futuregen 2.0 update
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© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
FutureGen 2.0 Update
D.K. McDonald, Technical Fellow, Babcock & Wilcox September 14, 2011
2nd Oxyfuel Combustion Conference
“We are passionate about innovation and technology leadership”
Power Generation Group
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1. State of Clean Energy in the United States
2. FutureGen 2.0 Project Description Project location Project Structure Project Schedule & Status Capture Process Description
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• No US Climate Bill, EPA GHG regulatory approach now “underway” in response, Clean Energy Standard forming: States pressing ahead, federalism at work (experiments in
democracy); renewables and CO2 limits Clean energy still desirable, but pace has slowed Wind power, solar, and nuclear recognized as clean
• DOE committed to 10 CCS demonstration projects leading to 2020 commercial deployment
• CO2 underground storage enablement with EPA Class VI rules
• Natural gas reserves attributable to US shale formations continue
to climb; seen by some as a clean transitional fuel to the future
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Ref: Cornell University “Assessment of the Greenhouse Gas Footprint of Natural Gas from Shale Formations Obtained by High-Volume, Slick Water Hydraulic Fracturing”, Robert W. Howarth, David R. Atkinson (rev. Jan. 26, 2011)
(extraction, processing, transport)
(Fugitive emissions as equivalent CO2)
(from combustion)
20 Year Time Frame
Greenhouse Gas Footprint of Natural Gas vs. Coal
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GS
GS
GS
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© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
Highest Net Efficiency (HHV)
Lowest Levelized Cost of Electricity (2007 US$, does not include AFUDC or Owner’s
costs)
References: DOE/NETL 2007 - 1291 “Pulverized Coal Oxy-combustion Power Plants” Rev. 2, DOE/NTL 2007-1281 “Cost and Baseline for Fossil Energy Plants” Rev.1 , and B&W/AL Integration Study
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© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
Near zero air emissions
Low fresh water use
Low wastewater
Conventional proven equipment
Looks like and operates like a current power plant (minimal retraining)
Construction lead time similar to conventional plants.
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© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
Meredosia Plant
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4
1 2 3 5
1 2 3
4 7
Boilers & Turbines
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© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
CO2 Pipeline & Storage Hub
Oxy-Combustion Repowering
Technology Collaboration
Agreement
Project Oversight
Project Management & Execution
ASU & CPU Oxy-Combustion Boiler and GQCS
Power Generation Group
Technology Providers
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© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
Four Phases
Status • DOE cooperative agreement signed 9/27/2010 • Teaming Agreement (AER, AL, and B&W PGG) signed 10/15/2010 • Project team mobilized • URS selected as Ameren’s A/E. • Phase 1 has proceeded on schedule. • Worley Parsons selected as B&W’s A/E in February 2011. • DOE & Management Phase 1 Reviews in progress.
Phase I Phase II Phase III Phase IV
Pre-FEED (Initial Front End
Engineering and Design)
October 2010 to October 2011
FEED (Final Front End
Engineering and Design)
October 2011 to October 2012
Procure, construct & Startup
November 2012 to April 2016
Test Period
May 2016 to December 2018
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© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
Technology Development – Oxy Coal
Define Functional Requirements Engineering / Modeling / Pilot Testing
Procure, Construction, Startup
Testing
Commercialization
Present
Large Scale Test of the Oxy Technology
Applications for DOE Funding
Phase 1
Award /Pre-FEED
Phase 2
FEED, NEPA
Phase 3
Phase 4
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© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
• Prove safety and control
• Develop cost basis for scale up to commercial sizes
• Prove operability and reliability of the integrated process – Steam cycle, Boiler Island, ASU and CPU
• Provide performance, emissions, and consumables data for future commercial guarantees
• Provide operating and maintenance experience for future commercial plants
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© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
• Meredosia, IL: Owned/operated by AER • 3-coal fired units • Unit 4, 200 MWe oil-fired built in 1975
Meredosia Plant Project Structure
• Capture – Ameren Energy Resources (AER), teamed with B&W and Air Liquide
• Transport & Storage – FutureGen Alliance • Repower Unit 4 steam turbine • Purpose-built Oxy-PC boiler • Illinois Coal, PRB blend possible
