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Coal Power Generation for the 21st Century:
 This is Not Your Father's Coal Power Plant

              Dr. Jeffrey N. Phillips
               Sr. Program Manager
           Bismarck Energy Conference
                   January 2012
Who is this guy?

      • Jeff Phillips
         – Senior Program Manager in Advanced Coal
           Group
         – Employed by EPRI since 2004
         – Previously worked for Fern Engineering (gas
           turbine consultants), Molten Metal Technology
           (waste gasification), and Shell Oil Co.
         – Participated in operation of Shell’s coal
           gasification demo plant and in the start-up of
           Buggenum IGCC
         – PhD research at Stanford focused on computer
           simulations of performance of IGCCs
© 2012 Electric Power Research Institute, Inc. All rights reserved.   2
Why Are You Here?

   During this workshop, I would like to learn about the following:
       1. ___________________________________________________
            ___________________________________________________
            ____________
       2. ___________________________________________________
            ___________________________________________________
            ____________
       3. ___________________________________________________
            ___________________________________________________
            ____________




© 2012 Electric Power Research Institute, Inc. All rights reserved.   3
Presentation Outline

   • Some Coal Power Plant Basics

   • A Brief History of Coal Power

   • 21st Century Coal Power Plants (two different kinds)

   • CO2 Capture & Storage




© 2012 Electric Power Research Institute, Inc. All rights reserved.   4
Carbon
                                                                      Ash (rock)
                                                                      Sulfur
                                                                      Nitrogen
                                                                      Hydrogen
                                                                      Mercury
                                                                      Water




© 2012 Electric Power Research Institute, Inc. All rights reserved.       5
What happens when coal burns?

   • Carbon => CO2 (carbon dioxide)
   • Ash => flyash
   • Sulfur => SO2, SO3 (SOx)
   • Nitrogen => N2 and NOx
   • Hydrogen => H2O
   • Mercury => Hg, HgCl2
   • Water => water vapor (H2O)

   • And you release a lot of heat!



© 2012 Electric Power Research Institute, Inc. All rights reserved.   6
Conventional Coal Plant



                                                                      12 MW           39 % Efficiency
                                                                                      (HHV basis)


                                                                              88 MW    2.5 MW own use


                                             100 MW                                                  39 MW
                                                                                           41.5 MW

                                                                       46.5 MW


© 2012 Electric Power Research Institute, Inc. All rights reserved.              7
Efficiency History of US Rankine Cycle Power
   Plants




© 2012 Electric Power Research Institute, Inc. All rights reserved.   8
Emissions History (& Projection) of US Coal
   Power Plants (Dates represent year plant began operating)
   90                                                                                      3000

   80
                                                                                           2500
   70

   60                                                                                      2000

   50                                                                                             SO2
                                                                                           1500
   40                                                                                             NOx
                                                                                                  CO2
   30                                                                                      1000

   20
                                                                                           500
   10

      0                                                                                    0
                             1921                                     1960   2008   2025

© 2012 Electric Power Research Institute, Inc. All rights reserved.          9
US Generation Capacity (Source: U.S. Energy Information
   Administration, Form EIA-860 Annual Electric Generator Report )




© 2012 Electric Power Research Institute, Inc. All rights reserved.   10
21st Century Power Plants

                                       Advanced Ultra-supercritical Technology




© 2012 Electric Power Research Institute, Inc. All rights reserved.   11
Definition


                                                                                                Net Plant    Net Plant Heat
               Nomenclature                                              Conditions
                                                                                                Efficiency    Rate (HHV)


                                                                      2400psig (16.5MPa)
                    Subcritical                                                                    35%        9751 Btu/kWh
                                                                  1050ºF/1050ºF (565ºC/565ºC)


                  Supercritical                                           >3600psig
                                                                                                   38%        8981 Btu/kWh
                     (SC)                                         1050ºF/1075ºF (565ºC/585ºC)


                                                                     >3600 psig (24.8MPa)
             Ultrasupercritical
                                                                  1100ºF/1150ºF (593ºC/621ºC)     >42%        8126 Btu/kWh
                   (USC)
                                                                          and above


                 “Advanced”                                           5000psig (34.5MPa)
              UltraSupercritical                                        1250ºF (677ºC)            >45%        7757 Btu/kWh
                   (A-USC)                                                and above


© 2012 Electric Power Research Institute, Inc. All rights reserved.                 12
Increasing Steam Temperature and Pressure Increases
   Thermal Efficiency and Decreases Emissions


                                     2 Percentage Point Efficiency Gain = 5% CO2 Reduction
                                             Subcritical Plant Range




                                                                       Supercritical
                                                                       Plant Range
                                                                       Commercial




                                                                                                Advanced Ultra-
                                                                                                 Supercritical
                                                                                                 Plant Range
                                            1000 F                                             1400 F
                                                                             Note: HHV Basis

                            “Least Regret” Strategy for CO2 Reduction?

© 2012 Electric Power Research Institute, Inc. All rights reserved.                    13
Materials for A-USC Coal Power Plants – U.S. Department of
               Energy (DOE) and Ohio Funded Project

                             1500

                             1400                              DOE Goal             750
                                                                                                                   • During 1st 60 years of the
                             1300
                                     Eddystone 1                                    700                              20th century, steam turbine
                             1200                                                   650                              temperatures rose from
    Temperature, Degrees F




                                                                                          Temperature, Degrees C
                             1100           Philo 6                                 600
                                                                                                                     250 C to 650 C
                             1000                                                   550

                             900
                                                                                    500                               – Thermal efficiency rose
                             800
                                                                                    450                                 from 4% to 40% (HHV)
                                                                                    400
                             700
                                                                                    350
                                                                                                                   • Eddystone experienced
                             600                                                    300                              several materials issues
                             500                                                    250
                                                                                    200
                                                                                                                      – Derated from 650 C to
                             400
                                1900 ’10 ’20 ’30 ’40 ’50 ’60 ’70 ’80 ’90 2000 ’10                                       615 C
                                                       Year

                                    Maximum Steam Turbine Inlet
                                                                                                                   • No improvements for 50
                                         Temperature History                                                         years!



© 2012 Electric Power Research Institute, Inc. All rights reserved.                  14
Acknowledgements: U.S. Department of Energy (US
   DOE) / Ohio Coal Development Office (OCDO) A-USC
   Steam Boiler and Turbine Consortia




                                                     Federal – State – National Laboratory
                                                            Non Profit – For Profit
                                                          Cost Sharing Consortium




© 2012 Electric Power Research Institute, Inc. All rights reserved.   15
Primary Technical Goals of US A-USC Materials
   Programs
      • Materials Technology Evaluation
                       • Focus on nickel-based alloys
                       • Development of fabrication and joining technology for
                         new alloys
      • Unique Conditions for US Program Considerations
                       • Higher-temperatures than European Program (760 C
                         versus 700 C) means additional alloys are being
                         evaluated
                       • Corrosion resistance for US coals
                       • Data for ASME code acceptance of new materials
                       • Phase II Boiler work includes Oxycombustion

© 2012 Electric Power Research Institute, Inc. All rights reserved.   16
Materials Limit the Current Technology
                                                                                                             o
                                                  Average Temperature for Rupture in 100,000 hours ( F)
                                                 1100                 1200               1300             1400
                        500                                                                                                     70
                                                                                    Inconel 740         Nickel-Based
                                                                                                        Alloys                  50
                        300
                                                                                                   Haynes 282
                                         CCA617                          Std. 617
                                                                                               Age Hardenable = A-USC           30
                                                                                                    760 C (1400°F)
                                                                                     °
         Stress (MPa)




