CoalFleet for Tomorrow - Future Coal Generation Options - Program 66

Transcription

1 CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 Program Description Program Overview Around the world, electricity is produced largely from fossil fuels, and coal often is the predominant fuel choice. However, as public concern over the environmental impacts of coal-based generation increases, new technologies and practices are needed to improve plant efficiency and reduce emissions of air pollutants and greenhouse gases. If coal is to continue to be a provider of competitively priced power, then cost-effective, reliable, and highly efficient new coal plant designs with near-zero emissions and CO 2 capture must be developed and made available to the industry. EPRI s CoalFleet for Tomorrow program (Program 66) targets the technical, economic, and institutional challenges to making highly efficient, near-zero-emission coal plants with CO 2 capture a prudent and practical power generation option. The program focuses on deploying a portfolio of advanced coal technologies, including integrated gasification combined-cycle (IGCC), ultra-supercritical pulverized coal (USC PC), and oxygen (rather than air) combustion for PC and circulating-fluidized-bed combustion (CFBC) units. The CoalFleet for Tomorrow program is part of EPRI s Advanced Coal Plant R&D Portfolio, which helps accelerate the development and commercial application of advanced coal-based power generation, including CO 2 capture technologies. New plant concepts and designs address technical risks, economic and environmental performance, and the challenges of deploying these new technologies. The programs also develop information needed to demonstrate the permanence and environmental safety of CO 2 storage. The goal is cost-effective coal-based generation with near-zero emissions and carbon capture and storage. Research Value The program focuses on advancing a portfolio of advanced coal technologies, including integrated gasification combined-cycle (IGCC), ultra-supercritical pulverized coal (USC PC), and oxygen (rather than air) combustion for PC and circulating-fluidized-bed combustion (CFBC) units. The program's R&D: Provides timely and accurate engineering and economic information about advanced coal technologies to support generators decision-making processes. Serves as a source of accurate information on the cost and status of advanced coal power generation technology for policymakers and regulators. Facilitates implementation of the EPRI-Coal Utilization Research Council (CURC) roadmap for the development of the next generation of coal power, including USC PC that will achieve 47% higher heating value (HHV) thermal efficiency (without CO 2 capture), and IGCCs based on high-firing-temperature (>2600ºF/1400ºC) combustion turbines and advanced membranes for O 2 production and CO 2 capture. Identifies optimal design strategies for integrating CO 2 capture and compression systems with coal power plants either for greenfield projects or retrofits to meet current and proposed CO 2 emission standards. Shortens the development time for promising CO 2 capture technologies (post-, pre-, and oxy-combustion) through the cosponsoring support of the U.S. Department of Energy (DOE's) National Carbon Capture Center - a "plug-and-play" pilot- and sub-pilot-plant-scale testing facility. Working with advanced coal power project owners and developers, power industry equipment and service suppliers, and independent world-class experts, this program develops evaluation tools and technologies to help guide the design of innovative coal plant systems that manage cost and risk. EPRI works with DOE, CURC, and numerous international organizations to include technology and information from public and private sources in coordinating advanced coal research, development, and demonstration. p. 1

2 Engineering and economic evaluations and market assessments of advanced coal generation options help power generators screen technology options and conduct feasibility studies that assess the economics, operating performance, and technological risks of both gasification- and combustion-based advanced coal generation technologies. The CoalFleet roadmap for IGCCs sets out a plan for driving down capital cost by 30% by 2025 and, at the same time, improving thermal efficiency with CO 2 capture from today's level of about 30% to almost 40% by CoalFleet's UltraGen strategy lays out a plan for improving the thermal efficiency of PCs by increasing steam temperatures in prudent steps to 1400 F (760 C) while implementing improved CO 2 capture and compression. The end point is a design that will achieve almost 40% thermal efficiency by 2025, while creating fewer CO 2 emissions than a natural-gas-fired combined-cycle unit. Accomplishments Program deliverables support organizations considering the deployment of advanced coal power generation technology, either now or in the future. For example: Engineering and economic information is used by industry to support its coal technology evaluations and generation asset planning. Congressional testimony and other outreach activities have provided guidance on technical objectives and levels of research, development, and demonstration funding needed for coal-power CO 2 capture and storage technologies to reach commercial readiness. Vital laboratory and in-service test data support qualification of high-temperature boiler and steam turbine materials for USC steam conditions of up to 760ºC (1400ºF). In September, 2011 the ASME Boiler and Pressure Vessel Code Committee approved a code case for Inconel 740 based on data accumulated in a US DOE project co-sponsored by CoalFleet and led by EPRI technical experts. Work to qualify other high-temperature materials continues. CoalFleet has invested more than $4 million in the development of its IGCC User Design Basis Specification, the most comprehensive compilation on IGCC state-of-the-art and lessons learned available anywhere. The 1,500-page document covers all aspects of IGCC design including feedstock choice, environmental and safety issues, and designing for reliable operation and maintenance. A series of multimillion-dollar engineering studies have provided up-to-date cost and performance information on state-of-the-art IGCC and USC PC designs. Among other conclusions, the studies have shown that increasing PC thermal efficiency by using advanced steam conditions will provide costeffective (<$15/tonne) reductions in CO 2 emissions, and that judicious use of pre-investment in some CO 2 capture equipment will significantly moderate the cost and efficiency impact of retrofitting CO 2 capture in an IGCC. A recent CoalFleet analysis quantified the value of being able to periodically turn off CO 2 capture systems and offer the resulting increase in net power generation on the rolling reserve capacity market. Such a strategy could reduce the net cost of adding CO 2 capture by several hundred dollars per kw. Current Year Activities The program R&D for 2013 will focus on informing stakeholders about the status of advanced coal power generation technologies and advancing the development of technologies that can provide a significant improvement in the economics of coal power plants with CO 2 capture and storage. Specific efforts will include: d engineering-economic evaluations and assessments of market trends and commercial technology offerings Optimized designs for integrating CO 2 capture and compression processes in both new power plants and retrofits Analysis of options to improve the load-following economics of advanced coal power plants with CO 2 capture Vital laboratory and in-service test data to support qualification of USC boiler and steam turbine materials Investigations of novel power generation concepts that have the promise of delivering near-zero emissions, high thermal efficiencies, or both CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 2

