The New Clean Coal Technologies

The New Clean Coal Technologies

Energy Summit:“Advancing Domestic Resources in an Era of Carbon Challenges”

December 4, 2007Stonewall Resort

Roanoke West VirginiaRoanoke, West Virginia

Joseph P. Strakey

National Energy Technology Laboratory

Office of Fossil Energy

Carbon Capture TechnologiesCoal-fired Power PlantsCoal-fired Power Plants

Technology options & examplesPre-combustion (IGCC)Post-combustion (Amine scrubbing, Chilled Ammonia)Oxyfuel combustionOxyfuel combustion

Cost/efficiency comparisons (bituminous coal)New: IGCC, Subcritical PC, Supercritical PCRetrofit

FutureGen, R&D ProgramOb i / l i Observations / conclusions

J. P. Strakey–WV Energy Summit 12/04/07

Examples of Pre-CombustionCO2 Capture Systems2 p y

Coal Gasification to Produce SNGBeulah North Dakota

Petcoke Gasification to Produce H2Coffeyville Kansas


Beulah, North DakotaCoffeyville, Kansas

Source: E.S. Rubin, Carnegie Mellon

Examples of Post-Combustion CO2 Captureat Coal-Fired Power Plantsat Coal Fired Power Plants

AES Shady Point Power PlantCaptures 2-3% of CO2 from a

320MWe CFB plant

AES Warrior Run Power PlantCaptures 10% of CO2 from a205 MWe (gross) CFB plant

C b l d M l d


Panama, Oklahoma Cumberland, Maryland

Source: AES and E.S. Rubin, Carnegie Mellon

Example of Oxyfuel Combustion Capture System

The Vattenfall 30 MWth Oxy-Coal Pilot Boiler with CO2 capture at Schwarze Pumpe (Germany),Schwarze Pumpe (Germany), starting mid-2008


Pilot

Recent NETL Systems Studies

http://www.netl.doe.gov/technologies/carbon seq/Resources/Analysis/


http://www.netl.doe.gov/technologies/carbon_seq/Resources/Analysis/

IGCC Power Plant with CO2 Capture

Emission Controls:PM: Water scrubbing and/or candle filters to get 0.007 lb/MMBtuNO N dil ti t 120 Bt / f LHV t t 15 @15% ONOx: N2 dilution to ~120 Btu/scf LHV to get 15 ppmv @15% O2

SOx: Selexol AGR removal of sulfur to < 28 ppmv H2S in syngasClaus plant with tail gas recycle for ~99.8% overall S recovery

Hg: Activated carbon beds for ~95% removalAdvanced F-Class CC Turbine: 232 MWe

Gross Power (MW)2 Comb. Turbines: 464 MW (total)1 Steam Turbine: 230-275 MW

Advanced F-Class CC Turbine: 232 MWeSteam Conditions: 1800 psig/1000°F/1000°F


PC / Amine Scrubbing -- CO2 Capture Cases

Design Assumptions:

1 90% CO Capture1. 90% CO2 Capture

2. Sulfur polishing step to maintain <10 ppm SO2 into absorber

3. MEA regeneration steam is extracted from the IP/LP crossover pipe


PC / Cryogenic ASU Oxyfuel Combustion

Evaluate:1. Impact 95 versus 99% oxygen purity has on the CO21. Impact 95 versus 99% oxygen purity has on the CO2

purification/compression process

2. Minimum CO2 recycle rate

3. Co-sequestration (CO2/NOx/SOx) feasibility


2

Cost of Electricity Comparison -- New Plants(Baseline Study)

11.8811.4812.00

14.00(Baseline Study)

7.79

10.63

8 00

10.00+36% +86% +81%

6.40 6.336.00

8.00

2.00

4.00

0.00Avg IGCC Avg IGCC w/

CO2 CapturePC-Sub PC-Sub w/

CO2 CapturePC-Super PC-Super w/

CO2 Capture


January 2007 Dollars, Coal cost $1.80/106 Btu

DOE/NETL Report: “Cost and Performance Baseline for Fossil Energy Plants”, May 2007

Efficiency Comparison

50%

60%No CO2 Capture With CO2 Capture

39.5%

44.6%

32.1% 33.0% 32.1%

39.5%40%

sed

on H

HV

27.2%

32.1%28.3% 28.1%

32.1%

20%

30%

ienc

y (%

) bas

10%

20%

Effi

ci

0%C ase 1 SC PC

A ir- f iredC ase 2 U SCPC A ir - f ired

B aseline A vgIGC C

C ase 3 SCPC A ir- f ired

M EA

C ase 4 U SCPC A ir- f ired

M EA

C ase 5 SCPC C ryoOxyf ired

C ase 6 U SCPC C ryoOxyf ired

C ase 7 SCPC IT MOxyf ired

B aseline A vgIGC C

Supercritical (SC): 3,500 Psig/1,110oF/1,150oF (Current state-of-the-art)


Supe c t ca (SC) 3,500 s g/ , 0 / , 50 (Cu e t state o t e a t)

Ultra-supercritical (USC): 4,000 Psig/1,350oF/1,400oF (Advanced Materials Program Target:2015—2020)

