advanced coal technology work group march 6 2007 presentation · 2015-05-06 · chilled ammonia...
TRANSCRIPT
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ACT Presentation
March 6, 2007 Carl Bozzuto – Executive Consultant
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One Vision for New Coal Power Portfolio of Clean Technologies
COAL
Fuel Cell
O2
i
CO2
IGCC
IGCC
H2 H2 GT
CO22
CFB USC CFB
O2 or PC
PC USC PC
COMPLETE
combustion CO22
CO2
Carbonate looping
CO22LOOPING
CO2 Capture And
Sequestration
PARTIAL COMBUSTION PETROCHEMICAL
water sh ft
Scrubbing
Air
AIR BLOWN IGCC
Oxygen Fired CFB
COMBUSTION
Air Post-
capture
Concentrated
Near-zero emissions Carbon Free Power
CHEMICAL
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Natural Gas
Steam Coal
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Drivers for New Coal Build North America
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� l
� Economi� Fuel Cost � i ivi
t
� Coal i� +
America
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� l
� Fuel di
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98
2000
2002
2004
2006
2008
2010
2012
2014
Deli i
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New Coal CapacityFaces Challenges
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� Utilization of all l� Competitive costs
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� ity � t
�Environmental � Near zero emissions … � and a carbon strategy
Base Energy needs versus Peak ng Capacity
Base oad demand expected to increase at roughly GDP
cs
End User pr ce shocks dr ng demand for low cos energy
availabil ty and prevalence 200 Years of Reserves in North
Advent of OTC (over the counter) markets for coal and emissions
Environmenta regulations drive new clean plants
versity
vered Pr ce
US
$M
M B
TU
Source: U.S. EIA
Economics ow cost domestic coals …and opportunity fuels
Operations Highest reliability and commercial availabilOperating parameters to mee demands of grid
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5
)
) CFB
PC and CFB
:
¾ ¾ ¾ ly
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Operating Coal Combustion –
Source: Energy Velocity database ( EPA CEMS 2005 data
SubBit. PC
IGCC (operating
Bit. PC
Clean Coal technologies have demonstrated the lowest emissions
Exceed Requirements Cost Effectively Reliab
2005 Wtd Avg NOx Emissions - US Coal Units
0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08
Lbs/
MM
Btu
Top 20 - Lowest NOx emitters
2005 Wtg. Avg SO2 Emissions - US Coal Units
0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08
Lbs/
MM
Btu
Top 20 - Lowest SOx emitters
Best in Class Emissions
Ultra Clean Coal CombustionEmissions Control Capability
� Today’s state-of-the-art � NOx >95% reduction with optimized firing systems and SCR
� SO2 >99% capture with Wet FGD and DBA � Particulates 99.99% capture � Hg 80- 95% capture (coal dependent)
� Next steps � Continued improvements � Integrated Multi-pollutant systems to reduce costs � High Hg capture on all coals (without reliance on ACI) � Introduction of CO2 capture
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tion
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Multi-pollutant
� ly
� l il�
– No i fly ash �
– ign � ital
– i– t
� i le/� Avoi 2
� i l l– SO2: l ) – Hg: / ) – lb/ ) – NOx l
• (
Controls SOx, PM10/PM2.5
APC Systems Integrated APC systems based around commercialproven and reliable technologies Use readi y ava able reagents Produces reusable byproduct(s)
mpact on Superior cost/performance ratio:
Extremely compact desReduces cap costs for equipment, erec and BOP
Fewer moving parts reduces ma ntenance costs Superior environmen al performance
Reduced perm tting schedu cost ded cost for SO credits
Targeted emiss ons eve s: 0.02 b/MMBTU (> 99.5%
1.0 lb TBTU (> 90%PM: 0.01 MMBTU (99.99%
: 0.05 b/MMBTU w/SCR “Polishing” Level TBD) w/o SCR
Mercury & NOx
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� ) �
�
When Additional Control is Needed Mercury Capture Technologies
Additives: Halogen(sPowdered Activated Carbon Halogenated Powdered Activated Carbon
= Potential additive injection points
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Vers
35-37%
37-38
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3480/1005/1050 (psi/°F/°F)
