Enhancing Lignite’s Future Through Research & Development
Enhancing Lignite’s Future Through Research & Development
Michael Jones Ph.D. Vice President, R&D
Lignite Energy Council
Michael Jones Ph.D. Vice President, R&D
Lignite Energy Council
State-industry R&D partnership
Lignite resource
Current energy conversion technologies
Future energy conversion technologies
Emission Control Technologies
Summary
Lignite Jeopardy Game
State-industry R&D partnership
Lignite resource
Current energy conversion technologies
Future energy conversion technologies
Emission Control Technologies
Summary
Lignite Jeopardy Game
Agenda Agenda
Lignite Research Council’s R&D ProgramLignite Research Council’s R&D Program
Public / Private PartnershipPublic / Private Partnership
Lignite EnergyCouncil
Lignite EnergyCouncil
State ofNorth Dakota
State ofNorth Dakota
http://www.lignite.com/ResDev/index.htmhttp://www.nd.gov/ndic/lrc-infopage.htm
An Industry/Government PartnershipAn Industry/Government Partnership
Cleaner Coal Technology PathsCleaner Coal Technology Paths
Coal Cleaning
More efficient power plants
More effective technologies to reduce SO2, NOx, Hg & CO2
emissions
Coal Cleaning
More efficient power plants
More effective technologies to reduce SO2, NOx, Hg & CO2
emissions
Leveraging State DollarsLeveraging State Dollars
For every state dollar, six dollars is invested from industry & other sources in lignite-related R&D projects
For every state dollar, six dollars is invested from industry & other sources in lignite-related R&D projects==
Active Lignite Research Projects Active Lignite Research Projects
Quick Review of Active Projects (24) 1 LEC Lignite Vision 21 Program project 3 Separate LV21P projects 3 Mercury-related projects 1 NOx-related project 4 Lignite gasification-related projects 8 CO2 Carbon Capture & Storage-related projects 1 Regional marketing project (PAE) 1 Lignite-fueled Ag production – Red Trail Project 1 Coal combustion products projects 1 Air toxic metals project – CATM
Quick Review of Active Projects (24) 1 LEC Lignite Vision 21 Program project 3 Separate LV21P projects 3 Mercury-related projects 1 NOx-related project 4 Lignite gasification-related projects 8 CO2 Carbon Capture & Storage-related projects 1 Regional marketing project (PAE) 1 Lignite-fueled Ag production – Red Trail Project 1 Coal combustion products projects 1 Air toxic metals project – CATM
State-industry R&D partnership
Lignite resource
Current energy conversion technologies
Future energy conversion technologies
Controlling emissions
Summary
Lignite Jeopardy Game
State-industry R&D partnership
Lignite resource
Current energy conversion technologies
Future energy conversion technologies
Controlling emissions
Summary
Lignite Jeopardy Game
Agenda Agenda
Future of Lignite Future of Lignite
The resource: 800 year supply of ligniteThe resource: 800 year supply of lignite
R&D holds the keyto expanding lignite’s economic benefits
R&D holds the keyto expanding lignite’s economic benefits
A Look at Lignite A Look at Lignite
Organic Matter C, H, O, S, N
Organic Matter C, H, O, S, N
Inorganic Matter SiO2, Al2O3 -Clays, FeS2
Inorganic Matter SiO2, Al2O3 -Clays, FeS2
LigniteLignite
WaterWater
55%55%
10%10%35%35%
Electric PowerGeneration - 79%
Synthetic NaturalGas - 13.5%
Specialty Products 7.5%
ND Lignite ConsumptionND Lignite Consumption
State-industry R&D partnership
Lignite resource
Current energy conversion technologies
Future energy conversion technologies
Controlling emissions
Summary
Lignite Jeopardy Game
State-industry R&D partnership
Lignite resource
Current energy conversion technologies
Future energy conversion technologies
Controlling emissions
Summary
Lignite Jeopardy Game
Agenda Agenda
Current Energy Conversion Technologies Current Energy Conversion Technologies
Pulverized Coal-Fired BoilersPulverized Coal-Fired Boilers
2400 PSI Steam; 1000ºF
Up to 600 MW/unit in ND
30-32% Efficient
2400 PSI Steam; 1000ºF
Up to 600 MW/unit in ND
30-32% Efficient
Current Energy Conversion Technologies Current Energy Conversion Technologies
Pulverized Coal-Fired Boilers Pulverized Coal-Fired Boilers
Antelope Valley StationAntelope Valley Station Coal Creek Station Coal Creek Station M.R. Young Station M.R. Young Station
Current Energy Conversion Technologies Current Energy Conversion Technologies
Pulverized Coal-Fired Boilers Pulverized Coal-Fired Boilers
Coyote StationCoyote Station Leland Olds StationLeland Olds StationStanton StationStanton Station
State-industry R&D partnership
Lignite resource
