MATERIALS CHALLENGES FOR CARBON ABATEMENT TECHNOLOGIES

Derek AllenChairman of APGTF-M and MatUK Energy Materials

Working Groups

Alstom Power

Content

• APGTF-M History• UK Energy Materials-current status• Materials challenges

– Conventional high efficiency plant– Advanced CCS plant

• Conclusions

History

• 1995:-Foresight Programme. IOM-Fossil PP Materials taskforce established

• 1999:-became support group to APGTF (APGTF-M)

• 2006:-Materials UK formed and spawned an Energy Materials working group

• 2006:-EuMat Advanced Materials Technology Platform formed an ‘energy materials working group’

APGTF-Materials support group

Brought together the UK fossil plant materials community with an excellent track record in materials RD&D.

Led to Participation in Numerous UK & EUProgrammes:-•COST•Cleaner coal programme•DTI Technology•EU FP programmes

APGTF-M

APGTFRequirements for Materials R&D Requirements for Materials R&D

for Coalfor Coal--fuelled Powerfuelled PowerPlant:Plant:--Into the 21st CenturyInto the 21st Century

Authors:-ALSTOM:- D.Allen, R.VanstoneMitsui Babcock Ltd:- L.BuchananRolls Royce Industrial Power:- S.BeechBritish Coal:- J.Oakey

IOM Taskforce Report :-September 1997

•Alstom•Corus•E.ON•RWE•Rolls Royce•Doosan Babcock•Howmet

•Chromalloy•NPL•Siemens•Cranfield Uni•NottinghamUni•EPSRC

Current APGTF-M Members

Materials UK-Energy Working Group

MatUK

Energy WorkingGroup

Advisory Commitee

RenewablesFossil/Nuclear

Regulatory/ Policies/Social/Skills

T&D/storage Conservation

Task Groups

Development of Strategic Research Agenda

Coordination and development of Strategy and deployment plan

Implementation

A Group formed and led by industry to:-•deliver a strategic research agenda and deployment plan for Energy Materials•Advisory Group to stakeholders and funding bodies

MatUK –Energy Materials Group members

• Advisory Committee. Industry Alstom, E.ON UK, JohnsonMatthey, UKAEA, Siemens, Pilkington, Doosan Babcock, British Energy, BP, Rolls Royce, BNFL, Corus and Alcan.

Other members:- Qinetiq, NPL, Manchester University, TWI, Oxford University, DTI, Imperial College, CranfieldUniversity, UKERC, EPSRC and RDA’s.

• Additional organisations welcome to form a balanced sector view.

• Secretariat supplied by DTI

• Currently self-funded

The full picture?

APGTF-M

APGTF

MatUK

Energy WorkingGroup

Advisory Commitee

RenewablesFossil/Nuclear

T&D/storage Conservation

EuMaT

Energy Materials Model’g Multi-

func

Regulatory/ Policies/Social/Skills

Delivering a coordinated RD&D Energy Materials strategy for UK and Europe

Materials Challenges

Perspective

For many of the proposed ‘advanced’ CAT technologies,

materials limitations will be one of the major show-stoppers for full

scale demonstration.

1960 1980 2000 2020

35

40

45

50

55

30

Supercritical Boilers/turbines

Sub Critical Boilers

Plant efficiency

% NCV

Year

Target AD700

50 – 55%

46%

New Chinese Orders

42%

Chinese fleet 38%

OldPlants 30%

Increasing Efficiency

Lower CO2

emissionsAvailable Advanced Supercritical Technology being offered

NOW

38%

32%

UK/US

fleet

Emissions Reduction by Improvements In Plant Efficiency

Achieving efficiency through materials

540 C180 bar

42%

<600 C240 bar

47%

600-650 C240-300 bar

50%

>700 C>300 bar

55%

Improved materials

TempPressureEfficiency

New designs

conventionalplant

current advanced

plant

DTI, COST 522, 536

ThermieAD700

low alloy steels

9-12%Cr steels

nickel alloys

+

Materials challenges (1)

