The Future of IGCC Technology CCPC-EPRI IGCC Roadmap Results Ronald L. Schoff (rschoff@epri.com) Electric Power Research Institute Sr. Project Manager IEA CCT2011 Conference Zaragoza, Spain May 10, 2011
Taking CCS from Lab to Commercialization Laboratory Pilot Plant Demonstration Commercially Available CCS Each step in the commercialization process is important 2
New Technology Deployment Curve (Current State of the Art) R&D Roadmaps Process Improvements IGCC SCPC R&D Roadmaps are Critical to Improving Cost Competitiveness 3
Statement of Work Base Case Modeling Coal Preparation & Feeding Oxygen Production High Temperature & Pressure Sulfur Recovery (HTPSR) Hydrogen Membrane Advanced CO 2 Capture Downstream CO 2 Processing Advanced Gas Turbines Supercritical Steam Turbines Mid-Term and Long-Term Technology Advancement Cases 4
Approach Thermodynamic Evaluation AspenPlus steady-state process modeling Jacobs base case + input from vendors and GateCycle Qualitative Economic Analysis Jacobs base case + EPRI COE calculation methodology Evaluation of Commercialization Status Study Designed to Provide Actionable Information to CCPC 5
Base Case Process Flow Diagram 6
Base Case Plant Configuration Air Separation Unit: conventional cryogenic design Gasification Island: Siemens Syngas and CO 2 Processing Water-Gas Shift: conventional technology Acid Gas Removal: Selexol Sulfur Recovery: O 2 -fired Claus CO 2 Compression: conventional technology Power Block (2x1 Configuration) Gas Turbines: GE 7F Syngas Steam Turbine: subcritical steam conditions 7
Performance Comparison: Base Case EPRI Base Case Total Gross Power (MWe) 678 Total Auxiliary Load (MWe) 221 Net Plant Power Output (MWe) 457 Net Plant Efficiency, HHV 29% Thermal Input, HHV (MWe) 1,580 CO 2 Captured 92% Total Plant Cost ($MM) 2,880 Total Plant Cost ($/kw) 6,300 LCOE ($/MWh) 175 Alberta Sub-bituminous coal Elevation: 1,067m (3,500 ft) US Gulf Coast Cost Basis June 2010 Dollars Engineering cost adder: 15% Project contingency: 20% Capacity factor: 85% CO 2 T&S costs: $10/tonne 12.5% carrying charge factor Cost Reconciliation w/ Similar DOE & EPRI Cases Underway 8
Oxygen Production Case Process Flow Diagram 9
Oxygen Production Case Advanced oxygen system treated as a black box in model In: Air, natural gas and auxiliary power Out: Oxygen (99.5%vol) and Nitrogen (<2%vol O 2 ) Significant reduction in ASU auxiliary load Results: + 1.7% NPE - $1,100/kW TPC - $23/MWhr LCOE OXYGEN OXYGEN BLOWER AIR HEAT EXCHANGE FUEL AIR HRSG OXYGEN STEAM ELECTRIC POWER ION TRANSPORT MEMBRANE 10
HTPSR (Bechtel Pressure Swing Claus) Case Process Flow Diagram Coal Air Air Separation Unit Oxygen Coal Drying and Feed Gasification Island Steam Water Gas Shift Syngas Cooling & Hg Removal Bechtel Pressure Swing Claus CO 2 Capture & Processing CO 2 To Pipeline Slag Sulfur Water Syngas Diluent (N 2 ) Syngas Conditioning HRSG Air Gas Turbine Steam Turbine 11
HTPSR (BPSC) Case Background Information Bechtel Pressure Swing Claus treated as black box In: 38 C syngas and auxiliary power Out: Sulfur-free syngas, sulfur, steam Selexol downstream for CO 2 removal Results: + 1.0% NPE - $290/kW TPC - $7/MWhr LCOE 12
Hydrogen Membrane (Eltron HTM) Case Process Flow Diagram Coal CO 2 To Pipeline Air Air Separation Unit Oxygen Coal Drying and Feed Gasification Island Steam Water Gas Shift Syngas Cooling & Hg Removal Bechtel Pressure Swing Claus Water CO 2 Processing Hydrogen Membrane Slag Sulfur Syngas Diluent (N 2 ) Syngas Conditioning HRSG Air Gas Turbine Steam Turbine 13
