Abstract Process Economics Program Report 180B CARBON CAPTURE FROM COAL FIRED POWER GENERATION (DECEMBER 2008 REPUBLISHED MARCH 2009) The most expensive part of the overall carbon capture and storage process is capturing CO 2 from a power plant. Maintaining coal as a viable source of electric power thus depends critically upon improving plant efficiency in order to produce less CO 2 for a given amount of power generation, and on finding more cost-effective ways to capture the CO 2 produced either before or after combustion. Pre-combustion efforts have focused on integrated gasification-combined cycle (IGCC) systems, in which coal is processed with oxygen and steam under pressure to form a synthesis gas that can be fired directly in a gas turbine. The CO 2 can be removed relatively efficiently from the synthesis gas, but CO cannot, so before firing, the gas is sent to a water gas shift reactor that converts the majority of CO to CO 2 and hydrogen. Following water gas shift, other gas conditioning operations are required including gas cooling and mercury removal before CO 2 is removed from the synthesis gas using absorption. The extent of CO 2 removed by this means is about 90%. Conventional coal plants are faced with a more difficult task of capturing post combustion CO 2 from flue gas at atmospheric pressure. The CO 2 concentration of the flue gas from a supercritical pulverized coal (SCPC) power plant is typically less than 15%, with most of the remaining gas composition being nitrogen from the air used to support combustion. Nevertheless about 90% of the CO 2 can potentially be removed from the flue gas by a post combustion process. In this report we describe and review the economic units involved in the production of power from coal without and with the baseline techniques for carbon capture from post and pre-combustion capture using high grade bituminous coal for which IGCC is well suited. Economics are then compared four ways (without and with CO 2 capture) to ultimately discover the cost of CO 2 removed from nominal 550 MW supercritical combustion and IGCC power plants. SRI Consulting PEP Report 180B
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CONTENTS 1 INTRODUCTION... 1-1 GEOSTORAGE OF ACID GASES... 1-2 Small Scale Sour Gas Disposal... 1-2 Metallurgy... 1-4 Acid Gas Dehydration... 1-5 Acid Gas Injection Facilities... 1-5 The Injection Well... 1-6 Conclusions... 1-7 CO 2 Storage... 1-7 MINERAL CARBONATION AND INDUSTRIAL USE OF CO 2... 1-10 Mineral Carbonation... 1-10 Processing... 1-11 Land Clearing... 1-12 Air Quality... 1-12 Tailings... 1-12 Leaching of Metals... 1-12 Reclamation... 1-12 Industrial Use of CO 2... 1-13 Chemicals and Polymers Production... 1-13 Fuel Production Using CO 2... 1-14 Capture of CO 2 in Biomass... 1-14 CARBON CAPTURE... 1-15 Post Combustion Capture... 1-15 Pre Combustion Capture... 1-15 Oxyfuel Combustion Capture... 1-16 Carbon Capture Processes... 1-16 2 SUMMARY... 2-1 BASIS FOR TECHNOLOGY COMPARISON... 2-1 SRI Consulting iii PEP Report 180B
