Status of Coal Utilization and Its Future Direction: A US Perspective

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Rachel Preston
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1 Status of Coal Utilization and Its Future Direction: A US Perspective Jeffrey N. Phillips (jphillip@epri.com) Senior Program Manager Advanced Generation Tokyo, Japan September 7, 2011

Coal Capacity Additions by Year Source: NETL Tracking New Coal-Fired Power

Proposed and Forecasted Coal-Fired Capacity Source: NETL Tracking New Coal-Fired

4 Materials for A-USC Coal Power Plants U.S. Department of Energy (DOE) and Ohio Funded Project Temperature, Degrees F Eddystone 1 Philo 6 DOE Goal Year Maximum Steam Turbine Inlet Temperature History Temperature, Degrees C During 1 st 60 years of the 20 th century, steam turbine temperatures rose from 250 C to 650 C Thermal efficiency rose from 4% to 40% (HHV) Eddystone experienced several materials issues Derated from 650 C to 615 C No improvements for 50 years! 2011 Electric Power Research Institute, Inc. All rights reserved. 4

5 Participants: U.S. DOE / Ohio Coal Development Office A-USC Steam Boiler and Turbine Consortia Federal State National Laboratory Non Profit For Profit Cost Sharing Consortium 2010 Electric Power Research Institute, Inc. All rights reserved. 5

6 U.S. DOE OCDO Advanced USC Project Accomplishments Fabrication Processes General design studies show favorable economics Welding Technology Developments Steam-Side Oxidation Fireside Corrosion (High-Sulfur Coal & In-Plant Testing) HP Turbine Concept 2010 Electric Power Research Institute, Inc. All rights reserved. 6

News on A-USC Materials Development (hot off the press) In April 2011, at their works in Houston, Wyman-Gordon successfully extruded a 7.2-tonne ingot of Inconel 740 into a pipe section 0.

7 News on A-USC Materials Development (hot off the press) In April 2011, at their works in Houston, Wyman-Gordon successfully extruded a 7.2-tonne ingot of Inconel 740 into a pipe section 0.38-m OD, 10.5-m long with m wall thickness Tests are in progress to determine the properties on the extruded material 2010 Electric Power Research Institute, Inc. All rights reserved. 7

0B DOE Archer Daniels Midland CO 2 capture from Ethanol plant CO 2 stored in saline reservoir $208M - Total $141M - DOE HECA Commercial Demo of Advanced IGCC w/ Full Carbon Capture ~$2.

8 CCPI FutureGen 2.0 ICCS Area 1 U.S. Dept. of Energy CCS Projects Locations & Cost Share FutureGen 2.0 Large-scale Testing of Oxy-Combustion w/ CO 2 Capture and Sequestration in Saline Formation Plant: $737M Total; $590M DOE Trans. & Storage: $553M Total; $459M DOE Project: ~$1.3B Total; ~$1.0B DOE Archer Daniels Midland CO 2 capture from Ethanol plant CO 2 stored in saline reservoir $208M - Total $141M - DOE HECA Commercial Demo of Advanced IGCC w/ Full Carbon Capture ~$2.8B Total $408M DOE Summit TX Clean Energy Commercial Demo of Advanced IGCC w/ Full Carbon Capture ~$1.7B Total $450M DOE Air Products CO 2 capture from Steam Methane Reformers EOR in eastern TX oilfields $431M - Total $284M - DOE Southern Company Kemper County IGCC Project IGCC-Transport Gasifier w/carbon Capture ~$2.67B Total $270M DOE NRG W.A. Parish Generating Station Post Combustion CO 2 Capture $339M Total $167M DOE Leucadia Energy CO 2 capture from Methanol plant EOR in eastern TX oilfields $436M - Total $261M - DOE 8

9 Southern Company Services, Inc. CCPI-2 Kemper County, MS 582 MWe (net) IGCC: 2 KBR Transport Gasifiers, 2 Siemens Combustion Turbines, 1 Toshiba Steam Turbine Mississippi Lignite Fuel ~67% CO 2 capture (Selexol process) 3,000,000 tons CO 2 /year EOR Sequestration site TBD (Start 2014) Total Project: $2.4 Billion DOE Share: $270 Million (13%) Project Awarded Jan 2006 Project moved to MS Dec 2008 Construction July 2010 NEPA ROD August 2010 Operations May 2014 Advanced IGCC with CO 2 Capture Status NEPA Record of Decision on August 19, 2010 Construction initiated on July 16,

10 Kemper County IGCC Construction Update

11 Kemper County IGCC Construction Update

12 FutureGen 2.0 Oxy-Combustion w/co 2 Sequestration Meredosia, IL and Morgan Co., IL 200 MWe Gross oxy-combustion repowering of Ameren s Meredosia Unit 4 steam turbine (Start 2016) 90% CO 2 capture (cryogenic separation) 1,300,000 tons CO 2 /year Deep saline sequestration in Mt. Simon formation Total Project: $1.3 Billion DOE Share: $1.05 Billion (81%) Status Pre-FEED in progress Sequestration site characterization and validation NEPA in progress, public scoping meetings 2 nd Quarter CY

Improve efficiency, then deploy CCS

Global coal-fired electricity generation (TWh) Improve efficiency, then deploy CCS Decrease generation from subcritical Install CCS* on plants over supercritical Increase generation from high-efficiency