Ways of reducing accounted CO2

emissions in coal-fired power plant to precede and facilitate adoption of CCS

Dr John Topper, Managing Director

IEA Clean Coal Centre, London

STEP-TREC Programme,Trichy,

November, 2012

Contents

Plant up-grades

Advanced ultra-supercritical programmes in Europe, USA, Japan, China

Biomass co-firing with coal

1.Plant up-gradesAdvanced ultrasupercritical programmes in Europe, USA, Japan, China

1.Biomass co-firing with coal

Data for hard coal-fired power plants from VGB 2007; data for lignite plants from C Henderson, IEA Clean Coal Centre; efficiencies are LHV,net

CO2 emission reduction by key technologies

Energy Efficiency makes big change but deep cuts of CO2 emission can be done only by Carbon Capture and Storage (CCS)

>2030

but deep cutsonly by CCS

Average worldwidehard coal

30.0%

1116 gCO2/kWh

38%

881 gCO2/kWh

EU av hard coal

45%

743 gCO2/kWh

State-of-the artPC/IGCC hard coal

50%

669 gCO2/kWh

Advanced R&DHard coal

gCO

2/kW

h

Latrobe Valley lignite (Australia)

28-29.0%

1400 gCO2/kWh EU state-of-the-art lignite

43-44%

930 gCO2/kWh

55%

740 gCO2/kWh

Advanced lignite

Decrease generation from subcritical Install CCS* on plants over supercritical

Increase generation from high-efficiency technology (SC or better)

Glo

bal c

oal-f

ired

elec

tric

ity

gene

ratio

n (T

Wh)

Supercritical

HELE Plants with CCS*

USC

Subcritical

*CCS (Post-combustion, Oxyfuel, Pre-combustion CO2 capture)

IGCC

Improve efficiency, then deploy CCS

* CCS fitted to SC (or better) units.

Source: Burnard IEA 2012

Data for hard coal-fired power plants from VGB 2007, for lignite plants from RWE and C Henderson, IEA Clean Coal Centre; efficiencies are LHV,net

Potential for Up-Grading

>2030

but deep cutsonly by CCS

Air preheater

FGD

Sealing technology

NOx control

Boiler heat up

Turbine upgrade

Feed water pump

Average worldwidehard coal

30%

1116 gCO2/kWh

38%

881 gCO2/kWh

EU av hard coal

45%

743 gCO2/kWh

State-of-the artPC/IGCC hard coal

50%

669 gCO2/kWh

Advanced R&DHard coal

gCO

2/kW

h

Latrobe Valley lignite

28-29%

1450 gCO2/kWh EU state-of-the-art lignite

43-44%

950 gCO2/kWh

51-53%

750 gCO2/kWh

Advanced lignite

To be held at E.ON’s Technology Centre at Ratcliffe-on-Soar, UK on 19-20 March 2013

Call for papers now openhttp://upgrading2.coalconferences.org

Some presentations from 1st Workshop

1st workshop was held in Melbourne, Australia in April 2012. Presentations are at

http://upgrading.coalconferences.org/ibis/Upgrading-workshop/my-event

Recommended“Challenging the Efficiency Limitation of the Existing Coal Fired Power

Technology” Session 1; Weizhong Feng “Performance Monitoring & Improvements through Deployment of

Cost-Effective Technologies” session 2; Scott Smouse “Increase in Efficiency of Coal Dust-Fired Steam Generators using the

Latest Low NOx Firing System” session 3; Karl Heinz Failing “Coal-Fired Power Plant Upgrade and Capacity Increase Solutions”

session 6; Ragi Panesar “Modernisation solutions for steam turbine power plants in a carbon

price environment” session 6; Michael Bielinski

Shanghai Waigaoqiao No 3

2 x 1000 MW tower type, ultra-supercritical, single reheat, tangential firing, spiral tube water wall, pulverized coal fired boiler. Commissioned in 2008 by Shanghai Boiler Works through technology transfer from Alstom in Germany.

Steam Parameters: 28MPa, 605C/603C.

