coal fleet overview 2010

CoalFleet for Tomorrow® 2010 Program

December 2009

Dr. Jeff Phillips ([email protected]) Sr. Program ManagerAdvanced Generation

mailto:[email protected]

2© 2007 Electric Power Research Institute, Inc. All rights reserved.

Outline

• Introduction

• Project Set Focus and Deliverables

– 66A

– 66B

– 66C

• 2010 Supplemental Project Opportunities

• Your Feedback


EPRI’s CoalFleet forTomorrow Program

• Build an industry-led program toaccelerate the deployment ofadvanced coal-based power plants;members now span six continents

• Employ “learning by doing” approach; generalize actual deployment projects (50 & 60 Hz) to create design guides

• Augment ongoing RD&D to speed marketintroduction of improved designs and materials

• Deliver benefits of standardization to IGCC (integration gasification combined cycle), USC PC (ultra-supercritical pulverized-coal), and Oxy-combustion (in PCs and circulating fluidized beds)– Lower costs, especially with CO2 capture– High reliability and efficiency– Near-zero SOX, NOX, and PM emissions– Shorter project schedule– Easier financing and insuring

Further information availableat www.epri.com/coalfleet


2009 CoalFleet Participants Span 6 Continents

Air Products & Chemicals Alliant Energy Corp. American Electric Power Arch Coal Babcock & Wilcox Company Bechtel Corp. Buckeye Power California Energy Commission CPS Energy Doosan Heavy Industries and Construction Duke Energy Corp. Dynegy EDF Electricite de France Edison International Entergy ESKOM E.ON US Exelon Corp. GE Energy Global Carbon Capture & Storage Institute Great Plains Energy Services, Inc. Great River Energy

Hoosier Energy Rural Electric Coop., Inc. Iberdrola KBR Luminant Minnesota Power Oglethorpe Power Pratt & Whitney Rocketdyne Praxair Rio Tinto Salt River Project Siemens Southern California Edison Southern Company Stanwell Corporation TransAlta Energy Corp. Tri-State G&T Union Fenosa U.S. Dept of Energy (NETL) 8 additional US Power Companies 7 additional Int’l Power Companies 1 additional Technology Supplier


All Stakeholders at the same table in CoalFleet

GENERATORSTechnology/Fuel Users

SUPPLIERS/OEMsTechnology Developers/Suppliers

EPCs/ENGINEERSPlant Designers/Integrators

CONSTRUCTORSPlant Construction

COAL/RAIL COMPANIESCoal Suppliers

GovernmentRD&D/Incentives


CoalFleet Project Structure

• Project Set 66A

• Engineering – Economic Evaluations of Coal Power Generation

• Comparative Economics

• Analysis of Fuel Markets

• Surveillance of Technology Developments and Government Incentives

• Project Set 66B

• IGCCs & Polygeneration Design Guidelines

• Technology watch

• Pre-combustion capture

• Sponsorship of US Dept of Energy’s National Carbon Capture Center

• Project Set 66C

• Advanced PC Design Guidelines

• Ultra-Supercritical Boilers & Steam Turbines

• Post-Combustion CO2 Capture Integration

• Oxy-Combustion

You can join one, two or all three project sets. There is a discount if you join all three.


CoalFleet Staff

Jeff Phillips

George Booras

66ANeville Holt

66B

John Wheeldon

66C

Rob Steele Adele Fowler Paul Huntzinger Andy Maxson Dave Thimsen

Des Dillon

Jack Parkes

Ron Schoff

Jose Marasigan


Project Set 66AEngineering and Economic Evaluations and Market

Assessments of Advanced Coal Power Options


Focus & Goals of PS66A

• Provide timely and trustworthy engineering and economic information on advanced coal technologies to support generators’ decision-making processes

• Provide unbiased assessment of the capabilities of advanced coal technologies

• Provide up-to-date information on the development status of advanced coal technologies

