Pre - Combustion for Coal Fired Power Plant

by

Monica Lupion
IEA Greenhouse Gas R&D Programme
2009 Summer School
25th August 2009. Lorne (Australia)

*Corresponding Authors Email:

m.lupion@ciuden.es

Presentation Outline

Introduction
General overview of the Pre-Combustion Technology

Gasification

Technology Overview
Basic Chemistry
Types of Gasifiers
Combustion versus Gasification

IGCC

IGCC Overview
IGCC Comparison
Large Scale IGCC Projects
Key IGCC Market Barriers

IGCC with CO2 Capture

General Overview
Economics of IGCC with CO2 capture

Introduction
General overview of the Pre-Combustion Technology

General Overview of Pre-Combustion Technology

Pre-combustion capture process is not a new concept

Primarily based on production of synthetic gas, separating the
CO2 and using the decarbonised gaseous fuel for the gas turbine

One of the main elements is the gasification of the fuel

feedstock to produce syngas
Gasification technologies could produce a waste gas
stream, which has high concentration of CO2
This offers an opportunity to capture CO2 at low cost

It should be noted that CO2 capture is not a process

requirement, but could be easily implemented if
warranted
4

General Overview of Pre-Combustion Technology

CO23-15%

CO240%

CO2>95%

Adapted from EPRI 2007

General Overview of Pre-Combustion Technology

CO23-15%

CO240%

CO2>95%

Adapted from EPRI 2007

Gasification
Technology Overview

Technology overview

Technology overview

Gasification
Basic Chemistry

10

Technology Overview: Basic Chemistry

A partial oxidation process that can convert any hydrocarbon

into hydrogen and carbon monoxide (synthesis gas or syngas)

(CH)n + O2

H2 + CO

For example:

2 CH4

[ Methane]

O2
[Oxygen]

Process Conditions:

4H2
[Hydrogen]

2 CO

[Carbon Monoxide]

950-1550 C, 25-70 bar

11

Technology Overview: Basic Chemistry

Severe thermo-chemical operating conditions

Carbon
monoxide

H2O

Chlorine
Nitrogen

Hydrogen

Carbon
dioxide

Mineral
matter

Ash

Water

Ammonia

Carbon
Sulphur

Hydrogen

Hydrosulfuric
Acid, H2S

Hydrochloric
Acid, HCl

O2
REACTANTS

PRODUCTS

12

Technology Overview: Basic Chemistry

CONCEPT
Partial oxidation process to produce syngas
GASIFICATION AGENTS
Elemental OXYGEN:
AIR
Elemental OXYGEN:
O2
Combined OXYGEN:
H2O
Mixtures OXYGEN/WATER

POOR SYNGAS (CO + H2 + N2)

WATER SYNGAS (CO + H2)

IDEAL GASIFICATION
CARBON

CARBON MONOXIDE

INEFFICIENCIES:

PARTIAL FORMATION CO2

INCOMPLETE CARBON OXIDATION

COLLATERAL REACTIONS:

PYROLISIS
HYDROGENATION (C + 2 H2

CH4 )
13

Technology Overview: Basic Chemistry

14

Technology Overview: Basic Chemistry

COAL
HEAT
VOLATILES

GASES
673 k

PYROLISIS

PRIMARY
REACTIONS

AIR/OXYGEN
STEAM
973 k

SECUNDARY
REACTIONS

COKE
+
MINERAL MATTER

CO

H
2

CO
2

CH
4

GASIFICATION

COMBUSTION

GASIFICATION

To keep T

15

Gasification
Types of Gasifiers

16

17

Technology Overview: Gasifiers

3 MAYOR TYPES OF GASIFIERS

Moving Bed

Fluidized Bed

Entrained Flow

GASIFIERS CHARACTERISATION

Reactants and products inlet

Particle size

Resident time

Operating Temperature

Operating Pressure

BASIC GASIFICATION CHEMISTRY

Gasifier Vessel: CxHy + O2
CO + H2

Water/Gas Shift: CO + H2O
H2 + CO2
17

18

Technology Overview: Gasifiers

First Generation Gasifiers

Pressure

Temperature

(bar)

(C)

C % Resident time

Particle Size

Moving Bed
(LURGI)

99

1-1/2 h

30

1100

>10 mm

Fluidized Bed
(WINKLER)

70

3/4 h

900

0-10 mm

1500

70% 200 mesh x down

(dry)

Entrained Flow
(KOPPERS88-98
TOTZEK)

