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1 ROYAL SOCIETY OF CHEMISTRY TECHNOLOGY IN THE USE OF COAL Professor James Harrison FRSC FEng
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ROYAL SOCIETY OF CHEMISTRY
TECHNOLOGY IN THE USE OF COAL
Professor James Harrison FRSC FEng
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National Coal Board
1947
Mines 958
Manpower 718000
Use –electricity 28
-domestic 37
-steel 43
-other 80
Total Use Mt 188
3
4
5
6
1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 20000
200
400
600
800
hot blast temperature >1200 °C
burden distribution
coal injection
improved sinter quality
oxygen enrichment
top pressure
oil injection and burden preparation
Red
ucti
on
ag
en
t co
nsu
mp
tio
n (
kg
/t h
ot
meta
l)
oil
theoretical minimum414 kg /t hot metal
coke
coal
Source: Thyssen-Krupp, Germany
Figure 1: Carbon usage in blast furnace ironmaking and associated technology developments over the last 50 years
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8
9
10
11
12
RSC MARCH
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14
15
The water-gas reaction :-C +H2O ↔ H2 + CO - heat + 131.6kJ/mol
heat for the reaction can be provided externally or by combining the reaction with combustion reactions:-
C +O2 ↔ CO2 + heat - 94.1k/mol
The water- shift reaction,CO + H2O ↔ H2 + CO2 + heat - 41.7kJ/mol
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Siemens Fuel Gasifier (SFG) Standard Design
• Cooling screen– short start-up / shut-down
– low maintenance
– high availability
– high conversion rate
• Full quench– simple and reliable
– ideal for CO sour shift
• Dry feeding– high efficiency
Coal / Feedstock
Oxygen Steam
Quench
Water
Raw Gas
Venturi
Wash
Partial
Condenser
Raw Gas to
CO Shift &
gas cleaning
Reaction
1300 to
1800°C
Quench
170 to 230°C
Black Water
Treatment
Waste Water
Sludge
LP Steam
Slag
Vent Gas
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Development of IGCC net plant
efficiencies for coal-based IGCC plants
without CCS
1970 1975 1980 1985 1990 1995 2000 2005Year of Commissioning
Lünen
Germany
(V93)
Increasing plant sizes and efficiencies of demonstration plants
Net Plant
Efficiency
in %
(LHV)
35
40
45
50
Buggenum
Netherlands
(V94.2)
Puertollano
Spain
(V94.3)
European demonstration plants with dry-fed coal gasifiers
US demonstration plants with slurry-fed coal gasifiers
2010
Japanese demonstration plant with dry-fed coal gasifier
Clean Coal
Power
Cool
Water
Tampa
Wabash
River
World’s first
IGCC plant
Puertollano plant efficiency for ISO conditions and high quality coal
Achievable with
today’s
F class
gas tubines
without CCS
Achievable
with today’s
E class
gas turbines
without CCS
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IGCC with CO2 Removal
O2 N2
Air
BFW
BFWSteam
Steam
Turbine
HRSG
Coal
PrepGas Cooling
Gasification
C + H2O =
CO + H2
Sulfur
Removal
Air
Separation
Unit
Clean Syngas
Air
Hydrogen
CO2 to use or sequestrationSulfur
Shift
CO+ H2O =
CO2 + H2
Steam
Gas
Turbine
“Sour” Syngas
& CO2
7MW 74MW
26.2MW48MW
37MW
14.5MW
10.7MW
Net Coal to Power:
26.2 + 14.5 – 10.7 =
30.2% (HHV basis)
18MW
100MW
IGCC schematic from US DOE22.5 MW
PRB Coal
With 90% CCS
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Full scale modelling
500MWe boiler
Looking at oxygen enhancement and oxyfuel combustion
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Test facility scale
modelling
Large Eddy
Simulations
LES
RANS
Axial velocity contours Temperature contours
LESLES
RANS
RANS
Temperature on flame surface
Clean Energy Systems Process
Recycle Water
C.W.
Cond.
FuelProcessing
Plant
CrudeFuel
AirSeparation
Plant
Air
N2
Coal, RefineryResidues, or
Biomass
NG, Oil orLandfill Gas
HP IP LP
O2
Fuel*
CO2Recovery
* CH4, CO, H2, etc.
