Chemical Looping Combustion Coal Power Technology
Development Prototype
CO2 Capture Technology ConferenceUS DOE/NETL, Pittsburgh
24-26 March 2009
Herb Andrus
Alstom Chemical Looping Development – March 24-26, 2009 - P 2© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Development
• Project Overview
• Technology
• Project Objectives
• Project Methodology
• Future Plans
Alstom Chemical Looping Development – March 24-26, 2009 - P 3© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
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N°2 worldwidein urban transport(metro and trams)
Alstom makes 1 metro in 4 and 1 tram in 3
The Alstom Group – Two main activitiesEquipment & services for power generation & rail transport
> 76,000 staff in > 70 countriesTotal orders 2007/08 :
€23.5 bn
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Project Overview
• US DOE Program:Plants Capture and Emissions Program
• Funding: $6.3MM– Cooperative Agreement: September 2008– US DOE: 80%– Alstom: 20%
• Performance dates:– Budget Period 1: Sept ’08 - Sept ’09– Budget Period 2: Oct ’09 - Mar ‘11
• Project Participants:– Alstom
• PEMM Corp• Univ. of British Columbia
Alstom Chemical Looping Development – March 24-26, 2009 - P 5© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Overall Objective:
Develop, test and commercialize a limestone-based chemical looping system for existing and new pulverized coal-fired power plants, for the following performance:
• Over 90% CO2 capture from Coal
• Less than 20% increase in COE for Existing Coal-fired Plant
• Capital cost – 20% lower than Conventional Boiler Island for new plant (not including CO2 compression)
• Less than $20/ton, avoided cost of CO2 capture (with CO2 compression)
Chemical Looping: a way to Capture CO2 Efficiently, at Low Cost
Alstom Chemical Looping Development – March 24-26, 2009 - P 6© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping ProgramDevelopmental Status
Fuel and Limestone
Prep
PC/CFBSteam
Generator
Power BlockST / GTGas Clean Up
ChemicalLooping
CO2 RecoveryOption
Standard Equipment
DevelopmentalEquipment
Replace:
Ash Disposal Switch Yard
Alstom Chemical Looping Development – March 24-26, 2009 - P 7© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Development
• Project Overview
• Technology
• Project Objectives
• Project Methodology
• Future Plans
Alstom Chemical Looping Development – March 24-26, 2009 - P 8© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping ConceptWhy do it?: Lowest Cost Option for Capturing CO2 from Coal
What is it?: Oxy-Firing without Oxygen PlantSolid Oxygen Carrier Circulates between Oxidizer and Reducer
Oxygen Carrier: Carries Oxygen, Heat and Fuel Energy
Carrier picks up O2 in the Oxidizer, leaves N2 behind
Carrier Burns the Fuel in the Reducer
Heat produces Steam for Power
Oxygen Carrier:Metal Oxide: Fe, Ni, Mn, Cu…Ores or on Substrates
Limestone-based carriers
Metal Oxides:Process Development: CHALMERS UNIVERSITY
Equipment Development: ALSTOM
Limestone-based: ALSTOM
Steam Ox
ReMe MeO
Air
Fuel CO2 + H2O
N2 + O2Ox
RedMe MeO
Air
Fuel CO2 + H2O
N2 + O2
Air reactor (Oxidizer)
Fuel reactor (Reducer)
METAL OXIDE
Alstom Chemical Looping Development – March 24-26, 2009 - P 9© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Concept
Chemical Looping FlexibilityOption 1: Chemical Looping Combustion
Excess Air-to-Fuel
Product Gas is CO2
Heat Produces Steam for Power
Option 2: Chemical Looping Gasification
Excess Fuel-to-Air
Product gas is SynGas
No Inherent CO2 Capture
Option 3: Hydrogen Production
Add CaO – CaCO3 Loop to Option 2
Add Calciner
Product Gas is Hydrogen
Calciner Off-Gas is CO2Oxidizer
Reducer
Calciner
Hot Solids
Cold Solids
CaCO3 CaO
CaS
Hydrogen
Coal,Steam
CO2
Air
CaCO3
Depleted Air, Ash,CaSO4
OxidizerReducer
Calciner
Hot Solids
Cold Solids
CaCO3 CaO
CaS
CaSO4CaSO4
Product Gas
Coal,Steam
CO2
Air
CaCO3
Depleted Air, Ash,CaSO4
Steam toPower Cycle
Limestone-based
Alstom Chemical Looping Development – March 24-26, 2009 - P 10© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Options and Applications
