Overview of RecentOverview of RecentAccomplishments and Accomplishments and

Work in ProgressWork in Progress

Edward S. Rubin Carnegie Mellon University

Project Review Meeting National Energy Technology Laboratory

April 2, 2001

Outline of TodayOutline of Today’’s Presentations Presentation

Brief History of the Project Recent Accomplishments

IECM technologiesToward Vision 21

Work in ProgressFuture PlansOpen Discussion

Project HistoryProject History

“Development of the Integrated Environmental Control Model”

– CORs: C. Drummond, L. Gould, P. Rawls, T. Feeley, G. Gibbon

– September 1992 - April 2000

“Development and Application of Optimal Design Capability for Coal Gasification Systems”

– CORs: K.Williams, G. Gibbon– September 1992 - present

Because of the . . .

Increasing complexity of advanced processesMultiple options for component design & selectionStrong interactions among system componentsSignificant performance and cost uncertainties

Advanced Design and Analysis Advanced Design and Analysis Methods Are NeededMethods Are Needed

ObjectivesObjectives

Develop a comprehensive modeling framework to estimate the performance, environmental emissions, and cost of coal-based power generation technologies

Develop a method for comparing alternative options on a systematic basis, including the effects of uncertainty

ApproachApproach

Process Technology ModelsEngineering Economic ModelsAdvanced Software CapabilitiesSystems Analysis Framework

Integrated EnvironmentalIntegrated EnvironmentalControl Model (IECM)Control Model (IECM)

CoalCleaning

CombustionControls

Flue Gas Cleanup & Waste Management

NOxRemoval

ParticulateRemoval

CombinedSOx/NOxRemoval

AdvancedParticulateRemoval

SO2Removal

Calculate detailed mass and energy flowsEmploy empirical relationships and models based on available dataPredict component and system efficiencyPredict multi-media environmental emissions

Process Performance ModelsProcess Performance Models

Direct capital cost of major process areasTotal system capital costFixed operating costsVariable operating costsTotal cost of electricityLinked to process performance models

Process Cost ModelsProcess Cost Models

Probabilistic Software CapabilityProbabilistic Software Capability

Can specify parameter values as distribution functions to reflect uncertainty or variability in model input data

Explicitly quantifies the effects of uncertainty on predicted performance, emissions, and cost, yielding confidence intervals for uncertain results

IECM Software PackageIECM Software Package

PowerPowerPlantPlantModelModel

GraphicalGraphicalUserUser

InterfaceInterface

Plant andPlant andFuelFuel

DatabasesDatabases

Fuel PropertiesFuel PropertiesHeating ValueHeating ValueCompositionCompositionDelivered CostDelivered Cost

Plant DesignPlant DesignFurnace TypeFurnace TypeEmission ControlsEmission ControlsSolid Waste MgmtSolid Waste MgmtChemical InputsChemical Inputs

Cost DataCost DataO&M CostsO&M CostsCapital CostsCapital CostsFinancial FactorsFinancial Factors

Plant & ProcessPlant & ProcessPerformancePerformance

-- efficiencyefficiency-- resource useresource use

EnvironmentalEnvironmentalEmissionsEmissions

-- air, landair, land

Plant & ProcessPlant & ProcessCosts Costs -- capitalcapital

-- O&MO&M-- COECOE

The IECM is Publicly AvailableThe IECM is Publicly Available

Web Access:

ftp://ftp.netl.doe.gov/pub/IECM

Preliminary IECM User GroupPreliminary IECM User Group

ABB Power Plant ControlAmerican Electric Power Consol, Inc.Energy & Env. Research Corp.Exportech Company, Inc.FirstEnergy Corp.FLS Miljo A/SFoster Wheeler Development Corp.Lehigh UniversityLower Colorado River AuthorityMcDermott Technology, Inc.Mitsui Babcock Energy LTD.