                                                                                                                                     Stress (ksi)
                        100

                         80
                                                                                                                                10
                         60
                                9-12Cr Creep-Strength                                                                           8
                                              Steels = USC                    Solid Soln’ = A-USC
                                Enhanced FerriticC (1150°F)                  Advanced Austenitic                                              Minimum
                                              620 Steels                         ~700 C (1300°F)
                         40     (Gr. 91, 92, 122)                            Alloys (Super 304H,                                6               Desired
                                                                             347HFG, NF709, etc.)                Haynes 230
                                                                                                                                               Strength at
                                                                                                                                               Application
                              550                     600             650                700           750                800
                                                Average Temperature for Rupture in 100,000 hours ( C)
                                                                                                             o                                Temperature

© 2012 Electric Power Research Institute, Inc. All rights reserved.                 17
US Dept of Energy – Ohio Coal Development
     Office Advanced USC Project

Accomplishments over the past 10 years                                                                         Fabrication Processes

General design studies show
    favorable economics




                                                                        Welding Technology Developments



Steam-Side
  Oxidation
                                                                                                               HP Turbine Concept




                                                                        Fireside Corrosion (High Sulfur Coal
                                                                           & In-Plant Testing)
  © 2012 Electric Power Research Institute, Inc. All rights reserved.                  18
Successes: Air-cooled probes

Cleaned surface of an air-cooled probe exposed for 2 years in
 a coal-fired boiler at A-USC temperatures




       Inconel 740 shows lower wastage than a high chromium cladding
        (50/50), a 23% Cr wrought alloy (HR6W), and weld overlays (WO)
© 2012 Electric Power Research Institute, Inc. All rights reserved.   19
Successes: Welding Technology

                                                                       Today: Repeatable 3” (75mm) thick Inconel 740
                                                                                   welds without cracking




    Original Inconel 740 weld trials
(Liquation cracking in heat affected zone)
Consortium
  Research



                          Consortium research has demonstrated revolutionary
                                progress in nickel-based alloy welding

 © 2012 Electric Power Research Institute, Inc. All rights reserved.      20
Major Conclusions from the DOE/OCDO
                 Materials Project
                                                                      • Boiler and steam turbine materials have been
                                                                        identified for use in a760 C
                                                                                                1400°F A-USC power plant
                                                                         – They can be welded, forged, bent, fabricated
                                                                             and have excellent fire-side and steam side
                                                                             corrosion resistance.
                                                                         – Welded rotors with no evidence of strain-age
                                                                             cracking
                                                                         – Investigating non-welded super-alloy rotors.
                                                                      • The designs of boiler and steam turbine are similar
                                                                        to those of modern SC power plants.
                                                                      • Operation is similar to SC PC plants
                                                                         – Maintenance is more exacting and staff training
                                                                             is required.
                                                                      • Most of work is done but some tasks still to be
                                                                         completed
                                                                         – All will be ready for a demonstration project to be
                                                                             initiated in 2015/16 period.
© 2012 Electric Power Research Institute, Inc. All rights reserved.            21
Cost of Electricity and CO2 Avoid Costs for US-
   based Coal Power Plants

                                             70
       Cost of Electricity ($/MWhr) or CO2
           Avoided Cost ($/metric ton)




                                             60

                                             50

                                             40                                                          600degC $/MWhr
                                                                                                         760degC $/MWhr
                                             30                                                          CO2 avoided cost
                                             20

                                             10

                                             0
                                                              EPRI                  NETL

                                                  (NETL electricity costs are higher due to smaller plant size)

© 2012 Electric Power Research Institute, Inc. All rights reserved.           22
A Low Cost Option for CO2 Emissions
   Reductions from New Coal Plants?

   • The EPRI and NETL studies calculated costs of $12-
     $15/metric ton of avoided CO2 emissions from using 760 C
     technology instead of 600 C designs
   • This is far lower than the cost estimates of both
     organizations for avoiding CO2 emissions with the use of
     CO2 capture and geologic storage
      – Those cost estimates range from circa $50 to $90/metric
        ton
   • The cost of building 760 C plants is expected to come
     down over time as more experience is gained



© 2012 Electric Power Research Institute, Inc. All rights reserved.   23
For More Information

   • Results from the DOE/OCDO A-USC materials project are
     summarized in EPRI report 1022770 (available for free at
     epri.com)
   • EPRI’s economic analysis of A-USC power plants is
     described in EPRI report 1015699 (also available at no cost
     at www.epri.com)
   • NETL’s economic analysis of A-USC power plants with and
     without CCS is available at www.netl.doe.gov




© 2012 Electric Power Research Institute, Inc. All rights reserved.   24
State-of-the-Art Emissions Control




© 2012 Electric Power Research Institute, Inc. All rights reserved.   25
J-Power Isogo Coal Power Plant


                                                           Old        New Unit           New Unit #1       New Unit #2
                                                           Units      #1 Permit            Actual            Permit

               NOx, ppm                                       159        20              14 max, 9-10          13
                                                                                            typical
               NOx,                                                     0.03                                  0.02
               lb/MMBtu
               SOx, ppm                                        60        20            5 ppm max, 2-3          10
                                                                                           typical
               SOx,                                                     0.05                                  0.025
               lb/MMBtu
               PM, mg/Nm3                                      50        10            3 max, <1 typical       5
               PM,                                                      0.01                                  0.005
               lb/MMBtu

© 2012 Electric Power Research Institute, Inc. All rights reserved.               26
Isogo Coal and Flyash Storage & Stack




© 2012 Electric Power Research Institute, Inc. All rights reserved.   27
Isogo Low Nox Burners




© 2012 Electric Power Research Institute, Inc. All rights reserved.   28
Isogo “ReAct” Process for SOx, NOx, and Hg
   Control – Based on Activated Carbon




© 2012 Electric Power Research Institute, Inc. All rights reserved.   29
Isogo Sulfuric Acid Plant for
                                                                             control of SOx emissions




© 2012 Electric Power Research Institute, Inc. All rights reserved.   30
21st Century Power Plants

                                                                      IGCCs




© 2012 Electric Power Research Institute, Inc. All rights reserved.     31
What is gasification?

   • Similar to combustion (burning) but with less than half the
     amount of oxygen needed to fully burn the coal
   • Combustion: excess air
   • Gasification: excess fuel (by a lot!!)




© 2012 Electric Power Research Institute, Inc. All rights reserved.   32
Combustion & Gasification Products




                                                                      (MAF = Moisture & Ash Free Basis)
© 2012 Electric Power Research Institute, Inc. All rights reserved.                33
1000ºC




© 2012 Electric Power Research Institute, Inc. All rights reserved.   34
1000ºC




© 2012 Electric Power Research Institute, Inc. All rights reserved.   35
1400ºC




© 2012 Electric Power Research Institute, Inc. All rights reserved.   36
© 2012 Electric Power Research Institute, Inc. All rights reserved.   37
Gas Turbine “simple cycle”


                                                 100 MW
                                                                                         65 MW




        35 MW

                                                                           35% Efficiency
                                                                           (HHV basis)
© 2012 Electric Power Research Institute, Inc. All rights reserved.   38
Combined Cycle

                                                               27 MW             100 MW

                                                                                          Fuel

                                          38 MW
                                                                             65 MW

  17 MW                                                                                          35 MW


                                                                            17 + 35 = 52 MW
                                        21 MW to                            52% Efficiency!
                                        condenser                           (HHV basis)

© 2012 Electric Power Research Institute, Inc. All rights reserved.    39
100MW                                                         Net Coal to Power:
                                                                                  28 + 20 – 9 = 39%
                                                                                  (HHV basis)




