Coal-Biomass to Liquids + Electricity with CCS as Repowering Options for Existing Coal Power Plant Sites

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1 Coal-Biomass to Liquids + Electricity with CCS as Repowering Options for Existing Coal Power Plant Sites Robert H. Williams Princeton Environmental Institute Princeton University Invited Presentation at International Advanced Coal Technologies Conference Laramie, Wyoming 24 June 2010

2 Outline Coal power decarbonization challenge Difficulties posed by decarbonization via CCS retrofits Introducing coproduction technologies based on coal and coal/biomass as repowering alternatives to CCS retrofits Economic comparison of CCS retrofits and these repowering alternatives Why coproduction options outperform CCS retrofits Comparison of biomass/coal coproduction options to biofuel alternatives for providing low-carbon transportation fuels Summary and conclusions

3 Toward Decarbonization of US Coal Power US coal power accounts for: ½ of electricity ⅓ of CO 2 emissions from fossil fuel burning Decarbonizing existing coal plant sites warrants priority under serious C-mitigation policy Options: CCS retrofit for pulverized coal plant (PC-CCS retrofit) Repower with alternative electric technologies Definitions: Retrofit: retain plant but add equipment to scrub CO 2 from flue gases Repower: bulldoze site and rebuild there but retain all infrastructure or rebuild elsewhere if site unsuitable

4 Outlook for CCS Retrofits in C-Constrained World Average age of US coal capacity = 37 years retrofit opportunities in US are based largely on commercially available technology (e.g., amine scrubbers) CCS retrofits via existing technology offer a low capital-cost investment opportunity but are very: Energy-intensive Water intensive Costly Among gasification-based repowering options those involving co-production of synthetic fuels and electricity are especially attractive in C-constrained world of high oil prices

5 Gasification-Based Electricity and Fuels Production Low value feedstocks Coal Pet Coke Oil Residue Biomass Wastes Oxygen H 2 O ` Gasification Gas Cleanup CO 2 Storage CO, H 2, H 2 S, H 2 O, CO 2 CO 2 Removal WGS: CO + H 2 O H 2 + CO 2 H 2 S Removal SULFUR RECOVERY High-Value Energy Products Combined Cycle Power Block Gas & Steam Turbines Clean Syngas (H 2 + CO) Marketable Byproducts Sulfur Catalytic Synthesis Electricity Steam Fischer Tropsch DME MeOH MTG Slag Transportation Fuels Precombustion capture lower energy penalty than for post-combustion Ultra-low emissions of SO 2, NO x, PM, Hg at low incremental cost Low H 2 O requirements Modest solid waste management problems Flexibility: Can make electricity, fuels, or combinations thereof

6 Liquid Phase Synthesis of Synthetic Fuels TYPICAL CONDITIONS P = atm. T = o C Liquid Phase Reactor High single-pass C conversion and thermodynamic advantages of coproduction often most favorable economics are for once- through configurations that provide electricity as major coproduct better than for recycle configurations that maximize liquid fuel output Basic overall reaction for Fischer-Tropsch liquids (FTL): CO + 2H - C H - + H O over Fe- or Co- based catalyst 2 2 2

7 Focus on XTLE-CCS (X to FTL + electricity in once-through system configurations) coal Grinding & Slurry Prep water air Oxygen Plant oxygen Gasification & Quench slag Syngas Scrubber N 2 to gas turbine Water Gas Shift gas expander cooling Acid Gas Removal F-T raw FT Synthesis product syngas Refinery H 2 Prod CO 2 enriched methanol HC Recovery syncrude unconverted syngas + C 1 - C 4 FT gases light ends finished gasoline & diesel blendstocks F-T Refining N 2 Saturator GTCC Power Island CO2 Removal flue gas net export electricity CO bar CO 2 to pipeline Flash CO 2 Flash Regenerator H 2 S + CO 2 To Claus/SCOT methanol Refrigeration Plant methanol coal oxygen Grinding & Slurry Prep water biomass Gasification & Quench slag Chopping & Lock hopper CO 2 Syngas Scrubber oxygen steam FB Gasifier & Cyclone dry ash Water Gas Shift Tar Cracking gas expander cooling gas cooling Filter Acid Gas Removal F-T Synthesis syngas Refinery H 2 Prod raw FT product CO 2 enriched methanol HC Recovery syncrude unconverted syngas + C 1 - C 4 FT gases F-T Refining light ends finished gasoline & diesel blendstocks GTCC Power Island CO 2 Removal flue gas net export electricity CO bar CO 2 to pipeline Flash CO 2 Flash Regenerator H 2 S + CO 2 To Claus/SCOT methanol Refrigeration Plant methanol X = C [coal only (top diagram)] or C = CB [coal + biomass (bottom diagram)] FTL analysis based on Fe catalyst H 2 /CO = 1.0 for syngas to synthesis reactor