3 Estimated 2013 Program Funding $4.0M Program Manager Jeffrey Phillips, , Summary of Projects PS66A Engineering and Economic Evaluations and Market Assessments of Advanced Coal Generation Options (062001) Project Set Description This project set helps power generators screen technology options and conduct feasibility studies that assess the economics, operating performance, life-cycle greenhouse gas emissions, and technological risks of both gasification- and combustion-based advanced coal generation technologies with CO 2 capture systems, and compares them to natural-gas-fired alternatives. The project set monitors the status of advanced coal power generation technologies and provides information on numbers and types of commercial-scale coal power plants being built in markets of interest to our members. In addition, the project set analyzes the operating flexibility and cycling capability of advanced coal plants and evaluates the potential benefits of novel and innovative power cycles. Project Number Project Title Description P Advanced Coal Technologies Knowledge Base; Assessment of Economics, Experience, and Markets P Analysis of Operating Flexibility & Other Emerging Topics This project helps power generators understand the performance and cost, as well as the technical and financial risks, of advanced coal technologies. This project analyzes the operating flexibility and cycling capability of advanced coal plants with CO 2 capture systems and evaluates the economic value of designing in that capability. P Novel and Innovative Power Cycles This project will assess the potential efficiency and cost benefits of novel and innovative power cycles that can be incorporated in advanced coal plants. P Advanced Coal Technologies Knowledge Base; Assessment of Economics, Experience, and Markets (062002) Electricity suppliers face tremendous challenges to producing affordable electricity, including fluctuating natural gas prices, energy supply concerns, and the need to address climate change. Worldwide demand for new coal power generation (along with high demand for mining equipment, ore-processing facilities, oil refineries, chemical/fertilizer plants, and other capital-intensive industrial facilities) resulted in very large increases in the price of advanced coal technologies that peaked in mid The economic downturn in mid-2009 reversed some of the escalating trends; however, capital costs now appear to be heading back up toward their 2008 peaks. In addition, project financing has become more problematic and costly. Generation planners need up-todate information to make decisions. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 3

4 This project helps power generators understand the technical and financial risks of advanced coal technologies. Two annual reports address in-service advanced coal plants and new commercial designs, while an online library of information and links at provide situational (i.e., fuel, location, and timeframe-specific) comparisons of technologies in terms of cost, performance, emissions, and CO 2 capture convertibility. CoalFleet arranges site tours, featuring advanced coal generation technology developments as a part of two technical workshops during the year. Timely and accurate engineering and economic information on advanced coal technologies Expert assessments of the capabilities of advanced coal technologies Up-to-date information on the development status of advanced coal technologies Site tours, featuring advanced coal generation technology developments The online knowledge base and the annual assessment reports serve as reference documents to support planning for new generation capacity, and as guides for selecting technologies to include in preliminary feasibility studies for new coal generation capacity. Attendance at CoalFleet workshops provides members with an opportunity to visit sites of important advanced coal technology developments and receive previews and summaries of project deliverables. Members can use these workshop materials to fully understand the program results and integrate them in their own planning. In addition, members have year-round access to CoalFleet's technical experts to answer questions about the status, cost, and performance of advanced coal power generation technologies. Through CoalFleet's sponsorship of the DOE National Carbon Capture Center (NCCC) in Wilsonville, Alabama, CO 2 capture test results will be made available and interpreted by EPRI's advanced coal technology experts (note that this information will be provided to funders of any of the three CoalFleet project sets). Engineering/Economic Evaluations of Advanced Coal Technologies with Carbon Capture and Storage: This annual report presents a current picture of technology, cost, and performance trends for advanced fossil power plants, with and without CO 2 capture, by summarizing results from recent studies by EPRI, the National Energy Technology Laboratory, and other sources and by providing context with discussion of regulatory and economic drivers. Coal Technologies with CO2 Capture - Status, Risks, and Markets 2013: This project is designed to update members on the latest activities associated with CO 2 capture, essentially summarizing all things CoalFleet in one document. The report opens by discussing worldwide coal markets and the latest thoughts on issues associated with new coal projects. It then covers pre-, post-, and oxy-combustion technologies, providing information about the challenges and advantages of each and details on existing and new systems. In addition, efficiency improvements and their impacts on CO 2 capture are described. The report also gives updates on new and existing capture projects worldwide, covering all capture technologies with photos and renderings. The final chapter provides insights on selected new concepts for example, in previous years, this chapter included supercritical CO 2 Brayton cycles and pressurized oxy-combustion. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 4