                                                                       19MW
  9MW
                                                                               15MW        79MW

                                                                               51MW
                  20MW                                                                                     28MW
                                                                       47MW
                                                                                      IGCC schematic from US DOE
                                                               27 MW
© 2012 Electric Power Research Institute, Inc. All rights reserved.       40
Existing Coal-based IGCCs



                                                                      Nakoso (Japan)




                      Puertollano (Spain)                                              Wabash (Indiana)




                              Polk (Florida)                                      Buggenum (Netherlands)
© 2012 Electric Power Research Institute, Inc. All rights reserved.          41
Other Solid Fuel IGCCs

   • The first IGCC was built in Lunen, Germany in 1972
      – 170 MW (no longer in service)
   • EPRI helped fund the 125 MW Cool Water project in the
     1980s – moved to Kansas in 1990s for pet coke-to-fertilizer
     project
   • Dow built a 165 MW demo unit in the 1980s
      – Plaquemine, LA (no longer in service)
   • Texaco built two small IGCCs at refineries in the 1990s
   • The largest coal-based IGCC was built in the Czech
     Republic in the 1990s - Vresova



© 2012 Electric Power Research Institute, Inc. All rights reserved.   42
Vresova IGCC: 26 Lurgi Gasifiers, 2 GE 9E gas
   turbines = 398 MW net output




                Photo copyright by Sokolovska uhelna,
                         used with permission


© 2012 Electric Power Research Institute, Inc. All rights reserved.   43
Under Construction


                                                                       • Duke Energy is building a 618
                                                                         MW IGCC in Indiana
                                                                         (Edwardsport)
                                                                       • A Chinese consortium is
                                                                         building a 250 MW IGCC
                                                                         (GreenGen project)
                                                                       • Dongguan Tianming Electric
                                                                         Power Co. is building a coal
                                                                         gasifier in China that will supply
                                                                         syngas to an existing 120 MW
                                                                         combined cycle
                                                                       • Korean Western started
                                                                         construction last year on a 300
                                                                         MW IGCC (2016 start-up)
                                                                       • And one more (stay tuned)
© 2012 Electric Power Research Institute, Inc. All rights reserved.   44
CO2 Capture & Storage




© 2012 Electric Power Research Institute, Inc. All rights reserved.   45
Latest CoalFleet Levelized Cost of Electricity
   Estimates ($/MWhr) for New 600-700 MW Plants
         Based on Powder River Basin Coal, Midwest US site and $10/ton cost for storing CO2
                 140

                 120

                 100

                    80
                                                                                No CCS
                    60                                                          CCS

                    40

                    20

                        0
                                Post-Combustion Oxy-Combustion Pre-Combustion
                  Results Would Be Different for Bituminous or Lignite Coals

© 2012 Electric Power Research Institute, Inc. All rights reserved.   46
The Challenges for Post-combustion CO2
      Capture

      • What to do with CO2?
         – SO2: ~ 1,400 ppmv in flue gas       Can’t use consumable sorbents for
                                                 CO2 capture (like those used for
         – CO2: ~140,000 ppmv in flue gas                 SO2 Capture).
      • Current option
         – Scrub the flue gas with solutions which react with and can
            then be stripped of the CO2
      • Putting the CO2 in the ground (100-175 bar/1500-2500 psi)
      • Even with state-of-the-art amine solvents the energy penalty
        is large



               750 MW plant without CCS nets 541 MW with CCS (28% loss)

© 2012 Electric Power Research Institute, Inc. All rights reserved.   47
Largest CO2 Capture System Ever Built on a
   Coal Power Plant

   • 1150 STD CO2 from 100 MW Lubbock Power & Light unit
   • Operational 1983-1984 for EOR Floods
   • Dow Amine Technology




© 2012 Electric Power Research Institute, Inc. All rights reserved.   48
Major PC Post-Combustion Capture Projects in
      Development Worldwide – September 2011
      Country                   Project                               Location           MW                   Technology        Notes
      US                        NRG                                   Parish, Texas      60                   Fluor MEA         CCPI 3 EOR
      Canada                    SaskPower                             Boundary Dam       100                  Cansolv           In construction
                                TransAlta                             Wabamun, Alberta   125                  Chilled Ammonia   EOR & Saline
      Germany                   Vattenfall                            Janeschwalde       125                  Chilled Ammonia   On shore Saline
      Netherlands               E.ON et al.                           Maasvlakte         250 MW of new 1100   Amine.            Offshore gas
                                                                                         MW                                     field
      Poland                    PGE Elektrownia                       Belchatow          250 MW of 858 MW     Advanced Amine    Saline reservoir


      Romania                   Turceni                                                  330                  TBD               Saline
      UK                        Scottish Power                        Longannet          300                  Aker              North Sea
                                                                                                                                storage




                             Only 1 is under construction, will the others follow?

© 2012 Electric Power Research Institute, Inc. All rights reserved.                      49
Minimum Energy versus State of the Art

      • 7.5% versus 28%!
         – There is clearly room for improvement!

                             20
                             18
                             16
         % of Original MWe




                             14
                             12
                             10                                                          Ideal
                              8                                                          State-of-Art
                              6
                              4
                              2
                              0
                                                     Capture               Compression

© 2012 Electric Power Research Institute, Inc. All rights reserved.   50
Capture Technologies Reviewed:
      (EPRI Reports 1016995, 1017644, 1019812)

                                                                                        Adsorption (18)
Absorption (56)
                                                                                         CO2         N2         Binding site

         CO2                                                                                              CO2
                                              NH2-R                                         CO2


                                            NH2-R                                                               Substrate
                N2

                                                       NH2-R
                                                                       Membrane (17)
                                                                                  CO2



                                                                                  N2
                Other (17)
                     Cryo, Mineralization


 © 2012 Electric Power Research Institute, Inc. All rights reserved.         51
Historic and Anticipated Improvement in Post-
   Combustion Capture Energy Intensity


                                Generation by a coal-fired power plant




                                                Dilute MEA            Improved Amines     Advanced Concepts
                                                                                          – Advanced amines
                                                                                          – Non-aqueous solvents
                                                                                          – Phase separating solvents
                                                                                          – Membranes
                                                                                          – Solid sorbents


                               Thermodynamic minimum energy for capture and compression




                   Need to Continue Progress to Bring Down Cost of Capture
© 2012 Electric Power Research Institute, Inc. All rights reserved.         52
Oxy-Combustion Overview




© 2012 Electric Power Research Institute, Inc. All rights reserved.   53
Major Coal OxyCombustion projects in
      Development Worldwide – September 2011
      Country                             Project                     Location             MW        Technology      Notes

      US                                  FutureGen 2                 Meredosia, IL        200       B&W, Air        FG Alliance for
                                                                                                     Liquide         Storage. Est.
                                                                                                                     S/U 2016
      Germany                             Vattenfall                  Janeschwalde         250 MWe   Alstom, Linde   S/U 2015

      Spain                               Endesa                      Compostella          300 MWe   Foster          In FEED. Est
                                                                                           CFB       Wheeler CFB     S/U 2016
      Australia                           CS Energy                   Callide              90 MWt    IHI, Air        S/U 2011
                                                                                                     Liquide
      Korea                               KOSEP-                      Yongdong Power       125 MW    TBD             S/U 2017
                                          KEPCO                       station




                                Only 1 under construction. Will the others follow?