CONTENTS (Continued) TECHNOLOGY AND ECONOMICS PROCESS PERFORMANCE... 2-2 ENCOURAGING FURTHER DEVELOPMENT... 2-10 CONCLUSIONS... 2-10 CHEMICAL INDUSTRY PARTICIPATION IN CARBON CAPTURE PROCESS DEVELOPMENT... 2-12 3 INDUSTRY STATUS... 3-1 GLOBAL WARMING... 3-1 Present Global CO 2 Emissions... 3-3 US CO 2 Emissions... 3-5 COAL RESOURCES, RESERVES, AND RECENT ACTIVITY... 3-6 Global Coal Consumption... 3-7 Global Coal Industry... 3-10 Coal Production and Forecast... 3-11 Chinese Coal Industry... 3-12 Coal Demand... 3-13 US Coal Industry... 3-14 Characteristics of Coal... 3-17 Fuel Diversity for New U.S. Power Plants... 3-19 Carbon Capture Projects... 3-20 COAL AND THE ECONOMY... 3-24 Coal Use Patterns in the United States... 3-25 Coal, Sustainability and Energy Security... 3-28 Coal and Sustainability... 3-29 SUMMARY... 3-29 CONCLUSIONS... 3-30 4 TECHNOLOGY REVIEW... 4-1 SRI Consulting iv PEP Report 180B
CONTENTS (Continued) INTRODUCTION... 4-1 BACKGROUND... 4-1 TECHNOLOGY EVALUATION FRAMEWORK... 4-3 COAL PREPARATION... 4-6 Coal Water Slurry Gasifiers... 4-6 Dried Feed Coal Gasification Systems... 4-6 SUPERCRITICAL PC POWER... 4-7 Particulate Emissions... 4-8 SO x Emissions... 4-9 Climate Change... 4-10 Modern PC Coal Fired Power Generation... 4-11 Water Chemistry Issues... 4-13 PC Hard Coal Boiler Feed Systems... 4-14 Wet Flue Gas Desulfurization... 4-15 Limestone Handling and Reagent Preparation System... 4-16 Flue Gas Desulfurization System... 4-16 By-product Dewatering... 4-17 NO x Control... 4-19 Utilization of Fly Ash and By-products from SO 2 Controls... 4-19 Soft Coal Feed Drying... 4-20 UPGRADING POWDER RIVER BASIN COAL... 4-23 ENCOAL Mild Coal Gasification Process... 4-26 ENCOAL Process Concept... 4-26 Possible Work-arounds to Upgrading PRB Coal... 4-29 Clyde Bergemann s Solution for PRB Coal... 4-31 Furnace Cleaning... 4-31 SmartCannon (Water Cannon)... 4-32 SRI Consulting v PEP Report 180B
CONTENTS (Continued) SmartSensor (Heat Flux Sensor)... 4-33 Coal Processing of Lignite... 4-33 ADVANCED U.S. GOVERNMENT SPONSORED R&D... 4-36 Innovative Technologies... 4-37 Materials Improvements... 4-37 Advanced Acid Gas Removal... 4-37 Advanced Gasification Projects... 4-38 Gas Cleaning and Conditioning... 4-39 Gas Separation... 4-40 Systems and Industry Analysis... 4-40 World Database... 4-40 Financial Model... 4-40 Gasification and the Future... 4-40 IGCC... 4-42 GASIFICATION... 4-43 Gasifier Reactor Design... 4-48 Steam Integration... 4-49 Air and Nitrogen Integration... 4-49 Nitrogen Integration... 4-50 Oxygen Supply... 4-50 Warming the Cold Box... 4-54 Deriming the Cold Box... 4-54 Cooling Down the Cold Box for Re-start... 4-55 Future Potential Developments in ASU Design... 4-55 NO x Abatement... 4-56 Third Generation IGCC Design... 4-57 IGCC WITH CO 2 CAPTURE... 4-60 ACID GAS REMOVAL... 4-61 SRI Consulting vi PEP Report 180B