2400/1005/1005167/540/540
4000/1075/1110 (psi/°F/°F)
38-41%
Commercial State of Art
ritical
US-DOE :Ultra-Supercritical Boiler ProjectOperating Target: 1400°F/5500 psig
European Thermie ProjectOperating Target: 1292°F/ 4500 psig
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Efficiency –Critical to emissions strategy
/ 10% co-
/
Coal wfiring biomass
100% Coal
Existing US coal fleet @ avg 33%
Commercial Supercritical
First of kind IGCC
Net Plant Efficiency (HHV), %
Source: National Coal Council From EPRI study
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1960 1980 2000 2020
--
T91
Up to )
)
Superc
2010
Sliding
US-DOE :Ultra-Supercritical Boiler Project °
°
Progression of Plant Efficiency via Advanced Steam Conditions and Plant Designs
Material Development
Efficiency (net) HH Typical Steam Paramet
%- 43%
TARGET 48 - 50 %
Ni-based Materials
Mature Supercritical
Advanced Austenitic Materials
5400/1300/1325(psi/°F/°F
4000/1110/1150(psi/°F/°F
Subcritical Technology
UltraSupercritical
Advanced USC
Pressure Supercritical
Operating Target: 1400 F/5500 psig
European Thermie Project Operating Target: 1292 F/ 4500 psig
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Supercritical Cycles 147 GW, 230 Supercritical Coal Fired Boilers Ordered Since 1990
Clear Trend to Advanced
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0
10
20
30
40
50
60
70
80
0
20
40
60
80
100
120 Number of UnitsGW
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0
10
20
30
40
50
/
i(
Meeting the Goals for
<1050 F or unknown
1050 F 1110 F
>=1110 F <1050 F or unknown
1050 F 1110 F
>=1110 F
Maximum of SH or RH Temp Maximum of SH or RH Temp
POLK WABASH IGCC
Target for New IGCC*
SCPC Today USC Target Next Gen IGCC Plan
t Eff
cien
cy %
HH
V B
asis
)
Coal Based Power - Efficiency
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Increased Value for Efficiency
i l /l
0 2 4 6 8
10 12 14 16
20 25 30 35 40 45 50
An al l i
~$10M/yr
Compared to 34% subcr tica efficiency, 11,000 BTU b coal, 80% capacity factor
Efficiency
Coal Price USD/Short Ton
500 MW Unit
nu Fue Sav ngs, MUSD
42%
40%
38%
36%
~$6.5M/yr
CO2 Mitigation Options – for Coal Based Power
9Increase efficiency Maximize MWs per lb of carbon processed
9Fuel switch with biomass Partial replacement of fossil fuels =
proportional reduction in CO2
9Then, and only then ….Capture remaining CO2 for EOR/Sequestration
= Logical path to lowest cost of carbon reduction
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Iiple suppliers driving
Advanced Amine Scrubbing
CO2 Adsorption with Solids
l t 2f l
f
CO2
2CO2 ing
tCO2ammonia based
Further Improvements in Solvents, Thermal ntegration, and Application of Membranes Technologies Focused on Reducing Cost and Power Usage – Multinnovations
Being Developed by the University of Oslo & SINTEF Materials & Chemistry (Oslo, Norway), in Cooperation with ALSTOM
Use Regenerative Air-Heater-Like Device with Solid Absorbent Materia o Capture ~ 60% COrom F ue Gas.
Being Developed by Toshiba, with Support rom ALSTOM
Wheel
Uses Refrigeration Principle to Capture CO from Flue Gas. Process Being Developed by Ecole de Mines de Paris, France, with ALSTOM Support
Frost
Demonstration in 2006. Advantage of lower cos s than Amines. Applicable for retrofit & new applications
Scrubbing options –
Status Technology
CO2 Capture – Post Combustion
Technology Validation & Demonstration
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N2
O2
O2, N 2 Fuel H2O
CO2
Oxygen Firing to produce concentrated CO2 stream
CO2
¾ 2 to >90% for reduced
Compressor
Air Separation Unit (ASU Boiler
Air in-leakage
Condenser
Recycle
3 MWt pilot CFB
Oxygen Firing – Direct concentration of COcapture costs
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Vattenfall..., ALSTOM, others
2008Test of the oxyfuelprocess chain
1:60Pilot Plant 30 MWth
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30 MWth Oxy-fired PC Pilot Plant – Vattenfall
Location of pilot plant in the Industrial Park Schwarze Pumpe
2020approx. 4-5
Commercial Plant approx. 1000 MWel
2015Realisation with CO2 sequestration,
1:20Demo Plant 600 MWth
CEBra, BTU Cottbus, Vattenfall, ALSTOM
2005Fundamentals of oxyfuel combustion with flue gas recirculation
1:50Test Plant 500 kWth
Universities (Stuttgart, Chalmers, Dresden) Vattenfall, ALSTOM..