5 P Analysis of Operating Flexibility & Other Emerging Topics (073429) New, advanced coal power plants represent investments of a billion dollars or more, with an expected service life of 50 years or longer. The rapidly changing prices of fossil fuels and the potential impact of CO 2 regulations, energy security initiatives, and other policies on fuel and power markets make power plant design and construction decisions more difficult. In addition, increased renewable energy generation capacity on power systems will require coal-fired power plants with CO 2 capture systems to operate more frequently in loadfollowing and cycling modes. This project will examine cost-effective options for improving the load-following capabilities of both combustion and gasification-based advanced coal-fired power plants equipped with CO 2 capture systems. Turndown strategies, auxiliary load-shifting options, and peaking options based on more detailed analyses in project sets B and C will be investigated. For example, avoiding the extraction of steam would improve load-following response for post-combustion capture systems. For gasification-based plants, options for poly-generation will be examined to determine whether they are amenable to cyclic operation and whether they would be economically attractive. Load-following strategies could make advanced coal-fired plants a low-cost option for peak power. As more renewable generation options are added, the ability to rapidly change the power output of advanced coal-fired power plants will be essential in maintaining power system reliability. Information from the project can be used to help reduce constraints on ramping and turndown for CO 2 capture technologies incorporated with combustion-based power plants. Poly-generation may improve overall IGCC economics due to better utilization of the capital-intensive gasification system. By maintaining gasifier operation at full capacity in a poly-generation plant, operators may find it more easy to rapidly increase electrical power output. The results from this project will help plant designers make design decisions that can maximize operating flexibility of combustion or gasification-based power plants while also supporting decisions on generating assets. Analysis of Operating Flexibility for Advanced Coal Power Plants: This report analyzes the operating flexibility and cycling capability of advanced coal plants with CO 2 capture systems and evaluates the economic value of designing in that capability. P Novel and Innovative Power Cycles (073430) Improving efficiency and reducing capital costs are key requirements for electricity suppliers considering advanced coal-based power generation. Novel and innovative power cycles that currently are being developed for other applications may be adapted for use in either combustion-or gasificationbased power plants. With the introduction of output-based emission standards, achieving significantly improved efficiencies will lead to lower emissions and reduced compliance cost. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 5

6 This project provides insights and preliminary economic assessments of selected novel and innovative power cycle concepts. One example is the supercritical CO 2 Brayton cycle, which is being evaluated in more detail as part of project sets B and C. Other examples may include topping and/or bottoming cycles that use working fluids other than steam. The project also will include an assessment of the process and equipment development status for each cycle. Integration options and preliminary operability assessments for both combustion and gasification-based plants also will be examined. Identification of the potential efficiency and cost improvements offered by innovative power cycles Assessment of options for integrating novel power cycles into both combustion- and gasification-based power plants Understanding of the technical status, research and development needs, and timetable for commercializing these power cycles. Results from this survey of novel and innovative power cycles will give members up-to-date information on the potential efficiency and cost improvements that may be incorporated in the next generation of advanced coalbased power plants. EPRI members can use this information to guide R&D decisions. Assessment of Novel and Innovative Power Cycles: This report assesses the potential efficiency and cost benefits of novel and innovative power cycles that can be incorporated in advanced coal plants. PS66B Gasification-Based Power Plant Development and Deployment (IGCC) (062004) Project Set Description The low emissions and water use of integrated gasification combined-cycle (IGCC) technology together with the already proven ability to capture CO 2 from pressurized synthesis gas at scale of a million tons per year or more make IGCC a technology that cannot be ignored in an era when CO 2 emissions are scrutinized. Gasification-based processes also offer options for co-production of power and clean transportation fuels or hydrogen and other chemicals, or even dedicated facilities for producing fuels, fertilizer, or substitute natural gas. The CoalFleet IGCC R&D Roadmap has shown that there is significant potential for improving the economics of IGCCs with CO 2 capture. Consequently, this project set focuses on advancing the development of the technologies in the roadmap. This advancement is accomplished by joining research collaboratives for various technologies and through support of the DOE's National Carbon Capture Center for hosting sub-pilot and pilot scale tests of pre-combustion CO 2 capture technologies. In addition, lessons learned from current IGCCs are incorporated in design guidelines for new IGCC plants. Project Number Project Title Description P Coal Gasification Technology Status - Annual The annual update provides a concise summary of coal gasification technologies written by EPRI's experts. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 6

