Atmospheric Iron-Based Coal Direct Chemical Looping ......• The Babcock & Wilcox • The Ohio...
Transcript of Atmospheric Iron-Based Coal Direct Chemical Looping ......• The Babcock & Wilcox • The Ohio...
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .1
Atmospheric Iron-Based Coal Direct Chemical Looping Process for Power
Production: Phase II
Pittsburgh, PA. August 12, 2016
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .2
Project Objectives
Phase I Project objectives: 2012 -2013 • Evaluate commercial viability of OSU’s coal-direct chemical looping
process for power production with CO2 capture.
• Perform a techno-economic evaluation of the commercial design.
Phase II Project Objectives: 2013-2017 • Conducting laboratory testing and small pilot-scale testing to
reduce technology gaps identified in Phase I.
• Update design and cost performance of the commercial 550 MWe CDCL power plant
• Re-evaluate the CDCL technology and identify development pathway for commercialization in year 2025.
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .3
Project Participants Federal Agencies:
• DOE/NETL State Agency:
• Ohio Development Service Agency Project participants:
• The Babcock & Wilcox • The Ohio State University • Clear Skies Consulting
Industrial Review Committee: • American Electric Power • Dayton Power & Light • Dover Light & Power • Duke Energy • First Energy • Consol Energy
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .4
Outline Commercialization Path
Phase I: CDCL Concept and Techno-Economic Analysis
Phase I: Technology Gaps
Phase II-A: Laboratory Testing and Studies
Phase II-B: 250 kWth Pilot Design and Construction
Project Schedule
Conclusions and Acknowledgments
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .5
Commercialization Path
OSU’s Laboratory
Scale
Scal
e
OSU’s Sub-Pilot 25 kWth
B&W’s Pilot
10 MWth
Demo 50 MWth
Commercial 100 - 550 MWth
2004 2008 2014 2020 2016 2025
Time
Work performed under this
award
Phase II B&W’s 250
kWth
B&W’s Phase I
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .6
Outline Commercialization Path
Phase I: CDCL Concept and Techno-Economic Analysis
Phase I: Technology Gaps
Phase II-A: Laboratory Testing and Studies
Phase II-B: 250 kWth Pilot Design and Construction
Project Schedule
Conclusions and Acknowledgments
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .7
Chemical Looping Concept
Reducer
Fe + FeO
Fe2O3
CO2 + H2O
Coal
Air In
Combustor
Heat out
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .8
CDCL Moving Bed Reactor Concept
Volatiles
Bottom Section
Top Section
Char
Volatilization
Coal
CO2
Fe/FeO Enhancer
Fe2O3
H2O+CO2 (Ash, Hg, Se, As)
Bottom Section* C + CO2 2 CO 2 CO + Fe2O3 Fe + FeO + 2 CO2
* Reactions not balanced
Top Section* CxHy + Fe2O3 Fe + FeO + CO2 + H2O CO + Fe2O3 Fe + FeO + CO2 H2 + Fe2O3 Fe + FeO + H2O
Coal Volatilization* Coal C + CxHy (Volatiles)
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .9
CDCL Commercial Plant Design and Engineering
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .10
CDCL Technology Comparison
Base Plant
MEA Plant
CDCL Plant
Coal Feed, kg/h 185,759 256,652 205,358
CO2 Emissions, kg/MWhnet 801 111 31
CO2 Capture Efficiency, % 0 90 96.5
Net Power Output, MWe 550 550 550
Net Plant HHV Heat Rate, kJ/kWh (Btu/kWh)
9,165 (8,687)
12,663 (12,002)
10,084 (9,558)
Net Plant HHV Efficiency, % 39.3 28.5 35.6
Cost of Electricity, $/MWh 80.96 132.56 102.67
Increase in Cost of Electricity, % - 63.7 26.8
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .11
Outline Commercialization Path
Phase I: CDCL Concept and Techno-Economic Analysis
Phase I: Technology Gaps
Phase II-A: Laboratory Testing and Studies
Phase II-B: 250 kWth Pilot Design and Construction
Project Schedule
Conclusions and Acknowledgments
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .12
Coal Reducer
Combustor
Riser
Distributor
Air
To Convection pass
Reducer • Coal Injection and distribution • Char residence time • Ash Separation • Enhancer Gas • Fate of alkali & Agglomeration • Fate of S, Hg, and N
Combustor • In-bed Heat exchanger
Technology Gap Analysis
Operation • Start up, shut down, turn down
Particles • Attrition • Reactivity • Deactivation
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .13
Outline Commercialization Path
Phase I: CDCL Concept and Techno-Economic Analysis
Phase I: Technology Gaps
Phase II-A: Laboratory Testing and Studies
Phase II-B: 250 kWth Pilot Design and Construction
Project Schedule
Conclusions and Acknowledgments
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .14
Alkaline Agglomeration Test
-2-101234567
850 900 950 1000 1050D
P (in
H2O
)Temperature (oC)
9.10% after oxidized
9.10% in air
Alkaline injection test inn BFB
Particles aglomerate at very high alkaline content : ~9.1wt.%
Heater
CO2 Flow
DP
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .15
Paraticle Regeneration
(b)
Agglomerated particle caused by alkaline can be regenerated in the combustor.