Few
seconds

18

Technology Overview: Gasifiers

Moving Bed Gasifiers

Dry carbon fuel is fed through
the top of the gasifier. As it
slowly drops through the
vessel, it reacts with steam
and oxygen as they flow in
opposite in directions over the
bed. The fuel goes through the
process until it is completely
spent leaving behind low
temperature syngas and dry
ash. Trace contaminants are
later scrubbed from the
syngas

Source: EPRI

19

Technology Overview: Gasifiers

Fluidized Bed Gasifiers

Steam and oxygen flow
upwards through the reactor
tower while fuel is injected
into, and remains suspended
in, this stream while
gasification takes place.
Moderate temperature syngas
exits the while dry (unmelted)
ash is evacuated at the bottom

Source: EPRI

20

Technology Overview: Gasifiers

Entrained Flow Gasifiers

Fuel can be fed dry or wet
(mixed with water) into the
gasifier. The reactants
(steam and oxygen) flow unidirectionally through the
gasifier, as the stages of
gasification take place, until
high temperature syngas
exits the reactor. Molten slag
drops out at the bottom
Source: EPRI

21

Technology Overview: Gasifiers

22

22

Technology Overview: Gasifiers

23

23

Technology Overview: Gasifiers

24

24

Gasification
Combustion vs Gasification

25

Combustion vs Gasificacion

Combustion

Gasification

SO2 & SO3 is scrubbed out of

stack gas reacted with
limestone to form gypsum

H2S & COS are easily removed

from syngas and converted to
solid sulfur or sulfuric acid

NOX controlled with low NOX

burners and catalytic conversion
(SCR)

NH3 washes out of gas with

water, thermal NOX controlled by
diluent injection, optional SCR
for deeper NOX removal

Flyash removed via ESP or bag

filters

Ash is converted to glassy slag

which is inert and usable

Hg can be removed by
contacting flue gas with activated
carbon

>90% of Hg removed by passing

high pressure syngas thru
activated carbon bed
26

Presentation Outline

Introduction
General overview of the Pre-Combustion Technology

Gasification

Technology Overview
Basic Chemistry
Types of Gasifiers
Combustion versus Gasification

IGCC

IGCC Overview
IGCC Comparison
Large Scale IGCC Projects
Key IGCC Market Barriers

IGCC with CO2 Capture

General Overview
Economics of IGCC with CO2 capture

27

IGCC
IGCC overview

28

IGCC Overview

29

29

30

IGCC Overview

Particulate
Removal

Gas
Cleanup

Shift
Reactor

Synthesis Gas
Conversion

Fuels and
Chemicals

Gasifier

Particulates
Sulfur By-product

Gaseous
Constituents

Hydrogen
Separation

Solid By-product

Hydrogen
Combustor

Air Separator
Air
Coal,
Petroleum coke,
Biomass,
Waste, etc.

Oxygen

Compressed Air

Solids

Carbon Dioxide
Sequestration

Air

Gas
Turbine

Fuel Cells

Electric
Power

Electric
Power
Generator
Air
Heat Recovery
Steam Generator
Steam
Solid By-product

Steam

Stack
Generator

Steam Turbine

Electric
Power

30

IGCC Overview

Sulfur removed (99.5-99.99%) from syngas using commercial

gas processing technology
NOx emissions controlled by firing temperature modulation in
the gas turbine. Possible addition of SCR if needed
Particulates removed from the syngas by filters and water wash
prior to combustion so emissions are negligible
Current IGCC designs available with SCR to achieve ~3ppmv
each of SOx, NOx
Mercury >90% removed from the syngas by absorption on
activated carbon bed
By-product slag is vitreous and inert and often salable
CO2 under pressure takes less energy to remove than from PC
flue gas at atmospheric pressure
Source: EPRI

31

IGCC
IGCC Comparison

32

IGCC vs Conventional Coal PS

33

Pre-combustion clean-up of fuel prior to power generation

Environmental Technology => Greatest potential for future
 Proven lowest NOX, SOX, particulate matter and lower hazardous
air pollutants
 Proven mercury and carbon dioxide removal
 Lower water usage, lower solids production
 Sulfur and non-leachable slag by-products
 CO2 under pressure takes less energy to remove than from PC
flue gas at atmospheric pressure (Gas volume is <1% of flue gas
from same MW size PC)

Proven polygeneration flexibility, now and in future

 Power, hydrogen, steam, chemicals, zero-sulfur diesel

Practical opportunity to retrofit carbon capture equipment

33

IGCC vs Conventional Coal PS

34

Solid Wastes
 Less Volume: IGCC produce about half the solid wastes of
conventional coal plants
 Better Form: IGCC solid wastes are less likely to leach toxic
metals than fly ash from conventional coal plants because
IGCC ash melts and is vitrified (encased in a glass-like
substance)

