vcea 36th annual conference 2015: the future of …...mgsc secarb mrcsp national energy technology...
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BIG SKY
WESTCARB
SWP
PCOR
MGSC
SECARB
MRCSP
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
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3National Energy Technology Laboratory
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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5National Energy Technology Laboratory
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
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
12National Energy Technology Laboratory
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
13National Energy Technology Laboratory
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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16National Energy Technology Laboratory
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!
21National Energy Technology Laboratory
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
BIG SKYBIG SKY
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PCORPCOR
MGSCMGSC
SECARBSECARB
MRCSPMRCSP
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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23National Energy Technology Laboratory
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
24National Energy Technology Laboratory
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
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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
28National Energy Technology Laboratory
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
“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
3535National Energy Technology Laboratory
WWW.NETL.DOE.GOV