NETRA A Maharatna Company NETRA Presentation On Carbon mitigation technologies 20 th Dec. 2011...

NETRA A Maharatna Company

NETRA Presentation

On Carbon mitigation

technologies20th Dec. 2011

Prakash D Hirani

NTPC Energy Technology Research Alliance Developing Economic and Green Energy Technologies


Presentation Outline

• NTPC overview (5 slides)

• About NETRA (12 slides)

•Carbon sequestration (26 slides)


NTPC Overview

NETRA A Maharatna Company 35 Years since Inception and ‘Energizing India

PAN India Presence

NETRA A Maharatna Company Performance Highlights - Operational

Consistently Delivering

NETRA A Maharatna Company Capacity Addition by 2017

Long Term Corporate Plan prepared for next 21 years upto GW by 2032 to position NTPC as the World’s largest and best power producer and leader in Green Power

NETRA A Maharatna Company Global Stature

Number 1 independent power producer in Asia in 2010 (by Platts, a division of McGraw-Hill companies)

# 1 in the world in capacity utilization# 3 in Asia in electricity output and # 10 in the world# 3 in the world in plant availability

10th largest generator in the world

NETRA A Maharatna Company Environmental Initiatives

More than 30 Million tons of CO2 has been avoided in NTPC


About NETRA


Climate Change

New & Renewable

Energy

Efficiency and Availability

Improvement& Cost reduction

Focus Areas of NETRA

Support to Stations


Principle:Ramagundam fly ash contains 4.5% CaO (i.e. 1 T/Hr. per 200 MW unit) which requires 0.78 T CO2 for carbonation

Lab. Studies conducted and established carbonation by mixing CO2 in ash Slurry with Ramagundam fly ash.

Objectives:1. CO2 Utilization2. Reduction in scaling in ash pipelines3. Reduction in acid consumption4. Reduction in acidic gases from flue gas5. Reduction in maintenance cost6. Carbonated ash for construction purposes or Agriculture use

Further Activities (Ramagundam)• Design of a pilot plant for 1 T/hour of Ash Slurry

• Fabrication & Installation at site

• Trials at Ramagundam

• Feasibility Report

Chimney

Flue gas Scrubber

ESP

Flue gas

Treated Ash Slurry to Ash Pond/disposal

ID Fan

Blower

Tests with Dadri Flue gas Carbonated fly ash after 2 days in air

Feasibility of CO2 capture technology by aqueous carbonation of ash at Ramagundam

Schematic of trials


Installation of integrated biodiesel pilot unit from Installation of integrated biodiesel pilot unit from Pomognia fruit at DadriPomognia fruit at Dadri

Benefit: Benefit: Unique technology, self powered useful in Unique technology, self powered useful in remote areasremote areas

Technique:Technique:•Previous Previous set up produces only raw oil from fruit using set up produces only raw oil from fruit using expeller. Cake and shells were used as manure (Utilization expeller. Cake and shells were used as manure (Utilization 15% energy)15% energy)•Now, Shell and cakes are gasified and power is also Now, Shell and cakes are gasified and power is also generated to make the system self driven (Utilization 83% generated to make the system self driven (Utilization 83% energy)energy)

Status: Pilot setup is demonstrated at Pilot setup is demonstrated at Dadri and surplus Dadri and surplus power is also generated for lighting. Patent filedpower is also generated for lighting. Patent filed

From 65 Kg Pomognia Fruit

Biodiesel: 8kg

Electricity production: 24Kwh

Integrated biodiesel pilot plant at DadriIntegrated biodiesel pilot plant at Dadri

ObjectiveObjective: : Demonstrating utilization of 83% of energy from Pomognia fruit in form Demonstrating utilization of 83% of energy from Pomognia fruit in form of Biodiesel and power instead of existing 15% (total) of Biodiesel and power instead of existing 15% (total)

