Overview of Alstom s Chemical Looping Programs

Transcription

1 Overview of Alstom s Chemical Looping Programs Frank Kluger, I. Abdulally, H. Andrus, A. Levasseur, C.Beal, J.Marion 5 Th Meeting of the IEAGHG International Oxyfuel Combustion Research Network Wuhan, China - October 28, 2015

2 Chemical Looping Process Advanced oxy combustion technology without ASUs GPU, Gas processing unit FGC, Flue gas condenser Desulfurization/ Particulate control Particulate control Purification CO2 To storage Water Fuel reactor ((Reducer) Air reactor (Oxidizer) No cryogenic air separation unit (ASU) No large gas recirculation Two interconnected CFB boilers Limestone or metal oxide powder as oxygen carrier Ash Transformational coal power technology IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 2

3 Chemical Looping Plant Product Vision and Market Product Attributes: Lowest cost option for coal Power Generation with CCS Lowest energy penalty Fuel flexible Near zero emissions Useful solid ash by-product Application flexible Coal power, syngas, hydrogen Feasible with CFB basis CLC Power Plant Targets: Efficiency <10% CCS penalty vs Plant w/o CCS LCoE <30% increase vs. Plant without CCS (stretch target < 20%) CO 2 Capture Cost < $25/ton (stretch target < $15/ton) IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P MWe Chemical Looping Combustion Steam Generator

4 Alstom - Chemical Looping Process Managed Development and Scale-up Steps Reference Design Studies Demonstration MWe Commercial Scale >100 MWe Prototype Bench Tests Pilot Plant 65 kwth CFD Modeling, Controls and Tool Development Cold Flow Models IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 4

5 Alstom - Chemical Looping Process Managed Development and Scale-up Steps We are here, Significant progress made 1 st Worldwide to achieve Auto Thermal Operation Reference Design Studies Demonstration MWe Commercial Scale >100 MWe Prototype Bench Tests Pilot Plant 65 kwth CFD Modeling, Controls and Tool Development Cold Flow Models IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 5

6 Alstom s Chemical Looping Development Two Programs Metal-oxide based Limestone based EU co-funded US DOE co-funded Metal based oxygen carriers such as Fe, Ni, Mn, Cu. Focus on Fe ores ---- ilmenite (FeTiO 3 ) ore Limestone-based oxygen carrier CaS, CaSO 4 Abundant; environmentally benign, inexpensive Built-in sulfur control Process based on CFB flow regime Carbon stripper for minimizing unburned carbon Process based on solids transport regime Sorbent reactivation for increased limestone utilization Alstom is pursuing two different chemical looping technologies IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 6

7 MeOx-Based Chemical Looping Process Alstom Development History MeOx-Based Chemical Looping Program Date Project Title Grace-EU-FP ENCAP-EU-FP CLC Gaspower - EU-FP6 EU-ÉCLAIR/ ACCLAIM (RFCS) CLC Development for Gaseous Fuels 10 kw th Testing (Chalmers), 70 MW e CLC CFB Design (Alstom) CLC Development for Solid Fuels 10 kw th Testing (Chalmers), 455 MW e CLC CFB Design (Alstom) CLC Development for Gaseous Fuels 10 kw th Long-Term Testing (Chalmers), 120 kw th Testing (Vienna), 70 MW e CLC CFB Design (Alstom) CLC Development for Solid Fuels 100 kw th Testing (Chalmers), 1 MW th Testing (Darmstadt), Industrial Design and Product Assessment (Alstom) Chalmers University 10 kw th and 100 kw th Pilot Facilities Darmstadt University 1 MW th Prototype IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 7

8 Alstom MeOx Testing Program Metal Oxide-based Process ÉCLAIR & ACCLAIM Programs: 1MW th MeOx Prototype in Darmstadt: Goals: Design and operation of a 1 MWth CLC with coal Assess technical, environmental, economical potential Improve conversion efficiency Results: Gasification conditions achieved Autothermal combustion achieved Partners: ACCL AIM TECHNISCHE UNIVERSITÄT DARMSTADT MeOx Supporting Tests: 100 kwth pilot and cold flow model at Chalmers Univ. Goals: Validation of solids circulation on cold flow model Parametric test on the 100 kwth Path Forward: Tests planned with alternative oxygen carriers (iron ore) to improve conversion efficiency IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P kw th Pilot Plant Cold Flow Model

9 Limestone-Based Chemical Looping (LCL ) Process Alstom Development History Limestone-Based Chemical Looping Program Date Project Title Alstom Bench Scale Kinetics & Engineering Feasibility 2003 Alstom Design and Build LCL PDU 65kW PDU Alstom/DOE Combustion and Gasification looping test Alstom/DOE Alstom/DOE Calcium looping - WGS- H 2 Production and CO 2 Capture Convert PDU to 65 kw th Pilot Plant - Two fans, Automatic Controls Concepts Alstom/DOE Installation and Testing of 3 MW th Prototype Alstom/DOE Alstom/DOE LCL-C TM Techno-economic Assessment and Gap Analysis 3 MW th LCL-C TM Prototype and Support Testing to Address Gaps Alstom/DOE IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 9 LCL-G TM Testing at Bench, 100mm Pilot and 3 MW th Prototype 3MW th Prototype

