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CHEMICAL LOOPING COAL GASIFICATION SUB-PILOT UNIT DEMONSTRATION AND ECONOMIC ASSESSMENT FOR IGCC APPLICATIONS Award #: DE-FE0026185 Project Kickoff Meeting | December 7 th , 2015 Liang-Shih Fan Department of Chemical and Biomolecular Engineering
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CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

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Page 1: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

CHEMICALLOOPINGCOALGASIFICATIONSUB-PILOTUNITDEMONSTRATIONANDECONOMIC

ASSESSMENTFORIGCCAPPLICATIONS

Award#:DE-FE0026185

ProjectKickoffMeeting | December7th,2015

Liang-Shih FanDepartment of Chemical and Biomolecular Engineering

Page 2: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Outline

• Background• ProjectTeam• TechnicalApproach• ProjectManagement

Page 3: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Metal Oxide as Oxygen Carrier:

Oxidizerreduced

metal oxideoxidation

CH4

Reducermetal oxidereduction

Air

FeO/Fe

Fe2O3

CO2 + H2O Depleted AirCombustion: Complete Fuel Oxidation

FeO/Fe + Air (O2) à Fe2O3

Fe2O3 + CH4 à FeO/Fe + CO2 + H2O(oxidized) (reduced)

Chung, E.Y., Wang, W.K., Alkhatib, H., Nadgouda, S., Jindra, M.A., Sofranko, J.A., Fan, L.-S. 2015 AIChE Spring Meeting. April 2015.Chueh, W. C., Falter, C., Abbott, M., Scipio, D., Furler, P., Haile, S.M., Steinfeld, A. Science. 2010.

Reducer:

Oxidizer:

CO + H2Gasification: Partial Fuel Oxidation

FeO/Fe + Air (O2) à Fe2O3

Fe2O3 + CH4à FeO/Fe + CO + H2(oxidized) (reduced)

Reducer:

Oxidizer:

Oxidizerreduced

metal oxideoxidation

CH4

Reducermetal oxidereduction

Air

FeO/Fe

Fe2O3

Depleted Air

Solar/Nuclear Chemical Looping: Water SplittingChemicals Production: Selective OxidationHydrocarbons

Chemicals(Olefins)

Solar Energyor

Nuclear Energy

O2

Oxidized Metal Oxide

Reduced Metal Oxide Oxidizer

reduced metal oxideoxidation

Reducermetal oxidereductionOxidized

Metal Oxide

Reduced Metal Oxide Oxidizer

reduced catalytic metal oxideoxidation

Reducercatalytic

metal oxidereduction

Air

Depleted Air

H2O

H2

Chemical Looping Redox Applications

Luo, S., Zeng, L., Fan, L.-S., Annual Review of Chemical and Biomolecular Engineering. July 2015.

Page 4: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Fixed Bed Tests

1998

Bench Scale Tests

2001

Pilot Scale Demonstration

2010 to date

Sub-Pilot CDCL Process Tests

2007

CCR Process

SCL ProcessSTS

Process

ParticleSynthesis

1993

TGA Tests

Evolution of OSU Chemical Looping Technology

Fan, L.-S., Zeng, L., Luo, S. AIChE Journal. 2015.

Page 5: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

1.E-01

1.E+00

1.E+01

1.E+02

1.E+03

1.E+04

1.E+05

1.E+06

1.E+07

200 400 600 800 1000

Temperature (C)

PCO

2/PC

O

Fe2O3

Fe3O4

FeO

Fe1.E-01

1.E+00

1.E+01

1.E+02

1.E+03

1.E+04

1.E+05

1.E+06

1.E+07

200 400 600 800 1000

Temperature (C)

PCO

2/PC

O

Fe2O3

Fe3O4

FeO

Fe

Fluidized Bed Moving Bed

Chemical Looping Reactor Design

Large Small

Page 6: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Feed

stock Coal

NaturalGasOilPetcokeBiomassWasteSyngasF-Tlighthydrocarbon

Driver Chemical Looping

Combustion (CLC)Chemical LoopingGasification (CLG)Carbonation-Calcination Reaction(CCR)CalciumLoopingProcess(CLP)DirectChemicalSynthesis (withEcoCatalytic)

Applica

tionsand

Produ

cts CO2 Capture/Emission

ControlElectricity/heat• RetrofittoPC• NewPlant• CombinedCycle• SOFCHydrogenCLGSyngasLiquidfuel• F-TSynthesis• CO2 Hydrogenation• OlefinstoLiquidFuelChemicals• Olefins• Ammonia

Metal Oxide Development

Thomas, T. J., Fan, L.-S., Gupta, P., Velazquez-Vargas, L.G. U.S. Patent 7,767,191.