From 1 Hectare plantation

Biodiesel: 1 Ton

Electricity gen: 4800 Kwh

Saving Power: 3800Kwh

Payback: 5 Years


Status : Technical specification for Ramagundam STPS completed, NIT by Apr2011

Chimney

12 oC

7 oC

Comparison with vapor compression

FGHR VAM Demo

Vapour compression system

Capital cost (Mn 34.2 8.5

Auxiliary power (kWe)

86 137

NPV of Operating cost for 25 year Mn

13.8 22.1

C Credit @ 10 USD / ton of CO2 in Lacs

70 ---

Objective- Waste heat from flue gas for 100TR Air Conditioning at RamagundamBenefit- • Utilizes Waste heat instead of electrical power/ steam to generate Air

Conditioning• Green house gas free Air conditioning.• Auxiliary Power Saving of 0.4 MU per year (266 ton of CO2) • Initial cost of demonstration pilot plant is high, but expected to come down after

large scale deployment

ID Fan

HeatRecovery (500 kW th )

Vapor Absorption Machine(100 T R)

155 oC

130oC

90 oC

80 oC

Hot Flue Gas Hot Flue Gas

HeatRecovery (500 kW th )

Fan

Waste Heat Recovery System: FGHR-AC Pilot PlantWaste Heat Recovery System: FGHR-AC Pilot Plant


Objective

Status:

S.No Activities Status / Schedule

1 Development of 5kW test loop and Experimentation

Completed in Dec 2010

2 Analysis of results and report 15.03.11

• Based on analysis of 5kW results Technical specifications for 100 kW Pilot plant shall be prepared for deployment in one of NTPC station.

Use of ammonia-water mixture as working fluid instead of water & taking advantage of variable temperature boiling and condensation

Technique

More efficient utilization of low grade/waste heat from flue gases, LP steam, solar energy for increasing cycle efficiency and power generation

BenefitsEfficiency improvement by around 1 % compare to Rankine cycle in low temperature range source (150oC ; Sink-32oC)

Am

mon

ia V

apor

Sep

arat

or

Ammonia VaporSuperheating

RecuperationHeat Exchanger

Am

mon

ia A

bsor

ber

Turb

ine

Qsup`

W

RE

PC

PC=Partial Condenser, RE = Re-BoilerMulti -composition Aqua Ammonia Liquor Absorption

Engine

Qout

Qin

Am

mon

ia V

apor

Sep

arat

or

Ammonia VaporSuperheating

RecuperationHeat Exchanger

Am

mon

ia A

bsor

ber

Turb

ine

Turb

ine

Qsup`

W

RE

PC

PC=Partial Condenser, RE = Re-BoilerMulti -composition Aqua Ammonia Liquor Absorption

Engine

Qout

Qin

Aqua Ammonia Power CycleAqua Ammonia Power Cycle

NETRA A Maharatna Company Solar Platform

S.No Project Deliverable

18-sensor Solar Radiation Station

Ground Level Solar Radiation Data: Global, Diffuse, DNI, UV, IR, Albedo, Sun Shine Duration

2

Setting up of Solar based HVAC system

1. GHG free, low CO2 Solar HVAC

2. Thermal storage for lean/non-solar period operation

3. Can be replicated in power plants

3

Setting up of 1 MW Solar R&D Project at NETRA

1. Proofing of solar thermal technology for low cost solar power – CLFR

2. R&D test bed for component & prototype testing

3. Insight & feedback for O&M issues of solar thermal power plant

4 Setting up of Solar PV Multi-technology test bed and measurement lab

1. Solar PV R&D test bed of five different

technology for performance assessment.

