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1 ACT Presentation March 6, 2007 Carl Bozzuto – Executive Consultant 3 One Vision for New Coal Power Portfolio of Clean Technologies COAL Fuel Cell O 2 i CO2 IGCC IGCC H 2 H 2 GT CO2 2 CFB USC CFB O 2 or PC PC USC PC COMPLETE combustion CO2 2 CO2 Carbonate looping CO2 2 LOOPING CO2 Capture And Sequestration PARTIAL COMBUSTION PETROCHEMICAL water sh ft Scrubbing Air AIR BLOWN IGCC Oxygen Fired CFB COMBUSTION Air Post- capture Concentrated Near-zero emissions Carbon Free Power CHEMICAL 1
16

Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

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Page 1: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

2

1

ACT Presentation

March 6, 2007 Carl Bozzuto – Executive Consultant

3

One Vision for New Coal Power Portfolio of Clean Technologies

COAL

Fuel Cell

O2

i

CO2

IGCC

IGCC

H2 H2 GT

CO22

CFB USC CFB

O2 or PC

PC USC PC

COMPLETE

combustion CO22

CO2

Carbonate looping

CO22LOOPING

CO2 Capture And

Sequestration

PARTIAL COMBUSTION PETROCHEMICAL

water sh ft

Scrubbing

Air

AIR BLOWN IGCC

Oxygen Fired CFB

COMBUSTION

Air Post-

capture

Concentrated

Near-zero emissions Carbon Free Power

CHEMICAL

1

Page 2: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

Natural Gas

Steam Coal

3

Drivers for New Coal Build North America

� i

� l

� Economi� Fuel Cost � i ivi

t

� Coal i� +

America

� l

� Fuel di

0

1

2

3

4

5

6

7

8

9 19

98

2000

2002

2004

2006

2008

2010

2012

2014

Deli i

/

4

New Coal CapacityFaces Challenges

� Utilization of all l� Competitive costs

� ity � t

�Environmental � Near zero emissions … � and a carbon strategy

Base Energy needs versus Peak ng Capacity

Base oad demand expected to increase at roughly GDP

cs

End User pr ce shocks dr ng demand for low cos energy

availabil ty and prevalence 200 Years of Reserves in North

Advent of OTC (over the counter) markets for coal and emissions

Environmenta regulations drive new clean plants

versity

vered Pr ce

US

$M

M B

TU

Source: U.S. EIA

Economics ow cost domestic coals …and opportunity fuels

Operations Highest reliability and commercial availabilOperating parameters to mee demands of grid

2

Page 3: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

5

)

) CFB

PC and CFB

:

¾ ¾ ¾ ly

0

Operating Coal Combustion –

Source: Energy Velocity database ( EPA CEMS 2005 data

SubBit. PC

IGCC (operating

Bit. PC

Clean Coal technologies have demonstrated the lowest emissions

Exceed Requirements Cost Effectively Reliab

2005 Wtd Avg NOx Emissions - US Coal Units

0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08

Lbs/

MM

Btu

Top 20 - Lowest NOx emitters

2005 Wtg. Avg SO2 Emissions - US Coal Units

0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08

Lbs/

MM

Btu

Top 20 - Lowest SOx emitters

Best in Class Emissions

Ultra Clean Coal CombustionEmissions 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 � Integrated Multi-pollutant systems to reduce costs � High Hg capture on all coals (without reliance on ACI) � Introduction of CO2 capture

3

6

Page 4: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

tion

7

Multi-pollutant

� ly

� l il�

– No i fly ash �

– ign � ital

– i– t

� i le/� Avoi 2

� i l l– SO2: l ) – Hg: / ) – lb/ ) – NOx l

• (

Controls SOx, PM10/PM2.5

APC Systems Integrated APC systems based around commercialproven and reliable technologies Use readi y ava able reagents Produces reusable byproduct(s)

mpact on Superior cost/performance ratio:

Extremely compact desReduces cap costs for equipment, erec and BOP

Fewer moving parts reduces ma ntenance costs Superior environmen al performance

Reduced perm tting schedu cost ded cost for SO credits

Targeted emiss ons eve s: 0.02 b/MMBTU (> 99.5%

1.0 lb TBTU (> 90%PM: 0.01 MMBTU (99.99%

: 0.05 b/MMBTU w/SCR “Polishing” Level TBD) w/o SCR

Mercury & NOx

8

� ) �

When Additional Control is Needed ­Mercury Capture Technologies

Additives: Halogen(sPowdered Activated Carbon Halogenated Powdered Activated Carbon

