Advanced Fossil Fuel Technologies: Critical Element of Green Bridge Institution

Astana, Kazakhstan March 9, 2016

US Experience in the Advanced Fossil Fuel Technologies

Barry Worthington

Executive Director

United States Energy Association

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Coal Benefaction Strategies…

• Physical cleaning or Coal Washing (best option) – Removes impurities such as ash, rocks, and sulfur by

crushing the coal and “washing” away the denser impurities

• Briquetting coal – Uses binders to reduce sulfur dioxide emissions and

some toxic emissions

• Blending – Improves quality and combustion to save cost

• Biological cleaning – Uses microbes to eat away sulfur in coal

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Raw Coal Unloading

Storage Crushing

Screening

• Fine vs Coarse

Coal Dewatering

Drying

Final Coal Storage

Coal Cleaning Process Flow

REFUSE/WASTE

The removal of mineral matter including pyritic sulfur can reduce SO2 emissions by 40%, CO2 emissions by ~5% and improve the efficiency of the power plant by guaranteeing consistent heat value.

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Coal drying

• Pre-drying is critical for high moisture coals. – ~40% moisture content = 4% efficiency drop – ~60% moisture content = 9% efficiency drop

• Pre-drying reduces the boiler size and increases efficiency. – This also lowers CO2 and toxic emissions.

• It is best to dry using low grade/waste heat. – A low temperature coal drying process has been

developed by Great River Energy using a fluidized bed dryer (FBD) called DryFineTM.

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DryfineTM

Source: Effect of Dryfine Low Temperature Coal Drying Process on Emissions from Coal-Fired Power Plant by Bulligner et al., 2012 5

During Combustion

Fluidized-Bed Combustion (FCB)

SO2 Controls

NOx Controls

OxyCombustion

CO2 Controls

Post-Combustion

SO2 Controls

NOx Controls

Particulate Matter (PM)

Mercury Controls

Waste Controls

Upcoming Technology

Emission Control Technologies

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Emission Control Technologies

During Combustion: Processes designed to occur inside the furnace while coal is being combusted

• Fluidized-Bed Combustion (FBC)

– Finely ground coal, mixed with limestone, is injected with hot air into the boiler. As the coal burns, the limestone soaks up the sulfur

– Can reduce the amount of sulfur release by over 95%

– Boiler temperatures also drop from 2700°F (1480°C) in conventional boilers to about 1500°F (~820°C), which mitigates the production of nitrogen pollutants

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Emission Control Technologies

• OxyCombustion – Used with pulverized

coal-fired boilers – Replaces the

combustion air with a mixture of oxygen and recycled flue gas and/or water for temperature control

– Exiting flue gas, that is not recirculated, is rich in CO2 and ready for utilization or sequestration

Source: USDOE, Office of Fossil Fuels, Advanced Combustion Technologies http://energy.gov/fe/science-innovation/clean-coal-research/advanced-combustion-technologies

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Emission Control Technologies Post-Combustion Processes

• SO2 controls – Wet processes use sorbents to capture SO2

• NOx controls – Primary Abatement: reduction of NOx produced in the

primary combustion zone • Low excess air (LEA) combustion, Low NOx burners (LNB),

Staged Combustion (SC), Flue Gas Recirculation (FGR), NOx reburning

– Flue gas treatment: reduction of NOx in flue gas • Selective catalytically reduction (SCR), Selection non-

catalytic Reduction (SNCR), Zero Ammonia technology (ZAT)

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Emission Control Technologies • Particulate Matter Controls

– Electrostatic precipitators (ESP), fabric filter or baghouses, wet particulate scrubbers, cyclones and hot gas filtration systems

– ESP and baghouses are key technologies

Source:http://www.babcock.com/products/Pages/Dry-Electrostatic-Precipitator.aspx Source:http://www.envirotrain.co.uk/module-a/a3-effects-of-releases/a3-

10control-of-releases/a3-10-1physical/a3-10-1-1-bag-house 10

Emission Control Technologies

• Mercury Emissions Control

– Activated carbon injection, Oxidation catalysts, etc.

• Waste Control

– Processes to minimize refuse and waste such as fly ash

• Upcoming Technology

– Electro-catalytic oxidation technology (ECO)

• 90% reduction in NOx, SO2, PM2.5 and Hg

– Ohio State Carbonation Ash Reactivation (OSCAR)

– Low Temperature Oxidation (LoTOx)

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History of Power Plant Efficiency Peak Efficiency seen

in a power plant (47%) *

Efficiency drops as emissions control technologies are

implemented

12.3 kg of coal = 1 kwh

Global average efficiency is 33% .47 kg of coal =

1 kwh

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Coal Generation Strategies

• Fluidized Bed Combustion (FBC)

• Supercritical/Ultra-supercritical CO2

– Operates at higher temperatures and pressures resulting in increased efficiencies over conventional PCC units and significant CO2 reductions.

– Supercritical steam cycle technology has existed for decades, but recent R&D efforts are focusing increasing the efficiency levels of ultra-supercritical units to ~50%.

• Gasification – Integrated Gasification Combined Cycle (IGCC) plants use a

gasifier to convert coal, or other carbon-based materials, to syngas, which drives a combined cycle turbine.

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Ultra-supercritical Steam Generation

• 600 Megawatts • Cost= $1.8

billion • Operating since

Dec. 20, 2012

• Emissions controls: SCR , Dry flue gas desulfurization, baghouse, activated carbon injection

• Supercritical steam system works at temperature above 1100°F (593°C) increasing efficiency and reducing fuel consumption, solid waste, water use, and costs.