ExcessWater
EOR, ECBM, orSequestration
DirectSales
HX
ElectGen.
Multi-stageTurbines
Gas Generator
CO2
RH
Recycle Water
C.W.
Cond.
FuelProcessing
Plant
CrudeFuel
FuelProcessing
Plant
CrudeFuel
AirSeparation
Plant
Air
N2
AirSeparation
Plant
Air
N2
AirSeparation
Plant
Air
N2
Coal, RefineryResidues, or
Biomass
NG, Oil orLandfill Gas
HP IP LP
O2
Fuel*
CO2Recovery
CO2Recovery
* CH4, CO, H2, etc.
ExcessWater
EOR, ECBM, orSequestration
DirectSales
HX
ElectGen.
Multi-stageTurbines
Gas Generator
CO2
RH
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No Clear Winners in Current DesignsEPR I 600 M W (net) PC and IG C C C ost o f E lectric ity
W ith and W ithout C O 2 C apture (Illino is #6 C oal)
40
60
80
100
120
140
160
S upercritica l
PC
G E R adiant
Q uench
G E Total
Q uench
Shell G as
Q uench
E-G as FSQ
30
-Yr l
ev
eli
ze
d C
OE
, $
/MW
h (
Co
ns
tan
t 2
00
7$
)
.
N o C apture
R etro fit C apture
N ew C apture
C O E Inc ludes $10/tonne for C O2 Transportation and S equestration
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A Roadmap for CO2 Capture
and Storage
2005 2010 2015 2020
Source: DOE-NETL Carbon Sequestration R&D Roadmap
Modified to add Chilled Ammonia example
Start multiple full
scale demos
Start larger scale demos
– capture and storage
Bench-scale – post-
combustion capture
Now Objective
Needs: Multiple large-scale CAPTURE and STORAGE demos
Timing: 2020 objective start today, parallel paths
Realistic? A challenge – need technical, policy, funding alignment
“Small” demos
(1.7 MW Ammonia, etc.)Complete larger scale
capture demos
Commercial
availability CCS
McKinsey: Gap for economic
feasibility of CCS to be filled in the
mid-term
0
10
20
30
40
50
60
70
80
90
>Demonstrationphase (2015)
>Early commercial
phase (2020+)
>Mature commercial
pase (2030+)
>€/t CO2
Econonic
gap
Carbon price forecast
Commercial phase:
Cost of CCS expected
to be in the range of the
future carbon price
Demonstration
phase:
Not economic on
standalone basis
* Carbon price for 2015 from 2008-15 estimates from Deutsche Bank, New Carbon Finance, Soc Gen, UBS,Point Carbon,assumed constant afterwards
Source: Reuters; Team analysis
>Source: McKinsey
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Estimates of available UK generating capacity (in GW)
Note: This figure is based on a graph contained in EdF’s submission to the UK
government’s
Energy Review in 2006. The statistics were based on views and plausible
future scenarios at
the time of submission
The scale of the challenge for
target emissions reductions
(UKCCC)
UK CCC Page 38, Figure 2.1
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Worldwide Market Scenario in
2015
• Transit Buses*
– 130,000-150,000 buses in service
• Light Duty Vehicles*
– 17- 80 million vehicles in service
• Hydrogen Required†
– 2.5 - 9 million tonnes per year
• Current Largest Merchant H2 Plant
– 100,000 tonne/year
• Sources:
• *UBS Warburg Global Equity Research, Ballard June
2000
• †OGDEN et al, Princeton University
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Hydrogen for Transport
• Biomass
• Renewable electricity
• Electricity - nuclear or coal
• Nuclear - chemical cycles
• Coal gasification
The water-gas reaction :-C +H2O ↔H2 + CO - heat + 131.6kJ/mol
The water- shift reaction,CO + H2O ↔ H2 + CO2 + heat - 41.7kJ/mol
CaO + CO2 ↔ CaCO3 +heat -178kJ/mol
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What UCG
involves
© IEA Clean Coal Centre www.iea-coal.org.uk
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© IEA Clean Coal Centre www.iea-coal.org.uk
Worldwide activities
The scale of the challenge for
target emissions reductions
(UKCCC)
UK CCC Page 38, Figure 2.1