• Arrange site tours featuring advanced coal generation technology developments

• Provide concise summaries of legislative initiatives as well as policy implementation actions

• Dig beyond the business page headlines to understand the technical and regulatory drivers of fuel prices

Engineering and Economic Evaluations & Market Assessmentsof Advanced Coal Power Generation Options


2010 PS 66A Deliverables Planned

• Operating Experience, Risk, and Market Assessment of Advanced Clean Coal Technologies – Tech Update

• Engineering & Economic Evaluations (“EEE”) of Advanced Coal Power Plants Tech Update

• Continue Knowledge Base A updates• Compliance Strategies in Response to Potential/New US CCS Legislation

• CoalFleet Outreach Communications Initiative• 3 Technical Meetings and Technology tours

– 2 in US, one outside US– Seeking suggestions for tour locations


EPRI PC and IGCC Cost of Electricity with and without CO2 Capture (Illinois #6 Coal)(All IGCC and CCS cases have +10% TPC contingency for 1st of a kind)EPRI 600 MW (net) PC and IGCC Cost of Electricity

With and Without CO2 Capture (Illinois #6 Coal)

40

60

80

100

120

140

160

SupercriticalPC

GE RadiantQuench

GE TotalQuench

Shell GasQuench

E-Gas FSQ

30-Y

r le

veli

zed

CO

E,

$/M

Wh

(C

on

stan

t 20

07$)

.

No Capture

Retrofit Capture

New Capture

COE Includes $10/tonne for CO2 Transportation and Sequestration

$100+/MWhr is the bottom line for new coal with CCS unless technology is improved


Operating Experience, Risk, and Market Assessment of Clean Coal Technologies Report

• Covers PC, Fluidized Bed and IGCC projects and technology improvements

– Also addresses the challenges new coal projects are facing


Knowledge Base A(Technology Characterization and Economics)

PurposeServe as a reference for in-house generation planning studies

Content• Topic pages on:

– Design studies (includes performance and cost estimates of various advanced coal technologies conducted by power generators, EPRI, DOE, and other public entities)

– Technology characterization (includes relevant EPRI testimony to U.S. Congress)

– Carbon Capture and Storage (contains links to presentations, studies, reports, and organizations covering CCS)

– Useful Links (e.g., to sites that monitor domestic fuel and electricity prices and emissions as well as sites of research organizations, advocacy groups, and commissions active in clean coal technology)

• Program and Technical Meeting presentations


New Focus Areas for PS66A in 2010

• National Carbon Capture Center Annual Report

– This report will be available to funders of any P66 project set

– Will summarize the results and analyze the potential impact of the pre-combustion and oxy-combustion technologies tested at the DoE’s National Carbon Capture Center in Wilsonville, Alabama

• Lifecycle CO2 Footprint Analysis

– Will work with the IEA’s Greenhouse Gas Programme to identify a more complete picture of the greenhouse gas emissions associated with different power generation options


Project Set 66BGasification-Based Power Plant Development

and Deployment Support


Project Set 66B—Encouraging Deployment of Gasification-Based Coal Power Plants

Goals of PS66B Deliverables• Faster Learning Curve by Providing Independent

Technical Expertise to Early Deployment Projects

• Lower Costs and Lower Risks Through Standard Designs and Permitting Guidelines

• Lower Cost-of-Electricity through Improved Technology


PS66B Funders Currently Advancing IGCC Projects

• Duke Energy (Edwardsport, IN)

• BP and Rio Tinto (Hydrogen Energy’s Kern County, CA)

• Southern Co (Kemper County, MS)

• Stanwell (Queensland’s Wandoan project)

• SCE (Utah)

• Doosan (Korea)

• Eskom (RSA, based on underground coal gasification)


Knowledge Base B(IGCC)

Purpose

Serve as a reference for generation planning studies and in-house IGCC plant feasibility studies

