demonstration of the allam cycle: an …...demonstration of the allam cycle: an update on the...

DEMONSTRATION OF THE ALLAM CYCLE: AN UPDATE ON THE DEVELOPMENT STATUS OF A HIGH EFFICIENCY SUPERCRITICAL CARBON DIOXIDE POWER PROCESS EMPLOYING FULL CARBON CAPTURE

APRIL 2017 The information in this material contains intellectual property of 8 Rivers Capital, LLC and its affiliates. 1

UKCCSRC BIANNUAL IMPERIAL COLLEGE11-12 April 2017

creating tomorrow’s infrastructure...

Flow Diagram of the Natural Gas Allam Cycle


59% (LHV) net efficiency, with capture of >97% of carbon

200-400 bar; 6-12 pressure ratio

CO2 and water are the only byproducts

All components, other than combustor and turbine, currently available

740H now in commercial use at two facilities

Combustor and turbine developed by Toshiba

Overview of the Allam Cycle

• Oxy-combustion of natural gas with O2/CO2 mixture; adiabatic temp approaching 2000oC (K)

• 300 bar and 1150oC at the turbine inlet after mixing of combustion exhaust gas with pre-heated recycle CO2 (A)

• 720oC turbine exhaust preheats 300 bar Recycle CO2 (B-C)

• Separation of condensed water followed by CO2 compressionand pumping (C-I)

• 20% of the total heat input is derived from the ASU and CO2

Recycle Compressor heat of compression which assists in heating recycle CO2 (I-J)

• Pure CO2 product produced between 30 bar and 300 bar.


A. Turbine Inlet

B. Turbine Outlet

C. Cold End HX

D. Cooling to Ambient

E. Compression

F. Intercooling

G. Compression

H. Compressor Aftercooler

I. Supercritical Pumping

J. Low Temp. Recuperation

K. High Temp. Recuperation

1150 oC300 bar

720 oC30 bar

RECUPERATION

Primary Benefits of the Allam Cycle


1. Produces electricity from fossil fuels at a cost that is competitive with, or lower than, electricity from conventional systems while eliminating CO2 emissions

• High efficiency, with carbon capture

• Natural gas: ~59% (LHV)• Coal: ~50% (LHV), dependent on feedstock• Inclusive of all equipment/processes including ASU and production of pipeline pressure CO₂.

• Capital costs targeted to be on par with combined cycle, lower than IGCC and SCPC

• $900-1200/kW for natural gas• $1500 to $2000/ Kw depending on site and existing facilities

• No air emissions

• Near-100% capture of CO₂ at high purity and pressure

• No other air emissions: NOX, SOX, UHC, heavy metals

• Ability for gas cycle to operate with zero water with minor impact on efficiency

• Ability to burn raw, unprocessed gases

Since the Initial Introduction of the Allam Cycle at GHGT-11…



2014 Layout

Since the Initial Introduction of the Allam Cycle at GHGT-11…

Since the Initial Introduction of the Allam Cycle at GHGT-11…• NET Power, LLC was established to develop the natural gas version of the Allam Cycle, owned by 8

Rivers, Exelon, and CB&I. Toshiba is developing the first-of-a-kind turbine for the plant.

• NET Power has begun commissioning a 50 MWth demonstration plant in La Porte, Texas this December 2016 with first-fire planned Summer 2017.


Site as of October 17, 2016

Technical Development of the NET Power Demonstration Plant

• CB&I has led detailed design, procurement and construction.

• Exelon will operate the facility.

• 8 Rivers has provided the proprietary process design, dynamic simulation, and control philosophy with ongoing development.

• Toshiba has developed the novel turbine and combustor.

• The demonstration main process heat exchanger is supplied by Heatric.

• Oxygen is supplied via pipeline from an adjacent Air Liquide ASU.


The Toshiba Turbine and Combustor

APRIL 2017The information in this material contains intellectual property of 8 Rivers Capital,

LLC and its affiliates. 9

Toshiba announced

shipment of the 25MWe

turbine to the world’s first

direct-fired supercritical oxy-

combustion CO₂ power

cycle on November 1, 2016

The Toshiba Turbine and Combustor (cont.)

