Advanced Energy Systems –Gasification SystemsGasification SystemsCoal and Coal‐Biomass to Liquids

Nelson Rekos, DirectorProject Financing & Technology Deployment Division June 2015

7th Freiberg Inner Mongolia Coal Conversion and Syngas Conference

Gasification Systems Program

C&CBTL Program

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Google: “Gasifipedia” for more information, and “Gasification Animation” for 3‐minute YouTube video on basic chemistry, benefits and products (40 second clip)

I t t d G ifi ti C bi d C l (IGCC) ith C b C t

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Integrated Gasification Combined Cycle (IGCC) with Carbon Capture and Storage – primarily enhanced oil recovery (EOR) at this time

IGCC Technology in Early CommercializationNation’s First Commercial Scale IGCC PlantsNation’s First Commercial‐Scale IGCC Plants

The Cleanest Coal‐Based Plant at the time: Each Achieving >97% Sulfur Removal and >90% NOX Reduction

Wabash River CB&I “E Gas” gasifier– CB&I  E‐Gas  gasifier

– 1996 Power Plant of the Year Award*

Bituminous Coal

Tampa Electric 

Bituminous CoalNow Operates Primarily on 

P l C k– GE gasifier– 1997 Power Plant of the Year Award*

Petroleum Coke

– First dispatch power generator

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*Power Magazine

Past Decade Drivers Changed for Gasification

• Greenhouse Gas (GHG) emissions became a serious global concernconcernMaking hydrogen became a program focus

I 2009 t l i d d hifti t t thi• In 2009, natural gas prices dropped; shifting to meet this new cost bar is more problematicMany ongoing projects were abandoned; in particular thoseMany ongoing projects were abandoned; in particular, those focusing on making Synthetic Natural Gas

• One big gasification project continued: Duke Energy’s• One big gasification project continued: Duke Energy s Edwardsport Station in Knox County, Indiana– No carbon captureNo carbon capture– Began “commercial operation” in June 2013 – Cost Overruns

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Cost Overruns 

Gasification Systems Program R&DMature R&D Anticipated BenefitsMature R&D Anticipated Benefits

RTI Warm Gas Cleanup$

APCI Ion Transport Membrane$72M ARRA Award – progress made

Hot Compressed Air

Raw l

Warm Gas Cleaning

$173M ARRA AwardSuccessful 50 MWe tests

Oxygen Membrane 

OxygenFuelGas

in combination with  Advanced CO2 Capture2.6% pt efficiency increase

12% COE dyg7% capital cost reduction

5% COE reduction Clean Fuel Gas

12% COE decrease

H2‐Rich StreamWater‐Gas Shift

up to 0.8% pt efficiency increase (preliminary)

Feedstock

CO2increase (preliminary)

Coal Feed Pump 1% COE reduction Recall: Advances here also reduce the cost of 

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transportation fuel production

China – Perspectives

• Industry is not focused on U.S. profits– Cooperative agreements require at least 20% cost‐share– From 2010 to the present, 119 gasifiers have been deployed, with 98% in China and 2% in the United StatesTo partner with industry they need to see path to profit– To partner with industry they need to see path to profit

• GHG emissions are a global issueglobal issue

• China has a very active gasification R&Dgasification R&D program China

U.S.

7http://photos.mongabay.com/09/forecast_co2.jpg

U.S. Coal Demonstrated Reserve BaseApproximately 485 Billion Short TonsAnthracite Approximately 485 Billion Short TonsAnthracite

The higher the rank, generally:

High-Rank Coal 46%

Bituminous

• More BTUs per ton• Less ash and water• Less reactive

China ~126 Billion

Short Tons~46%

Illinois, West Virginia,Ohio, Pennsylvania,

Entrained GasifierHigh efficiencyLow availability

Short Tons

Bituminous &

A th itOhio, Pennsylvania,W. Kentucky Commercially available

M t

Anthracite~54%

Sub-Bituminous

Low-RankSub-

Bituminous

Montana,Wyoming Lignite

~16%

~30%The lower the rank, generally:• More reactive• Fewer BTUs per tonLow Rank

Coal ~54%

Bituminous

Montana Texas Mississippi Transport Gasifier

p• Gasifies more completely at 

lower temperatures

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LigniteMontana, Texas, Mississippi,