Steam turbine materials

11

Operation at higher temperatures• Plant life extension (modelling + LTP)• Improved T (>700C) + creep performance• More aggressive environment• More demanding surface properties (steam

oxidation, wear)-coatings development

Enable more aerodynamic steam path• Highly stressed low temperature steam path• Stronger rotors and blades coupled with

resistance to SCC

Incremental developments are vital

Materials challenges (2)

Boiler materials

•Ferritic materials with operational temperatures to 650C either through intrinsic properties or a combination of this and surface engineering

•Austenitic materials capable of temperatures up to 700C and then beyond

•Joining technologies

•Superalloys materials capable of temperatures up to 750C and beyond in aggressive environments

•Materials modelling capabilities to reduce lead time for new alloys to hit the market place

Materials challenges (3)

Gas Turbine Materials• Higher temperature blading/combustors

– Thermal cycling

• Combustor & blading alloys for aggressive environments

• Coatings (corrosion, oxidation, TBC, SMART) • Stronger disc alloys (steels and Ni-base)• Lightweighting (last stage blading)

Big drive for fuel flexibility & reliability

CCS technologies

Post Combustion Capture – Amine Scrubbing

Materials and related issues

• Durability of scrubber• Life of amine solvent • Operational flexibility• Scale-up to power plant

requirements

CO2 recovery from flue gas with chemical solvent

CCS technologies

Oxy-Combustion – Pulverised Coal PlantsMaterials and related issues

•Water wall and superheatermaterials – fouling, slaggingand corrosion• Concentration of contaminants with flue gas recycling• CO2/H2O condenser durability• Contaminants in the CO2stream for disposal

30 MWth Schwarze Pumpe (Vattenfall) Pilot Plant

CCS technologies

Entrained Flow Gasification – with CO2 Capture

COAL SLURRY& OXYGEN

SLAG

QUENCH MAKE-UP

RECYCLE OF HEAT FOR UPGRADING

DESATURATOR

COLD MAKE-UP WATER

SYNGAS FUEL

SHIFT REACTOR

HP STEAM

BFW

BFW

LP STEAM

SULPHUR

CARBON DIOXIDE.

Materials and related issues

• Syngas cooler conditions• Syngas cooler materials• Gasifier refractory linings• Gas cleaning technology options• Gas turbine durability• H2 separation membranes

Pd/AgPolymerCeramic

CCS technologies

Oxygen separation membranes (ceramic) for CCS systems

Norsk Hydro AZEP system forNatural gas firing

Praxair integrated system

Materials issuesNeed tolerance to CO2, , good mechanical properties, chemical stability at high temperature

CCS technologies

Materials and related issues

• Pipeline/compressor materials – corrosion• Welding/NDT• Corrosion inhibitors• CO2 contaminant levels

CO2 Transport - pipelinesCO2 pipelines:

3500 km in use today Capacity > 45 Mt/y

WeyburnPipeline length 325 km19 MtCO2 over 15 years of EOR.

Photo: Dakota Gasification

SUMMARY

• Improved efficiency of ‘Conventional’ and existing plant– High temp materials to 700C+ (pf)– Coatings developments– Life extension & modelling (full life cycle)– Low cost manufacture, joining & processingIncremental developments continue to be important

• New plant-including CCS– Materials for aggressive environments (oxidising, reducing, corroding)– High Temperature– Novel materials development (eg filters, membranes, sorbents)– Upscaling and life cycle considerationsDisruptive technologies maybe needed

Conclusions

•For all future advanced power plant both with and without CCS, materials will continue to play a key underpinning role

•Design and materials must be integrated- Materials issues should be considered at the earliest stage of concept design. -Development, validation and demonstration of ‘new’ materials typically takes 10 years

•For many of the proposed ‘large scale’ CAT demonstrators, materials will be a likely show-stopper-upscaling is not trivial

•CAT technologies must be supported by a coherent materials development programme

EPSRC, DTI, EC Are they in place???