Pilot-Scale Demonstration of a Novel, Low-Cost Oxygen Supply Process and its Integration with Oxy-Fuel Coal-Fired Boilers: Final Report Page: 45 of 206
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ADVANCED OXYGEN FIRING A CO2 CAPTURE RETROFIT STUDY OF
LINE CERAMIC AUTOTHERMAL RECOVERY PROCESS AMERICAN ELECTRIC POWER'S
CONESVILLE UNIT NO 5
5.2.1.1 Boiler Island Leakage Control: ...................................................................................................... 77
5 .2 .1 .2 D u c tw o rk : ......................................................................................................................................... 7 7
5 .2 .1 .3 F a n s :.................................................................................................................................................. 7 7
5.2.1.4 Combustion System : ......................................................................................................................... 77
5.2.1.5 New Boiler Equipm ent: .................................................................................................................... 77
5 .2 .1 .6 C o n tro ls:............................................................................................................................................ 7 8
5.2.2 Flue Gas Desulfurization System Modifications (Cases 3a, 3b, and 3c only) .................. 78
5.2.2.1 Modified FGD System Process Description and Process Flow Diagram (Cases 3a, 3b, and 3c only).
.......................................................................................................................................................... 78
5.2.2.2 Modified FGD System Equipment Layout (Cases 3a, 3b, and 3c only) .................... 78
5.2.2.3 Secondary FGD Absorber Effluent (Cases 3a, 3b, and 3c only).................................................... 79
5.3 Steam Cycle M modifications ........................................................................................................................ 79
5.3.1 Cryogenic ASU Based Case 2 ............................................................................................................... 80
5.3.2 Flue Gas Sweep Cases (3a, 3b, and 3c) ............................................................................................... 80
5.3.3 Steam Sweep Cases (4a and 4b) ............................................................................................................ 81
6 C o st A n a ly sis ......................................................................................................................................................... 8 3
6.1 Cost Estim action Basis ................................................................................................................................. 83
6 .2 F u e l C o sts ................................................................................................................................................... 8 4
6.3 New Equipm ent and Plant M odification Costs........................................................................................... 85
6.3.1 Oxygen Production System Costs.......................................................................................................... 85
6.3.1.1 Cryogenic ASU System Costs .......................................................................................................... 85
6.3.1.2 CAR System Costs............................................................................................................................ 85
6.3.2 Gas Processing Unit Costs ..................................................................................................................... 86
6.3.3 Boiler M odification Costs...................................................................................................................... 87
6.3.4 FGD System Modification Costs (Cases 3a, 3b, and 3c only)............................................................... 87
6.3.5 Retrofit Investm ent Cost Sum m ary ................................................................................................... 88
6.4 Operating and M aintenance Costs .............................................................................................................. 89
7 Econom ic Analysis ................................................................................................................................................ 90
7.1 Econom ic Study Scope, Outputs, and Assumptions............................................................................... 90
7.2 Econom ic Analysis Results ........................................................................................................................ 91
8 Results and Conclusions ........................................................................................................................................ 95
9 B ib lio g rap h y .......................................................................................................................................................... 9 7
10 A p p e n d ix I ......................................................................................................................................................... 9 8
10.1 Concept B: CO2 Separation with Oxygen Firing and Flue Gas Recirculation......................................... 98
10.1.1 Overall System Description and M aterial and Energy Balance ............................................................. 98
10.1.2 Air Separation Unit.............................................................................................................................. 104
10.1.2.1 Background ................................................................................................................................ 105
10.1.2.2 Oxygen Purity Considerations.................................................................................................... 105
10.1.2.3 M ajor Vendors Experience......................................................................................................... 106
10.1.2.4 Power Consumption ................................................................................................................... 106
10.1.2.5 Plot Plan Requirem ents .............................................................................................................. 106
10.1.2.6 Investm ent and Operation and M aintenance Costs .................................................................... 107
10.1.3 Boiler Heat Transfer Analysis ............................................................................................................. 107
10.1.3.1 Furnace Analysis ........................................................................................................................ 108
10.1.3.2 Convection Pass Analysis .......................................................................................................... 115
10.1.4 Boiler System M odifications ............................................................................................................... 117
10 .1 .4 .1 B o iler.......................................................................................................................................... 1 17
10.1.4.2 Ducts and Dampers and Fans ..................................................................................................... 117
10.1.4.3 Oxygen Heater ........................................................................................................................... 119
10.1.4.4 Parallel Low Pressure Feedwater Heater.................................................................................... 120
10.1.4.5 Controls and Instrum entation:.................................................................................................... 122
10.1.4.6 M odified Boiler Drawings.......................................................................................................... 122
10.1.5 Steam Cycle System ............................................................................................................................ 122
10.1.6 Flue Gas Desulfurization and Electrostatic Precipitator Systems Performance Issues ........................ 123
10.1.6.1 Flue Gas Desulfurization System Perform ance Issues ............................................................... 123
Alstom Power Inc xvi August 22, 2008
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Krishnamurthy, Krish; Acharya, Divy & Fitch, Frank. Pilot-Scale Demonstration of a Novel, Low-Cost Oxygen Supply Process and its Integration with Oxy-Fuel Coal-Fired Boilers: Final Report, report, September 30, 2008; United States. (https://digital.library.unt.edu/ark:/67531/metadc934636/m1/45/: accessed April 23, 2024), University of North Texas Libraries, UNT Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.