Coal IGCC forCoal IGCC forHydrogen Production,Hydrogen Production,

COCO22 Recovery and Electricity Recovery and Electricity

Review for theReview for theAspen Global Climate Change InstituteAspen Global Climate Change Institute

July 23July 23rdrd, 2000, 2000by Richard D. Doctor, John Molburg,by Richard D. Doctor, John Molburg,

Norman F. Brockmeier,Norman F. Brockmeier,and and Prakash Prakash ThimmapuramThimmapuram

Project team:Project team:

Richard D. DoctorRichard D. DoctorJohn C. MolburgJohn C. Molburg

Norm F. BrockmeierNorm F. BrockmeierPrakashPrakash R. Thimmapuram R. Thimmapuram

Argonne National LaboratoryArgonne National LaboratoryArgonne, IllinoisArgonne, Illinois

IGCC full-energy cycle analysisIGCC full-energy cycle analysis

IGCC - Study BasisIGCC - Study Basis Both the Shell and Texaco entrained gasifierBoth the Shell and Texaco entrained gasifier

systems are under consideration.systems are under consideration. ShiftShift willl willl need to be integrated into the processneed to be integrated into the process

design which will be modified to produce Hdesign which will be modified to produce H22,,recover COrecover CO22, and produce electricity, and produce electricity

A full-energy cycle analysis will be developedA full-energy cycle analysis will be developedbased on an Aspenbased on an Aspen77 simulation of plant with a simulation of plant with aspecial focus shift, sulfur, COspecial focus shift, sulfur, CO2 2 recovery, PSA for recovery, PSA forhydrogen, and power generationhydrogen, and power generation

Feed will be Illinois #6 coalFeed will be Illinois #6 coal High purity HHigh purity H2 2 sent 100 km by pipelinesent 100 km by pipeline Supercritical-COSupercritical-CO22 sent 500 km by pipeline sent 500 km by pipeline

IGCC - Study BasisIGCC - Study Basis

Linkage to SAIC for LC Advantage Linkage to SAIC for LC Advantage ––Victor Victor GorokhovGorokhov and and MasoodMasood Ramezan Ramezan

Power use in deep-miningPower use in deep-miningIllinois #6 coalIllinois #6 coal

Ancillary

Break and convey

Drilling

Ventillation

Dewatering

Hoisting

MINING

0 2 4 6 8 10 12 14 16

Ancillary

Break and convey

Drilling

Ventillation

Dewatering

Hoisting

MINING

Graph - Mining Electricity (kWh/1,000kg coal)

Graph - Mining Electricity (kWh/1,000kg coal)

Coal methane emission importanceCoal methane emission importanceBryant, E., Climate Bryant, E., Climate Process and changeProcess and change, Cambridge (1997) p.119, Cambridge (1997) p.119

Concentration Warming Life

ppm in 1994 % years

CO2CO2

356.000 1 63.8 55

CH4CH4

1.725 56 19.2 14

N2O N2O

0.311 280 5.7 120

Diesel-rail fuel efficiencyDiesel-rail fuel efficiencychanges with grades and curveschanges with grades and curvesStodolskyStodolsky, F., et al., 3rd Total Life-cycle Conf.,, F., et al., 3rd Total Life-cycle Conf., Graz Graz, Austria (Dec. 1998), Austria (Dec. 1998)

Greenhouse gas emissions beforeGasification plant

TRANSPORT - #2 diesel:161kmround trip

COAL PREPARATION 2x4"

MINING

0 500 1000 1500 2000 2500 3000

TRANSPORT - #2 diesel:161kmround trip

COAL PREPARATION 2x4"

MINING

N2O gm/hCH4 kg/hCO2 kg/h

Conclusions: Mining & transportConclusions: Mining & transport

Coal bed methane is an importantCoal bed methane is an importantuncontrolled emissionuncontrolled emission

Diesel rail transport emissions of NDiesel rail transport emissions of N22O areO areless than 10% of typical values for Illinoisless than 10% of typical values for Illinois

Regulations for diesel fuel are reducingRegulations for diesel fuel are reducingsulfur - hence Nsulfur - hence N22O from diesel should beO from diesel should belower in the futurelower in the future

IGCC with COIGCC with CO22 and H and H22 recovery recovery

Major material flows forGasification plant

Coal

O2

Solid waste

Sulfur

SO2

CO2 (143 bar)

H2 (31 bar)

-16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6

Coal

O2

Solid waste

Sulfur

SO2

CO2 (143 bar)

H2 (31 bar)

10**4 kg/h

10**6 nm**3/d

Shift precedes HShift precedes H22S removal toS removal toyeildyeild a high-H a high-H22 synthesis gas synthesis gas

GylcolGylcol recovery of H recovery of H22S toS toClaus-SCOT tail gas for sulfurClaus-SCOT tail gas for sulfur

GylcolGylcol CO CO22 recovery to recovery tosupercritical compression 143barsupercritical compression 143bar

Pressure-swing adsorption (PSA)Pressure-swing adsorption (PSA)for Hfor H22 purification to 99.999% purification to 99.999%

Power balance forGasification plant excluding H2

Coal preparation

O2

Gasifier island

Glycol H2S/CO2

Power recovery

CO2 to 143 bar

H2 to 31 bar

H2 storage

Power island

Miscellaneous (5%)

Turbine air

Gas turbine

Steam turbine

NET POWER

-200 -150 -100 -50 0 50 100 150 200 250

Coal preparation

O2

Gasifier island

Glycol H2S/CO2

Power recovery

CO2 to 143 bar

H2 to 31 bar

H2 storage

Power island

Miscellaneous (5%)