7 Project Number Project Title Description P Options for Improving Cycling Economics of Gasification-Based Power Plants P Plant Design Guidelines for IGCC P Advanced IGCC Improvements and Next- Generation Designs with CO2 Capture This project investigates options for improving load-following capabilities of an IGCC by shifting syngas production to nonpower products during periods of low power demand and by shifting large auxiliary loads such as oxygen-production and CO 2 compression from peak power to low-power-demand periods. Reduces the risk of deploying a new IGCC by supporting the use of standardized and optimized IGCC designs, which maximize plant reliability and shorten project development cycles. This project identifies optimum IGCC design configurations for nearterm plants and fosters longer-term development of IGCC with improved CO 2 capture technologies. P Coal Gasification Technology Status - Annual (062005) IGCC technology is evolving rapidly in response to cost concerns, the desire to accommodate low-rank coal, and the need to provide a better transition from conventional operation to CO 2 separation. Several new gasification technologies are being scaled up, and a number of new technologies for improving low-rank coal performance and syngas clean-up economics are under development. Generation planners need information about which technologies are ready for deployment and economically viable. This project provides technical insight into the status, challenges, and opportunities associated with various gasification technologies and feedstock options, including coal, petroleum residuals, and biomass and wastes via an annual report covering technical developments and operating experience. Quarterly updates on commercial gasification projects in development and new technology developments are made available in Knowledge Base B. The project also includes plant visits arranged through the Gasification User Association (GUA), a related supplemental project. Impartial technology assessments written by world-class gasification experts Up-to-date information on the status of coal gasification technology development Increased confidence in decisions about future plant design, project schedules, and implementation timing Project planners and developers can use the information contained in the annual report, as well as insights gained during plant visits and CoalFleet technical meetings and webcasts, to understand opportunities and risks involved in deploying coal gasification technologies. Previous annual reports developed by this project are used as reference documents by EPRI members and are considered to be among the best available source of information on the existing fleet of coal-based IGCC units and other pertinent coal gasification facilities. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 7

8 Gasification Technology Status - December 2013: This annual report contains updates on the operating experience and lessons learned at IGCC plants, the status of commercial gasification projects in developments, and the technology readiness level of new gasification, gas processing, and power generation innovations (gas turbines, fuel cells). P Options for Improving Cycling Economics of Gasification-Based Power Plants (062006) As more renewable generation capacity is added, the need to operate coal power plants in a load-following mode will increase. This project examines ways to enhance the cycling capabilities of an IGCC and to find economic uses of the syngas production capacity for nonpower products during periods of low power demand. Options for poly-generation will be examined to determine whether they are amenable to cyclic operation and whether they would be economically attractive. In addition, the project will investigate design changes that would allow an IGCC to quickly supply additional power during peak demand periods (e.g., supplemental firing of the heat recovery steam generator [HRSG]) and enable deeper load reductions without negatively affecting heat rate. Because at least 60% of the investment in an IGCC is in equipment outside of the power generation block, IGCC economics would be improved if the syngas production equipment did not stand idle during periods of low power demand. By maintaining syngas production at full capacity, it may be easier to rapidly increase power output when called upon, and the thermal cycling of the syngas production equipment will be minimized The results from this project, together with previous economic modeling results from project set 66A, will help plant designers make decisions that can maximize operating flexibility of a gasification-based power plant while also supporting decisions on capital investments. Options for Improved Cycling Economics of IGCC Plants: This report will review the cycling experience of existing IGCC plants with regard to frequency of cycling, operating limitations, and the effect on efficiency and operating costs. IGCC plants with coproduction of chemicals, fuels, and CO 2 can offer baseload operation with increased coproduction when power demand decreases. Previous studies of IGCC poly-generation will be reviewed with regard to their applicability to current IGCC designs with CO 2 capture. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 8