2. Related Test and measurement equipment

5

In-house development of two axis solar tracker for heliostat application

Can be used for:

1. Mounting measuring instruments

2. Photovoltaic module to harness more energy.

3. Heliostat for natural lighting/solar tower


Solar tracker, tracks the movement of sun Used for focusing

• Various measuring instruments to the sun.• Photovoltaic module to the sun for harnessing

more energy.• heliostat for natural lighting/solar tower

Features:•Microprocessor controlled•Track the sun with 0.072 Deg of accuracy.•Power Consumption – 28 Watt

Cost - Rs. 30,000/- approximately (Market cost Rs. 5 lacs)

In-house development of two axis solar tracker for heliostat application

Power supply unit

Stepper motor

Microcontroller Unit

Motor Driving Circuit

Real time clock


Why MSW to Energy ?MSW

Contains 70 % organic content, suitable material to be used as a fuel resource (presently considered as a waste, creates pollution)

Advantages of using MSW

Represents a renewable energy source Considered as carbon neutral fuel (CO2 neutral fuels)

Pollutant emissions are lower than coal Can be exploited for their energy instead of destined to landfill

Energy content of typical treated Indian MSW = 3766 Kcal/kg

NETRA A Maharatna Company Waste to Energy

Technology :

Using high pressure steam to convert municipal solid waste (MSW) into solid fuel, and it may be used as a co-firing fuel in boiler / stand alone system.

Comparison with other technologies

1. Use of Saturated steam for treatment (All in one process)

(other technology uses – 1. Dry – 2. Shred – 3. Compress with binders to

produce pellets – Energy intensive process)

2. Requires low energy consumption (only steam is required)

3. Produce grounded fuel with uniform properties

4. Moisture removal is easy (Inherent moisture is removed)

(Others – Only surface moisture is removed)

5. Increase the shelf life of the fuel (fuel becomes non hygroscopic)

(others – Moisture will be reabsorbed by the fuel)

6. Removes bad / stinky odor (Sterilize the waste)

NETRA A Maharatna Company Treatment Performance

Experiment Result of treated MSW

* Calorific value comparable to the Indian coal

Proposed Usage of MSW

Paper Waste

Kitchen Waste

**

Solid FuelSteam

Treatment MSW

Co-firing with coal

Stand alone system


Plant schematic

Boiler


Proposed steam treatment

Improves drying performance Suitable for mixed MSW It can produce uniformly grounded fuel Fuel with uniform properties Higher density Removes stinky odor Removal of inherent moistureRequires 39 % less energy compared to traditional methods


Carbon Sequestration

Carbon Capture Technologies


CO2 Management

CO2 CaptureUtilization

FuelChemicals

Single source CO2 Emission

Geological storageOceanic storage

Physical & chemical methods

Physical & chemical methods

Biological methods

Biological methods

AbsorptionAdsorptionMembraneCryogenic distillation

BacteriaAlgaeOther related items

Storage


• There are three option to control the CO2 emission without severely or negatively changing the standards of living:

- Increase in energy efficiency

- Switching over to less carbon intensive source of energy

- Carbon sequestration

The Energy-Carbon ConflictThe Energy-Carbon Conflict

Major steps for carbon sequestration:

• CCapture -CO2 separation from flue gases

• TTransport -Probably in liquid form at high pressure

• FFix -Back to mother Earth- storage in geological formation

The Separated gas may also be used for:

- Use for enhanced coal bed methane [ECBM] recovery

- Use for enhanced oil recovery [EOR]

- Making value added products


Carbon Emission Reduction Technologies

Efficiency Enhancement

CO2 Capture

• Combustion efficiency improvement in conventional power plant • Low grade heat utilization

