TF, August 2010

Oxy-combustion Technology Research through the DOE-NETL Existing Plants

Capture Program

August 12, 2010

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• Full-service DOE Federal laboratory

• Dedicated to energy RD&D, domestic energy resources

• Fundamental science through technology demonstration

• Unique industry–academia–government collaborations

National Energy Technology LaboratoryPittsburgh, PA

Morgantown,WV

Fairbanks, AKSugar Land,

TX

West VirginiaPennsylvaniaOregon

Albany,OR

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DOE’s IEP Program Structure

CO2

H2O

Membranes

Oxy-combustion

CompressionSolidSorbents

CO2 Capture

Advanced Solvents Advanced

Cooling

Non-traditional sources

Reuse & Recovery

Water Minimization

Mercury

Systems Analyses

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IEP Program Budget

Water 7%

Mercury 3%

Sorbents12%

Solvents 33%

Membranes12%

Oxycombustion23%

Program10%

FY10 Budget Allocation

45 Total ProjectsOrganizations• Industry 17• University 8• National Laboratories 4• Non-Profit 6Total 35

$36

$50 $52

$65

0

10

20

30

40

50

60

70

80

2008 2009 2010 2011

Annual Budget

$Mill

ions

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DOE/NETL CCS Program Goals

90% CO2 capture

99%+ storage permanence

Pre-combustion Capture (IGCC)

< 10% increase in COE1

Post- and Oxy-combustion Capture

< 35% increase in COE2

By 2020, have available for commercial deployment, technologies and best practices for achieving:

*Cost of Electricity includes 50 mile pipeline transport and saline formation storage, 100 years of monitoring

1. Impact of Cost Escalation on Power Systems R&D Goals—Re-baselining APS, CS & FC GPRA R&D Goals, DOE/NETL July 20082. Existing Plants, Emissions & Capture Program—Setting Program Goals, U.S. DOE/National Energy Technology Laboratory, Draft Final Report, February 2009

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IEP CO2 Emissions Control R&D Activities

• Post-Combustion CO2Control – Solvents– Sorbents– Membranes

• Oxy-Combustion CO2Control– Chemical looping

• CO2 Compression

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Oxy-combustion Technologies

R&D Focus New oxyfuel boilers

- Advanced materials and burners- Corrosion

Retrofit existing air boilers- Air leakage, - Heat transfer, corrosion

Low-cost oxygen CO2 purification Co-capture (CO2 + SOx, NOx, O2)

Partners• Jupiter Oxygen Corporation• Babcock & Wilcox• Air Products• Alstom

• Foster Wheeler• Praxair• Reaction Engineering International• Southern Research

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Oxy-combustion Projects SummaryPerformer(Project ID)

Coal Type(s) Tested

FiringConfiguration(s)

Test Size in MWth

Additional Info

Alstom (NT41146) Bituminous CFB 3.0 CO2 simulated recycle gas

Air Liquide (NT41586) Sub-bituminous Wall 1.5 CO2 simulated recycle gas

Alstom (NT42205) Bituminous CFB 3.0 CO2 simulated recycle gas

Southern Research (NT42430)

BituminousSub-bituminous

Wall 1.0 Recycled flue gas retrofit

B&W (NT42747) BituminousSub-bituminous

Lignite

CycloneWall

1.8 Recycled flue gas retrofit

Linde (NT42748) BituminousSub-bituminous

Lignite

T-fired 0.08 Baseline Tests for CAR system testing

Jupiter Oxygen (NT42811)

Bituminous Wall 15 Recycled flue gas retrofit

REI (NT05288) BituminousSub-bituminous

Wall 0.1, 1.2 Detailed mechanism development

Alstom (NT05290) BituminousSub-bituminous

Lignite

T-fired 15 Recycled flue gas retrofit

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Oxy-Combustion for Tangential-Fired Boiler Alstom Power

• Pilot-scale tests at 15 MWth

• Goal is to minimize capital and operating costs

• Status:

– Completed test campaigns on PRB, low S Bituminous, high S Bituminous

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• Stable operation over a broad range of test conditions• Ability to produce >90% CO2 Flue Gas (dry basis)• For both PRB and WV Bituminous:

– Able to operate at low excess O2 (<2% at Economizer Outlet)

– Low CO Emissions (near Zero)– Low Carbon in Fly ash– Lower NOx under oxy-firing

• Roughly 50% reduction from air-fired on lb NOx/MMBtu• Heat transfer profile adjustable by changing operating

conditions• SO2 to SO3 conversion similar; SO3 conc. 3x higher than

air-fired

BSF Test Campaign 1 & 2 ResultsAlstom Power

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Oxy-combustion Impacts on Existing Coal-fired Boilers Reaction Engineering International

• Evaluate impacts of retrofitting existing coal-fired boilers for oxy-combustion

• Multi-scale experiments (0.1 kW, 100 kW, 1.2 MW)

• Computational fluid dynamic modeling

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REI Testing Results

(1.2 MWth)

0

100

200

300

400

500

600

0.7 0.75 0.8 0.85 0.9 0.95 1 1.05 1.1 1.15 1.2

Burner SR

NO

x [p

pmv,

dry

]

Air-FiredOxy-Fired, 1.8 A/F, 21-23% Pri O2Oxy-Fired, 1.9 A/F, 21-23% Pri O2Oxy-Fired, 2.0 A/F, 21-23% Pri O2Oxy-Fired, 1.8 A/F, 10-21% Pri O2Oxy-Fired, 1.8 A/F, 3% Pri O2

0.000

0.100

0.200

0.300

0.400

0.500

0.600

0.700

0.7 0.8 0.9 1 1.1 1.2

NO

x Em

itted

[lb/

MB

tu]

Burner SR

Air-FiredOxy-Fired, 1.8 A/F, 21-23% Pri O2Oxy-Fired, 1.9 A/F, 21-23% Pri O2Oxy-Fired, 2.0 A/F, 21-23% Pri O2Oxy-Fired, 1.8 A/F, 10-21% Pri O2Oxy-Fired, 1.8 A/F, 3% Pri O2

Flame Stability

Match Air-fired Flame Behavior•Momentum Attached•Gas/Fuel Mass Ratio Attached•Primary Velocity Detached

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Boiler Material Development for Oxy-Combustion Foster Wheeler NA, Corp.

• Investigation of oxy-combustion effects on durability of boiler tube materials

• Computational fluid dynamic modeling will predict gas compositions

• Laboratory testing to determine effects on conventional and higher-alloy boiler tubes

• Testing 10 Waterwall & 10 Superheater/Reheater Materials

– Each material coated with representative deposits

• Air and oxy-fired conditionsHeat Flux

(Btu/hr-ft2)

Division Walls

Burners

OFA Ports

Waterwalls

Heat Flux

(Btu/hr-ft2)

Division Walls

Burners

OFA Ports

Waterwalls

Heat Flux

(Btu/hr-ft2)

Division Walls

Burners

OFA Ports

Waterwalls

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Flue Gas Purification for Oxy-Combustion Air Products and Chemicals, Inc.

• CO2 may need to be cleaned of acidic impurities such as HCl and SO2 before being transported by pipeline for sequestration

• Feasibility of purifying CO2from oxy-combustion will be studied

1. SO2/NOx removal at 1-30 atmospheres pressure

2. Inert removal at 30-110 atmospheres pressure

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WV Bituminous Test ResultsAir Products and Chemicals, Inc.

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AirCH4, CO, H2

CO2, H2O

1000oC, 1832 F

3-5 psig~ 500 psig

O2-

e-

O2 + 4e- → 2O2-

AirCH4, CO, H2

CO2, H2O

1000oC, 1832 F

3-5 psig~ 500 psig

O2-

e-

O2 + 4e- → 2O2-

OTM Based Oxy-combustion for CO2 Capture from Coal Power Plants

Participants: Praxair, University of Utah

Step-change Technology•Reduced O2 power cost (~75%)•Reliability at pressure and with gaseous fuel impurities

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OTM Based Oxy-combustion for CO2Capture from Coal Power Plants

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To Find Out More About NETL’s CO2 Capture R&D:

http://www.netl.doe.gov/technologies/coalpower/ewr/index.htmlhttp://www.netl.doe.gov/technologies/coalpower/ewr/index.html