Current energy conversion technologies
Future energy conversion technologies
Controlling emissions
Summary
Lignite Jeopardy Game
State-industry R&D partnership
Lignite resource
Current energy conversion technologies
Future energy conversion technologies
Controlling emissions
Summary
Lignite Jeopardy Game
Agenda Agenda
Future Generating Technologies Future Generating Technologies
Advanced Pulverized Coal
Oxy-fuel Combustion
Integrated Gasification Combined Cycle (IGCC)
Advanced Pulverized Coal
Oxy-fuel Combustion
Integrated Gasification Combined Cycle (IGCC)
Supercritical Pulverized Coal Power Plant
3500 PSI Steam; 1050ºF
Up to 1300 MW / unit
35-40% Efficient
3500 PSI Steam; 1050ºF
Up to 1300 MW / unit
35-40% Efficient
Future Generating TechnologiesFuture Generating Technologies
Future Generating Technologies Future Generating Technologies
Oxy-combustionOxy-combustion Technology
consideration to capture CO2
Energy penalty ~ 1/3 (450 MW Gross yields 300 MW Net)
First demonstrations underway in US and Europe
Technology consideration to capture CO2
Energy penalty ~ 1/3 (450 MW Gross yields 300 MW Net)
First demonstrations underway in US and Europe
Future Generating Technologies Future Generating Technologies
IGCC IGCC
Up to 300 MW / Unit
40-45% Efficient
Cost, availability & lack of lignite experience are issues
Up to 300 MW / Unit
40-45% Efficient
Cost, availability & lack of lignite experience are issues
Future Generating TechnologiesFuture Generating Technologies
Gasification End Products
Electric Power
Synthetic Natural Gas
Liquid Transportation Fuels
Hydrogen
Chemicals
Gasification End Products
Electric Power
Synthetic Natural Gas
Liquid Transportation Fuels
Hydrogen
Chemicals
Coal-to-Liquids Coal-to-Liquids
Headwaters Inc., North American Coal Corp. & Falkirk Mining Co. are exploring a coal-to-liquid fuels project near Underwood, ND
Will gasify coal and convert it into ultra-clean gasoline, LPG, propane & electricity
12 million tons of coal to produce 30,000 barrels per day of gasoline
Conducting feasibility studies; next step is decision to conduct a front-end engineering & design study ($50+ million)
Construction start – 2012???; commercial start – 2015???
Headwaters Inc., North American Coal Corp. & Falkirk Mining Co. are exploring a coal-to-liquid fuels project near Underwood, ND
Will gasify coal and convert it into ultra-clean gasoline, LPG, propane & electricity
12 million tons of coal to produce 30,000 barrels per day of gasoline
Conducting feasibility studies; next step is decision to conduct a front-end engineering & design study ($50+ million)
Construction start – 2012???; commercial start – 2015???
Coal-to-Hydrogen-PowerCoal-to-Hydrogen-Power
Great Northern Project Development is exploring a coal-to-hydrogen project near South Heart, ND
Will use ~2.4 million tons of lignite / year
To gasify lignite and convert it into hydrogen for use in combustion turbine
Conducting feasibility studies; about to move into a front-end engineering & design study ($30+ million)
Construction start – 2012???; commercial start – 2015???
Great Northern Project Development is exploring a coal-to-hydrogen project near South Heart, ND
Will use ~2.4 million tons of lignite / year
To gasify lignite and convert it into hydrogen for use in combustion turbine
Conducting feasibility studies; about to move into a front-end engineering & design study ($30+ million)
Construction start – 2012???; commercial start – 2015???
State-industry R&D partnership
Lignite resource
Current energy conversion technologies
Future energy conversion technologies
Controlling emissions
Summary
Lignite Jeopardy Game
State-industry R&D partnership
Lignite resource
Current energy conversion technologies
Future energy conversion technologies
Controlling emissions
Summary
Lignite Jeopardy Game
Agenda Agenda
Emission Control TechnologiesEmission Control Technologies
Particulate Matter (PM) reduction >99.99%
Sulfur Dioxide (SO2) reduction >97%
Nitrogen Oxides (NOx) reduction 50% → > 90% goal
Mercury (Hg) reduction 50% -90% → > 90% goal
Carbon Dioxide (CO2) ??? %
Particulate Matter (PM) reduction >99.99%
Sulfur Dioxide (SO2) reduction >97%
Nitrogen Oxides (NOx) reduction 50% → > 90% goal
Mercury (Hg) reduction 50% -90% → > 90% goal
Carbon Dioxide (CO2) ??? %
WetScrubber
Boiler
Stack
Baghouse
Coal
Overfire Air, low NOx, burners, injection of ammonia
Emission Control TechnologiesEmission Control Technologies
Electrostatic Precipitator
Stack
Dry Scrubber
Capturing Mercury Is Difficult!Capturing Mercury Is Difficult!