Levelized Cost of Electricity Comparison

14

No CO2 Capture With CO2 Capture11.4

11.010.7

11.410.6

11.3

10

12

h

6.3 6.5

7.8

6

8

COE,

¢/k

Wh

2

4

LC

0

2

C ase 1 SC PCA ir- f ired

C ase 2 U SCPC A ir - f ired

B aseline A vgIGC C

C ase 3 SCPC A ir - f ired

C ase 4 U SCPC A ir - f ired

C ase 5 SC PCC ryo

C ase 6 U SCPC C ryo

C ase 7 SC PCITM Oxyf ired

B aseline A vgIGC C


Includes costs for CO2 Transport, Storage, & Monitoring

M EA M EA Oxyf ired Oxyf ired

Calculating CO2 Mitigation Costs

CO2 AvoidedCO2 Avoided(COEcapture – COEbase)

(Emissionsbase – Emissionscapture)Reference

PlantCO2 Avoided

CO2 Captured CapturePlant

2

CO2 Captured

(COEcapture – COEbase)(CO2 Removed)

0 0.2 0.4 0.6 0.8 1

(larger)

tonne CO2/kWh


13

CO2 Capture Mitigation Costs

82 828090

100 % Increase in COE over Case 1 (6.29 ¢/kWh)

$/tonne CO2 Avoided82

7582

71

80 $73

$55$63

$75$67

60

70

80

n C

OE

void

ed

40

50

60

Incr

ease

innn

e C

O2 A

v

10

20

30% I

$/to

n

0

10

Case 3 SC- Air Case 4 USC- Air Case 5 SCCryoASU

Case 6 USCCryoASU

Case 7 SC ITM


*Including CO2 transport, storage and monitoring costs

Raw Water Usage per MWnet Comparison

2225

No CO2 Capture With CO2 Capture

1820

/ M

Wne

t

10

13

1012

10

15

usag

e, g

pm

6

88

5

10

Raw

Wat

er u

0C ase 1 SC PC

A ir- f iredC ase 2 U SCPC A ir- f ired

B aseline A vgIGC C

C ase 3 SCPC A ir- f ired

C ase 4 U SCPC A ir- f ired

C ase 5 SCPC C ryo

C ase 6 U SCPC C ryo

C ase 7 SCPC ITM

B aseline A vgIGC C

R


M EA M EA Oxyf ired Oxyf ired Oxyf ired

rofit Study - Post-Combustion Amine CO2 ScrubbingAEP C ill U it #5 S b iti l 463MW ( )AEP Conesville Unit #5, Subcritical, 463MWe (gross)

CO2 Avoided CostCO2 Avoided Cost

Study Highlights: Efficiency & Capital Cost

Coal-based plants using today’s technology are efficient and clean IGCC & PC: 39% HHV (without capture on bituminous coal)IGCC & PC: 39%, HHV (without capture on bituminous coal) Meet or exceed current environmental requirements Today’s capture technology can remove 90% of CO2,

but at a significant increase in COE and decrease inbut at a significant increase in COE and decrease in efficiency

Total Plant Cost: IGCC ~20% higher than PC capexTotal Plant Cost: IGCC 20% higher than PC capex PC: $1,600/kW (average) IGCC: $1,900/kW (average)

Total Plant Cost with Capture: PC > IGCC capex IGCC: $2,500/kW (average) PC (Amine): $2,900/kW (average)( ) ( g ) PC (Oxyfuel): $2,900/kW

Study Highlights: COE

20 year levelized COE: PC lowest cost option PC: 6.4 ¢/kWh (average) IGCC: 7.8 ¢/kWh (average)

With CCS: IGCC lowest cost option IGCC: 10.6 ¢/kWh (average) PC (Amine): 11.4 ¢/kWh (average) PC (Oxyfuel): 11.3 ¢/kWh

FutureGenFutureGen

orld’s first near zero-emission, full-scale al-based power plant to:

Co-produce electricity & H2from coal with IGCC

al-based power plant to:

Emit virtually no air pollutantsCapture & permanently sequester CO2 (1 million tonnes/yr)Integrate operations at full-Integrate operations at fullscale (275 MWe) – a key step

FutureGen FutureGen ProjectA billion-dollar, 10-year project to create the world’s first coal-based, near-zero emission electricity plant with carbon capture and sequestration Illinois

Industry-led project Twelve leading companies with operations on six

continents

Tuscola

Mattoon

Industry will choose project site & backbone technologies Down-selected to four potential sites

G t i ht d ti i ti OdGovernment oversight and participation United States, China, India, South Korea, Japan, Australia

Odessa Brazos

Texas

Technology Advances Are Starting to Emerge

Post-combustion

Pre-combustionChemical looping

Oxycombustion

CO2 Compression

loopingOTM boilerBiological processes

Ionic liquidsMOFsEnzymaticPBI

Advanced physical

Enzymatic membranesCAR process

PBI membranes Solid sorbentsp y

solventsAdvanced amine solvents

Amine solventsPhysical

Membrane systemsITMs

Physical solventsCryogenic oxygen

20+ yearsPresent 5+ years 10+ years 15+ years

CO2 Compression

20+ yearsPresent 5+ years 10+ years 15+ years

Time to Commercialization

Additional Observations

Technology is available today for carbon capture from new and retrofitted coal-fired IGCC and PC power plants, however:plants, however: It is expensive Parasitic load is high

Reliability needs to be proven Reliability needs to be proven Sequestration needs to be adequately demonstrated,

especially in deep saline reservoirs with large-volume CO injectionCO2 injection

DOE RD&D program is targeting the key issues Lower cost, advanced technology (R&D program) Proving sequestration (sequestration program, Regional

Partnerships) Integration (FutureGen, CCPI)

For Additional InformationNETL

www.netl.doe.govOffice of Fossil Energy

www.fe.doe.govFutureGen Alliance

www.futuregenalliance.org/

Joe Strakey412-386-6124

[email protected]

Documents

The New Clean Coal Technologies