2004 2005
Fundamentals of oxyfuel combustion
Laboratory Tests 10 / 55 kWth
PartnersComObjectiveScale-up Factor
Development Steps
2020approx. 4-5
CommercialPlant approx. 1000 MWel
2015Realisation with CO2 sequestration,
1:20Demo Plant600 MWth
Vattenfall..., ALSTOM, others
2008Test of the oxyfuel process chain
1:60Pilot Plant 30 MWth
CEBra, BTU Cottbus, Vattenfall, ALSTOM
2005Fundamentals of oxyfuel combustion with flue gasrecirculation
1:50Test Plant 500 kWth
Universities (Stuttgart, Chalmers, Dresden)Vattenfall, ALSTOM..
20042005
Fundamentals of oxyfuel combustion
LaboratoryTests 10 / 55 kWth
PartnersComObjectiveScale-up Factor
Development Steps
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G Boiler
CO2 liquid
M
Stripper
MEA CO2 Absorber
CO2 Compressor
SteamTurbine
MEA
Amine-Based Absorption - CO2 Capture
� MEA has demonstrated performance on coal based flue gas
� Work required to address:
� Regeneration power
� Compression ratio
� Cost of solvent
SHADY POINT, OKLAHOMA, USA An AES CFB power plant with
MEA CO2 separation
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---
Flue GaCoolingSystem
EnergyRecover
EnergyRecovery
CO2
Tower
Energy
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Advancements Absorption Stripping CO2 Capture
� Ionic Liquids “designer solvents”
� “Piperazine” - alternative solvent
� Process integration and improvement has driven cost down from 70 to 40-50 $/ton CO2 further progress expected
¾With industry focus on improvements, advanced amines likely to be competitive solution for post combustion capture
Amine scrubbing continues to develop
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CO2 Capture InnovationsChilled Ammonia System
s
yRecovery
Existing SO2 Scrubber
Flue Gas
� Ammonia reacts with CO2 and water and forms ammonia carbonate or bicarbonate
� Moderately raising the temperature reverses the above reactions – producing CO2
� Regeneration at high pressure
CO2 Lean
CO2 Rich
CO
2 A
bsor
ptio
n To
wer
Existing Stack
Concentrated CO2 to SequestrationEnergy
Recovery
EnergyRecovery
Flui
d R
egen
erat
ion
Flue
Gas
Coo
ling
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Advantages of Chilled Ammonia
� High efficiency capture of CO2
� Low heat of reaction
� High capacity for CO2 per unit of solution
� Easy and low temperature regeneration
� Low cost reagent
� No degradation during absorption-regeneration
� Tolerance to oxygen and contaminations in flue gas
Post Combustion CO2 CaptureChilled Ammonia
Without CO2 Removal
MEA-Fluor Dan. Proc.