Water Use
 Less Water: IGCC units use 20%-50% less water than
conventional coal plants and can utilize dry cooling to
minimize water use
34

IGCC vs Conventional Coal PS

35

35

IGCC
Large Scale IGCC Projects

36

Large Scale IGCC Projects

Coal IGCC in Operation Worldwide

37

Large Scale IGCC Projects

Nuon- Buggenum, Netherlands 250 MW IGCC

38

Large Scale IGCC Projects

Wabash 260 MW IGCC Repowering

39

Large Scale IGCC Projects

Tampa Electric - Polk 250 MW IGCC

40

Large Scale IGCC Projects

300 MWe ELCOGAS IGCC (Puertollano, Spain)

Gasifier
ASU

Coal Preparation

Turbines:
GT&ST

Gas
Depuration

41

Large Scale IGCC Projects

250MWe Air Blown IGCC (Fukushima, Japan)

42

IGCC
Key IGCC Market Barriers

43

Key IGCC Market Barriers

Unfamiliar and uncomfortable technology to power industry:

chemical plant not combustion boiler
Currently higher capital and operating costs relative to
supercritical boilers
Standard designs and guarantee packages not yet fully developed
Reluctance of customers to be early adopters, and assume
technology application risk
Environmental benefits threaten existing coal power fleet
Questions about feasibility and cost using low-rank coals,
particularly lignite
IGCC is an emerging industry, vs. established boiler industry
Real interest in coal gasification to SNG, zero sulfur diesel,
ammonia and other chemicals will assist IGCC development
44

Key IGCC Market Barriers

Will reliability hinder the

deployment of IGCC?
Record for IGCCs
availability has been poor
but improving.
Complexity of the plant
could be a turn off to
prospective investors or
power generation company
Cost is another issue
Source: EPRI

45

Key IGCC Market Barriers

IGCC Improvement Opportunities

Gas Turbines redesign to recover the derating, lost

performance and efficiency with syngas and hydrogen firing
Reduce ASU consumption: Ion Transfer Membrane, ITM (?)
Gas separation membranes and processes (such as
dedusting systems for particles depuration) that can operate
at warmer temperatures
Longer term possiblities such as Solid Oxide FC would
eliminate the need for shift and CO2 removal

46

Key IGCC Market Barriers

Development in Gas Turbine Technology: Horizontal Silo

COMBUSTION CHAMBER

TURBINE

AIR INLET

COMBUSTION CHAMBER

COMPRESSOR

47

Key IGCC Market Barriers

Development in Gas Turbine Technology: Annular Combustor

48

49

Key IGCC Market Barriers

Oxygen Production (I)

Source: NETL

49

Key IGCC Market Barriers

Oxygen Production (II)

Source: NETL

50

Presentation Outline

Introduction
General overview of the Pre-Combustion Technology

Gasification

Technology Overview
Basic Chemistry
Types of Gasifiers
Combustion versus Gasification

IGCC

IGCC Overview
IGCC Comparison
Large Scale IGCC Projects
Key IGCC Market Barriers

IGCC with CO2 Capture

General Overview
Economics of IGCC with CO2 capture

51

IGCC with CO2 capture

General Overview

52

IGCC with CO2 capture: General Overview

IGCC with CO2 capture and Hydrogen coproduction

53

IGCC with CO2 capture: General Overview

Advantages
High CO2 concentration and high overall pressure
Lower energy consumption for CO2 separation as compared
to post-combustion capture
Compact equipment

Proven CO2 separation technology

Possibility of co-production of hydrogen

Disadvantages
IGCC is unfamiliar technology for power generators
Existing coal fired plants have low availability
IGCC without CO2 capture has generally higher costs than
pulverised coal combustion
54

IGCC with CO2 capture: General Overview

CO2 Emissions from Sub-bituminous Coal

1.0
0.9
CO2 Emissions (t/MWh)

0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
SCPC
Reference

SCPC Oxyfuel

SCPC - Amine

IGCC
Reference

IGCC Capture

55

IGCC with CO2 capture: General Overview

CO2 Emissions from Lignite Coal

1.0
0.9

CO2 Emissions (t/MWh)

0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
SCPC
Reference

SCPC Oxyfuel

SCPC - Amine

IGCC
Reference

IGCC Capture
56

IGCC with CO2 capture: General Overview

Coal Gasification Plants w/CO2 Capture (Today)

IGCC and CO2 removal offered
commercially:
Have not operated in an integrated manner

Three U.S. non-power facilities and many

plants in China recover CO2
Coffeyville
Eastman
Great Plains

The Great Plains Synfuels Plant

http://www.dakotagas.com/Companyinfo/index.html

Great Plains recovered CO2 used for EOR:

2.7 million tons CO2 per year
~340 MWe if it were an IGCC

No Coal IGCC Currently Recovers CO2

Weyburn Pipeline
http://www.ptrc.ca/access/DesktopDefault.asp
x

Source: EPRI

57

IGCC with CO2 capture: General Overview

Gasifier Design Features for CCS

High pressure (70 bar). Single stage entrained flow gasifier

 High pressure operation lowers the cost of CO2 removal and compression

Dry coal feed. Fuel flexibility. Coal pu

Partial water quench to temperature for gas filter.
Hot or warm gas filter for slag/ash removal

58

IGCC with CO2 capture

Economics of IGCC with CO2 capture

59

Economics of IGCC with CO2 capture

CO2 costs

// t AVOIDED CO2

100
90

/t AVOIDED CO2

90

80

1 CAPTURE

25-32

70
60
50

60

50

45

2 TRANSPORT

4-6

40
35

30

30

20

3 STORAGE

4-12

10
TOTAL

0
2015

2020

35-50

2030

Demonstration Early
phase
commercial
( 2015)
phase
( 2020+)

Mature
commercial
phase
(2030+)

CO2 cost breakdown

of early commercial units

Avoided CO2 cost

From Carbon Capture & Storage: Assessing the Economics. The McKinsey Company. September 2008

60

Economics of IGCC with CO2 capture

Avoided CO2 vs. captured CO2
EFFICIENCY

PULVERIZED COAL

IMPROVEMENT
EMITTED
BASE CASE,
NO CAPTURE
POWER PLANT
PRODUCED CO2
CAPTURE PLANT
COE

COE

CAPTURED CO2

CAPTURE PLANT
EMISSIONS

AVOIDED CO2
BASE CASE
0

CAPTURE
EFFICIENCY
IMPROVEMENT

0,2

0,4
0,6
0,8
CO2 PRODUCED (kg/kWh)

CCS

DIFFERENCE

1,0

AVOIDED CO2 COST:

CE
(CO2,BASE CO2,CCS )EMITTED

61

Economics of IGCC with CO2 capture

Capital Cost Estimates

When comparing capital cost estimates, it is important to

know what is included and more importantly
what is not included!
Total Capital Requirement (TCR) is much higher than Total
Plant Cost (TPC)
Other issues impacting reported costs:
Capital charge rates
Capacity factors
Plant size (larger plants have economies of scale)
B Stobbs
IEAGHG Summer School 2008

62

Economics of IGCC with CO2 capture

CCPC Phase II Unit Cost Comparisons (TPC)

8,000
7,000

$ /k W ne t

6,000
5,000

Sub-bituminous

4,000

Lignite

3,000

Bituminous

2,000
1,000
PC
Reference
Plant

Amine
Scrubbing

Oxyfuel

IGCC
Reference
Plant

IGCC
Capture
Ready

IGCC
Capture

B Stobbs
IEAGHG Summer School 2008

63

Economics of IGCC with CO2 capture

CCPC Phase II COE Comparisons

250

$ /M W h

200
Sub-bituminous

150

Lignite
Bituminous

100

Sub-bit pre-FEED

50
0
PC Reference
Amine
Plant
Scrubbing

Oxyfuel

IGCC
IGCC Capture IGCC Capture
Reference
Ready
Plant

B Stobbs

IEAGHG Summer School 2008

64

Economics of IGCC with CO2 capture

Electricity costs from large power stations by 2020

90
80

TRANSPORT AND STORAGE

COSTS NOT INCLUDED

NO CAPTURE
PRE-COMBUSTION
POST-COMBUSTION
OXYCOMBUSTION

HARD COALS

LIGNITES

70

EUR/MWh

60
50
40
30
20
10
0

Global process efficiency must be increased in order to reduce

costs and improve competitiveness

65

Economics of IGCC with CO2 capture

66

Source: EPRI

66

Economics of IGCC with CO2 capture

Source: EPRI

67

Economics of IGCC with CO2 capture

Coal Characteristics Drive Technology Selection

IGCC w/ CCS

Bituminous Coal

Sub-Bituminous Coal

Lignite Coal

PC w/ CCS

Usually Favored

Water use limits

Lower elevation
Lower moisture
Lower ash

Higher elevation
Higher moisture
Higher ash
Higher ambient temp.

Usually Favored

Source: EPRI

68

Thank you!!!

Monica Lupion
Fundacion Ciudad de la Energia CIUDEN
m.lupion@ciuden.es
IEA Greenhouse Gas R&D Programme.2009 Summer School
69