Technology Advances in Post-Combustion Capture to Approach a

Viable Business case

Prachi Singh, John Davison IEA Greenhouse Gas R&D Programme, UK

& Luca Mancuso, Noemi Ferrari

Foster Wheeler, Italy

Scope of the project

Perform technical and economical assessment of Newly build Coal fired Power Plants with the leading CO2 capture technology (Location: The Netherlands)

Currently this work is in progress

Following cases will be presented Supercritical Pulverized Coal (SCPC) SCPC + CO2 Capture

SCPC + Biomass co-firing + CO2 Capture

Sensitivity Analysis: Cooling System Sea water & Air cooling SCPC SCPC + CO2 Capture

SCPC without CO2 Capture

Fuel flow rate 325t/h

Thermal input LHV 2335MWth

Main steam condition

270bar(a) /600 C

Reheat steam condition

60bar(a) /620 C

Gross output 1076.7MWe

Net output 1032.7MWe

Gross efficiency LHV 46.1%

Net efficiency LHV 44.1%

Fuel consumption 2.27MWth /MWe

Specific CO2 emission

741.8 kg/MWh

Flue Gas Treatment

Alstom Wet Flue Gas Desulphurization (WFGD) SO2 10ppmv*, SO3 13ppmv*

(CO2 Capture Case)

Selective Catalytic Reduction (SCR)

NOx <130mg/Nm3* (CO2 Capture Case)

*(6% dry O2)

CO2 Capture Technology Amine based solvent CO2 Absorption process

Several companies are offering CO2 capture technology:

• Aker Clean Carbon: Amine based solvent process • Alstom: Ammonia based process (CAP) • CANSOLV: Amine based solvent; Combined SO2/CO2 removal • CB&I: MEA based scrubbing technology • FLUOR: Econamine FG Plus process • HTC Energy: Purenergy CCS Capture SystemTM, amine based • Mitsubishi Heavy Industries (MHI): KS-1 process, based on a

formulation of sterically hindered amines • SIEMENS: Amino acid salt solution based process

Some of the above-listed suppliers were asked to support the study; amongst them, CANSOLV has provided specific data for this study

Cansolv CO2 Capture Process 90% CO2 removal

2×50% Train

•Absorber Intercooling •Lean Flash Mechanical Vapor recompression

CO2~ 14 vol% NO2 ~1ppmv SO2 ~1 ppmv 122 C

37 C

SCPC with CO2 Capture: Steam Integration

Steam Extraction

Condensate preheated at stripper overhead condenser and compressor intercoolers

SCPC with CO2 Capture: Biomass Co-firing

Co-fire biomass to meet net zero CO2 emission (7.5%)

Modification of coal burner for biomass

injection lance

Slight increase in flue gas flow rate and CO2

concentration

CO2 Compression and Dehydration

Two parallel trains, including compressor, separation drums, coolers, dehydration system and final pump

• Four stage centrifugal compressor, electrically driven, includes anti-surge control, vent, inter-coolers, knockout drums and condensate draining facilities as appropriate

• At each compression stage outlet, part of the heat is recovered to pre-heat the condensate from the steam cycle

CO2 from the third compression stage is routed to the dehydration unit (consist of two bed), via a solid desiccant, (e.g. Activated Alumina and Molecular Sieves)

Finally CO2 is delivered at 110 bar, Dense phase to pipeline for transportation

Water Consumption

Cooling water system is based on Natural Draft Cooling Tower

SCPC+CO2

Electricity Consumption

CO2 capture and compression energy consumption is 62%

Plant Performance

Overall Plant performance Unit SCPC SCPC+

CO2 SCPC+

Bio+ CO2

Coal flow rate t/h 325.0 325.0 300.6

Biomass flow rate t/h - - 86.4

Fuel LHV kJ/kg 25870 25870 21725

Thermal Energy of Feedstock (LHV) MWth 2335 2335 2335

Gross Electric Power Output MWe 1076.7 958.1 948.8

Net Electric Power Output MWe 1032.7 824.9 811.0

Gross Electrical Efficiency (LHV) % 46.1% 41.0% 40.6%

Net Electrical Efficiency ( LHV) % 44.1% 35.2% 34.6% Efficiency Reduction compared to SCPC

