Life Cycle Analysis of Coal and Natural Gas-fired Power Plants

Life Cycle Analysis of Coal and

Natural Gas-fired Power Plants

Phil DiPietro

U.S. DOE, National Energy Technology Laboratory

Presented to EPRI Coal Fleet July 20, 2010

Attachment A.ANR:VGS.RTP.3-1i

VGS013315

NATIONAL ENE,GY TECHNOLOGY LA30?ATOVY 2

MISSION

Advancing energy options to fuel our economy,

strengthen our security and improve our

environment

National Energy Technology Laboratory

Pittsburgh, PA

Morgantown,

WV

Fairbanks, AK

Sugar Land,

TX

West VirginiaPennsylvaniaOregon

Albany,

OR

VGS013316

I

I I

NATIONAL ENE,GY TECHNOLOGY LA3CRATOVY 3

NETL FY 2010 Budget ($M)

FY10

AppropriationFY11 Request

FE Coal R&D 407.4 402.3

CCPI/FutureGen 643.0 0.0

FE Oil & Gas R&D 87.8 0.0

FE Program Direction 125.2 120.4

Plant & Capital Equip. 20.0 20.0

Envir. Restoration 9.9 9.9

FE Earmarks 36.9 0.0

EERE R&D 425.0 430.0

OE 81.0 97.0

Other-DOE 5.0 6.0

Non-DOE/WFO 29.0 25.0

NETL Total 1,870.2 1,110.6

PMC (Golden/NREL) 950.0 850.0

TOTAL 2,820.2 1,960.6

VGS013317


Context

On April 13, 2010, representatives from EPRI and NETL

met at the Pittsburgh Marriott to discuss collaborations

between the two entities.

The purpose of this presentation is to share

information with EPRI and look for ways to follow up.

NETL became interested in full life cycle analysis when

considering liquid fuels and biomass co-firing, will

soon publish LCA documents on power platforms.

VGS013318


Life Cycle Assessment

Compilation and evaluation of the inputs, outputs and the

potential environmental impacts of a product or process

throughout its life cycle, from raw material acquisition to

the final disposal

LC Stage #1

Raw Material Acquisition

(RMA)

LC Stage #2

Raw Material Transport

(RMT)

LC Stage #3

Energy Conversion

Facility

(ECF)

LC Stage #4

Product Transport

(PT)

LC Stage #5

End Use

Upstream Emissions Downstream Emissions

VGS013319


Why LCA? #1

• Upstream greenhouse gas emissions factors

(kg CO2e/MMbtu @ plant gate)

– Subbituminous coal 1.2

– Domestic crude oil 4.9

– Lignite coal 5.2

– Bituminous coal 9.2

– Imported crude oil 11.0

– Corn Stover 20.0

– Oil Sands, Canada 21.0

– Natural gas 23.2

– Switch Grass 27.0

– LNG (Trinidad) 39.9

Coal has favorable

upstream GHG

emissions compared to

other fuels

VGS013320


797

103

948

218

0

100

200

300

400

500

600

700

800

900

1000

IGCC IGCC/CCS

Glo

bal

War

min

g P

ote

nti

al(k

g C

O2e

/MW

H)

Combustion Only (Busbar) Total Life Cycle

Why LCA? #2

Non-combustion emissions

become more significant after

CCS is applied

VGS013321


Why LCA? #3

• Life Cycle Analysis establishes a platform for talking

about embodied GHG emissions and trade impacts

– Heavy crudes versus enhanced oil recovery

– LNG versus shale gas

– Imported manufactured goods due to higher energy

prices

VGS013322


Why Not LCA?