9 P Plant Design Guidelines for IGCC (062007) High capital costs, uncertain reliability, long project schedules, lack of standardization, and unique environmental permitting procedures are obstacles to deploying IGCC technology, which can offer superior environmental performance and could be the lowest-cost generating option for coal plants with CO 2 capture. Improved design guidance will enable program participants to move from using first-of-a-kind designs to designs based on lessons learned from early adopters of the technology. This project supports the deployment of more reliable and economical IGCCs through the use of reference plant designs. It updates and expands an already world-class design guide for IGCC power plants with and without CO 2 capture. Through the project also provides a continuously updated online reference library (Knowledge Base B) of design studies, operational and experience-based lessons-learned reports, and current project information. Lessons learned by existing IGCC plants and CoalFleet members developing new IGCC projects are incorporated into design guidelines, so that all members can benefit from the knowledge gained by early movers. The objective of this project is to reduce the risk of deploying coal-powered IGCC plants by promoting the use of reference designs that meet the requirements of power generation companies. The project provides: Online IGCC reference information (Knowledge Base B) IGCC User Design Basis Specification (UDBS), which provides power plant developers with the most detailed design guidance for IGCC plants available Pre-design and generic design specification reports, which condense public filing documents and nonproprietary descriptions of new IGCC project designs into user-friendly reports Participation in the IGCC Design Guidelines Working Group, which can aid in developing in-house IGCC expertise Participants may be able to save millions of dollars in engineering costs and shave several months off a project schedule by adopting existing designs and technologies for their projects, allowing for minor adjustments to meet site-specific requirements. Knowledge Base B provides around-the-clock access to technical reference information on gasification and IGCC power plants. The User Design Basis Specification can be used as a primer on IGCC technology and design tradeoffs, as well as a template for creating an IGCC specification document to which suppliers can submit bids. The pre-design and generic design specifications provide concise descriptions of IGCC early-deployment project designs and give members important technical information on the design and performance of a specific supplier s technology. Plant Design Guidelines for IGCC: This annual report updates and expands a generic user design basis document as well as technology- and fuel-specific design specifications for IGCC power plants, both with and without CO 2 capture. Lessons learned by both existing IGCC plants as well as CoalFleet members developing new IGCC projects are incorporated. Report CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 9

10 P Advanced IGCC Improvements and Next-Generation Designs with CO2 Capture (062009) Growing concern about the impact of CO 2 emissions on climate change, increasingly stringent environmental regulations, and market competition from non-coal energy sources is accelerating the need to develop lowercost methods for producing power from coal-based power plants with low emissions This project evaluates options for improving IGCC performance generally for all coal types, and for integration with water-gas shift reactors for CO 2 capture and hydrogen production. The project will examine various levels of CO 2 capture, from 20% up to practical maximums, to understand the incremental cost of capturing increasing amounts of CO 2. In addition, the project will evaluate emerging design options for plants with CO 2 capture. A primary focus of this project is to improve the economics of IGCCs, including those with CO 2 capture, through evaluation of design and construction optimizations in addition to the development of new, advanced technologies. The CoalFleet Integrated Gasification Combined Cycle R&D Roadmap, issued in 2012, updated the 2007 CoalFleet roadmap for improving IGCC reliability, availability, performance, and cost by defining new performance and economic targets. Technologies from the updated roadmap will be selected for further due diligence in order to identify development activities in which EPRI and its members might engage. A secondary focus of this project is to continue the series of engineering-economic studies that examine nearterm and advanced options for commercial-scale IGCCs. As a starting point, plant configurations defined in the UDBS (P66.004) have been evaluated and published in three technical reports (Phase ; Phase ; and Phase ). These case studies were expanded to look at the impacts of additional coal types and advanced turbine, gasification, and gas cleanup technologies. Additional case studies will be conducted on an as-needed basis and in line with the goals of the new IGCC R&D roadmap. Independent engineering-economic evaluations of IGCC design options Identification of the potential advantages and risks of new technologies proposed for IGCCs with CO 2 capture Lower-cost methods of capturing CO 2 from coal-based power plants Increased IGCC operating availability, which will improve IGCC economics Results from the engineering-economic case studies will give members realistic, up-to-date information on the cost and performance of near-term commercial IGCC technology. They also will provide guidance on the most economical design configurations for various operating scenarios. This project will monitor progress in implementing the CoalFleet RD&D Augmentation Plan and provide independent assessments of proposed advances, such as improved instrumentation, controls, and processes that could improve IGCC performance on low-rank coals. EPRI members can use this information to guide R&D decisions and anticipate when these enhancements will be commercially available. Progress in Advanced IGCC designs with CO2 Capture: This technical update report will contain the results of advanced IGCC design work, including the results of system analysis studies, due diligence efforts, and updates on the status of development for various IGCC-supporting technologies. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 10

