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

Capture Program

Sept. 2009

September 10, 2009Cottbus, Germany

National Energy Technology LaboratoryWhere Energy Challenges Converge and Energy Solutions Emerge

• Only government owned & operated DOE national labD di t d t RD&D d ti

gy g g gy g

• Dedicated to energy RD&D, domestic energy resources• Fundamental science through technology demonstration• Unique industry academia government collaborations• Unique industry–academia–government collaborations

2

R. Boyle, 02/11/2009

West VirginiaPennsylvaniaOregon

In Order to Implement CCS, Most New Coal Plants Will Require Technology Developed by the IEP Programq gy p y g

Operating Plants BuiltBetween 2000 and 2008 Plants Under Construction

Near Construction95 percent would require post-combustion retrofits

Near Constructionor Permitted

88 percent would require post-

3

combustion retrofits

Source NETL, Tracking New Coal-Fired Power Plants, 2008

DOE’s IEP Program Structure

CO2 Capture Water Minimization

COCO22

HH OO

Oxy-combustion

Advanced Solvents Advanced

CoolingReuse & Recovery

HH22OO

Membranes

CompressionSolidSorbents Non-

traditional sources

Membranes

Systems

MercuryAnalyses

4

IEP Key Activity/Component Funding

Technology Area/Budget Line Funding ($000's)

Key Activity /Component FY 2008Enacted

FY2009Enacted

FY2010 CBR

1 CO2 Capture and Compression 27,362 27,932 36,0002 Water Management 6 000 12 000 02 Water Management 6,000 12,000 03 Air Toxics (Mercury)/ Fine

Particulates 0 5,000 04 Program Assessment 2,719 5,068 5,000Total 36,081 50,000 41,000

5

FY09 Innovations for Existing Plants Program42 Total Projects42 Total ProjectsOrganizations• Industry 17• University 7• National Laboratories 3• Non-Profit 6Total 33

FY09 Budget Allocation

Annual Budget

6

Deployment Barriers for CO2 Capture on New and Existing Coal Plants TodayNew and Existing Coal Plants Today

1. Scale-up200 /d * 15 000 /d• ~200 tons/day* to 15,000 tons/day

2. Energy demand• 20% to 30% in power output20% to 30% in power output

3. Cost• Increase Cost of Electricity

4. Regulatory framework• Transport — pipeline network

• Storage

• Liability

7

*Existing post-combustion experience

DOE/NETL CCS Program GoalsBy 2020 have available for commercial deploymentBy 2020, have available for commercial deployment,

technologies and best practices for achieving:

90% CO2 capture

99%+ storage permanence

Pre-combustion Capture (IGCC)

< 10% increase in COE1< 10% increase in COE1

Post- and Oxy-combustion Capture

< 35% increase in COE2

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

8

y p p p g , y g

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

IEP CO2 Emissions Control R&D Activities

• Post-Combustion CO2Control – Solvents– Sorbents– Membranes

• Oxy-Combustion CO2ControlControl– Chemical looping

• CO Compression• CO2 Compression

9

Existing Plants ProgramCO2 Capture Extramural ResearchCO2 Capture Extramural Research

$40,000

$50,000

$60,000

s

$10 000

$20,000

$30,000

$100

0s

GovernmentTotal

Government

Total$0

$10,000

Post Combustion Oxy-combustion

CO2 Compression

Total External Research Value: $67.5 M U.S. DOE$95.8 M Total30% overall cost share

10

CO2 Capture Extramural Research BreakdownBreakdown

$20,000

$25,000

$10,000

$15,000

$100

0s

T t l

$0

$5,000Government

Total

Government

Total

Total External Research Value: $67.5 M U.S. DOE$95.8 M Total

11

30% overall cost share

Oxy-combustion Technologies

R&D Focus New oxyfuel boilers

- Advanced materials and burnersAdvanced materials and burners- Corrosion

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

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

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

Alstom • Foster Wheeler• Ohio State• Praxair

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• Air Products Praxair• Reaction Engineering International

NETL Office of Research & Development

• Oxy-combustion R&D Areas– Materials

Th l Fl id– Thermal-Fluids– Laboratory Experiments – Process Modeling and Design– Facility Experiments– CFD Modeling– IPR™ Process DevelopmentIPR Process Development

• Chemical Looping Combustion– Development and analysis of oxygen carriers

Design of reactors for ash fuel and oxygen carrier– Design of reactors for ash, fuel and oxygen carrier transport

13

Integrated Pollutant Removal (IPR)*

Base

TWR H2 H3 H4 H5

STG1 STG2 STG3 STG4

45psia

190psia

600600psiapsia

2000psia

V4 V8 V11

FGR tap

H1 CAPTURE

14

*As implemented at Jupiter Oxygen Corporation in Hammond IN

NETL Office of Research & Development (con’t)(con t)

•Developed oxy-fuel flat-flame burner facility– Current fuels: methane (~natural gas) H2 H2/CO

