Oxy-combustion Technology Research through the ... - IEAGHG
Transcript of Oxy-combustion Technology Research through the ... - IEAGHG
Oxy-combustion Technology Research through the DOE-NETL Existing Plantsthrough the DOE NETL Existing Plants
Capture Program
Sept. 2009
September 10, 2009Cottbus, Germany
National Energy Technology LaboratoryWhere Energy Challenges Converge and Energy Solutions Emerge
• Only government owned & operated DOE national labD di t d t RD&D d ti
gy g g gy g
• Dedicated to energy RD&D, domestic energy resources• Fundamental science through technology demonstration• Unique industry academia government collaborations• Unique industry–academia–government collaborations
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R. Boyle, 02/11/2009
West VirginiaPennsylvaniaOregon
In Order to Implement CCS, Most New Coal Plants Will Require Technology Developed by the IEP Programq gy p y g
Operating Plants BuiltBetween 2000 and 2008 Plants Under Construction
Near Construction95 percent would require post-combustion retrofits
Near Constructionor Permitted
88 percent would require post-
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combustion retrofits
Source NETL, Tracking New Coal-Fired Power Plants, 2008
DOE’s IEP Program Structure
CO2 Capture Water Minimization
COCO22
HH OO
Oxy-combustion
Advanced Solvents Advanced
CoolingReuse & Recovery
HH22OO
Membranes
CompressionSolidSorbents Non-
traditional sources
Membranes
Systems
MercuryAnalyses
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IEP Key Activity/Component Funding
Technology Area/Budget Line Funding ($000's)
Key Activity /Component FY 2008Enacted
FY2009Enacted
FY2010 CBR
1 CO2 Capture and Compression 27,362 27,932 36,0002 Water Management 6 000 12 000 02 Water Management 6,000 12,000 03 Air Toxics (Mercury)/ Fine
Particulates 0 5,000 04 Program Assessment 2,719 5,068 5,000Total 36,081 50,000 41,000
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FY09 Innovations for Existing Plants Program42 Total Projects42 Total ProjectsOrganizations• Industry 17• University 7• National Laboratories 3• Non-Profit 6Total 33
FY09 Budget Allocation
Annual Budget
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Deployment Barriers for CO2 Capture on New and Existing Coal Plants TodayNew and Existing Coal Plants Today
1. Scale-up200 /d * 15 000 /d• ~200 tons/day* to 15,000 tons/day
2. Energy demand• 20% to 30% in power output20% to 30% in power output
3. Cost• Increase Cost of Electricity
4. Regulatory framework• Transport — pipeline network
• Storage
• Liability
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*Existing post-combustion experience
DOE/NETL CCS Program GoalsBy 2020 have available for commercial deploymentBy 2020, have available for commercial deployment,
technologies and best practices for achieving:
90% CO2 capture
99%+ storage permanence
Pre-combustion Capture (IGCC)
< 10% increase in COE1< 10% increase in COE1
Post- and Oxy-combustion Capture
< 35% increase in COE2
*Cost of Electricity includes 50 mile pipeline transport and saline formation storage, 100 years of monitoring
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y p p p g , y g
1. Impact of Cost Escalation on Power Systems R&D Goals—Re-baselining APS, CS & FC GPRA R&D Goals, DOE/NETL July 20082. Existing Plants, Emissions & Capture Program—Setting Program Goals, U.S. DOE/National Energy Technology Laboratory, Draft Final Report, February 2009
IEP CO2 Emissions Control R&D Activities
• Post-Combustion CO2Control – Solvents– Sorbents– Membranes
• Oxy-Combustion CO2ControlControl– Chemical looping
• CO Compression• CO2 Compression
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Existing Plants ProgramCO2 Capture Extramural ResearchCO2 Capture Extramural Research
$40,000
$50,000
$60,000
s
$10 000
$20,000
$30,000
$100
0s
GovernmentTotal
Government
Total$0
$10,000
Post Combustion Oxy-combustion
CO2 Compression
Total External Research Value: $67.5 M U.S. DOE$95.8 M Total30% overall cost share
