FutureGen 2.0 Update

Transcription

1 Power Generation Group We are passionate about innovation and technology leadership FutureGen 2.0 Update 2 nd Oxyfuel Combustion Conference D.K. McDonald, Technical Fellow, Babcock & Wilcox September 14, 2011

2 1. State of Clean Energy in the United States 2. FutureGen 2.0 Project Description Project location Project Structure Project Schedule & Status Capture Process Description 2

3 No US Climate Bill, EPA GHG regulatory approach now underway in response, Clean Energy Standard forming: States pressing ahead, federalism at work (experiments in democracy); renewables and CO 2 limits Clean energy still desirable, but pace has slowed Wind power, solar, and nuclear recognized as clean DOE committed to 10 CCS demonstration projects leading to 2020 commercial deployment CO 2 underground storage enablement with EPA Class VI rules Natural gas reserves attributable to US shale formations continue to climb; seen by some as a clean transitional fuel to the future 3

4 Greenhouse Gas Footprint of Natural Gas vs. Coal (Fugitive emissions as equivalent CO2) (extraction, processing, transport) (from combustion) 20 Year Time Frame Ref: Cornell University Assessment of the Greenhouse Gas Footprint of Natural Gas from Shale Formations Obtained by High-Volume, Slick Water Hydraulic Fracturing, Robert W. Howarth, David R. Atkinson (rev. Jan. 26, 2011) 4

5 GS GS GS 5

6 6

7 Highest Net Efficiency (HHV) Lowest Levelized Cost of Electricity (2007 US$, does not include AFUDC or Owner s costs) References: DOE/NETL Pulverized Coal Oxy-combustion Power Plants Rev. 2, DOE/NTL Cost and Baseline for Fossil Energy Plants Rev.1, and B&W/AL Integration Study 7

8 Near zero air emissions Low fresh water use Low wastewater Conventional proven equipment Looks like and operates like a current power plant (minimal retraining) Construction lead time similar to conventional plants. 8

9 Meredosia Plant Boilers & Turbines

10 Project Oversight Oxy-Combustion Repowering Technology Collaboration Agreement CO 2 Pipeline & Storage Hub Project Management & Execution Power Generation Group Oxy-Combustion Boiler and GQCS ASU & CPU Technology Providers 10

11 Four Phases Phase I Phase II Phase III Phase IV Pre-FEED (Initial Front End Engineering and Design) October 2010 to October 2011 Status FEED (Final Front End Engineering and Design) October 2011 to October 2012 Procure, construct & Startup November 2012 to April 2016 Test Period May 2016 to December 2018 DOE cooperative agreement signed 9/27/2010 Teaming Agreement (AER, AL, and B&W PGG) signed 10/15/2010 Project team mobilized URS selected as Ameren s A/E. Phase 1 has proceeded on schedule. Worley Parsons selected as B&W s A/E in February DOE & Management Phase 1 Reviews in progress. 11

12 Technology Development Oxy Coal Define Functional Requirements Engineering / Modeling / Pilot Testing Large Scale Test of the Oxy Technology Applications for DOE Funding Phase 1 Award /Pre-FEED Phase 2 FEED, NEPA Phase 3 Procure, Construction, Startup Phase 4 Testing Commercialization Present 12

13 Prove safety and control Develop cost basis for scale up to commercial sizes Prove operability and reliability of the integrated process Steam cycle, Boiler Island, ASU and CPU Provide performance, emissions, and consumables data for future commercial guarantees Provide operating and maintenance experience for future commercial plants 13

14 Meredosia Plant Meredosia, IL: Owned/operated by AER 3-coal fired units Unit 4, 200 MWe oil-fired built in 1975 Project Structure Capture Ameren Energy Resources (AER), teamed with B&W and Air Liquide Transport & Storage FutureGen Alliance Repower Unit 4 steam turbine Purpose-built Oxy-PC boiler Illinois Coal, PRB blend possible Project Timeline Project awarded Sept. 29, 2010 FEED and NEPA complete June, 2012 Ready to test, end 2015 Main Fuel Illinois #6 10,500 Btu/lb (24,423 kj/kg) 3.2 % sulfur, 0.12% chlorine 14