North DakotaTransport Gasifier

Developed by DOE for low rank coal

Development of the TRIGTM

Low Rank Coal Gasification with High AvailabilityLow‐Rank Coal Gasification with High Availability

Lignite and Sub‐Bituminous Coal

Late1930s

FirstCommercial

FCC Unitfor Exxon

1942

1951

Orthoflow™A Design

Orthoflow™C Design

Early1960s

C Design

ResidFCCs

1976

1980s 1990 1996 1999 2014

Orthoflow™ F Design

Design Based on Pilot Plant Grand Forks, ND TRIGTM In Kemper Birmingham, ALgFCC Technology Tech Center 2,600 Hours Test Run TRIG In Kemper

County, MS, USAg

14,000+ Hours Test Run

DOE Cost: 25 Years and Approximately $400 M

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TRIGTM Leverages Long History of KBR Fluid Catalytic Cracking (FCC) Expertise

National Carbon Capture Center (NCCC)Key Gasification Systems and C&CBTL ResearchKey Gasification Systems and C&CBTL Research

• NCCC was used to develop the TRIG transport gasifier ‐‐p p gtoday it’s a world‐class test facility

• In FY13 ‐ 7,921 total hours were spent testing third‐party t h l itechnologies

• Projects Tested at NCCC:Long term candle filter tests– Long‐term candle filter tests

– Long‐term refractory durability tests (transport gasifier).– Water‐gas shift (WGS) tests to reduce steam useWater gas shift (WGS) tests to reduce steam use– Low‐rank coal dry feed system (transport gasifier)– OSU syngas chemical looping (ARPA‐E)y g p g ( )– Coal‐biomass operation (DOD)(transport gasifier)– Laser sensor (Stanford University) (Cross Cutting Program)

10National Carbon Capture Center

American Recovery and Reinvestment Act Success!Research Triangle Institute’s Syngas Cleanup TechnologyResearch Triangle Institute s Syngas Cleanup Technology

• ARRA funding enabled accelerated testing from successful 0.3 MWe tests t 50 MW t T El t i C ’ P lk P St ti 167 f ldto 50 MWe at a Tampa Electric Company’s Polk Power Station ‐‐ a 167‐fold increase in scale

• Tests to date surpass goals for both sulfur removal and low operating costs• Project is on track to be completed under budget

TECO may run theTECO may run the equipment post‐project to make ammonia – long term technology validation at novalidation at no cost to the DOE

RTI P id t W H ld DOE’ J li F i d

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RTI President Wayne Holden, DOE’s Julio Friedmann, TECO Vice President Tom Hernandez

http://www.netl.doe.gov/research/coal/energy‐systems/gasification/project‐information/proj?k=FE0000489

Interesting FY14 Program AdditionI Sit Bi G ifi ti

• Coalbed methane is made from several types of

In‐Situ Bio‐Gasification

• Coalbed methane is made from several types of microbes working in concert with each other in the absence of oxygen: likely to be slowabsence of oxygen:  likely to be slow

• In FY14 three small projects were awarded to accelerate nature – best microbes, key nutrients and increasingnature  best microbes, key nutrients and increasing coal surface area

• DNA manipulation is not part of any of our workDNA manipulation is not part of any of our work• FOA topic for FY15 – field test site preparation• and FY16 field tests• and FY16 – field tests

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ORD FY15‐ Gasification‐ FWP SummaryDevelopment of Reacting Multiphase Models for AdvancedDevelopment of Reacting Multiphase Models for Advanced Gasification ProcessesExperimentation for Model Development and Validationp pNew concepts for gasification and fuel conversionMaterial Interactions During Gasification g

New Gasification Concepts

Click to add references

New Gasification Concepts(NETL Microwave reactor shown;Includes others + novel reactors)

Experimental validation and model development

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Additional Activities and AchievementsMFIX Continues the March Toward World Domination

TRIG CFD Model

FY14 new registrations          229– University 175– Industry 29– National Labs 11National Labs 11– Others 14

Total MFIX registrations   3,513University 2506– University                                    2506

– Industry   559– National Labs                                163– Other                                              285

https://hpc.netl.doe.gov/ 14

15http://www.netl.doe.gov/research/coal/energy‐systems/gasification/coal‐gasification‐magazine

