Gasification Research in Australia: supporting deployment of low emissions power technologies. David Harris CSIRO Advanced Coal Technologies

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1 Gasification Research in Australia: supporting deployment of low emissions power technologies David Harris CSIRO Advanced Coal Technologies Australia-Korea Green Growth Workshop Melbourne, March 2011

2 CSIRO Advanced Coal Technology CSIRO has brought all its coal research activities together into a single research program across the entire coal value chain Director: Dr John Carras ~170 staff Focus is on innovative science and technology to address the challenges facing coal The three major areas of activity are Coal Production mining, fugitive emissions, preparation Coal Utilisation: high efficiency energy from coal gasification, syngas, liquid fuels, coal fired diesel engines, direct carbon fuel cell CO 2 Capture, Transport and Storage saline formations, coal seams, monitoring Goal - To maximise the benefits from Australia s coal resources in an environmentally and socially responsible manner.

3 Technology efficiency impact on CO 2 emissions Tonnes CO 2 per MWh (Electrical) Current Australian technology Brown coal pulverised fuel Black coal pulverised fuel Open cycle gas turbine Brown coal Integrated Drying Gasification Combined Cycle Super/ultra critical pulverised fuel Thermal efficiency % Black coal Integrated Gasification Combined Cycle In use Future Integrated gasification fuel cell DICE Combined cycle gas turbine DCFC

4 Low Emissions Power Generation Post-combustion capture Energy Conversion Capture of CO 2 Energy / Power ASU Oxy-fuel combustion Coal Energy Conversion Capture of CO 2 Storage/Use of CO 2 Gasification Pre-combustion decarbonisation Syngas (CO+H 2 ) CO Shift CO 2 /H 2 separation Energy / Power or H 2 / CO Source: adapted from IEA Clean Coal Centre

5 Gasification: a flexible enabling technology Brown Gasification Source: Shell 2007

6 World Gasification Capacity and Planned Growth Feedstock Product Region Strongest activity: coal gasification Asia & North America Power, chemicals & synfuels products Source: US DoE and Gasification Technology Council, 2010

7 Gasification for Power Generation Emissions and Environment NOx and SOx remarkably low without extra scrubbing units Slagging gasifiers lead to reduction in fine particles and solid wastes Less Water: IGCC units use 20%-50% less water than conventional coal plants Efficiency Current IGCC match state of the art pf units Still early on the learning curve Flexibility Feedstock flexibility is high, especially entrained flow gasifiers Product flexibility: polygen :power, fuel, H 2 Carbon Capture and Storage IGCC well-suited for CO 2 capture Incremental cost < pf technology Challenges Demonstrated reliability (integrated system) and availability Cost Acceptance by power industry

8 Coal Gasification & IGCC Research in Australia To improve the understanding of coal performance in gasification technologies, supporting: Use of Australian coals in new technologies Implementation of advanced coal technologies in Australia Development of high efficiency IGCC-CCS systems High pressure, high temperature coal conversion measurements Effects of reaction conditions and coal type Development of coal test procedures Fundamental investigations of coal gasification reactions mechanisms, kinetics, models Slag formation and flow Syngas cleaning & processing Gas separation (H 2 /CO 2 ) Technology performance models

9 Interrogating the Gasification Process Gas Analysis Laboratory investigations to understand the important processes that combine to gasify coal under practical conditions. Larger-scale testing to recombine process steps under process conditions Predictive capability of gasification behaviour Assess coals for specific gasification technologies Develop operating strategies Troubleshooting gasification processes Support technology development slag O 2 CO/CO 2 CO + H 2 CO 2 and H 2 O flux

10 High Pressure Entrained Flow Reactor (PEFR) Entrained-flow reactor Capable of 20 bar pressure, 1500 C wall temperature Coal feed rate of 1-5 kg/hr Gas mixtures of O 2, CO 2, H 2 O and N 2 Adjustable sampling probe - char and gas samples collected at different residence times (0.5-3s) Preheating and mixing Feeder Three-section reaction zone Water quench Sampling probe and gas analysis Gas Analysis

11 CO 2 /char reaction rate at high temperature bar total pressure, 5 bar CO 2 partial pressure CRC252 Sub bit, high vol CRC272 Bituminous 1673 K 1573 K 1473 K 1373 K 1273 K CRC281 Semi anthracite Char conversion (%) Residence time (s) Residence time (s) Residence time (s) CRC252 CRC272 CRC281

12 Gasification modelling C+O2 C+CO2 C+H2O Carbon conversion Reaction rate (kg/kg/s) Carbon conversion (%) Gas T Particle flow Distance from reactor top (m) Model needed for interrogation and application of measurements Integration of fundamentals with system and technology models relationships with international programs, pilot and demo plant operators Australia has no pilot or commercial scale gasification plant Collaboration is essential to apply knowledge and to validate outcomes 1 st Pilot scale test program conducted in 2007 (Siemens, Germany) KIER and others have advanced test and pilot scale facilities

13 Technology development: Syngas Processing & H 2 Separation Current technology Coal Gasifier Gas Cleaner CO+H 2 High T Shift Low T Shift CO 2 +H 2 Gas separation H 2 CO 2 Membrane Shifter Membrane Reactor Coal CO + H 2 O = CO 2 +H 2 H 2 CO 2 Key cost and efficiency drivers: Increase temperature of gas cleaning and processing Development and application of membrane separation systems Integrate gas processing and separation stages with membrane reactors

14 Catalytic membrane reactor Prototype planar proof-of-concept device Greater-than-equilibrium conversion achieved Pure H 2 product >70% H 2 recovery demonstrated CO conversion (%) no membrane 1 bar H 2 product 0 bar H 2 product equilibrium syngas feed rate (cm 3 /min) / membrane area (cm 2 )

15 Membranes Hydrogen permeability V based alloys have been developed: Improved flux (8x Pd) Reduced cost (~5x less than Pd alloys) Practical membrane thickness (US DoE targets met at 65µm) These meet DoE performance targets and could be economic The 2015 DOE durability target is 5 years Durability testing and performance with real syngas ongoing Amorphous membranes performance slightly less than Pd but cost is only 1-2% of Pd Permeability (mol m -1 s -1 Pa -0.5 ) 1e-7 9e-8 V-Ti-Ni 8e-8 7e-8 6e-8 5e-8 V-Ni-Pd 4e-8 V-Ni-Al V 85 Ni 15 3e-8 Pd 75 Ag 25 2e-8 Pd 1e-8 a-ni 42 Nb 28 Zr Temperature ( C) V alloys Pd alloys Ni-based amorphous alloys

16 Summary Gasification provides a high efficiency technology platform for low emissions power systems Development pathway for power, hydrogen & polygeneration systems Coal gasification performance data and models to support technology selection, improvement and deployment New research in key areas where breakthroughs are needed to improve cost and reliability Power, chemicals, liquid fuels, hydrogen Syngas cleaning, processing, gas separation Cost, scale and efficiency are key drivers Major national and international partnerships are needed to facilitate research development, demonstration and deployment Coordination and critical mass are critical r2.gif

17 Thank You Contact: David Harris Phone: David.Harris@csiro.au