10 Limestone Chemical Looping (LCL ) Development Advanced Oxy Combustion Project Objectives and Status DOE/NETL Cooperative Agreement Bench-scale testing and engineering studies Techno-economic studies on 4 LCL-C cases DOE/NETL Cooperative Agreement Address main technology gaps Various bench and pilot support testing 3 MW th prototype tests incorporating system modifications Update techno-economic study IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 10

11 Chemical Looping Development US DOE-sponsored techno-economic analysis Conducted techno-economic analysis following DOE s strict evaluation/estimation procedure All cases for constant 550 MW(net) output Design parameters dictated by US DOE Quality Guidelines for Energy Systems Studies Baseline case: US DOE study results for 550-MW supercritical, pulverized coal plant without CCS Another comparison case: US DOE SC oxy-pc performance data Process modeling using Aspen Plus and Thermoflow Performance evaluation based on available test data (e.g., 3-MWth pilot testing used for chemical looping performance) IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 11

12 Techno-Economic Study: LCL-Combustion Study Cases: (Applying DOE Economic Methodologies and Guidelines) Case 1 LCL-C system using transport reactors Case 2 LCL-C system with the Reducer reactor in the CFB mode Case 3 LCL-C system of Case 1 with an advanced ultra-supercritical (AUSC, 350bar/730 o C/760 o C) steam cycle Case 4 LCL-C system with pressurized Reducer reactor with an AUSC steam cycle Comparison Basis: State-of-the-art SCPC case Case 11 from Cost and Performance Baseline for Fossil Energy Plants Volume 1, DOE/NETL-2010/1397 1st generation Oxy-combustion PC case Case 5 from Pulverized Coal Oxy-combustion Power Plants, DOE/NETL-2007/1291 IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 12

13 Chemical Looping Development US DOE-sponsored techno-economic analysis Baseline: Alstom SC US DOE Oxy SCPC US DOE SCPC Chem Loop Plant, plant plant, no capture case (a) Nominal output (net, MW) Capacity factor (%) Alstom: > 95% HHV efficiency (% HHV) DOE goal: >90% CO 2 capture (%) CO 2 emitted rate (lb/mwh) EPC overnight cost ($/kw) Cost of Electricity Breakdown Fuel ($/MWh) Capital ($/MWh) O&M fixed ($/MWh) O&M variable ($/MWh) T&S adder to COE ($/MWh) st yr COE (w/o T&S, $/MWh) LCOE (w/o T&S, $/MWh) Fuel cost ($/MMBtu) 2.94 Alstom: <20% Construction period (yrs) 5 DOE goal: <35% 5 5 Operational period (yrs) % Increase Levelized COE IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 13

14 Relocation of Alstom Power Plant Labs and Chemical Looping pilot Dec to June 2015 INSERT IMAGE HERE (Ideally as high resolution as possible) Alstom Clean Energy Lab Inauguration 21 August 2015 DOE leaders with Alstom staff at CLC pilots 40 th Clearwater Conference - Levasseur 3 June 2015 ALSTOM All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

15 Alstom LCL Testing Program Limestone-based Process Main objectives: Autothermal operation of 3-MWth prototype in combustion mode Address technical gaps through prototype testing Obtain info to design, build and operate a demo plant Achievement: First autothermal operation achieved in July 2012; 500+ hrs of operation Recent steps: Relocated 3-MWth pilot completed in 2015 Commissioned and ran pilot in July 2015 Further develop LCL process IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 15

16 Limestone Chemical Looping (LCL ) Development Advanced Gasification Project Objectives and Status Objective: To further develop LCL-G technology for generation of high-h 2 syngas from coal for liquid fuel production and/or power generation with CO 2 capture. Scope: Small-scale developmental testing (including 100mm diameter 50ft LCL-G pilot tests) Cold flow model testing Computational modeling simulations 3.0 MWth prototype testing Techno-economic assessments IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 16

17 Alstom Chemical Looping Summary A break-through technology (efficiency & economics) Lowest LCoE of all known coal power with CCS options Basis in CFB boilers and steam power plant technology A flexible technology (new or retrofit) to produce syngas, hydrogen or power Chemical Looping Combustion (MeOx and Limestone-based) being validated at 1 to 3 MWth prototype scale Technical challenges remain, which are being addressed at pilot scale Before commercial unit, a demonstration steam generator unit ~10-50 MWe scale is needed Potential of being the lowest cost CO 2 capture option for coal IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 17

18 Acknowledgements and Disclaimer THANKS TO MANY PARTNERS WHO HAVE SUPPORTED AND/OR WORKED WITH ALSTOM ON THE EFFORTS PRESENTED. PARTICULAR ACKNOWLEGEMENT TO US DOE NETL, EU Frame Program, EU RFCS, Acknowledgement Some of work presented was supported by the U S Department of Energy through the National Energy Technology Laboratories The guidance and direction of NETL is acknowledged and appreciated. Disclaimer Parts of this presentation were prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. Information disclosed herein is furnished to the recipient solely for the use thereof as has been agreed upon with ALSTOM and all rights to such information are reserved by ALSTOM. The recipient of the information disclosed herein agrees, as a condition of its receipt of such information, that ALSTOM shall have no liability for any direct or indirect damages including special, punitive, incidental, or consequential damages caused by, or arising from, the recipient s use or non-use of the information IEAGHG Int. Oxyfuel Combustion Network Alstom Chemical Looping J. Marion 28 Oct P 18

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