Energy Saving EffectsShanghai Waigaoqiao No.3

Niederaussem K, Germany

Most efficient lignite-fired plantOperating net efficiency 43.2% LHV/37% HHV High steam conditions 27.5 MPa/580C/600C at turbine; initial difficulties

solved using 27% Cr materials in critical areasUnique heat recovery arrangements with heat extraction to low

temperatures – complex feedwater circuitLow backpressure: 200 m cooling tower, 14.7C condenser inletLignite drying demonstration plant being installed to process 25% of fuel

feed to enable even higher efficiencyNOx abatement Combustion measuresParticulates removal ESPDesulphurisation Wet FGD

USC, tower boiler, tangential wall firing, lignite of 50-60% moisture, inland

RWE’s WTA lignite drying process

Lignite drying

Vattenfall’s PFBD process

There should be cost savings in a new boiler that will largely offset the cost of the drier (including elimination of beater mills and hot furnace gas recycle systems, smaller flue gas volume). It will also allow plants to have greater turndown

Data for hard coal-fired power plants from VGB 2007, for lignite plants from RWE and C Henderson, IEA Clean Coal Centre; efficiencies are LHV,net

Potential for Advanced Ultra-Supercritical

Around another 5% efficiency is possible in moving from today’s best steam temperatures of around 610C to 700+C

>2030

but deep cutsonly by CCS

Average worldwidehard coal

30%

1116 gCO2/kWh

38%

881 gCO2/kWh

EU av hard coal

45%

743 gCO2/kWh

State-of-the artPC/IGCC hard coal

50%

669 gCO2/kWh

Advanced R&DHard coal

gCO

2/kW

h

Latrobe Valley lignite

28-29%

1450 gCO2/kWh EU state-of-the-art lignite

43-44%

950 gCO2/kWh

51-53%

750 gCO2/kWh

Advanced lignite

>700C, materials

Work is being undertaken in EU, Japan, USA, India and China to develop these high temperature (700˚C plus) systems to increase the efficiency of generation to around 50%, LHV basis, and so reduce CO2 emissions

Anyone can access the papers given at the recent workshop indicated below. IEA CCC will also publish a review report on the topic in 2013

http://ausc.coalconferences.org/ibis/ausc.coalconferences/my-event

A-USC technology

Material development for future 700°C technologyEuropean funded R&D with participation of HPE

AD 700/1 01.01.1998-31.12.2001(basics, materials)

AD 700/2 01.01.2002-31.12.2006(first component tests, weld tests)

COMTES 700 (AD 700/3)01.07.2004-31.12.2014(component test facility for 700°C)

ENCIO 2011-2017welding and repair conceptBehaviour of different Ni based alloysHPE: coordinator engineering and manufacturing

1616

700°C SH heating surfaces

21

4

ENCIO Test Facility

3

Dipl.-Ing. Marc D. Jedamzik, 700°C steam generator technology – HPE activities and scope of work in R&D projects Hitachi Power Europe GmbH

Ongoing developments

Europe:

AD700 / Thermie700 (material development and plant design for 700 °C)

Comtes (testing of components at 700 °C)

EON 50+ Kraftwerk (building of power plant operating at 700 °C) –

postponed >5 yrs

Similar projects in US, Japan and China

Next logical step would be to make real size components

At the same time looking at even higher steam temperatures (up to 750

C)

A-USC technology in Japan

Materials in Japanese double-reheat A-USC design (Fukuda M, 9th Liege Conference: Materials for Advanced Power Engineering, 2010)

DOE, the State of Ohio Office of Coal Development and Industry have teamed to develop next generation

technology which will provide efficiency and environmental gains

A uniquely qualified industry team - Energy Industry of Ohio, all the major US boiler manufacturers, US steam turbine manufacturers, Oak Ridge National lab, Ohio

organizations, and EPRI

An aggressive goal – 760C (1400F) steam temperature

A-USC Development ProgramsUSA (760C)

Alstom A-USC Development – IEA Workshop-Vienna, AU – Sept. 19-20 2012- P 21

2: Material Properties

4: Fireside Corrosion

4: Fireside Corrosion

5: Welding

6: 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 1400°F (760°C)

U.S. DOE/OCDO: A-USC Steam Boiler Consortium

760oC vs 700oC – USA Rationale

Continuous evolution of steam conditions (historical trend) exploits materials to their maximum capacity.– Nickel alloys can permit steam temperatures to reach 760oC.