= Potential additive injection points

4

Page 5: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

Vers

35-37%

37-38

41

3480/1005/1050 (psi/°F/°F)

2400/1005/1005167/540/540

4000/1075/1110 (psi/°F/°F)

38-41%

Commercial State of Art

ritical

US-DOE :Ultra-Supercritical Boiler ProjectOperating Target: 1400°F/5500 psig

European Thermie ProjectOperating Target: 1292°F/ 4500 psig

9

Efficiency –Critical to emissions strategy

/ 10% co-

/

Coal wfiring biomass

100% Coal

Existing US coal fleet @ avg 33%

Commercial Supercritical

First of kind IGCC

Net Plant Efficiency (HHV), %

Source: National Coal Council From EPRI study

10

1960 1980 2000 2020

--

T91

Up to )

)

Superc

2010

Sliding

US-DOE :Ultra-Supercritical Boiler Project °

°

Progression of Plant Efficiency via Advanced Steam Conditions and Plant Designs

Material Development

Efficiency (net) HH Typical Steam Paramet

%- 43%

TARGET 48 - 50 %

Ni-based Materials

Mature Supercritical

Advanced Austenitic Materials

5400/1300/1325(psi/°F/°F

4000/1110/1150(psi/°F/°F

Subcritical Technology

UltraSupercritical

Advanced USC

Pressure Supercritical

Operating Target: 1400 F/5500 psig

European Thermie Project Operating Target: 1292 F/ 4500 psig

5

Page 6: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

Supercritical Cycles 147 GW, 230 Supercritical Coal Fired Boilers Ordered Since 1990

Clear Trend to Advanced

11

0

10

20

30

40

50

60

70

80

0

20

40

60

80

100

120 Number of UnitsGW

12

0

10

20

30

40

50

/

i(

Meeting the Goals for

<1050 F or unknown

1050 F ­1110 F

>=1110 F <1050 F or unknown

1050 F ­1110 F

>=1110 F

Maximum of SH or RH Temp Maximum of SH or RH Temp

POLK WABASH IGCC

Target for New IGCC*

SCPC Today USC Target Next Gen IGCC Plan

t Eff

cien

cy %

HH

V B

asis

)

Coal Based Power - Efficiency

6

Page 7: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

13

Increased Value for Efficiency

i l /l

0 2 4 6 8

10 12 14 16

20 25 30 35 40 45 50

An al l i

~$10M/yr

Compared to 34% subcr tica efficiency, 11,000 BTU b coal, 80% capacity factor

Efficiency

Coal Price USD/Short Ton

500 MW Unit

nu Fue Sav ngs, MUSD

42%

40%

38%

36%

~$6.5M/yr

CO2 Mitigation Options – for Coal Based Power

9Increase efficiency Maximize MWs per lb of carbon processed

9Fuel switch with biomass Partial replacement of fossil fuels =

proportional reduction in CO2

9Then, and only then ….Capture remaining CO2 for EOR/Sequestration

= Logical path to lowest cost of carbon reduction

7

14

Page 8: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

15

Iiple suppliers driving

Advanced Amine Scrubbing

CO2 Adsorption with Solids

l t 2f l

f

CO2

2CO2 ing

tCO2ammonia based

Further Improvements in Solvents, Thermal ntegration, and Application of Membranes Technologies Focused on Reducing Cost and Power Usage – Multinnovations

Being Developed by the University of Oslo & SINTEF Materials & Chemistry (Oslo, Norway), in Cooperation with ALSTOM

Use Regenerative Air-Heater-Like Device with Solid Absorbent Materia o Capture ~ 60% COrom F ue Gas.

Being Developed by Toshiba, with Support rom ALSTOM

Wheel

Uses Refrigeration Principle to Capture CO from Flue Gas. Process Being Developed by Ecole de Mines de Paris, France, with ALSTOM Support

Frost

Demonstration in 2006. Advantage of lower cos s than Amines. Applicable for retrofit & new applications

Scrubbing options –

Status Technology

CO2 Capture – Post Combustion

Technology Validation & Demonstration

16

)

N2

O2

O2, N 2 Fuel H2O

CO2

Oxygen Firing to produce concentrated CO2 stream

CO2

¾ 2 to >90% for reduced

Compressor

Air Separation Unit (ASU Boiler

Air in-leakage

Condenser

Recycle

3 MWt pilot CFB

Oxygen Firing – Direct concentration of COcapture costs

8

Page 9: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

Vattenfall..., ALSTOM, others

2008Test of the oxyfuelprocess chain

1:60Pilot Plant 30 MWth

17

30 MWth Oxy-fired PC Pilot Plant – Vattenfall

Location of pilot plant in the Industrial Park Schwarze Pumpe

2020approx. 4-5

Commercial Plant approx. 1000 MWel

2015Realisation with CO2 sequestration,

1:20Demo Plant 600 MWth

CEBra, BTU Cottbus, Vattenfall, ALSTOM

2005Fundamentals of oxyfuel combustion with flue gas recirculation

1:50Test Plant 500 kWth

Universities (Stuttgart, Chalmers, Dresden) Vattenfall, ALSTOM..

