The Potential of Advanced Technologies to Reduce IGCC ...Advanced Technologies Pathway for IGCC with Carbon Capture • Today CCS adds >30% to cost of IGCC • Successful R&D can enable

GTC Conference, Colorado Springs, CO, October 7, 2009

The Potential of Advanced Technologies

to Reduce IGCC Carbon Capture Costs

Kristin GerdesAnalyst

2

Advanced Technologies Pathway for IGCC

with Carbon Capture

• Today CCS adds >30% to cost of IGCC

• Successful R&D can enable improved performance

and reduction in cost for IGCC with CCS

Incorporation of advanced technologies over time

25%

30%

35%

40%

45%

50%

Efficiency(HHV)

CaptureNon-Capture Reference

1,000

1,500

2,000

2,500

3,000

Total Plant Cost(2007$/kW)

4

6

8

10

12

Levelized Cost of Electricity

(2007¢/kWh)

3

IGCC Non-Capture Reference Plant

• Technology– Illinois #6 Bituminous coal

– Single-stage slurry-fed entrained radiant gasifier

– Cryogenic air separation unit

– Adv F-class gas turbine

– Solvent-based acid gas removal

– Steam Cycle 1800 psig/1050°F/1050°F

– Process simulation software

• Economics– 2007 dollars (constant)

– Capital costs from Parsons, vendor sources

• Owner’s costs excluded

– 17.5% capital charge factor

– Coal price $1.80/MMBtu

– Greenfield, midwestern USA, 0 ft elevation

– 80% capacity factor

4

Today’s CCS Adds 30% to COE of IGCC

Added for CCS Baseline (90% CO2 capture)

– Two-stage water-gas-shift reactors

– Additional physical solvent stage for CO2 separation

– CO2 compression

– Transportation, storage and monitoring (TS&M) of CO2

IGCC

Baseline

IGCC with

CCS*Delta

Net Plant Efficiency

(HHV)38.2% 32.5% -6% pt

Total Plant Cost**

($/kW, 2007$)1,800 2,400 +$600/kW

20-year levelized COE

(¢/kWh, 2007$)7.80 10.3 +30%

* 90% CO2 capture

** TPC excludes owner’s costs

Oxygen

Production

Gasifier

and Syngas

Cooling

Gas

Cleanup

Power

Island

Coal

Feed

O2

Air

Air

H2 Fuel

CO2

Compression

CO2

CO2

Separation

Water Gas

Shift

N2

5

Advanced Technology Progression

Technology Advancements

Coal Feed System Slurry Feed Dry Coal Feed Pump

Oxygen Production Cryogenic Air Separation Ion Transport Membrane

Gas Cleanup Cold Gas Cleanup Warm Gas Cleanup

H2 Turbine Advanced F Adv H2 Turbine Next Gen Adv Turb

CO2 Separation Physical Solvent H2 Membrane

Capacity Factor 80% 85% 90%

Oxygen

Production

Gasifier

and Syngas

Cooling

Gas

Cleanup

and Shift

Hydrogen

Turbine

Steam

Bottoming

Cycle

Coal

FeedRaw

Syngas

O2

Air Air

Hot

Flue

Gas Flue Gas

To Stack

H2 Fuel

N2

CO2

Compression

CO2CO2

Separation

CO2

Transport,

Storage and

Monitoring

6

Advanced Technologies Pathway

• Advanced technologies introduced in approximate

order of development

• Evaluate cumulative COE benefits over time

4

6

8

10

12

Leve

lize

d C

ost

of

Ele

ctri

city

(2

00

7¢/

kWh

)

Today's IGCC with CCS

Approximate development of advanced technologies over time

Non-capture Reference

7

25%

30%

35%

40%

45%

Ref

eren

ce

Co

al P

um

p

Efficiency(HHV)

1,000

1,500

2,000

2,500

3,000

Ref

eren

ce

Co

al P

um

p


4

6

8

10

12

Ref

eren

ce

Co

al P

um

p


(2007¢/kWh)

Non-Capture Reference

Coal Feed Pump

• Increased gasifier cold gas efficiency with

elimination of slurry

• Reduced coal feed, auxiliary load, and net power

+ 1%pt

8

4

6

8

10

12

Ref

eren

ce

Co

al P

um

p

85

% C

F


(2007¢/kWh)


Reliability, Availability and Maintainability

• Current materials and instrumentation limited life in harsh environment

• Advanced materials and instrumentation

– Corrosion and erosion resistant materials

– In-situ repair techniques

– Real-time measurement

• 5% capacity factor improvement to 85% provides 4% COE reduction

9

25%

30%

35%

40%

45%

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

Efficiency(HHV)

1,000

1,500

2,000

2,500

3,000

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU


4

6

8

10

12

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU


(2007¢/kWh)


Warm Gas Cleanup (WGCU)

• Warm transport desulfurization process replaces cold gas desulfurization– Eliminates sour water stripper and improves heat recovery

