Clean Coal Technology - National Conference of State ... · Robert G. Hilton August 5, 2012 Clean Coal Technology Presented to the National Conference of State Legislatures

Robert G. Hilton

August 5, 2012

Clean Coal Technology

Presented to the National

Conference of State Legislatures

Agenda

1st topic Combustion Page 2

2nd topic Criteria Pollutants Page 10

3rd topic CO2 Capture Page 18

Sub. vs. Supercritical Cycle Impact on Emissions

Plant Efficiency, %*

Plant Efficiency, %

Fuel Consumption/Total Emissions

including CO2

Subcritical Supercritical 34 - 37 37 - 41

Plant Efficiency, Btu / kw-hr 10,000 - 9,200 9,200 - 8,300

34%

Base

37%

Base-8%

41%

Base-17%

* HHV Basis

NAM SC Plant Experience – J.Marion – Clearwater Conf. – 7 June 2010 - P 4 All data at BMCR, operating data

Supercritical Boiler

Carbon Dioxide Emissions vs Net Plant Efficiency

(Based on firing Pittsburgh #8 Coal)

0.60

0.65

0.70

0.75

0.80

0.85

0.90

37% 38% 39% 40% 41% 42% 43% 44% 45% 46% 47% 48% 49% 50%

Net Plant Efficiency, (LHV)%

CO

2 E

mis

sio

ns

, to

nn

e/M

Wh

0%

5%

10%

15%

20%

25%

30%

Pe

rce

nt

CO

2 R

ed

uc

tio

n

CO2 Emission, tonne/MWhPercent CO2 Reduction from

Subcritical PC Plant

Efficiency increase from Subcritical to USC can, for example,

yield up to 25% CO2 reduction

• Co-firing with biomass to 10% can lead to 10% reduction in CO2

Comparison of Coal Based Power Options –

CO2 Reduction

Advanced Ultrasupercritical PC

Plant Range

Commercial

Supercritical

Existing US coal fleet @

avg 33%

• Efficiency increase from Subcritical to USC can, for example, yield up to 25% CO2 reduction

100% Coal

firing Coal w/ 10%

co biomass

Source: EPRI

Modern day

subcritical

NAM SC Plant Experience – J.Marion – Clearwater Conf. – 7 June 2010 - P 6

Path to More Efficient Steam Power Plants

- Efficiency (net) HHV

- Steam Parameter

25 - 30%

33%

Once Through Technology

3480/1005/1050 ( psi /°F/°F) 240/540/565 (bar/°C/°C)

2400/1005/1005 167/540/540

Sliding Pressure Supercritical

5400/1300/1325( psi /°F/°F) 375/700/720 (bar/°C/°C)

4000/1110/1150( psi /°F/°F) 275/600/620 (bar/°C/°C)

4000/1075/1110 ( psi /°F/°F) 275/580/600 (bar/°C/°C)

38 - 40%

T91 Adv Austenitic Materials

1960 1980 2000 2020 1960 1980 2000 2020

- Efficiency (net) HHV

- Steam Parameter

25 - 30%

33%

Once Through Technology

3480/1005/1050 ( psi /°F/°F) 240/540/565 (bar/°C/°C)

2400/1005/1005 167/540/540

Sliding Pressure Supercritical

5400/1300/1325( psi /°F/°F) 375/700/720 (bar/°C/°C)

4000/1110/1150( psi /°F/°F) 275/600/620 (bar/°C/°C)

4000/1075/1110 ( psi /°F/°F) 275/580/600 (bar/°C/°C)

38 - 40%

T91 Adv Austenitic Materials

1960 1980 2000 2020 1960 1980 2000 2020

5400/1330/1400( psi /°F/°F) 375/730/760 (bar/°C/°C)

39 - 41%

48% - 51%

50% - 53%

43% - 46%

49% - 52%

Ni - based Materials

45% - 48%

Precipitation Strengthened Ni - based Materials

5400/1330/1400( psi /°F/°F) 375/730/760 (bar/°C/°C)

