CCES Colorado Clean Energy Solutions

Transcription

1 CCES Colorado Clean Energy Solutions Carbon Rountable and Symposium October 1, 2009 Current CO 2 Technology Options and Advanced R&D Pathway Solutions Jared Ciferno, Technology Manager Existing Plants Program

2 National Energy Technology Laboratory Where Energy Challenges Converge and Energy Solutions Emerge Only government owned & operated DOE national lab Dedicated to energy RD&D, domestic energy resources Fundamental science through technology demonstration Unique industry academia government collaborations Oregon Pennsylvania West Virginia 2

3 3,000 U.S. Electricity Generation CO 2 Emissions Forecast Million Metric Tons CO 2 /Year 2,500 2,000 1,500 1, Existing Coal Natural Gas New Coal Petroleum 78% of year 2030 CO 2 Emissions from Existing Coal Plants Values Calculated from Energy Information Administration s Annual Energy Outlook ARRA Reference Case Scenario, AEO Does not consider PC with CCS

4 CO 2 Experience Technology Enablers 1. Comparatively small volumes 200 to 4,000 TPD CO 2 2. High value products 3. Specialized operating environments GAS ABSORPTION Chemical Solvents GAS ADSORPTION GAS ABSORPTION Physical Solvents GAS SEPARATION MEMBRANES Natural Gas Sweetening Hydrogen Ammonia Hydrocarbon Refining Chemical Synthesis Dehydration Gas Processing Air Separation Carbon Dioxide Natural Gas Processing Enhanced Oil Recovery Food & Chemical Grade CO 2 Nitrogen Enhanced Oil Recovery Air Separation Chemical Plants Gasifiers Coal-Fired Boilers Time

5 Deployment Barriers for CO 2 on New and Existing Coal Plants Today 1. Scale-up Current PC capture ~200 tons/day 550 MWe plant produces 13,000 tons/day 2. Energy Demand 20% to 30% in power output 3. Cost Increase Cost of Electricity (COE) 4. Regulatory framework Transport pipeline network Storage 5

6 Fossil Energy CO 2 Options Pulverized Coal (PC) Post-combustion PC Oxy-combustion Gasification (IGCC) Pre-combustion 6 Source: Cost and Performance Baseline for Fossil Energy Power Plants study, Volume 1: Bituminous Coal and Natural Gas to Electricity; NETL, May 2007.

7 Fossil Energy CO 2 Solutions Post-combustion (existing, new PC) Pre-combustion (IGCC) Oxycombustion (new PC) Chemical looping Cost Reduction Benefit CO 2 compression (all) Amine solvents Physical solvents Cryogenic oxygen Advanced physical solvents Advanced chemical solvents Ammonia CO 2 compression PBI membranes Solid sorbents Membrane systems ITMs Biomass cofiring Ionic liquids Metal organic frameworks Enzymatic membranes OTM boiler Biological processes OTM O 2 Transport Membrane (PC) ITM O 2 Ion Transport Membrane (PC or IGCC) 2015 Time to Commercialization 2020

8 Supercritical PC Power Plant Amine Scrubbing CO 2 Amine scrubbing Advantages: Proven Technology Petroleum refining, NG purification Chemical solvent High loadings at low CO 2 partial pressure Relatively cheap chemical ($2-3/lb) Tunable to 0 to 90+% capture 8 Steam: 3500 psig/1110 F/1150 F NOx: LNB, OFA and SCR SOx: Wet limestone FGD PM: Baghouse *CO2 Process Flow Diagram in Appendix TPD: Short Ton per Day TPY: Short Ton per Year Reference: Pulverized Coal Oxycombustion Power Plants Volume 1 Bituminous Coal to Electricity, U.S. Department of Energy/National Energy Technology Laboratory, Revision 2 Final Report, August 2008

9 PC CO 2 Efficiency Impact New Plant, Bituminous Coal, Amine Scrubbing Without CO 2 With CO % Net Efficiency (% HHV) % 35% 33% 31% 28% CO 2 2 s s New PC PC net efficiency by by 4 to to 12% pts. 5 0 Existing New 30% CO2 50% CO2 70% CO2 90% CO2 9 References: Pulverized Coal Oxycombustion Power Plants Volume 1 Bituminous Coal to Electricity, U.S. Department of Energy/National Energy Technology Laboratory, Revision 2 Final Report, August 2008 Integrated Environmental Control Model 2008