• Lowest Cost CO2 Capture Option• Competitive with or without CO2 Capture
• CO2 Capture - PC/CFB Retrofit• CO2 Capture - Ready Power Plant• Advanced Steam Cycles
• IGCC with Downstream CO2 Capture• Industrial SynGas• Coal-to-Liquid Fuels
• CO2 Capture - PC/CFB Power Plant• CO2 Capture - Ready PC/CFB Power Plant• Advanced Steam Cycles• IGCC with CO2 Capture• Fuel Cell Cycles• Industrial Hydrogen, CO2
Option 3 – Hydrogen with CO2 Capture
Option 2 – Syngas with no CO2 Capture
Reducer Oxidizer
CaSO4 CaS
N2
AirCoalCaCO3
Ash, CaSO4To Disposal
CO2Steam
Option 1 – Combustion with CO2 Capture
Reducer Oxidizer
CaSO4 CaS
N2
AirCoalCaCO3Steam Ash, CaSO4
To Disposal
SyngasCO2, N2
Calciner CO2
Reducer Oxidizer
CaSO4 CaS
N2
AirCoalCaCO3Steam Ash, CaSO4
To Disposal
H2
Applications
Alstom Chemical Looping Development – March 24-26, 2009 - P 11© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
CO2 Capture in Power PlantsRelative Economics
Chemical Looping CO2 Avoided Cost: $11-13/ton of CO2
4.00
5.00
6.00
7.00
8.00
9.00
0 10 20 30 40 50 CO 2 Allowance Price ($/Ton CO2 Emitted)
(Cents/
kWhr
)
IGCC H Class (E-Gas) with Capture- SpareIGCC H Class (E-Gas) with Capture
6-Regenerative Carbonate Cyclewith Capture10-Advanced O2 Fired CFB withCaptureOxygen Transport Membrane CFB
14-Ammonia Scrubbing
4-Chemical Looping Combustionwith Capture (Metal Oxides)3-Chemical Looping Combustionwith Capture (CaS)1-Chemical Looping Gasification7FA with Capture (CaS)Air Fired PC w/o Capture(3915/1085/1148)
Advanced MEA
4.00
5.00
6.00
7.00
8.00
9.00
0 10 20 30 40 50 CO 2 Allowance Price ($/Ton CO2 Emitted)
Comparable range of costs for conventional technologies
4-Chemical Looping Combustionwith Capture (Metal Oxides)3-Chemical Looping Combustionwith Capture (CaS)1-Chemical Looping Gasification7FA with Capture (CaS)Air Fired PC w/o Capture(3915/1085/1148)
Chemical Looping cases Reference casecases Reference case
Basis: • Plant size 400 MWe • Steam conditions 3915 psia/1085 degF/1148 degF/2.5in Hga • Cost basis 2006, $US • Coal cost 1.5 $/MMBtu • Levelized capital charge 13.8% • Capacity factor 85%
Cost
of E
lectri
city
cent
s/Kw-
hr
Reference: DOE GHG Phase I, Bozzuto, et.al, Alstom Power, 2003
2006 $’s
Alstom Chemical Looping Development – March 24-26, 2009 - P 12© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Equipment Comparison
Building Volume 100% 48%Boiler/Gasifier Weight 100% 65%
220’ 127’
Significant Volume & Weight Reduction
Air Fired CFB
183’ 140’
Chemical Looping Plant
Alstom Chemical Looping Development – March 24-26, 2009 - P 13© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Technology
Pulverized Coal Power Plant - Retrofit Concepts
Existing Steam
TurbinePower Block
Steam
Feed WaterGenerator
Air
Fluegas
ExistingPC Boiler
ExistingCoal
Pulverizer
CoalLimestone
(CaCO3)
Reducer Oxidizer
CaSO4 CaS
N2 to Stack
AirAsh, CaSO4to DisposalCalcinerCO2
H2CO2- free
Boiler fuel(H2)
Steam
Concept 1 – Chemical Looping – CO2 Free Fuel; Minimum Boiler Modification-
Concept 2 – Chemical Looping Oxidizer Replaces / Modifies Boiler
Feed Water
ExistingSteam
TurbinePower Block
Steam
Generator
ExistingCoal
Pulverizer
CoalLimestone(CaCO3)
Reducer Oxidizer
CaSO4 CaS
N2 to Existing Stack
Air
Ash, CaSO4to Disposal
CO2
Steam
Alstom Chemical Looping Development – March 24-26, 2009 - P 14© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Designed and Built by Alstom
• Allows Testing of Individual Loops and Processes
• 3 Year Successful Test Program – Completed
• All Chemistry/Rates Verified
• Phase 3 - Pilot Plant− Two Exhaust Fans/Stacks− Automatic Solids Transport Controls
AshCoolers (6)
SolidsHeater
SealpotControlValves (2)
2-StageCyclones (2)
SprayCoolers &Filters (5)
ReducerOxidizer
ProductGasBurner
Chemical Looping Pilot PlantAlstom’s Chemical Looping Pilot Facility (65 kWt)
Alstom Chemical Looping Development – March 24-26, 2009 - P 15© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Cold Flow Model – Flow Stability, Scale-up
15 Foot Model
Figure 6-6 Laser Solids Velocity Probe.