Turbine air

Gas turbine

Steam turbine

NET POWER

MW

Hydrogen and electricity fromGasification plant

In-Plant use

Gross Power

H2 Equivalent

-300 -200 -100 0 100 200 300 400 500

In-Plant use

Gross Power

H2 Equivalent

MW

COCO22 supercritical pipelines are supercritical pipelines arecurrently operated for EORcurrently operated for EOR

COCO2 2 for Enhanced Oil Recoveryfor Enhanced Oil Recovery

Purity: Not critical, dry, H2S benefits EORbut should be limited

Production still to be set Shipment: 500 km; 330 mm pipe at 143 bar Capacity factor: 95% Capital recovery: 12% Transmission linked to CO2 infrastructure

HH22 pipelines use lower pressures pipelines use lower pressures& shorter runs than natural gas& shorter runs than natural gas

Hydrogen productHydrogen product

Purity: HPurity: H22 at 99.999%, 119.9 KJ/g (LHV) at 99.999%, 119.9 KJ/g (LHV) Production go for high purity product andProduction go for high purity product and

send send blowdownblowdown to turbines to turbines Shipment: 100 km; 343 mm pipe at 30 barShipment: 100 km; 343 mm pipe at 30 bar Capacity factor: 95%Capacity factor: 95% Capital recovery: 12%Capital recovery: 12% Transmission: 0.171 $/10Transmission: 0.171 $/1033 scfscf; 0.564 $/GJ; 0.564 $/GJ

Advanced HAdvanced H22 Turbine Cycle Turbine CycleBannister, R.L., Bannister, R.L., J.Eng. of Gas Turbines and PowerJ.Eng. of Gas Turbines and Power, ASME, 120:276, Apr.1998, ASME, 120:276, Apr.1998

High-efficiency HHigh-efficiency H22 turbine goals turbine goalsBannister, R.L., Bannister, R.L., J.Eng. of Gas Turbines and PowerJ.Eng. of Gas Turbines and Power, ASME, 120:276, Apr.1998, ASME, 120:276, Apr.1998

OO22 from pressure vacuum swing from pressure vacuum swingabsorptionabsorption SelinSelin, R.,, R., ScandanavianScandanavian J. of Metallurgy J. of Metallurgy, 27:88 (1998), 27:88 (1998)

Electricity: OElectricity: O22-blown KRW IGCC-blown KRW IGCCall values for full-energy cycleall values for full-energy cycle

No CONo CO22 recovery: recovery: 396-MW full-cycle at 0.83 kgCO396-MW full-cycle at 0.83 kgCO22/kWh/kWh

With COWith CO22 recovery: recovery:366-MW full-cycle at 0.20 kgCO366-MW full-cycle at 0.20 kgCO22/kWh/kWh

With COWith CO22 and H and H22 recovery to fuel cells: recovery to fuel cells:•• 344-MW full-cycle at 0.22 kgCO344-MW full-cycle at 0.22 kgCO22/kWh/kWh

52-MW52-MW busbar busbar and 298-MW solid-oxide FC and 298-MW solid-oxide FC•• 377-MW full-cycle at 0.20 kgCO377-MW full-cycle at 0.20 kgCO22/kWh/kWh

52-MW52-MW busbar busbar and 332-MW alkaline FC and 332-MW alkaline FC

Equivalent COEquivalent CO22 greenhouse greenhouseemissions 396 MW net-cycleemissions 396 MW net-cycle

Base Case - no CO2recovery

Glycol CO2 and H2Srecovery

PSA H2 to solid oxidefuel cell

PSA H2 to alkaline fuelcells

PSA H2 to hydrogenturbine

0 50 100 150 200 250 300 350 400

Base Case - no CO2recovery

Glycol CO2 and H2Srecovery

PSA H2 to solid oxidefuel cell

PSA H2 to alkaline fuelcells

PSA H2 to hydrogenturbine

Make-up power - Equivalent CO2 Emissions1,000 kg/hPlant - Equivalent CO2 Emissions 1,000 kg/h

Total Power MW

Conclusions: IGCC plantConclusions: IGCC plant

COCO22 as a supercritical product (143 bar) can be as a supercritical product (143 bar) can berecovered from coal gasification. Where there isrecovered from coal gasification. Where there isan Enhanced Oil Recovery market, this isan Enhanced Oil Recovery market, this iseconomical. The need for high pipeline-utilizationeconomical. The need for high pipeline-utilizationis critical.is critical.

Hydrogen can be recovered at high purityHydrogen can be recovered at high purity(99.999%) for sale from coal gasification, the need(99.999%) for sale from coal gasification, the needfor high pipeline-utilization is critical. Pressuresfor high pipeline-utilization is critical. Pressuresof 35 bar are optimal.of 35 bar are optimal.

Status Status –– June 2000 June 2000

ASPEN 10.1 upgrade on IGCC programs isASPEN 10.1 upgrade on IGCC programs isnow operationalnow operational

Linkage with SAIC has been establishedLinkage with SAIC has been established Linkage with Equation of State modelingLinkage with Equation of State modeling

community for ASPEN has been establishedcommunity for ASPEN has been established Process economics will be treated in a moreProcess economics will be treated in a more

detailed mannerdetailed manner Optimization of Shift integration has begunOptimization of Shift integration has begun

Conclusions: HConclusions: H22 use use

Conversion efficiencies need to approachConversion efficiencies need to approach77% to match the Base Case output:77% to match the Base Case output:•• Solid-oxide fuel cell efficiencies are 53-58%Solid-oxide fuel cell efficiencies are 53-58%•• Alkaline fuel cell efficiencies near 70%Alkaline fuel cell efficiencies near 70%

Hydrogen can be delivered as a commodityHydrogen can be delivered as a commodity