11 PS66C Combustion-Based Power Plant Development and Deployment (062010) Project Set Description This project set covers a range of coal-fired power generation projects focused on identifying process designs and integration approaches that lower the cost of CO 2 capture and storage (CCS) for new and retrofit applications. Special attention will be paid to establish how best to meet the greenhouse gas emission standards for new plants that have been recently established or proposed in several countries. Included is fundamental work to qualify stronger, more corrosion-resistant materials that allow boilers and steam turbines to operate at higher temperatures with increased generating efficiency; innovative technologies for oxy-combustion power plants; design strategies to facilitate greater load-following and cycling capabilities in new power plants; and studies to identify the most cost-effective means of integrating the power plant with the CO 2 postcombustion capture (PCC) plant. Project Number Project Title Description P Design and Materials Development for Post- Ferritic (1200ºF 1400ºF) Advanced Ultra- Supercritical PC Plants P Evaluation of Oxy- Combustion for Advanced PC and CFBC Plants P Analysis of Load-Following Strategies for PCs with CO2 Capture Systems P Integration of Post- Combustion CO2 Capture Technologies with Advanced PC and CFBC Plants This project focuses on validating the advanced materials needed for boilers and steam turbines to operate with main steam conditions of up to 1400 F (760 C) and 5000 psi (345 bar). This project assesses the development status and economics of oxycombustion as applied to steam-electric power plants and the role that oxy-combustion is expected to play in reducing CO 2 capture costs. This project examines options for improving the load-following capabilities of coal-fired power plants equipped with CO 2 capture systems either (PCC) or oxy-combustion. This project undertakes engineering-economic studies to identify cost-saving improvements for commercial-scale applications of PCC technologies. P Design and Materials Development for Post-Ferritic (1200ºF 1400ºF) Advanced Ultra- Supercritical PC Plants (062011) Part of the overall strategy for reducing the cost of CCS is to increase generating efficiency and lower the CO 2 per MWh released from the PC boiler. This approach benefits both post-combustion capture and oxycombustion, and is applicable to pulverized coal (PC) and circulating fluidized-bed combustion (CFBC) technology. The maximum steam temperature achievable with ferritic steels is below 1160 F (630 C), limiting efficiency to less than 40 percent (higher heating value basis, HHV) for a power plant burning bituminous coal and operating at conditions typical for the United States. It is projected that nickel alloys -- materials with greater strength and corrosion resistance than ferritic steels -- will allow steam temperatures up to 1400 F (760 C) and raise generating efficiency to more than 45 percent (HHV). However, these alloys are more expensive and more difficult to weld than ferritic steels, and to date have not been used in coal-fired power plant applications. For use in these more efficient advanced ultrasupercritical (A-USC) power plant designs, the materials need to be fully characterized and tested under commercially representative operating conditions. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 11

12 This U.S. Department of Energy (DOE)-sponsored project (a collaborative of public agencies, research laboratories, and industry) is evaluating nickel alloys for use in steam turbines and air- and oxygen-fired boilers. Candidate materials are tested in the laboratory and on operating power plants simulating A-USC operating conditions of up to 1400 F (760 C) and 5000 psi (345 bar). The information developed includes creep strength, resistance to fireside and steamside corrosion (with and without coatings), welding procedures, and fabrication techniques. Inconel 740, a nickel alloy with outstanding strength and corrosion resistance at 1400 F (760 C) has received Code Approval, and an 8-ton (7.2-tonne) ingot has been extruded into a thick-walled pipe section. Data are being collected for Code Approval of an equally remarkable nickel-alloy, Haynes 282, for use in the steam turbine. Programs of ten and five years duration, respectively, to characterize boiler and steam materials are complete, and three-year follow-on programs are in progress to resolve issues such as the repair of aged components and more detailed evaluations of selected candidate alloys for rotors, casings, and valves. Plans are being made to develop a component test facility to be installed in an operating boiler. This facility will be a circuit containing evaporative and superheat sections, raising steam at 1400 F (760 C) and 5000 psi (345 bar), and includes turbine and pressure relief valves. The facility will demonstrate the suitability of the materials and fabrication procedures used for commercial application. An Advanced Generation Advisory Panel of power producers will help ensure that the test facility fulfills power industry requirements and follows the path towards demonstration and commercialization of the technology. Assessment work carried out in Project confirms the economic advantage of CO 2 emission reductions offered by A-USC power plants. An annual progress report will be published summarizing accomplishments on boiler and steam turbine materials and components. This report, which includes EPRI s perspective on the results, will become available to members once DOE has reviewed the results. Also included will be summaries of the results of system studies by EPRI and technology suppliers, and a review of progress made worldwide in advancing A-USC technology. Results of this project could accelerate acceptance of new A-USC materials by codes and standards organizations, prospective buyers, financiers, and insurers, supporting their introduction into the commercial marketplace. By enabling efficiencies greater than 45% (HHV), these advanced materials could allow reductions in fuel consumption and reduce CO 2 to below 1500 lb/mwh gross (680 kg/mwh), more than 30% lower than the current U.S. fleet average for PC power plants. Reducing the CO 2 /MWh from the power plant reduces the amount to be captured and so contributes to lowering the cost of CCS. Demonstration of advanced materials in a power plant environment significantly reduces the risk of unavailability for initial applications of advanced A-USC PC plants. Members will gain early access to information resulting from this project s research and will get priority in hosting demonstrations of new designs and materials. Once demonstrated, advanced materials will significantly reduce the capital cost and unavailability risk for new, highly efficient A-USC PC plants. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 12