CONTENTS (Continued) Acid Gas Removal Solvents... 4-63 Sulfur Recovery Process... 4-66 Oxygen Claus Process... 4-69 Claus Tail Gas Treating... 4-73 Hydrogenation and Hydrolysis Processes... 4-73 Other Systems using Hydrogenation and Subsequent Sulfur Removal... 4-74 Sulfuric Acid... 4-75 Water Gas Shift... 4-77 High Temperature Shift... 4-77 Low Temperature Shift... 4-78 Sour Gas Shift... 4-79 COS Hydrolysis... 4-80 Mercury Removal... 4-81 Initializing Simulations... 4-81 IGCC AIR BLOWN GASIFICATION... 4-84 MDEA Acid Gas Removal for Air Blown Gasification... 4-86 Gasifier Contaminants... 4-88 Metal Carbonyls... 4-88 COS Removal... 4-88 Foam Promoters... 4-88 Heat Stable Amine Salts... 4-89 Selexol Based CO 2 Capture... 4-90 5 SUPERCRITICAL PC TECHNOLOGY AND ECONOMICS... 5-1 BACKGROUND... 5-1 Turbine Generator Set... 5-3 High-Pressure Turbine (HPT)... 5-4 Intermediate-Pressure Turbine (IPT)... 5-4 Low-Pressure Turbine (LPT)... 5-4 SRI Consulting vii PEP Report 180B
CONTENTS (Continued) Once-Through Boilers... 5-4 Fuel Flexibility... 5-4 Air and Combustion System... 5-5 Other Cycle Components... 5-5 Fuel Feed and Storage Systems... 5-5 Bulk Storage... 5-6 Silo Storage... 5-8 Bunker Storage... 5-8 Feeder Design... 5-8 Coal Blending... 5-9 NO x Control... 5-10 Particulates Removal... 5-10 Electrostatic Precipitators... 5-10 Fabric Filter/Baghouse... 5-11 Sulfur Dioxide Removal... 5-12 Wet Scrubbers... 5-13 Auxiliary Facilities... 5-17 Soot Blowers... 5-17 Limestone Storage, Handling and Reagent Preparation System... 5-19 Reagent Preparation... 5-19 SO 2 Absorption... 5-20 Slurry Dewatering and Disposal... 5-21 Final Disposal... 5-21 Wet FGD System Water Balance... 5-21 Bottom and Fly Ash By-Product Storage and Handling System... 5-22 Fly Ash Systems... 5-22 Vacuum Systems... 5-22 Pressure Systems... 5-23 Combination Vacuum/Pressure Systems... 5-24 Dense Phase Systems... 5-24 Separation and Storage... 5-24 SRI Consulting viii PEP Report 180B
CONTENTS (Continued) Bottom Ash Conveying and Storage... 5-25 Economizer Ash Systems... 5-26 Mill Rejects... 5-27 Operational Issues... 5-27 Life Cycle Costs of Supercritical Coal Fired Power Plants... 5-27 PROCESS DESCRIPTION... 5-28 Coal and Sorbent Receiving and Storage... 5-29 Steam Generation and Ancillaries... 5-29 Feedwater and Steam... 5-30 Air and Combustion Feed... 5-30 Fuel Feed... 5-30 Ash Removal... 5-30 Burners... 5-30 Air Preheaters... 5-31 Soot Blowers... 5-32 NO x Control System... 5-32 Particulate Control... 5-33 Mercury Removal... 5-33 Flue Gas Desulfurization... 5-34 Carbon Dioxide Removal... 5-34 Improved Solvent Formation... 5-35 SO 2 Polishing, Flue Gas Cooling... 5-36 Circulating Water System... 5-37 CO 2 Absorption... 5-37 Water Wash Section... 5-37 Rich/Lean Heat Exchange... 5-37 Solvent Stripper... 5-38 Solvent Stripper Reclaimer... 5-38 Corrosion Control... 5-38 SRI Consulting ix PEP Report 180B
