VCEA 36th Annual Conference 2015: The Future of …...MGSC SECARB MRCSP National Energy Technology...

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National Energy Technology Laboratory

VCEA 36th Annual Conference2015: The Future of Clean Coal Technologies

Sean I. Plasynski, Ph.D.

Director, Strategic Center for Coal

May 19, 2015

2National Energy Technology Laboratory

104 QBtu / Year81% Fossil Energy

5,546 mmt CO2

Renewables11%

Nuclear8%

Coal18%

Gas30%

Oil33%

740 QBtu / Year79% Fossil Energy43,111 mmt CO2

Renewables15%

Nuclear6%

Coal29%

Gas23%

Oil27%

2035

+7%

+43%

2011

97 QBtu / Year82% Fossil Energy

5,498 mmt CO2

Renewables9%

Nuclear9%

Coal20%

Gas26%

Oil36%

519 QBtu / Year 82% Fossil Energy31,162 mmt CO2

Renewables13%

Nuclear5%

Coal29%

Gas21%

Oil32%

U.S. and World Energy Demand

U.S. data from EIA, Annual Energy Outlook 2014; World data from IEA, World Energy Outlook 2013

Un

ite

d S

tate

sW

orl

d


Where Has Clean Coal Taken Us to Date

-100%

-50%

0%

50%

100%

150%

200%

1970 1975 1980 1985 1990 1995 2000 2005 2010

Ch

an

ges f

rom

1970

CoalkWh

SOx

tons

NOx

tons

PM10tons

Emissions have declined despite

increased coal use.

NETL/FE RD&D has History of Success Assisting Coal Power Sector to

Meet Environmental Challenges

The 800 pound gorilla in the roomAnnual Emissions from a Typical 500-MW Coal Plant

0

1

2

3

4

SOx NOx PM CO2

Mil

lio

n T

on

s p

er

Year

Uncontrolled

Controlled

Source: Steam 40th Edition, Babcock & Wilcox 1992, page 32-2

Annual CO2

emissions

measured in

MILLIONS

of tons

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National Energy Technology Laboratory

• Partner in DOE’s national laboratory system

• Five key laboratories,located in regions rich in coaloil, and natural gas

• Developing critical science and technologyto advance energy systems to use domestic resources with minimal environmental impact

• Dedicated to solving complex problems with cutting-edge research & development and technical expertise

• The Nation’s only laboratory focused on fossil energy

• The only government-owned, government-operated DOE national lab

Developing technology options to enable the continued use of America’s (and the world’s) secure, abundant and affordable coal resources by:

– Supporting RD&D aimed at improving the performance and reducing the cost of coal-based Carbon Capture and Storage (CCS) systems for climate change mitigation.

– Investigating a range of advances in combustion, gasification, turbines, fuels and fuel cell technology capable of increasing base power plant efficiency, improving plant economics and reducingthe amount of CO2 generated and other environmental impacts.

– Offices in SCC focused on R&D, Demonstrations, System Analysis

Strategic Center for Coal

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Where are we now………..

Major CCS Demonstration ProjectsDemonstrating 1st Gen Technology

Project Locations & Cost Share

CCPI

ICCS Area 1

Southern CompanyKemper County IGCC Project

Transport Gasifier w/ Carbon Capture~$6.4 B – Total; $270M – DOE

EOR – ~3.0 MM TPY; mid-2016 start

Petra NovaW.A. Parish Generating Station

Post Combustion CO2 Capture$1B – Total; $167M – DOE

EOR – ~1.4 MM TPY; early 2017 start

Summit TX Clean EnergyCommercial Demo of Adv. IGCC w/

Full Carbon Capture; EOR in Permian Basin

~$3.5B – Total; $450M – DOEEOR – ~1.84 MMTPY; late 2018 start

HECACommercial Demo of Advanced

IGCC w/ Full Carbon Capture~$5B – Total; $408M – DOE

EOR – ~2.6 MM TPY; mid-2020 start

Air Products & Chemicals, Inc.CO2 Capture from Steam Methane Reformers

EOR in Eastern TX Oilfields$431M – Total; $284M – DOE

EOR – ~0.93 MM TPY; started December 2012;2 MMT stored as of May 15, 2015

Archer Daniels MidlandCO2 Capture from Ethanol PlantCO2 Stored in Saline Reservoir$208M – Total; $141M – DOE

SALINE– ~0.9 MM TPY; Sept. 2015 start

OPERATION

TowardFinancial

Close

TowardFinancial

Close

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SE

E EEE

http://nrgcarbon360.com

Petra Nova – NRG W.A. ParishConceptual Overview

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Integration of Carbon Capture at Existing Plant Protocols for CO2 Monitoring

to Ensure Permanence

Identify Areas for Cost Reduction

http://nrgcarbon360.com/

Petra Nova – NRG W.A. Parish Advanced Post Combustion CO2 Capture

• Thompsons, TX (near Houston)