National Power Plc.Niksa Energy AssociatesPacific Corp.Pennsylvania Electric AssociationPotomac Electric Power Co.Savvy EngineeringSierra Pacific Power Co.Southern Company Services, Inc.Stone & Webster Engineering Corp.Tampa Electric Co.University of California, BerkeleyUS Environmental Protection Agency

Overview of Overview of Recent AccomplishmentsRecent Accomplishments

Combustion NOx controls (v 3.3)Mercury control technologies (v 3.4)IGCC systems (current and advanced)Solid oxide fuel cells CO2 capture and sequestration systemsFlexible fuel optionsEnhanced software capabilities

Newest Versions ofNewest Versions ofthe IECM ...the IECM ...

n

New IECM Modules for New IECM Modules for Combustion Combustion NONOxx ControlsControls

Version 3.3Selective Non-Catalytic Reduction (SNCR)Low NOx Burners (LNB)LNB + Overfire airLNB + SNCRNatural Gas ReburnTangential, Wall & Cyclone Firing

New IECM Modules for New IECM Modules for Mercury ControlsMercury Controls

Version 3.4Carbon injection systemsFlue gas humidification optionEffects of coal type (eastern vs. western)Effects of control technology selection

– Particulate collector– FGD system– SCR system

MultiMulti--Pollutant InteractionsPollutant Interactions

CriteriaAir

Pollutants

PMSO2

NOx

HazardousAir

Pollutants

HgHClH2SO4

A Special AnnouncementA Special Announcement

n

Model ApplicationsModel Applications

Process designTechnology evaluationCost estimationR&D management

Risk analysisEnvironmental complianceMarketing studiesStrategic planning

Current Activities and PlansCurrent Activities and Plans(PC plants)(PC plants)

Refine existing models for mercury control and other pollutants as new data become available Couple the IECM to a database of U.S. power plant and fuel characteristicsAnalyze options, costs and emission reductions associated with use of control technologies for criteria pollutants and air toxicsExplore IECM applications to the DOE Power Plant Improvement Initiative

Toward Vision 21 ...Toward Vision 21 ...

n

Model Software ImprovementsModel Software Improvements

Increased FlexibilityMultiple fuel types (coal, oil, gas)Multiple plant types (combustion, IGCC, fuel cells, gas turbines, etc)Easy and fast integration of new modules

Additional FeaturesPlant configurationsResults tools

User Interface ImprovementsUser Interface Improvements

Increased FlexibilityConfiguration of flowsheetsTwo-dimensional flowsheetsInterface database compiler

Additional FeaturesMultiple technology navigation menuMultiple session results

– Comparisons of up to six sessions– Differences between two cases

Comparisons of Competing OptionsComparisons of Competing Options

Select Gasification Combined Select Gasification Combined Cycle (IGCC) OptionsCycle (IGCC) Options

Select Select GasifierGasifier

Select Oxygen PlantSelect Oxygen Plant

Select Gas Cleanup SystemSelect Gas Cleanup System

Select Byproduct RecoverySelect Byproduct Recovery

Current Status of IGCC ModelsCurrent Status of IGCC Models

Response surface model of advanced IGCC system (KRW gasifier + hot gas cleanup) is completed; implementation in the IECM framework is nearing completion.Response surface model of baseline IGCC system (Texaco gasifier + cold gas cleanup) is under development; expected completion in June.

Set IGCC Process ParametersSet IGCC Process Parameters

IGCC Process AreasIGCC Process Areas

Coal HandlingLimestone HandlingOxidant FeedGasificationSulfationZinc Ferrite

Boiler Feedwater SystemGas TurbineHeat Recovery Steam GenerationSelective Catalytic ReductionSteam TurbineGeneral Facilities

IGCC Fixed O&M CostsIGCC Fixed O&M CostsFuels

Coal CostFuel Oil CostLPG - Flare Cost

ReagentsSulfuric Acid CostNaOH CostHydrazine CostMorpholine CostLimestone CostLime CostSoda Ash Cost

SCR SystemSCR Catalyst CostAmmonia Cost

Zinc Ferrite SystemZinc Ferrite Sorbent CostPlant Air Adsorbent Cost

Waste Water SystemCorrosion Inhibitor CostSurfactant CostChlorine CostBiocide CostWaste Water CostRaw Water Cost