40 Foot Model
Laser Solids Velocity Probe
Chemical Looping Cold Flow Model
Alstom Chemical Looping Development – March 24-26, 2009 - P 16© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Kinetics
Chemical Looping - Kinetics Summary
1.E-011.E+001.E+011.E+021.E+031.E+041.E+051.E+061.E+071.E+08
7 8 9 10
1/Temp (degK * 10^4)
k's
(%/s
ec-a
ta),
exce
ptk(
wgs
) (%
/sec
-ata
^2)
Pitt 8 Carbon Gasification
Charcoal Gasification
CaSO4 Reduction (FBHE ash)
CaSO4 Reduction (FBHE ash w/ SA
CO2 Capture (FBHE ash)
CO2 Capture (FBHE ash w/ SA)
Water Gas Shift (FBHE ash)
Water Gas Shift (FBHE ash w/ SA)
CaS Oxidation
1400 degF2000 degF
Kinetic Rates exceed Design Requirements
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US DOE Phase I, II, III - Accomplishments
Chemical LoopingPilot Plant Development
• All Milestones Successfully Completed – On-time, On-budget• Pilot Testing (65 kWt) – Successfully Complete• 15-foot Cold Flow Model testing completed – Stable Solids Transport
achieved• 40-foot Cold Flow Model – Stability achieved, Scaleup verified• Internal and ASME/US DOE Peer Reviews Successfully completed• Alstom’s Phase IVA - Prototype (3 MWt):
US DOE Cooperative Agreement - Sept, 2008
Alstom Chemical Looping Development – March 24-26, 2009 - P 18© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Development
• Project Overview
• Technology
• Project Objectives
• Project Methodology
• Future Plans
Alstom Chemical Looping Development – March 24-26, 2009 - P 19© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping PrototypePhase IVA
Chemical Looping 3 MWt Prototype Facility Preliminary Concept
• 1000 lb/hr coal flow• 1st Integrated Operation• 1st Autothermal Operation
Phase IV Objective:Obtain the engineering and operating informationrequired to build and operate a reliable, commercial-sizedemonstration plant.
Alstom Chemical Looping Development – March 24-26, 2009 - P 20© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Development
• Project Overview
• Technology
• Project Objectives
• Project Methodology
• Future Plans
Alstom Chemical Looping Development – March 24-26, 2009 - P 21© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
• Prototype Location – Alstom Power, Windsor, CT.– All Equipment Necessary for Viable Demo Design– 1000 lb coal / hr – Combustion, Syngas, Hydrogen– Design, Construction, Operation, Maintenance, Modification by Alstom
N2 Rich Fluegas
OxidizerReducer
Process Steam
Limestone
CombustionAir
Solids Drain
Coal
Stack
Medium-Btu Gasto Cooler and
Fuel Compression
AshCooler
Calciner
TubularAir
Heater
CO2CO2 rich product to Gas Processing System
MBHE
SolidsReturn
CaS
HotSolids
CaSO44
MBG (H2)
CaCO33
CaOOxygen TransportChemical Loop
CarbonateChemical Loop
CalcinerThermal Loop
Phase IVA – Prototype Concept
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Chemical Looping Development - Phase IVASolids Transport Testing
• Prototype Cold Flow Model (CFM)– Startup and operating methods
– Identify/Solve critical technical aspects
– Improve plant arrangement
– Assist cost study
• High Solids Load Tests in 40-ft CFM– Solids/gas Transport design tool
– Quantify the key parameters in this region
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Chemical Looping Development – Phase IVADesign/Build/Test Program
• Small-scale Cold Flow Modeling– Vessels scaled from the Prototype plant design
– Control and distribution of solids/gas flow
– Startup procedures
– Identify critical areas (e.g. erosion, control) for the prototype plant design
– Prototype operator training
– Prototype solids transport problem solving
• Design/Test Prototype plant – Complete the design tools for the prototype plant
– Complete the prototype sizing and selections for all vessels
– Prototype Operation/Testing/Modification/Development
– Update commercial economics analysis and specs recheck
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Prototype Schedule
Alstom Chemical Looping Development – March 24-26, 2009 - P 25© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping Development
• Project Overview
• Technology
• Project Objectives
• Project Methodology
• Future Plans
Alstom Chemical Looping Development – March 24-26, 2009 - P 26© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
Chemical Looping DevelopmentPhases IV, V, VI
Prototype (1000 lb/coal/hr)
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Chemical Looping Development Plan
• Demonstration Plant – Phase V: – Objective: Demonstrate Reliability and Performance
– Electric Utility Sponsor/Existing site – locate during Phase IV
– 50 to 100 MWe
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