10 PC CO 2 COE Impact New Plant, Bituminous Coal, Amine Scrubbing 12 Without CO 2 With CO 2 Cost of Electricity (cents/kwh) To To Match New NGCC 800 lb/mwh ~ 65% To To Match CA Proposed 1,100 lb/mwh CO 2 2 s s Existing COE by by ~ 4 5X 5X 0 Existing New 30% CO2 TPC ~ $1,600/kW 50% CO2 70% CO2 TPC ~ $2,300 - $2,900/kW 90% CO2 10 References: Pulverized Coal Oxycombustion Power Plants Volume 1 Bituminous Coal to Electricity, U.S. Department of Energy/National Energy Technology Laboratory, Revision 2 Final Report, August 2008 Integrated Environmental Control Model 2008

11 Advanced CO 2 Solvents Advanced Solvent R&D Focus High CO 2 loading capacity Minimize regeneration energy Fast reaction kinetics Non-corrosive No solvent degradation Low cost Reaction pathway computed from density functional theory E (Kcal/mol) R RNH 2+CO Italcs for JEFFAMINE -1.3 (-2.0)[-2.4] ( ) for MEA Complex TS1 [ ] for Methylamine -2.3 (-3.1) [-4.2] -2.1 (-2.6) [-2.4] Carbamic O zwitterions H C O HO 2 O C H HO 2 C C N C O H 2 H C N H H 2 H H -7.4 (-9.3) [-12.3] Complex2 TS2-8.8(-12.6)[-14.7] O H HO 2 C C O Carbamate C N H 2C OH H (-20.2)[-20.4] 2 H H CH OH N 2 H 2C H H O H CH 2 H HO 2 N C C O H C N H H 2 H The results from the B3LYP/6-31G(d) level using CPCM model + RNH 2 Design 1,1-di-isopropyl JEFFAMINE Heat of reaction = -9.4kcal/mol New compounds with lower heats of reaction 1,1-di-isopropyl MEA Heat of reaction = -10.4kcal/mol Source: Novel High Capacity Oligomers for Low Cost CO 2, GE Global Research, GE Energy, University of Pittsburgh Annual NETL CO2 Technology for Existing Plants R&D Meeting, March 24-26, 2009 Project Types Ionic liquids Novel high capacity oligomers Potassium carbonate/enzymes CO 2 capture additives Solvent Screening and Synthesis Recent chemical formulations show: 50% increase capacity vs. MEA < 48% increase in COE Laboratory-scale 11 Partners (5 Projects): University of Notre Dame, Georgia Tech., Illinois St. Geological Survey, GE Research Corporation, Lawrence Berkeley Nat. Lab

12 Solid CO 2 Sorbents Advantages Low regeneration energy (no water, low heat capacity, low heat of reaction) High equilibrium capacity high surface area Fast kinetics Challenges System design - Pressure drop - Heat integration - Solid transport Durability (attrition, chemical stability) Advanced Sorbent R&D Focus High CO 2 loading capacity Minimize regeneration energy Fast reaction kinetics Durable - Thermally & chemically stable Gas/solid systems - Low pressure drop, heat management Project Types Sorbent systems development Carbonates Metal organic frameworks Metal zeolites Laboratory-scale 12 Partners (6 Projects): RTI, UOP, University of Akron, ADA, SRI, TDA

13 CO 2 Membranes Advantages Simple operation; no chemical reactions, no moving parts Tolerance to high levels of wet acid gases Compact and modular with a small footprint Relatively low energy use; no additional water used (recovers water from flue gas) Advanced Membrane R&D Focus High CO 2 /N 2 selectivity & permeability Durability - Chemically (SO 2 ), thermally - Physically Membrane systems - Process design critical Low cost - Capital and energy penalty Polaris TM Challenges Low flue gas CO 2 partial pressure Particulate matter and potential impact on membrane life Cost reduction and device scale-up Power plant integration (e.g. sweep gas) CO 2 /N 2 selectivity Commercial CA membranes Target area identified from design calculations 100 1,000 10,000 CO 2 permeance (gpu) Laboratory to Pilot-scale 1 TPD CO 2, 6 month test 13 Partners: MTR, RTI