• Two of the non-intuitive things that LCA gets right

are not significant in fossil power pathways

– Cost of construction and decommissioning

– Nuances of allocating interventions among by-

products

• Differences between apples and oranges (farms and

coal mines) can get lost in the LCA structure, no way

to combine disparate interventions

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Five Baseload Power Plant Technologies

Evaluated with and without CCS

• Coal Cases

– Integrated Gasification Combined Cycle (IGCC)

– Super-Critical Pulverized Coal (SCPC)

– Existing Sub-Critical Pulverized Coal (EXPC)

• Natural Gas Cases

– Combined Cycle with Liquefied Gas (NGCC-LNG)

– Combined Cycle with Domestic (NGCC)

VGS013324


Major Data Sources

• Power LCA Builds Upon the Following NETL Techno-

economic Analysis Studies:

– Cost and Performance Baseline for Fossil Energy

Plants; Volume I (Bituminous Coal and Natural Gas to

Electricity); May 2007

– Carbon Dioxide Capture from Existing Coal-Fired

Power Plants; November 2007

VGS013325

• • • •


Full Life Cycle GHG Emissions

-

200

400

600

800

1,000

1,200

NG

CC

NG

CC

-LN

G

SCP

C

IGC

C

EXP

C

NG

CC

NG

CC

-LN

G

SCP

C

IGC

C

EXP

C

No CCS CCS

Full

Life

Cyc

le G

HG

Em

issi

on

s (k

g C

O2e

/MW

h)

Raw Materials Acquisition Raw Material Transport

Energy Conversion Facility Product Transport (T&D)

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Full Life Cycle and Combustion Only GHG

Emissions

797

103

948

218

0

100

200

300

400

500

600

700

800

900

1000

IGCC IGCC/CCS

Glo

bal

War

min

g P

ote

nti

al(k

g C

O2e

/MW

H)


VGS013327


Factors Driving the Difference Between

Combustion-only GHG Emissions and LCA

IGCC/CCS Case

GWP SourceContribution to the delta Assumptions

Coal Mine Methane 65.3% 360 scf CH4/ton coal (Illinois No. 6)

Train Transport 13.1% 1,200 miles (Ill to Mississippi), 328 BTU/ton-mile

T&D Losses 6.8% 7% resistive loss

CO2 Storage Leaks 5.7% 1% over 100 years

CO2 Pipeline Leaks 2.8% 0.5% per 100 miles

Coal Mining 2.7% 33 kWh electricity per ton coal mined

SF6 emissions 2.5%4 transformers, 690 lbs of fluid/transformer,0.1% loss/year

Plant Const. & Decomm.

1.0%Decommissioning emissions are 10% of construction emissions

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Stage #1: Raw Material Acquisition

Coal ExtractionOperation Mine Decommissioning

Stage #3:Energy Conversion Facility With CCS System Construction Installation Plant Construction/

Installation 1

Plant Operation >-10. Carbon Capture (CC),

Operation

fi r Plant

Decommissioning

-111.• CO2 Pipeline, Operation -111' CO2 Sequestration,

Operation

• • • Deinstallation •

Stage #2:Raw Material Transport

Train Operation Train & Rail

Manufacturing

Stage #4:Product Transport

Transmission & Distribution, Operation

End Use

Mine Constructions

NATIONAL ENE,GY TECHNOLOGY LA3CRATCRY 15

LCA’s Expanded Boundary for IGCC

Traditional

Power

Study

Boundary

LCA study boundary

extends from extraction of

raw materials from the

earth (e.g., coal mining)

thru delivery of the power

to the end customer.

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Train & Rail Manufacturing

Train Operation

Deinsta I lation

Plant Decommissioning

ge #2:Raw Material Transport

'Stage #3:Energy Conversion Facility

Plant Construction/ Installation

Plant Operation

rWFth CCS System

Carbon Capture (CC), Operation

Construction & Installation

-*COQ Pipeline, Operation CO2 Sequestration,

Operation

I-Stage #4:Product Transport

Transm ssion & Distribution, Operation

Mine Constructions 1Coal Extraction Operation

ic

(Stage #1: Raw Material Acquisition

Mine Decommissioning

End Use


Coal Mining is a Critical Source of Emissions

in a CCS System

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cast iron zinc

V Longwall Mining System,

Con struction • Hydraulic Shield, 28.2 Tons, 2

Meter • line Pan, 2.5 Tom • Electric Head Drive, 65 Tons • Electric Tail Drive, 45 Tons • I K —ectr.c Shearer, 62.5 Tons • Electric Stage Loader, 90 Tons

Illinois No. 6 Underground Coal Mine System, Construction

• Continuous Miner, 755 HP .• Conveyor System, 48 Inch •• Shuttle Car, 95 Horsepower