Content

• Data from operating IGCC plants• Design data on large gasification

units worldwide• List and details (e.g., EIS, FEED

and permit application) of proposed and in-progress gasification projects

• Link to IGCC permits database• IGCC feasibility studies

• Bibliography of IGCC literature• IGCC education (contains primer

and links to CoalFleet IGCC 101 and 102 recorded webcasts and presentations)

• Useful industry Web links• Program and technical meeting

presentations


User Design Basis Specification (UDBS)—2009 and 2010

• Defines power company technical requirements for a site-specific IGCC plant; supplier alliances to propose plants that meet the UDBS

• One update in 2009 and one in 2010

• Areas of focus for updates include:– Operations and Maintenance

• Including CO2 Capture venting issues

– Add Uhde’s Prenflo gasification process

– Incorporation of “IGCC cases studies” results in UDBS

– Development of on-line UDBS in Knowledge Base B• Allows for more frequent updates as new content becomes

available


IGCC Permitting—2009 and 2010

• 2009

– Permits Database – continuous updates of on-line version

– Downloadable database in PDF format issued in April

• 2010

– Continue to update on-line version of database


IGCC Engineering & Economic Evaluations2009–10 Study Content

• 50 Hz F-Frame Gas Turbine Cases

– Northeast The Netherlands Site• Coal Type

– Eastern Australian export coal• Gasification Technologies

– General Electric, Siemens, Shell, Prenflo PDQ, Mitsubishi Heavy Industries

• Greenfield Carbon Capture and Storage

• Sensitivity Analyses

– G-Frame GT, Cost Estimates for CO2 Liquefaction and HP Gasification cases

• 2008-09 Capital Costs Revisited


New Area of Focus in 2010 for PS66B

• Advanced concepts for pre-combustion CO2 capture

– Will survey developing technologies to identify promising advancements which could improve the economics of pre-combustion CO2 capture

– Survey will also feed into the work EPRI is sponsoring at the NCCC


Project Set 66CCombustion-Based Power Plant Development

and Deployment Support


Project Set 66C Objectives

• Qualification of stronger, more corrosion-resistant materials to allow boilers and steam turbines to operate at higher, more efficient temperatures

• Design guidelines and on-line information libraries that provide the latest design and performance information for advanced boilers and steam turbines, environmental controls, and CO2 capture technologies integrated with the power plant

• Engineering and economic evaluation of advanced power plant designs and CO2 capture technologies, including post-combustion and oxy-combustion options

• Marshalling industry support for large-scale demonstrations to accelerate commercialization of advanced technologies

Promote development and demonstration of cost-effective coal-fired power plants with increased generating efficiency, near-zero emissions of criteria pollutants, and fully integrated CO2 capture and storage


DOE’s USC Boiler Materials Program

• Aimed at proving the materials that will be required to achieve a thermal efficiency of 47% (HHV) without CO2 capture

• No show-stoppers: Confident of 1350°F (730°C) main steam and 1400°F (760°C) reheat


Maximum Usage Temperature

1000

1200

1400

1600

3000 4000 5000 6000

Max

imu

m M

idw

all T

emp

erat

ure

- F

T22

T91 T92304H

Super 304H

Haynes 230

IN 617

IN 740

T23

HR3C

3000 4000 5000 6000

Pressure, psig


DOE’s USC Steam Turbine Materials Program

• Completed simulation of heat transfer of large IP rotor forging and evaluated cracking susceptibility for various ingot cooling rates

• Creep and low-cycle fatigue tests in various stages of completion for 19 candidate alloys selected by GE for non-welded rotor application

• Thermo-gravimetric oxidation studies completed on several rotor alloys and parabolic rate constants determined

• Successful welding trials for a welded rotor materials identified by ALSTOM and Siemens

• Casing candidate materials selected by Siemens and casing design complete


Advanced PC Guidelines - 2010

• Design and performance information for cost-effective advanced coal-fired power plants with near-zero emissions (NZE) , and integrated with the CO2 capture plant

