21st Century Coal Power: Recent Developments in Coal Power Generation Technology - Jeffrey Phillips, Electric Power Research Institute (EPRI)

Dr. Jeffrey N. Phillips

Senior Research Manager

Generation Summit

February 25, 2013

21st Century Coal Power Recent Developments in Coal Power Generation Technology

2 © 2013 Electric Power Research Institute, Inc. All rights reserved.

Presentation Outline

• Some fossil power plant basics

• A History Lesson

• 21st Century coal power plants

• What to do about CO2?


Conventional Coal Plant

100 MW

12 MW

88 MW

41.5 MW

46.5 MW

39 % Efficiency (HHV basis)

2.5 MW own use

39 MW


Gas Turbine “simple cycle”

100 MW

35 MW

65 MW

35% Efficiency (HHV basis)


Combined Cycle

100 MW

Fuel

35 MW 17 MW

65 MW

27 MW

21 MW to

condenser

38 MW

17 + 35 = 52 MW

52% Efficiency! (HHV basis)


A History Lesson

(the original Dr. Phillips)


1500

1400

1300

1200

1100

1000

900

800

700

600

500

400

750

700

650

600

550

500

450

400

350

300

250

200

1900 ’10 ’20 ’30 ’40 ’50 ’60 ’70 ’80 ’90 2000 ’10

Year

Tem

pera

ture

, D

eg

rees F

Tem

pera

ture

, D

eg

rees C

Eddystone 1

Philo 6

History of Steam Conditions for Fossil Fired Power Plants

• During 1st 60 years of the

20th century, steam turbine

temperatures rose from

500°F to 1200°F

– Thermal efficiency rose

from 4% to 40% (HHV)

• Eddystone experienced

several materials issues

– Derated from 1200°F to

1140°F

• No improvements for 50+

years! Maximum Steam Turbine Inlet

Temperature History


A Different Story for Gas Turbines! (Note: Pentagon has funded R&D for jet engines for many years)

500

1000

1500

2000

2500

3000

1930 1940 1950 1960 1970 1980 1990 2000 2010

Year

Max. T

urb

ine In

let

Tem

p. (D

eg

F)

Gas Turbines Steam Turbines


Emissions History of US Coal Power Plants (Dates

represent year plant began operating)

0

500

1000

1500

2000

2500

3000

0

10

20

30

40

50

60

70

80

90

1921 1960 2008 NGCC

CO

2, lb

/MW

hr

SO

x &

NO

x,

lb/M

Wh

r

SO2

NOx

CO2

Natural Gas has a natural advantage when it comes to CO2 emissions


US Generation Capacity (Source: U.S. Energy Information

Administration, www.eia.doe.gov)

Most coal power plants in the US are more than 30 years old


21st Century Coal Power Plants


Su

bc

riti

ca

l P

lan

t R

an

ge

Co

mm

erc

ial

Su

pe

rcri

tic

al

Pla

nt

Ran

ge

Ad

va

nc

ed

Ult

ra-

Su

pe

rcri

tic

al

Pla

nt

Ran

ge

2 Percentage Point Efficiency Gain = 5% CO2 Reduction

Su

bc

riti

ca

l P

lan

t R

an

ge

Co

mm

erc

ial

Su

pe

rcri

tic

al

Pla

nt

Ran

ge

Ad

va

nc

ed

Ult

ra-

Su

pe

rcri

tic

al

Pla

nt

Ran

ge

2 Percentage Point Efficiency Gain = 5% CO2 Reduction

Increasing Steam Temperature and Pressure Increases

Thermal Efficiency and Decreases Emissions

Note: HHV Basis

1400°F 1000°F

“Least Regrets” Strategy for CO2 Reduction?


Acknowledgements: U.S. Department of Energy (US DOE)

/ Ohio Coal Development Office (OCDO) A-USC Steam

Boiler and Turbine Consortia


Highlights of the Boiler Consortium Work

IN740 Pipe Extrusion Weld Development

Steamside Oxidation Fireside Corrosion


Major Step: Code Case 2702 (Inconel®740H)

now Approved for Use in Section I

• Approved: Sept. 26, 2011

• Maximum Use Temperature: 800°C (1472°F)

• Rules for:

– Chemistry

– Heat-treatment

– Welding

– Post-weld heat-

treatment

– Cold-forming

– Weld strength reduction

factors

Approved for B31.1 in September 2012


What is gasification?

• Similar to combustion (burning) but with less than half the

amount of oxygen needed to fully burn the coal

• Combustion: excess air

• Gasification: excess fuel (by a lot!!)