Gasification and C&CBTL ProgramsBackup SlidesBackup Slides

1. History:  early history, impact on WWII and Apartheid, US DOE program through first power demonstrations

2. Program Goals and R&D Highlights3. Interesting Odds and Ends3. Interesting Odds and Ends

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Gasification in the United States1970s to 1984

• The 1973 oil crisis resulted in DOE being formed in 1977• 1973 and 1979 Arab oil embargos and natural gas shortages

1970s to 1984

• 1973 and 1979 Arab oil embargos and natural gas shortages • In 1977, the DOE Gasification Program began

– Primary gasification focus was on sulfur removal, particulate control, increasing efficienc and lo ering costsincreasing efficiency, and lowering costs

• In 1983, Eastman Chemicals built a first‐of‐its‐kind coal gasification plant producing chemicals

l l ( ) d f– General Electric (GE) entrained gasifier– Still operating; primarily makes plastics

• 1984 – The first DOE‐supported IGCC demonstration in operation

Bituminous Coal

– GE entrained gasifier• 1984 – The Great Plains Gasification Plant begins operations in 

North Dakota

Bituminous Coal

o t a ota– Lurgi moving‐bed gasifier– Primary product: synthetic natural gas (SNG)– Still operating; sells CO to Canadian oil fields for EOR

Lignite

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– Still operating; sells CO2 to Canadian oil fields for EOR

U.S. Department of Energy Gasification1990s1990s

• Enabled by DOE support: two IGCC plants were operating with outstanding environmental performance, and they continue to make power today

• DOE sought a gasification process to cost‐effectivelyDOE sought a gasification process to cost effectively gasify lower‐cost low‐rank coal: Transport Reactor Integrated Gasifier (TRIG) development begang ( ) p g

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Research in ITM Oxygen Membrane TechnologyAi P d tAir Products 

ITM Wafer

• The stack is made of numerous wafers• 99% purity shown in a 5‐TPD test unit• A 100 TPD test facility has been built and• A 100‐TPD test facility has been built and 

testing is underwayThis would be an excellent technology to test next at smaller industry scale, 

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perhaps the steel industry, as a bridge to large‐scale power production

Three Major DOE‐Supported DemonstrationsSummit HECA and Kemper

• All will sell power (200 to 580 MW) and CO2 for use in EOR

Summit, HECA and Kemper

p ( ) 2

• Two projects will co‐produce urea and capture 90% of CO2:– Summit Texas Clean Energy (Summit) – Will use a Siemens Gasifier

– Hydrogen Energy California (HECA) – Will use a Mitsubishi H I d t i (MHI) bl ifiHeavy Industries (MHI) oxygen‐blown gasifier

• Southern Company Services, Inc.’s Clean Coal Power Initiative – Round 2 (CCPI‐2; Kemper) is nearing completionInitiative  Round 2 (CCPI 2; Kemper) is nearing completion of construction– Two TRIG transport gasifiersp g– Air‐blown– >67% carbon capture

Culmination of DOE‐supported transport gasifier R&D began in the 

l

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late 1990s

Recently Awarded ProjectsTaking Advantage of Polygeneration Capabilities

Most FY13 and FY14 Funding Opportunity Announcement (FOA) Gasification d d l b l b h h

Taking Advantage of Polygeneration Capabilities

System Program awards required applicability to both IGCC with 90% CCS and either methanol or FT diesel production.

• Seven new technologies were awarded in 2013Seven new technologies were awarded in 2013• Four projects awarded in 2014 for larger projects with the same focus• Several small‐scale projects will be awarded in 2015 in novel oxygen production, catalytic gasification, and  C&CBTL Gasification Lower Costy g ,bio‐gasification Program:

GHG and costs equivalent to 

conventional oil

Gasification Systems Program:  IGCC with 90% 

Lower‐Cost Syngas 

Benefits Both Programs’  conventional oil 

refiningCCS Objectives

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DOE Development of Direct Coal Liquefaction

Lawrenceville, NJ30 bpd

Catlettsburg, KY1,800 bpd

L di Sh h ChiLeading to Shenhua China DCL plant

Shenhua Plant Inner Mongolia China

22Lepinski, Overview of Coal Liquefaction November 2005

Shenhua Plant, Inner Mongolia, China17,000 bpd

Thank You

7th Freiberg Inner Mongolia Coal Conversion and Syngas Conference