Hydrogen Membrane (Eltron HTM) Case Eltron HTM system treated as a black box in model In: Sulfur-free H 2 -rich syngas Out: High purity H 2 and CO 2 with remaining impurities Bechtel Pressure Swing Claus system upstream CO 2 purification downstream Results: + 2.7% NPE - $940/kW TPC - $23/MWhr LCOE 14
Advanced Gas Turbines Case Process Flow Diagram 15
Advanced Gas Turbines Firing Temperature Evolution of Gas Turbines F-Class GT: ~2500 F [1370 C] (GE 7F and Siemens 5000F) H-Class GT: ~2600 F [1430 C] (Manufacturers?) J-Class GT: ~2700 F [1480 C] (MHI) X-Class GT: ~3100 F [1700 C] Increased air extraction Up to 10.5% Higher output Higher net plant efficiency U08-102701 Image provided by Siemens. Used with permission. All rights reserved. 16
Results Summary: Base Case and Advanced Gas Turbine Cases EPRI Base Case H-Class GT Case J-Class GT Case X-Class GT Case Total Gross Power (MWe) 678 1,058 1,212 1,381 Total Auxiliary Load (MWe) 221 300 321 353 Net Plant Power Output (MWe) 457 758 891 1,028 Net Plant Efficiency, HHV 29% 31% 33% 35% Thermal Input, HHV (MWe) 1,580 2,420 2,690 2,980 CO 2 Captured 92% 92% 92% 92% Total Plant Cost ($MM) 2,880 4,050 4,435 4,880 Total Plant Cost ($/kw) 6,300 5,340 4,980 4,750 LCOE ($/MWh) 175 150 140 134 Advanced Gas Turbines Can Significantly Improve Plant Performance and Cost 17
Long-Term Technology Advancement Case Process Flow Diagram 18
Performance Comparison: Base Case and Long-Term Technology Advancement Case EPRI Base Case Long-Term Tech Adv. Case Total Gross Power (MWe) 678 1,260 Total Auxiliary Load (MWe) 221 236 Net Plant Power Output (MWe) 457 1,024 Net Plant Efficiency, HHV 29% 40% Thermal Input, HHV (MWe) 1,580 2,570 CO 2 Captured 92% 89% Total Plant Cost ($MM) 2,880 3,340 Total Plant Cost ($/kw) 6,300 3,260 LCOE ($/MWh) 175 94 Net Power is 124% higher for Long- Term case Single train 500 MW plant possible TPC 15% higher Specific TPC and LCOE ~50% lower Significant Potential Exists to Improve Plant Performance While Reducing Costs 19
X-Class GT IGCC CCS Technology Roadmap Summary of Performance Results 14.0% 12.0% 10.0% 8.0% 6.0% 4.0% 2.0% Net Plant Efficiency Improvements (Over Base Case) 0.0% Base Case Coal Beneficiation Oxygen Production High T/P Sulfur Recovery Hydrogen Membrane Advanced CO2 Capture Downstream CO2 Processing H-Class GT J-Class GT Supercritical ST (w/j-class GT) Mid-Term Tech Advancement Long-Term Tech Advancement 20
Summary of Economic Results Specific Total Plant Cost ($/kw) $7,000 $6,000 $5,000 $4,000 Specific Total Plant Cost ($/kw) $3,000 Base Case Coal Ben. O2 Production HTPSR H2 Membrane Adv. CC Adv. CPU H-Class GT J-Class GT SC ST (w/j GT) X-Class GT Mid-Term TA Long-Term TA 21
Summary of Economic Results Cost of Electricity ($/MWhr) $175 $150 $125 $100 Cost of Electricity ($/MWhr) $75 Base Case Coal Ben. O2 Production HTPSR H2 Membrane Adv. CC Adv. CPU H-Class GT J-Class GT SC ST (w/j GT) X-Class GT Mid-Term TA Long-Term TA 22
Closing Thoughts Study corroborates results from other Roadmaps Technologies identified to replace efficiency loss of CO 2 capture while reducing plant costs Additional Activities: US DOE & EU Demonstrations CO 2 liquefaction and pumping Advanced WGS Catalysts and Designs Advanced gas turbine research Other ideas welcome 2011 EPRI CoalFleet IGCC R&D Roadmap Underway 23
Acknowledgements Canadian Clean Power Coalition (Funding & Direction) Air Products & Chemicals (ITM Oxygen & Sour PSA) Becthel (Pressure Swing Claus BPSC) Eltron R&D (Hydrogen Transport Membrane HTM) Pratt & Whitney Rocketdyne (Compact Gasifier) Ramgen (Shockwave CO 2 Compression) Sherritt Technologies (Coal Beneficiation) US DOE/NETL (General) EPRI Technical Team (Golden, Bedilion, Steele) 24
Together Shaping the Future of Electricity 25