© 2012 Electric Power Research Institute, Inc. All rights reserved.                   54
Meredosia Plant
  •    Meredosia, IL: Owned/operated by AER
  •    5-coal fired units (4 not operating), 1-oil fired unit
  •    4- steam turbines (2 not operating)                                                Providing $1.1 Billion
  •    Unit 4, 200 MWe oil-fired built in 1975
                                                                                 Project Structure
                                                                           • Capture – Ameren Energy Resources
                                                                             (AER), teamed with B&W and Air Liquide
                                                                           • Transport & Storage – FutureGen Alliance
                                                                           • Repower Unit 4 steam turbine
                                                                           • Purpose-built Oxy-PC boiler
                                                                           • Illinois Coal, PRB blend possible

                                                                                 Project Timeline
                                                                           • Project awarded Sept. 29, 2010
                                                                           • FEED and NEPA complete June, 2012
                                                                           • “Ready to test,” early 2016


      Source: Babcock & Wilcox
© 2012 Electric Power Research Institute, Inc. All rights reserved.   55
                                                                                                                55
Advanced-USC + Oxy-Combustion

• 760°C/1400°F Steam Cycle Benefits Oxy
   – Higher Efficiency Means Less Coal and
     Less Oxygen Required
   – Less CO2 to Compress
   – Hotter Temperatures in Fire Box → Less
     Surface Area (below)




                                                                       • Recent Successes
                                                                          – ASME Boiler Code approval of
                                                                            Inconel 740
                                                                          – Extrusion of Large Diameter
                                                                            Inconel 740 Pipe (above)
                            Air , Low O2 , High O2

© 2012 Electric Power Research Institute, Inc. All rights reserved.   56
IGCC with CO2 Capture
Process Flow Diagram
                                                                            Steam
                                                                       (Case Dependent)

                Air                                                                                                        Sulfur       Sulfur
                                                                                                                          Recovery
                                                                         Water Gas                                          Unit
                                                                           Shift
           Air                                                                                                     Tail              Acid
                                                                                                                   Gas               Gas
        Separation
           Unit
                            Oxygen                                                                                          H2S                    CO2
                                             Gasification                 COS                    Syngas Cooling           Acid Gas               Acid Gas
                             Coal              Island                   Hydrolysis                & Hg Removal            Removal                Removal
                                                                                                                            Unit                   Unit




                                                   Slag

                                                                                                                                                                       CO2
                                                                                                                                                                    To Pipeline
                                                                                                                                                             CO2
                                 Syngas Diluent (N2)                                                                                                        Comp.

                                                                                                            Syngas
                          Extraction Air
                                                                                                          Conditioning




                                                                                          HRSG



          Air
                                                    Gas Turbine                                                                        Steam Turbine

 © 2012 Electric Power Research Institute, Inc. All rights reserved.                       57
Dakota Gasification Substitute Natural Gas
      (SNG) Production Facility

                                  Lignite

                                                                                                             CO2 to
                                                   “Syngas”                                               Enhanced Oil
                                                                                           CO2 Pipeline    Recovery
                                                                                                          ~3 million tons CO2/yr


                                                                          CO2                                   SNG to
                                                                      Production &          Methanation          pipeline
                                                                        Removal

                                                                                       H2-rich
                                                                                       syngas
              Gasification & Heat
                  Recovery
                                                                       Supplies natural gas power
          Owned by Dakota                                                plants (approx 1000 MW)
            Gasification                                               connected to NG pipeline grid
© 2012 Electric Power Research Institute, Inc. All rights reserved.             58
Major IGCC + CCS Projects in Development
      Worldwide – September 2011
      Country                  Project                   Location       MW    Gasification   Gas       Coal          Notes
                                                                        Net   Technology     turbine
      US                       HECA                      California     250   GE Quench      GE        Western Bit   In FEED.
                               SCS                                                                     & Pet coke    EOR. Urea
                               Southern                  Mississippi    524   KBR Air        Siemens   Lignite       Under
                                                                              blown                                  construction
                                                                                                                     EOR
                               Summit                    Texas          200   Siemens        Siemens   PRB           In FEED.
                               Power                                                                                 EOR. Urea
                               Future                    Pennsylvania   250   TPRI (China)   TBD       Anthracite    Permits
                               Fuels                                                                                 obtained
      UK                       Don                       Yorkshire      800   Shell          GE                      EU NER 300
                               Valley                                                                                candidate
      Australia                Wandoan                   Queensland     350   GE Radiant     GE        Queensland    Pre FEED




                                Only 1 under construction. Will the others follow?

© 2012 Electric Power Research Institute, Inc. All rights reserved.             59
The First IGCC with CO2 Capture


      • Mississippi Power                                                  Kemper County
        received approval last
        year to build a 582 MW
        IGCC
      • Will consume local lignite
        and capture 65% of
        coal’s carbon as CO2
      • The CO2 will be sold for
        use in enhanced oil
        recovery
      • Receiving US Dept of
        Energy support


© 2012 Electric Power Research Institute, Inc. All rights reserved.   60
Ratcliffe (Kemper County, MS) IGCC
         Construction Update
Ratcliffe (Kemper County, MS) IGCC
         Construction Update
Two Additional IGCCs selected for Dept of
   Energy Funding
   Hydrogen Energy California                                              Texas Clean Energy Project
   • San Joaquin Valley                                                    • West Texas
   • GE gasification                                                       • Siemens Gasification
   • Petroleum Coke and                                                    • Powder River Basin Coal
     Bituminous Coal                                                       • Products
   • Products                                                                 – Power
      – Power                                                                 – Ammonia/Urea
      – CO2 for Enhanced Oil                                                  – CO2 for Enhanced Oil
        Recovery                                                                Recovery




© 2012 Electric Power Research Institute, Inc. All rights reserved.   63
“It’s the Sink, Stupid!”




© 2012 Electric Power Research Institute, Inc. All rights reserved.   64
Phase III DOE Regional Partnership Update


          • Target >1MtCO2/yr
          • Includes Large-scale capture
            and/or geologic storage
            demonstration projects
          • Injection natural and man-
            made CO2 sources
          • 10 year program
                  – 2 yr permitting
                  – 4 yr injection
                  – 4 yr monitoring/closure
          • DOE Funding up to $66M
            USD per project
            FY2008 – 2017
                                                                           US Department of Energy Seven Regional Partnerships
                                                                                 (NETL website, shows status as of 2010)



© 2012 Electric Power Research Institute, Inc. All rights reserved.   65
Current Phase III Plans

      Partnership                        Lead                         Industry         Site             CO2           CO2
                                         Organizations                Partner                           Source        Rate
      Big Sky                            Montana                      Various          Toole County,    Natural       250kt/yr
                                         State U.                                      MT               CO2
      MGSC                               IL Geo. Surv.                ADM              Decatur, IL      Ethanol       250kt/yr
                                         Schlumberger
      MRCSP                              Battelle Mem.                Core Energy,     Otsego County,   Nat. Gas      250 kt/yr
                                         Institute                    DTE              MI               Processing
      PCOR                               U. North                     1. Spectra E.    Fort Nelson, BC Nat. Gas       2 Mt/yr
                                         Dakota                       2. CoP.          Bell Creek, MT Nat. Gas        1 Mt/yr
      SECARB                             SSEB, EPRI,                  1. Denbury       Cranfield, MS    Natural CO2   1.5 Mt/yr
                                         TBEG                         2. South. Co     Plant Daniel, AL Elec.Power    150kt/yr
      SWP                                NM Tech. &                                    Farnham          Natural CO2   +1Mt/yr
                                         U. Utah                                       Dome, UT
      WESTCARB Berkeley Lab
               Schlumberger
    Partnerships experiencing siting issues shown in red (see background slides)
© 2012 Electric Power Research Institute, Inc. All rights reserved.               66
CCS Projects
                                           Locations & Cost Share
         CCPI
         FutureGen 2.0
                                                              FutureGen 2.0
         ICCS Area 1                             Large-scale Testing of Oxy-Combustion w/ CO2
                                                 Capture and Sequestration in Saline Formation         Archer Daniels Midland
                                                       Plant: $737M – Total; $590M – DOE               CO2 capture from Ethanol plant
                                                  Trans. & Storage: $553M – Total; $459M– DOE           CO2 stored in saline reservoir
                                                     Project: ~$1.3B – Total; ~$1.0B – DOE                      $208M - Total
                                                                                                                $141M - DOE