• Combustion: produces heat

• Gasification: produces “syngas” and some heat


15MW 79MW

28MW 51MW

47MW

20MW

9MW

Net Coal to Power:

28 + 20 – 9 = 39% (HHV basis)

19MW

100MW

IGCC schematic from US DOE 27 MW


Duke Edwardsport IGCC – In Start-up Phase

• Edwardsport, IN

• 618 MW

• Consumes coal from Indiana

• Uses GE Energy gasification

technology and gas turbines

• Construction Began: March

2008

• First firing of gas turbine on

natural gas: March 2012

• First gasification of coal:

October 2012

Courtesy of Duke Power

EPRI will hold technical meeting & tour here in June 2013


CO2 Capture in Coal Power Systems


CO2 Storage – Main Focus is Injection Into

Geological Formations

• Saline reservoirs

– 100’s of years capacity

– Little experience

• Economical, but lesser

capacity options

– Depleted oil & gas

reservoirs / enhanced oil

recovery

– Unmineable coal

beds/enhanced coal-bed

methane recovery

Courtesy of Peter Cook, CO2CRC


Project Goals

• Construct and operate a 19

km (12 mile) CO2 pipeline that

will transport CO2 from Plant

Barry to the Citronelle Dome in

Alabama USA

• Inject 100,000–300,000

metric tons of CO2 into the

Paluxy Formation (saline)

• Conduct monitoring activities

before (8 mos), during (2 yrs)

and after (3 yrs) injection

• Close out the site

SECARB Transport & Storage Project Overview


• Target reservoir is the Lower Cretaceous Paluxy Formation (2,865 –3,200 m; 9,400–10,500 ft)

• Massive 335 m (1,100 ft) interval of stacked fluvial sands and confining units

• Numerous reservoir seals and confining units above the Paluxy (at least 5)

• Structural dome has proven four-way closure

SECARB Geology Overview

Injection Zone

Confining Zone

Rodessa Formation


CO2 Injection Started 21-Aug-2012

CO2 booster pump at wellhead (maximum

delivery pressure 22.8 MPa (3,300 psig)

• Current CO2 injection rates and wellhead pressures

• 500 tonnes/d (9.64 MMscf/d)

• 9.06 MPa (1,314 psig)

More than 50,000 tons of CO2 already stored

CO2 capture at Plant Barry


Oxy-Combustion Capture of CO2


Oxy-Combustion Overview


27

FutureGen 2.0 Oxy-Combustion w/ CO2 Sequestration

• Meredosia, IL & Morgan Co., IL

• 167 MWe gross oxy-combustion

repowering of Ameren’s Meredosia

Unit 4 steam turbine

• 90% CO2 capture (cryogenic

separation) 1,000,000 tons CO2 /year

• Deep saline sequestration in Mt.

Simon formation ~30 miles east of

power plant

• Total Project: $1.65 Billion

DOE Share: $1.05 Billion

Key Dates

Complete FEED: Sep 2013

Construction: Sep 2014

Commercial Operation: Sept 2017

Status

Phase 1 (Pre-FEED) completed

Initial sequestration site

characterization completed

Phase 2 (NEPA, Design and

Permitting) initiated February 1, 2014


Pre-Combustion Capture of CO2


Dakota Gasification Substitute Natural Gas

(SNG) Production Facility

CO2 to

Enhanced Oil

Recovery

SNG to

pipeline

Gasification & Heat

Recovery

CO2

Production &

Removal Methanation

“Syngas”

H2-rich

syngas

CO2 Pipeline

Supplies natural gas power

plants (approx 1000 MW)

connected to NG pipeline grid Owned by Dakota

Gasification

Lignite

~3 million tons CO2/yr

30

Southern Company Services, Inc. CCPI-2 Advanced IGCC with CO2 Capture

Plant Site Plant Site

Status

Plant construction >50% complete;

>4,000 construction workers on site

CO2 off-take agreements signed

Lignite mine under development

Subsystems (water treatment, cooling

towers) to begin pre-commissioning

Combustion turbine startup: Jul 2013

Gasifier heat-up: Dec 2013

Key Dates

Project Awarded: Jan 30, 2006

Project moved to MS: Dec 5, 2008

NEPA Record of Decision: Aug 19, 2010

Initiate excavation work: Sept 27, 2010

Operations: May 2014

• Kemper County, MS

• 582 MWe (net); 58 MWe duct firing; 2 TRIGTM

gasifiers, 2 Siemens combustion turbines, 1

Toshiba steam turbine

• Fuel: Mississippi lignite

• ~67-69% CO2 capture (Selexol® process);

3,000,000 tons CO2/year

• EOR; Denbury Onshore LLC, Treetop

Midstream Services LLC

• Total DOE Project: $2.01 Billion;

DOE Share: $270 Million (13%)

• Total estimated plant cost: ~ $3 Billion

31


Together…Shaping the Future of Electricity

Business

21st Century Coal Power: Recent Developments in Coal Power Generation Technology - Jeffrey Phillips, Electric Power Research Institute (EPRI)