Water usage and loss of power in power plants with CO2 capture

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1 Water usage and loss of power in power plants with CO2 capture Luca Mancuso Process Manager Paolo Cotone Principal Process Engineer Power Division - Foster Wheeler Italiana 14 th September EPRI Advanced Coal & CO2 Capture & Storage Seminar - Rome

2 Introduction This study was carried out by Foster Wheeler for IEA Greenhouse Gas R&D Programme (IEA GHG) to analyze and optimize water usage and related power losses in power plants without and with CO2 capture The study evaluates bituminous-coal-fired power plants, using the following technologies: USC-PC boiler Oxy-fired USC-PC boiler IGCC, GE Energy quench-type gasifier 2

3 Reference studies The study takes reference from previous reports, part of the IEA GHG R&D Programme, assessing coal power generation plants without and with CO2 capture Report Number PH4/33 (Nov 2004) Improvement in power generation with post-combustion capture of CO2 Report Number 2005/9 (July 2005) Oxy Combustion Processes for CO2 Capture from Power Plant Report Number PH4/19 (May 2003) Potential for improvement in gasification combined cycle power generation with CO2 capture 3

4 Objectives of the study Establish a rigorous accounting and comparison of water usage in different power plants with and without CO2 capture; Establish a methodology for comparing water usage in power plants Provide benchmark data for potential improvements and R&D programs Assess performance, s and impact on water usage of power plants located in areas where water supply is severely limited (dry-land) 4

5 Design Bases Eastern Australian Bituminous Coal (S = 1.1% wt, dry ash free bases) Emission limits USC PC / Oxyfuel (1) IGCC (2) NOx (as NO 2 ) 200 mg/nm 3 80 mg/nm 3 SOx (as SO 2 ) 200 mg/nm 3 10 mg/nm 3 Note: 6% O 2 vol dry Particulate 30 mg/nm 3 10 mg/nm 3 15% O 2 vol dry Location Reference cases wet land: NE coast of The Netherlands (as per original reports) Dry land cases: dry in land region in South Africa 5

6 Design Bases Ambient temperature Reference cases wet land: 9 C Dry land cases: 14 C Cooling water: Reference cases wet land: Sea CW (primary system): C Dry land cases: MCW (secondary system): C Sea CW (primary system): N/A MCW (secondary system): C CO2 characteristics at plant B.L.: Pressure: 110 bar g (Supercritical) Purity: CO 2 : > 99% mol (> 95% for oxyfuel combustion cases) 6

7 Study cases Case 1: Pulverised coal-fired power plant with ultrasupercritical steam cycle without CO 2 capture (USC-PC without CCS) Case 2: Pulverised coal fired power plant with ultrasupercritical steam cycle with post-combustion CO 2 capture based on standard MEA solvent (USC-PC with CCS) Case 3: Pulverised coal fired power plant with ultrasupercritical steam cycle using oxyfuel combustion for CO 2 capture Case 4: IGCC using GEE Quench type gasifier without CO 2 capture (IGCC without CCS) Case 5: IGCC using GEE Quench type gasifier with pre-combustion CO 2 capture based on physical solvent (IGCC with CCS) 7

8 Study cases (cont d) For each alternative, case without and with limitation on water usage is evaluated Two concepts are applied in relation to the water usage: Water withdrawal refers to the total water taken from a source and sent back to the same source Water consumption refers to the irrecoverable loss of water that is not returned to the source 8

9 Case #1 - USC PC without CCS (wet land) 9

10 Case #1 - USC PC without CCS (dry land) 10

11 USC-PC w/o CCS: performance - 5 (SW pumps) + 7 (air condenser) +1 Flue gas blower incresase +1.5 DCC circuit 11

12 Case #2 - USC PC with CCS Dry land case 12

13 USC-PC w CCS: performance - 10 (SW pumps) + 5 (air condenser) +1.4 Flue gas blower incresase +20 AGR and compression +0.5 DCC circuit 13

14 Case #3 - Oxyfuel Dry land case 14

15 Oxy USC-PC: performance - 6 (SW pumps) + 5 (air condenser) + 6 CO2 compression + 6 ASU 15

16 Case #4 IGCC without CCS Dry land case 16

17 IGCC w/o CCS: performance - 8 (SW pumps) + 6 (air condenser) + 6 booster blower +5.5 DCC circuit ASU 17

18 Case #5 IGCC with CCS Dry land case 18

19 IGCC w CCS: performance - 10 (SW pumps) + 6 (air condenser) + 6 booster blower +13 DCC circuit ASU + 4 AGR and CO2 compression 19

20 Analysis of performance results Efficiency penalty due to water usage limitation in a relatively narrow range of variation, i despite the differences of the various technologies involved Most of the power loss is due to different condensing pressure (74 vs. 40 mbar) Higher penalty in CCS cases: CO2 capture and compression are heavily affected by the limitation on water usage CO2 capture: CO2 compression: higher temperature at absorber inlet solvent circulation increase regeneration heat increase higher temperature at compressor inlet (air intercooling) lead to compressor power absorption increase Higher impact on post combustion cases 20

21 Economic analysis Bases of the estimate: Location Wet land: The Netherlands Dry land cases: South Africa Cost level: Fuel s: Cost of coal: 4Q /GJ (same as all reference studies) 21

22 Economic analysis (cont d) Bases for evaluation of Cost of Electricity (COE): 10% discount rate 25 operating years No of CO 2 transport and storage considered No selling price attributed to the sequestered CO 2 Bases for evaluation of Cost of Water saved: Electricity : 50 /MWh Delta TIC between wet and dry land case Delta net power output between wet and dry land case Delta O&M Costs between wet and dry land case 22