                HECA
     Commercial Demo of Advanced
      IGCC w/ Full Carbon Capture
            ~$2.8B – Total
             $408M – DOE

                                                         Air Products
                                           CO2 capture from Steam Methane Reformers
                                                  EOR in eastern TX oilfields
                                                                                                              Southern Company
                                                                                                          Kemper County IGCC Project
                                                          $431M - Total
     Summit TX Clean Energy                                                                                 IGCC-Transport Gasifier
                                                          $284M - DOE                                          w/Carbon Capture
     Commercial Demo of Advanced
      IGCC w/ Full Carbon Capture                                                                               ~$2.67B – Total
            ~$1.7B – Total                                                                                       $270M – DOE
             $450M – DOE

                           NRG
                W.A. Parish Generating Station                                    Leucadia Energy
                Post Combustion CO2 Capture                                 CO2 capture from Methanol plant
                        $339M – Total                                         EOR in eastern TX oilfields
                        $167M – DOE                                                  $436M - Total
                                                                                     $261M - DOE
67
Important International Storage Projects


         Project                         Country                      Injection Amount Reservoir Storage Type       Operator/Partner
                                                                                                                   Cenovus, Apache,
    Weyburn-                                                                            Oil Field Carbonate
                                         Canada                       2.8 MMt CO2/yr                              Petroleum Technology
  Midale Project                                                                       Enhanced Oil Recovery
                                                                                                                    Research Center
     Sleipner                        Norway (off-
                                                                       1 MMt CO2/yr    Saline Marine Sandstone        StatoilHydro
      Project                          shore)
    Snøhvit CO2                      Norway (off-                       700,000 Mt
                                                                                       Saline Marine Sandstone        StatoilHydro
      Storage                          shore)                             CO2/yr
                                                                                                                 GeoForschungsZentrum,
       CO2SINK                          Germany                       60,000 Mt CO2       Saline Sandstone
                                                                                                                    Potsdam (GFZ)
   In Salah Gas                                                                                                      BP, Sonatrach,
                                          Algeria                      1 MMt CO2/yr     Gas Field Sandstone
       Field                                                                                                          StatoilHydro
                                                                                        Gas Field and Saline
   Otway Basin                          Australia                     65,000 Mt CO2                                    CO2CRC
                                                                                            Sandstone
                                                                        100,000 Mt
    Ordos Basin                            China                                              Ordos Basin            Shenhua Coal
                                                                          CO2/yr




© 2012 Electric Power Research Institute, Inc. All rights reserved.                      68
For More Information

      • EPRI Report 1023468
      • Issued last month
      • Free download for all
        members




© 2012 Electric Power Research Institute, Inc. All rights reserved.   69
Together…Shaping the Future of Electricity




© 2012 Electric Power Research Institute, Inc. All rights reserved.   70

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21st Century Coal Power Generation Advances