• 240 MWe slipstream at NRG Energy’s W.A. Parish power plant (originally 60 MWe)

• Fuel: PRB sub-bituminous coal

• 90% CO2 capture (KM CDR Process®) 1,400,000 tonnes CO2/year

• EOR: Hilcorp West Ranch oil field

• Total Project Cost: ~$1 billion DOE Share: $167 million

Key Dates

Project Awarded: May 2010

Air Permit: December 2012

NEPA Record of Decision: May 2013

Financial Close: July 2014

Construction: March 2014 (LNTP);

July 2014 (NTP)

Operation: January 2017

Status

Start cooling tower foundation: October 2014

Start absorber foundation: December 2014

Complete all pilings January 2015

Start absorber/quencher foundation Feb. 2015

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CCPICCPI

Air Products & Chemicals, Inc.Steam Methane Reforming with CO2 Capture

• Port Arthur, TX (Hydrogen plant at Valero Refinery)

• 90%+ CO2 capture (Vacuum Swing Adsorption) from 2 steam-methane reformers (SMRs) yielding ~925,000 tonnes CO2/year

• CO2 to Denbury “Green” pipeline for EOR in West Hastings, TX oilfield

• Total Project: $431 MM; DOE Share: $284 MM (66%)

Key Dates

Phase 2 Awarded: June 15, 2010

FEED completed: November 2010

Permit By Rule (PBR) and Standard Air Permits issued: May 2011

NEPA FONSI: July 2011

Construction started: Aug. 2011

Operation started: Dec. 2012

Status

PA-1 initiated operation: March 3, 2013

PA-2 initiated operation: Dec. 16, 2012

Full capacity achieved: April 2013

Has operated at >100% of design when necessary

2,000,000 tonnes CO2 delivered as on 5/15/15

OPERATION

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ICCS ICCS


Carbon CaptureDeveloping post-combustion and pre-combustion CO2 capture technologies for new and existing power plants that reduce capital and operating costs and parasitic energy loads.

Carbon StorageAdvancing safe, cost-effective, permanent geologic storage of CO2 by developing tools to increase understanding of geologic reservoirs and CO2 behavior in the subsurface.

Advanced Energy Systems

Developing a new generation of highly-efficient clean coal power systems capable of producing lower-cost electricity while significantly reducing CO2 emissions.

Crosscutting Technology

Fostering the R&D of materials, instrumentation, sensors, and controls targeted at enhancing the availability and reducing the costs of advanced power systems. Developing computation, simulation, and modeling tools to shorten development timelines and optimize design.

Coal R&D Focus AreasDelivering Next Generation Technologies

0%

5%

10%

15%

20%

25%

30%

35%

40%

Po

we

r G

en

era

tio

n P

en

alty

[%

of

Pla

nt

Ou

tpu

t]Great Strides Made in Clean Coal R&DThermodynamic Improvements Drive Cost Reductions

2005 2012 2020

$100+/Tonne(FOAK)

~ $60/Tonne(NOAK)

< $40/Tonne(NOAK)

Energy Penalty Reductions Enable Cost Reductions

Energy Penalty Reductions Enable Cost Reductions

Relative to Supercritical PC Plant w/o Capture (39.3%

HHV efficiency)

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National Carbon Capture Center…Key tool…

Pilot Solvent Test Unit

Post Combustion

PC4 Facility – 4.3MWe Real PC flue gas Bench through pilot scale ~25,000 hours of testing 15 Technologies tested “Tech-Flexible”

Pre Combustion

6.3MWe Trig gasifier Air- or O2 fired syngas Bench through pilot scale ~20,000 hours of testing 13 gasifier runs “Tech-Flexible”

– World Class Carbon Capture Technology Test Facility –

TRIG Gasifier

5 year $187.5 M ($150 M DOE)

Independent Test Facility

Supports Capture & Gasification

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During Past Year, NETL Operated Its First Five Small Pilot-Scale CO2 Capture Projects

Linde – Solvent TechnologyNational Carbon Capture Center

1.0 MWe

Membrane Technology & Research – Membrane Technology

National Carbon Capture Center1.0 MWe

Neumann Systems Group –Solvent Technology

Martin Drake Power Plant0.5 MWe

University of Kentucky – Solvent Technology

E.W. Brown Generating Station0.7 MWe

ADA-ES – Sorbent TechnologyAlabama Power’s Plant Miller

1.0 MWe

All projects were operational during the year ending January 2015.