23 Economic summary CASE Total investment % TIC increase operating hours O&M s Specific Investment COE Cost of water saved M % h/y M /y Euro/kWe c /kwh c /t 1 wet ,884 (90%) , dry % 7,884 (90%) , wet 1, , (88%) , dry 1, % 7,709 (88%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) ,

24 Economic summary CASE Total investment % TIC increase operating hours O&M s Specific Investment COE Cost of water saved M % h/y M /y Euro/kWe c /kwh c /t 1 wet ,884 (90%) , dry % 7,884 (90%) , wet 1, , (88%) , dry 1, % 7,709 (88%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , TIC percentage increase falls in a narrow range of variation (4% and 8%), despite the differences of the various technologies involved 24

25 Economic summary CASE Total investment % TIC increase operating hours O&M s Specific Investment COE Cost of water saved M % h/y M /y Euro/kWe c /kwh c /t 1 wet ,884 (90%) , dry % 7,884 (90%) , wet 1, , (88%) , dry 1, % 7,709 (88%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , Cases without CO2 capture: dry land design TIC percentage increase higher in IGCC than in USC-PC. Impact on investment for USC-PC limited to power island and utilities, while for IGCC the dry land design also impacts the ASU 25

26 Economic summary CASE Total investment % TIC increase operating hours O&M s Specific Investment COE Cost of water saved M % h/y M /y Euro/kWe c /kwh c /t 1 wet ,884 (90%) , dry % 7,884 (90%) , wet 1, , (88%) , dry 1, % 7,709 (88%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , Cases with CO2 capture: dry land TIC percentage increase higher in USC-PC than in IGCC. In USC-PC the dry land design affects the CO2 capture and compression investment e, in addition to the units mentioned ed before. e Impact on IGCC plants pa is lower 26

27 Economic summary CASE Total investment % TIC increase operating hours O&M s Specific Investment COE Cost of water saved M % h/y M /y Euro/kWe c /kwh c /t 1 wet ,884 (90%) , dry % 7,884 (90%) , wet 1, , (88%) , dry 1, % 7,709 (88%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , Similar TIC percentage increase in IGCC with and without CO2 capture. Difference between the two cases mainly limited to the CO2 compression unit that, from an economic point of view, counts for less than one percentage point 27

28 Economic summary CASE Total investment % TIC increase operating hours O&M s Specific Investment COE Cost of water saved M % h/y M /y Euro/kWe c /kwh c /t 1 wet ,884 (90%) , dry % 7,884 (90%) , wet 1, , (88%) , dry 1, % 7,709 (88%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , Highest TIC percentage increase in USC PC with CO2 capture CO2 capture and compression units represents a significant part of the overall investment e 28

29 Economic summary CASE Total investment % TIC increase operating hours O&M s Specific Investment COE Cost of water saved M % h/y M /y Euro/kWe c /kwh c /t 1 wet ,884 (90%) , dry % 7,884 (90%) , wet 1, , (88%) , dry 1, % 7,709 (88%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , Lowest TIC percentage increase for the oxy-fuel case: - CO2 purification leads to the condensation of the water from the boiler flue gases. No need for further water recovery system in the dry land cases - Much lower dry land impact on ASU compressors and intercoolers: O 2 from ASU made available at a lower pressure with respect to IGCC 29

30 Economic summary CASE Total investment % TIC increase operating hours O&M s Specific Investment COE Cost of water saved M % h/y M /y Euro/kWe c /kwh c /t 1 wet ,884 (90%) , dry % 7,884 (90%) , wet 1, , (88%) , dry 1, % 7,709 (88%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , Variable O&M s: the only significant difference is the water make-up in IGCC Fixed O&M s: partially constant (fuel, labour and consumables); partially increased proportionally with the investment of the plant on the same basis as the wet land case (maintenance, insurance and local taxes) 30

31 Economic summary CASE Total investment % TIC increase operating hours O&M s Specific Investment COE Cost of water saved M % h/y M /y Euro/kWe c /kwh c /t 1 wet ,884 (90%) , dry % 7,884 (90%) , wet 1, , (88%) , dry 1, % 7,709 (88%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , Cost of water saved very low in USC-PC with CCS and in IGCC with CCS. The significant increase in investment (approx +85M ) is compensated by the huge amount of water saved (approx 270 t/h) 31

32 Economic summary CASE Total investment % TIC increase operating hours O&M s Specific Investment COE Cost of water saved M % h/y M /y Euro/kWe c /kwh c /t 1 wet ,884 (90%) , dry % 7,884 (90%) , wet 1, , (88%) , dry 1, % 7,709 (88%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , wet 1, ,446 (85%) , dry 1, % 7,446 (85%) , Cost of water saved much higher in the oxyfuel case. Low investment increase (+46 M ) is needed for a limited amount of water saved (33 t/h). This is because the water requirement is small also in the wet land case 32

33 Normalized of electricity 200% 180% 160% 140% 145% 163% 159% 178% 178% 157% 139% 126% 120% 100% 80% 60% 100% 108% +12% +12% +10% +13% 40% +8% 20% 0% 1 wet 1 dry 2 wet 2 dry 3 wet 3 dry 4 wet 4 dry 5 wet 5 dry COE percentage increase falls in a relative narrow range of variation (8% and 13%) 33

34 THANK YOU Any question: EPRI Advanced Coal & CO2 Capture & Storage Seminar - Rome

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