8 Electric Power Options 1600 MW Input System Stand-Alone Power Options FTL (B/D) Electric Power (MW) GHGI CAPEX Written off PC-V ($10 9 ) PC-CCS retrofit Once-Through Coproduction Options for Repowering CTLE-CCS 7, CBTLE-CCS-11% BIO (energy, HHV) 7, CBTLE-CCS-39% BIO (energy, HHV) 8, Recycle Option for Comparison [4.4% BIO (energy) = 7% BIO (mass)] CBTL-CCS-4.4% BIO (energy, HHV) 11, GHGI (Fuel-cycle wide GHG emissions)/(emissions for displaced fossil energy) Assumption: displaced fossil energy = equivalent crude oil-derived products /electricity from written-off PC-V plant For once-through systems, FTL ~ ⅔ of energy output; electricity ~ ⅓ of energy output

9 Framework for Economic Analysis No attempt to be up-to-date on CAPEX/estimate FOAK CAPEX Goal: Estimate NOAK CAPEX Provide credible analytical basis for making comparisons among options Approach: Base plant cost estimates (as much as possible) on "2007 NETL $" (i.e. component costs estimated for 2007 as presented in 2007 NETL Baseline Power study) Incorporate additional cost estimates from other reports (for components not covered by that NETL study) by using Chemical Engineering Plant Cost Index to convert other cost estimates to 2007 dollars Key assumptions: Feedstock prices: $1.7/GJ (coal); $5.0/GJ (biomass) CO 2 transport + storage cost = $15/t CO 2

10 Levelized Generation $80/bbl vs P ghge 140 Levelized Generation Cost, $ per MWh Written-off PC-V PC-CCS retrofit CTLE-CCS CBTLE-CCS-11% BIO CBTLE-CCS-39% BIO New supercritical PC-V GHG Emissions Price, $ per tonne of CO 2eq All XTLE-CCS options provide less costly electricity than PC-CCS retrofit over most of indicated range for P ghge At estimated P ghge for 2030 under Waxman-Markey ($65/t CO 2eq ), generation cost for CBTLE-CCS-39% BIO generation cost for new supercritical $0/t CO 2eq

11 Why Are Generation Cost vs P ghge Slopes So Radically Different for 3 XTLE-CCS Technologies? 140 Levelized Generation Cost, $ per MWh GHG Emissions Price, $ per tonne of CO 2eq Written-off PC-V PC-CCS retrofit CTLE-CCS CBTLE-CCS-11% BIO CBTLE-CCS-39% BIO As P ghge increases by $100/t CO 2eq, price of of crude oil-derived products displaced by FTL increases by $1.1/gallon of gasoline equivalent Change in levelized generation cost (in $/MWh) for XTLE-CCS as P ghge increases by $100/t = (c) x ($1.1/gge) Impact of system GHG emissions and FTL credit on generation cost vs P ghge System Gallons of gasoline equivalent (gge) per MWh e (a) Gasoline-equivalent (b) Crude oilderived products (a) (b) (c) = quantity having same GHG emissions as system displaced by FTL CTLE-CCS CBTLE-CCS-11% BIO CBTLE-CCS-39% BIO

