text: The Future of Coal-Based Power Generation With CCS UN CCS Summit James Katzer MIT Energy Initiative web.mit.edu/coal/ - PDF
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  1 The Future of Coal-Based Power Generation With CCS UN CCS Summit James Katzer MIT Energy Initiative web.mit.edu/coal/ 1
  2 Times Are Changing As Yogi Berra said: The Future Ain t What It Used to Be 2
  3 Overview Coal-Based Electricity Generating Technologies Without and with CO 2 capture Criteria emissions performance today and future potential Cost and performance impacts CO 2 Transport and Sequestration Conclusions A Forward View Coal is and will remain, by necessity, a key component in our electricity generating portfolio for the foreseeable future. 3
  4 Base Design Conditions for Generation Technologies New greenfield unit Emissions controlled to below today s best demonstrated performance Illinois # 6 high-sulfur bituminous coal Used Carnegie-Mellon model for consistent design comparisons Costs based on 2000 to 2004 detailed design costs; indexed to 2007 $ with process construction cost index Integrated existing commercial technology Single-condition indicative cost comparisons done; coal type, site, location, etc. will affect cost numbers Important issue is comparison among technologies w/o and w CO 4 2 capture
  5 Advanced PC Power Plant 5
  6 The New Generation of Power Plants Neideraussem Lignite-fired Power Plant, 965 MWe (net), 43.3% (HHV) 6
  7 PC Power Plant Schematic Stack Gas T = 55 C Air Coal Combustion Block Flue Gas T=149 C O 2 = 5% Flue Gas Treatment CO 2 = 11% Steam Steam Cycle Block 500 MW 7
  8 PC Thermal Efficiencies Sub-Critical Unit Operation to 1025 o F and 3200 psi 33 to 37 % (HHV) Supercritical Unit Typical operation 1050 o F and 3530 psi 37 to 42 % (HHV) Ultra-Supercritical Unit Typical o F and 4650 psi 42 to 45 % (HHV) 8
  9 PC Plant with Amine-Based CO 2 Capture Stack Gas Air Coal Combustion Block Flue Gas T=149 C Upgraded FGD 11% CO 2 CO 2 Capture Steam Let-down turbine LP steam CO 2 Compression CO 2 Steam Cycle Block Generating efficiency is 29.3% for new supercritical plant with CO 2 -capture; down from 38.5 % for supercritical no-capture plant; a 9.2 percentage point drop. To maintain constant electrical output requires 32% increase in coal consumption 500 MWe 9
  10 Oxygen-Driven Power Generation Issue: Low flue-gas CO 2 concentration due to high nitrogen dilution causes large impact of capture Solution: Substitute oxygen for air eliminating the nitrogen dilution, compress flue gas directly [Oxy-fuel PC combustion] Solution: Gasify the coal and remove the CO 2 at high pressure [IGCC] 10
  11 Oxy-Fuel PC Generation/Capture Air O 2 Air Separation Unit N 2 Gas Recycle Gas Gas Stack Gas Coal Block Combustion Block Gas Flue Gas ESP & FGD CO 2 2 Purification/ Compression Supercritical CO 2 to Sequestration Steam Steam Cycle Block kw 500 MWe Of interest only for CO 2 capture for sequestration Addresses the issue of high energy costs for capture and recovery Requires air separation unit and associated energy usage 11
  12 Oxy-Fuel PC Generation/Capture Current Status Active pilot-scale development Vattenfall planned new 30 MW th CO 2 -free coal steam plant with 2008 start-up in Germany Hamilton, Ohio planning 25 MW e 1963 power boiler retrofit, 2009 start-up Oxy-Fuel PC shows potential of lower COE and lower CO 2 avoided cost than other PC capture technologies 12
  13 IGCC Plant Power Block Cryogenic Oxygen Syngas 7FA Combustion Turbine Water Steam Mercury Removal Air Steam Steam Turbine HRSG Stack Electricity Coal Quench Gasifier Particulate Removal Sulfur Removal Pure Sulfur Slag/Fines Solids GJS/CE-01/ Gasifier type is biggest variable: Texaco & E Gas: slurry feed & higher pressure, ~39% efficiency potential Shell: dry feed and lower pressure, more costly, ~41% efficiency potential 13
  14 IGCC without and with CO 2 Capture W/O CO 2 Capture Coal Sulfur Air ASU O 2 Gasifier Gas Clean Up CC Power Block POWER Slag With CO 2 Capture Coal Sulfur CO 2 Air ASU O 2 Gasifier Shift Gas Clean Up CC Power Block POWER Slag H 2 The Shift reaction converts CO to CO 2 & hydrogen; the CO 2 is then removed. 14
  15 Performance and Costs of Generating Technologies Subcritical PC Supercritical PC Oxy-Fuel PC IGCC w/o capture w/ capture w/o capture w/ capture w/capture w/o capture w/capture PERFORMANCE Heat Rate, Btu/kWe-h 9,950 13,600 8,870 11,700 11,200 8,890 10,900 Efficiency (HHV) 34.3% 25.1% 38.5% 29.3% 30.6% 38.4% 31.2% CO 2 emitted, g/kwe-h COSTS Total Plant Cost, $/kwe $1,580 $2,760 $1,650 $2,650 $2,350 $1,770 $2,340 Cost of Electricity Inv. Charge, 15.1% Fuel, $1.50/MMBtu O&M, /kwe-h COE, /kwe-h Cost of CO 2 avoided vs. same technology w/o capture, $/tonne Basis: 500 MWe plant. Illinois # 6 coal, 85% capacity factor, COE at bus bar. Based on design studies between 2000 and 2004, a period of cost stability, indexed to 2007 $ using construction cost index. 15