V

Buildings and Pavement for

Illinois No. 6 Coal Mine, Construction

Commissioning/ Decommissioning

water

asphalt) (rubber steel

✓ T V V

Coal Preparation Facility for Illinois No. 6 Coal Mine, Construction

Steel Coal Loading Silo, 325 Tons Coal Stockpile Stacker, 450 Tonnes Coal Crusher, 25400016 Coal Cleaning Facility Wastewater Treatment Plant, Underground Coal Mine

■

Illinois No. 6 Underground Bituminous Coal Mine Construction

Illinois No, 6 Underground Bituminous Coal

Mine Operation

coal


Detail of Illinois No. 6 Coal Acquisition Processes

VGS013331

tb fb. 0 \ \ ' 'c\ \

ric Ic Ic ' ts\OC% 1 . 03 •SO •00 \-.

,_<2716 • & Ov ,,S% A‘9'c

i

NV .r _ ‘ e,c 7 .e • •c• ns; _c,G)

6A- \c\ • \)..\cf6 ,zo \,,

N Q9 N?

1?0 0.<7 • 'C.•

•

MC; NATIONAL ENE,GY TECHNOLOGY LA30?ATOVY 18

Methane Content by Coal Origin

242

342 344379

445

360

0

100

200

300

400

500

Co

al C

H4

Co

nte

nt

(scf

/to

n)

VGS013332

• •


NGCC-LNG Global Warming Potential

362

42

524

206

0

100

200

300

400

500

600

NGCC-LNG NGCC-LNG/CCS

Glo

bal

War

min

g P

ote

nti

al(k

g C

O2e

/MW

h)


VGS013333


Factors Affecting the Difference Between Combustion

and Full Life Cycle Emissions, NGCC-LNG

NGCC-LNG/CCS Case

GWP Source Contribution Assumptions

Liquefaction 44.3%Port Fortin, Trinidad; uses 23% of incoming NG for liquefaction

Drilling Operation 19.6% Offshore gas-only well

Regasification 12.4% Via combustion of a portion of the NG

Tanker Operation 8.8% Boil-off rate: 0.15%/day to, 0.10%/day return

Natural gas pipeline 7.5% 334.6 km, 0% loss factor assumed

Power T&D Losses 2.1% “Make-up power” for 7% Transmission & Distribution Loss

Substation SF6 2.0% 4 transformers, 690 lbs of fluid/transformer, 0.1% loss/year

CO2 Storage Leak 2.0% 1% over 100 years

CO2 Pipeline Operation 1.0% 0.5% per 100 miles

Plant Const. & Decomm. 0.3%Decommissioning emissions are 10% of construction emissions

VGS013334

It a 23 ice

MC; NATIONAL ENE,GY TECHNOLOGY LA30?ATOVY 21

NG Consumed or Lost for LNG process

Nature

LC Stage #1

NG Extraction + Pipeline

LC Stage #1

NG Lique-faction

LC Stage #2

LNG Water Tanker

Transport

LC Stage #2

LNG Water Tanker

Docking

LC Stage #2

NG Regasific

ation

LC Stage #2

Pipeline Delivery to NGCC

LC Stage

#3

• 1.3 kg of gas extracted for every 1 kg delivered

– 0.29 kg (22%) consumed as fuel

– 0.008 kg (1%) lost to atmosphereVGS013335

h 1

• •

M

MC; NATIONAL ENE,GY TECHNOLOGY LA3CRATOVY 22

Power LCA Study Results:

Criteria Air Pollutants (NOX)

0.0

0.5

1.0

1.5

2.0

2.5w

o/C

CS

w/C

CS

wo

/CC

S

w/C

CS

wo

/CC

S

w/C

CS

wo

/CC

S

w/C

CS

wo

/CC

S

w/C

CS

IGCC NGCC-LNG NGCC SCPC EXPC

Life

Cyc

le N

Ox

(kg/

MW

h)

RMA RMT ECF

VGS013336


Ranked Results

• By assigning ranks in each of 3 major categories for

each generation type, there are no clear winners, and

lots of tradeoffs

Ranks

GWP LCOECapital

Cost

No CCS

IGCC 9 5 8

NGCC-LNG 7 3 2

NGCC 6 3 2

SCPC 8 2 6

EXPC 10 1* 1*

With CCS

IGCC 3 9 9

NGCC-LNG 2 7 4

NGCC 1 7 4

SCPC 5 10 10

EXPC 4 6* 7*

* These ranks are based on the incremental cost of adding decommissioning and CCS with

replacement power to and existing plant.