13 Progress Report on A-USC Technology Development: This annual report will contain updates on the development progress of materials for use in advanced ultrasupercritical (A-USC) boilers and turbines, and will contain summaries of recent engineering and economic evaluations of pulverized coal power plants utilizing A-USC technology. P Evaluation of Oxy-Combustion for Advanced PC and CFBC Plants (065779) Boilers designed to burn coal in a blend of oxygen and recycled flue gas (rich in CO 2 ), instead of air, offer a third technology platform for separating and concentrating CO 2 and provide an alternative to post-combustion or precombustion capture processes. Known as oxy-combustion, this approach offers potentially lower costs and lower energy penalties for CO 2 capture at PC and CFBC plants, particularly if emerging low-cost oxygen production technologies reach commercial fruition. Power plants that employ oxy-coal technology for CCS produce a flue gas rich in CO 2 (80%-90% by volume). When moisture is removed, this raw flue gas may be suitable for storage without further processing. Where the geology or regulations require, relatively straightforward partial condensation CO 2 purification technology can be employed to achieve any required purity. A co-benefit of oxy-combustion is the dramatic reduction in the emission of conventional pollutants (CO, volatile organic compounds [VOCs], particulate matter [PM], SO 2, NOX, and hazardous air pollutants [HAPs]) achieved through the addition of known technologies to the CO 2 purification unit. This project will advance the understanding of oxy-combustion technologies for PC and CFBC plants and assess their potential to reduce the cost of CO 2 capture. Achieving this objective will involve evaluating pilot plant results, completing design studies for demonstration- and commercial-scale units, and reviewing how the technology is being advanced worldwide. Models will be developed to identify how best to integrate the power plant with oxygen production and CO 2 purification, and to assess the thermodynamic and economic benefits of incorporating oxy-combustion with A-USC technology. Accurate information on the status of oxy-combustion technologies, pilot plant results, and technical challenges faced along with prospects for their resolution. Determination of oxy-combustion's performance characteristics and the timeframe for its commercialization, leading to identification of oxy-combustion as an economically attractive option for the implementation of CCS. Assessment of the status and performance/economic characteristics of developmental oxy-combustion technologies such as pressurized designs and chemical looping. Members will have early access to objective information about oxy-combustion technology, pilot test results, and early unit design decisions, improving the ability to evaluate the oxy-fuel combustion option for their specific requirements. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 13

14 on Oxy-Coal Development Activities Worldwide: This project provides a review of oxy-combustion development activities throughout the world. The report opens by reviewing oxy-combustion concepts and giving details on potential designs and the relative advantages and disadvantages. It then delves into each sub-system related to oxy-combustion (air separation, burner/boiler, air quality control, and CO 2 purification), giving the latest updates on technologies and associated development issues, pulling from work reported at the 2nd IEA Conference on Oxy-Flue Combustion. The report also gives updates on new and existing oxy-combustion projects worldwide, including both developmental and field demonstrations. The final chapter concludes by discussing selected new concepts in oxy-combustion. The appendix also provides a detailed and useful bibliography of the latest oxy-related references and web links. Evaluation of Oxy-Combustion for Advanced PC and CFBC Plants: CFBC technology offers unique capabilities that could reduce the capital costs of an oxy-coal power plant with CO 2 capture. An assessment of the cost reduction potential and corresponding performance of oxy-cfbc technology (in comparison to PC technology) will be prepared. P Analysis of Load-Following Strategies for PCs with CO2 Capture Systems (062013) Increased renewable energy generation capacity on power systems will require coal-fired power plants to operate more frequently in a load-following mode. However, the addition of CO 2 capture systems could hinder a plant's ability to follow load unless that capability is incorporated from the beginning. This project will examine cost-effective options for improving the load-following capabilities of coal-fired power plants equipped with CO 2 capture systems either PCC or oxy-combustion. Turndown strategies, as well as auxiliary load-shifting options, such as delayed regeneration of capture solvents and off-peak storage of oxygen for later use, will be investigated. For PCC, avoiding the extraction of steam would improve load-following response, and measures such as heat from renewable sources (e.g., solar or geothermal) and waste heat from gas turbines will be evaluated using in-house models. In later years, a dynamic simulator may be developed to allow more detailed analysis of load-following issues. Load-following strategies could make new coal-fired plants a low-cost option for peak power. As more renewable generation options are added, having the ability to change the power output of a coalfired power plant rapidly will be essential in maintaining power system reliability. Information to reduce constraints on ramping and turndown for CO 2 capture technologies incorporated with PC and CFBC units. The results from this project, together with the results from the economic modeling in project P66.001, will help coal plant designers make cost-effective decisions on investments needed to accommodate expected loadfollowing scenarios. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 14