CONTENTS (Continued) Absorption/Stripping... 5-38 Liquid Distribution... 5-40 Support Structure for Column Internals... 5-40 Plate and Frame Exchanger Train Minimization... 5-40 Reboiler Shell Count Minimization... 5-41 Gas Compression and Drying... 5-41 Power Generation... 5-41 Balance of Plant... 5-42 Ash Handling System... 5-42 Ducting and Stack... 5-42 Water Treatment... 5-42 SYSTEM DESIGN BASES AND ASSUMPTIONS... 5-43 BLOCK FLOW DIAGRAM... 5-45 Total Plant Air Emissions... 5-46 PROCESS ECONOMICS... 5-47 Block Flow Diagrams... 5-47 Stream Flows... 5-47 Energy Balances... 5-47 Major Equipment Lists... 5-47 Total Capital Investment... 5-47 Operating and Maintenance Costs... 5-47 6 IGCC PROCESS DESIGN AND ECONOMICS... 6-1 INTRODUCTION... 6-1 OVERVIEW OF AN IGCC SYSTEM... 6-2 SYSTEM DESIGN BASIS AND ASSUMPTIONS... 6-4 MAJOR COMPONENTS OF AN IGCC SYSTEM... 6-6 Coal Handling Equipment... 6-6 Coal Slurry Preparation... 6-7 SRI Consulting x PEP Report 180B
CONTENTS (Continued) Air Separation Unit... 6-8 Gasifier... 6-11 Gasifier System Syngas Cooling... 6-13 Gasifier Quench... 6-15 Slag Handling... 6-15 Particulate Removal... 6-16 Syngas Scrubber/Sour Water Stripper... 6-17 COS Hydrolysis (without capture)... 6-17 Syngas Cleanup... 6-18 Water Gas Shift... 6-19 Selection of Technology... 6-20 Mercury Removal... 6-21 Acid Gas Removal... 6-21 Sulfur Recovery/Tail Gas Clean-up... 6-23 Oxygen Blown Claus... 6-24 Tail Gas Treating... 6-25 Flare Stack... 6-25 CO 2 Compression and Dehydration... 6-25 POWER BLOCK... 6-26 Gas Combustion Turbines... 6-26 Combustion Turbine Firing Control Issues for Low Calorie Value Fuel... 6-26 Gas Turbine Operations... 6-27 Heat Recovery Steam Generator... 6-30 Allowable Back Pressure... 6-33 Steam Pressure and Temperature... 6-33 Pinch Point and Approach Temperature... 6-33 Stack Outlet Temperatures... 6-33 Emissions... 6-34 SRI Consulting xi PEP Report 180B
CONTENTS (Concluded) Steam Turbine Generator... 6-34 TOTAL PLANT AIR EMISSIONS... 6-34 PROCESS ECONOMICS... 6-35 Block Flow Diagrams... 6-35 Stream Flows... 6-36 Energy Balances... 6-36 Major Equipment Lists... 6-36 Total Capital Investment... 6-36 Operating Maintenance Costs... 6-36 APPENDIX A: PATENT SUMMARY... A-1 APPENDIX B: DESIGN AND COST BASES... B-1 APPENDIX C: CITED REFERENCES... C-1 APPENDIX D: PATENT REFERENCES BY COMPANY... D-1 APPENDIX E: PROCESS FLOW DIAGRAM... E-1 SRI Consulting xii PEP Report 180B
ILLUSTRATIONS 2.1 Carbon Capture from Coal-Fired Power Generation Plant Capital Cost Intensity... 2-5 2.2 Carbon Capture from Coal-Fired Power Generation Levelized Cost of Electricity by Cost Categories... 2-7 3.1 Climate Change Risk... 3-2 3.2 Atmospheric Concentration of Carbon Dioxide 1000 2007... 3-3 3.3 World Carbon Emissions from Fossil Fuel Burning... 3-4 3.4 Top Greenhouse Gases and their Contributions to Global Emissions by Source 3-5 3.5 Total World Primary Energy Consumption, % by Fuel 2007... 3-6 3.6 World Recoverable Coal Reserves... 3-7 3.7 US Coal Use by Sector... 3-8 3.8 Global Coal Consumption... 3-9 3.9 World Coal Trade Flows... 3-10 3.10 Global Coal Production and Forecast... 3-11 3.11 Energy Consumption by Sector... 3-13 3.12 Worldwide Demand for Coal-Fired Power 2008... 3-14 3.13 Geographical Distribution of US Coal Basins... 3-15 3.14 Types of Coal... 3-18 3.15 Fuel Diversity for New US Power Plants... 3-19 3.16 Energy Source by Consuming Sector - 2007... 3-26 3.17 Sources of U.S. Energy Supply 2007... 3-27 3.18 Coal Energy Market 2007... 3-27 4.1 Pulverized Coal Fired Boiler Process Flow Schematic... 4-7 4.2 Diagram of a Typical Coal-Fired Thermal Power Plant... 4-12 4.3 Wet Flue Gas Desulfurization Process Flow Schematic... 4-16 4.4 Soft Coal Feed Drying by the WTA Process Process Flow Schematic... 4-20 SRI Consulting xiii PEP Report 180B