  16 Emissions Performance Technology Case Particulates SO 2 NO x Mercury PC Plant lb/mm Btu lb/mm Btu lb/mm Btu % removed Typical Best Commercial (99.5%) 0.04 (99+%) 0.03 (90+%) 90 Design w CO2 Cap (99.5+%) (99.99%) 0.03 (95+%) IGCC Plant Best Commercial (99.8%) Design w CO2 Cap (99.9%) 0.01 >95 PC emissions control technology continues to improve; further, emissions reductions potential exists. Design case with CO 2 capture from recent EPRI evaluation. IGCC emissions performance (best commercial) is well below current requirements and can be further improved; should be similar to NGCC 16
  17 Incremental Costs of Advanced PC Emissions Control Vs. No-Control Capital Cost* [$/kw e ] O&M [ /kw e -h] COE** [ /kw e -h] PM control NO x SO Incremental *** control cost * Incremental capital costs are for a new-build plant ** Incremental COE impact for Illinois #6 coal with 99.3 % PM reduction, 99.4% SOx reduction, and >90 % NOx reduction. *** When this is added to the no-control COE for SC PC, the total COE is 5.5 /kw e -h. Note: To reduce emissions by a factor of two further would increase the cost by about an additional 0.25 /kw e -h. Today s high levels of emissions control increase the cost of electricity by ~1 /kw e -h out of about 5.5 /kw e -h or about 20 %. 17
  18 Carbon Capture and Sequestration (CCS) 18
  19 Location of Saline Aquifers, Oil and Gas Fields, and Coal Plants 19
  20 A Potential CCS Power Plant Project From Battelle GTSP Report 20
  21 CO 2 Capture Through Sequestration* Technology PC IGCC CCS Step /kw e -h /kw e -h Capture Compression Transport Injection Totals There are no apparent technical or economic show-stoppers to CCS today. Bus Bar COE increase in about 50%. * Costs are estimates for existing CCS technology with Illinois #6 Coal; they will vary with coal type, with generating technology, with site and with reservoir properties. Here, they are meant to be indicative of relative magnitude. 21
  22 The Future of Coal Although the COE for IGCC is lower for Bituminous coal, differences narrow for lower rank coals and at elevation; cost improvements for PC could further narrow the gap. Also, Oxy-fuel PC looks competitive. It is too early to pick winners for coal-based power generation with capture. Emissions from coal-based power generation can be very low; and with CO 2 capture, even lower, to the extent of really being very clean. With CO 2 capture and sequestration, coal can provide electricity at a cost competitive with wind and nuclear. Thus, coal would appear to continue to be an economic choice for baseload generation of very low emissions electricity, including low CO 2 emissions. 22
  23 CCS Findings and Observations Technologies for CO 2 capture with generation are all commercial, but will benefit from operation at scale to improve cost/performance Current information indicates that it is technically feasible to safely store large quantities of CO 2 in saline aquifers, and the storage capacity of such aquifers is very large. However, there are issues that require resolution Broad range of regulatory issues require resolution (permitting, liability, monitoring, ownership, ) Need to gain political and public confidence in the safety and efficacy of geologic sequestration 23
  24 CCS A Way Forward MIT Coal Report Recommendations Solid technical program to resolve scientific & technical issues associated with injection & storage of Gt quantities of CO 2 /yr In the U.S., 3 to 5 large-scale CCS demonstration projects of 1 million tonnes CO 2 per year, using different generation technologies, focusing on different geologies, and operated for several years to resolve outstanding technical, scientific, liability, policy, and regulatory issues Effectively demonstrate dynamic operation of fully-integrated infrastructure systems including coal conversion, CO 2 capture, CO 2 transport, and CO 2 injection in a continuously operating manner over extended time periods. This research and demonstration program is needed to develop the required information in a timely manner so that we have robust technology options available to apply when society decides to manage CO 2 emissions from power generation and other major stationary sources. 24
  Review of EPA Works Approval Application from Dual Gas Pty Ltd
  EXPERT S REPORT Review of EPA Works Approval Application from Dual Gas Pty Ltd Reviewer Malcolm McIntosh Qualifications BE (Mech) Hons Melbourne University BSc Melbourne University Diploma Mechanical Engineering