A hypothetical example:
Dome filled with 30 billion ping pong balls
30 mercury balls
Remove 27 balls for 90% Hg capture
A hypothetical example:
Dome filled with 30 billion ping pong balls
30 mercury balls
Remove 27 balls for 90% Hg capture
Houston Astrodome
WetScrubber
BoilerStack
Baghouse
Coal
OxidationChemicals
Mercury Control OptionsMercury Control Options
Electrostatic Precipitator
Stack
Dry Scrubber
Activated Carbon & Oxidation Chemicals
Summary of CO2 Capture TechnologiesSummary of CO2 Capture Technologies
Absorption Adsorption Membranes Cryogenics Others
Chemical
Physical
AminesCausticsAmino acid saltsOthers
SelexolRectisolIonic liquidsOthers
Chemical(TSA)
Physical (PSA, TSA)
Metal oxidesMetal organic frameworks Others
ZeolitesActivated Carbons Si/Al gels
Organic
Inorganic
PolysulphoneCellulose derivativesPolymideLiquid EnzymeOthers
MetallicCeramicsOthers
ChemicalLooping
CO2 Hydrates
Oxycombustion
Microbial/ Algae
Carbon Capture R&D processes being Carbon Capture R&D processes being explored by the National Energy explored by the National Energy
Technology LaboratoriesTechnology Laboratories
Carbon Capture R&D processes being Carbon Capture R&D processes being explored by the National Energy explored by the National Energy
Technology LaboratoriesTechnology Laboratories
Carbon Capture TechnologiesCarbon Capture Technologies
EERC Oxyfuel / Amine Scrubbing Study (2/07)
Conclusions assuming 90% capture of CO2:
Amine scrubbing & oxyfuel models were developed and shared with industry
Amine scrubbing results in cost of electricity (COE) of 10.8 cents/kWh (4.6 cents/kWh without carbon capture)
Oxyfuel combustion results in COE of 10.9 cents/kWh (4.6 cents/kWh without carbon capture)
EERC Oxyfuel / Amine Scrubbing Study (2/07)
Conclusions assuming 90% capture of CO2:
Amine scrubbing & oxyfuel models were developed and shared with industry
Amine scrubbing results in cost of electricity (COE) of 10.8 cents/kWh (4.6 cents/kWh without carbon capture)
Oxyfuel combustion results in COE of 10.9 cents/kWh (4.6 cents/kWh without carbon capture)
DOE CCS Program Goals DOE CCS Program Goals
By 2020, have available for commercial deployment technologies and best practices for achieving:
90% CO2 capture 99%+ storage permanence < 10% increase in COE (pre-
combustion capture) < 35% increase in COE (post- and
oxy-combustion)
By 2020, have available for commercial deployment technologies and best practices for achieving:
90% CO2 capture 99%+ storage permanence < 10% increase in COE (pre-
combustion capture) < 35% increase in COE (post- and
oxy-combustion)
CO2 Capture Technology R&D Timeline
20102008 20162012 2020 2024
Large-Scale Field Testing
Laboratory-Bench-Pilot Scale R&D
Full-Scale Demos
Commercial Deployment
NDIC Funding Commitment Carbon capture-related projects:
Carbozyme membrane technology $260,000 Partnership for CO2 capture 300,000 Canadian Clean Power Coalition 130,000 AVS Carbon Capture FEED 2,700,000 Partnership for CO2 capture II 150,000 Oxy-firing Alstom 550,000 Evaluation of Novel CO2 Capture 50,000
$4,140,000 Carbon storage-related projects:
PCOR Phase II $720,000 PCOR Phase III 2,400,000
$3,120,000 Total CCS commitment $7,260,000
NDIC Funding Commitment Carbon capture-related projects:
Carbozyme membrane technology $260,000 Partnership for CO2 capture 300,000 Canadian Clean Power Coalition 130,000 AVS Carbon Capture FEED 2,700,000 Partnership for CO2 capture II 150,000 Oxy-firing Alstom 550,000 Evaluation of Novel CO2 Capture 50,000
$4,140,000 Carbon storage-related projects:
PCOR Phase II $720,000 PCOR Phase III 2,400,000
$3,120,000 Total CCS commitment $7,260,000
Carbon Management Initiatives NDIC Investment Carbon Management Initiatives NDIC Investment
Partnership for CO2 Capture
EERC project approved by LRC/NDIC – May 2008
