epri low co2 emission coal r&d for kpic

1© 2009 Electric Power Research Institute, Inc. All rights reserved.

EPRI’s Low CO2 Emission Coal Power Research, Development and Demonstration Programs

November 2009

Jeffrey N. PhillipsSr. Program Manager

Advanced Generation Options


Introduction

• EPRI’s efforts are focused on:– Reducing CO2 emissions on kg/MWhr basis by

increasing thermal efficiency of coal power plants– Improving the economics of pre-combustion, post-

combustion, and oxy-combustion CO2 capture technologies

• EPRI’s efforts range from lab tests to large demonstrations


Decreasing CO2 Emissions with More Efficient Designs


Increased Efficiency = Reduced Fuel & Emissions

Advanced steam conditions can reduce CO2 emissions by 30-33% compared to average U.S. coal power plant

Adapted by I.Wright, ORNL from B. Vitalis, Babcock Power


2: Material Properties3: Steamside Oxidation4: Fireside Corrosion

5: Welding6: Fabricability

7: Coatings

8: Design Data & Rules (including Code interface)

1: Conceptual Design

Develop the materials technology to fabricate and operate a A-USC Steam Boiler with

Steam Parameter up to 760°C

Advanced-Ultrasupercritical Steam Boiler Consortium Phase I & II

http://www.fwc.com/

http://www.alstom.com/

http://www.netl.doe.gov/main.html


Advanced-Ultrasupercritical Steam Turbine Consortium Phase II

• Steam Conditions from boiler and phase I turbine studies– 730°C, 39MPa Main Steam– 760°C, Re-heat– Size to 1000MW

• Tasks– Rotor/Disc Testing (near full-size forgings)– Blade/Airfoil Alloy Testing– Valve Internals Alloy Testing– Rotor Alloy Welding and Characterization– Cast Casing Alloy Testing– Casing Welding and Repair

http://www.netl.doe.gov/main.html


Economic Analysis Shows Advanced USC Provides Cost-Effective CO2 Reductions

582ºC SCPC

680ºC A-USC

Thermal Efficiency, %HHV 38.5 42.7

Levelized Cost of Electricity $/MWh

53.3 55.3

CO2 emissions, kg/MWh 853 765

Avoided CO2 emissions cost, $/metric ton vs. 582ºC SCPC

N/A 22.5

Reference: EPRI Technical Report 1015699, September 2008


CoalFleet IGCC User Design Basis Specification (see EPRI Report 1017501, Nov. 2009)

• Defines power company technical requirements for a site-specific IGCC plant; supplier alliances to propose plants that meet the UDBS

• UDBS represents major collaborative effort– All sectors of industry engaged– 30+ people developed UDBS Ver. 9– Approved by all CoalFleet members

• Robust, 1600-page industry-developedand tested guideline, primer, andlessons-learned compendium

• Flexible, yet promoting of standardized, optimized designs• Already in use by numerous CoalFleet participants

EPRI

USER DESIGN BASIS SPECIFICATION

Report 1017501


IGCC Case StudiesPerformance Summary (see EPRI Report 1019368, October 2009)


IGCC Engineering and Economic Evaluations2009–10 Study Content

• 50 Hz F-Frame Gas Turbine Cases– Northeast Netherlands site

• Coal Type– Eastern Australian export coal

• Gasification Technologies– General Electric, Siemens, Shell,

Prenflo PDQ, Mitsubishi Heavy Industries, ConocoPhillips• Greenfield Carbon Capture and Storage• Sensitivity Analyses

– G-Frame GT, Cost Estimates for CO2 Liquefaction and HP Gasification cases

• 2008–09 Capital Costs Revisited


ITM for Low Cost Oxygen Production Overview

• A ceramic membrane to separate oxygen from air• Intermediate-sized 150 tons O2/day test unit integrated with 5-15 MWe

turbomachinery system– Utilizes commercial-scale ceramic membrane modules for

oxygen separation– Representative of arrangement for full-scale

IGCC plant with CCS• Three-year program to design,

build, and test system– Team: Air Products (with Ceramatec and

Siemens), DOE, and EPRI • EPRI has launched the collaborative

– Builds on major investments by Air Products and DOE– Will incorporate real-world utility plant design and

integration considerations– Forms a bridge to commercial IGCC application– May enhance oxy-combustion applications

• Additional organizations are welcome to join the collaborative

0.5 tons O2/day ITM

Modules

Images courtesy Air Products. © Air Products. All rights reserved.


ITM for Low Cost Oxygen Production Potential Benefits

• Reduces barriers to IGCC technology deployment – Decreases capital cost by ~7%– Decreases auxiliary power consumption by ~6% – Improves plant efficiency by ~1 percentage point– Reduces oxygen plant footprint by 50%– Reduces cooling water requirement by 60%

• Large forecast growth in oxygen plant market should drive learning-by-doing cost reduction after commercialization

• Potential use with oxy-combustion boilers


Improving the Economics of CO2 Capture & Storage


Challenges for Post-Combustion CO2 Capture

• What to do with CO2?