• Fusion of a USC steam turbine (double casing design) with the design of gas turbine (cooled and coated blades). The inner casing is internally cooled.

• NG and oxidant mixture of 20% O2 & 80% CO2 is mixed with 700oC recycle CO2 to provide a turbine inlet temperature of 1150oC at 300 bar

• 5MW combustor test with 700oC oxidant flow confirmed calculated performance. Diffusion flame, no premixing gives stable combustion conditions.

• 200MWth turbine unit scaled to 50MWth by partial arc admission to the turbine blades, minimizing risk for the commercial-scale turbine

• The use of pure O2 means very low NOX formation. Trace NOX will be formed from fuel-derived N2 in the natural gas.


Left: Test stand for a 5

MWth combustor

operating at 300bar

Below: Rotor and Outer

Casing of Demonstration

Turbine (Courtesy:

Toshiba)

Main Process Heat Exchanger

• The demonstration Printed Circuit Heat Exchanger has been supplied by Heatric

• Large SA/V allows for high P & T operation with tight approach.

• Stacks of 1.6mm thick plates are photo masked then chemically etched to produce complex passage arrangements

• The plates are diffusion bonded at high T to form a homogeneous monolithic block.

• The main recuperator operates over a range from 50oC to 705oC . It has a multi-stream configuration in 4 sections

• 617 alloy for T > 550oC

• 316L alloy T < 550oC.

• The demonstration recycle compressor aftercooler is also PCHE type


Demonstration plant main process heat exchanger network (Courtesy: Heatric)

Low Temperature Section Aftercooler being lowered into position

Simulator Development and DCS Implementation

• 8 Rivers developed a fully integrated dynamic simulation with engineered sizes, weights, volumes, inventories, and control loops used in the plant.

• Produced using ASPEN Dynamics and Custom Modeller. Then integrated with Emerson’s Ovation platform.

• The model has supported:

• process optimization,

• planning of plant commissioning,

• planned plant operation,

• the refinement of diagnostic procedures

• validate, tune, and improve control

• The simulator has been used to verify and optimize start-up, shutdown, and ramping.

• Operator training has commenced.


Plant Construction and Layout

• CB&I-led construction of the NET Power demonstration plant began in Q1 2016 in La Porte, TX

• O2 at 17 bar is supplied by Air Liquide.

• The turbine drives an electric generator on one end and the CO2 recycle compressor on the other.

• The CO2 compressor acts as an over-speed brake in the event of a load disconnection.


Direct

Contact

Cooler

Main

Pumps

Turbine and

Main

CompressorMain

Compressor

Aftercooler

Demonstration Test Plan will Obtain Data Necessary for Scale-Up to Commercial Operations1. Individual system testing and commissioning

1. Safety systems

2. Control functionality using the simulator

3. Start-up of individual components (where possible)

4. Combustor testing with and without the turbine

2. Performance testing

1. Test the system up to full load to determine final performance characteristics of the combustion turbine, compressors, pumps, and heat exchangers

3. Mechanical integrity testing

1. Start-up, shutdown, ramping up and down and emergency procedures.

2. Optimization of overall system performance

3. Performance testing of all individual items of equipment.

4. Sustained operation runs


Commercialization of the Allam Cycle

Produces electricity using hydrocarbon fuels at costs that are competitive with, or lower than, current electricity costs while inherently capturing near 100% of CO2 and combustion derived

impurities at pipeline pressure and quality.

The world must continue to rely on hydrocarbon fuels to meet the major part of future power demands. Low power costs are required. This can only be sustainable with full carbon capture.

Our cycle points the way.

NET Power is currently developing the detailed design and costing for a natural gas fired 300MWe commercial plant with

planned operation in 2020


The 300MWe Commercial Natural Gas Plant is Currently in Pre-FEED Design


• A detailed pre-FEED design study is underway.