OSU Chemical Looping Platform Technology

Page 7: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

OSU Chemical Looping Platform Processes

Counter-current: Full Combustion Co-current: Full Gasification

Fan, L.-S., Zeng, L., Luo, S. AIChE Journal. 2015.

Simplicity: One Loop

Unique Reducer Configuration:

Moving Bed

Unique Flow Controller:

Non-Mechanical L-Valve

Two Basic Modes

CO2 out

MOVING BEDREDUCER

Fuel in

MOVING BEDREDUCER

Fuel in

Syngas out

FLUIDIZED BEDCOMBUSTOR

FLUIDIZED BEDCOMBUSTOR

Fe2O3

Fe/FeO Fe/FeO

Fe2O3

Air in

Depleted Air Depleted Air

Air in

Page 8: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

• Ease insyngasproductionandqualitycontrol– Mildoperationcondition (850-1,000℃)– Advancedoxygencarrierparticlecanhelpachievehighsyngas yieldand

selectivity (>90%,lowinCH4,H2O,CO2)• Standaloneandflexibleenergymanagement

– Noneedforgasifierandairseparation unit– Effective integration withIGCCprocess

• Efficiency improvement andcostreduction

CLG Process Advantages

GEE OSU CLG

Gasifier/ReducerInput

H2O (mol H2O/mol C) 0.426 0.01 - 0.4

Gasifier/ReducerOutput

H2 (mol H2/mol C) 0.678 0.48-0.70

CO(mol CO/mol C) 0.707 0.91-0.93

CO2 (mol CO2/mol C) 0.270 0.09-0.06*Carbon value based on as-received coal (Illinois #6)

Page 9: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Stan

dard

Gib

bs F

ree

Ener

gy o

f Rea

ctio

ns (k

J/m

olO

2)

Temperature (oC)

Modified Ellingham Diagram

OxygenCarrierSelection

Reactivityandrecyclabilityofselectedparticleconfirmed

Page 10: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

ClassicalThermodynamics:CH4 andFe2O3

20

30

40

50

60

70

80

90

100

0 0.5 1 1.5 2 2.5 3 3.5

%CH4 conversion– 99.80%Co

nver

sion

, Yie

ld (%

)

(1.38)(0.38)

H2/CO = 1.97

92.14 %

Fe2O3/CH4 molar ratio

IncreasingFe2O3/CH4 ratiodecreasessyngasyield,whichqualitativelyagreeswithabinitio thermodynamiccalculation

%SolidConversion– 33.33%

Oxygen Vacancy Rich Oxygen Vacancy Lean

Page 11: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

20

30

40

50

60

70

80

90

100

0 0.5 1 1.5 2

%Con

version

Fe2O3/Cinput (molarratio)

%Syngas%Solids%Cconv.

92.8%

Fuel input100 % Illinois #6 Coal

Carbonconversion– 100.0%

0.35

0.90

ClassicalThermodynamics:100%Coal

Page 12: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

• CoalmixedwithOxygenCarrierparticles• Tests performed:

• Methanetosyngas• Sub-bituminous andbituminous coaltosyngas• Co-injectionofmethane• Co-injectionofmethaneandsteam

CLGBenchScaleStudies

Page 13: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

0%

10%

20%

30%

40%

50%

60%

70%

0 20 40 60 80

Concentra

tion(%,D

ry)

Time(min)

H2

CO

CO2

CH40%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 20 40 60 80 100

Con

cent

ratio

n / P

urity

Time (min)

SyngasPurity

H2

CO

CO2

CH4

• Coalvolatiletests:CH4 tosyngas• CH4 conversion:>95%• Syngaspurity:>88%• H2:CORatio:2:1

