Project: Advanced Oxy-Combustion Technology Development and Scale Up for New and Existing Coal-Fired Power Plants (Phase II) (Final Report)
The objective of this project was to develop an advanced Oxy-Combustion Pressurized Fluidized Bed Combustor (Oxy-PFBC) technology and mature it to TRL 6 through pilot testing. Performance goals included demonstrating capture of 90% or greater of the produced carbon dioxide, with no more than a 35% increase in the cost of electricity. A 1 MWth pilot scale plant was designed, built and operated at CanmetENERGY in Ottawa. Extensive support work was carried out on component testing, analysis and commercial planning. The team members included GTI, Linde, Natural Resources Canada (CanmetENERGY), Pennsylvania State University, Electric Power Research Institute (EPRI), and General Electric. Additional research was provided by the University of Ottawa. Funding was provided by the US Department of Energy, Alberta Innovates and each of the team members. The total funding for Phase II was $\$$18.537M with $\$$12.058M. The period of performance for Phase II was from July 1, 2014 through December 31, 2018. Component testing conducted in preparation for pilot testing included cold flow testing at atmospheric and pressurized conditions, and coal and limestone reactivity tests at elevated temperatures and pressures. These tests validated in-bed heat exchanger heat transfer capability, bed stability, and coal particle residence time predictions. They also quantified coal and limestone reactivity at the expected combustor temperatures and pressures. The 1 MWth pilot testing achieved all performance goals with the exception of carbon conversion. The combustor achieved oxy-combustion at the full target pressure of 8 bar. Two key combustor performance goals that were achieved include exceeding the target sulfur capture in the combustor as well as exceeding the acid dewpoint target at full operating pressure. This validates assumptions about the pressures that can be achieved without acid gas condensation and the associated corrosion risks. The ability to achieve target operating pressures supports combustor cost assumptions. In addition, the CO 2 processing unit (CPU), demonstrated a new technology, the deoxidation (DeOxo) reactor. The CPU achieved all of its performance targets, while the DeOxo reactor demonstrated the ability to achieve 100 ppm or less of oxygen in the flue gas stream to meet CO 2 pipeline specs. The pilot combustor was damaged during testing and an incident investigation was conducted. The primary cause of the hardware damage was due to anomalous temperature readings, caused by sensors buried and insulated in bed particles trapped by heat exchanger tubes near the wall. This led to higher gas velocities than intended, which then caused lower fuel residence time, lower carbon conversion, freeboard burning, and undetected excess temperatures in the combustor. As a result, the TRL 6 goal was not achieved. Updated technoeconomic analysis predicts that the Oxy-PFBC can achieve the goal of <35% increase in COE with 90% CO 2 capture if the carbon conversion performance target can be demonstrated in future testing.