Transcript Document 7197349

Clean Coal Combustion:
Meeting the Challenge of
Environmental and Carbon
Constraints
A.R. Ericson
Our Vision for New Coal Power
Portfolio of Clean Technologies
Near-zero emissions
O2
Oxygen Fired CFB
or PC
COMPLETE
COMBUSTION
PC
Concentrated
CO2
Postcombustion
capture
USC PC
Air
USC CFB
CFB
CHEMICAL
LOOPING
CO2
Scrubbing
PARTIAL
COMBUSTION
CO22
Carbonate
looping
COAL
Carbon
Free
Power
CO22
CO2 Capture
And
Sequestration
CO22
PETROCHEMICAL
O2
IGCC
water shift
H2
H2 GT
Air
IGCC
2
AIR BLOWN IGCC
Fuel Cell
3
Presentation Roadmap
Outlook for New Ultra Clean Coal Capacity
3

Market Realities

Environmental Performance – Mission Critical

Advanced Cycle Designs

Coal Generation in a Carbon Constrained World
Drivers for New Capacity
North America
Our economies continue to drive
electricity demand growth
Source: NERC 2006 Long Term
Reliability Assessment
4
Existing US Coal Fleet
Expanding output to meet demand
74
72
70
68
66
64
62
60
58
56
54
1994
5
1995
1996
1997
1998
1999 2000
Year
2001
2002
2003
2004
2005
Capacity Factor %
Equivalent to 45 GW of new coal capacity
Drivers for New Coal Build
North America

9
Natural Gas
8
 Base load demand expected to
increase at roughly GDP
Steam Coal
US$/MM BTU
7
6

Economics
 Fuel Cost
 End User price shocks driving
demand for low cost energy

Coal availability and prevalence
5
4
3
2
 200+ Years of Reserves in North
America
1
2014
2012
2010
2008
2006
2004
2002
2000
1998
0

Advent of OTC (over the counter)
markets for coal and emissions

Environmental regulations drive new
clean plants

Fuel diversity
Delivered Price
Source: U.S. EIA
6
Base Energy needs versus Peaking
Capacity
New Coal Capacity
Faces Challenges
 Economics
 Utilization of all low cost domestic coals …and opportunity fuels
 Competitive costs
 Operations
 Highest reliability and commercial availability
 Operating parameters to meet demands of grid
Environmental
 Near zero emissions …
 and a carbon strategy
7
Meeting the Goals for
Coal Based Power - Emissions
8
Operating Coal Combustion –
Best in Class Emissions
2005 Wtg. Avg SO2 Emissions - US Coal Units
0.08
0.07
Top 20 - Lowest SOx emitters
Lbs/MMBtu
0.06
0.05
0.04
PC and CFB
Clean Coal technologies have
demonstrated the
lowest emissions :
0.03
0.02
 Exceed Requirements
0.01
 Cost Effectively
 Reliably
0
Lbs/MMBtu
2005 Wtd Avg NOx Emissions - US Coal Units
9
0.08
0.07
0.06
0.05
0.04
0.03
0.02
0.01
0.00
Top 20 - Lowest NOx emitters
Bit. PC
SubBit. PC
CFB
IGCC (operating)
Source: Energy Velocity database ( EPA CEMS 2005 data )
Ultra Clean Coal Combustion
Emissions Control Capability

Today’s state-of-the-art
 NOx >95% reduction with optimized firing systems and SCR

SO2 >99% capture with Wet FGD and DBA

Particulates 99.99% capture
Hg 80- 95% capture (coal dependent)