  • 1. Coal Power Generation for the 21st Century: This is Not Your Father's Coal Power Plant Dr. Jeffrey N. Phillips Sr. Program Manager Bismarck Energy Conference January 2012
  • 2. Who is this guy? • Jeff Phillips – Senior Program Manager in Advanced Coal Group – Employed by EPRI since 2004 – Previously worked for Fern Engineering (gas turbine consultants), Molten Metal Technology (waste gasification), and Shell Oil Co. – Participated in operation of Shell’s coal gasification demo plant and in the start-up of Buggenum IGCC – PhD research at Stanford focused on computer simulations of performance of IGCCs © 2012 Electric Power Research Institute, Inc. All rights reserved. 2
  • 3. Why Are You Here? During this workshop, I would like to learn about the following: 1. ___________________________________________________ ___________________________________________________ ____________ 2. ___________________________________________________ ___________________________________________________ ____________ 3. ___________________________________________________ ___________________________________________________ ____________ © 2012 Electric Power Research Institute, Inc. All rights reserved. 3
  • 4. Presentation Outline • Some Coal Power Plant Basics • A Brief History of Coal Power • 21st Century Coal Power Plants (two different kinds) • CO2 Capture & Storage © 2012 Electric Power Research Institute, Inc. All rights reserved. 4
  • 5. Carbon Ash (rock) Sulfur Nitrogen Hydrogen Mercury Water © 2012 Electric Power Research Institute, Inc. All rights reserved. 5
  • 6. What happens when coal burns? • Carbon => CO2 (carbon dioxide) • Ash => flyash • Sulfur => SO2, SO3 (SOx) • Nitrogen => N2 and NOx • Hydrogen => H2O • Mercury => Hg, HgCl2 • Water => water vapor (H2O) • And you release a lot of heat! © 2012 Electric Power Research Institute, Inc. All rights reserved. 6
  • 7. Conventional Coal Plant 12 MW 39 % Efficiency (HHV basis) 88 MW 2.5 MW own use 100 MW 39 MW 41.5 MW 46.5 MW © 2012 Electric Power Research Institute, Inc. All rights reserved. 7
  • 8. Efficiency History of US Rankine Cycle Power Plants © 2012 Electric Power Research Institute, Inc. All rights reserved. 8
  • 9. Emissions History (& Projection) of US Coal Power Plants (Dates represent year plant began operating) 90 3000 80 2500 70 60 2000 50 SO2 1500 40 NOx CO2 30 1000 20 500 10 0 0 1921 1960 2008 2025 © 2012 Electric Power Research Institute, Inc. All rights reserved. 9
  • 10. US Generation Capacity (Source: U.S. Energy Information Administration, Form EIA-860 Annual Electric Generator Report ) © 2012 Electric Power Research Institute, Inc. All rights reserved. 10
  • 11. 21st Century Power Plants Advanced Ultra-supercritical Technology © 2012 Electric Power Research Institute, Inc. All rights reserved. 11
  • 12. Definition Net Plant Net Plant Heat Nomenclature Conditions Efficiency Rate (HHV) 2400psig (16.5MPa) Subcritical 35% 9751 Btu/kWh 1050ºF/1050ºF (565ºC/565ºC) Supercritical >3600psig 38% 8981 Btu/kWh (SC) 1050ºF/1075ºF (565ºC/585ºC) >3600 psig (24.8MPa) Ultrasupercritical 1100ºF/1150ºF (593ºC/621ºC) >42% 8126 Btu/kWh (USC) and above “Advanced” 5000psig (34.5MPa) UltraSupercritical 1250ºF (677ºC) >45% 7757 Btu/kWh (A-USC) and above © 2012 Electric Power Research Institute, Inc. All rights reserved. 12
  • 13. Increasing Steam Temperature and Pressure Increases Thermal Efficiency and Decreases Emissions 2 Percentage Point Efficiency Gain = 5% CO2 Reduction Subcritical Plant Range Supercritical Plant Range Commercial Advanced Ultra- Supercritical Plant Range 1000 F 1400 F Note: HHV Basis “Least Regret” Strategy for CO2 Reduction? © 2012 Electric Power Research Institute, Inc. All rights reserved. 13
  • 14. Materials for A-USC Coal Power Plants – U.S. Department of Energy (DOE) and Ohio Funded Project 1500 1400 DOE Goal 750 • During 1st 60 years of the 1300 Eddystone 1 700 20th century, steam turbine 1200 650 temperatures rose from Temperature, Degrees F Temperature, Degrees C 1100 Philo 6 600 250 C to 650 C 1000 550 900 500 – Thermal efficiency rose 800 450 from 4% to 40% (HHV) 400 700 350 • Eddystone experienced 600 300 several materials issues 500 250 200 – Derated from 650 C to 400 1900 ’10 ’20 ’30 ’40 ’50 ’60 ’70 ’80 ’90 2000 ’10 615 C Year Maximum Steam Turbine Inlet • No improvements for 50 Temperature History years! © 2012 Electric Power Research Institute, Inc. All rights reserved. 14
  • 15. Acknowledgements: U.S. Department of Energy (US DOE) / Ohio Coal Development Office (OCDO) A-USC Steam Boiler and Turbine Consortia Federal – State – National Laboratory Non Profit – For Profit Cost Sharing Consortium © 2012 Electric Power Research Institute, Inc. All rights reserved. 15
  • 16. Primary Technical Goals of US A-USC Materials Programs • Materials Technology Evaluation • Focus on nickel-based alloys • Development of fabrication and joining technology for new alloys • Unique Conditions for US Program Considerations • Higher-temperatures than European Program (760 C versus 700 C) means additional alloys are being evaluated • Corrosion resistance for US coals • Data for ASME code acceptance of new materials • Phase II Boiler work includes Oxycombustion © 2012 Electric Power Research Institute, Inc. All rights reserved. 16
  • 17. Materials Limit the Current Technology o Average Temperature for Rupture in 100,000 hours ( F) 1100 1200 1300 1400 500 70 Inconel 740 Nickel-Based Alloys 50 300 Haynes 282 CCA617 Std. 617 Age Hardenable = A-USC 30 760 C (1400°F) ° Stress (MPa) Stress (ksi) 100 80 10 60 9-12Cr Creep-Strength 8 Steels = USC Solid Soln’ = A-USC Enhanced FerriticC (1150°F) Advanced Austenitic Minimum 620 Steels ~700 C (1300°F) 40 (Gr. 91, 92, 122) Alloys (Super 304H, 6 Desired 347HFG, NF709, etc.) Haynes 230 Strength at Application 550 600 650 700 750 800 Average Temperature for Rupture in 100,000 hours ( C) o Temperature © 2012 Electric Power Research Institute, Inc. All rights reserved. 17
  • 18. US Dept of Energy – Ohio Coal Development Office Advanced USC Project Accomplishments over the past 10 years Fabrication Processes General design studies show favorable economics Welding Technology Developments Steam-Side Oxidation HP Turbine Concept Fireside Corrosion (High Sulfur Coal & In-Plant Testing) © 2012 Electric Power Research Institute, Inc. All rights reserved. 18
  • 19. Successes: Air-cooled probes Cleaned surface of an air-cooled probe exposed for 2 years in a coal-fired boiler at A-USC temperatures Inconel 740 shows lower wastage than a high chromium cladding (50/50), a 23% Cr wrought alloy (HR6W), and weld overlays (WO) © 2012 Electric Power Research Institute, Inc. All rights reserved. 19
  • 20. Successes: Welding Technology Today: Repeatable 3” (75mm) thick Inconel 740 welds without cracking Original Inconel 740 weld trials (Liquation cracking in heat affected zone) Consortium Research Consortium research has demonstrated revolutionary progress in nickel-based alloy welding © 2012 Electric Power Research Institute, Inc. All rights reserved. 20
  • 21. Major Conclusions from the DOE/OCDO Materials Project • Boiler and steam turbine materials have been identified for use in a760 C 1400°F A-USC power plant – They can be welded, forged, bent, fabricated and have excellent fire-side and steam side corrosion resistance. – Welded rotors with no evidence of strain-age cracking – Investigating non-welded super-alloy rotors. • The designs of boiler and steam turbine are similar to those of modern SC power plants. • Operation is similar to SC PC plants – Maintenance is more exacting and staff training is required. • Most of work is done but some tasks still to be completed – All will be ready for a demonstration project to be initiated in 2015/16 period. © 2012 Electric Power Research Institute, Inc. All rights reserved. 21