VGS013337

• • ■

x

0 NATIONAL ENE,GY TECHNOLOGY LA30?ATOVY 24

Cost of Power vs. LC GWP Performance

IGCC

NGCC-LNG NGCC

SCPC

EXPC

EXPC/CCS

IGCC/CCS NGCC-LNG/CCS

NGCC/CCS

SCPC/CCS

$0.00

$0.02

$0.04

$0.06

$0.08

$0.10

$0.12

0 200 400 600 800 1,000 1,200

LCO

E ($

/kW

h)

Life Cycle Global Warming Potential (kg CO2e/MWh)

VGS013338


Power LCA Study Results

CaseNameplate

Capacity (MW)

Capacity Factor

Capital Cost

($/kW)

LCOE(Mills/kWh)

Criteria Air Pollutants(kg/MWh)

Water Use(liters/MWh) GWP

(kg CO2e /MWh)NOx SOx PM Withdrawal Consumption

IGCC 640 80% $2,106 77.4 0.28 0.08 0.08 1,694 1,107 948

IGCC/CCS 556 80% $2,911 104.0 0.29 0.08 0.09 2,203 1,366 218

NGCC-LNG 560 85% $712 68.3 0.44 0.20 0.01 1,136 908 524

NGCC-LNG/CCS 482 85% $1,547 97.2 0.51 0.23 0.01 2,031 1,596 206

NGCC 560 85% $712 68.3 0.56 0.004 0.004 1,132 819 419

NGCC/CCS 482 85% $1,547 97.2 0.65 0.005 0.005 2,027 1,493 84

SCPC 550 85% $1,853 65.1 0.31 0.38 0.06 2,570 1,688 943

SCPC/CCS 546 85% $3,469 115.1 0.45 0.03 0.09 4,895 3,366 248

EXPC 430 85% $196 27.7 2.06 2.38 0.70 3,079 2,003 1,109

EXPC/CCS + RP 430 85% $2,020 125.3 0.46 1.31 0.02 6,038 3,407 444

EXPC/CCS 336 85% $2,020 88.7 0.03 0.03 0.03 5,343 4,086 296

VGS013339


Upstream Emissions: kg CO2e/MMBtu Fuel

Coal Crude Oil Natural Gas BiomassB

itu

min

ou

s (I

ll #6

) U

nd

ergr

ou

nd

Min

e

Sub

-Bit

um

ino

us

Surf

ace

Min

e

Lign

ite

U

nd

ergr

ou

nd

Min

e

Imp

ort

D

rilli

ng

Do

me

stic

D

rilli

ng

Oil

San

ds

Surf

ace

Min

e

Do

me

stic

D

rilli

ng

LNG

(Tr

inid

ad)

Off

sho

re D

rilli

ng

Co

rn G

rain

Fa

rm H

arve

st

Co

rn S

tove

r Fa

rm H

arve

st

Swit

chgr

ass

Farm

Har

vest

SRW

C

Pla

nta

tio

n H

arve

st

Material Acquisition

7.69 0.824 4.66 9.2 4.2 20.0 19.9 27.2 23.9 19.7 26.7 32.4

Transport Method

Unit Train PipelinePipelin

eTanker, Pipeline

Truck

Material Transport

1.46 0.373 0.492 1.8 0.7 1.0 3.3 12.7 0.182 0.304 0.377 0.133

Total Upstream

9.2 1.20 5.2 11.0 4.9 21.0 23.2 39.9 24.1 20.0 27.1 32.5

VGS013340


Contact Information

Timothy SkoneLead General Engineer

Situational Analysis & Benefits(412) 386-4495

[email protected]

Robert JamesGeneral Engineer

Situational Analysis & Benefits(304) 285-4309

[email protected]

Joe Marriott, PhDAssociate

Booz Allen Hamilton(412) 928-4700

[email protected]

VGS013341

Documents

Life Cycle Analysis of Coal and Natural Gas-fired Power Plants