Kerry Bowers Presentation

6/9/11

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National Carbon Capture Center at the Power Systems Development Facility

Every day, every job, safely.

Kerry Bowers, Director, National Carbon Capture Center RECS 2011

About Us

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Challenge of CO2 Capture = Cost

Source: Data from Cost and Performance Baseline for Fossil Energy Plants, volume 1: Bituminous Coal and Natural Gas to Electricity, Final Report; NETL, May 2007

Post-Combustion Capture Cost

4%

5%

9%

4%

9%

2%

4%

0%

5%

10%

15%

20%

25%

30%

35%

40%

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Trans., Stor. & Monit.

Compression capital

Capture capital

Capture operating

Capture steam

Capture aux. pow er

Compression pow er

Parasitic Power ↑COE by 17%

Operating Cost ↑COE by 4%

Capital Cost ↑COE by 15%

Tota

l CO

E in

crea

se (%

)

Pre-Combustion Capture Cost

Parasitic Power loss is more than ½ of the incremental cost of CO2 capture...

...while incremental Capital adds another ¼ to the incremental cost.

Carbon Capture Terminology

•  Post-combustion

•  Pre-combustion

•  Oxy-combustion

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§  Cooperative Agreement with DOE; managed by NETL.

§  Scope of Work involves all 3 major areas of CO2 capture:

Post-combustion

• Build test infrastructure at Plant Gaston

• Partner with solvent and process developers for evaluation

• Move technology forward to demonstration phase

Pre-combustion

• Utilize and expand existing syngas infrastructure

• Provide test site for syngas CO2 capture technology evaluation

• Use data in engineering of full-scale systems

Oxy-combustion

• Scoping / screening studies of new pressurized oxy- combustion process.

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National Carbon Capture Center

Goals of the NCCC §  Offer a unique flexible testing facility where processes can be tested on coal

derived gas at various scales

§  Serve as a technology development facilitator by providing facilities for technology scale-up

§  Solicit and incorporate activities and projects from a wide variety of participants and partners. Find “Best-in-class” Technology.

§  Deliver innovation through a cross-cutting, collaborative project that provides an accelerated pathway to cost-effective CO2 capture technology for coal fueled power production

Pre-combustion Post-combustion Oxy-combustion

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Prog

ress

to C

omm

ercia

lizat

ion à

Technology Development Time Scale à

Basic R&D - Lab Scale

Commercial Demonstration

Focus of NCCC Technical Program

Transfer laboratory work to more realistic conditions

Sub-system or component testing at larger-scale

Small Pilot Unit

Large Pilot Unit

Commercial CO2 Capture Deployment

SoCo MHI 25 MW Test at Plant Barry

Fundamental science & laboratory development

Integrated CO2 capture system testing

Pre-Combustion CO2 Capture

Sensor Development

Feed System Development

Fuel Flexibility Syngas Cleanup/CO2 Capture

Particulate/Ash Removal

Transport Gasifier

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Alabama Power Plant E.C. Gaston Wilsonville, Alabama

Location of Post-Combustion Facility

Confidential and Proprietary

FGD

Stack

ID Fan

Pilot Solvent Test Unit (PSTU)

Bench Scale Test Units

Post-Combustion Carbon Capture Center (PC4) Plant Gaston

#1

#2

Pilot Test Unit #2

#3

#4

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Pilot Solvent

Test Unit

Plant Gaston

Bench Scale

Post-Combustion CO2 Capture

Pilot Scale Module

Site Preparation

PSTU modular fabrication

PSTU module delivery and installation Post-Combustion CO2 Capture

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PSTU Commissioning

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-­‐  Emergency  Ac/on  Plans    

-­‐  Environmental  Guidelines  

-­‐  Opera/ng  Procedures  

-­‐  Training  

-­‐  Walk-­‐downs  -­‐  Hang  Valve  Tags  -­‐  Rota/ng  Equipment  Checkouts  

-­‐  Hydro  Tests  

-­‐  Process  Controls  Configura/on    

-­‐  Controls  Graphics  -­‐  Data  Collec/on  System  Configura/on  

-­‐  Loop  Checks  -­‐  Func/onal  Control    Checks  

-­‐  Ini/al  Test  with  Flue  Gas  

-­‐  Baseline  Test  with  MEA  

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•  Operated as an air-blown combustor at the PSDF from 1996 to 1999

•  Excellent results – High throughput, nearly complete carbon conversion, low NOx, low SOx

•  Key attributes: –  Very high solids circulation rate –  Robust mechanical design –  Solids cooler –  Pressurized operation

Ø  Transport Oxy-Combustion (TROC™)

O2

Transport Combustor

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Typical Oxy-Combustion

Fan

Gas Heater

Low-pres CO2 Compr.

Coal Prep

Comb. Boiler

Hg capture

High-pres CO2 Compr.

coal

CO2

water steam

byproduct

airoxygen

CO2 Purification

vent gas (incl. CO2)

Cooling Drying

ash

Arrow thickness is proportional to the mass flow.

recycle CO2

water

FGDID FanESP or baghouse

airinfiltration

Hgash

sorbent

Cryo. ASU

Fan

primary gas

secondary gas

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Coal Prep

TROC w/ Solids Cooler

Flue Gas Cooler PCD Hg

Capture

High-pres CO2 Compr.

coal

CO2

water steam

ash

airCryo. ASU

oxygen

CO2 Purification

vent gas (incl. CO2)

Cooling Drying

recycle CO2

Pressur. Feed

sorbent

O2 Pres.

water steam

ash

Arrow thickness is proportional to the mass flow.

recycle CO2

waterHg

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Transport Oxy-Combustion

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Steam Generator TROC™

Amine CO2 Capture

Steam Turbine

Steam Turbine

CO2-CPU

ASU-O2

Repowering Retrofit Study

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BOP

FGD

SCR

Baghouse

BOP

Benefits of NCCC for CO2 Capture R&D

à Accelerating CO2 capture technology commercialization

•  Serve as centralized R&D facility –  Reduce redundancy of multiple test facilities –  Leverage existing R&D infrastructure and people

•  Make available realistic syngas and flue gas for process

verification –  Flexible in capacity & process conditions –  Compare different technologies

•  Offer Southern’s expertise in process engineering and Power

plant O&M –  Identify critical issues –  Assist in scaling up technologies

•  Provide independent data acquisition and analysis

–  Validate laboratory performance in real industrial settings –  Enable simulation, modeling and economic assessments

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Questions?