Mitglied der Helmholtz-Ge meinschaft

Oxygen Supply for Oxyfuel Power Plants by

Oxy-Vac-Jül Process

Jewgeni Nazarko, Michael Weber, Ernst Riensche, Detlef Stolten

Institute of Energy and Climate Research IEK-3

21. June 2011 ICEPE 2011, Frankfurt am Main

 Contents

• Targets for process development

• O2-membrane materials

• Basic concepts for O2-membrane processes

• Energetic potential of the OXY-VAC-JÜL process

• Summary

21. June 2011 | Michael Weber | IEK-3 Folie 2

 State of the art cryogenic air separation for CCS

Spec. power demand

O2-Purity CO2-purification Efficiency loss
Application O2-supply
[Vol.-%] & compression [%-pts.]
[kWhel/tO2] [kWhel/tCO2]
Standard gas supply >99.5 245(1) 128 7.3 + 4.0 = 11.3
IGCC, Oxyfuel 95 175(1) 135 5.2 + 4,2 = 9.4
Oxyfuel 95 169(2) 135 5.0 + 4.2 = 9.2
Source: Boundary conditions:
(1) Linde 20°C, rel. humidity 60%, 101325 Pa, cool. w. 15°C  coal: Klein Kopje
(2) Air Liquide 15°C, rel. humidity 60%, 101325 Pa  oxidant ratio: 1.15
not incuded: efficiency of compressor drives  flue gas recycle rate: 67%
heat of regeneration for driers
 leak air: 2%
cooling system
 CO2-sep degree: 90%
21. June 2011 | Michael Weber | IEK-3 Folie 3
 Cryogenic air separation as benchmark

O2-Purity from membrane separation: 100%

Spec. power demand

O2-Purity Efficiency loss
Application O2-supply CO2-purification
[Vol.-%] [%-point]
[kWhel/tO2] [kWhel/tCO2]
Gas companies >99,5 245 128 7,3 + 4,0 = 11,3
IGCC, Oxyfuel 95 175 135 5,2 + 4,2 = 9,4

Target efficiency loss for membrane based O2-supply: < 5.4 %

21. June 2011 | Michael Weber | IEK-3 Folie 4
 Oxygen supply using Perovskite membranes

Feed gas / Retentat /

air O2 waste air

4e-
2O2-
A O2-flux
O 2
-
2
4e- 2O
O
P t/O
O ermea
B O2 P t / O2
Source: Skinner, 2003 O2-Membrane

structure: cubic ABO3

Feed
1 RT ionel p(O2 )
flux (Wagner-Eq.) : J O
2 L 1 2L / L 16F 2 ln
p(O Permeat )
C ion el 2

Analyze energetic potential. Then optimize efficiency vs. cost (membrane area).
21. June 2011 | Michael Weber | IEK-3 Folie 5
 Driving force and operation temperature

oxy-clean // oxy-sweep
concepts
3-way-modules // 4-way-modules

21. June 2011 | Michael Weber | IEK-3 Folie 6

 Driving force generation and heating methods for
oxy-clean concepts

Siemens – OTM-Clean

Air
O
2

Oxy-Vac-Jül

Air

O2
21. June 2011 | Michael Weber | IEK-3 Folie 7
 Driving force generation and heating methods for
oxy-sweep concepts

Siemens – Oxycoal-AC

Forschungszentrum Jülich – Oxy-Sweep-Jül

21. June 2011 | Michael Weber | IEK-3 Folie 8

 Classification of the membrane based oxyfuel concepts

OXYCOAL- VAC- OXY-SWEEP-

OXY-CLEAN
AC JÜL
Compressor Compressor
Driving force Feed side ------
and turbine and turbine
generation
Sweep with ---- / vacuum Sweep with
Perm. side flue gas suction flue gas
Feed side 10-20 bar 10-20 bar 1 bar
Total pressure
Perm. side 1 bar 1 bar / < 1 bar bar 1 bar
Compressor / Compressor / r/ Recuperator /
Heating of membrane feed gas flue gas flue gas gas flue gas
Reference power plant Externally Externally power Steam power
(without CCS) Fired CC Fired CC plant

Flue gas recycling (temp. level) hot cold hot-cold-hot

Flue gas recycling (flow rate) large small very large

21. June 2011 | Michael Weber | IEK-3 Folie 9

 Contents

• Targets for process development

• O2-membrane materials

• Basic concepts

• OXY-VAC-JÜL process
o Cycle
o Boundary conditions
o Benefits of basic process integration
o Energy demand as a function of the degree of O2-separation