• IGCC

• Super critical & Ultra super critical technology

• Advanced class gas turbine

• Hydrogen technology & fuel Cell

Pre-combustion

During Combustion

Post combustion


Pre-Combustion During -Combustion Post-Combustion

• IGCC - Gas turbine - Hydrogen separation for Fuel Cell

• CFBC

• PFBC

• Oxy- fuel Combustion • Pulverized coal

fired based plant

CO2 Capture Technologies

NETRA A Maharatna Company Pulverized coal

based

Power Plant

Fuel

Air CO2 Separation

Flue gas

Post Combustion approach

Pre-combustion approach

Oxy-fuel Combustion

Fuel

Air Separation

Oxygen

Air

CO2

CO2

IGCC Fuel

Air

Shift reaction & CO2 separation

Gas

GT CO2 Separation Flue gas

H2

CO2

CO2


CO2 Capture Fundamental Research is required to develop

Cost Effective Technology

Fundamental R&D may not required as Options are known

Major Issues are

• Environmental and Safety• CO2 piping network • Long Term Integrity of CO2 storage • Monitoring and Verification • Legal Frame Work

CO2 Fixation

CO2 Transport

Major steps for carbon sequestration

NETRA A Maharatna Company Technologies for CO2 SeparationTechnologies for CO2 Separation

CO2 Capture Process

Physical Separation

Chemical Separation

Membrane

Separation

Hybrid Separation

Cryogenic Distillation

High Pressure

Separation


Need for Cost effective Technologies

Indian condition

FGD / SCRSystem

To be installed

CO2 Capture

Western country

FGD / SCRSystem

Already existing

Higher Generation cost

Flue gas

Carbon Capture TechnologiesCarbon Capture Technologies

CO2 Capture Technology

The Separated CO2 may also be used for: - Use for enhanced coal bed methane [ECBM] recovery- Use for enhanced oil recovery [EOR]- Making value added products

NETRA A Maharatna Company Challenges in Carbon CaptureChallenges in Carbon Capture

Combustion in boiler at Atmospheric pressure

Low CO2 concentration in Flue Gas: GT / Gas fired boiler is 4-5%

Low CO2 concentration in Flue Gas: Coal fired boiler: 13-15%

Low Discharge pressure of

Flue Gas: 350-500 mmwc

Combustion in boiler at Atmospheric pressure

Facts

High Energy for

pressurization

Bulky equipment - Higher capital

costs

High partial pressure based CO2 separation

process like Benefild or Catacrab cannot be used

Issues

Low partial pressure of CO2

1. Low partial pressure of CO2


2. High temperature of flue gases

Facts

Flue gas temperature

is generally 140-160 °C

Present solvent based

process operates at 40-

50 °C

CO2 laden solvent is

regenerated at 120 °C -

130 °C

Issues

Cooling is

required for

CO2 separation

Flue gas

cooling below

50°C is required

for membrane

or PSA process

Concerns

Cooling is very energy intensive process

Lower temperatures also pose risk of acid corrosion


3. SOx Removal

Flue gases from coal fired units contains 700-1200 mg/Nm3 of SOx

In amine process, SO2 reacts with amines to form thermally stable corrosive salt.

SO3 forms sulfuric acid mist in cooler causing corrosion

SOx may adversely reacts with membrane materials or solid adsorbent or may get adsorbed on adsorbent

Facts:

The acceptable limits of SO2 for solvent process is 10 ppmv

A lime stone or wet FGD system followed by caustic soda or soda ash based scrubber is must for SO2 removal

Issues:

Cost of FGD (not mandatory otherwise), results in higher cost of CO2 capture

Concerns:


Level in flue gas 500- 800 mg/Nm3

In amine process, solvent degradation due to formation of thermally stable salts

Corrosion due to nitric acid formation

Adverse reaction or adsorbed in solid absorbents

Facts

NOx may degrade membrane materials

NOX is removed by SCR process at 250-300 °C

Plugging of catalyst by fly ash is a problem

Flue gas heating to reaction temperature not possible when SCR is after Economizer.