  • 22. Cost of Electricity and CO2 Avoid Costs for US- based Coal Power Plants 70 Cost of Electricity ($/MWhr) or CO2 Avoided Cost ($/metric ton) 60 50 40 600degC $/MWhr 760degC $/MWhr 30 CO2 avoided cost 20 10 0 EPRI NETL (NETL electricity costs are higher due to smaller plant size) © 2012 Electric Power Research Institute, Inc. All rights reserved. 22
  • 23. A Low Cost Option for CO2 Emissions Reductions from New Coal Plants? • The EPRI and NETL studies calculated costs of $12- $15/metric ton of avoided CO2 emissions from using 760 C technology instead of 600 C designs • This is far lower than the cost estimates of both organizations for avoiding CO2 emissions with the use of CO2 capture and geologic storage – Those cost estimates range from circa $50 to $90/metric ton • The cost of building 760 C plants is expected to come down over time as more experience is gained © 2012 Electric Power Research Institute, Inc. All rights reserved. 23
  • 24. For More Information • Results from the DOE/OCDO A-USC materials project are summarized in EPRI report 1022770 (available for free at epri.com) • EPRI’s economic analysis of A-USC power plants is described in EPRI report 1015699 (also available at no cost at www.epri.com) • NETL’s economic analysis of A-USC power plants with and without CCS is available at www.netl.doe.gov © 2012 Electric Power Research Institute, Inc. All rights reserved. 24
  • 25. State-of-the-Art Emissions Control © 2012 Electric Power Research Institute, Inc. All rights reserved. 25
  • 26. J-Power Isogo Coal Power Plant Old New Unit New Unit #1 New Unit #2 Units #1 Permit Actual Permit NOx, ppm 159 20 14 max, 9-10 13 typical NOx, 0.03 0.02 lb/MMBtu SOx, ppm 60 20 5 ppm max, 2-3 10 typical SOx, 0.05 0.025 lb/MMBtu PM, mg/Nm3 50 10 3 max, <1 typical 5 PM, 0.01 0.005 lb/MMBtu © 2012 Electric Power Research Institute, Inc. All rights reserved. 26
  • 27. Isogo Coal and Flyash Storage & Stack © 2012 Electric Power Research Institute, Inc. All rights reserved. 27
  • 28. Isogo Low Nox Burners © 2012 Electric Power Research Institute, Inc. All rights reserved. 28
  • 29. Isogo “ReAct” Process for SOx, NOx, and Hg Control – Based on Activated Carbon © 2012 Electric Power Research Institute, Inc. All rights reserved. 29
  • 30. Isogo Sulfuric Acid Plant for control of SOx emissions © 2012 Electric Power Research Institute, Inc. All rights reserved. 30
  • 31. 21st Century Power Plants IGCCs © 2012 Electric Power Research Institute, Inc. All rights reserved. 31
  • 32. What is gasification? • Similar to combustion (burning) but with less than half the amount of oxygen needed to fully burn the coal • Combustion: excess air • Gasification: excess fuel (by a lot!!) © 2012 Electric Power Research Institute, Inc. All rights reserved. 32
  • 33. Combustion & Gasification Products (MAF = Moisture & Ash Free Basis) © 2012 Electric Power Research Institute, Inc. All rights reserved. 33
  • 34. 1000ºC © 2012 Electric Power Research Institute, Inc. All rights reserved. 34
  • 35. 1000ºC © 2012 Electric Power Research Institute, Inc. All rights reserved. 35
  • 36. 1400ºC © 2012 Electric Power Research Institute, Inc. All rights reserved. 36
  • 37. © 2012 Electric Power Research Institute, Inc. All rights reserved. 37
  • 38. Gas Turbine “simple cycle” 100 MW 65 MW 35 MW 35% Efficiency (HHV basis) © 2012 Electric Power Research Institute, Inc. All rights reserved. 38
  • 39. Combined Cycle 27 MW 100 MW Fuel 38 MW 65 MW 17 MW 35 MW 17 + 35 = 52 MW 21 MW to 52% Efficiency! condenser (HHV basis) © 2012 Electric Power Research Institute, Inc. All rights reserved. 39
  • 40. 100MW Net Coal to Power: 28 + 20 – 9 = 39% (HHV basis) 19MW 9MW 15MW 79MW 51MW 20MW 28MW 47MW IGCC schematic from US DOE 27 MW © 2012 Electric Power Research Institute, Inc. All rights reserved. 40
  • 41. Existing Coal-based IGCCs Nakoso (Japan) Puertollano (Spain) Wabash (Indiana) Polk (Florida) Buggenum (Netherlands) © 2012 Electric Power Research Institute, Inc. All rights reserved. 41
  • 42. Other Solid Fuel IGCCs • The first IGCC was built in Lunen, Germany in 1972 – 170 MW (no longer in service) • EPRI helped fund the 125 MW Cool Water project in the 1980s – moved to Kansas in 1990s for pet coke-to-fertilizer project • Dow built a 165 MW demo unit in the 1980s – Plaquemine, LA (no longer in service) • Texaco built two small IGCCs at refineries in the 1990s • The largest coal-based IGCC was built in the Czech Republic in the 1990s - Vresova © 2012 Electric Power Research Institute, Inc. All rights reserved. 42
  • 43. Vresova IGCC: 26 Lurgi Gasifiers, 2 GE 9E gas turbines = 398 MW net output Photo copyright by Sokolovska uhelna, used with permission © 2012 Electric Power Research Institute, Inc. All rights reserved. 43
  • 44. Under Construction • Duke Energy is building a 618 MW IGCC in Indiana (Edwardsport) • A Chinese consortium is building a 250 MW IGCC (GreenGen project) • Dongguan Tianming Electric Power Co. is building a coal gasifier in China that will supply syngas to an existing 120 MW combined cycle • Korean Western started construction last year on a 300 MW IGCC (2016 start-up) • And one more (stay tuned) © 2012 Electric Power Research Institute, Inc. All rights reserved. 44
  • 45. CO2 Capture & Storage © 2012 Electric Power Research Institute, Inc. All rights reserved. 45
  • 46. Latest CoalFleet Levelized Cost of Electricity Estimates ($/MWhr) for New 600-700 MW Plants Based on Powder River Basin Coal, Midwest US site and $10/ton cost for storing CO2 140 120 100 80 No CCS 60 CCS 40 20 0 Post-Combustion Oxy-Combustion Pre-Combustion Results Would Be Different for Bituminous or Lignite Coals © 2012 Electric Power Research Institute, Inc. All rights reserved. 46
  • 47. The Challenges for Post-combustion CO2 Capture • What to do with CO2? – SO2: ~ 1,400 ppmv in flue gas Can’t use consumable sorbents for CO2 capture (like those used for – CO2: ~140,000 ppmv in flue gas SO2 Capture). • Current option – Scrub the flue gas with solutions which react with and can then be stripped of the CO2 • Putting the CO2 in the ground (100-175 bar/1500-2500 psi) • Even with state-of-the-art amine solvents the energy penalty is large 750 MW plant without CCS nets 541 MW with CCS (28% loss) © 2012 Electric Power Research Institute, Inc. All rights reserved. 47
  • 48. Largest CO2 Capture System Ever Built on a Coal Power Plant • 1150 STD CO2 from 100 MW Lubbock Power & Light unit • Operational 1983-1984 for EOR Floods • Dow Amine Technology © 2012 Electric Power Research Institute, Inc. All rights reserved. 48
  • 49. Major PC Post-Combustion Capture Projects in Development Worldwide – September 2011 Country Project Location MW Technology Notes US NRG Parish, Texas 60 Fluor MEA CCPI 3 EOR Canada SaskPower Boundary Dam 100 Cansolv In construction TransAlta Wabamun, Alberta 125 Chilled Ammonia EOR & Saline Germany Vattenfall Janeschwalde 125 Chilled Ammonia On shore Saline Netherlands E.ON et al. Maasvlakte 250 MW of new 1100 Amine. Offshore gas MW field Poland PGE Elektrownia Belchatow 250 MW of 858 MW Advanced Amine Saline reservoir Romania Turceni 330 TBD Saline UK Scottish Power Longannet 300 Aker North Sea storage Only 1 is under construction, will the others follow? © 2012 Electric Power Research Institute, Inc. All rights reserved. 49
  • 50. Minimum Energy versus State of the Art • 7.5% versus 28%! – There is clearly room for improvement! 20 18 16 % of Original MWe 14 12 10 Ideal 8 State-of-Art 6 4 2 0 Capture Compression © 2012 Electric Power Research Institute, Inc. All rights reserved. 50
  • 51. Capture Technologies Reviewed: (EPRI Reports 1016995, 1017644, 1019812) Adsorption (18) Absorption (56) CO2 N2 Binding site CO2 CO2 NH2-R CO2 NH2-R Substrate N2 NH2-R Membrane (17) CO2 N2 Other (17) Cryo, Mineralization © 2012 Electric Power Research Institute, Inc. All rights reserved. 51
  • 52. Historic and Anticipated Improvement in Post- Combustion Capture Energy Intensity Generation by a coal-fired power plant Dilute MEA Improved Amines Advanced Concepts – Advanced amines – Non-aqueous solvents – Phase separating solvents – Membranes – Solid sorbents Thermodynamic minimum energy for capture and compression Need to Continue Progress to Bring Down Cost of Capture © 2012 Electric Power Research Institute, Inc. All rights reserved. 52
