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National Carbon Capture Center:National Carbon Capture Center:National Carbon Capture Center: National Carbon Capture Center: PostPost--Combustion FocusCombustion Focus
Project NT0000749Project NT0000749Project NT0000749Project NT0000749
Doug MaxwellDoug Maxwell2010 NETL CO2010 NETL CO22 Capture Technology MeetingCapture Technology Meeting22 p g gp g g
September 15, 2010September 15, 2010
Southern Company Facts and FiguresSouthern Company Facts and Figures
• Regulated UtilitiesAlabama PowerGeorgia Power
• >42,900 MW of capacity• Diversified sources of energy (2009 generation)
Georgia Power Gulf PowerMississippi PowerSouthern Nuclear
-57% coal -23% gas -16% nuclear -4% hydro
• Competitive PowerSouthern PowerSouthern Generation RegulatedSouthern Generation
• OtherSouthern LINC Wireless
RegulatedService Territory
Southern Telecom
“The highest rated electric utility in America by the American Customer Satisfaction Index over the past 10 years.”
National Carbon Capture CenterNational Carbon Capture CenterNew Cooperative Agreement DE-NT0000749 effective October 1, 2008 for five years through September 31, 2013 2013
National Carbon Capture Center established at Power Systems Development Facility in Wilsonville, AL
DOE/NETL Project Manager –Mike MosserMike Mosser
The National Carbon Capture CenterThe National Carbon Capture CenterManaged and Operated for DOE by Southern CompanyManaged and Operated for DOE by Southern Company
Bringing together science and innovation in technology development, Bringing together science and innovation in technology development, along with realalong with real--world testing capability, to achieve costworld testing capability, to achieve cost--effective effective
and reliable capture of carbon dioxide from coaland reliable capture of carbon dioxide from coal--based power based power pp ppgeneration.generation.
• Flexible testing at various scales• Facilities for scale-up from bench to engineering-scale• Collaboration with wide variety of participants and partners• Finding “best-in-class” technology• Accelerated path to cost-effective CO2 capture technology
All 3 j f CO2 C t • All 3 major areas of CO2 Capture: -Post Combustion -Pre-combustion -Oxy-combustion
PilotPilot--scalescale Engineering-scale-Oxy-combustion
Bench-scale
Focus of NCCC Technical ProgramFocus of NCCC Technical ProgramLab
ScaleCommercialDemonstrationComponent
ValidationPilot UnitProcess
Development Unit
zatio
n om
mer
cializ
Integrated system testing under realistic
diti
Extended lab work under realistic
conditions
ogre
ss to
Co conditions
(e.g. PSTU)(e.g. MPT, NETL FC)
Sub-system testing
Pro Sub system testing
under realistic conditions(e.g. MTR)
Technology Development Time Scale
Located at the Power Systems Development Facility Located at the Power Systems Development Facility ( S )( S )(PSDF) in Wilsonville, Alabama(PSDF) in Wilsonville, Alabama
Pre-combustion CO2 capture facility Post-combustion CO2 capture facility
Topics TodayTopics TodayTopics TodayTopics Today
Pilot Solvent Test Unit (PSTU) Process Design Pilot Solvent Test Unit (PSTU) Process Design Pilot Solvent Test Unit (PSTU) Process Design Pilot Solvent Test Unit (PSTU) Process Design and Test Planningand Test Planning
&&&&PostPost--Combustion Carbon Capture Center (PC4) Combustion Carbon Capture Center (PC4)
Construction UpdateConstruction Update
Alabama Power Plant E.C. GastonAlabama Power Plant E.C. GastonWilsonville, AlabamaWilsonville, AlabamaWilsonville, AlabamaWilsonville, Alabama
ExistingPSDF
Locationof Post-CombustionFacility
PostPost--Combustion Carbon Capture Center (PC4)Combustion Carbon Capture Center (PC4)Plant GastonPlant Gaston
Bench Scale Test Units#4
FGDSt
ack < 0.1 MWe
< 2 tpd CO2 SSTU
#3
ID Fans ADA
1 MWe20 tpd CO2
Pilot Test Unit #2
Pilot Solvent Test Unit
0.5 MWe35 000 lb/h
Scrubbed Flue Gas to Other Units
Test Unit (PSTU)10 tpd CO2
35,000 lb/h
PostPost--Combustion LayoutCombustion LayoutyyPSTU Balance of Plant
Control Room Admin Building
Bench ScaleAdmin Building
Pilot Solvent Test UnitPilot Solvent Test Unit• Build a highly flexible test bed using a real flue
gas for post-combustion CO2 capture• Long-term testing of newly-developed and
potential solvents from 3rd party developers• Baseline solvent for sizing: 20-30%wt MEABaseline solvent for sizing: 20 30%wt MEA• Overall CO2 removal rate: ≥ 90%• Flue gas flow rate: 5,000 lb/hr (~0.5 MW, ~10 g (
t/d CO2)• Turndown ratios: 2:1 for gas, 3~5:1 for liquid• Modular structure arrangement• Modular structure arrangement• Flexible process configuration and testing
conditions
Washing Tower
To Other Units in PC4
To Stack
C501
Simplified PSTU PFDSimplified PSTU PFD
Pre-ScrubberC l /
AbsorberC401