2004 2005

Fundamentals of oxyfuel combustion

Laboratory Tests 10 / 55 kWth

PartnersComObjectiveScale-up Factor

Development Steps

2020approx. 4-5

CommercialPlant approx. 1000 MWel

2015Realisation with CO2 sequestration,

1:20Demo Plant600 MWth

Vattenfall..., ALSTOM, others

2008Test of the oxyfuel process chain

1:60Pilot Plant 30 MWth

CEBra, BTU Cottbus, Vattenfall, ALSTOM

2005Fundamentals of oxyfuel combustion with flue gasrecirculation

1:50Test Plant 500 kWth

Universities (Stuttgart, Chalmers, Dresden)Vattenfall, ALSTOM..

20042005

Fundamentals of oxyfuel combustion

LaboratoryTests 10 / 55 kWth

PartnersComObjectiveScale-up Factor

Development Steps

18

G Boiler

CO2 liquid

M

Stripper

MEA CO2 Absorber

CO2 Compressor

SteamTurbine

MEA

Amine-Based Absorption - CO2 Capture

� MEA has demonstrated performance on coal based flue gas

� Work required to address:

� Regeneration power

� Compression ratio

� Cost of solvent

SHADY POINT, OKLAHOMA, USA An AES CFB power plant with

MEA CO2 separation

9

Page 10: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

---

Flue GaCoolingSystem

EnergyRecover

EnergyRecovery

CO2

Tower

Energy

19

Advancements Absorption Stripping CO2 Capture

� 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

¾With industry focus on improvements, advanced amines likely to be competitive solution for post combustion capture

Amine scrubbing continues to develop

20

CO2 Capture InnovationsChilled Ammonia System

s

yRecovery

Existing SO2 Scrubber

Flue Gas

� Ammonia reacts with CO2 and water and forms ammonia carbonate or bicarbonate

� Moderately raising the temperature reverses the above reactions – producing CO2

� Regeneration at high pressure

CO2 Lean

CO2 Rich

CO

2 A

bsor

ptio

n To

wer

Existing Stack

Concentrated CO2 to SequestrationEnergy

Recovery

EnergyRecovery

Flui

d R

egen

erat

ion

Flue

Gas

Coo

ling

10

Page 11: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

21

Advantages of Chilled Ammonia

� 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

Post Combustion CO2 CaptureChilled Ammonia

Without CO2 Removal

MEA-Fluor Dan. Proc.

NH3

Total power plant cost, M$ 528 652 648 Net power output, MWe 462 329 421

Levelized cost of power, c/KWh 5.15 8.56 6.21 CO2 Emission, lb/kwh 1.71 0.24 0.19 Avoided Cost, $/ton CO2 Base 51.1 19.7

22

11

Page 12: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

1990 1995 2000 2005 2010 2015 2020

Going Down The Experience Curve forPost Combustion CO2 Capture

23

0

500Hea

t of R

eact

ion

(BTU

/lb)

1995 2000 2005 2010 2015

Study ( )

ABB

/lb

1000

1500

2000

2500

3000

2001 Parsons Fluor

Lumnus

Process Optimization

Advanced Amines

Process Innovations

ALSTOM’s Chilled

Ammonia Process

Significant Improvements Are Being Achieved

Values From Current Projects

1,350 BTU

24

We Energies Pleasant Prairie Host Site Location for 5MW Pilot

12

Page 13: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

25

Carbon Free PowerAdvanced Combustion

Innovative Combustion Options for 2010 and Beyond

¾ Oxygen Firing – Direct concentration of CO2 to >90% for reduced capture costs

¾ Chemical Looping –Leapfrog technology with potential to achieve significantly lower costs than PC/CFB/IGCC