ILLUSTRATIONS (Continued) 4.5 Approximate Analysis of Coal by Rank... 4-22 4.6 Higher Heating Value of Coal by Rank... 4-22 4.7 ENSORB Process to Upgrade PRB Coal Process Flow Schematic... 4-27 4.8 Lignite Coal Drying Process Flow Schematic... 4-34 4.9 US Lignite Coal Resource Regions... 4-36 4.10 GEE Gasification Radiant Cooling Only... 4-45 4.11 GEE Radiant + Convective Cooler Configuration... 4-46 4.12 Alternative Integration Schemes for IGCC... 4-48 4.13 Air Separation Unit... 4-50 4.14 Linde Cycle for Air Separation... 4-53 4.15 Simplified Block Flow Diagram of a Grass Roots Oxygen Blown IGCC with Carbon Capture... 4-61 4.16 Acid Gas Removal... 4-62 4.17 Equilibrium Data on H 2 S and CO 2 in Various Solvents... 4-65 4.18 Process Flow Schematic Generic Claus Process... 4-67 4.19 Standard Claus Process Simplified Process Flow Schematic... 4-68 4.20 The Lurgi OxyClaus Burner... 4-70 4.21 Typical Scot Tail Gas Treatment Plant Process Flow Schematic... 4-74 4.22 Integration of the Claus Unit with an IGCC Process Flow Schematic... 4-75 4.23 Topsoe Wet Sulfuric Acid Plant Process Flow Schematic... 4-76 4.24 Water Gas Shift with a Saturate/Desaturate Configuration Process Flow Schematic... 4-78 4.25 Generic Water Gas Shift for IGCC with Carbon Capture... 4-79 4.26 MHI Two Stage Entrained Flow Gasifier... 4-85 4.27 Mitsubishi Air Blown IGCC System Block Flow Diagram... 4-86 SRI Consulting xiv PEP Report 180B
ILLUSTRATIONS (Concluded) 4.28 MDEA AGR for Air Blown Gasification System Generic Process Flow Diagram... 4-87 4.29 Selexol Based CO 2 Capture System for Air Blown Gasification Block Flow Diagram Grass Roots Design... 4-91 4.30 Sour Gas Shift w/o By-pass Block Flow Diagram... 4-91 4.31 Sour Gas Shift w/o COS Hydrolysis Unit Block Flow Diagram... 4-92 4.32 Capture Ready Design Block Flow Diagram... 4-92 5.1 Supercritical Pulverized Coal Power Plant Simplified Process Flow Schematic (w/o CO 2 Capture)... 5-2 5.2 Wet Flue Gas Desulfurization Process Flow Schematic... 5-13 5.3 Post Combustion CO 2 Capture Fluor Econamine FG + -MEA Absorption... 5-36 5.4 Supercritical PC without CO 2 Capture Process Flow Diagram... E-3 5.5 Supercritical PC with CO 2 Capture Process Flow Diagram... E-5 6.1 IGCC Power Plant Generic Process Flow Schematic... 6-2 6.2 Typical IGCC Integrated Design Simplified Process Flow Schematic... 6-4 6.3 ASU Process Flow Schematic... 6-9 6.4 Alternative Gas Clean- Up Process... 6-19 6.5 Three Pressure Level HSRG Configuration... 6-32 6.6 GEE-IGCC w/o CO2 Capture Process Block Flow Diagram... E-7 6.7 GEE-IGCC with CO2 Capture Process Block Flow Diagram... E-9 SRI Consulting xv PEP Report 180B
