ROYAL SOCIETY OF CHEMISTRY TECHNOLOGY IN THE USE OF COAL Professor James Harrison FRSC FEng 1
National Coal Board 1947 Mines 958 Manpower 718000 Use electricity 28 -domestic 37 -steel 43 -other 80 Total Use Mt 188 2
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Reduction agent consumption (kg/t hot metal) Figure 1: Carbon usage in blast furnace ironmaking and associated technology developments over the last 50 years 800 600 400 oil injection and burden preparation hot blast temperature >1200 C theoretical minimum 414 kg /t hot metal oxygen enrichment top pressure burden distribution improved sinter quality coal injection oil coal 200 coke 0 1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 Source: Thyssen-Krupp, Germany 6
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The water-gas reaction :- C +H 2 O H 2 + CO - heat + 131.6kJ/mol heat for the reaction can be provided externally or by combining the reaction with combustion reactions:- C +O 2 CO 2 + heat - 94.1k/mol The water- shift reaction, CO + H 2 O H 2 + CO 2 + heat - 41.7kJ/mol 15
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Siemens Fuel Gasifier (SFG) Standard Design Cooling screen short start-up / shut-down low maintenance high availability high conversion rate Full quench simple and reliable Quench ideal for CO sour shift Water Dry feeding high efficiency LP Steam Coal / Feedstock Oxygen Steam Reaction 1300 to 1800 C Quench Venturi Wash Raw Gas 170 to 230 C Black Water Treatment Partial Condenser Raw Gas to CO Shift & gas cleaning Vent Gas Waste Water Slag Sludge 17
Development of IGCC net plant efficiencies for coal-based IGCC plants without CCS Net Plant Efficiency in % (LHV) 50 45 40 35 European demonstration plants with dry-fed coal gasifiers US demonstration plants with slurry-fed coal gasifiers Japanese demonstration plant with dry-fed coal gasifier World s first IGCC plant Lünen Germany (V93) Cool Water Buggenum Netherlands (V94.2) Wabash River Puertollano Spain (V94.3) Tampa Clean Coal Power 1970 1975 1980 1985 1990 1995 2000 2005 2010 Year of Commissioning Increasing plant sizes and efficiencies of demonstration plants Puertollano plant efficiency for ISO conditions and high quality coal Achievable with today s F class gas tubines without CCS Achievable with today s E class gas turbines without CCS 18
IGCC with CO 2 Removal Steam Sour Syngas Sulfur CO 2 to use or sequestration Coal Prep Gasification C + H 2 O = CO + H 2 Gas Cooling Shift CO+ H 2 O = CO 2 + H 2 Sulfur & CO 2 Removal O 2 N2 Clean Syngas Hydrogen Air Separation Unit Gas Turbine Air BFW Air Steam HRSG BFW Steam Turbine PRB Coal 100MW With 90% CCS Net Coal to Power: 26.2 + 14.5 10.7 = 30.2% (HHV basis) 10.7MW 14.5MW 22.5 MW 18MW 37MW 7MW 74MW 48MW 26.2MW IGCC schematic from US DOE 19
Full scale modelling 500MWe boiler Looking at oxygen enhancement and oxyfuel combustion 20
LES RANS Temperature on flame surface Test facility scale modelling Large Eddy Simulations LES LES RANS RANS Axial velocity contours Temperature contours Clean Energy Systems Process N 2 Air Air Separation Plant O 2 Gas Generator RH * CH 4, CO, H 2, etc. Crude Fuel Fuel Processing Plant Fuel* Recycle Water HP IP LP Multi-stage Turbines Elect Gen. HX Coal, Refinery Residues, or Biomass Direct Sales CO 2 Recovery CO 2 Cond. C.W. NG, Oil or Landfill Gas EOR, ECBM, or Sequestration Excess Water 21
30-Y r levelized C O E, $/M W h (C onstant 2007$). No Clear Winners in Current Designs 160 140 E P R I 600 M W (net) P C and IG C C C ost of E lectricity W ith and W ithout C O 2 C apture (Illinois #6 C oal) N o C ap tu re C O E Includes $10/tonne for C O 2 Transportation and S equestration R etro fit C ap tu re N ew C ap tu re 120 100 80 60 40 S upercritical PC GE Radiant Q uench GE Total Q uench Shell Gas Q uench E -Gas FSQ 22
Econonic gap A Roadmap for CO 2 Capture and Storage Now Objective Small demos (1.7 MW Ammonia, etc.) Complete larger scale capture demos Commercial availability CCS 2005 2010 2015 2020 Bench-scale postcombustion capture Start larger scale demos capture and storage Start multiple full scale demos Needs: Multiple large-scale CAPTURE and STORAGE demos Timing: 2020 objective start today, parallel paths Realistic? A challenge need technical, policy, funding alignment Source: DOE-NETL Carbon Sequestration R&D Roadmap Modified to add Chilled Ammonia example McKinsey: Gap for economic feasibility of CCS to be filled in the > /t CO 2 90 mid-term 80 Commercial phase: Cost of CCS expected to be in the range of the future carbon price Demonstration phase: Not economic on standalone basis 70 60 50 40 30 Carbon price forecast 20 10 0 >Demonstration phase (2015) >Early commercial phase (2020+) >Mature commercial pase (2030+) >Source: McKinsey * Carbon price for 2015 from 2008-15 estimates from Deutsche Bank, New Carbon Finance, Soc Gen, UBS,Point Carbon,assumed constant afterwards Source: Reuters; Team analysis 23
Estimates of available UK generating capacity (in GW) Note: This figure is based on a graph contained in EdF s submission to the UK government s Energy Review in 2006. The statistics were based on views and plausible future scenarios at the time of submission The scale of the challenge for target emissions reductions (UKCCC) UK CCC Page 38, Figure 2.1 24
Worldwide Market Scenario in 2015 Transit Buses* 130,000-150,000 buses in service Light Duty Vehicles* 17-80 million vehicles in service Hydrogen Required 2.5-9 million tonnes per year Current Largest Merchant H 2 Plant 100,000 tonne/year Sources: *UBS Warburg Global Equity Research, Ballard June 2000 OGDEN et al, Princeton University 25
Hydrogen for Transport Biomass Renewable electricity Electricity - nuclear or coal Nuclear - chemical cycles Coal gasification The water-gas reaction :- C +H 2 O H 2 + CO - heat + 131.6kJ/mol The water- shift reaction, CO + H 2 O H 2 + CO 2 + heat - 41.7kJ/mol CaO + CO 2 CaCO 3 +heat -178kJ/mol 26
What UCG involves IEA Clean Coal Centre www.iea-coal.org.uk 27
Worldwide activities IEA Clean Coal Centre www.iea-coal.org.uk The scale of the challenge for target emissions reductions (UKCCC) UK CCC Page 38, Figure 2.1 28