Issues

SNCR at high temperature is an option

Cost of NOx removal results in higher cost of CO2 capture

Development of Nox / corrosion resistant process will be better option

Concern

4. NOx Removal


5. Fly Ash in Flue Gas

Facts:About 100 -150 mg/Nm3 of fly ash present in flue gases

Issues:This causes plugging, erosion, solvent degradation etc. in solvent based process

Fly ash may also plug membranes and solid adsorbents


Flue gas is cooled and scrubbed in a direct contact cooler

CO2 is adsorbed in 15-20 % aqueous solution of MEA at 40-45 ºC in a Absorption Tower

The absorbed CO2 is regenerated by stripping around 120-130 ºC

Steam (3 kg/cm2) required for regeneration is supplied by a reboiler

Regeneration, the most energy intensive process, requires 2 ton of steam per ton of CO2 Corrosion is a major issue

Absorption Process

most widely used Technology

Chemical Absorption ProcessChemical Absorption Process


Pri. Amine

High Regeneration Energy

LowerRegeneration

Energy

Introduction of

StericHindrance

RegenerationTarget

100 °C

Waste Heat Utilization of flue

Gas for Reboiler

Solvent Development Solvent Development

NETRA A Maharatna Company Chemical Process for CO2 SeparationChemical Process for CO2 Separation

Major Concerns:

• In amine process, 80-90%of total energy required, is consumed in

solvent regeneration

• For a 210 MW coal fired boiler the total energy requirement is about

65 MWe of power.

• This will bring down total efficiency by at least 30%.

• This will approximately double the power generation cost

NETRA A Maharatna Company Efficiency Enhancement: The IGCC TechnologyEfficiency Enhancement: The IGCC Technology

IGCC Fuel

Air Shift reaction & CO2 separation

Gas

GT CO2 Separation Flue gas

H2

CO2

CO2

The IGCC Cycle

Variation of CO2 with Efficieny

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0.2 0.3 0.4 0.5 0.6Overall Efficiency (LHV)

CO

2 E

mis

sio

ns-

Kg

/KW

h

Coal Gas

PC

Simple Cycle Gas Turbine

CCGT

IGCC

Improvement of overall efficiency would reduce the CO2 emission

level.

CO2 Emission: CO2 Emission: 0.80-0.85 Ton/MW

For 200 MW Size Unit: 160-170 T/Hr

For 500 MW Size Unit: 400-425 T/Hr


Absorption Process

Gas Absorption Membrane

Gas Separation Membrane

Membrane process

The Cycle

Carbon Capture Technologies: MembraneCarbon Capture Technologies: Membrane

Gas Clean-Up

Polymer Membrane [T< 100C]

Gas Cleanup & Ceramic

Membrane

[H2]

[CO2]

WGSRIGCC[H2, CO]


Absorbents

Ionic Liquids Non-Corrosive molten organic salts Alkyl ammonium, Phosphonium,

Imidazolium and pyridinium halide salt Aqueous solution of KOH, NaOH,

Na2CO3, NH3 etc.

Membrane process

Carbon Capture Technologies: MembraneCarbon Capture Technologies: Membrane

Needs large efforts on development of Membrane with right permeability

& selectivity.

Flue gas

Membrane

CO2

CO2 absorbing liquid


N2 [Primary]

CO2[Secondary]

De-

sorp

tio

n C

ycle

Ad

sorp

tio

n C

ycle

Gas

Cle

anu

pF

lue

Gas

CO

2, N

2

Carbon Capture Technologies: AdsorptionCarbon Capture Technologies: Adsorption

The Cycle Works on a Pressure

Temperature / Vacuum swing

process

Research issues • Development of high

performing adsorbents based on zeolite, mesoporous material, hydrotalcte etc.

