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
[email protected] www.iea-coal.org