Cost of (precipitation strengthened) nickel-based alloys for 760oC applications is predicted to be similar to their weaker (solution strengthened) counterparts for 700oC applications.– More nickel alloy for 760oC, but not more expensive.

Conventional steam generator designs (tower and two pass) and steam turbine design can be configured for 760oC steam temperatures.– Familiar technology but extensive Ni alloy heat exchange surface

Alstom A-USC Development – IEA Workshop-Vienna, AU – Sept. 19-20 2012- P 23

A-USC Steam Turbine Program: Phase I (complete)

Scoping Studies – Downselect MaterialsKey Issues

– Welded rotors materials– Non-welded rotor materials

Oxidation & SPE Studies

(Siemens, ALSTOM)

Task 12.1

Review State of the Art and Identify Candidates

for 760oC Application

(All)

Design & Econ Studies(ALSTOM)

Assistance (Siemens & GE Energy)

Task 12. 5

Rotors, BucketsBolting

Task 12. 3

Non Welded Rotors (GE)

Task 12. 3

Material property data characterization, microstructural and steam oxidation

studies

(ORNL)

Castings (Siemens) Task 12. 4

MechanicalProperties (Siemens)

Task 12. 4

WeldedRotors (Siemens,

Alstom

Task 12. 2

Mechanical Properties of

Materials (GE)

Task 12. 3

Weldability Studies

(Siemens, ALSTOM)Task 12. 2

Mechanical Properties(Siemens,ALSTOM)

Task 12. 2

– Air Casting– Erosion resistance

– Oxidation resistance

Steam Turbine Phase II Work

Using Selected Materials from Phase ITasks

– 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

28

Ⅱ. R&D Proposal

China -R&D Plan of the National 700 USC Technology℃

Biomass co-firing with coal

IEA CCC reports on co-firing

Support mechanisms for co-firing secondary fuels with coalNigel Dong – in progress

Cofiring high ratios of biomass with coal                                               Rohan Fernando, CCC/194, Jan 2012

Co-gasification and indirect cofiring of coal and biomassRohan Fernando, CCC/158, Nov 2009

Cofiring of coal with waste fuelsRohan Fernando, CCC/126, Sept 2007

Fuels for biomass cofiringRohan Fernando, CCC/102, Oct 2005

Co-utilisation of coal and other fuels in cement kilnsIrene Smith, CCC/71, Aug 2003

Experience of indirect cofiring of biomass and coalRohan Fernando, CCC/64, Oct 2002

Prospects for co-utilisation of coal with other fuels - GHG emissions reductionIrene Smith, Katerina Rousaki, CCC/60, May 2002

Experience of cofiring waste with coalRobert Davidson, CCC/15, 2002

Cofiring of coal and wasteJames Ekmann and others, IEACR/90, 1996

Current status of co-firing worldwide

N.B. Data from the Cofiring Database Version 2.0 compiled by © IEA Bioenergy Task32, last updated in 2009

European Union co-firing biomass and coal

Distribution of co-firing plants in Europe

N.B. Data from the Cofiring Database Version 2.0 compiled by © IEA Bioenergy Task32, last updated in 2009

Total:169

installations

European Union incentives

9 Member Countries:

AustriaBelgiumDenmark FinlandGermanyItalyNetherlandsSwedenUnited Kingdom

Categories of mechanisms:

Disincentives for fossil fuels Taxation on GHGs emissions Market viability measures

Feed-in tariff Renewable obligation

Investment/production support

Feed-in tariff dominates in EU:Pass on the cost to end users

Biomass demand - Europe

2009 Renewable Energy Directive commits EU members to increase the share of renewable energy to 20% by 2020

Each EU country has a national Renewable Energy Action Plan (nREAP)

2020 EU targets require additional 40 million odt of solid biomass for electricity and 50 M odt for heating and cooling

In UK, projected demand for woodchips will exceed by 5 times local available supply

The EU to face a deficit of 80-210 Mt of wood across all sectors by 2020.

