Clean Coal Technologies
International Seminar: Does Fossil Energy have a role in
© IEA Clean Coal Centre www.iea-coal.org.uk
International Seminar: Does Fossil Energy have a role insustainability and security of supply?
Dr John TopperManaging Director, IEA Clean Coal Centre
27 June 2007, Brasilia
MEMBERS
Italy JapanRep. ofKorea UK
Spain
USA
AustriaCanada
Germany
CEC
© IEA Clean Coal Centre www.iea-coal.org.uk
BHELIndia
Anglo Coal S. Africa
ESKOM S. Africa
Netherlands Group
BG Group, UK
BRICC China
ACIC, Australia
CANZ, New Zealand
Eletrobras,Brazil
DPG, Denmark
Suek,Russia
SIG, Sweden
Schlumberger in process
CONTENTS OF THIS PRESENTATION
Coal for Power Generation– Current state of the art and impending
developments in efficiencies
Carbon Capture and Storage Technologies
© IEA Clean Coal Centre www.iea-coal.org.uk
Carbon Capture and Storage Technologies– Coal combustion and gasification systems– Storage
Coal to Liquids
COAL FOR POWER TODAY
© IEA Clean Coal Centre www.iea-coal.org.uk
What is State-of-the-Art and what are theprospects?
Pulverised coal combustion
100’s of GWe units to ~1000 MWe
Efficiency to mid-40s% (HHV) in bestlocations
Conventional emissions control wellestablished
How will it be in 10 or 20 years?Still the most deployed coal technology
~
Mills
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Still the most deployed coal technology
Advanced emissions control
Further incremental efficiencyimprovements
Progression to very high steam conditions~ 50% efficiencies
CCS on some plants using flue gasscrubbing or oxygen firing
Limestoneslurry
Gypsum
Mills
Air heater
Ash
Air
Coal
AshStack
FGD
SCRFlue gas
Operating Supercritical Plant
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Nordjylland 3, Denmark, 1998 (384 MWe net)bituminous coals
© IEA Clean Coal Centre www.iea-coal.org.uk
Courtesy Vattenfall
Niederaussem K, Germany, 2002 (965 MWe net)lignite
© IEA Clean Coal Centre www.iea-coal.org.uk
Courtesy RWE Power
Isogo New Unit 1, Japan, 2002 (568 MWe net)mainly bituminous coals
© IEA Clean Coal Centre www.iea-coal.org.uk
Courtesy J-POWER
Isogo New Unit 1, Japan – highlights
• Near zero conventional emissions (NOx 20 mg/m3, sulphur oxides 6mg/m3, particulates 1 mg/m3, at 6% O2, dry); full waste utilisation
• Highest steam conditions: 25.0 MPa/600C/610C at turbine: ASME
USC, tower boiler, opposed wall firing, intbitum and Japanese coals, warm sea water
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• Highest steam conditions: 25.0 MPa/600C/610C at turbine: ASMECC 2328 steels in S/H; P122 for main steam pipework
• Operating net efficiency >42% LHV/40.6% HHV• Efficiency tempered slightly by 21C CW, fewer FW heating stages• Dry regenerable activated coke FGD (ReACT)• NOx abatement Combustion measures and SCR• Particulates removal ESP• Isogo New Unit 2 will use ReACT specifically for multi-pollutant
control, including mercury
Host Plant, Scholven F, E.ON COMTES700
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Lagisza Supercritical CFBC – new design
• The world’s first CFBCunit with supercriticalsteam conditions
• Largest CFBC; 460 MWe
• Start-up in 2009
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• Start-up in 2009
• Emissions of SOx, NOxand particulates lowerthan required by latestEU LCPD limits.
