Clean Coal Technology Presented to the National Conference of State Legislatures Robert G. Hilton August 5, 2012
Agenda 1st topic Combustion Page 2 2nd topic Criteria Pollutants Page 10 3rd topic CO2 Capture Page 18
Sub. vs. Supercritical Cycle Impact on Emissions Subcritical Supercritical Plant Efficiency, %* 34-37 37-41 Plant Efficiency, Btu / kw-hr 10,000-9,200 9,200-8,300 Plant Efficiency, % 34% 37% 41% Fuel Consumption/Total Emissions including CO 2 Base Base-8% Base-17% * HHV Basis
Supercritical Boiler NAM SC Plant Experience J.Marion Clearwater Conf. 7 June 2010 - P 4 All data at BMCR, operating data
CO2 Emissions, tonne/mwh Percent CO2 Reduction Comparison of Coal Based Power Options CO2 Reduction Carbon Dioxide Emissions vs Net Plant Efficiency (Based on firing Pittsburgh #8 Coal) Source: EPRI 0.90 30% 0.85 CO 2 Emission, tonne/mwh Percent CO 2 Reduction from Subcritical PC Plant 25% 100% Coal 0.80 20% 0.75 Coal w/ 10% co firing biomass Advanced Ultrasupercritical PC Plant Range 15% 0.70 10% 0.65 Modern day subcritical Commercial Supercritical 5% 0.60 0% 37% 38% 39% 40% 41% 42% 43% 44% 45% 46% 47% 48% 49% 50% Existing US coal fleet @ avg 33% Net Plant Efficiency, (LHV)% Efficiency increase from Subcritical to USC can, for example, Co-firing with biomass to 10% can lead to 10% reduction in CO2 yield up to 25% CO 2 reduction Efficiency increase from Subcritical to USC can, for example, yield up to 25% CO 2 reduction
Path to More Efficient Steam Power Plants - Efficiency (net) HHV 25-30% - Steam Parameter tower 33% 3480/1005/1050 ( psi / F/ F) 240/540/565 (bar/ C/ C) 2400/1005/1005 Once Through Sliding Pressure 167/540/540 Technology Supercritical 38-40% T91 FGHR Aux Power 39-41% Adv Austenitic Materials RH/RH FGHR Excess Air 43% - 46% 4000/1110/1150( psi / F/ F) 275/600/620 (bar/ C/ C) 4000/1075/1110 ( psi / F/ F) 275/580/600 (bar/ C/ C) 50% - 53% 49% - 52% Precipitation Strengthened 48% - 51% Ni - based Materials 45% - 48% Bottoming Cycle Ni - based Materials 5400/1330/1400( psi / F/ F) 375/730/760 (bar/ C/ C) 5400/1300/1325( psi / F/ F) 375/700/720 (bar/ C/ C) 1960 1980 2000 2020 Economics continue to drive efficiency improvements. This will be achieved by several technological steps including higher steam conditions enabled by cost effective materials advances NAM SC Plant Experience J.Marion Clearwater Conf. 7 June 2010 - P 6
Partnerships: Ultrasupercritical Materials European: Emax Project Operating Target: 700 C / 310 bar 1292 F / 4500 psig US-DOE :Ultra-Supercritical Boiler Project Operating Target: 760 C / 379 bar 1400 F / 5500 psig All major US boiler manufacturers, Oak Ridge National lab and EPRI NAM SC Plant Experience J.Marion Clearwater Conf. 7 June 2010 - P 7
Integrated Gasification Combined Cycle (IGCC)
Oxy-Combustion Process Technology Overview Principle Fuel is burned in a mixture of oxygen and re-circulated flue-gas. Due to the absence of Nitrogen, the resulting flue gas is enriched in CO 2 After water condensing and further purification, CO 2 can be compressed and send for storage or re-use. Advantages Reliability: main components exist, only adaptation to power gen and scaleup All types of boilers / firing systems adaptable to oxy to cover complete fuel range Rapid scale-up to large size (1,000 MWe range) possible after large demos. Retrofit in Oxy can be addressed High efficiency and competitiveness of supercritical/ultra-supercritical cycles and large unit size will be key benefits Large panel of entities involved in development, contributing to
Chemical Looping Combustion 2008-2012 Prototype Testing of Limestone Chemical Looping CLC Development Status CLC is a break-through CCUS technology in terms of efficiency and economics, with potential to significantly lower cost of CO 2 capture CLC is a flexible technology that can be configured in new or retrofit applications to produce syngas, hydrogen or power from coal Currently validating 3 MW th CLC prototype using limestone as oxygen carrier What s Next? Optimization testing on prototype Next step before commercial unit will be Scale-up to 10-50 MWe Demonstration
Agenda 1st topic Combustion Page 2 2nd topic Criteria Pollutants Page 10 3rd topic CO2 Capture Page 18
Pollutants Controlled Sulfur Oxides 184,000 Mw installed Nitrogen Oxides 140,000 Mw installed Particulate Matter 320,000 Mw Installed - PM 10 - PM 2.5 Mercury 65,000 Mw Installed Heavy Metals Acid Gases Installation figures are Power only and do not include Industrial
Emissions and Technology Particulate Control Systems DESP Dry Electrostatic Precipitator LRFF Low-Ratio Fabric Filter WESP Wet Electrostatic Precipitator HRFF High-Ratio Fabric Filter Tech Options for Air Emissions - BHilton 2 Dec 2011
Emissions and Technology Mercury Control Systems PAC Powdered Activated Carbon Brominated Milled Carbojn Additive Storage Tank Boiler Additive Technology
Emission Control Technologies SO 2 & Acid Gas Control Systems Dry Flue Gas Desulfurization Spray Dry Absorber- SDA Fluid Bed Dry Absorber Dry Sorbent Injection - DSI
Emission Control Technologies NO x Control System SCR Selective Catalytic Reduction SNCR- Selective Non-Catalytic Reduction
Wet Flue Gas Desulfurization and Integrated Systems
Agenda 1st topic Combustion Page 2 2nd topic Criteria pollutants Page 10 3rd topic CO2 Capture Page 17
Post Combustion CO2 Capture Advanced Amines Chilled Ammonia
Principle Advanced Amine Process Technology Overview An amine based solvent reacts with the CO2 in the flue gas Raising the temperature reverses this reaction, the CO2 is released and the solvent recycled Advantages Proven in natural gas & syngas purification CO2 capture from flue gas is a new application More efficient capture of CO2 and less solvent degradation than MEA Higher tolerance against oxygen & trace contaminants Source: Alstom
Chilled Ammonia Process Technology Overview Principle Ammonium carbonate solution reacts with CO2 of cooled flue gas to form ammonium bicarbonate Raising the temperature reverses this reaction, pressurized CO2 is released, the solution is recycled Advantages High CO2 purity Tolerant to oxygen and flue gas impurities Stable reagent, no degradation nor emission of trace contaminants Low-cost, globally available reagent
Other CO2 Technologies in Development Dry Sorbents Enzymes Cryogenic Regenerable Sorbents Biological Capture Membranes Metal Organic Frameworks (MOFs) Chemical Processing for Reuse
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