The Netherlands

plant name size/type biomass cofiring ratio

operational issues

Amercentrale 8 645 MWe/PCC

wood pelletscitrus pellets

20% (mass)

mill capacity

Amercentrale 9 600 MWe, 350 MWth/PCC

‘’ 30% (mass)

‘’

+ gasifier 26 MWe/15 MWth

demolition wood

5% impurities in fuel

Borselle 406 MWe/PCC

cocoa residuepalm kernel

30% fly ash qualityfouling

Gelderland 13 602 MWe/PCC

demolition wood

30% milling issues

Denmark

plant name size/type biomass cofiring ratio

operational issues

Amager 1 80 MWe + 330 dh/PCC

wood pelletsstraw pellets

35-100%35-90%

Studstrup 1 152 MWe/PCC

straw 20% some slagging

Studstrup 3 350 MWe/PCC

straw 20% straw handling

Studstrup 4 350 MWe/PCC

straw 20% scr plugging

Grena 17 MWe/CFB straw 50% Severe corrosion and bed agglomeration

Avedore 2 800 MWth/USC

wood pellets 70-80% Coal ash added to prevent corrosion

United States

plant name size/type biomass cofiring ratio

operational issues

Allen 273 MWe/cyclone

sawdust 20% (mass)

small red. in boiler efficiency

Seward 32 MWe/PCC sawdust 18% (mass)

-

Plant Gadsden

70 MWe/PCC switchgrass 7% (th) Small red. in boiler efficiency

‘’

‘’ wood chips 15% (mass)

mill issues

Drax Power Limited

Drax is a pioneer in biomass direct injection technology

New 500MW co-firing facility is largest in the world

Capacity to co-fire >1.5m tonnes pellets per year

40

Drax Power in UK - 500MW Co-firing Facility

Drax Power Limited

Breaking down the Supply Chain

Planting and Harvesting

Pelletising

Ocean Freight

Transportation Port Loading

Port Discharge

Transportation Storage/ Site Processing Renewable Power

UK Biomass ImportedBiomass

Drax Power Limited42

Biomass Storage

Road storage

Rail storage

Drax Power Limited43

Biomass processing

Processing tower – biomass pellets

are processed into ‘dust’ before injection

into boilers for combustion

Drax Power Limited44

UK Supply Chain Investment – Drax Woodyard

► On site facility to process UK grown energy crops

Fuel delivery , storage and handling

Biomass has much lower bulk densities and heating values than coal → delivery and storage issues

Handling and flow properties more problematical due to fibrous nature of fuel

Biomass biologically active → fuel deterioration → health and safety issues

Milling

Standard coal mills are not ideal for biomass due to fibrous nature of fuel

Co-milling possible up to 5% cofiring ratios

Higher ratios require separate milling– inject into burner itself (Studstrup)– inject into pipework upstream of the burner (Drax)– inject into dedicated biomass burners (Plant

Gadsden)

Slagging, fouling and corrosion

Coal ash contains alumino-silicates, biomass ash contains alkaline species → lower fusion temperatures → increased slagging and fouling

Biomass contains lower ash content than coal

Wood ash contains magnesium → higher fusion temperatures

Torrefaction

Thermochemical process which improves the properties of biomass regarding handling and utilisation

Heating the biomass at 200 – 300 C for 1 hr under reducing conditions

Friable, less fibrous, heating value (19-22 MJ/kg), homogeneous, less prone to degradation

Superior handling, storage and milling properties

“Sustainability issues and public attitudes to biomass co-firing”

An IEA Clean Coal Centre ReportBy Deborah Adams and Rohan Fernando

Draft due soonFinal report January 2013

Life Cycle Assessment (1)

Energy balance – energy inputs:bioenergy output GHG balance – 5-10% that of fossil fuels Other environmental impacts – N-based emissions

from agriculture Carbon pools – above ground, below ground, dead

wood, litter and soil, especially soil organic carbon and land use changes

Timescale of biomass growth – emissions immediate, but can take many years to reabsorb CO2 by tree growth

Life cycle assessment (2)

Land use changes – such as forest to plantation Indirect land use changes – land changes from food

production to bioenergy, and food production goes elsewhere, such as on forestry land

Non-CO2 emissions from soils – N2O from agriculture Agricultural residue removal – can impact soil

organic C turnover Efficient biomass use Efficient land use – should a piece of land be used

for energy crops or C storage?

CLEAN COAL TECHNOLOGY THAT WORKS

The End – Thank you for your attention

John.topper@iea-coal.org www.iea-coal.org