• Located to NE ofKatowice, Poland
TOWARDS ZERO EMISSIONS
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CarbonReduction
`IncreasedEfficiency`
`Zero Emissions`Trajectory
Key issue will be value of CO2
Carbon Abatement TechnologyOptions are complementary
© IEA Clean Coal Centre www.iea-coal.org.uk
Time
Efficiency`Trajectory
Near-term Mid-term Long-term
Zero emissions will need the most efficient plant
Capture and Storage Process(Courtesy of CO2CRC)
© IEA Clean Coal Centre www.iea-coal.org.uk
©C
O2C
RC
Schematic representation of capturesystems.
© IEA Clean Coal Centre www.iea-coal.org.uk
160 T/D CO2 Capture Plant(Supplied by MHI of Japan and using their KS 1
Solvent)
Client: Petronas Fertilizer (Keda) Sdn. Bhd.
Location: Kedah Darul Aman, Malaysia
CO2 Capture: in Malaysia
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Feed Gas: Steam Reformer Flue Gas
Capacity: Flue Gas 47,000 Nm3/H(Max. Capacity = 210 T/D)
Use of CO2: Urea Production
Start Up: October 1999
CASTOR CO2 capture pilot plant
© IEA Clean Coal Centre www.iea-coal.org.uk
Esbjerg power plantCapacity: 1 t CO2 / h5000 Nm3/h flue gas (coalcombustion)In operation since early 2006
Potential for Cost Reduction
250
300
350
400
450REDUCTIONS IN FGD COSTS IN USA
(Boward and Brinkmann, 1998)
© IEA Clean Coal Centre www.iea-coal.org.uk
400
275200
100125
0
50
100
150
200
250
1970 1980 1990 1997 2000
$/kW
Path to zero emissions for PCC
Hg activities:removal methodscharacterisation
First commercial salesPCC-ZETs Advanced PCC-ZETsBest SO , NOx, particulates
Advanced USC PCC demonon-CO2 capture
Advanced USC PCCcommercial
non-CO2 capture
Post 2015Now 2010
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S/C PCC
PCC-ZETsretrofits and new
Advanced PCC-ZETsBest SO2, NOx, particulatescontrol deployment
CO2 capture:large plant
chemical scrubbing demo
CO2 capture R&D activities:solvents, heat integration
other absorbentsmembrane contactors
adsorptionoxy-coal test programmes
Non-cryogenic oxygenplants commercial
Oxy-coal demos
Oxy-coal large plant demo
COCO22 Capture Ready PlantCapture Ready Plant• A plant which can include CO2 capture when the
necessary regulatory or economic drivers are in place• Avoids the risk of stranded assets and ‘carbon lock-in’• Developers must eliminate factors which would
www.ieagreen.org.uk
• Developers must eliminate factors which wouldprevent installation and operation of CO2 capture
• This might include• A study of options for capture retrofit• Include sufficient space and access for additional
facilities• Identify reasonable route(s) to storage of CO2
Vattenfall Oxy Fuel Technology(Courtesy Vatenfall)
The size of the plant will be about 30 MWth and theenergy will be utilized
The technologyused is the“Oxyfueltechnology”
Adjacent to the
© IEA Clean Coal Centre www.iea-coal.org.uk
Adjacent to theSchwarze PumpePower plant andwill utiliseinfrastructure.