39 - 41%

48% - 51%

50% - 53%

43% - 46%

49% - 52%

Ni - based Materials

45% - 48%

Precipitation Strengthened Ni - based Materials

tower tower

tower tower

tower tower

FGHR

Aux Power

RH/RH

FGHR

Excess Air

Bottoming

Cycle

Economics continue to drive efficiency improvements. This will be achieved by

several technological steps including higher steam conditions enabled by cost

effective materials advances

NAM SC Plant Experience – J.Marion – Clearwater Conf. – 7 June 2010 - P 7

Partnerships: Ultrasupercritical Materials

European: Emax Project

Operating Target: 700 C / 310 bar

1292 F / 4500 psig

US-DOE :Ultra-Supercritical Boiler Project

Operating Target: 760 C / 379 bar

1400 F / 5500 psig

All major US boiler manufacturers, Oak Ridge

National lab and EPRI

Integrated Gasification Combined Cycle (IGCC)

Oxy-Combustion Process Technology Overview

Principle Fuel is burned in a mixture of oxygen and re-circulated flue-gas. Due to the absence of Nitrogen, the resulting flue gas is enriched in CO2After water condensing and further purification, CO2 can be compressed and send for storage or re-use.

Advantages

Reliability: main components exist, only adaptation to power gen and scale-up

All types of boilers / firing systems adaptable to oxy to cover complete fuel range

Rapid scale-up to large size (1,000 MWe range) possible after large demos. Retrofit in Oxy can be addressed

High efficiency and competitiveness of supercritical/ultra-supercritical cycles and large unit size will be key benefits

Large panel of entities involved in development, contributing to reaching solid consensus.

• CLC is a break-through CCUS technology in

terms of efficiency and economics, with potential

to significantly lower cost of CO2 capture

• CLC is a flexible technology that can be

configured in new or retrofit applications to

produce syngas, hydrogen or power from coal

• Currently validating 3 MWth CLC prototype using

limestone as oxygen carrier

CLC Development Status

What’s Next?

• Optimization testing on prototype

• Next step before commercial unit

will be Scale-up to 10-50 MWe

Demonstration

Chemical Looping Combustion

2008 - 2012 Prototype Testing

of Limestone Chemical Looping

Agenda

1st topic Combustion Page 2

2nd topic Criteria Pollutants Page 10

3rd topic CO2 Capture Page 18

Sulfur Oxides 184,000 Mw installed

Nitrogen Oxides 140,000 Mw installed

Particulate Matter 320,000 Mw Installed

- PM10

- PM2.5

Mercury 65,000 Mw Installed

Heavy Metals

Acid Gases

Installation figures are Power only and do not include Industrial

Pollutants Controlled

HRFF—High-Ratio Fabric Filter WESP—Wet Electrostatic Precipitator

DESP—Dry Electrostatic Precipitator

Emissions and Technology

Particulate Control Systems

LRFF—Low-Ratio Fabric Filter

Tech Options for Air Emissions - BHilton 2 Dec 2011

Mercury Control Systems

Brominated Milled Carbojn PAC—Powdered Activated Carbon

Additive Storage Tank Boiler Additive Technology

Emissions and Technology

Spray Dry Absorber- SDA Fluid Bed Dry Absorber

Dry Sorbent Injection - DSI

SO2 & Acid Gas Control Systems Dry Flue Gas Desulfurization

Emission Control Technologies

NOx Control System

SCR—Selective Catalytic Reduction SNCR- Selective Non-Catalytic

Reduction

Emission Control Technologies

Wet Flue Gas Desulfurization

and Integrated Systems

Agenda

1st topic Combustion Page 2

2nd topic Criteria pollutants Page 10

3rd topic CO2 Capture Page 17

Post Combustion CO2 Capture

• Advanced Amines

• Chilled Ammonia

Advanced Amine Process Technology Overview

Advantages

• Proven in natural gas & syngas purification

• CO2 capture from flue gas is a new application

• More efficient capture of CO2 and less solvent degradation than MEA

• Higher tolerance against oxygen & trace contaminants

Source: Alstom

Principle

• An amine based solvent reacts with the CO2 in the flue gas

• Raising the temperature reverses this reaction, the CO2 is released and the solvent recycled

Principle

• Ammonium carbonate solution reacts with CO2 of cooled flue gas to form ammonium bicarbonate

• Raising the temperature reverses this reaction, pressurized CO2 is released, the solution is recycled

Chilled Ammonia Process Technology Overview

Advantages

• High CO2 purity

• Tolerant to oxygen and flue gas impurities

• Stable reagent, no degradation nor emission of trace contaminants

• Low-cost, globally available reagent

Other CO2 Technologies in Development

•Dry Sorbents

•Enzymes

•Cryogenic

•Regenerable Sorbents

•Biological Capture

•Membranes

•Metal Organic Frameworks (MOFs)

•Chemical Processing for Reuse

www.alstom.com