• Major equipment is in an advanced stage of readiness:

• Turbine and Combustor: The demonstration turbine size allows verification of the design for the 511 MWth commercial turbine.

• Heat Exchanger: increase in size and quantity of cores for the commercial system.

• ASU: The 3550 MT/day, 99.5% O2 ASU has been demonstrated at this size by all major suppliers.

• Compressors: The physical linkage of the CO2

compressor and turbine is within the size capability of major compressor vendors.

• Pumps: The multistage CO2 pumps are demonstrated at the design duties required.

Excellent performance at high ambient conditions: 31C Air, 289 MW net

NET Power 300 MWe Commercial Plant

Net power output 303 MW at ISO Conditions

Natural gas thermal input 511 MW

LHV Efficiency 59.30%

Oxygen consumption 3555 MT/day (contained)

CO₂ Produced 2400 MT/day at 150 bar

Turbine outlet flow 923 kg/s

Turbine inlet condition 300 bar at 1158°C

Turbine outlet condition 30 bar at 727°C (approximately)

Other Applications of the Allam Cycle

Countries which import LNG can heat the compressed LNG to pipeline temperature and liquefy the ambient temperature turbine exhaust eliminating the CO2 compressor and increasing the effective efficiency of a 1000Mw power station to about 66% (LHV basis)

Steam from a supercritical coal fired boiler at typically 300bar and 600oC can be superheated to 720oC in the recuperator heat exchanger giving a large increase in the coal power station efficiency and capturing 100% of the CO2 produced from the additional fuel required to superheat the steam plus the power produced from the Allam col power system.

CO2 captured at typically 150bar pipeline pressure can be injected into oil wells for enhanced oil recovery. Associated natural gas separated from the oil which will contain a large quantity of CO2 can be used directly as fuel for the Allam cycle power system allowing efficient capture and recycling of the CO2.

Natural gas containing say 25 mol% H2S can be used directly as fuel in the Allam cycle. The dilution of combustion gases with recycled CO2 would result in 0.86% SO2 in the turbine exhaust. Injection of a few hundred ppm of NO/NO2 derived from NH3 oxidation will remove all this SO2 as H2SO4 for conversion to gypsum.

CO2 captured can be used for enhanced coal bed CH4 production.


Applications of the Allam Cycle

APRIL 2017The information in this material contains intellectual property of 8 Rivers Capital,

LLC and its affiliates. 18

LNG Regas(67% Efficient)

Direct EOR (65% Efficient)

Solar Hybrid (74% Efficient)

Steam superheat with theAllam

cycle, from an existing coal

power station

Current-Steam, 290 bar, 600C

New-285 bar 700C to 720C

Allam Cycle for Solid Fuels (Coal)


• Lowest cost electricity from coal with inherent 100% CO₂ capture. No additional capture or compression equipment needed

• Simple water quench design

• No pre-combustion acid gas removal, all impurities are oxidized in the combustor to SOx and NOx and removed in DCC (DENS process)

• All sensible heat in the fuel gas is recovered at fuel value; directly improving efficiency.

• Process simplification significantly reduces cost vs. IGCC

Efficiency LHV HHV

Gross Turbine Output 76.3% 72.5%Coal prep & feed -0.2% -0.2%

ASU -10.2% -9.7%CO2, Syngas Comp. -9.1% -8.7%Other Auxiliaries -6.5% -6.1%

Net Efficiency 50.3% 47.8%

The Allam Cycle can be used with a range of solid fuels

while maintaining the benefits of the core cycle.