Develop & demonstrate a range of CO2 capture technologies to include pre-combustion, post-combustion & oxy-combustion technologies
$3.4 million project (DOE/EERC $2.4 M; Industry $750 K; NDIC $300 K)
Start date: 6/08; Completion date: 06/10
Phase II, ~$2M, Start 7/10
Partnership for CO2 Capture
EERC project approved by LRC/NDIC – May 2008
Develop & demonstrate a range of CO2 capture technologies to include pre-combustion, post-combustion & oxy-combustion technologies
$3.4 million project (DOE/EERC $2.4 M; Industry $750 K; NDIC $300 K)
Start date: 6/08; Completion date: 06/10
Phase II, ~$2M, Start 7/10
Carbon Management Initiatives Carbon Management Initiatives
Plains Carbon Dioxide Reduction Partnership (PCOR)
Phase I – Characterization of sources & sinks (2003-2005)
Phase II – Small-scale field validation tests (2005-2009)
Phase III – Large volume carbon storage test (2008-2017)
Plains Carbon Dioxide Reduction Partnership (PCOR)
Phase I – Characterization of sources & sinks (2003-2005)
Phase II – Small-scale field validation tests (2005-2009)
Phase III – Large volume carbon storage test (2008-2017)
Carbon Management Initiatives
PCOR Phase III (2008-2017) Large-scale demo projects over 10
years
Capturing CO2 from AVS & storage in geological formations
CO2 storage to include enhanced oil recovery & deep saline aquifer storage
DOE committed $67 million
NDIC committed $2.4 million – 2/08 Total Project Cost (capture &
storage) >$300 M
PCOR Phase III (2008-2017) Large-scale demo projects over 10
years
Capturing CO2 from AVS & storage in geological formations
CO2 storage to include enhanced oil recovery & deep saline aquifer storage
DOE committed $67 million
NDIC committed $2.4 million – 2/08 Total Project Cost (capture &
storage) >$300 M
Carbon Management Initiatives
Carbon Management InitiativesCarbon Management Initiatives
Carbon Capture Project at AVS
Demonstration / commercialization project
AVS – two 450 MW units
120 MW slipstream
Capture 90% of CO2 (Powerspan technology)
57 MMSCF or 3,000 tons CO2 / day
CO2 to be used in enhanced oil recovery (EOR) in western North Dakota
FEED study in 2010
Construction in 2011 ???
Operational in 2014 ???
Carbon Capture Project at AVS
Demonstration / commercialization project
AVS – two 450 MW units
120 MW slipstream
Capture 90% of CO2 (Powerspan technology)
57 MMSCF or 3,000 tons CO2 / day
CO2 to be used in enhanced oil recovery (EOR) in western North Dakota
FEED study in 2010
Construction in 2011 ???
Operational in 2014 ???
Carbon Sequestration - EORCarbon Sequestration - EOR
Carbon Sequestration
SaskPower CO2 capture & storage project
$1.4 billion, 7-year demonstration project announced 2/27/08
Partnership: Gov. of Canada, Gov. of Sask., SaskPower & industry
Project at Boundary Dam 150 MW Unit III (existing unit)
Designed to capture ~ 1 million tons CO2 / year
CO2 capture technology & vendor to be determined
CO2 to be used for EOR
Expected to be fully operational by 2015
Carbon Sequestration
SaskPower CO2 capture & storage project
$1.4 billion, 7-year demonstration project announced 2/27/08
Partnership: Gov. of Canada, Gov. of Sask., SaskPower & industry
Project at Boundary Dam 150 MW Unit III (existing unit)
Designed to capture ~ 1 million tons CO2 / year
CO2 capture technology & vendor to be determined
CO2 to be used for EOR
Expected to be fully operational by 2015
Carbon Management Initiatives Carbon Management Initiatives
Carbon Management Initiatives DOE Carbon Sequestration Program Carbon Management Initiatives DOE Carbon Sequestration Program
Coal Drying Activity Coal Drying Activity
As mined, lignite is approximately one-third moisture. This makes it uneconomical to transport by rail. However, a coal drying facility is now operational at Coal Creek Station that may make transporting lignite a more economical proposition.