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .16
Particle Characterization
Photograph of TGA Analyzer
Gas Delivery System
31.50
32.00
32.50
33.00
33.50
34.00
34.50
35.00
35.50
36.00
0 200 400 600 800 1000 1200
Wei
ght (
mg)
Time (min)
particles 100 cycles 1200 C
Recyclability Test
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .17
Particle Reduction Studies
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
495 495.5 496 496.5 497 497.5 498 498.5 499
Degr
ee o
f oxi
datio
n (0
= F
e, 1
=Fe2
O3)
Time during 3rd cycle (min)
850 C850 C1000 C1000 C1000 C1150 C1150 C
Gas and fines
Particles
Bottom Moving Bed
Top Moving Bed
Combustor
Coal + CO 2
CO 2
Air
Riser
1150 C
850 C
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .18
Particle Oxidation Studies
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
489 489.5 490 490.5 491 491.5 492
Degr
ee o
f oxi
datio
n (0
= F
e, 1
=Fe2
O3)
Time during 3rd cycle (min)
850 C
850 C
1000 C
1000 C
1000 C
1150 C
1150 C
Gas and fines
Particles
Bottom Moving Bed
Top Moving Bed
Combustor
Coal + CO 2
CO 2
Air
Riser
1150 C
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .19
Coal Flow Model Tests: Fines entrainment
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .20
Char & Ash Residence Time in Moving Bed
0.6
0.7
0.8
0.9
1
1.1
1.2
1.3
1.4
1.5
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
0 50 100 150 200 250
Pres
sure
dro
p (in
of w
ater
)
Time (s)
dp1 (inH2O)
dp3 (inH2O)
dp4 (inH2O)
dp2 (inH2O)
Fines Residence Time
5CFM, 160g flint clay
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .21
25 kWth Sub-Pilot Demonstration
• > 800 hours of operational experience
• > 200 hours continuous successful operation
• Smooth solids circulation • Complete ash separation in
reducer. • Achieve nearly pure CO2 from
reducer outlet • 17 test campaigns completed
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .22
Reducer Carbon Conversion Profile
Reducer Gas Concentration Profile
0%
1%
2%
3%
4%
5%
90%91%92%93%94%95%96%97%98%99%
100%
0 50 100 150 200
Con
cent
ratio
n C
O, C
H4,
O2
(%)
Con
cent
ratio
n C
O2
(%)
Time (min)
CO2
CO
CH4
CH4
CO2
CO
0%10%20%30%40%50%60%70%80%90%
100%
10 60 110
Car
bon
Con
vers
ion
(%)
Time of reaction (min)
00.050.10.150.20.250.30.350.40.450.5
0
2
4
6
8
10
2 4 6 8 10 12 14 16 18
Con
cent
ratio
n (%
) CO
, CH
4, C
O2
Con
cent
ratio
n (%
) O2
Time (min)
CO2
O2
CO
Combustor Gas Concentration Profile
CO CO2
O2
Sample Data: PRB Process Performance • Continuous steady carbon conversion
from reducer throughout all solid fuel loading (5- 25kWth)
• <0.25% CO and CH4 in reducer outlet = full fuel conversion to CO2/H2O
• <0.1% CO and CO2 in combustor = negligible carbon carry over, nearly 100% carbon capture
200-hour Sub-Pilot Continuous CDCL Demonstration
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .23
Outline Commercialization Path
Phase I: CDCL Concept and Techno-Economic Analysis
Phase I: Technology Gaps
Phase II-A: Laboratory Testing and Studies
Phase II-B: 250 kWth Pilot Design and Construction
Project Schedule
Conclusions and Acknowledgments
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .24
Pilot Unit Design
Physical Specifications •Materials: Refractory lined Carbon Steel •Overall Height: 32 ft •Footprint = 20’ x 20’ Process Specifications •Thermal rating: 250 kWth •Coal Feed Rate: 70 lb/hr •Coal size: Pulverized coal •Max Operating Temperature: 2012 oF •Oxygen Carrier: Iron based •Reducer : Counter-current moving bed •Combustor : Bubbling bed •Particle tranport: Pneumatic
Oxygen Carrier Specifications •Active metal: Iron based •Size: 1.5 mm
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .25
Outline Commercialization Path
Phase I: CDCL Concept and Techno-Economic Analysis
Phase I: Technology Gaps
Phase II-A: Laboratory Testing and Studies
Phase II-B: 250 kWth Pilot Design and Construction
Project Schedule
Conclusions and Acknowledgments
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .26
Project Schedule
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
Task 1. Project Management and Planning
Project Management and Planning
Task 2. Laboratory Testing
Large Scale Particle ManufacturingOxygen Carrier (Particle) Characterization
Task 3. Pilot Facility Design, Construction and Testing
Pilot Plant Facility Design Test Facility Cost Estimate
Pilot Plant Facility ConstructionPilot Plant Facility Commissioning & Testing
Task 4.Data Analysis and Update of Commercial Plant Economic Analysis
Data Reduction and Analysis Commercial Plant Design and Cost Analysis
Update Next Scale Pilot Plant Design
Task 5. Phase II Final Report
Final Report and Close out Documents
2017Phase II 2015 2016
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .27
Outline Commercialization Path
Phase I: CDCL Concept and Techno-Economic Analysis
Phase I: Technology Gaps
Phase II-A: Laboratory Testing and Studies
Phase II-B: 250 kWth Pilot Design and Construction
Project Schedule
Conclusions and Acknowledgments
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .28
Conclusions
• CDCL offers a cost-effective alternative for coal-based power generation with carbon capture
• The commercial CDCL modular design is ideal for commercial deployment of the technology
• Cold flow model and laboratory testing is confirming assumptions and design features of the 250 kWth pilot unit and the commercial design
• The design of 250 kWth pilot plant has been completed, the unit is under construction and we are moving soon towards the comissioning and testing phase
© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .29
Acknowledgments
This material is based upon work supported by the Department of Energy under Award
Number DE-FE0009761 and The Ohio Coal Development Office under Award Number
OER-CDO-D-15-02.