12 CBTLE-CCS-39% BIO Generation Cost vs P ghge at Alternative Crude Oil Prices 140 Levelized Generation Cost, $ per MWh Written-off PC-V PC-CCS retrofit CBTLE-CCS-39% BIO, $80/bbl CBTLE-CCS-39% BIO, $60/bbl CBTLE-CCS-39% BIO, $100/bbl GHG Emissions Price, $ per tonne of CO 2eq Each $1/bbl increase in oil price $1.35/MWh reduction in levelized generation cost High biomass co-processing rate protects investor against oil price collapse risk under strong carbon mitigation policy

13 Economic Dispatch Competition Levelized generation costs presented above are for assumed 85% capacity factor (CF) for power-only systems and 90% CF for XTLE systems (designed as must-run baseload power plants) In real world CFs are determined mainly by economic dispatch competition: Power generators bid to sell electricity in hourly markets at prices down to minimum dispatch cost (MDC) determined by: Revenues = short run marginal cost (SRMC) XTLE systems have two revenue streams so that: MDC ($ per MWh) = SRMC ($ per MWh) (FTL revenues per MWh) At sufficiently high oil price, MDC = $0/MWh for an XTLE option At sufficiently high oil prices XTLE systems will be able to both defend high capacity factors and force down capacity factors of competing options What are these oil prices?

14 Economic Dispatch Competiton Minimum Dispatch Cost, $ per MWh Written-off PC-V plant PC-CCS retrofit CBTLE-CCS-39% BIO, $50/bbl CBTLE-CCS-39% BIO, $60/bbl CBTLE-CCS-39% BIO, $70/bbl Nuclear GHG Emissions Price, $ per tonne of CO P ghge = $0/t CO 2eq, CBTLE-CCS-39% BIO dispatched before: Written off PC-V plants for oil price > $54 a barrel Nuclear plants for oil price > $67 a barrel MDC = P ghge = $0/t CO 2eq for oil price = $74 a barrel

15 Coproduction Contribution to Attractive Economics for Low-C Power Generation via XTLE-CCS Large FTL coproduct credit at current crude oil prices Ultra-low minimum dispatch cost even at oil prices lower than at present Low energy penalty and capture cost for CCS compared to stand-alone power High marginal efficiency (MEE) of power generation

16 Energy Penalty for CO 2 Capture Energy penalty for CCS, % CCS Retrofit CIGCC-V--> CIGCC-CCS CTLE-V--> CTLE-CCS CBTLE-V --> CBTLE-CCS CCS retrofit: high penalty (flue gas 0.15 atm) CIGCC-CCS: lower penalty (pre-combustion 10 bar) XTLE-CCS: ultra-low penalty: (i) pre-combustion capture; (ii) generation of pure CO 2 intrinsic to synfuels manufacture; and (iii) high marginal efficiency of making electricity coproduct

17 CO 2 Capture Cost Trend Similar to Energy Penalty 40 Capture Cost, $ per tonne of CO2 captured PC-CCS Retrofit CIGCC-CCS CTLE-CCS, $80/bbl CBTLE-CCS-39% BIO, $80/bbl

18 Outstanding Performance of XTLE-CCS Systems Due Partly to High Power Generation Efficiency System HHV Efficiency of Power Generation Written-off coal power plant 34% CCS retrofit of same via amine scrubbers 25% New supercritical PC-V plant 39% New CIGCC-CCS plant 32% New CTLE-CCS plant New CBTLE-CCS-39% BIO plant 42% (MEE) 44% (MEE) Marginal Energy Efficiency (MEE) for Power Generation (Δ E)/(Δ F) where (for recycle and once-through systems having same FTL output levels): (Δ E) Increase in electricity output in shifting from recycle to once-through (Δ F) Increase in fuel input (HHV) in shifting from recycle to once-through High MEE arises because coproduction enables full utilization of low-quality waste heat generated in synthesis and other upstream exotherms