• Cycle of CO2 extractions (PSA, VSA, TSA)

• Process integration • Attrition issue


Technology Development

for post-combustion capture

of CO2 by AdsorptionCSIR (IIP), DEHRADUN

PROCESS DEV & OPTIMIZATION

CSMCRI, BHAVNAGAR

ADSORBENT DEVELOPMENT

IIT, MUMBAI

SIMULATION MODELING & PROCESS DESIGN

NEERI, NAGPUR

ADSORBENT DEVELOPMENT

Netra Research on CO2 Capture


Conventional amine based CO2 capture process is cost and energy intensive

PSA process is being developed as an alternative process

In PSA process • CO2 is selectively adsorbed on adsorbent under moderate pressure • Adsorbed CO2 is recovered under vacuum

Research components in process development

• Development of materials for CO2 adsorption

• Development of PSA process using the materials • Modeling and simulation of PSA process • Experimentation in PSA test unit and

process optimization

Pressure Swing Adsorption (PSA) process for CO2 capture from flue gas

PSA test unit

PSA Unit

Synthetic Flue Gas CO2 : 12- 13 %

Moisture : 4- 5 %Oxygen : 3-4 %

Nitrogen : 78-81 %Temperature : 50-55 °C

CO2 purity ~ 85 %recovery ~ 75%

• Three Indian and PCT patent application filed on CO2 selective zeolite based adsorption materials

• The PSA unit has been shifted to NETRA from IIP for further development of the process

• Pilot scale development of the process in collaboration with GNFC and CSMCRI is under active consideration


Highly selective adsorbent

developed at CSMCRI superior to conventional

adsorbents

0102030405060708090

100

Two bed VSA

Three bed VSA

%CO2 purity

%CO2 Recovery

Over 92% CO2 purities at 80% recoveries achieved at 55 0C from CO2

levels of 11% in flue gas.Simulation model validated

Outcome


• Over 80% recovery of high purity (>90%) CO2 from flue gas at moderate temperature and low pressure

• Preliminary estimates of Power requirements 0.30 Kw-hr/kg CO2 recovered at 550C , lower than current amine based absorption processes

• Base adsorbent material is commercially available

• Process does not generate any waste stream requiring further treatment

Highlights

NETRA A Maharatna Company Carbon Sequestration

• CO2 Capture and its geological storage is energy & cost intensive (60-80USD/Tonne CO2), uncertain and not yet proven

• India’s focus for CO2 mitigation is directed towards biological fixation/utilization of CO2 in addition to efficiency improvement and use of renewable

CO2 to Bio-oil : Micro Algal Process • Able to produce bio-oil, neutraceuticals, cattle food, etc. • Oil content upto 40% • Potential algal species are Dunaliella, Nannochloris, Spirulina • 30 times more oil production than other energy plantations for

same land • No need for agricultural land – may avoid bio-oil crop conflict

• Typical CO2 consumption : 100 gm/m2/day

• Requirement of land for algal cultivation is an issue

• Commercial process for algae to bio-oil using CO2 from power

plant yet to establish • Extensive global R&D for development of the process

CO2 Fixation Initiative

Micro-algaeAbsorbs CO2

Produces

• Bio-fuel

• Micronutrients

• Animal feed


• Algae commercially grown for nutritional, feed and specialty products• Lipid / oil content : 2% to 40% • Algae generate 7-30 times more oil than bio-plants like Jathropa, Ratanjot etc• Global R&D for development of the process in open pond and photo-bioreactorsystem

• Typically for a open pond system CO2 consumption rate : 100 gm/ square meter/ day Dry algae production rate : 20 gm / square meter / day Oil production : 30%

IOCL-R&D & NETRA through MoU between IOCL & NTPC

Process Open race way pond

Majorsteps

• Process development in Lab. scale • 1000 m2 open pond pilot study at NTPC’s power station

Present status

• Lab. scale developed has been started • Area of app 1500 Sq M identified at Faridabad Gas Power Plant

Algae

1000 sq. meter algae based pilot plant

Micro-Algal process for mitigation of CO2

• Benefit : The pilot study will help in assesing the feasibility of using flue gas as CO2 source & the possibility of producing bio-diesel


49

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NETRA A Maharatna Company NETRA Presentation On Carbon mitigation technologies 20 th Dec. 2011...

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