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National Carbon Capture Center: National Carbon Capture Center: National Carbon Capture Center: National Carbon Capture Center: Post Post-Combustion Focus Combustion Focus Project NT0000749 Project NT0000749 Project NT0000749 Project NT0000749 Doug Maxwell Doug Maxwell 2010 NETL CO 2010 NETL CO 2 Capture Technology Meeting Capture Technology Meeting 2 September 15, 2010 September 15, 2010

National Carbon Capture Center:National Carbon Capture ......National Carbon Capture Center New Cooperative Agreement DE-NT0000749 effective October 1, 2008 for five years through

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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?