  • 53. Oxy-Combustion Overview © 2012 Electric Power Research Institute, Inc. All rights reserved. 53
  • 54. Major Coal OxyCombustion projects in Development Worldwide – September 2011 Country Project Location MW Technology Notes US FutureGen 2 Meredosia, IL 200 B&W, Air FG Alliance for Liquide Storage. Est. S/U 2016 Germany Vattenfall Janeschwalde 250 MWe Alstom, Linde S/U 2015 Spain Endesa Compostella 300 MWe Foster In FEED. Est CFB Wheeler CFB S/U 2016 Australia CS Energy Callide 90 MWt IHI, Air S/U 2011 Liquide Korea KOSEP- Yongdong Power 125 MW TBD S/U 2017 KEPCO station Only 1 under construction. Will the others follow? © 2012 Electric Power Research Institute, Inc. All rights reserved. 54
  • 55. Meredosia Plant • Meredosia, IL: Owned/operated by AER • 5-coal fired units (4 not operating), 1-oil fired unit • 4- steam turbines (2 not operating) Providing $1.1 Billion • Unit 4, 200 MWe oil-fired built in 1975 Project Structure • Capture – Ameren Energy Resources (AER), teamed with B&W and Air Liquide • Transport & Storage – FutureGen Alliance • Repower Unit 4 steam turbine • Purpose-built Oxy-PC boiler • Illinois Coal, PRB blend possible Project Timeline • Project awarded Sept. 29, 2010 • FEED and NEPA complete June, 2012 • “Ready to test,” early 2016 Source: Babcock & Wilcox © 2012 Electric Power Research Institute, Inc. All rights reserved. 55 55
  • 56. Advanced-USC + Oxy-Combustion • 760°C/1400°F Steam Cycle Benefits Oxy – Higher Efficiency Means Less Coal and Less Oxygen Required – Less CO2 to Compress – Hotter Temperatures in Fire Box → Less Surface Area (below) • Recent Successes – ASME Boiler Code approval of Inconel 740 – Extrusion of Large Diameter Inconel 740 Pipe (above) Air , Low O2 , High O2 © 2012 Electric Power Research Institute, Inc. All rights reserved. 56
  • 57. IGCC with CO2 Capture Process Flow Diagram Steam (Case Dependent) Air Sulfur Sulfur Recovery Water Gas Unit Shift Air Tail Acid Gas Gas Separation Unit Oxygen H2S CO2 Gasification COS Syngas Cooling Acid Gas Acid Gas Coal Island Hydrolysis & Hg Removal Removal Removal Unit Unit Slag CO2 To Pipeline CO2 Syngas Diluent (N2) Comp. Syngas Extraction Air Conditioning HRSG Air Gas Turbine Steam Turbine © 2012 Electric Power Research Institute, Inc. All rights reserved. 57
  • 58. Dakota Gasification Substitute Natural Gas (SNG) Production Facility Lignite CO2 to “Syngas” Enhanced Oil CO2 Pipeline Recovery ~3 million tons CO2/yr CO2 SNG to Production & Methanation pipeline Removal H2-rich syngas Gasification & Heat Recovery Supplies natural gas power Owned by Dakota plants (approx 1000 MW) Gasification connected to NG pipeline grid © 2012 Electric Power Research Institute, Inc. All rights reserved. 58
  • 59. Major IGCC + CCS Projects in Development Worldwide – September 2011 Country Project Location MW Gasification Gas Coal Notes Net Technology turbine US HECA California 250 GE Quench GE Western Bit In FEED. SCS & Pet coke EOR. Urea Southern Mississippi 524 KBR Air Siemens Lignite Under blown construction EOR Summit Texas 200 Siemens Siemens PRB In FEED. Power EOR. Urea Future Pennsylvania 250 TPRI (China) TBD Anthracite Permits Fuels obtained UK Don Yorkshire 800 Shell GE EU NER 300 Valley candidate Australia Wandoan Queensland 350 GE Radiant GE Queensland Pre FEED Only 1 under construction. Will the others follow? © 2012 Electric Power Research Institute, Inc. All rights reserved. 59
  • 60. The First IGCC with CO2 Capture • Mississippi Power Kemper County received approval last year to build a 582 MW IGCC • Will consume local lignite and capture 65% of coal’s carbon as CO2 • The CO2 will be sold for use in enhanced oil recovery • Receiving US Dept of Energy support © 2012 Electric Power Research Institute, Inc. All rights reserved. 60
  • 61. Ratcliffe (Kemper County, MS) IGCC Construction Update
  • 62. Ratcliffe (Kemper County, MS) IGCC Construction Update
  • 63. Two Additional IGCCs selected for Dept of Energy Funding Hydrogen Energy California Texas Clean Energy Project • San Joaquin Valley • West Texas • GE gasification • Siemens Gasification • Petroleum Coke and • Powder River Basin Coal Bituminous Coal • Products • Products – Power – Power – Ammonia/Urea – CO2 for Enhanced Oil – CO2 for Enhanced Oil Recovery Recovery © 2012 Electric Power Research Institute, Inc. All rights reserved. 63
  • 64. “It’s the Sink, Stupid!” © 2012 Electric Power Research Institute, Inc. All rights reserved. 64
  • 65. Phase III DOE Regional Partnership Update • Target >1MtCO2/yr • Includes Large-scale capture and/or geologic storage demonstration projects • Injection natural and man- made CO2 sources • 10 year program – 2 yr permitting – 4 yr injection – 4 yr monitoring/closure • DOE Funding up to $66M USD per project FY2008 – 2017 US Department of Energy Seven Regional Partnerships (NETL website, shows status as of 2010) © 2012 Electric Power Research Institute, Inc. All rights reserved. 65
  • 66. Current Phase III Plans Partnership Lead Industry Site CO2 CO2 Organizations Partner Source Rate Big Sky Montana Various Toole County, Natural 250kt/yr State U. MT CO2 MGSC IL Geo. Surv. ADM Decatur, IL Ethanol 250kt/yr Schlumberger MRCSP Battelle Mem. Core Energy, Otsego County, Nat. Gas 250 kt/yr Institute DTE MI Processing PCOR U. North 1. Spectra E. Fort Nelson, BC Nat. Gas 2 Mt/yr Dakota 2. CoP. Bell Creek, MT Nat. Gas 1 Mt/yr SECARB SSEB, EPRI, 1. Denbury Cranfield, MS Natural CO2 1.5 Mt/yr TBEG 2. South. Co Plant Daniel, AL Elec.Power 150kt/yr SWP NM Tech. & Farnham Natural CO2 +1Mt/yr U. Utah Dome, UT WESTCARB Berkeley Lab Schlumberger Partnerships experiencing siting issues shown in red (see background slides) © 2012 Electric Power Research Institute, Inc. All rights reserved. 66
  • 67. CCS Projects Locations & Cost Share CCPI FutureGen 2.0 FutureGen 2.0 ICCS Area 1 Large-scale Testing of Oxy-Combustion w/ CO2 Capture and Sequestration in Saline Formation Archer Daniels Midland Plant: $737M – Total; $590M – DOE CO2 capture from Ethanol plant Trans. & Storage: $553M – Total; $459M– DOE CO2 stored in saline reservoir Project: ~$1.3B – Total; ~$1.0B – DOE $208M - Total $141M - DOE HECA Commercial Demo of Advanced IGCC w/ Full Carbon Capture ~$2.8B – Total $408M – DOE Air Products CO2 capture from Steam Methane Reformers EOR in eastern TX oilfields Southern Company Kemper County IGCC Project $431M - Total Summit TX Clean Energy IGCC-Transport Gasifier $284M - DOE w/Carbon Capture Commercial Demo of Advanced IGCC w/ Full Carbon Capture ~$2.67B – Total ~$1.7B – Total $270M – DOE $450M – DOE NRG W.A. Parish Generating Station Leucadia Energy Post Combustion CO2 Capture CO2 capture from Methanol plant $339M – Total EOR in eastern TX oilfields $167M – DOE $436M - Total $261M - DOE 67
  • 68. Important International Storage Projects Project Country Injection Amount Reservoir Storage Type Operator/Partner Cenovus, Apache, Weyburn- Oil Field Carbonate Canada 2.8 MMt CO2/yr Petroleum Technology Midale Project Enhanced Oil Recovery Research Center Sleipner Norway (off- 1 MMt CO2/yr Saline Marine Sandstone StatoilHydro Project shore) Snøhvit CO2 Norway (off- 700,000 Mt Saline Marine Sandstone StatoilHydro Storage shore) CO2/yr GeoForschungsZentrum, CO2SINK Germany 60,000 Mt CO2 Saline Sandstone Potsdam (GFZ) In Salah Gas BP, Sonatrach, Algeria 1 MMt CO2/yr Gas Field Sandstone Field StatoilHydro Gas Field and Saline Otway Basin Australia 65,000 Mt CO2 CO2CRC Sandstone 100,000 Mt Ordos Basin China Ordos Basin Shenhua Coal CO2/yr © 2012 Electric Power Research Institute, Inc. All rights reserved. 68
  • 69. For More Information • EPRI Report 1023468 • Issued last month • Free download for all members © 2012 Electric Power Research Institute, Inc. All rights reserved. 69
  • 70. Together…Shaping the Future of Electricity © 2012 Electric Power Research Institute, Inc. All rights reserved. 70