26

Oxidizer

Calciner

Cold Solids

CaCO3

4

Hydrogen

Coal,

CO2

Air

3

4

Oxidizer 4

CO2 & H2O

Coal, Limestone Air

4

Combustion

Future Technologies for CO2 Capture

Hot Solids

Reducer

CaO

CaS

CaSO

Steam

CaCO

Depleted Air, Ash, CaSO

Reducer

CaS

CaSO

Depleted Air, Ash, CaSO

Chemical Looping

Chemical Looping Gasification

Chemical Looping

13

Page 14: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

27

0 2 4 6 8

10

SCPC

IGCC

SCPCw/M

EA

Oxyfir

ing w CO2

SCPCad

v amines

IGCC

F turbine

SCPCNH3

USCPCad

v CO2

IGCC

H turb

ine wad

v CO2

Multiple Paths to CO2 ReductionInnovations for the Future

No CO2 Capture 2

t t

iati tLe

veliz

ed C

OE

cent

s/K

whr

------------------------------With CO Capture---------------------------

Technology Choices Reduce Risk and Lower Costs

Note: Costs include compression , bu do not include sequestra ion – equal for all technologies

‘Hatched’ Range reflects cost var on from fuels and uncer ainty

28

Market Trends

175

150

125

100

Month

Carbon Steel Price Trends

Inde

x B

ase

1982

01/02 01/03 01/04 01/05 01/06

14

Page 15: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

29

il

June

Aug

ust il

June

Aug

ust il

June

Aug

ust il

June

Aug

ust il

June

Aug

ust il

June

Aug

ust il

June

Aug

ust

i i i

Market Trends

Nickel Trend: 2000 - 2006

1.80 2.20 2.60 3.00 3.40 3.80 4.20 4.60 5.00 5.40 5.80 6.20 6.60 7.00 7.40 7.80 8.20 8.60 9.00 9.40 9.80

10.20 10.60 11.00 11.40 11.80 12.20 12.60 13.00 13.40 13.80 14.20 14.60 15.00 15.40 15.80 16.20

Janu

ary

Febr

uary

M

arch

A

pr May July

Sep

tem

ber

Oct

ober

N

ovem

ber

Dec

embe

r Ja

nuar

y Fe

brua

ry

Mar

ch

Apr May July

Sep

tem

ber

Oct

ober

N

ovem

ber

Dec

embe

r Ja

nuar

y Fe

brua

ry

Mar

ch

Apr May July

Sep

tem

ber

Oct

ober

N

ovem

ber

Dec

embe

r Ja

nuar

y Fe

brua

ry

Mar

ch

Apr May July

Sep

tem

ber

Oct

ober

N

ovem

ber

Dec

embe

r Ja

nuar

y Fe

brua

ry

Mar

ch

Apr May July

Sep

tem

ber

Oct

ober

N

ovem

ber

Dec

embe

r Ja

nuar

y Fe

brua

ry

Mar

ch

Apr May July

Sep

tem

ber

Oct

ober

N

ovem

ber

Dec

embe

r Ja

nuar

y Fe

brua

ry

Mar

ch

Apr May July

Sep

tem

ber

Oct

ober

N

ovem

ber

Dec

embe

r

2000 2001 2002 2003 2004 2005 2006 Month / Year

Spot

Nic

kel

Low N Avg. Spot N High N

30

0

CO2 Al ( 2 )

/)

I l i

I l i

iw i

i ia

i ii i

)Air Fi /( )

i)

f - I) w i

f - I) w i

SCPC Adv a e CO2

CO2 Capture

cases

4.00

5.00

6.00

7.00

8.00

9.00

10 20 30 40 50

low ance Price $/Ton CO Em itted

(Cen

tskW

h r

GCC H Cass (E-Gas) w th Capture - Spare

GCC H Cass (E-Gas) w th Capture

10-Advanced O2 Fred CFB th Capture

PC w th Chilled AmmonCO2 Capture

3-Chemcal Loop ng Combust on w th Capture (CaS

red PC w o Capture 3915/1085/1148

PC CO2 Scrubb ng - MEA (Parsons

Re GCC 7FA (GE-Texaco Heat Recovery th Capture Re GCC 7FA (GE-Texaco Heat Recovery th Capture - Spare

min

Technology Innovations

PC with ‘old MEA’

Chemical Looping

IGCC

Ammonia scrubbing

Oxygen Firing

PC with adv MEA’

15

Page 16: Advanced Coal Technology Work Group March 6 2007 Presentation · 2015-05-06 · Chilled Ammonia System s Recoveryy Existing SO 2 Scrubber Flue Gas Ammonia reacts with CO 2 and water

31

CO2 Capture Innovative options continue to emerge and develop

� 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)

Conclusions

� 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, andmore 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

16

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