– Estimated capital costs similar for each technology

+ 1%pt

- $60/kW - 2% COE

10

25%

30%

35%

40%

45%

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

Efficiency(HHV)

1,000

1,500

2,000

2,500

3,000

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b


4

6

8

10

12

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b


(2007¢/kWh)


Hydrogen Membrane for CO2 Separation

+ 3%pt

- $400/kW- 13% COE

• Mixed conducting ceramic membrane separates hydrogen at

pressure and temperature

– Reduces CO2 compression load and regeneration steam requirements

• Target costs of membrane significantly less than solvent

separation, coupled with increase in net power

11

25%

30%

35%

40%

45%

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1

Efficiency(HHV)

1,000

1,500

2,000

2,500

3,000

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1


4

6

8

10

12

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1


(2007¢/kWh)


Advanced Hydrogen Turbine (AHT-1)

+ 2%pt

- $190/kW - 7% COE

• Higher pressure ratio, firing temperature and design for H2-rich fuels improve turbine performance– Allows air integration reducing ASU auxiliary power

– Increases steam cycle temperature improving steam cycle efficiency

• Increase in power rating has economy of scale benefit

12

25%

30%

35%

40%

45%

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1

ITM

Efficiency(HHV)

1,000

1,500

2,000

2,500

3,000

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1

ITM


4

6

8

10

12

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1

ITM


(2007¢/kWh)


Ion Transport Membrane (ITM)

- $130/kW- 5% COE

• ITM replaces cryogenic ASU system for oxygen production– ASU is 15% of capital costs, consumes 10-15% of power

• Anticipated capital cost reductions drive COE benefit

13

25%

30%

35%

40%

45%

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1

ITM

AH

T-2Efficiency

(HHV)

1,000

1,500

2,000

2,500

3,000

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1

ITM

AH

T-2


4

6

8

10

12

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1

ITM

AH

T-2


(2007¢/kWh)


Next Generation Adv H2 Turbine (AHT-2)

+ 1.5%pt

25%

30%

35%

40%

45%

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1

ITM

AH

T-2Efficiency

(HHV)

1,000

1,500

2,000

2,500

3,000

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1

ITM

AH

T-2


4

6

8

10

12

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1

ITM

AH

T-2


(2007¢/kWh)


- 10% COE- $240/kW

- 1% COE

• Further turbine advancements increase pressure ratio, firing temperature, stage efficiencies and power rating– Reduction to single train has competing economy of scale

impacts

- $20/kW

14

Reliability, Availability and Maintainability

• Further advancements in

materials, sensors and

incorporation of advanced

controls as well as

operating experience has

potential to push availability

higher

• 5% capacity factor

improvement to 90%

provides 3% COE reduction

4

6

8

10

12

Ref

eren

ce

Co

al P

um

p

85

% C

F

WG

CU

H2

Mem

b

AH

T-1

ITM

AH

T-2

90

% C

F


(2007¢/kWh)


15

Summary of Pathway Potential

Technology Addition Impact

Efficiency

Increase*

(% points)

TPC

Reduction*

(2007$/kW)

COE

Reduction*

(2007¢/kWh)

Coal feed pump Increase cold gas efficiency 0.8 -10 -0.1

Gasifier materials and

instrumentation

Increase capacity factor to

85%0.0 0 -0.4

Warm gas cleanup

and hydrogen

membrane

Eliminates cold gas cleanup

thermal penalties and

reduces capital cost3.7 -450 -1.4

Advanced H2 turbineIncreases power output and

allows air integration1.8 -190 -0.7

Ion transport

membraneReduces capital cost 0.3 -130 -0.4

Next generation

advanced H2 turbine

Increases power output,

efficiency1.5 -20 -0.1

Advanced sensors

and controls

Increases capacity factor to

90%0.0 0 -0.2

IGCC with CCS Pathway Impact +8.0% pts -$800/kW -3.3¢/kWh

* Incremental increase over preceding case with initial comparison to baseline IGCC with conventional CCS technology

16

Conclusions

Advanced technologies offer pathway to CCS at

significantly lower cost and better performance

than conventional IGCC with CCS

♦ 8 percentage points improvement in efficiency

♦ > 30% ($800/kW) reduction in total plant cost

♦ > 30% (3.3 ¢/kWh) reduction in levelized COE

17

Acknowledgements

• NETL

– Julianne Klara, Senior Analyst

– Gary Stiegel, Gasification Technology Manager

– Richard Dennis, Advanced Turbines Technology

Manager

– Sean Plasynski, Sequestration Technology Manager

• Noblis (modeling and analysis)

– John Plunkett, David Gray, Charles White, Sal

Salerno, Glen Tomlinson

Additional information available at:

http://www.netl.doe.gov/energy-analyses




Documents

The Potential of Advanced Technologies to Reduce IGCC ...Advanced Technologies Pathway for IGCC with Carbon Capture • Today CCS adds >30% to cost of IGCC • Successful R&D can enable