1 MWe Slipstream: Novel Amine-Based Post-Combustion ProcessLinde, LLC

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Project SummaryProject SummaryApproach

Test BASF’s advanced amine-based solvent technology and Linde’s equipment process innovations on a 1 MWe

slipstream at the National Carbon Capture Center

Start Up1/12/2015 – stable within a week

Advantages• Solvent more stable, higher capacity, faster kinetics and

~30% lower energy demand than MEA• 60% lower electrical energy load• Novel intercooler, integrated absorber/wash unit• High pressure regeneration• Low cost MOC (projected ~30% capital savings)

Status• Treated >800 hours of flue gas• > 90% capture rate• Good mass balance closures• Absorber Capacity tested =1.0 MWe ramp to 1.5 MWe

1 MWe Slipstream: Low Pressure Membrane ContactorsMembrane Technology & Research

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Project SummaryProject Summary

Approach

Develop and test a spiral-wound membrane process on a 1 MWe slipstream at the National Carbon Capture Center

Start Up1/2/2015

Advantages• Compact equipment• Smaller footprint• Efficient scale-up 20-25x larger

than current modules• Capital cost reduction• Reduced process complexity

Status• >400 hours on flue gas• 87% CO2 removal• BOP issues• Plate & frame installed

6

ft

Program Area Key Technology Number of R&D Projects Total

TRL 2-4Lab/Bench

TRL 5-6Small Pilot

TRL 7+Large Pilot

Post-Combustion Capture

Solvents 14 6 1 21

Sorbents 9 3 - 12

Membranes 7 2 - 9

Pre-Combustion Capture

Solvents 1 - - 1

Sorbents - 2 - 2

Membranes 3 - - 3

Compression Compression - 1 - 1

Totals 34 14 1 49

Capture Program: Active Portfolio Distribution

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Funding Opportunity Announcement: “Small (0.5-5.0 MW) and Large Scale (10-+25.0 MW) Pilots for Reducing the Cost of CO2 Capture and Compression”

Funding Opportunity Announcement: “Lab - and Bench-Scale Applications for R & D of Transformational CO2 Capture Technologies for Coal-Fired Power Plants”

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Significant Size Reductions!

Conventional Absorber

NeuStream-C

ATK

~1/3rd the Footprint of Solvent-Based Capture

Great Strides Made in Clean Coal R&DCost Reductions Becoming Critical – And Achievable!

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Storage Infrastructure Regional Carbon Sequestration Partnerships

Seven Regional Partnerships400+ distinct organizations, 43 states, 4 Canadian Provinces

• Engage regional, state, and local governments

• Determine regional sequestration benefits

• Baseline region for sources and sinks

• Establish monitoring and verification protocols

• Address regulatory, environmental, and outreach issues

• Validate sequestration technology and infrastructure

Development Phase (2008-2018+)Development Phase (2008-2018+)

8 large-scale injections (over 1 million tons each)

Commercial scale understanding

Regulatory, liability, ownership issues

Validation Phase (2005-2013)Validation Phase (2005-2013)

19 injection tests in saline formations, depleted oil, unmineable coal seams, and basalt

Characterization Phase (2003-2005)Characterization Phase (2003-2005)

Search of potential storage locations and CO2 sources

Found potential for 100s of years of storage

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NETL Projects Inject 10M Tonnes of CO2

Equivalent of 2 million passenger vehicles from road for a year

GHG emissions charts: http://www2.epa.gov/carbon-pollution-standards; http://www2.epa.gov/sites/production/files/2014-05/ghg-chart.png

Plains CO2 Reduction Partnership1,660,570

Air Products and Chemicals, Inc.

1,881,000

Southwest Regional Partnership

245,387

Midwest Regional Carbon Sequestration Partnership

331,002

Southeast Regional Carbon Sequestration Partnership

4,858,002

Midwest Geological Sequestration Consortium

999,215

Metric tons injected as of March 31, 2015PCOR-Bell Creek Field Project

MGSC –Illinois Basin Decatur Project

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American Recovery and Reinvestment Act Success!Research Triangle Institute’s Warm-Syngas Cleanup Technology

• ARRA funding enabled accelerated successful testing at Tampa Electric Company’s Polk Power Station

• 50 MWe tests from previous scale of 0.3 MWe -- a 167-fold increase in scale

• Tests to date surpass goals for both sulfur removal and low operating costs

• Project is on track to be completed under budget

• Expected to reduce cost of electricity with carbon capture by 12%, and increase efficiency by 2.6 percentage points

• TECO may run the cleanup equipment post-project to make ammonia

RTI President Wayne Holden, DOE’s Julio Friedman, TECO Vice President Tom Hernandez

Why Pursue Advanced Combustion?