T501 P501
S602
E601
E501
P404Cooler/ Condenser
F
F C F
C101
C301T401
F402/3/4
F405P602
E601P404
P401 P405
Regenerator
BlowerInter Coolers
F
Flue Gas F
F
C601F301
F405
P201
E301 E401
E405
P402
Reboiler
R/L HX
Water
T101 P101T301 P301
Steam
P201
E402
E404
Steam
ReboilerReclaimer
F
Process
Process
Water
Solvent
T701
T402 T403 BOPP406
E602E603
S603
P701
FProcess03Condensate
BOPF401
P408 P403
PSTU PSTU –– A Flexible Test PlatformA Flexible Test PlatformAbsorber
Wash Tower
Regenerator
Pre-Scrubber
Cooler/C d
Reboiler
Condenser Reclaimer
L/R HX
Blower
Next StepsNext StepsNext StepsNext Steps
•Complete PSTU and BOP Installation•Complete PSTU and BOP Installation
•System Integrity and Functional Check
•PSTU/BOP System Commissioning
•Baseline Tests with MEA
•Test New Solvents from Developers•Test New Solvents from Developers
PSTU Test PlanningPSTU Test Planning
Item Media Tentative S h d l
DurationSchedule
Commissioning Water &20% MEA
4Q ‘10 – 1Q ‘11 As Needed
Baseline Run MEA 1Q , 2011 500~1000 hr
B&W New Solvent 2Q, 2011 TBD
Developer A New Solvent TBD TBD
Developer B New Solvent/System TBD TBD
Developer C New Solvent/System TBD TBD
… … … …
PSTU Equipment Design ValidationPSTU Equipment Design ValidationItems:•Hydraulic Performance (Q, P, ΔP, H, …)
Th l P f (E T ΔT A h H t L )•Thermal Performance (E, T, ΔT, Approach, Heat Loss, …)
•Instrument Accuracy and Rangeability
•Control Logic and Strategy (Global, Local, …)g gy ( , , )
•Operability and Flexibility (Robustness, Turndown, …)
Methods and Approaches:Methods and Approaches:•Separate and Independent Measurements of Key Parameters (Cross-Check)
•Calibrations of Key Instruments
•Heat and Material Balance
•Modeling and Simulation
G d Li id A l (L b A l i t C Ch k)•Gas and Liquid Analyses (Lab Analysis to Cross-Check)
Performance EvaluationPerformance EvaluationObjective: CO2 Removal ≥ Goal (e.g., 90%)
While: Minimizing Energy and Water Consumptiong gy p
By Optimizing:–Lean and Rich Loading (CO2/Solvent)g ( 2 )
–Solvent Circulation Rate (L/G Ratio)
–Steam Consumption (S/L Ratio)
–Temperature Profile (Reaction, Regeneration, Bed, In/Out, …)
–Hardware/Process Configuration (Packing, Flow Path, …)
–Other Parameters
Design of Experiment (DoE) Develop Test MatrixDesign of Experiment (DoE) Develop Test Matrix
Washing Tower
To Stack
C501
Control and Monitor Key Control and Monitor Key ParametersParameters CO2
Water Balance
Emission
Pre-ScrubberC l /
AbsorberTo Other Units in PC4C401
T501 P501
S602
E601
E501
P404
ParametersParametersRate
Cooler/ Condenser
F
F C F
C101
C301T401
F402/3/4
F405P602
E601P404
P401 P405
L/GLean
LoadingInlet
Temp
Regenerator
BlowerInter Coolers
F
Flue Gas F
F
C601F301
F405
P201
E301 E401
E405
P402
g
Temp Profile
Gas Comp.
Reboiler
R/L HX
Water
T101 P101T301 P301
Steam
P201
E402
E404
Steam S/LSolvent Degradation
p
ReboilerReclaimer
F
Process
Process
Water
Solvent
T701
T402 T403 BOPP406
E602E603
S603
P701
Rich L di
Conc.Degradation
Products
FProcess03Condensate
BOPF401
P408 P403Loading
Solvent EvaluationSolvent EvaluationSolvent EvaluationSolvent Evaluation•Kinetics•Loading Capacity•Heat of Reaction•Regeneration Energy Consumption•Degradation Potential and Productsg•Corrosion Intensity•Others
SummarySummarySummarySummary
•Our Objective – Establish a Flexible Test Bed•Our Objective – Establish a Flexible Test Bed
•Our Mission – Test New Solvents•Our Mission – Test New Solvents
•Our Results – Get Data to Advance Technology•Our Results – Get Data to Advance Technology
•Our Status – It Will Be Ready Soon•Our Status – It Will Be Ready Soon
PostPost--Combustion Site PreparationCombustion Site Preparationpp
Site Preparation & Plant TieSite Preparation & Plant Tie--InsInsReroute Underground Piping & Underground Firewater System
Flue Gas Supply Flue Gas Return Utilities (steam, water…)
System
Caisson and Column FoundationCaisson and Column Foundation
• 72 Caissons
• 30 Micropiles
• 28 utility• 28 utility bridge support column units
Modular Utility Bridge AssemblyModular Utility Bridge Assembly
Modular Utility Bridge AssemblyModular Utility Bridge Assembly
Modular Utility Bridge AssemblyModular Utility Bridge Assembly
Bridge Module InterconnectionsBridge Module Interconnections
Pilot Solvent Test Unit AssemblyPilot Solvent Test Unit Assembly
Pilot Solvent Test Unit DeliveryPilot Solvent Test Unit Delivery
Pilot Solvent Test Unit InstallationPilot Solvent Test Unit Installation
Pilot Solvent Test Unit InstallationPilot Solvent Test Unit Installation
Pilot Solvent Test UnitPilot Solvent Test Unit
Balance of PlantBalance of Plant
Cooling Tower
Solvent Storage Tanks
Control Room/Admin BuildingControl Room/Admin Buildinggg
Transformer & MCC Building InstallationTransformer & MCC Building Installation
Questions?Questions?