Hydrogen-Oxygen with steamHydrogen-Oxygen with steam

– Current fuels: methane (~natural gas), H2, H2/CO– Oxidants: O2 or air– Diluents:

St t 18 h• Steam - up to 18pph• CO2 capability has just been added

• Radiative Property Measurementsp y

Black Body SourceHyperspectral Imager

Black Body SourceHyperspectral Imager

Flat Flame BurnerFlat Flame Burner

15

Oxy-combustion Projects SummaryPerformer Coal Type(s) Firing Test Size in Additional Info(Project ID) Tested Configuration(s) MWth

Alstom (NT41146) Bituminous CFB 3.0 CO2 simulated recycle gas

Ai Li id (NT41586) S b bit i W ll 1 5 CO i l t d lAir Liquide (NT41586) Sub-bituminous Wall 1.5 CO2 simulated recycle gas

Alstom (NT42205) Bituminous CFB 3.0 CO2 simulated recycle gas

Southern Research Bituminous Wall 1 0 Recycled flue gasSouthern 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(NT42811) retrofit

REI (NT05288) BituminousSub-bituminous

Wall 0.1, 1.2 Detailed mechanism development

Alstom (NT05290) BituminousSub-bituminous

T-fired 15 Recycled flue gas retrofit

16

Sub bituminousLignite

retrofit

Oxy-Combustion for Tangential-Fired Boiler Alstom PowerAlstom Power

• Pilot-scale tests at 15 MWth

• Goal is to minimize capital and operating costs

• Status:

– Retrofit complete

– PRB Test Run in Sept 2009

– Bituminous Test Run in lateBituminous Test Run in late 2009

17

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

E l t i t f t fitti• 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

18

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

• Investigation of oxy-combustion ff t d bilit f b il t beffects on durability of boiler tube

materials

• Computational fluid dynamic

Division WallsDivision WallsDivision Walls

• Computational fluid dynamic modeling will predict gas compositions Burners

OFA Ports

WaterwallsBurners

OFA Ports

WaterwallsBurners

OFA Ports

Waterwalls

• Laboratory testing to determine effects on conventional and higher-ll b il t b

WaterwallsWaterwallsWaterwalls

alloy boiler tubesHeat Flux

(Btu/hr-ft2)

Heat Flux

(Btu/hr-ft2)

Heat Flux

(Btu/hr-ft2)

19

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

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

2. Inert removal at 30-110 atmospheres pressure

20

Flue Gas Purification for Oxy-Combustion Praxair, Inc.Praxair, Inc.

• Development of flue gas purification for oxy-combustion retrofitscombustion retrofits

• 99 percent SO2 and mercury removal• >90 percent NOx removal• For high sulfur coal:

• SO2 sulfuric acid

• NOx nitric acidNOx nitric acid

• Mercury mercuric sulfate

• For low sulfur coal:• SO2 gypsum• SO2 gypsum

• Mercury activated carbon process

• O2, N2, Ar separated and vented

21

Chemical Looping Retrofit for Existing Power Plantsfor Existing Power Plants

Alstom Power

• Development of chemical looping for CO2 capture and

tiseparation

• Limestone-based oxygen carrier

• Fully integrated prototype facility will be designed, constructed, and operatedand operated

22

Chemical Looping Retrofit for Existing Power Plantsfor Existing Power Plants

The Ohio State University Research Foundation

• Development of coal direct chemical looping

• Iron oxide-based oxygen carrier

• Can be retrofitted on existing coal fired plantcoal-fired plant

• Bench and sub-pilot testing

23

Advanced CO2 Compression

R&D Focus Reduce capital costs Increase efficiency Increase efficiency Integration with CO2 capture process Modeling Heat recovery Reduced footprint

Projects:• New CO2 compressors — Ramgen & Dresser Rand

• 13,000 hp demonstration test in 2011• Novel CO2 compression processes — Southwest Research

Institute

24

NETL Systems AnalysesA l i FAnalysis Focus Assessment of state-of-the-art and advanced technologies Guide Research

• Compare best potential technologies to current SOACompare best potential technologies to current SOA• Identify process conditions and performance targetsProject national benefits of advanced technologies

Modeling of novel energy conversion processesTechnolog integration• Technology integration

• Overall technical & environmental performance Engineering Economics

• CAPEX, O&M, COE, CO2 Mitigation Cost2 g

2009 Studies:• Solid sorbents (MOFs)So d so be ts ( O s)• Post-combustion membranes• Ionic liquids• Advanced oxy-combustion

Am

ine

Scru

bber

Am

ine

Reg

ener

ator

25

Advanced oxy combustion

RD&D Timeline to Commercial DeploymentPost-Combustion CO2 CapturePost Combustion CO2 Capture

LaboratoryLaboratory--Bench Scale R&DBench Scale R&D

Pilot-Scale Field Testing

yy

Full-Scale Field Testing

Commercial Deployment

20102008 20162012 2020 2024

26

For Additional InformationNETL

www.netl.doe.govOffice of Fossil Energy

www.fe.doe.gov

27

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

28

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