The Future of IGCC Technology CCPC-EPRI IGCC Roadmap Results

Ronald L. Schoff (rschoff@epri.com) Electric Power Research Institute Sr. Project Manager

IEA CCT2011 Conference Zaragoza, Spain May 10, 2011

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IGCC CCS Technology Roadmap Taking CCS from Lab to Commercialization

Laboratory Pilot Plant Demonstration Commercially Available

CCS

Each step in the commercialization process is importantEach step in the commercialization process is important

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New Technology Deployment Curve (Current State of the Art)

IGCC

SCPC

R&D Roadmaps Process Improvements

R&D Roadmaps are Critical to Improving Cost CompetitivenessR&D Roadmaps are Critical to Improving Cost Competitiveness

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IGCC CCS Technology Roadmap Statement of Work

• Base Case Modeling

• Coal Preparation & Feeding

• Oxygen Production

• High Temperature & Pressure Sulfur Recovery (HTPSR)

• Hydrogen Membrane

• Advanced CO2 Capture

• Downstream CO2 Processing

• Advanced Gas Turbines

• Supercritical Steam Turbines

• Mid-Term and Long-Term Technology Advancement Cases

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IGCC CCS Technology Roadmap Approach

• Thermodynamic Evaluation– AspenPlus steady-state process modeling– Jacobs base case + input from vendors and GateCycle

• Qualitative Economic Analysis– Jacobs base case + EPRI COE calculation

methodology

• Evaluation of Commercialization Status

Study Designed to Provide Actionable Information to CCPCStudy Designed to Provide Actionable Information to CCPC

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IGCC CCS Technology Roadmap Base Case Process Flow Diagram

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IGCC CCS Technology Roadmap Base Case Plant Configuration

• Air Separation Unit: conventional cryogenic design• Gasification Island: Siemens• Syngas and CO2 Processing

– Water-Gas Shift: conventional technology– Acid Gas Removal: Selexol– Sulfur Recovery: O2 -fired Claus– CO2 Compression: conventional technology

• Power Block (2x1 Configuration)– Gas Turbines: GE 7F Syngas– Steam Turbine: subcritical steam conditions

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IGCC CCS Technology Roadmap Performance Comparison: Base Case

EPRI Base Case

Total Gross Power (MWe) 678

Total Auxiliary Load (MWe) 221

Net Plant Power Output (MWe) 457

Net Plant Efficiency, HHV 29%

Thermal Input, HHV (MWe) 1,580

CO2 Captured 92%

Total Plant Cost ($MM) 2,880

Total Plant Cost ($/kW) 6,300

LCOE ($/MWh) 175

• Alberta Sub-bituminous coal• Elevation: 1,067m (3,500 ft)

• US Gulf Coast Cost Basis• June 2010 Dollars• Engineering cost adder: 15%• Project contingency: 20%• Capacity factor: 85%• CO2 T&S costs: $10/tonne• 12.5% carrying charge factor

Cost Reconciliation w/ Similar DOE & EPRI Cases UnderwayCost Reconciliation w/ Similar DOE & EPRI Cases Underway

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IGCC CCS Technology Roadmap Oxygen Production Case Process Flow Diagram

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IGCC CCS Technology Roadmap Oxygen Production Case

• Advanced oxygen system treated as a “black box” in model• In: Air, natural gas and auxiliary power• Out: Oxygen (99.5%vol) and Nitrogen (<2%vol O2 )

• Significant reduction in ASU auxiliary load

• Results:• + 1.7% NPE• - $1,100/kW TPC• - $23/MWhr LCOE

AIROXYGEN

FUEL

HEATEXCHANGE

IONTRANSPORTMEMBRANE

HRSG

STEAM

OXYGENBLOWER

ELECTRICPOWER

OXYGEN

‘AIR’

AIROXYGEN

FUEL

HEATEXCHANGE

IONTRANSPORTMEMBRANE

HRSG

STEAM

OXYGENBLOWER

ELECTRICPOWER

OXYGEN

‘AIR’

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IGCC CCS Technology Roadmap HTPSR (Bechtel Pressure Swing Claus) Case Process Flow Diagram

Steam

Water Gas Shift

Syngas Diluent (N2)

Coal

Oxygen Gasification Island

Slag

AirSeparation

UnitBechtel

Pressure Swing Claus

CO2To Pipeline

Air

Air

Sulfur

Gas Turbine

Syngas Cooling & Hg Removal

Steam Turbine

HRSG

Coal Drying and Feed

CO2 Capture &

Processing

Water

Syngas Conditioning

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IGCC CCS Technology Roadmap HTPSR (BPSC) Case Background Information

• Bechtel Pressure Swing Claus treated as “black box”– In: 38°C syngas and auxiliary power– Out: Sulfur-free syngas, sulfur, steam

• Selexol downstream for CO2 removal

• Results:• + 1.0% NPE• - $290/kW TPC• - $7/MWhr LCOE

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IGCC CCS Technology Roadmap Hydrogen Membrane (Eltron HTM) Case Process Flow Diagram

Steam

Water Gas Shift

Syngas Diluent (N2)

Coal

Oxygen Gasification Island

Slag

AirSeparation

UnitBechtel

Pressure Swing Claus

CO2To Pipeline

Air

Air

Sulfur

Gas Turbine

Syngas Cooling & Hg Removal

Steam Turbine

HRSG

Coal Drying and Feed

CO2Processing

Water

Syngas Conditioning

Hydrogen Membrane

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IGCC CCS Technology Roadmap Hydrogen Membrane (Eltron HTM) Case

• Eltron HTM system treated as a “black box” in model– In: Sulfur-free H2 -rich syngas– Out: High purity H2 and CO2 with remaining impurities