% - 8.9% 9.5%

Net CO2 emission per net power production

kg/MWh 741.8 91.0 0.0

Environmental Impact

Gaseous Emission SCPC SCPC+ CO2 SCPC+ Bio+ CO2

Wet gas flow rate, kg/h 3,740,000 2,977,000 3,030,000 Flow, Nm3/h (1) 2,857,000 2,410,000 2,445,000 Temperature, °C 90 95 95 Composition (% vol) (% vol) (% vol)

Ar 0.85 1 1 N2 71.4 84.66 84.38 O2 3.2 4.13 4.11

CO2 13.68 1.58 1.6 H2O 10.88 8.62 8.62

Emission mg/Nm3 (1) mg/Nm3 (1) mg/Nm3 (1) NOx < 150 < 50 mg/Nm3 (1) < 50 mg/Nm3 (1) SOx < 150 < 1 ppmv (1) < 1 ppmv (1)

Particulate < 10 < 10 mg/Nm3 (1) < 10 mg/Nm3 (1) (1) Dry gas, O2 content 6% vol.

Sensitivity Analysis: Cooling System

Sea water (SW) Once through seawater, directly pumped from sea to heat exchanger Air cooling (AC) Ambient air is used as cooling medium In SW & AC cases raw

water consumption is lower than Base case (Cooling tower)

Sensitivity Analysis: Cooling System

Operational Cost

• Fixed cost include Direct labour, Administrative/General overheads, Insurance & Local taxes, Maintenance;

• Chemical & Waste disposal include solvent • Coal 2.5 €/GJ (LHV)

Variable Cost

Total Plant Cost

SCPC Total Plant Cost: 1,490m€

SCPC + CO2 Total Plant Cost: 2,279m€

Levelised Cost of Electricity (LCOE)

Bituminous Coal: 2,5 €/GJ (LHV); Discount rate: 8% CO2 transport & storage: 10 €/t; 85% load factor; Constant €, 2013

Conclusions

Net Efficiency reduction for SCPC plant was found to be 8.9% points for CO2 capture case and for biomass and CO2 capture case 9.5% points

Impact of cooling system on plant Net Efficiency for sea water and air cooling is +/- 0.6% points for SCPC case and +/- 0.4% points for SCPC+CO2 case

15% increase in operation cost and 53% increase in capital cost for SCPC with CO2 capture plant

Levelised cost of electricity for SCPC with CO2 capture case was found to be 94.7€/MWh (52 €/MWh)

October 5th - 9th 2014 AUSTIN, TX – USA www.GHGT.info

•Call for papers 27th Sep. 2013 •Deadline for abstracts 10th Jan. 2014 •Registration opens 7th Mar. 2014 •Authors notified 2nd May 2014 •Early bird closes 13th June 2014

prachi.singh@ieaghg.org

Sensitivity Analysis: Cooling System

Overall Plant Performance

Unit SCPC SCPC-

SW SCPC-

AC SCPC +

CO2

SCPC-SW + CO2

SCPC-AC + CO2

Fuel flow rate t/h 325 325 325 325 325 325 Gross Electric Power output

MWe 1077 1091 1062 958 969 947

Net Electric Power output

MWe 1033 1048 1018 825 835 816

Gross Electrical Efficiency (LHV)

% 46.1% 46.7% 45.5% 41.0% 41.5% 40.6%

Net Electrical Efficiency (LHV)

% 44.1% 44.7% 43.5% 35.2% 35.6% 34.8%

Fuel Consumption per net power production

MWth/MWe 2.27 2.24 2.30 2.84 2.81 2.87

CO2 emission per net power production

kg/MWh 741.8 731.2 752.3 91.0 89.9 92.0