Maximization of Net Output for Boundary Dam Unit 3 Carbon Dioxide Capture Demonstration Project

This paper presents the historical data during the design process of Boundary Dam Unit 3 Carbon Dioxide Capture Demonstration Project (BD3 ICCS) focusing net output improvement. BD3 ICCS is known as the first commercial CO2 capture and storage facility integrated to a coal-fired power plant. Without CO2 capture, pre-upgraded BD3 produced a 150 MW gross output and a net output of 139 MW. Initial models incorporating CCS calculated a net power output of 80.95 MW which indicated a reduction in net output of approximately 42% - an unfavorable value. This paper recounts the optimizing, retrofitting and upgrading options that were investigated in order to maximize the net output during the design process of BD3 ICCS. Several factors were taken into consideration including technology for CO2 compression, turbine refurbishment, steam extraction and optimization, flue gas cooler (FGC) installation for heat recovery, main steam temperature, boiler refurbishment and others. The final integrated model produced a net output of 110.88 MW – a 29.93 MW increase when compared to the initial cases. Selecting optimum technology for CO2 compression accounted for 24% of the 29.93 MW improvement. Turbine refurbishment and corrected turbine degradation was responsible for 20 % of the net output increase. Recovering heat via flue gas cooling and condensate preheating increased the net output by another 13 %. Furthermore, boiler refurbishments and increases to the main steam temperature increased the net output by 5% and 7% respectively. This paper presents the analysis of each aspect in detail; including the design criteria and decision making steps during the engineering design process. However, it should be noted that the data presented here was design data and might be slightly different from the current operation.