Next steps
 Continued improvements



10
Integrated Multi-pollutant systems to reduce costs
High Hg capture on all coals (without reliance on ACI)
Introduction of CO2 capture
11
Karlshamn Power Plant
Unit 3
 Power
capacity:
3 x 340 MW
 Fuel:
Heavy fuel oil
(max. 3.5% S)
12
FLOWPAC
Karlshamm Performance Levels
Sulfur Content in the Fuel: 2.5%
Inlet Gas Conditions (at ESP outlet)
English
Metric
Flue Gas Flow
~ 870,000 acfm
1,080,000 Nm3/hr
Flue Gas Temp
270°F
130°C
Particulate Matter (PM)
0.025 lb/MMBTU
30 mg/Nm3
Outlet Gas Conditions (at stack)
13
SO2
(>99% w/ no additives)
< 19 ppmv
< 55 mg/Nm3
SO3
(~70% removal)
< 1 ppmv
< 2 mg/Nm3
PM
(>60% removal -oil soot)
< 0.01 lb/MMBTU
< 2 mg/Nm3
When Additional Control is Needed Mercury Capture Technologies
Additives:
 Halogen(s)
 Powdered Activated Carbon
 Halogenated Powdered Activated
Carbon
14
= Potential additive injection
points
Multi-pollutant
APC Systems
 Integrated APC systems based around commercially
proven and reliable technologies
 Use readily available reagents
 Produces reusable byproduct(s)
– No impact on fly ash
 Superior cost/performance ratio:
– Extremely compact design
 Reduces capital costs for equipment, erection
and BOP
– Fewer moving parts reduces maintenance costs
– Superior environmental performance
 Reduced permitting schedule/cost
 Avoided cost for SO2 credits
 Targeted emissions levels:
– SO2: 0.02 lb/MMBTU (> 99.5%)
– Hg: 1.0 lb/TBTU (> 90%)
– PM: 0.01 lb/MMBTU (99.99%)
– NOx: 0.05 lb/MMBTU w/SCR
• “Polishing” (Level TBD) w/o SCR
15
Controls SOx, PM10/PM2.5 Mercury & NOx
Meeting the Challenge Advanced Cycles
16
Increased Value for Efficiency
500 MW Unit
Efficiency
16
14
12
10
8
6
4
2
0
~$10M/yr
42%
~$6.5M/yr
40%
38%
36%
20
25
30
35
40
45
50
Coal Price USD/Short Ton
Compared to 34% subcritical efficiency, 11,000 BTU/lb coal, 80% capacity factor
17
Efficiency –
Critical to emissions strategy
Source: National Coal Council
From EPRI study
100% Coal
Coal w/ 10%
co-firingbiomass
Commercial
Supercritical
Existing US coal
fleet @ avg 33%
18
Net Plant Efficiency (HHV), %
Clear Trend to Supercritical
for Global Steam Power
Worldwide orders for new coal generation
Supercritical PC
Subcritical PC
CFB
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
2000
19
2001
2002
2003
2004
2005
Clear Trend to Advanced
Supercritical Cycles
147 GW, 230 Supercritical Coal Fired Boilers Ordered Since 1990
GW
80
Number of Units
120
70
100
60
80
50
40
60
30
40
20
20
10
0
0
< 1050 F
or
unknown
1050 F 1110 F
> = 1110 F
Maximum of SH or RH Temp
20
< 1050 F
or
unknown
1050 F 1110 F
> = 1110 F
Maximum of SH or RH Temp
Supercritical
Flexible for power grid needs
Operating Performance
Turndown – Supercritical PC/CFB units have
– Flexibility to rapidly change load
– Turndown to lower minimum loads during off peak
– Maintain efficiency when operating at part loads
Excellent startup ramp rates to meet grid demand
250
Supercritical
Drum
200
after 2 hr shutdown
 Warm Start Up,
150
after 8 hr shutdown
100
 Cold Start Up,
50
after 36 hr shutdown
0
21
 Hot Start Up,
First Fire to Turbine Synch, Minute with Bypass System
Progression of Plant Efficiency via Advanced Steam
Conditions and Plant Designs
TARGET
48 - 50 %
US-DOE :Ultra-Supercritical Boiler Project
38-41%
Operating Target: 1400°F/5500 psig
41%- 43%
Up to
5400/1300/1325(psi/°F/°F)
37-38
European
Thermie Project
35-37%
-Efficiency (net) HHV
Operating Target:3480/1005/1050
1292°F/ (psi/°F/°F)
4500 psig 4000/1075/1110
-Typical Steam Parameters
(psi/°F/°F)
2400/1005/1005
167/540/540
Subcritical
Technology
Sliding
Mature
Pressure
Supercritical Supercritical
Material Development
22
1980
4000/1110/1150(psi/°F/°F)
UltraSupercritical
Commercial
State of Art
Supercritical
Ni-based
Materials
T91
1960
Advanced USC
Advanced
Austenitic
Materials
2000
2010
2020
Plant Efficiency % (HHV Basis)
Meeting the Goals for
Coal Based Power - Efficiency
23
50
40
30
20
10
0
POLK/WABASH
IGCC
Target for New
IGCC*
SCPC Today
USC Target
Next Gen IGCC
Meeting the Challenge
CO2 Reduction
24
CO2 Mitigation Options –
for Coal Based Power
Increase efficiency
Maximize MWs per lb of carbon processed
Fuel switch with biomass
Partial replacement of fossil fuels =
proportional reduction in CO2
Then, and only then ….Capture remaining CO2
for EOR/Sequestration
= Logical path to lowest cost of carbon reduction
25
CO2 Capture
Innovative options continue to emerge and develop



26
Post Combustion Capture
 Adsorption
 Absorption
 Hydrate based
 Cryogenics / Refrigeration based
Oxy-fuel Firing
 External oxygen supply
 integrated membrane-based
 Oxygen carriers (chemical looping)
Decarbonization
 reforming (fuel decarbonization)
 carbonate reactions (combustion decarbonization)
Amine-Based Absorption - CO2 Capture
MEA
CO2 Compressor
M
MEA CO2
Absorber
Stripper
CO2
liquid
SHADY POINT, OKLAHOMA, USA
An AES CFB power plant with
MEA CO2 separation
Steam Turbine
Boiler
G
27