15 FGA announce Morgan County selected Feb. 28 th 4500 ft (1372 m) Deep Saline Formation (DSF) in Morgan County ( 32 miles (51.5 km) pipeline from the plant) Meredosia Reservoir Potential CO2 Storage Resource (billion metric tons) Mt. Simon Sandstone - 27 to 109 State Potential CO2 Storage Resource (billion metric tons) Illinois 20 to 79 Indiana 7.9 to 32 Kentucky 1.5 to 6.3 Total 29 to 117 billion metric tons 15

16 AER s Meredosia Unit 4 Oil fired boiler built in 1975 to be demolished Turbine/generator is 202 MWe 2400 psig (166 bar), 1000F (538C) main & reheat Low operating hours Well maintained and periodically operated Infrastructure exists Coal yard and handling equipment Barge unloading Transmission capacity in place Space available for new equipment Existing site infrastructure saves capital cost The right size - demonstrates retrofit/repowering potential Large enough test to directly support commercial deployment Small enough to conserve capital and permit large scale integrated test 16

17 B&W AL Technology Purpose-built oxy-combustion system Confirms oxy-combustion is a viable for repowering, retrofit or new build Testing program will utilize Illinois bituminous & other coals Provides performance and operational data to improve designs Basis for industry acceptance Lowers equipment, operational, reliability & financial risks Demonstrates operability and reliability Provides basis for commercial guarantees Provides basis for financial institutions to invest 17

18 To Storage Steam; 2400psi, 1000F/1000F ASU Secondary (FD) Fan Air Intake Gas Htr CPU FD Fan Sorbent for SO 3 Recycle Damper Vent Burners Boiler Recycle Heater PJFF ID Fan WFGD DCCPS Gas Htr Coal Primary Fan Recycle Damper Cool Recycle Process Air Intake 18

19 Boiler Coal Bunkers PJFF ID Fans WFGD ASU Gypsum Pile Recycle Heater (Airheater) PR Fans SR Fans DCCPS CPU ~ 3,500 TPD CO2 to Storage 19

20 ASU Ash Silo Gypsum Pile Coal Bunkers PJFF ID Fans WFGD Boiler PR Fans Recycle Heater (Airheater) SR Fans DCCPS CPU 20

21 1 2 3 Boiler PJFF WFGD 1 Steam Turbine Building 4 5 DCCPS Stack 2 Boiler & GQCS ASU CPU 21

22 Boiler Sectional Side View 22

23 Trona DSI SO 3 1. Flue from Recycle Heater Outlet to DSI is lined to PJFF (could be below acid dew point - corrosion) PJFF removal of SO 3. Dry Sorbent Injection (SO 3 ) 23

24 Pulse Jet Fabric Filter (PJFF) % removal of 2 microns or larger 24

25 Wet Flue Gas Desulfurization (WFGD) SO ft (11.6m) reaction tank, 32 ft (9.75m) diameter absorber, 117 ft. (35.7m) tall removal of SO % removal of remaining SO % removal of HCl 5. Some remaining particulate 6. Disposable grade gypsum dewatering system provided 7. Blowdown (chloride control) used to wet ash 8. Flue to DCCPS and secondary gas reheater is lined 25

26 Direct Contact Cooler Polishing Scrubber (DCPS) H 2 O and SO 2 1. Temp 75F (24C) out at average ambient conditions (H 2 O) 2. 1 ppmv SO 2 or H 2 SO 4 leaving 3. 1 ppmv HCl 4. Some remaining particulate, some gypsum carryover 5. Outlet lined to gas reheater 6. Condensed water used in Wet Cooling Tower 7. WCT blowdown used in process 26

27 4000 metric tons of oxygen per day 96.5% oxidant purity ASU is designed as a baseload plant ASU turndown is 78% without venting (nominal) ASU is designed 1.5%/min ramp-up 4 hr backup oxidant system A scheduled for derime every 3 years 27

28 >3700 metric tons of flue gas per 80% CO2 by vol. Removes remaining SO2, SO3, moisture, solid particulate, Hg, and NOx. 90% CO2 recovery >97% CO2 purity, 99.8% expected Compresses to pipeline pressure of 2200 psi Same types of components as the ASU (cold box, compressors etc) CPU 28

29 Thank You! Questions?