Fuel will belignite, and hardcoal
Integrated gasification combined cycle (IGCC)
Demonstrations in USA and Europeand, shortly, in Japan
Cost/availability concerns have heldback orders but reference plants soon
Efficiency ~40-43% HHV
V. low emissions, Hg capture simpleCoal andoxygen Raw
gas
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V. low emissions, Hg capture simple
How will it be in 10 or 20 years?More widely deployed
Advanced performance and lower cost
New gasifier designs &polygeneration
CCS using pre-combustion capture
Gasification
gas
Cleanfuel gas
~Gasturbine
Waste heatboiler
Stack
Steamturbine ~
Byproductsand wastes
Slag
Air
Gascleaning
RWE’s Proposed IGCC with CCS plant
Drying Coal gasification Gas treatmentCO capture
Gas and steamturbine
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CO2 capture turbine
Power
Dry coal
Raw coal
Carbon
USA: New Technologies Emerging from R&D
Fuel Cells
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Gasification withCleanup Separation System
Integration
CarbonSequestration
OptimizedTurbinesH2 Production
Path to zero emissions for IGCC
HGCU R&D:particulates
SO2, NH3, CO2
Demonstration/commercialIGCC plants
Plus some slipstream CO2 capture projects
Post 2015Now 2010
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CurrentIGCCplants
IGCC ZETsdemonstrations
Commercial IGCCZETs plants
various technologiesmulti-productsnon-cryogenic oxygen
plants commercialCO2 capture R&D:membrane separationmembrane reactors
PSA
F-class hydrogen turbinedevelopment
and commercialisation(other markets)
Storage of CO2Storage of CO2
www.ieagreen.org.uk
COCO22 storage effectiveness increases with depthstorage effectiveness increases with depthCourtesy ofCO2CRC
www.ieagreen.org.uk
www.ieagreen.org.ukCourtesy of CO2CRC
COCO22 Injection and Storage ActivitiesInjection and Storage Activities
Nagaoka
HokkaidoQinshui Basin
Snohvit
Sleipner
SibillaRECOPOL
CO2 SINK
K-12B
West Pearl Queen
MountaineerWeyburn
Penn WestAlberta ECBM
Teapot DomeRangely
4 New CO2-EOR Pilots inCanada
50 Acid Gasinjection sites inNorth America
www.ieagreen.org.uk
Nagaoka
In Salah
Key
ECBM projects
EOR projects
Gas production Fields
Saline aquifier
Cerro Fortunoso
Frio
West Pearl QueenRangelyBurlington
70 CO2-EORprojects in U.S.A.
GorgonDepleted Oil Field
Otway Basin
www.co2captureandstorage.info
Source: National OccupationalHealth and Safety CommissionCompendium of Worker’sCompensation Statistics,Australia, 2001 -02, December2003
APPEA Safety IncidentDatabase 2003
www.ieagreen.org.uk
*Frequency rate is calculatedfor one week or more lost time
**Data used is 2003 statistics
Courtesy of CO2CRC
Current MembershipCurrent Membership
www.ieagreen.org.uk
COAL TO LIQUIDS
© IEA Clean Coal Centre www.iea-coal.org.uk
All slides sourced from IEA CIAB workshopon Coal to Liquids, Paris, November 2006
World is Consuming More Oiland Finding Less
30
40
50
60B
illio
ns
ofB
arre
ls
30
40
50
60
Past
Future
Production
© IEA Clean Coal Centre www.iea-coal.org.uk
Past discoveryby ExxonMobil
0
10
20
30
1930 1950 1970 1990 2010 2030 2050
Bill
ion
sof
Bar
rels
0
10
20
30
“GrowingGap”
Oil Markets
50
60
70
80
2005
2006
US$/bbl Dated Brent
© IEA Clean Coal Centre www.iea-coal.org.uk
10
20
30
40
50
Jan Mar May Jul Sep Nov
2004
2003
Source: Platt’s
DOE Fuel Price Forecasts 2003-2030
$10.00
$12.00
$14.00$16.00
$18.00
$20.00
$/m
mb
tu
Oil
Coal v’s Oil price forecasts in USA
© IEA Clean Coal Centre www.iea-coal.org.uk
Source: US DOE Annual Energy Outlook 2006
$0.00
$2.00
$4.00
$6.00
$8.00
$10.00
200
3
200
7
201
1
201
5
201
9
202
3
202
7
$/m
mb
tu
Oil
Coal
Coal to Liquids Technologies
Indirect Liquefaction
Based on gasificationConverts syngas (H2 and CO)into clean methanol orhydrocarbon liquidsCan also produce ultra-clean