• CoalTests:PRB• Coalconversion:>93%• Syngaspurity:>88%• H2:CORatio:0.64:1

• H2 richsyngasproducedco-injectingCH4 andH2Oco-injectionwithPRBcoal

• H2:CORatio:~1.8• Syngaspurity:>85%

Coal Volatile Tests

Temp.: 1000oCOC Flow: 20g/minCH4 Flow: 1.8 SLPMN2 Flow: 0.2 SLPM

Temp.:1000oCOC:20g/minCoal:4g/minN2:1 SLPM

Temp.:1000oCOC:20g/minCoal: 0.9g/minCH4:1.2SLPMH2O: 0.8g/minN2:1SLPM

PRB Coal TestsCo-Injection Test with PRB Coal

Coal:CH4:H2O:Fe2O3≈4:6:5:7 (mole ratio)

CLGBenchScaleStudies

0

10

20

30

40

50

60

70

0 11 22 33 44 55 66

Concentration(%,D

ry)

Time(min)

H2

CO

CO2CH4

Page 14: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

0%10%20%30%40%50%60%70%80%90%

100%

0 50 100 150 200

Gas

conc

entra

tion,

dry

bas

e, N

2 fr

ee

Time (min)

Illinois #6 Coal TestHigh CO2 Syngas Generation

CO2

CO

H2

CH4

Temp.: 1000oCOC Flow: 23g/minCoal:3g/minCH4 Flow: 0.87 SLPM

Temp.: 1000oCOC Flow: 20g/minCoal:2.8g/minCH4 Flow: 0.75 SLPM

• Sub-bituminouscoal(PRB)andbituminouscoal(Illinois#6)testedwithCH4 co-injection

• Highpuritysyngasgenerationachieved• H2:COratioof1:1achievedbyadjustingCH4

flowrateforbothcoalstested• SyngaswithvariableCO:CO2 ratiocanbe

generated• ExtremecaseofCO:CO2=0.1shownbelow

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 20 40 60 80 100

Coc

nent

ratio

n / P

urity

Time (min)

PRB Coal Test

SyngasPurity

H2

CO

CO2CH4

CLGBenchScaleStudies

Temp.: 950oCOC Flow: 20g/minCoal:0.75 g/minH4O Flow: 0.56 g/min

Page 15: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Ø 100%MethaneConversion

Ø 90%SyngasPurity

Ø 2:1Ratio– Suitablefor

LiquidFuelSynthesis

ExperimentalStudies– CoalVolatileTests

Page 16: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Ambient Air

ShellQuenchGasifier

WaterGas Shift

Coal

CoalPreparation

Low Temp Cooling&

Mercury Removal

Acid GasRemoval

(Rectisol)Sour

Syngas Bypass

SweetSyngas

CO2Compressor

CO2Product

MethanolSynthesis

CrudeMethanolProduct

Flash Gas &Tail Gas fromMethanolSynthesis toSteam Production

Sour WaterSystem

SourWater

ClausPlant

AcidGas

Sour Gas SulfurProduct

StrippedWaterFlash Gas

ElevatedPressure

ASU

WetScrubbin

g

Solid Waste

Coal Gasification for Methanol Production: DOE Baseline (Traditional) Process

N2

O2

National Energy Technology Lab. U.S. DOE/NETL Report 341-101514, 2014.

Steam

Page 17: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Ambient Air

OSUReducer

Coal

Low Temp Cooling&

Mercury Removal

Acid GasRemoval

(Rectisol)SweetSyngas

CO2Compressor

CO2Product

MethanolSynthesis

CrudeMethanolProduct

Tail Gas fromMethanolSynthesis toSteam ProductionSour Water

System

SourWater

ClausPlant

AcidGas

Sour Gas SulfurProduct

StrippedWaterFlash Gas

OSU Oxidizer

Coal Gasification for Methanol Production: OSU Process

N2

Sour Syngas

Fe2O3

2FeO

Kathe, M., Xu, D., Hsieh, T. L., Simpson, J., Statnick, R., Tong, A., Fan, L.-S. 2014. OSTI: 1185194.

Steam

Page 18: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

18

• AlowermethanolRequiredSellingPriceby$0.37/gal,a21%decrease• Lowertotalplantcapitalcostsby28%• Lowerthecapitalcostforsyngasgenerationequipmentbyover50%• Higherefficiencybased14% incoalconsumption• AmethanolRequiredSellingPricelowerthanthereference non-

capturecase,whichresults inCO2 capturecostlessthan0.