The coal drying project has its roots in a simple experiment that you can simulate in the classroom.
As mined, lignite is approximately one-third moisture. This makes it uneconomical to transport by rail. However, a coal drying facility is now operational at Coal Creek Station that may make transporting lignite a more economical proposition.
The coal drying project has its roots in a simple experiment that you can simulate in the classroom.
Coal Drying ProcedureCoal Drying Procedure
Weigh about 100 grams of lignite on a paper plate.
Place the coal onto a cookie sheet and place it in an oven set at its lowest temperature – 100 or 120F for four hours.
Reweigh the coal to determine the weight loss due to moisture and calculate the percent of moisture.
Weigh about 100 grams of lignite on a paper plate.
Place the coal onto a cookie sheet and place it in an oven set at its lowest temperature – 100 or 120F for four hours.
Reweigh the coal to determine the weight loss due to moisture and calculate the percent of moisture.
Coal Drying ProcedureCoal Drying Procedure
Alternative Drying Methods
Dry the lignite using the “waste” heat from a light bulb. This method will model Coal Creek’s use of waste heat from its boiler.
Simply place the lignite in a sunny window and let it dry. Weigh the sample each day until the weight is constant for two days.
Alternative Drying Methods
Dry the lignite using the “waste” heat from a light bulb. This method will model Coal Creek’s use of waste heat from its boiler.
Simply place the lignite in a sunny window and let it dry. Weigh the sample each day until the weight is constant for two days.
Coal Drying Activity (Cont.) Coal Drying Activity (Cont.)
Coal Creek pulverizes the coal prior to drying, so students can compare the rate of moisture loss and total amount of moisture lost between crushed and uncrushed coal.
Coal Creek pulverizes the coal prior to drying, so students can compare the rate of moisture loss and total amount of moisture lost between crushed and uncrushed coal.
Pulverized coal has greater surface area and should dry faster than coal in larger pieces.
Pulverized coal has greater surface area and should dry faster than coal in larger pieces.
Prototype Coal DryerPrototype Coal Dryer Prototype model built
adjacent to the plant (1/06)
Used waste heat to dry the coal after it was pulverized
Tests showed how much heat & time needed
Now 8 coal dryers have been installed to dry all of the coal (operational 12/09)
Prototype model built adjacent to the plant (1/06)
Used waste heat to dry the coal after it was pulverized
Tests showed how much heat & time needed
Now 8 coal dryers have been installed to dry all of the coal (operational 12/09)
Coal Drying – Using Waste HeatCoal Drying – Using Waste Heat
Waste Energy
Lignite
Exhaust
Gas
Non Fluidized
Fines
Dried Coal
Dryer
Bag House
Less fuel
Less emissions
Less maintenance
More generation
Greater efficiency
Greater value of lignite
Coal Cleaning at the MineCoal Cleaning at the Mine
Air jigging and magnetic separation
Significantly improved overall quality
Increased heat content & reduced ash, Hg & S
Used in conjunction with Coal Creek and Antelope Valley Stations’ operations
Air jigging and magnetic separation
Significantly improved overall quality
Increased heat content & reduced ash, Hg & S
Used in conjunction with Coal Creek and Antelope Valley Stations’ operations
Coal Technology R&D PathwaysCritical R&D Challenges to Near Zero Emissions From CoalCoal Technology R&D PathwaysCritical R&D Challenges to Near Zero Emissions From Coal
Advanced Coal
Power and Multiple Products
Improve Reliability
Maximize Efficiencies
Near Zero Criteria Pollutants
Near Zero Water Usage
Near Zero Greenhouse Gases
Pulverized Coal
Power Generation
Improve Efficiencies
Minimize Criteria Pollutants
Minimize Water Usage
Minimize Greenhouse Gases
Future PlantsNear Term Plants
Technology Bridge to Near Zero Emissions
2005 - 2025 2025 - 2050
Courtesy of NETL
U.S. needs more sources of energy & needs to lessen dependence on foreign sources
Lignite is a valuable source of energy & chemical products
R&D is critical in the wise use of this abundant resource
U.S. needs more sources of energy & needs to lessen dependence on foreign sources
Lignite is a valuable source of energy & chemical products
R&D is critical in the wise use of this abundant resource
SummarySummary
Questions? Questions?
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Activity Activity
LIGNITE JEOPARDY
GAME
LIGNITE JEOPARDY
GAME
Thanks for Listening!Thanks for Listening!