14 Pulverized Coal Oxy-combustion Coal + O 2 CO 2 + H 2 O PC Oxy-combustion Advantages: 1 st generation plants with existing cryogenic ASU cost competitive with conventional scrubbing Plant vs. unit operation multiple cost reduction opportunities Co-sequestration options Applicable to new and existing PC power plants 14 Reference: Pulverized Coal Oxycombustion Power Plants Volume 1 Bituminous Coal to Electricity, U.S. Department of Energy/National Energy Technology Laboratory, Revision 2 Final Report, August 2008

15 Pulverized Coal Oxy-combustion Challenges Existing cryogenic ASUs are capital and energy intensive Excess O 2 and inerts (N 2, Ar) CO 2 purification cost Existing boiler air infiltration Corrosion and process control Advanced Oxy-combustion R&D Focus New oxyfuel boilers - Advanced materials and burners - Corrosion Retrofit existing air boilers - Air leakage, heat transfer, corrosion - Process control Low-cost oxygen CO 2 purification Co-capture (CO 2 + SOx, NOx, O 2 ) 70 Percent Increase in COE Capital Cost COE by 29% Parasitic Power COE by 37% Trans., Stor., & Monit. Compression Capital ASU Capital Compression Power ASU Power 15 0 Laboratory to 5 MWe Pilot-scale No-capture base = 6.4 cents/kwh Partners (11 projects): Praxair, Air Products, Jupiter, Alstom, B&W, Foster Wheeler, REI, SRI

16 Chemical Looping Combustion Key Challenges Solids transport Heat Integration Air Reactor (Oxidizer) Steam Air Ox Me MeO Oxy-Firing without Oxygen Plant Solid Oxygen Carrier circulates between Oxidizer and Reducer Oxygen Carrier: Carries Oxygen, Heat and Fuel Energy N 2 + O Carrier picks up O 2 2 in the Oxidizer, leaves N2 behind Carrier Burns the Fuel in the Reducer Heat produces Steam for Power Red Fuel CO 2 + H 2 O Fuel Reactor (Reducer) Status 2010 Alstom Pilot test (1 MWe) 1000 lb/hr coal flow 1 st Integrated operation 1 st Autothermal Operation 16 Key Partners (2 projects): Alstom Power (Limestone Based), Ohio State (Metal Oxide)

17 PC Oxy-combustion Pathway Percent Increase in COE Amine Scrubbing Supercritical Oxyfuel Cryogenic ASU ADVANCED Ultra-Supercritical Cryogenic ASU ADVANCED Adv. Boiler O 2 Membrane Adv. Materials Co-Sequestration Ultra-Supercritical ADVANCED Chemical Looping or Ultra-Supercritical Adv. Boiler Adv. Materials Co-Sequestration O 2 Membrane Steam Conditions (psig/ o F/ o F) Supercritical: 3,500/1,110/1,150 Ultra-supercritical: 4,000/1,350/1,400 Note: As of 2009, most advanced cycles are in Japan. Example (3,685/1,120/1,115) 17 Reference: Pulverized Coal Oxycombustion power Plants, U.S. Department of Energy/National Energy Technology Laboratory, Final Report, August 2008

18 IGCC Power Plant With Pre-combustion Selexol TM CO 2 Scrubbing IGCC CO 2 Advantages: 1. High P CO2 2. Low Volume Syngas Stream Selexol TM CO 2 Advantages: 1. Physical Liquid Sorbent 2. Highly selective for H 2 S and CO 2 3. CO 2 is produced at some pressure years of commercial operation (55 worldwide plants) 1See Appendix for further design conditions: Coal type, Plant Location, Financial Criteria, etc. TPD: Short Ton per Day TPY: Short Ton per Year (at 80% Capacity Factor) 18 References: Cost and Performance Baseline for Fossil Energy Power Plants--Volume 1 Bituminous Coal to Electricity, U.S. Department of Energy/National Energy Technology Laboratory, Final Report, May 2007