OverallTechno-EconomicAnalysisSummary

Stream MassFlowlb/hr

Case DOE/NETLMBL-1,MBL-2 OSU-1 OSU-2

AsReceivedCoal 1,618,190 1,395,457 718,631

NaturalGastoOSUCLG NA NA 272,290

Oxygen fromAirSeparationUnit 10,10,968(95%O2) NA NASteamtogasifier,reformer,quench,

OSUCLG 1,533,584 1,624,318 693,587

Cleansyngasformethanolproduction 1,183,080 1,025,106 1,039,864

CapturedCO2 1,569,410(MLB-2) 1,302,138 663,393

Kathe, M., Xu, D., Hsieh, T. L., Simpson, J., Statnick, R., Tong, A., & Fan, L.-S. Chemical Looping Gasification for Hydrogen Enhanced Syngas Production with In-Situ CO2 Capture. 2014. OSTI: 1185194.

Performance modelling Results: 10,000 mtpd crude methanol system

Page 19: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

DOE baseline OSU CTS

Methanol Required Sale Price ($/gal):

DOE baseline: 1.78OSU CTS: 1.41

Gas

ifica

tion

equi

pmen

t cap

ital c

ost

( $M

M/1

0,00

0 tp

dcr

ude

met

hano

l)

$1,888 MM

$913 MM

$1,145 MM

$363 MM

$743 MM

$549 MM

Cost Analysis: Total Plant Capital Cost for 10,000 ton/day Methanol Production from Coal

Equipment Cost

Equipment Cost

BEC, Contingency

BEC, Contingency

Kathe, M., Xu, D., Hsieh, T. L., Simpson, J., Statnick, R., Tong, A., Fan, L.-S. 2014. OSTI: 1185194.

Page 20: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Outline

• Background• ProjectTeam• TechnicalApproach• ProjectManagement

Page 21: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Government Agencies• DOE/NETL: Darryl Shockley• Ohio Development Service Agency: Gregory PayneProject Partners• Ohio State University: Liang-Shih Fan (PI), Andrew Tong

(Co-PI)• WorleyParsons: James Simpson• Clear Skies: Robert Statnick

ProjectTeam

Page 22: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Outline

• Background• ProjectTeam• TechnicalApproach• ProjectManagement

Page 23: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

• PrepareChemicalLoopingGasification(CLG)technologyforacommerciallyrelevantdemonstrationby2020

• DesignandconstructanintegratedCLGsystematsub-pilotscalewithcoalasitsfeedstock– Continuouslyoperate thesystemanddemonstrate syngasandH2

production– Investigate thefatesofsomeimportant impurities, suchassulfurand

nitrogen

• Conducttechno-economicanalysisandoptimizetheCLGprocessforefficientelectricitygenerationwithreducedcarbonemission

TechnicalApproach- ProjectObjectives

Page 24: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

TechnicalApproach– TasksandSchedule

Page 25: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

TechnicalApproach– TasksandSchedule

Page 26: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

15kWth Sub-PilotReactorDesign• Integrated3-reactorsystem

– Non-mechanicaldevices– Computerizeddataacquisitionandprocesscontrol

• Design,Construction,andCommissioning– Detaileddesignandsafetyreview– Reactorfabrication– Installationonexistingstructure– Leakcheck,instrumentcalibration,functionalchecks,andfinalsafetyreview

Existing Structure

Page 27: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

3”

Gas inlet

Gas outlet

Solids inlet

Solids outlet

0

2

4

6

8

10

12

14

16

18

0 10 20 30 40 50 60

PressureDropThroughFuelReactor(in.H2

O)

GasFlowRate,SLPM

Fuel Reactor Design

• Co-Current Move Bed Arrangement

• Top Gas/Solids In• Bottom Gas/Solids Out

• Dipleg for solids/gas inlet

• Pressure Drop• Gas-Solids Relative

Velocity• Ergun Equation• Pressure Drop v.s.

