1. The Callide Oxyfuel Project aimed to demonstrate oxy-fuel combustion technology for carbon capture at a coal power plant in Queensland, Australia, capturing over 75 tons of CO2 per day. 2. The project involved constructing oxygen production facilities, retrofitting one boiler unit to burn coal with oxygen, and building a carbon dioxide capture plant to purify the flue gas and liquefy the CO2. 3. Over several years of operation, the project achieved over 6,500 hours of oxy-fuel boiler operation with routine switching between air and oxy-fuel modes and over 3,200 hours of carbon capture plant operation capturing over 85% of CO2.

1. Callide Oxyfuel Project Update
クリス・スペロ博士
カライド酸素燃焼プロジェクト・ディレクター
19 June 2014
Global CCS Institute Japan Regional Members’ Meeting

2. Presentation Overview
• Purpose of the presentation is to provide an overview of the Callide
Oxyfuel Project and considers:
• Historical background of PF and oxy-combustion
• Callide Oxyfuel technology description (Oxyfuel Boiler and CO2 Capture
Plant)
• Results of Oxy-fuel boiler and CO2 Capture trials
• Results of Storage assessments
• Lessons learned

3. Historical development of PF and oxy-combustion

4. The project, as formally established in 2008 has two broad goals, namely to:
• Demonstrate a complete and integrated process of oxy-fuel combustion of
pulverised coal within a National Electricity Market facility, incorporating
oxygen production, oxy-fuel combustion, CO2 processing and liquefaction, and
to assess CO2 transport and geological storage;
• Obtain detailed engineering design and costing data and operational
experience to under-pin the commercial development and deployment of new
and retrofit oxy-fuel boiler applications for electricity generation.
Configuration: 2 x 330 TPD ASUs, 30 MWe Oxyfuel boiler, 75 TPD CO2 Capture
Overall budget: CAPEX AU$180 million; OPEX $64 million
Operating Period: 2½ years
Project Goals, Cost and Operational Targets

5. Project Structure

6. Project Milestones

7. TECHNOLOGY DESCRIPTION

8. Oxyfuel boiler schematic

9. COP - Boiler works
ID Fan
H2O remover
PAH
SAH
Outlet
FGLPH

10. Carbon dioxide capture plant
Courtesy of Air Liquide
LP Scrubber
DriersHP Scrubber
Compressor
Cold box/
inerts separators
CO2 Capture: 75 t/day (net)
CO2 Capture rate: > 85%

11. ASU & CO2 capture plant
Compressor
Coldbox
LP
Scrubber
Quencher
HP
Scrubber
Driers
Filters

12. OXYFUEL BOILER
RESULTS AND LEARNINGS

13. Air-mode to Oxy-mode transition

14. 1. Optimisation of mode transition Air → Oxy, Oxy → Air, stable Oxy-mode
operation
2. Trials completed with a range of bituminous coals and semi-
anthracite/Callide blend
3. Combustion Efficiency: 50 – 60% decrease in unburnt Carbon
4. NOx emissions: Air (90 mg/MJ fuel) → Oxy (40 mg/MJ fuel)
5. Particulates: Air (2 – 2.5 g/s) →Oxy (1.6 – 2.3 g/s)
Oxyfuel boiler performance

15. CO2 CAPTURE (CPU)
RESULTS AND LEARNINGS

16. CPU – Environmental performance
•Low pressure scrubbers utilise a
caustic soda wash to remove SO2
from the gas stream (< 10 ppm in
gas phase).
•Nitrous Oxide (NO) passes
through the LP scrubbers but is
largely converted to NO2 during
flue gas compression.
•Trace elements in the gas phase
are also effectively extracted from
the gas phase in the Low Pressure
section of the CPU.
•The principal gaseous emissions
from the CPU are CO2 and NO2.
Considerable work has been done
to characterise the behaviour of
NOx in the CPU.

17. CPU – Process condensates
Test data indicates:
• LP area (caustic wet scrubbers and filters) remove particulates, SOX, NO2 and a major
portion of trace elements
• NO is converted to NO2 in the compressor and a significant portion is removed with
the intercooler and aftercooler condensates as Nitric Acid.
• Almost all the Hg that has passed through the LP sections (as Hgo) is removed with the
compressor condensates.

18. CO2 STORAGE ASSESSMENTS

19. Surat Basin Storage Tenements (South East Queensland)

20. Surat Basin Storage Capacity
Courtesy: Coal Bed Energy Consultants
Overall Surat Basin storage capacity > 850 Mt CO2

21. • Establishment of the Project (structure, business systems, budgets, and
schedules)
• Contract management
• Communications (with partners, Stakeholders and the Public)
• Identification and control of technical risks
• Operations and maintenance strategies and experience.
• Managing workplace health and safety, and the environment
• Transitioning of the power station culture and skill base from conventional
coal-fired power plant to more complex and multi-purpose facilities designed
to make electricity and capture CO2 and other emissions
• Enhancements that would be applied to the next scale up of the Oxyfuel and
CO2 capture technology
• Efficacy of the technology in general
High-level learnings

22. 1. The Callide Oxyfuel Project has been complex for 3 principal reasons:
• Large capital investment for a non-commercial demonstration, requiring a number of funding
agreements and equity.
• Engineer Procure Construct Manage (EPCM) for capital works involving a large number of
contracts.
• First-of-a-kind project, operating in an electricity market.
2. Supporting R&D and publications:
• ANLEC (University Newcastle, Macquarie University)
• ACALET
• Global CCS Institute (Lessons Learned Report; Appraisal of CO2 storage sites in Surat Basin)
• NEDO & METI (IHI R&D)
• Air Liquide R&D
3. The Project has demonstrated over 6500 hours of oxyfuel boiler operation, routine mode changes
air-oxy mode, over 3200 hours of CO2 capture plant operation and capture rates exceeding 85%
4. Next step is to consolidate the learnings from Callide A and to apply these to new projects
Concluding comments

23. Thank you
for more information: www.callideoxyfuel.com
Callide Oxyfuel Project – Participants