15 Design Considerations for CO2 Capture Plants with Load-Following Flexibility: The capture and storage of CO 2 place operational constraints on power plants with post-combustion capture (PCC) and those plants fired with oxygen. The need for flexible operation is of increasing importance because of the intermittent nature of many renewable energy sources. This work will investigate additional cost-effective measures to increase operational flexibility and further evaluate those measures identified in previous reports. P Integration of Post-Combustion CO2 Capture Technologies with Advanced PC and CFBC Plants (062015) Although technologies for PCC of CO 2 from flue gases have been applied commercially in the chemical and industrial gas industries at a small scale, none has been applied at the scale needed for a large coal-fired power plant. PCC design studies using the latest amine solvents suggest the energy requirements for solvent regeneration (expected to be provided by steam extracted from the turbine circuit) will be large, reducing plant output by 20% or more. However, considerable research is taking place around the world on improved solvents with lower heats of regeneration and alternatives to solvents such as adsorbents and membrane technology. Comprehensive and objective analyses of this rapidly changing field are needed to guide power producers planning to integrate PCC technology with new PC or CFBC units or to retrofit capture technology to existing units. This project evaluates various PCC technologies for application with new advanced PC and CFBC units. The project will address both designs for retrofit after initial operation without CO 2 capture as well as optimal integration of PCC processes in new units that will capture CO 2 upon initial commissioning. Two design integration approaches will be investigated. The most operationally flexible design, with the highest capital cost, will incorporate the ability to turn off the PCC system, allowing for increased power production during periods of peak demand. The least flexible design, with the lowest capital cost, also allows the capture system to be turned off, but the power production remains the same. Initial analyses are based on advanced amines, but alternative solvents and capture technologies will be evaluated as data become available. Models will be used to identify cost-effective thermal integration strategies to reduce the energy penalties associated with adding CO 2 capture, with the approach selected depending on the capture technology used and the characteristics of the power plant. The biggest contribution to the cost of electricity (COE) increase associated with PCC is the reduction in generating capacity arising from the steam extracted to regenerate the solvent. Analysis to date suggests the increase in COE could be halved by adding a gas turbine with heat recovery (but no steam turbine) to offset the power loss and replace the steam used for regeneration. A similar approach could be used for oxy-combustion, but as the heat demand is lower, the integration will be different. By providing estimates of how incorporating PCC processes into new PC and CFBC plants affects power plant costs, COE, thermal performance, and plant operation, the project will identify the most costeffective approaches to meeting greenhouse gas emission standards established or proposed for various countries around the world. Information on the modifications necessary to existing power plant components such as steam turbines and feed-water heaters, to achieve optimal heat integration of the power and capture plants. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 15

16 P66 members can incorporate insights from this project into their generation planning studies, plant feasibility and CO 2 capture readiness studies, and corporate carbon management strategies. Integration of Post-Combustion CO2 Capture Technologies with Advanced PC and CFBC Plants: This report will evaluate several approaches to minimizing the thermal and economic penalty of adding post-combustion CO 2 capture (PCC) to advanced PC and CFBC plants. The cases will evaluate ways to improve the heat integration between a PC boiler and a PCC system, as well as using gas-fired technologies to offset the loss of power when incorporating PCC. Gasification Users Association (GUA) (072905) Supplemental Projects Background, Objectives, and New Learnings The Gasification Users Association (GUA) provides users and potential users of gasification technology with a network to exchange non-confidential information on the practice and operation of gasification and its associated technologies, including air separation, gas cooling and clean-up, gas separation, and power generation. Gasification-based plants can provide for high-efficiency, reliable, and environmentally benign generation of electricity and production of other types of energy and chemicals. EPRI has helped advance development of gasification processes through its RD&D program and continues to help the industry apply the results of the work that it has sponsored, as well as related work. Project and Summary The GUA is an international organization that meets twice a year, usually in association with gasification or IGCC plant visits in the United States, Europe, or Asia. The annual meeting usually is held in conjunction with the Gasification Technologies Conference (sponsored by EPRI and the Gasification Technologies Council [GTC]). EPRI staff provides technical and management support for the GUA. EPRI arranges the meetings and agenda in cooperation with the members and provides an overview of the status of the technology, in addition to its applications and economics, at each meeting. An annual report includes comparisons of IGCC to other competing power generation technologies such as ultra-supercritical pulverized coal, fluidized-bed combustion, and natural gas combined cycles, as well as updates on gasification technology development activities and commercial projects. Benefits To ensure optimum development, the gasification and related technologies industry needs an avenue to exchange information about utility requirements, safety, training, reliability, and power generation considerations. For more than 20 years, the GUA has helped meet this need and today continues serving as an industry group, complementing the RD&D roles of EPRI, individual organizations, and government. CoalFleet for Tomorrow - Future Coal Generation Options - Program 66 p. 16