Project Timeline
• Project awarded Sept. 29, 2010 • FEED and NEPA complete June, 2012 • “Ready to test,” end 2015
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Main Fuel
• Illinois #6 • 10,500 Btu/lb (24,423 kJ/kg) • 3.2 % sulfur, 0.12% chlorine
© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
FGA announce Morgan County selected Feb. 28th 4500 ft (1372 m) Deep Saline Formation (DSF) in Morgan County (• 32 miles (51.5 km) pipeline from the plant)
Reservoir Potential CO2 Storage Resource (billion metric tons) Mt. Simon Sandstone - 27 to 109 State Potential CO2 Storage Resource (billion metric tons) Illinois 20 to 79 Indiana 7.9 to 32 Kentucky 1.5 to 6.3 Total 29 to 117 billion metric tons
Meredosia
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© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
AER’s Meredosia Unit 4 Oil fired boiler built in 1975 – to be demolished
Turbine/generator is 202 MWe 2400 psig (166 bar), 1000F (538C) main & reheat Low operating hours Well maintained and periodically operated
Infrastructure exists Coal yard and handling equipment Barge unloading Transmission capacity in place Space available for new equipment
Existing site infrastructure saves capital cost The “right size” - demonstrates retrofit/repowering potential Large enough test to directly support commercial deployment Small enough to conserve capital and permit large scale integrated test
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© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
Purpose-built oxy-combustion system Confirms oxy-combustion is a viable for repowering, retrofit or new build Testing program will utilize Illinois bituminous & other coals Provides performance and operational data to improve designs
Basis for industry acceptance Lowers equipment, operational, reliability & financial risks Demonstrates operability and reliability Provides basis for commercial guarantees Provides basis for financial institutions to invest
B&W – AL Technology
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© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
Coal
Boiler
Steam; 2400psi, 1000F/1000F
PJFF WFGD
Primary Fan
Secondary (FD) Fan
ID Fan
ASU
Burners
Recycle Damper
Air Intake
Air Intake
Recycle Damper
Cool Recycle Process
CPU
To Storage
Gas Htr DCCPS
Gas Htr
Sorbent for SO3
Recycle Heater
FD Fan
Vent
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~ 3,500 TPD CO2 to Storage
Boiler Coal Bunkers
Gypsum Pile
CPU
ASU
PJFF
Recycle Heater
(Airheater)
WFGD
DCCPS PR Fans
ID Fans
SR Fans
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Boiler
Coal Bunkers
Ash Silo Gypsum Pile
CPU
ASU
PJFF
Recycle Heater
(Airheater)
WFGD
DCCPS PR Fans
ID Fans
SR Fans
© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
Boiler & GQCS
ASU
CPU
Stack
Boiler
WFGD
DCCPS
PJFF
Steam Turbine Building
1
1
2
2
3
4
5
3 4
5
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Boiler Sectional Side View
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Trona DSI – SO3
1. Flue from Recycle Heater Outlet to DSI is lined to PJFF (could be below acid dew point - corrosion)
2. • 96 removal of SO3.
PJFF
Dry Sorbent Injection (SO3)
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1. • 99.99% removal of 2 microns or larger
Pulse Jet Fabric Filter (PJFF)
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Wet Flue Gas Desulfurization (WFGD) – SO2
1. 38 ft (11.6m) reaction tank, 32 ft (9.75m) diameter absorber, 117 ft. (35.7m) tall
2. • 98 removal of SO2. 3. • 30% removal of remaining SO3 4. • 98% removal of HCl 5. Some remaining particulate 6. Disposable grade gypsum –
dewatering system provided 7. Blowdown (chloride control) used
to wet ash 8. Flue to DCCPS and secondary
gas reheater is lined
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Direct Contact Cooler Polishing Scrubber (DCPS) – H2O and SO2 1. Temp 75F (24C) out at average ambient conditions
(H2O) 2. • 1 ppmv SO2 or H2SO4 leaving 3. • 1 ppmv HCl 4. Some remaining particulate, some gypsum carryover 5. Outlet lined to gas reheater 6. Condensed water used in Wet Cooling Tower 7. WCT blowdown used in process
© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. 27
• 4000 metric tons of oxygen per day • 96.5% oxidant purity • ASU is designed as a baseload plant • ASU turndown is 78% without venting (nominal) • ASU is designed 1.5%/min ramp-up • 4 hr backup oxidant system • A scheduled for derime every 3 years
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CPU
• >3700 metric tons of flue gas per day @ • 80% CO2 by vol.
• Removes remaining SO2, SO3, moisture, solid particulate, Hg, and NOx.
• 90% CO2 recovery • >97% CO2 purity, 99.8% expected • Compresses to pipeline pressure of 2200 psi • Same types of components as the ASU (cold
box, compressors etc)
© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved.
Thank You! Questions?
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