Impurity Removal in the Allam Cycle


Elimination of AGR significantly reduces capital costs, reduces operational costs and improves efficiency by 3% (HHV)

DeSNOx Process exploits well-demonstrated reactions for post-combustion impurity removal

Uniquely facilitated by Allam Cycle conditions

1. Wet sCO2 working fluid – corrosion-resistant materials already in use

2. High pressure (30 bar) – increases rate limiting reaction speed NO to NO2

3. Low Temperature (ambient) – favors NO2 production over NO

4. Available oxygen –excess oxygen required for complete combustion

5. Liquid water direct contact scrubbing to cool the 30 bar CO2

Converts SOX and NOX into

sulfuric and nitric acids

Reaction Sequence and Relative Speed

NO + ½ O₂ NO2 (1) Slow

2 NO2 N2O4 (2) Fast

2 NO2 + H2O HNO2 + HNO3 (3) Slow

3 HNO2 HNO3 + 2 NO + H₂O (4) Fast

NO2 + SO2 NO + SO3 (5) Fast

SO3 + H₂O H2SO4 (6) Fast

Market Potential of the Allam Cycle

• New power demand world-wide up to 2040 utilizing the Allam cycle would not produce sufficient CO2 to meet potential market demand for enhanced oil recovery and coal bed CH4 recovery.

• Potential direct CO2 emission taxes will be a bonus for the Allam cycle which is highly competitive with existing best technology power systems even with zero value for the CO2 produced.


8 Rivers is the world leader in sCO2 cycle development 8 Rivers has been working in-depth on supercritical CO2 power cycles since 2009

R J ALLAM invented of the Allam Cycle, a direct-fired, oxy-combustion supercritical CO2

power cycle that produces low-cost electricity from fossil fuels with near-zero emissions

Natural gas-fueled version being developed through 8 Rivers’ company NET Power

Coal-fueled version being advanced with industry/government consortium in North Dakota

With the Allam Cycle, 8 Rivers has become a leader in this field:

Major global patent portfolio developed

Built most significant commercial support for sCO2 cycle development in the world

Largest corporate consortium: major US power Cos, global engineering firms, large manufacturers

Raised most significant private funding: approximately over $350 million in equity and in-kind support

Many technical firsts:

Large-scale demonstration plant construction underway

5MWth combustion testing for oxy-fuel, sCO2 cycle conditions

Direct-fired dynamic model and simulator developed

Commercial control system developed


Conclusions

• Our cycle provides a sustainable and low cost solution for hydrocarbon fuels to achieve world objectives for stabilizing greenhouse gas emissions. It further addresses the critical issues of urban pollution and limitation of future temperature rise.

• The sequestration of produced CO2 can lead to increased oil and natural gas recovery to extend the sustainable life of hydrocarbon reserves. Inherent capture can also provide CO2 to reuse processes at low cost.

• The demonstration natural gas Allam Cycle in development by NET Power is entering the commissioning stages in La Porte, TX with first-fire planned for Summer 2017.

• A pre-FEED for the 300MWe commercial NET Power plant is underway.

• In addition, the Cycle offers ongoing integration potential with other important processes with reduced costs and zero-emissions.


APPENDIX

ADDITIONAL INFORMATION


Allam Cycle Coal development has generated large amount of support

Additional partners are being sought to join the team undertaking Phase 1 of a $5M development program with wide industry support

Program is now underway to address challenges posed by solid fuels:

1. Corrosion: additional impurities in coal present a risk to downstream equipment

• Initial Results: materials already used in the core Allam Cycle demonstrate a high corrosion tolerance under the current testcondition (pH=3.4). More aggressive static corrosion test (pH = 1.6 and lower) and dynamic corrosion test are ongoing.

2. Impurity removal: 8 Rivers has designed a process to remove impurities without the need for expensive pre-combustion AGR

• Initial Results: testing shows >90% removal of SOX and >80% removal of NOX with only a single, simple column and water, with minimum NOx and excess oxygen.

3. Gasifier selection: optimal gasifier for the Allam Cycle will be identified

• Initial Results: a list of 3 candidate systems will been identified by the end of October, 2016 for the next phase study, the team will work closely with vendors to optimize design

4. Design of syngas combustor: a system to burn low-BTU fuel in the Allam Cycle must be designed and tested

• Initial Results: a design and CFD analyses have been completed that show the system is capable of combusting a wide range of fuels. Testing will be completed in the next phase

Next phase is to build a commercial scale demonstration facility. This site could very well be in China


demonstration of the allam cycle: an …...demonstration of the allam cycle: an update on the...

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