– SO2: ~ 1,400 ppmv in flue gas

– CO2: ~140,000 ppmv in flue gas

• Concentrating flue gas CO2

– Best option at present: scrub the gas with highly alkaline solutions which can then be stripped of the CO2

• Putting the CO2 in the ground (required pressures: 100 – 175 bar)

• The overall capacity/efficiency penalty with current technology: – 750 MW plant will net 492 MW with CO2 Capture (258 MW loss)

Can’t use consumable sorbents for CO2 capture (like those used for SO2 Capture).


Capture Technologies Reviewed(see EPRI Report 1016995)

Absorption, Liquid• MHI, KS-1 • Chilled Ammonia (CAP)• CANSOLV• "7/2" MEA & PZ• CASTOR Solvent• IFP, Dual Phase• Econamine FG+• PowerSpan ECO2• Ionic Liquids, Notre Dame• Sargas• Skyonic Skymine• AWL• WowClean• Ionic Liquids, U. S. Carolina• MEA:MDEA• COCS Solvent, RITE• GRT• Immobilized Activator• Enzyme Catalysis• AEEA• D3• HTC Purenergy• RCO2• PARC Absorption electrodialysis• Akermin, Inc• Many basic amine solvents

Absorption, Liquid, cont.•InnoSepra•CarbonTrap•TNO CASTOR2•JustCatch•CO2 Solution•Three H Technologies, Inc.•CatalyteAbsorption, Solid•RTI•Hyperbranched Polyamine•Polyethyleneimine (PEI)•Amine on inert support•CO2 Wheel, ToshibaAdsorption•Metal Organic Frameworks (MOFs)•Advanced Mesoporous Materials•Heavy Reflux PSA•CO2CRC Adsorbent•U. Akron•U. Wyoming carbonaceous sorbent•ADA-ES•VMIMineralization•CCS Materials•Calera

Membrane, Active• MTR• RITE, Cardo polyimide• Tetramer Technologies• Poly(Ionic Liquid) Membrane• NanoGloWaMembrane, Support• Carbozyme• Coral• Kvaerner Membrane Contactor• PureStreamCryogenic• CO2 Frosting• EnecogenBiological Fixation• UNLV PRB• Independence BioProducts• Carbon Capture Corp.• GreenFuel• GSCleanTech• Conc. Solar Photoreactor• Many new Algae Systems


Assessing Technical Readiness Level (TRL)

TRL-9 Full-Scale Commercial Deployment

TRL-8 Sub-Scale Commercial Demonstration Plant

TRL-7 Pilot Plant, 5 to 25% of full-scale

TRL-6 Process Development Unit <5%

TRL-5 Component Test in Relevant Environment

TRL-4 Laboratory Component Testing

TRL-3 Analytical, “Proof of Concept”

TRL-2 Application Formulated

TRL-1 Basic Principles Observed

• Most candidate CO2 removal technologies assessed are still a “twinkle in the eye”

• Significant development time required to bring even the most ready technology to TRL-9

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• ~20 MWe demonstration facility at AEP’s Mountaineer plant

• ~90,000 tonnes-CO2/yr

– Next development step after 1.7 MWe R&D pilot at We Energies’ Pleasant Prairie Power Plant

– Injection into two on-site wells – 1–5 year injection program plus

post-injection monitoring– Started capturing CO2 on September 1 and injecting on October 1

• Alstom designed and built the facility, and will serve as lead operator for the first year. AEP may operate the facility for an additional 1-4 years.

• EPRI will measure and report unit performance, operability, and reliability over project duration; EPRI will also monitor CO2 storage performance

PVF 2-23-09, Photo courtesy of AEP/Alstom. All rights reserved.

AEP-Alstom Chilled Ammonia Post-Combustion CO2 Capture Scale-Up – Overview


Southern Co.-MHI KM-CDR Advanced Amine Post-Combustion CO2 Capture – Overview

• ~25 MWe demonstration facility at Alabama Power’s Plant Barry (~ 140,000 tonnes-CO2/year)

– Potentially lower regeneration energy than other amines; less corrosive; low O2 degradation

– Injection program under U.S. DOE’s Southeast Regional Carbon Sequestration Partnership (SECARB) Project—ongoing

– 4 years of CO2 injection plus 4 years of post-injection monitoring

– Startup scheduled for 4th Quarter 2010

• Southern Co. is leading the project and will install and operate the plant; MHI is designing the CO2 capture facility

• EPRI will measure and report CO2 capture performance, operability, and reliability

• EPRI is managing CO2 injection and monitoring operations under U.S. DOE research partnership


Questions?

Jeffrey [email protected]

Jong [email protected]

Together…Shaping the Future of Electricity

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epri low co2 emission coal r&d for kpic

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