• Two updates published in 2009, one update for 2010– Designing for availability

– Effective waste heat utilization and cooling systems

– Continuous emissions monitoring systems

• Re-organized report into “tree” structure to improve ease of access– General design information, heat rate improvements including

advanced steam conditions, environmental controls for NZE, and CO2 Capture

• Keeping sections at readable length and using Knowledge Base C to house supporting information


Evaluation of Post-Combustion CO2 Capture

• Nexant, supported by Bechtel Power Corporation and MHI, is conducting engineering and economic study of amine-based post-combustion CO2 capture plants integrated with 750-MW 1100°F (595°C) USC PC plant

• Phase 1 completed in 2008, based on PRB coal and MEA

– USC PC design completed: 0.03 lb/MBtu (~30 mg/Nm3) for NOX and SO2, 90 percent mercury capture, design heat rate 8890 Btu/kWh (9380 GJ/kWh), 38.4 percent efficient (HHV basis)

– Measures to improve economics of CO2 capture plant evaluated using MEA, because its physical and chemical properties know

• MHI’s KS-1 solvent will be evaluated in Phase 2 – results published later this year


New Focus Area for 66C in 2010

• Water Conservation Issues– Voted a top priority by members at March 2009

Advisors meeting– Will identify and assess the capital and operating costs

of emerging techniques designed specifically to lower the water consumption of coal-fired power plants

• CO2 Capture Retrofits– Will examine the technical issues involved in retrofitting

advanced amine-based post-combustion CO2 capture systems into existing coal power plants.

– Will build upon insights gained from on-going supplemental study of retrofitting 5 plants in North America


1/1/10 3/31/10 6/30/10 9/30/10 12/31/10Projects:

1. Advanced Coal Technologies Knowledge Base; Assessment of Economics, Experience, and Markets

2010 Program Plan: CoalFleet Project Set 66A—Engineering and Economic Evaluations and Market Assessments of Advanced Coal Generation Options

Tech Update1.1 Operating Experience, Risk, and Market Assessment of Advanced Coal Technologies w/ CCS

Key: Milestone

Deliverable

1.3 EPRIweb Advanced Coal Technologies Knowledge Base “A” (Technology Comparisons)

2. Analysis of Advanced Coal Plant Deployment Options and Government Initiatives for CCS Demonstrations

2.1 CoalFleet Outreach Communications Initiative

“What’s New” presentations at CoalFleet technical meeting (typ) (continuous updates)

1.2 Engineering/Economic Evaluations of Advanced Coal Technologies w/ CCS

Tech Update

3. Analysis of Fuel Markets and Capacity Requirements

1.4 CO2 Footprint Lifecycle AnalysisTech Update

Tech Resource

1.5 Engineering/Economic Evaluations of CCS Retrofits (Summary of Supplemental Project)

Tech Update (Final)

Tech Update2.2 Compliance Strategies in Response to Potential/New U.S. CCS Legislation

3.1 Global Power and Fuel Sector DevelopmentTech Update(Joint with P67)

© 2009 Electric Power Research Institute, Inc. All rights reserved.

Progress update at CoalFleet technical meeting (typ)

4. National Carbon Capture Center (NCCC)

Tech Update

6.1 NCCC Annual Report – Pre-Combustion and Oxy-Combustion Capture Activities***

***This report will be available to funders of any P66 project set


1/1/10 3/31/10 6/30/10 9/30/10 12/31/10Projects:

1. Coal Gasification Technology Status—Annual Update

4. Permitting Support for IGCC Power Plants

2010 Program Plan: CoalFleet Project 66B—Gasification-Based Power Plant Development and Deployment Support (IGCC)

Tech Update

Key: Milestone

Deliverable

2. Support for IGCC Early Deployment Projects

1.1 Coal Gasification Technology Status

3. Plant Design Guidelines for IGCC

2.1 CoalFleet Advanced Coal Development Consulting for Members’ IGCC Projects

3.2 IGCC User Design Basis Specification

4.1 CoalFleet IGCC Permitting Database

5. Advanced IGCC Improvements and Next-Generation Designs with CO2 Capture and Hydrogen Coproduction

5.1 EEE “Phase II” Case Studies for IGCC Plants with CCS Tech Update (Final)

Version 10

Presentations by utility reps at CoalFleet technical meeting (typ)