NH3
Total power plant cost, M$ 528 652 648 Net power output, MWe 462 329 421
Levelized cost of power, c/KWh 5.15 8.56 6.21 CO2 Emission, lb/kwh 1.71 0.24 0.19 Avoided Cost, $/ton CO2 Base 51.1 19.7
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1990 1995 2000 2005 2010 2015 2020
Going Down The Experience Curve forPost Combustion CO2 Capture
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0
500Hea
t of R
eact
ion
(BTU
/lb)
1995 2000 2005 2010 2015
Study ( )
ABB
/lb
1000
1500
2000
2500
3000
2001 Parsons Fluor
Lumnus
Process Optimization
Advanced Amines
Process Innovations
ALSTOM’s Chilled
Ammonia Process
Significant Improvements Are Being Achieved
Values From Current Projects
1,350 BTU
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We Energies Pleasant Prairie Host Site Location for 5MW Pilot
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Carbon Free PowerAdvanced Combustion
Innovative Combustion Options for 2010 and Beyond
¾ Oxygen Firing – Direct concentration of CO2 to >90% for reduced capture costs
¾ Chemical Looping –Leapfrog technology with potential to achieve significantly lower costs than PC/CFB/IGCC
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Oxidizer
Calciner
Cold Solids
CaCO3
4
Hydrogen
Coal,
CO2
Air
3
4
Oxidizer 4
CO2 & H2O
Coal, Limestone Air
4
Combustion
Future Technologies for CO2 Capture
Hot Solids
Reducer
CaO
CaS
CaSO
Steam
CaCO
Depleted Air, Ash, CaSO
Reducer
CaS
CaSO
Depleted Air, Ash, CaSO
Chemical Looping
Chemical Looping Gasification
Chemical Looping
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0 2 4 6 8
10
SCPC
IGCC
SCPCw/M
EA
Oxyfir
ing w CO2
SCPCad
v amines
IGCC
F turbine
SCPCNH3
USCPCad
v CO2
IGCC
H turb
ine wad
v CO2
Multiple Paths to CO2 ReductionInnovations for the Future
No CO2 Capture 2
t t
iati tLe
veliz
ed C
OE
cent
s/K
whr
------------------------------With CO Capture---------------------------
Technology Choices Reduce Risk and Lower Costs
Note: Costs include compression , bu do not include sequestra ion – equal for all technologies
‘Hatched’ Range reflects cost var on from fuels and uncer ainty
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Market Trends
175
150
125
100
Month
Carbon Steel Price Trends
Inde
x B
ase
1982
01/02 01/03 01/04 01/05 01/06
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il
June
Aug
ust il
June
Aug
ust il
June
Aug
ust il
June
Aug
ust il
June
Aug
ust il
June
Aug
ust il
June
Aug
ust
i i i
Market Trends
Nickel Trend: 2000 - 2006
1.80 2.20 2.60 3.00 3.40 3.80 4.20 4.60 5.00 5.40 5.80 6.20 6.60 7.00 7.40 7.80 8.20 8.60 9.00 9.40 9.80
10.20 10.60 11.00 11.40 11.80 12.20 12.60 13.00 13.40 13.80 14.20 14.60 15.00 15.40 15.80 16.20
Janu
ary
Febr
uary
M
arch
A
pr May July
Sep
tem
ber
Oct
ober
N
ovem
ber
Dec
embe
r Ja
nuar
y Fe
brua
ry
Mar
ch
Apr May July
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tem
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ober
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ovem
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Dec
embe
r Ja
nuar
y Fe
brua
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Mar
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Apr May July
Sep
tem
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Oct
ober
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ovem
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Dec
embe
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brua
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Apr May July
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tem
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Oct
ober
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ovem
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Dec
embe
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2000 2001 2002 2003 2004 2005 2006 Month / Year
Spot
Nic
kel
Low N Avg. Spot N High N
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CO2 Al ( 2 )
/)
I l i
I l i
iw i
i ia
i ii i
)Air Fi /( )
i)
f - I) w i
f - I) w i
SCPC Adv a e CO2
CO2 Capture
cases
4.00
5.00
6.00
7.00
8.00
9.00
10 20 30 40 50
low ance Price $/Ton CO Em itted
(Cen
tskW
h r
GCC H Cass (E-Gas) w th Capture - Spare
GCC H Cass (E-Gas) w th Capture
10-Advanced O2 Fred CFB th Capture
PC w th Chilled AmmonCO2 Capture
3-Chemcal Loop ng Combust on w th Capture (CaS
red PC w o Capture 3915/1085/1148
PC CO2 Scrubb ng - MEA (Parsons
Re GCC 7FA (GE-Texaco Heat Recovery th Capture Re GCC 7FA (GE-Texaco Heat Recovery th Capture - Spare
min
Technology Innovations
PC with ‘old MEA’
Chemical Looping
IGCC
Ammonia scrubbing
Oxygen Firing
PC with adv MEA’
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CO2 Capture Innovative options continue to emerge and develop
� Post Combustion Capture � Adsorption � Absorption � Hydrate based � Cryogenics / Refrigeration based
� Oxy-fuel Firing � External oxygen supply � integrated membrane-based � Oxygen carriers (chemical looping)
� Decarbonization � reforming (fuel decarbonization) � carbonate reactions (combustion decarbonization)
Conclusions
� New coal fired power plants shall be designed for highest efficiency to minimize CO2 and other emissions
� Lower cost, higher performance technologies for post combustion CO2 capture are actively being developed, andmore are emerging
� There is no single technology answer to suit all fuels and all applications
� The industry is best served by a portfolio approach to drive development of competitive coal power with carbon capture technology
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