TABLES 1.1 Estimated Long Term CO 2 Storage Capacity of Aquifers... 1-9 2.1 Process Performance Comparison IGCC vs. Supercritical Pulverized Coal... 2-3 2.2 Grassroots Baseline Economics for Future Innovative CO 2 Capture Evaluations 2-10 3.1 US Regional Coal Characteristics... 3-16 3.2 Typical Properties for Characteristic Coal Types... 3-17 3.3 Future Global CO 2 Capture Projects... 3-21 4.1 Comparative Resource Consumption and Emissions Rates... 4-4 4.2 Global Warming Potential of Some Greenhouse Gases... 4-11 4.3 Illinois #6 vs. Wyoming PRB Coal Salt Composition of Ash... 4-24 4.4 CO 2 Emissions for Hydrogen Production Technologies... 4-41 4.5 Selexol Unit CO 2 Based Input and Output Streams (w/o CCS)... 4-82 4.6 Selexol Unit CO 2 Based Input and Output Streams (w/ CCS)... 4-83 5.1 Effect of Various Design Parameter on SO 2 Removal... 5-16 5.2 CO 2 Compressor Interstage Pressures... 5-41 5.3 Plant Performance Summaries... 5-44 5.4 Feed Coal Composition... 5-45 5.5 Air Emissions... 5-46 5.6 Supercritical Coal Power Plant w/o CO 2 Capture Stream Flows... 5-48 5.7 Supercritical Coal Power Plant w/o CO 2 Capture Overall Energy Balance... 5-50 5.8 Supercritical PC w/o CO 2 Capture Major Equipment List... 5-51 5.9 Carbon Capture from Coal-Fired Power Generation Total Capital Investment... 5-57 5.10 Carbon Capture from Coal-Fired Power Generation Raw Materials Costs... 5-58 5.11 Carbon Capture from Coal-Fired Power Generation Plant Operating and Maintenance Cost... 5-59 SRI Consulting xvi PEP Report 180B
TABLES (Continued) 5.12 Supercritical Coal Power Plant with CO 2 Capture Stream Flows... 5-60 5.13 Supercritical PC with CO 2 Capture Overall Energy Balance... 5-63 5.14 Supercritical PC with CO 2 Capture Major Equipment List... 5-64 5.15 Carbon Capture from Coal-Fired Power Generation Total Capital Investment... 5-70 5.16 Carbon Capture from Coal-Fired Power Generation Raw Materials... 5-71 5.17 Carbon Capture from Coal-Fired Power Generation Plant Operating and Maintenance Cost... 5-72 6.1 Plant Performance Summaries... 6-5 6.2 Allowable Gas Fuel Contaminant Levels for F-Class Gas Turbines... 6-28 6.3 Classification of Fuel Gases... 6-29 6.4 Air Emissions... 6-35 6.5 IGCC w/o CO 2 Capture Stream Flows... 6-37 6.6 IGCC w/o CO 2 Capture Overall Energy Balance... 6-39 6.7 GEE IGCC w/o CO 2 Capture Major Equipment List... 6-40 6.8 Carbon Capture From Coal-Fired Power Generation Total Capital Investment... 6-46 6.9 Carbon Capture From Coal-Fired Power Generation Raw Materials Costs... 6-47 6.10 Carbon Capture From Coal-Fired Power Generation Plant Operating and Maintenance Cost... 6-48 6.11 IGCC with CO 2 Capture Stream Flows... 6-49 6.12 IGCC with CO 2 Capture Overall Energy Balance... 6-51 6.13 GEE IGCC with CO 2 Capture Major Equipment List... 6-52 SRI Consulting xvii PEP Report 180B
TABLES (Concluded) 6.14 Carbon Capture From Coal-Fired Power Generation Total Capital Investment... 6-59 6.15 Carbon Capture From Coal-Fired Power Generation Raw Materials Costs... 6-60 6.16 Carbon Capture From Coal-Fired Power Generation Plant Operating and Maintenance Cost... 6-61 SRI Consulting xviii PEP Report 180B