Velocity

ColdFlowModelStudies

Page 28: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

15kWth Sub-PilotReactorOperation• Parametricstudies

– Coal:Fe2O3 ratio– Coal:H2Oratio– Temperature– Residence time– Verifyperformance model

• PerformanceParameters– Coalconversion

𝑋"#$% =𝑛(,*+,-"+* + 𝑛(,"#/0-12#* + 𝑛(,#34,45+*

𝑛(,"#$%– Carboncaptureefficiency

𝜂( =𝑛(,*+,-"+* + 𝑛(,#34,45+*

𝑛(,"#$%– Syngaspurity

𝑆 = 𝑥(9,*+,-"+* + 𝑥:;,*+,-"+*– Gasification thermalefficiency

𝜂2 =𝐻𝐻𝑉*+,-"+* + 𝐻𝐻𝑉#34,45+*

𝐻𝐻𝑉"#$%

Page 29: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

TechnicalApproach– TasksandSchedule

Page 30: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

u Leading professional services provider to the energy, resource, and complex process industries

u Organized into Customer Sector Groups:

30

Company Overview

UpstreamHydrocarbonsFixed Offshore FacilitiesFloating Production SystemsDeepwater Solutions Subsea SystemsOffshore PipelinesOnshore PipelinesOnshore Oil & Gas Production FacilitiesHeavy Oil and Oil SandsLNGTerminals

DownstreamHydrocarbonsRefining PetrochemicalsChemicalsPolymersGasificationSulphur Management

PowerCoal-Fired PlantsAdvanced CoalNuclearGas Turbine/Combined CycleAir Quality ControlIntegrated Gasification Combined Cycle (IGCC)Transmission NetworksOperations & MaintenanceRenewable Energy

Minerals, Metals & ChemicalsBase MetalsCoalChemicalsFerrous MetalsAluminaAluminumIron OreGas Cleaning

Infrastructure &EnvironmentResource InfrastructureUrban InfrastructureCoastal and MarineWater and WastewaterTransportEnvironment

Page 31: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Techno-Economic Assessment

u Objectives: 1. Develop process models and configurations for and IGCC power

generation facilities incorporating OSU CLG technology.2. Develop economic comparison of facility designs incorporating

OSU CLG technology to IGCC reference cases.u Activities:

• Develop process models of OSU CLG technology in Aspen• Incorporate OSU CLG technology modules in Aspen IGCC process

models.• Estimate capital and operating costs based on Aspen modeling of

processes• Perform financial analysis to determine power production costs and

cost of CO2 captured.• Compare costs to DOE/NETL reference cases

Page 32: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

u Reference IGCC Power Production: • IGCC cases from Cost and Performance Baseline for Fossil

Energy Plants Volume 1b: Bituminous Coal (IGCC) to Electricity Revision 2b.

u OSU CLG Cases• No capture with 2 reactor CLG configuration• CO2 capture with 2 reactor CLG configuration

Options Considered

Page 33: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

CTS SYSTEM #1 (No CCS)

ReducerCoal

Preparation

Acid Gas

Removal

( H2S)

Sour Water

System

Sour

Water

Claus

Plant

Acid

Gas

Sour Gas

Sulfur

Product

Stripped Water

Air Nitrogen Diluent

Compressor

As Received

Coal

Ash Removal

Steam Gas Cooling

BFW Heating

& Knockout

Mercury

Removal

Spent-Air

to Stack

Gas

Turbine

Combustor

Air

2Χ Advanced

F CLASS

GAS TURBINE

Turbine Cooling AirElectricity

Production

HRSG

Steam

Turbine

HRSG

Combustor

Fe

O /

Fe F

e2 O

3

Syngas

Syngas

Reheat

&

Humidification

Page 34: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

CTS SYSTEM #2 (90% CCS)

2 Reactor Design:

Acid GasRemoval(Selexol) CO2 free

syngas

CO2 CompressorCO2

Product

Sour WaterSystem

SourWater

ClausPlant

AcidGas

Sour Gas SulfurProduct

Stripped Water

Nitrogen Diluent

Gas CoolingBFW Heating& Knockout

MercuryRemoval

Spent-Airto Stack

Gas Turbine

Combustor

Ambient Air

2Χ AdvancedF CLASS

GAS TURBINE

Turbine Cooling AirElectricity Production

HRSG

SteamTurbine

HRSG

ReducerCoalPreparation

Air

Compressor

Ash Removal

Steam

Combustor

FeO

/ Fe Fe2 O

3

Syngas

ShiftReactors

Quench,Scrubbing

As Received Coal

Syngas Reheat

& Humidification

Page 35: CHEMICAL LOOPING COAL GASIFICATION Library/Research/Coal/energy systems...CHEMICAL LOOPING COAL GASIFICATION ... • Project Management • Prepare Chemical Looping Gasification (CLG)

Evaluation Basis

u Fuel: Bituminous Coalu CO2 Removal: >90% based on raw syngas carbon contentu CO2 Product