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CO2 Capture Extramural Research BreakdownBreakdown
$20,000
$25,000
$10,000
$15,000
$100
0s
T t l
$0
$5,000Government
Total
Government
Total
Total External Research Value: $67.5 M U.S. DOE$95.8 M Total
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30% overall cost share
Oxy-combustion Technologies
R&D Focus New oxyfuel boilers
- Advanced materials and burnersAdvanced materials and burners- Corrosion
Retrofit existing air boilers- Air leakage, g ,- Heat transfer, corrosion
Low-cost oxygen CO2 purification Co-capture (CO2 + SOx, NOx, O2)
Partners• Jupiter Oxygen Corporation • Alstom• Jupiter Oxygen Corporation• Babcock & Wilcox• Southern Research• Air Products
Alstom • Foster Wheeler• Ohio State• Praxair
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• Air Products Praxair• Reaction Engineering International
NETL Office of Research & Development
• Oxy-combustion R&D Areas– Materials
Th l Fl id– Thermal-Fluids– Laboratory Experiments – Process Modeling and Design– Facility Experiments– CFD Modeling– IPR™ Process DevelopmentIPR Process Development
• Chemical Looping Combustion– Development and analysis of oxygen carriers
Design of reactors for ash fuel and oxygen carrier– Design of reactors for ash, fuel and oxygen carrier transport
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Integrated Pollutant Removal (IPR)*
Base
TWR H2 H3 H4 H5
STG1 STG2 STG3 STG4
45psia
190psia
600600psiapsia
2000psia
V4 V8 V11
FGR tap
H1 CAPTURE
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*As implemented at Jupiter Oxygen Corporation in Hammond IN
NETL Office of Research & Development (con’t)(con t)
•Developed oxy-fuel flat-flame burner facility– Current fuels: methane (~natural gas) H2 H2/CO
Hydrogen-Oxygen with steamHydrogen-Oxygen with steam
– Current fuels: methane (~natural gas), H2, H2/CO– Oxidants: O2 or air– Diluents:
St t 18 h• Steam - up to 18pph• CO2 capability has just been added
• Radiative Property Measurementsp y
Black Body SourceHyperspectral Imager
Black Body SourceHyperspectral Imager
Flat Flame BurnerFlat Flame Burner
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Oxy-combustion Projects SummaryPerformer Coal Type(s) Firing Test Size in Additional Info(Project ID) Tested Configuration(s) MWth
Alstom (NT41146) Bituminous CFB 3.0 CO2 simulated recycle gas
Ai Li id (NT41586) S b bit i W ll 1 5 CO i l t d lAir Liquide (NT41586) Sub-bituminous Wall 1.5 CO2 simulated recycle gas
Alstom (NT42205) Bituminous CFB 3.0 CO2 simulated recycle gas
Southern Research Bituminous Wall 1 0 Recycled flue gasSouthern Research (NT42430)
BituminousSub-bituminous
Wall 1.0 Recycled flue gas retrofit
B&W (NT42747) BituminousSub-bituminous
Lignite
CycloneWall
1.8 Recycled flue gas retrofit
Linde (NT42748) BituminousSub-bituminous
Lignite
T-fired 0.08 Baseline Tests for CAR system testing
Jupiter Oxygen (NT42811)
Bituminous Wall 15 Recycled flue gas retrofit(NT42811) retrofit
REI (NT05288) BituminousSub-bituminous
Wall 0.1, 1.2 Detailed mechanism development
Alstom (NT05290) BituminousSub-bituminous
T-fired 15 Recycled flue gas retrofit
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Sub bituminousLignite
retrofit
Oxy-Combustion for Tangential-Fired Boiler Alstom PowerAlstom Power
• Pilot-scale tests at 15 MWth
• Goal is to minimize capital and operating costs
• Status:
– Retrofit complete
– PRB Test Run in Sept 2009
– Bituminous Test Run in lateBituminous Test Run in late 2009
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Oxy-combustion Impacts on Existing Coal-fired Boilerson Existing Coal fired Boilers Reaction Engineering International
E l t i t f t fitti• Evaluate impacts of retrofitting existing coal-fired boilers for oxy-combustion
• Multi-scale experiments (0.1 kW, 100 kW, 1.2 MW)
• Computational fluid dynamic modeling
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Boiler Material Development for Oxy-Combustion Foster Wheeler NA, Corp.Foster Wheeler NA, Corp.