• Summary
21. June 2011 | Michael Weber | IEK-3 Folie 10
 OXY-VAC-JÜL Concept
dust remove
Advantage: dust removel

- Elimination of compression and CO2 rich stream

boiler
expansion of the fresh air
- Cold gas cleaning (as cryogenic) circulaton
air / exhaust air HEX O2-membrane blower
- Flue gas not contacting membrane
- preheated oxygen (vs. cryogenic) exhaust
air

Disadvantage: air / O2 HEX

- Special requirements on heat
exchangers and tubing resulting
from vacuum air blower
- Large HEX and ducts vacuum-
compressor
- O2-handling at high temperatures
(versus cryogenic processes) ambient air

21. June 2011 | Michael Weber | IEK-3 Folie 11

 Simulation flow sheet for integrated OXY-VAC-JÜL

PRO II Ebsilon

Advantage: Advantage:
- comprehensive data base - good convergence
- thermodynamics models

21. June 2011 | Michael Weber | IEK-3 Folie 12

 Conditions for Simulation
O2 pressure ratio: 1.1 370°C

350°C
term. T: 50 K 270°C

coal: Klein Kopje

efficiency: 75%
180°C
200°C
efficiency: 75%

600°C/620°C, 45 mbar
pressure losses
HEX & membr. ap.: reference plant NRW
20 mbar
21. June 2011 | Michael Weber | IEK-3 Folie 13
 Reducing efficiency loss by basic integration

-2,26 %-point
Values valid for
Wast heat utilisation from O2- degree of O2-separation: 60%
degree

cooling at feed water heating

+0,22
integration

Flue gas heat utilisation at heating 4 +0,21

Development and

Flue gas heat utilisation at heating 6 +0,12

Flue gas heat utilisation at heating 7 and 8 +0,83

2 Vacuumcompressor withinterstage cooling with cooling water +0,63

OXY-VAC-JÜL-concept without integration -4,27 %-point

1 2 3 4
Efficency loss without CO2 compression [%-point]

Energy use of O2-supply is substantially compensated by heat transfer to steam cycle

21. June 2011 | Michael Weber | IEK-3 Folie 14

 Optimizing the degree of O2-separation I

1600 0,16

Air - OXY-VAC-JÜL
1400 Air - Reference plant NRW 0,14

O2 -permeate pressure [bar]

O2-permeate pressure
1200 0,12
mass flow [kg/s]

1000

0,1

800

0,08

600

0,06

400 0,04

200 0,02

0 0
0,3 0,4 0,5 0,6 0,7 0,8
O2-separation degree [--]

Separation degree > 75% hardly justified

21. June 2011 | Michael Weber | IEK-3 Folie 15

 Power demand for oxygen supply
50

45 vacuum compressor
air blower
40
el. equiv. to heat from boiler
35
electrical power [MW l ]
e

30

25

20

15

10

0
0,3 0,4 0,5 0,6 0,7 0,8
O2-separation degree [--]

21. June 2011 | Michael Weber | IEK-3 Folie 16

 Net plant efficiency
waste heat & blower losses vacuum compressor
losses

39,8
-compression

39,6
0,2 %-point
39,4
39,2
range of interest
[%-point 2s]
Net efficien cy incl. CO

39

38,8 net efficiency

38,6

38,4

38,2

38
0,3 0,4 0,5 0,6 0,7 0,8
O2-separation degree [--]

Plant efficiency only 6,3 %-pts. below reference plant (target: < 9.4 %-points)
21. June 2011 | Michael Weber | IEK-3 Folie 17
 Energy demand for O2 supply
0, 3
state of the art
O2-Purity: 99,5 %
0,25
[kWhel / kg O2]

optimized for CCS

0,2
O2-Purity: 95 %
membrane system
0,15 O2-Purity: 99,5 %
Energy demand

0,1

0,05

OXY-VAC-JÜL
cryogenic
21. June 2011 | Michael Weber | IEK-3 Folie 18
 Summary & Outlook

• OXY-VAC-JÜL process could reach plant efficiency loss as low as 6.3 %-pts

• Basic improvements reduce impact of O2 supply from 4.3 to 2.3 %-pts.

• Energetic optimum degree of O2 separation at 60..70 %

=> future detailed analyses focus on a range from 50 to 75 %

Future tasks

• Develop design concepts for membrane apparatus & perifery components

• Estimate component cost as functions of design parameters

• Minimize CO2 avoidance cost by systematic adaption of design parameters

21. June 2011 | Michael Weber | IEK-3 Folie 19