Direct Liquefaction
Based on high-pressuredissolution and hydrogenationof coalMore energy efficient thanindirect liquefaction
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Can also produce ultra-cleandiesel or jet fuelCO2 can be captured forsequestrationCan co-produce electricpower or hydrogen
indirect liquefactionProduces high energy densityfuels
– Diesel with Low Cetane#
– High aromaticsUsed by Germany in WW 2,improved by U.S., now beingdeployed in China
Direct Coal Conversion to Liquid Fuels
Gas RecoveryTreatment
RefiningHydro-
treatingUnit
Coalconversion Diesel Fuel
Gasoline
LPG
Methane& Ethane
H2S, NH3, COx
H-Donor
Recycled H2Make-upH2
Coal +Catalyst
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Fractionation
SolventDeashing
Ash Reject
Heavy VacuumGas Oil
H-DonorSlurry
Slurry
Deashed OilGasifier
Unconverted Coal
Maturing Direct Coal Conversion
Originally developed in Germany in early 1900sUsed to produce military fuel in WWIIUS spent $3.6 billion on DCL from 1975-2000Technologies licensed to China in 2002
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Lawrenceville, NJ3 TPD
Catlettsburg, KY250 – 600 TPD
Inner Mongolia, China4,200 TPD
Direct Conversion
Advantages
Conceptually simpleprocessProduces high-octanegasolineMore energy efficient thanindirect conversion (i.e.more fuel / BTUs produced
Disadvantages
High aromatic contentLow-cetane number dieselPotential water and airemissions issuesFuels produced are not a
© IEA Clean Coal Centre www.iea-coal.org.uk
indirect conversion (i.e.more fuel / BTUs producedper ton of coal)Products have higherenergy density(BTU/gallon) than indirectconversion
Fuels produced are not agood environmental fit forthe U.S. marketMay have higher operatingexpenses than indirectconversion
Indirect Coal Conversion
Gasification &Gas Cleaning
Fischer-TropschSynthesis
FT ProductSeparation &
Upgrading
Oxygen/Steam
CoalBiomass
etc
H2 + COSyngas
CxHyLiquids& Wax
Catalyst
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Electric PowerGeneration
Sulfur,CO2
and Ash
Steam
Electricity
Steam Tail GasWater
&Oxygenates
Ultra-CleanLiquid Fuels& ChemicalFeedstocks
LiquidsSynthesis
Slurry / Fixed/ Fluid Bed
Indirect Coal Conversion
CoalNatural GasPet CokeBiomassWaste
Synthesis GasProduction• Gasification• Reforming
- Steam- POX- ATR
O2
ProductRecovery
TailGas Power
Generation
HydrogenRecovery
Wax
CO2Removal
H2 + COSyngas
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/ Fluid BedOxygen
PlantAir
NaphthaDiesel FuelChemicals
WaxHydrocracking
Liquids
Liquids
GE ConocoPhillipsKBR Shell Siemens
Catalyst
Indirect Conversion
Advantages
Ultra-clean productsWell suited for CO2captureWell suited for electricpower co-production
Disadvantages
Conceptually morecomplex than directconversionLess efficient fuelproduction than direct
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power co-productionMay have lower operatingexpenses than directconversion
production than directProduces low-octanegasolineFewer BTUs per gallonthan direct conversionproducts
Key drivers for a viable CTL business(Sasol’s View)
Access to:
large reserves of low cost gasifiablecoal (a minimum of approximately 2 – 4billion tons) at proposed location.
Minimum plant capacity: 80 000barrels per day to realize economy ofscale benefits.
© IEA Clean Coal Centre www.iea-coal.org.uk
scale benefits.
“Stranded coal” (e.g. due to quality orlocation) which can not be easilymonetised in other ways.
Drive for energy security supported by currentglobal energy dynamics
Ability and will to provide enabling support
THE END – Thank you for listening
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