19 IGCC CO 2 Efficiency Impact New Plant, Bituminous Coal, Selexol Scrubbing Without CO 2 With CO % Net Efficiency (% HHV) % 36% 35% 34% 32% CO 2 2 s s New IGCC net efficiency by by 3 to to 8% 8% pts. 5 0 Existing PC New IGCC 40% CO2 60% CO2 70% CO2 90% CO2 19 References: Cost and Performance Baseline for Fossil Energy Power Plants--Volume 1 Bituminous Coal to Electricity, U.S. Department of Energy/National Energy Technology Laboratory, Final Report, May 2007 Evaluation of Alternate Water Gas Shift Configurations for IGCC Systems, Draft Internal Report,, December 2007

20 IGCC CO 2 COE Impact New Plant, Bituminous Coal, Selexol Scrubbing 12 Without CO 2 With CO 2 Cost of Electricity (cents/kwh) To To Match New NGCC 800 lb/mwh To To Match CA Proposed 1,100 lb/mwh New IGCC with CO 2 2 s s Existing PC PC COE by by ~ 5X 5X 0 Existing PC New IGCC 40% CO2 60% CO2 70% CO2 90% CO2 TPC ~ $1,900/kW TPC ~ $2,300 $2,800/kW 20 References: Cost and Performance Baseline for Fossil Energy Power Plants--Volume 1 Bituminous Coal to Electricity, U.S. Department of Energy/National Energy Technology Laboratory, Final Report, May 2007 Evaluation of Alternate Water Gas Shift Configurations for IGCC Systems, Draft Internal Report,, December 2007

21 IGCC Pre-combustion CO 2 Technologies 10 new projects in 2009 H 2 /CO 2 Membranes Solid Sorbents Advanced Solvents IGCC CO 2 Advantages: 1. High pressure gas stream (High P CO2 ) 2. Low Volume Syngas Stream CO 2 Challenges: 1. Integrated power cycles system complexity 2. Additional water-gas-shift process 21

22 Recent Meeting Presentations 22

23 For More Information About the NETL Existing Plants Program NETL website: Office of Fossil Energy website: ww.fe.doe.gov Reference Shelf Annual CO2 Meeting Jared P. Ciferno Technology Manager, Innovation for Existing Plants National Energy Technology Laboratory U. S. Department of Energy (Tel)

24 CO 2 Goals By 2020, have available for commercial deployment, technologies that achieve: 90% CO 2 capture < 35% increase in COE for PC, < 10% for IGCC Set by Systems Analyses Evaluated by Systems Analyses 24 *Cost of Electricity includes 50 mile pipeline transport and saline formation storage, 100 years of monitoring Availability analysis of post-combustion carbon capture systems: minimum work input, McGlashan, N.R., Marquis, A.J., Mechanical Engineering Science, Proc. ImechE Vol. 221 Part C, 2007 Existing Plants, Emissions & Program Setting Program Goals, U.S. DOE/National Energy Technology Laboratory, Final Report, April 2009

25 RD&D Timeline to Commercial Deployment Commercial Deployment Large Demonstrations (CCPI) 100+ MWe *Solvents/Sorbents *CLC (2016) Large-Scale Field Testing 5 25 MWe *O2 Membrane (2016) Pilot-Scale Field Testing MWe *Solvents *O 2 Membrane (2011) *CO 2 Membrane (2012) - NCCC - Utility sites Laboratory-Bench Scale R&D

26 CO 2 from New Coal Plants NETL Baseline Study Bituminous Coal ~550 MW net Subcritical, Supercritical PC 3 IGCC Types Selexol and Amine CO NETL Oxyfuel Study Bituminous Coal 577 MW gross Supercritical, Ultra-Supercritical P Cryogenic and Membrane ASU CO 2 Purification Analysis 26 Source: Cost and Performance Baseline for Fossil Energy Power Plants study, Volume 1: Bituminous Coal and Natural Gas to Electricity; NETL, May Source: Pulverized Coal Oxycombustion Power Plants Volume 1 Bituminous Coal to Electricity, U.S. Department of Energy/National Energy Technology Laboratory, Revision 2 Final Report, August 2008