ByproductsSulfur Byproduct CostSulfuric Acid Byproduct Cost

ASPEN Model of an IGCC SystemASPEN Model of an IGCC System

CoalHandling

Gasification,Particulate &Ash Removal,Fines Recycle

GasTurbines

BoilerFeedwaterTreatment

SteamTurbine

SteamCycle

& SCR

SulfurRemovalProcess

SulfuricAcid Plant

SulfuricAcid

Rawwater

Coal Coal

CleanSyngas

Exhaust Gas

Gasifier Steam

Boiler Feedwater

Exhaust Gas

Shift & Regen.Steam

Cyclone

RawSyngas

Cyclone

Blowdown

Return Water

CoolingWater

Makeup

CoolingWaterBlowdown

Air

NetElectricityOutput

InternalElectricLoads

Ash Gasifier Air

AirTailgas

Off-GasCaptured Fines

Response Surface Model DevelopmentResponse Surface Model Development

Range of ParameterInputs, Ii

DetailedPerformance

Model

PerformanceOutputs (Oj)

PerformanceOutputs

(Oj)

Response SurfaceModel

Oj = f (Ii)

RegressionAnalysis

Response Surface ModelResponse Surface Modelfor an IGCC Systemfor an IGCC System

0.39

0.4

0.41

0.42

0.43

0.39 0.4 0.41 0.42 0.43

Actual Efficiency

Pred

icte

d Ef

ficie

ncy

Desktop Model of a ProcessDesktop Model of a Process

ResponseSurface

Model (RSM)

CostModel

InputAssumptions

Performance

Emissions

Cost

Additional Fuel and Technology Additional Fuel and Technology OptionsOptions

Simple Cycle Gas PlantSimple Cycle Gas Plant

Combined Cycle Gas PlantCombined Cycle Gas Plant

NGCC Plant with SCR SystemNGCC Plant with SCR System

Open Vision 21 Plant OptionsOpen Vision 21 Plant Options

Vision 21 WorkbenchVision 21 Workbench

Select Existing Select Existing Flowsheet Flowsheet -- 11

Water

Air

Air

GT

GT

ST

GC

HRSG

GA

ASU

FC

FC

Select Existing Select Existing FlowsheetFlowsheet -- 22

Air

Water

PFBC

ASU

CBTC

HRSG

GTST

FCGC

GC

GT

Configure a New SystemConfigure a New System

Air

H2

CO2

New Modules Under New Modules Under Development ...Development ...

n

Tubular SOFC DesignTubular SOFC Design

Air

ElectrolyteCathodeAnode

FuelInterconnect

SOFC Voltage vs. Current DensitySOFC Voltage vs. Current Density

0 100 200 300 400 500 600 700 800 900

10.90.80.70.60.50.40.30.20.1

0

Current Density (mA/cm2)

Vol

tage

(V)

COCO22 Capture TechnologiesCapture Technologies

MEACausticOther

Chemical

SelexolRectisolOther

Physical

Absorption

AluminaZeoliteActivated C

Adsorber Beds

Pressure SwingTemperature SwingWashing

Regeneration Method

Adsorption Cryogenics

PolyphenyleneoxidePolydimethylsiloxane

Gas Separation

Polypropelene

Gas Absorption

Ceramic BasedSystems

Membranes Microbial/AlgalSystems

CO2 Separation and Capture

Flas

h

MEAStorage

Flue Gas

CoolerCooler

Pump

Pump

ReboilerLean-hot

rich-hotrich-cool

lean-cool

MEAmakeup

CO2 productExhaust

Gas

Blower

SpentSorbent

H-Ex*

COCO22 Capture Using AmineCapture Using Amine--Based SystemBased System

Absorber

Regenerator

MultiMulti--Pollutant InteractionsPollutant Interactions

CriteriaAir

Pollutants

PMSO2

NOx

HazardousAir

Pollutants

HgHClH2SO4

CO2

CH4

GreenhouseGas

Emissions

Cost of COCost of CO22 AvoidedAvoided

0.00.10.20.30.40.50.60.70.80.91.0

45 50 55 60 65 70 75 80 85 90 95Mitigation cost ($/ton CO2 avoided)

Cum

ulat

ive

prob

abili

ty

Deterministic

Probabilistic

Application to MajorApplication to MajorPower Generation OptionsPower Generation Options

Combustion-basedGasification-based

Coal

Direct CombustionGas Reforming

Natural Gas

Fuel

Air

Oxygen

Oxidant

Pulverized CoalGas Turbines

Simple Cycle

Gas TurbinesCoal GasificationFuel CellsOther

Combined Cycle

Technology

Power Generation Technologies

IGCC Plant with COIGCC Plant with CO22 CaptureCapture

NGCC Plant with CONGCC Plant with CO2 2 CaptureCapture

To Succeed We Need ...To Succeed We Need ...n

Recipe for SuccessRecipe for Success

Talented Researchers

DOE Collaboration

Continuity of Funding

(blend in equal parts)