On-line database accessed through

Knowledge Base “B”

3.1 EPRIweb Advanced Coal Technologies Knowledge Base “B” (IGCC)

(continuous updates)


6. National Carbon Capture Center (NCCC)

Interpretive presentations at CoalFleet technical

meeting (typ)

Tech Update

“What’s New” presentations at CoalFleet technical meeting (typ)


6.1 NCCC Annual Report – Pre-Combustion and Oxy-Combustion Capture Activities

Tech Resource

3.3 IGCC Generic Design Specification

5.2 Advanced Concepts for Pre-Combustion CO2 Capture

Tech Resource

#4, Tech Update

Tech Update


1/1/10 3/31/10 6/30/10 9/30/10 12/31/10

Projects:

1. Plant Design Guidelines and Near-Zero Emission Designs for USC PC Plants

2010 Program Plan: CoalFleet Project 66C—Combustion-Based Power Plant Development and Deployment Support (PC and CFBC) Key: Milestone

Deliverable

4. Advanced PC and CFBC Project Development Guidance

Tech Update *

1.1 Advanced Coal Technologies Knowledge Base “C” (Advanced Combustion)

5.1 Technical Progress Report on Turbine Materials Development for USC Plants

5.2 Technical Progress Report on Boiler Materials Development for USC Plants


1.2 Guideline for Advanced PC Plants

5. Design and Materials Development for Post-Ferritic (1200°F–1400°F) Ultra-Supercritical PC Plants


Progress update at CoalFleet technical meeting (typ)

Version 7

1.3 Commercial Readiness of UltraGen II Tech Update

Tech Update *Progress update at CoalFleet

technical meeting (typ)

“What’s New” presentations at CoalFleet technical meeting (typ)

* Pending DOE approval to publish; historically, this has sometimes led to modest publication delays

Presentations by utility reps at CoalFleet technical meeting (typ)

1.5 Assessment of Heat Rate Improvement Measures

Tech Resource

1.4 Current Status of CFBC Technology Tech Update

4.1 CoalFleet Advanced Coal Project Development Consulting for Members’ PC/CFBC Projects

2. Integration of Post-Combustion CO2 Capture Technologies with Advanced PC & CFBC Plants 2.1 Integrating CO2 Capture Technologies into New PC and CFBC Plants—Alternative Process

Tech Update

Tech Update2.2 Retrofit of CO2 Post-Combustion Technology to the Existing Fleet

3. Evaluation of Oxy-Combustion for Advanced PC and CFBC Plants Tech Update3.1 Oxy-Combustion Developments, Pilot Operating Experience, and Designs for PC and CFB Plants

Tech Update

1.6 Review of Water Conservation MeasuresTech Update


2010 Supplemental Projects


Gasification Users Association

• EPRI’s GUA is an organization of users and potential users of gasification technology. Its purpose is to create a networking organization to exchange information of a non-confidential nature on the practice and operation of gasification and its associated technologies.

• Membership in the GUA is not included in PS66B (or all P66) membership

• Meets twice a year– Once in US after Gasification Technologies Conference

– Once overseas in conjunction with a gasification-related technical conference


Other Supplemental Projects

• Detailed technical support for advanced coal power project development

• EPRI is seeking development partners for the liquid CO2 coal slurry concept and laser-based syngas composition and temperature sensor that have been nurtured with Technology Innovation funds to date

– Outside sponsors needed for next step in development of these technologies


Your feedback


What do you want to see as R&D?

• EPRI wants to make sure you are getting what you need as a funder of our work

– What would you like to see in CoalFleet?

– How can we support you as a participant in CoalFleet?


Together…Shaping the Future of Electricity

coal fleet overview 2010

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