19 Biomass Coprocessing Contribution to Attractive Economics for Low-C Power Generation Negative GHG emissions benefit of photosynthetic CO 2 storage (> ½ of C in biomass is stored as CO 2 in geological formations along with CO 2 from coal) > cost penalty for expensive biomass at modest P ghge values Substantial reductions in GHG emissions with modest biomass inputs

20 Why Coprocessing Biomass/Coal in Coproduction Systems Is Preferable to Biofuels Applications of Lignocellulosic Feedstocks Enables faster shift than via cellulosic ethanol from food biomass to lignocellulosic biomass feedstocks for which production does not compete with food production or cause huge releases of CO 2 from standing biomass and/or soil carbon when new lands are cultivated Near-zero GHG emitting synfuels can be realized using ~ ½ as much biomass as for biofuels such as cellulosic ethanol Lower production costs than for biofuels derived from lignocellulosic feedstocks because of: Low cost of coal compared to biomass Economies of scale for coal energy conversion

21 Production Cost vs GHG Em Price for Low-C Fuels 4.0 Liquid Fuel Production Cost, $ per gge Cellulosic EthOH BTL-V BTL-CCS CBTL-CCS-45% BIO CBTLE-CCS-39% BIO Gasoline from $80/barrel crude oil GHG Emissions Price, $ per tonne of CO 2eq CBTLE-CCS-39% BIO outperforms all biofuel options! Lignocellulosic EthOH from switchgrass based on performance (future yield of 80 gallons/dry short ton), capital cost ($3.9 per gallon/year), other costs as estimated in NRC, America s Energy Future (2009) except that switchgrass cost, electricity coproduct electricity selling price, and financing rules are the same as for XTL analysis. All systems consume 0.5 million dt/y of biomass. BTL and CBTL systems are recycle options designed to maximize liquid fuel output.

22 Summary and Conclusions Coproduction systems with CCS that coprocess biomass with coal are economically attractive low-c options for repowering sites of written-off coal power plants under a C-mitigation policy Considered as low-c power generators these technologies offer a costcompetitive approach to synfuels requiring far less capital investment than via recycle configurations that maximize liquids fuels output thereby facilitating plant financing These systems are outstanding candidates for CO 2 EOR (low capture cost) These systems enable coal to provide transition to cost-competitive low-c transportation fuels at much lower GHG emissions prices than for biofuels Under a strong C-mitigation policy, systems coprocessing ~ 40% biomass would give investors high degree of protection against oil price collapse risk 1 st gen. technologies (coprocessing ~ 10% biomass/offering GHG emission rates ~ ½ rates for fossil energy displaced) are ready for commercial demos: Demonstrations with 1 st generation technologies could: Help establish quickly supply logistics for lignocellulosic biomass Generate cost cutting via early experience (learning by doing) Early plants might focus on CO2 EOR applications

23 Summary and Conclusions (cont.) Formidable institutional challenges: In managing 3 commodity products simultaneously In managing 2 different feedstocks simultaneously Who will own and operate CBTLE-CCS plants? Regulated electric utilities? Independent power producers? Generation and transmission Co-Ops? Coal companies? NGO opposition to coal use for synfuels ( bait and switch concern) Proposed US policy initiatives make it difficult for CBTLE-CCS to compete for energy decarbonization incentives for early mover projects CCS demonstration at commercial scales needed before CBTLE-CCS or other CCS options can be deployed routinely w/o C-mitigation policy CBTLE-CCS makes no economic sense Facilitating public policies needed

24 EXTRA SLIDES

25 Water Required per MWh of Fuel Input 250 Water Requiired, Gallons per MWh of Fuel Input Written off PC-V PC-CCS retrofit CIGCC-V CIGCC-CCS CBTLE-CCS -39% BIO Most water consumption is for cooling High H 2 O use rate for PC-CCS retrofits because of huge CCS energy penalty (low plant efficiency) Reduced H 2 O use rate for CIGCC because ST power (requiring condenser) accounts for only ~ 1/3 of power (rest from GT in GT/ST combined cycle) Even less H 2 O needed for CBTLE-CCS: it also uses GT/ST combined cycle for power but electricity accounts for only ~ 1/3 of energy output

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