• Investigation of oxy-combustion ff t d bilit f b il t beffects on durability of boiler tube
materials
• Computational fluid dynamic
Division WallsDivision WallsDivision Walls
• Computational fluid dynamic modeling will predict gas compositions Burners
OFA Ports
WaterwallsBurners
OFA Ports
WaterwallsBurners
OFA Ports
Waterwalls
• Laboratory testing to determine effects on conventional and higher-ll b il t b
WaterwallsWaterwallsWaterwalls
alloy boiler tubesHeat Flux
(Btu/hr-ft2)
Heat Flux
(Btu/hr-ft2)
Heat Flux
(Btu/hr-ft2)
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Flue Gas Purification for Oxy-Combustion Air Products and Chemicals, Inc.Air Products and Chemicals, Inc.
• CO2 may need to be cleaned of acidic impurities such as HCl and SO2 before being transported by pipeline for sequestration
• Feasibility of purifying CO2from oxy-combustion will be studiedstudied
1. SO2/NOx removal at 1-30 atmospheres pressure
2. Inert removal at 30-110 atmospheres pressure
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Flue Gas Purification for Oxy-Combustion Praxair, Inc.Praxair, Inc.
• Development of flue gas purification for oxy-combustion retrofitscombustion retrofits
• 99 percent SO2 and mercury removal• >90 percent NOx removal• For high sulfur coal:
• SO2 sulfuric acid
• NOx nitric acidNOx nitric acid
• Mercury mercuric sulfate
• For low sulfur coal:• SO2 gypsum• SO2 gypsum
• Mercury activated carbon process
• O2, N2, Ar separated and vented
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Chemical Looping Retrofit for Existing Power Plantsfor Existing Power Plants
Alstom Power
• Development of chemical looping for CO2 capture and
tiseparation
• Limestone-based oxygen carrier
• Fully integrated prototype facility will be designed, constructed, and operatedand operated
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Chemical Looping Retrofit for Existing Power Plantsfor Existing Power Plants
The Ohio State University Research Foundation
• Development of coal direct chemical looping
• Iron oxide-based oxygen carrier
• Can be retrofitted on existing coal fired plantcoal-fired plant
• Bench and sub-pilot testing
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Advanced CO2 Compression
R&D Focus Reduce capital costs Increase efficiency Increase efficiency Integration with CO2 capture process Modeling Heat recovery Reduced footprint
Projects:• New CO2 compressors — Ramgen & Dresser Rand
• 13,000 hp demonstration test in 2011• Novel CO2 compression processes — Southwest Research
Institute
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NETL Systems AnalysesA l i FAnalysis Focus Assessment of state-of-the-art and advanced technologies Guide Research
• Compare best potential technologies to current SOACompare best potential technologies to current SOA• Identify process conditions and performance targetsProject national benefits of advanced technologies
Modeling of novel energy conversion processesTechnolog integration• Technology integration
• Overall technical & environmental performance Engineering Economics
• CAPEX, O&M, COE, CO2 Mitigation Cost2 g
2009 Studies:• Solid sorbents (MOFs)So d so be ts ( O s)• Post-combustion membranes• Ionic liquids• Advanced oxy-combustion
Am
ine
Scru
bber
Am
ine
Reg
ener
ator
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Advanced oxy combustion
RD&D Timeline to Commercial DeploymentPost-Combustion CO2 CapturePost Combustion CO2 Capture
LaboratoryLaboratory--Bench Scale R&DBench Scale R&D
Pilot-Scale Field Testing
yy
Full-Scale Field Testing
Commercial Deployment
20102008 20162012 2020 2024
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For Additional InformationNETL
www.netl.doe.govOffice of Fossil Energy
www.fe.doe.gov
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To Find Out More About NETL’s CO2 Capture R&D:
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http://www.netl.doe.gov/technologies/coalpower/ewr/index.htmlhttp://www.netl.doe.gov/technologies/coalpower/ewr/index.html