John W. Turk, Jr. Plant AEP Southwest Electric Power Co. (SWEPCO)

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GHG Emission Reduction Incentive for Improved Efficiency

Sources: The Economist 2014 and IEA 2013 15

Advanced Natural Gas Technology

Simple Cycle

• Natural gas is combusted with compressed air to produce a high temperature gas to power a turbine.

• Conventional power plants produce 33% electricity (67% is waste).

Combined Cycle

• A gas turbine generator generates electricity; waste heat is used to make steam to generate additional electricity via a steam turbine.

• Combined cycle power plants produce 68% electricity.

Source: http://www.hk-phy.org/energy/power/elect_phy/flash/powerplant_e.html 16

Advanced Natural Gas Technology

Integrated Gasification Combined Cycle (IGCC)

• A coal gasification system converts coal into a synthesis gas (syngas)

• Hot syngas is processed to remove sulfur, mercury, and PM

• Syngas is used in combined cycle to fuel combustion turbine and exhaust heat captured to power a steam turbine

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Carbon Capture & Storage

• Mountaineer

• Kemper County

• Petra Nova WA Parish

• Texas Clean Energy Project (TCEP)

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Source: http://energy.gov/articles/infographic-carbon-capture-101 19

Mountaineer Project AEP

• Phase 1: 30MW slip stream from 1,300 MW Mountaineer Station • Cost= $668 million • Phase 1 came onto production in October 2009.

– By December 2010, 21,000 metric tons had been captured at >90% capture rate, ~4,400 hours of operation, and 15,000 metric tons stored.

– However in July 2011, Phase 2 was halted do to “unknown climate policy”.

• Capture Technology: Post-combustion capture with chilled ammonia, Sequestered in the Mt. Simon deep saline formation

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Kemper County Southern Power Company

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• 582 MW • Cost= Initial cost estimate $2.4

billion, Now $6.49 billion • Construction started June 2010 but

expected to start using coal in late 2016 • Original deadline May 2014

(has been burning Natural gas since August 2014)

Kemper County Southern Power Company

• “Mine to Mouth” project using onsite lignite coal

• Capture Technology : Pre-combustion IGCC plant using Transport Integrated Gasification (TRIG™) with a 65% capture rate

– Estimated ~ 3.5 Mt/yr of CO2

– Captured CO2 will be piped to onshore EOR field

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Petra Nova WA Parish NRG Energy JX Nippon

• A retrofit on a 240 MW slip stream from 610 MW unit

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• Cost= ~$1 billion • Broke ground Sept 14th,

2014 and projected to begin operating at the end of 2016.

• A 75 MW gas-powered peaking unit will provide power and steam to the carbon capture facility.

Petra Nova WA Parish NRG Energy JX Nippon

• Capture Technology: Post-combustion using KM-CDR amine technology developed by MHI and KEPCO, – Expected 90% capture rate = ~1.6 Mt of CO2 annually – Capture CO2 will be used in a EOR field 82 miles away

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TCEP Summit Power

• 400 MW capacity – Typical baseload is 377 MW -> 105.7 for project

equipment, 15.7 MW to compress CO2, 42.2 MW to produce urea

• Cost= ~$1.727 billion

• Expected to be operational in 2019; in planning stage

• Capture Technology: Coal gasification with Pre-Combustion capture using Siemens IGCC technology and Linde Rectisol acid-gas capture technology with a 90% CO2 capture rate – Will also sell 750,000 tons annually of urea byproduct

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Utilization

• CO2 is utilized in several industries such as fuel, chemical, oil & gas, power and cultivation.

• Conventional Uses – EOR+, EOR for Residual Oil Zones (ROZ), & Gas-to-liquids

(GTL) from syngas to transportation fuel

• Upcoming technologies – Blue Planet Ltd: CO2 to Cement – Brookhaven National Lab: Artificial photosynthesis to

convert CO2 into fuel

• Creative funding for novel ideas – NRG COSIA Carbon XPRIZE is a $20 million competition

for a breakthrough CO2 utilization technology

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Air Capture

• Costs and general thermodynamics are not in favor of CO2 extraction from ambient air.

– However this concept is gaining momentum.

• A startup company called Carbon Engineering aims commercialize CO2 air capture and has attracted investors such as Bill Gates.

Source: http://carbonengineering.com/our-technology/ 27

Carbon Engineering’s Air Contactor

Source: http://carbonengineering.com/our-technology/ 28

Capture liquid is pumped to the top and descends through the corrugated sheets.

Large fans push air through the corrugated plastic sheets.

CO2 in the air is captured as it contacts the liquid.

Air containing less CO2 exits through the backside.

Liquid is collected in a large tray and funneled into a sump.

Liquid is with captured CO2 is sent to a regeneration facility.

The regeneration facility extracts pure CO2 from the liquid and returns the liquid to the sump .

Many national policies and global agreements such as the Paris Agreement do not create a policy push for CCUS nor will they drive new projects. We must seek a policy push and parity through alternative mechanisms. Examples include: • Accelerated depreciation • Carbon valuation • Clean development

mechanism • Contracts for differences • Feed-in-tariffs • Grants • Green bonds

• Green climate fund • Investment tax credits • Portfolio standards • Preferential dispatch for

electricity production • Private activity bonds • Production tax credits • Public-private partnership • Loan guarantees

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Advanced Fossil Fuel Technologies: Critical Element of Green Bridge Institution

Astana, Kazakhstan March 9, 2016

US Experience in the Advanced Fossil Fuel Technologies

Barry Worthington

Executive Director

United States Energy Association

30