conventional coal fired combustors.
View project
Project


COAL UTILISATION

 * Chris Spero

View project
Project


CALLIDE OXYFUEL PROJECT

 * Chris Spero

View project
Article
Full-text available


OPTIMIZATION OF OXYGEN-BASED CFBC TECHNOLOGY WITH CO 2 CAPTURE

July 2017 · Energy Procedia
 * Sergio Espatolero
 * Luis M. Romeo

O2GEN project was running during more than three years and it was successfully
finished in January 2016. The main target was to develop the 2nd generation
oxyfuel circulating fluidized bed (CFB) power plants based on higher oxygen
concentrations with the aim of decreasing flue gas recirculation and the energy
penalty. Remarkable advances have been achieved in Air Separation (ASU) and
Compression ... [Show full abstract] and Purification Units (CPU) reducing
significantly their energy consumption. CFB boiler concept was proposed by
scaling-up from past designs. No special drawbacks were found regarding
combustion, heat transfer and emissions. Finally, a process integration
methodology was applied and overall efficiency was increased by heat
integration. Energy penalty was reduced from 10.5 to 7.3 efficiency points. The
new power plant lay-out avoids technical restrictions in the use of complex heat
exchangers and facilitates the operational flexibility of the system.
View full-text
Article
Full-text available


OPERATIONAL RESULTS OF OXYFUEL POWER PLANT (CALLIDE OXYFUEL PROJECT)

October 2016 · Mechanical Engineering Journal
 * Akihiro KOMAKI
 * Terutoshi Uchida
 * Chris Spero
 * [...]
 * Takahiro Goto

In 2013, CO2 levels surpassed 400 ppm for the first time in recorded history.
So, we are facing global warming due to the increase levels of atmospheric
carbon dioxide (CO2). As a method of reducing CO2 emissions from coal fired
power plants, there are carbon dioxide capture and storage (CCS) technologies.
Oxyfuel combustion is one of the CO2 Capture technologies and IHI have developed
it since ... [Show full abstract] 1989. Then, Callide Oxyfuel Project commenced
to apply oxyfiring technology in an existing coal fired power plant and to
demonstrate an oxyfuel power plant in March, 2008. Demonstration began in 2012
after existing boiler was retrofitted. During the demonstration for
approximately three years, many tests were conducted and many data were
collected for commercial use. As a result, we confirmed characteristics of
oxyfiring such as total heat absorption, combustion characteristics, emissions
of NOx, SOx, carbon-in-ash, operational flexibility from 15MWe (50%L) to 30MWe
(100%L) and behavior of injected CO2 at the injection site. Total heat
absorption of the boiler under oxyfiring was 2 to 3MW higher because of
decreasing heat loss in flue gas and rising temperature of boiler feed water by
a flue gas cooler. NO was decomposed in the furnace under oxyfiring because flue
gas was recirculated. On the other hand, reaction between SO2 and absorbent such
as Ca, Mg in ash was not so active regardless of high concentrated SO2 under
oxyfiring. Carbon-in-ash was almost 40%~70% in oxyfirng compared with in
airfiring because of longer residence time in the furnace. Operational
flexibility is important to control oxyfiring operation and it was confirmed
that oxyfiring can be operated as well as airfiring. In this paper, operational
results are presented in Callide Oxyfuel Project.
View full-text
Chapter
Full-text available


APPLICATION AND DEMONSTRATION OF OXYFUEL COMBUSTION TECHNOLOGIES TO THE EXISTING
POWER PLANT IN AUST...

August 2013
 * Terutoshi Uchida
 * Toshihiko Yamada
 * Chris Spero
 * [...]
 * Shuzo WATANABE

Oxyfuel combustion is able to directly make the highly concentrated CO2 from the
flue gas of pulverized coal fired power plant and, therefore, is expected as one
of the promising technologies for CO2 capture. We are advancing the Oxyfuel
combustion demonstration project, which is called Callide Oxyfuel Project, with
the support of both Australian and Japanese governments. Currently the boiler
... [Show full abstract] retrofit work is completed and the commissioning in air
combustion is going on. In this paper, we introduce the general outline of the
Callide Oxyfuel Project and its progress.
View full-text
Article


ICOPE-15-1036 OPERATIONAL RESULTS OF OXYFUEL POWER PLANT : CALLIDE OXYFUEL
PROJECT

November 2015 · The Proceedings of the International Conference on Power
Engineering (ICOPE)
 * Akihiro KOMAKI
 * Terutoshi Uchida
 * Chris Spero
 * [...]
 * Takahiro Goto

Coal is one of the important resources of electricity generation to maintain a
stable supply of power. Although, it is the main contributor to the rise of
energy-related CO_2 emission. According to "World Energy Outlook 2014", though
electricity demand has increased in the Organization for Economic Co-operation
and Development (OECD) and Non-OECD member countries, coal use will decrease
toward ... [Show full abstract] 2040 in OECD. However, coal use in Non-OECD will
increase up to about three times in 2040 as compared with 1990 (International
Energy Agency (IEA), 2014). This is why, we need to reduce CO_2 emission from
coal fired power plants in order to halt global warming. As a method of reducing
CO_2 emission, we have carbon dioxide capture and storage (CCS) technologies.
Oxyfuel combustion is one of the CCS technologies and IHI has developed it since
1989. Then, Callide Oxyfuel Project commenced to demonstrate oxyfuel power plant
in March, 2012. During the demonstrated operation for approximately three years,
many tests were conducted and many data were collected. As a result, we
confirmed the difference between airfiring and oxyfiring such as operational
flexibility, plant efficiency and combustion characteristics. In this paper, the
operational results of 30MWe oxyfuel power plant in the Project are presented.
Read more
Article
Full-text available


OXYFUEL COMBUSTION AS CO2 CAPTURE TECHNOLOGY ADVANCING FOR PRACTICAL USE -
CALLIDE OXYFUEL PROJECT -

December 2013 · Energy Procedia
 * Terutoshi Uchida
 * Toshihiko Yamada
 * Chris Spero
 * [...]
 * Takahiro Goto

CCS, CO2 capture and storage, is one of the ways to keep CO2 concentration in
atmosphere to be under certain value in order to mitigate the global warming and
expectation for its practical use soars all over the world. IHI have developed
the oxyfuel combustion technology as CO2 capture technology since 1989 and we
have been going forward the Callide oxyfuel Project in Australia since 2008. In
... [Show full abstract] this paper, we introduce the progress of the Callide
oxyfuel Project and the action toward the practical use of the oxyfuel
combustion technology.
View full-text
Last Updated: 03 Nov 2022
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