• Bechtel Pressure Swing Claus system upstream

• CO2 purification downstream

• Results:• + 2.7% NPE• - $940/kW TPC• - $23/MWhr LCOE

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IGCC CCS Technology Roadmap Advanced Gas Turbines Case Process Flow Diagram

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Advanced Gas Turbines

• Firing Temperature Evolution of Gas Turbines– F-Class GT: ~2500°F [1370°C] (GE 7F and Siemens

5000F)– H-Class GT: ~2600°F [1430°C] (Manufacturers?)– J-Class GT: ~2700°F [1480°C] (MHI)– X-Class GT: ~3100°F [1700°C]

• Increased air extraction

• Up to 10.5%

• Higher output

• Higher net plant efficiency

U08-102701 Image provided by Siemens. Used with permission. All rights reserved.

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IGCC CCS Technology Roadmap Results Summary: Base Case and Advanced Gas Turbine Cases

EPRI Base Case

H-Class GT Case

J-Class GT Case

X-Class GT Case

Total Gross Power (MWe) 678 1,058 1,212 1,381

Total Auxiliary Load (MWe) 221 300 321 353

Net Plant Power Output (MWe) 457 758 891 1,028

Net Plant Efficiency, HHV 29% 31% 33% 35%

Thermal Input, HHV (MWe) 1,580 2,420 2,690 2,980

CO2 Captured 92% 92% 92% 92%

Total Plant Cost ($MM) 2,880 4,050 4,435 4,880

Total Plant Cost ($/kW) 6,300 5,340 4,980 4,750

LCOE ($/MWh) 175 150 140 134

Advanced Gas Turbines Can Significantly Improve Plant Performance and Cost

Advanced Gas Turbines Can Significantly Improve Plant Performance and Cost

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IGCC CCS Technology Roadmap Long-Term Technology Advancement Case Process Flow Diagram

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IGCC CCS Technology Roadmap Performance Comparison: Base Case and Long-Term Technology Advancement Case

EPRI Base Case

Long-Term Tech Adv. Case

Total Gross Power (MWe) 678 1,260

Total Auxiliary Load (MWe) 221 236

Net Plant Power Output (MWe) 457 1,024

Net Plant Efficiency, HHV 29% 40%

Thermal Input, HHV (MWe) 1,580 2,570

CO2 Captured 92% 89%

Total Plant Cost ($MM) 2,880 3,340

Total Plant Cost ($/kW) 6,300 3,260

LCOE ($/MWh) 175 94

• Net Power is 124% higher for Long- Term case– Single train 500

MW plant possible

• TPC 15% higher• Specific TPC and

LCOE ~50% lower

Significant Potential Exists to Improve Plant Performance While Reducing Costs

Significant Potential Exists to Improve Plant Performance While Reducing Costs

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IGCC CCS Technology Roadmap Summary of Performance Results

0.0%

2.0%

4.0%

6.0%

8.0%

10.0%

12.0%

14.0%N

et P

lant

Effi

cien

cy Im

prov

emen

ts (O

ver B

ase

Cas

e)

Base C

ase

Coal Ben

eficia

tion

Oxygen

Producti

on

High T/P Sulfur R

ecove

ry

Hydro

gen M

embran

e

Advance

d CO2 C

apture

Downstrea

m CO2 P

roce

ssing

H-Clas

s GT

J-Clas

s GT

Supercrit

ical S

T (w/J-

Class G

T)X-C

lass G

T

Mid-Term Tec

h Adva

ncemen

t

Long-Term Tec

h Adva

ncemen

t

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IGCC CCS Technology Roadmap Summary of Economic Results – Specific Total Plant Cost ($/kW)

$3,000

$4,000

$5,000

$6,000

$7,000

Spec

ific

Tota

l Pla

nt C

ost (

$/kW

)

Base C

ase

Coal Ben

.O2 P

roducti

on

HTPSRH2 M

embran

eAdv.

CCAdv.

CPUH-C

lass G

TJ-C

lass G

TSC ST (w

/J GT)

X-Clas

s GT

Mid-Term TA

Long-Term TA

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IGCC CCS Technology Roadmap Summary of Economic Results – Cost of Electricity ($/MWhr)

$75

$100

$125

$150

$175

Cos

t of E

lect

ricity

($/M

Whr

)

Base C

ase

Coal Ben

.O2 P

roducti

on

HTPSRH2 M

embran

eAdv.

CCAdv.

CPUH-C

lass G

TJ-C

lass G

TSC ST (w

/J GT)

X-Clas

s GT

Mid-Term TA

Long-Term TA

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Closing Thoughts

• Study corroborates results from other Roadmaps• Technologies identified to replace efficiency loss of CO2

capture while reducing plant costs

Additional Activities:– US DOE & EU Demonstrations– CO2 liquefaction and pumping– Advanced WGS Catalysts

and Designs– Advanced gas turbine research– Other ideas welcome

• 2011 EPRI CoalFleet IGCC R&D Roadmap Underway

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Acknowledgements

• Canadian Clean Power Coalition (Funding & Direction)

• Air Products & Chemicals (ITM Oxygen & Sour PSA)

• Becthel (Pressure Swing Claus – BPSC)

• Eltron R&D (Hydrogen Transport Membrane – HTM)

• Pratt & Whitney Rocketdyne (Compact Gasifier)

• Ramgen (Shockwave CO2 Compression)

• Sherritt Technologies (Coal Beneficiation)

• US DOE/NETL (General)

• EPRI Technical Team (Golden, Bedilion, Steele)

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Together…Shaping the Future of Electricity