MEA has demonstrated performance on coal based flue gas

Work required to address:

Regeneration power

Compression ratio

Cost of solvent
Advancements
Absorption Stripping CO2 Capture
Amine scrubbing continues to develop

Ionic Liquids “designer solvents”

“Piperazine” - alternative solvent
Process integration and improvement has driven cost down from 70
to 40-50 $/ton CO2 --- further progress expected

With
industry focus on improvements, advanced amines likely to
be competitive solution for post combustion capture
28
CO2 Capture Innovations
Chilled Ammonia System
Existing
SO2 Scrubber
Flue Gas
Energy
Energy
Recovery
Recovery
29
Energy
Energy
Recovery
Recovery
CO2
Tower
Flue Gas
Cooling
System
Flue Gas
Cooling
 Regeneration at high pressure
CO2 Absorption
Tower
 Moderately raising the temperature
reverses the above reactions –
producing CO2
Concentrated
CO2 to Sequestration
CO2 Lean
CO2 Rich
Fluid
Regeneration
 Ammonia reacts with CO2 and water
and forms ammonia carbonate or
bicarbonate
Existing
Stack
Advantages of Chilled Ammonia
30

High efficiency capture of CO2

Low heat of reaction

High capacity for CO2 per unit of solution

Easy and low temperature regeneration

Low cost reagent

No degradation during absorption-regeneration

Tolerance to oxygen and contaminations in flue gas
We Energies Pleasant Prairie Host Site Location
for 5MW Pilot
31
Carbon Free Power
Advanced Combustion
Innovative Combustion Options for 2010 and Beyond
 Oxygen Firing – Direct concentration of CO2 to >90% for reduced
capture costs
 Chemical Looping –Leapfrog technology with potential to achieve
significantly lower costs than PC/CFB/IGCC
32
Oxygen Firing to produce concentrated CO2 stream
CO2
CO 2 Recycle
N2
Air Separation
Unit (ASU)
O2
Boiler
Condenser
Fuel
H2 O
O 2, N 2
Compressor
Air in-leakage
3 MWt pilot CFB

33
Oxygen Firing – Direct concentration of CO2 to >90% for reduced
capture costs
30 MWth Oxy-fired PC Pilot Plant –
Vattenfall
Location of pilot plant in the Industrial Park
Schwarze Pumpe
34
Development Scale-up Objective
Steps
Factor
Com Partners
Laboratory
Tests
10 / 55 kWth
Fundamentals of
oxyfuel combustion
2004
2005
Universities (Stuttgart,
Chalmers, Dresden)
Vattenfall, ALSTOM..
Test Plant
500 kWth
1:50
Fundamentals of
oxyfuel combustion
with flue gas
recirculation
2005
CEBra, BTU Cottbus,
Vattenfall, ALSTOM
Pilot Plant
30 MWth
1:60
Test of the oxyfuel
process chain
2008
Vattenfall...,
ALSTOM, others
Demo Plant
600 MWth
1:20
Realisation with CO2
sequestration,
2015
Commercial
Plant approx.
1000 MWel
approx.
4-5
2020
Future Technologies for CO2 Capture
Chemical Looping
Depleted Air, Ash,
CaSO4
CO2 & H2O
CaS
Coal,
Limestone
Reducer
Chemical Looping
Gasification
Air
CaSO4
Oxidizer
Calciner
CO2
CaCO3
Chemical Looping
Combustion
Hydrogen
CaCO3
Reducer
CaO Hot
Solids
CaS
CaSO4
Coal,
Steam
35
Cold Solids
Depleted
Air, Ash,
CaSO4
Air
Oxidizer
Multiple Paths to CO2 Reduction
Innovations for the Future
‘Hatched’ Range reflects cost variation from fuels and uncertainty
10
No CO2 Capture ------------------------------With CO2 Capture---------------------------
8
6
4
2
w
/M
O
EA
xy
fir
in
g
w
SC
CO
PC
2
ad
v
am
in
IG
es
CC
F
tu
rb
in
e
SC
PC
US
NH
IG
C
3
CC
PC
H
ad
tu
v
rb
C
O
in
2
e
w
ad
v
CO
2
SC
PC
IG
CC
0
SC
PC
Levelized COE cents/Kwhr
Technology Choices Reduce Risk and Lower Costs
Note: Costs include compression , but do not include sequestration – equal for all technologies
36
Conclusions
37

New coal fired power plants shall be designed for highest
efficiency to minimize CO2 and other emissions

Lower cost, higher performance technologies for post
combustion CO2 capture are actively being developed, and
more are emerging

There is no single technology answer to suit all fuels and all
applications

The industry is best served by a portfolio approach to drive
development of competitive coal power with carbon capture
technology
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