Comments andComments andDiscussionDiscussion

n

Configure Base PlantConfigure Base Plant

Select Select NONOxx ControlsControls

Select Particulate ControlsSelect Particulate Controls

Select SOSelect SO2 2 ControlsControls

Set Coal PropertiesSet Coal Properties

Set Base Plant ParametersSet Base Plant Parameters

Specify Input UncertaintiesSpecify Input Uncertainties

Results: Plant Mass FlowsResults: Plant Mass Flows

Results: Plant Cost SummaryResults: Plant Cost Summary

Control Technology DetailsControl Technology Details

Probabilistic ResultsProbabilistic Results

IECM CapabilitiesIECM Capabilities

A comprehensive modeling framework to estimate the performance, emissions, and cost of coal-based power plants

A tool for comparing alternative options on a systematic basis, including the effects of uncertainty in performance and cost

A Hierarchy of Models for A Hierarchy of Models for Technical and Policy AnalysisTechnical and Policy Analysis

Design options for a single

facility (tech. feasibility, cost,

efficiency,emissions)

Multi-facility(or multi-sector)optimization or

simulation (dynamic)

Integrated assessment

models(including

measures of impacts)

Detailed (mechanistic)

models or codes for specific processes or components

Conventional Process ModelingConventional Process Modeling(Deterministic Simulation)(Deterministic Simulation)

ProcessModel

ParameterValues

ResultsResults

Parameter UncertaintyParameter UncertaintyDistributionsDistributions

NORMAL UNIFORM LOGNORMAL

FRACTILETRIANGULAR BETA

Stochastic SimulationStochastic Simulation

StochasticModeler

SAMPLINGLOOP

ProcessModel

ParameterUncertainty

DistributionsResultsResults

Example of a Probabilistic ResultExample of a Probabilistic ResultC

umul

ativ

e Pr

obab

ility

Cum

ulat

ive

Prob

abili

ty

Total Capital Requirement ($/kW)Total Capital Requirement ($/kW)1000 1100 1200 1300 1400 1500

ProbabilisticResult

0.0

0.2

0.4

0.6

0.8

1.0

SorbentSulfur

Loading

GasifierFines

Carryover

CarbonRetention inBottom Ash

353025201510500.0

0.1

0.2

0.3

Sorbent Sulfur Loading, wt-%20151050

0.0

0.1

0.2

0.3

Carbon Retention in Bottom Ash% of coal feed carbon

3025201510500.00

0.05

0.10

0.15

0.20

Fines Carryover, % of coal feed

Expert Judgments on Expert Judgments on Key Model ParametersKey Model Parameters

Calculated Plant EfficiencyCalculated Plant Efficiency

444342414039380.0

0.2

0.4

0.6

0.8

1.0

ProbabilisticDeterministic

Net Plant Efficiency (%, HHV basis)

Cum

ulat

ive

Prob

abili

ty

Total Plant Capital CostTotal Plant Capital CostC

umul

ativ

e Pr

obab

ility

Total Capital Requirement ($1994/kW)1000 1100 1200 1300 1400 1500

DOE (1989)Probabilistic

0.0

0.2

0.4

0.6

0.8

1.0

524 MW net

Value of Targeted ResearchValue of Targeted Research

1201101009080706050400.0

0.2

0.4

0.6

0.8

1.0

Base Case UncertaintiesReduced Uncertainties inSelected Performanceand Cost Parameters

Levelized Cost of Electricity, Constant 1989 mills/kWh

Input Uncertainty Assumptions

Cum

ulat

ive

Prob

abili

ty

NETL 2001 Award CeremonyNETL 2001 Award Ceremony

March 28, 2001

Silver Awardto

NETL 2001 Award Ceremony

March 28, 2001

Silver Awardto

Mercury Control PerformanceMercury Control Performanceand Cost Model Teamand Cost Model Team

Developed a model that evaluated mercury control options for 12 different coal-fired plant configurations which EPA used in their final determination to regulate mercury.

Descriptor - include initials, /org#/date

Mercury Control Performanceand Cost Model Team

• Developed a model that evaluated mercurycontrol options for 12 different coal-fired plantconfigurations which EPA used in their finaldetermination to regulate mercury.