27 CO 2 from Existing PC Plants AEP Plant, Conesville Ohio Bituminous Coal 30 Yr. old subcritical PC Plant 463 MW gross ESP and Wet Lime FGD 30, 50, 70 and 90% Jim Bridger, Sweetwater Wy Subcritical PC on PRB coal 6,700 ft elevation 577 MW gross ESP and Wet Soda Ash FGD 62% and 90% CO Carbon Dioxide from Existing Coal-Fired Power Plants, U.S. Department of Energy-National Energy Technology Laboratory, Revised Final Report, November 2007

28 28 CO 2 Process

29 CO 2 Cost of Electricity Impact New Plant, Bituminous Coal, Amine Scrubbing 90 Percent Increase in COE % 5% 20% 7% 28% 11% 13% Capital Cost COE by 27% Operating Cost COE by 7% Parasitic Power COE by 52% Trans., Stor., & Monit. Compression Capital Capital Operating Steam Aux. Power Compression power 0 *No Base = 64 mills/kwh *90% CO 2 *Compression to 2,200 Psia *50 Mile Pipeline + Saline Formation Storage Years Monitoring 29 Source: Cost and Performance Baseline for Fossil Energy Power Plants study, Volume 1: Bituminous Coal and Natural Gas to Electricity; NETL, May 2007.

30 CO 2 Cost of Electricity Impact New Plant, Bituminous Coal, Oxy-combustion 70 Percent Increase in COE % 5% 20% 13% 24% Capital Cost COE by 29% Parasitic Power COE by 37% Trans., Stor., & Monit. Compression Capital ASU Capital Compression Power ASU Power 0 *No-capture Base = 64 mills/kwh *90% CO 2 *Compression to 2,200 Psia *50 Mile Pipeline + Saline Formation Storage Years Monitoring 30 Reference: Pulverized Coal Oxycombustion Power Plants Volume 1 Bituminous Coal to Electricity, U.S. Department of Energy/National Energy Technology Laboratory, Revision 2 Final Report, August 2008

31 PC Oxycombustion Efficiency Impact New Plant, Bituminous Coal Without CO 2 With 90% CO 2 40 Net Efficiency (% HHV) % 39% 28% 29% Existing New MEA Oxycombustion TPC ~ $1,600/kW TPC ~ $2,600 - $2,900/kW 31 References: Pulverized Coal Oxycombustion Power Plants Volume 1 Bituminous Coal to Electricity, U.S. Department of Energy/National Energy Technology Laboratory, Revision 2 Final Report, August 2008 Integrated Environmental Control Model 2008

32 PC Oxycombustion COE Impact New Plant, Bituminous Coal 12 Without CO 2 With 90% CO 2 Cost of Electricity (cents/kwh) Existing New MEA Oxycombustion 32 References: Pulverized Coal Oxycombustion Power Plants Volume 1 Bituminous Coal to Electricity, U.S. Department of Energy/National Energy Technology Laboratory, Revision 2 Final Report, August 2008 Integrated Environmental Control Model 2008

33 Oxy-Combustion Pilot with CO 2 Purification Alstom Power Air Products Flue Gas CO 2 Purification Slip-Stream Test: 2-stage compression/purification Removes SOx, NOx, O 2, & Inerts 33

34 Chemical Looping Combustion Challenges Solids transport Heat Integration Cold Flow Modeling Completed Kinetic Rates Exceed Design Requirements 2010 Alstom Pilot test (1 MWe) 1000 lb/hr coal flow 1 st Integrated operation 1 st Autothermal Operation Solids Heater 2-Stage Cyclones (2) Spray Coolers & Filters (5) Product Gas Burner Reducer Oxidizer Sealpot Control Valves (2) Ash Coolers (6) 34 Key Partners (2 projects): Alstom Power (Limestone Based), Ohio State (Metal Oxide)