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Advantages of Pressurized Oxy-combustion: Mass and volume of flue gas are reduced Latent heat recoverable Heat transfer rates increased No air in-leakage

Advantages of Chemical Looping Combustion: In-situ oxygen separation eliminates air

separation unit Uses conventional material of construction

and fabrication

69%

14%

15%

2%

PC Flue Gas Composition

N2+Ar CO2 H2O O2

57%

40%

3%

IGCC Syngas Composition

H2 CO2 H2O+CO+N2+Ar

71%

15%

12% 2%

Oxy-Combustion Flue Gas Composition

CO2 H2O N2+Ar O2

INCREASING CO2 CONCENTRATION -> REDUCED CAPTURE SYSTEM COST AND ENERGY

Aerojet RocketdyneOxy-Pressurized Fluidized

Bed Combustor (Oxy-PFBC)Pilot Facility

• Planned 1-MWe Pilot• Located at CANMET

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Alstom 1-MWe CLC PilotProposed Aerojet Rocketdyne

Oxy-PFBC Pilot

Alstom CLC Pilot Plant• World’s Largest CLC Pilot (1-MWe)• Achieved 40 hrs auto-thermal operation

Advanced Combustion Systems AccomplishmentsAdvancing Oxy-fuel Technologies from Lab through Pilot-Scale Testing

NETL-ORD CLC Reactor

Alstom 5-MWe Oxy-Combustion Pilot

Alstom 1-MWe CLC Pilot OSU CDLC 25-kWth

Reactor

Jupiter Oxygen 5-MWe

Oxy-Combustion Pilot

B&W 30-MWth Oxy-Combustion Burner

Testing

Oxy-combustion Chemical Looping Combustion

Completed Pilot-Scale Testing

“Advanced” Ultra Supercritical Power Plant Operating up to 5,000 psi and 1,400 °F (760 °C)

• Advanced Ultra Supercritical (AUSC) DOE goal for higher efficiency and much lower emissions, materials capable of:

– 1400 °F (760 °C)

– 5,000 psi (35 MPa)

– Oxygen firing

• Plant efficiency can be improved to 44% (HHV) at AUSC conditions

• CO2 Emissions reductions up to 15%

• Higher Efficiency means burning less coal and treating less flue gas for the same net plant output yielding lower balance of plant cost

• Meeting these targets requires:

– Novel uses of existing materials

– Adaptation of existing materials or use of new materials

• Component testing of materials

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Advanced Ultrasupercritical Materials Development Nickel based alloys that can perform up to 1400 deg F and up to 5500 psi steam pressure

Laboratory

TRL 2 to 3

2000 2005 2010 2015

Materials Development

Component Mockup

Steam Loop at Plant Barry

Proof of

Concept TRL 4

Component Test

TRL 4 to 5

Current R&D efforts bring components to TRL 5

Click to add references

Demonstrated ability to fabricate and weld nickel based super alloys

Long term creep testing (>50,000 hrsduration) of Inconel 740H to ensure confidence in life predictions to 300,000 hrs

ASME Boiler and Pressure Piping Code approval of Inconel 740H

Development of casting and forging techniques at large scale of Haynes 282 and other nickel super alloys

Weld repair procedure and testing protocol for Haynes 282 castings

Accomplishments

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Crosscutting Research: Innovative ConceptsOpportunities for the Future

Target Concepts and Research:

-That removes barriers to applying new technologies

- Has opportunity to transform a system

- Introduces step change improvements in a process

- Reduces cost associated with emerging technologies

- Removes/reduces environmental impacts

Nano materials

Advanced Manufacturing

Direct Power Extraction (DPE) Power Generation

Virtual and Immersive

Engineering

Thermal and Power Cycle

Improvements

Water Use/ Reuse Novel Cooling & Heat Transfer

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Future will Need: Integrated Solutions to Meet Goals

Crosscutting ResearchCO2 Storage

Advanced CO2 CaptureAdvanced Energy Systems

• Materials• Sensors/Controls• Computational Tools• Water Management• Novel Concepts

(DPE, REE)

• Combustion (oxy, PGC)• Gasification• Turbines• Fuel Cells• Chemical Looping• SCO2 Power Cycles

• COE reduced 20–30%• CO2 capture cost reduced from

$60 to <$40/tonne• Near-zero GHGs • Near-zero criteria pollutants• Minimal water usage

• Solvents• Sorbents• Membranes• Hybrids• Cryogenic Capture• CO2 Compression• Process Improvements

• Geologic Characterization

• Risk Assessment• Injection Tests• MVA• CO2 Use (e.g., EOR)

Improvements in Cost and Efficiency Neededfor both Base Power Plant and Carbon Capture System

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Future will need: Collaborations & PartnershipsKey to Past Successes and Needed for Innovative Solutions

Government

Industry Social Responsibilities

Academia

The Future of Clean Coal Technologies

It is looking bright…it has to be!

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It’s All About a Clean, Affordable Energy Future

For More Information, Contact NETL

the ENERGY labDelivering Yesterday and Preparing for Tomorrow


WWW.NETL.DOE.GOV

VCEA 36th Annual Conference 2015: The Future of …...MGSC SECARB MRCSP National Energy Technology...

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