• CO2 Purity: Enhanced Oil Recovery as listed in Exhibit 2-1 of the NETL QGESS titled “CO2 Impurity Design Parameters”. *

• CO2 Delivery Pressure: 2,215 psia• Transport and Storage (T&S): $10/tonne

u Plant Size: Sufficient syngas to fill two advanced F class gas turbines, 500-550 MW.

u Power Block: 2x1 Configuration, advanced F class gas turbinesu Ambient Conditions: Greenfield, Midwestern USAu Capacity Factor: 80%u Financial Structure: High risk IOU, capital charge factor = 0.124

http://www.netl.doe.gov/energy-analyses/refshelf/PubDetails.aspx?Action=View&PubId=420

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Capital and Operating Costs

u Reference Case• Capital and O&M cost will be determined from costs presented

DOE/NETL Cost and Performance Baseline Studies for coal-fired power.

u OSU CLG System• Sizing information of reactors and consumption rates for

consumables will be developed from Aspen modeling and guidance from OSU.

• ICARUS, from Aspen Tech., and in house parametric models will be used for developing costs for reactor vessels, absorbers, and other specialized process equipment based on the equipment size, basic design, and materials of construction information.

• Factored estimates for equipment such as pumps

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Capital Cost Breakdown

u Costs will be presented in 2011 dollarsu Factored estimates for equipment such as pumpsu Capital costs breakdown will be provided to illustrate the

contribution of various accounts (such as Coal & Sorbent Handling and Instrumentation & Control) to the total plant costs.

u Breakdown of accounts will include:• Equipment• Material• Labor

• Engineering, Construction• Management, Home Office and Fees• Process and Project Contingencies

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Operating and Maintenance Costs Breakdownu Operation and maintenance cost breakdown will

include:Fixed Variable

• Operating Labor• Maintenance Labor• Administrative & Support

Labor• Property Taxes and

Insurance• Maintenance Material

• Consumables• Water• Oxygen carrier• Solvents

• Waste Disposal• Fuel

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Economic Analysis

u Purpose:• Compare Cost of Electricity (COE) for systems including OSU CLC

technology to reference case developed by DOE/NETL.• Provide understanding of factors that impact COE

u Activities:• Determine COE and LCOE and cost of CO2 captured using DOE/NETL

Power Systems Financial Model or similar in house models.• Explore sensitivity of metrics on input parameters to economic model

including:− process efficiency− capital costs− operating costs

u Deliverables• Design basis report• Quarterly updates• Final techno-economic report

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Outline

• Background• ProjectTeam• TechnicalApproach• ProjectManagement

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NETL/DOE(

Prof.(Tong(Co1PI(

WorleyParsons( Postdoctoral(Research(Associate(

Techno'Economic+Analysis+Task%5%

2(Graduate(Research(Associates(

Prof.(Fan(PI(

4(Graduate(Research(Associates(

2(Postdoctoral(Research(Associates(

Detailed(Design(Task%2%

ConstrucEon(and(Commissioning(

Task%3%

Integrated(Unit(OperaEons(Task%4%

Clear(Skies(ConsulEng(

Project(Management(and(Planning(

Task%1%

ProjectManagement

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FederalFunding CostShareTheOhioStateUniversity $1,274,516 $157,186WorleyParsons $195,484 -ClearSkiesConsulting $30,000 $34,133OhioDevelopmentServicesAgency $500,000Total $1,500,000 $686,000

Category BudgetPersonnel $649,976FringeBenefits $152,252Travel $45,000Equipment $125,000Supplies $80,813Contractual $354,762Other $202,805TotalDirectCharges $1,610,608IndirectCharges $575,392Totals $2,186,000

ProjectBudget

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Budget Period Task Number Milestone Title/Description Planned

Completion DateVerification

Method

1 2Sub-pilot test unit design and quotes finalized and within budget 3/31/2016

Quarterly Report

1 3Sub-pilot system installation and commissioning completed 9/30/2016

Quarterly Report

1 4100 hours of cumulative sub-pilot unit operation achieved 2/28/2017 Final Report

1 5 Design basis for CLG-IGCC defined 12/31/2015Quarterly

Report

1 5Techno-Economic assessment of CLG for IGCC Application Completed

3/31/2017 Final Report

MilestoneLog

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Thanks