supercritical co production · 2018-04-17 · gasifier name vendor vendor headquarters system type...

SUPERCRITICAL CO2 CYCLES FOR POWER PRODUCTION

Presented at the 8th International Freiberg Conference on IGCC & XtL Technologies

Cologne, Germany

12–16 June, 2016

Jason D. Laumb

Principal Engineer

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DOE DISCLAIMER

This material is based upon work supported by the U.S. Department of Energy National Energy Technology Laboratory.

DisclaimerThis presentation was prepared as an account of work sponsored by an agency of the

United States Government. Neither the United States Government, nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes

any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed or represents that its use would not

infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors

expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

Acknowledgment

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NDIC DISCLAIMER

This report was prepared by the EERC pursuant to an agreement partially funded by theIndustrial Commission of North Dakota, and neither the EERC nor any of its subcontractors northe North Dakota Industrial Commission nor any person acting on behalf of either:

(A) Makes any warranty or representation, express or implied, with respect to theaccuracy, completeness, or usefulness of the information contained in this report orthat the use of any information, apparatus, method, or process disclosed in this reportmay not infringe privately owned rights; or

(B) Assumes any liabilities with respect to the use of, or for damages resulting from theuse of, any information, apparatus, method, or process disclosed in this report.

Reference herein to any specific commercial product, process, or service by trade name,trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement,recommendation, or favoring by the North Dakota Industrial Commission. The views andopinions of authors expressed herein do not necessarily state or reflect those of the NorthDakota Industrial Commission.

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OUTLINE

• Industry need• What is the Allam Cycle?

– History– Benefits

• Challenges with lignite/coal– Gasification– Corrosion– Impurity removal– Syngas combustion

• Progress to date• Future work

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INDUSTRY NEED AND POSITION

• Coal is challenged by environmental rules.

– Cost-effective carbon capture and storage (CCS) needed.

• Industry has/is researching many possible technical solutions for carbon on existing and new coal facilities.

• The Allam Cycle ‒ promising technology.

– Integrated CO2 capture = high efficiency.

– CO2 ready for enhanced oil recovery (EOR) applications.

• Greatly benefits North Dakota industry.

– Oil and gas industry.

– Lignite power generation.

Contains the intellectual property of 8 Rivers Capital, LLC and NET Power, LLC

The Allam Cycle is any supercritical CO₂ Brayton cycle that:

Is oxy‐fueled and direct‐fired.

Recuperates turbine exhaust heat via a recycle stream.

Is able to utilize a heat source in addition to the turbine exhaust.

Utilizes a turbine inlet temperature above 800°C (1000°‒1200°C optimal) and inlet pressure above 80 bar (200‒400 bar optimal).

Overview Freiberg: June 2016 6 | Allam Cycle

What is the Allam Cycle?What is the Allam Cycle?


8 Rivers has partnered with Exelon, CB&I, and Toshiba for the commercialization of the natural gas‐fired Allam Cycle via the entity known as NET Power.

50‐MWt demonstration plant under construction, planned start‐up in 2017.

Continuing to develop other applications of the Allam Cycle, including the coal‐fired Allam Cycle.


The Allam Cycle is being actively commercializedThe Allam Cycle is being actively commercialized

Coal‐Fired Development

Natural GasDevelopment


50‐MWth natural gas demonstration plant located in La Porte, TX.

Mirrors design of commercial plant to ensure scalability.

Includes all components of the Allam Cycle.

Oxygen will be pulled from a pipeline as opposed to a dedicated ASU.

Plant will undergo full performance evaluation.

Construction under way, equipment arriving.

Commissioning begins end 2016.

Full operations begin in Q2 2017.

Will test performance, reliability, controllability, and safety.

Program is fully funded.

$140 million raised for engineering, construction, and testing.

300‐MWe commercial plant under development.

Pre‐FEED study completed on full commercial plant.

Beginning FEED and early development work.

Toshiba well progressed on commercial turbine design.

Working with customers in power, oil and gas industries on development opportunities.


Core natural gas Allam Cycle is being demonstrated by NET PowerCore natural gas Allam Cycle is being demonstrated by NET Power


Overview

The Coal‐fired Allam Cycle simplifies power from coal gasificationThe Coal‐fired Allam Cycle simplifies power from coal gasification

Core Allam Cycle Natural Gas Process

• High efficiency with existing gasifier technologies.

• Minimal gasifier integration required, low complexity.

• Process simplification significantly reduces cost vs. IGCC.

• Zero emissions. No additional capture or compression equipment needed.

Efficiency LHV HHV

Gross Turbine Output 76.3% 72.5%Coal prep & feed ‐0.2% ‐0.2%

ASU ‐10.2% ‐9.7%CO2, Syngas Comp. ‐9.1% ‐8.7%Other Auxiliaries ‐6.5% ‐6.1%

Net Efficiency 50.3% 47.8%

The Allam Cycle can also be used with solid fuels.High efficiency and zero emissions achieved with existing gasification technologyand requires significantly less integration, complexity, and overall cost than IGCC.

Existing, mature, proven technology

Freiberg: 2016 9 | Allam Cycle



Allam Cycle achieves clean, low‐cost electricity competitive with all state‐of‐the‐art systemsAllam Cycle achieves clean, low‐cost electricity competitive with all state‐of‐the‐art systems

Note:• LCOE calculated using EPRI methodology.• Assumes $6.50/MMBtu natural gas and $2.00/MMBtu coal.• Cost ranges represent data from several sources: EIA (2013); Parsons Brinkerhoff (2013); NETL (2012); Black & Veatch (2012).

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KEY AREAS REQUIRED TO MITIGATE ADDITIONAL RISKS FOR COAL

• Metallurgy/corrosion• Evaluation tolerance of downstream system to potential impurities.• Dependent on gas cleanup system and coal type.

• Gasifier selection• Optimized system selection based on site and fuel.• Select for lowest LCOE, lowest risk system. Consider downstream implications.

• Gas cleanup• Evaluation of existing vs. proposed cleanup systems.• Coal and gasifier dependent.

• Syngas combustor• Key equipment development.• Dependent on gasifier output, fuel type, and required flexibility.

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CORROSION STUDIES

• Through work conducted by 8 Rivers and NETL, it was determined that carbon steels were not appropriate.

• Initial autoclave tests (120 hr, 50°C) have shown that the other selected alloys still hold promise.

• Testing at 50° and 90°C for 1000 hours is also being conducted.

Selected AlloysAlloy 20

AL-6XN

347 Stainless

321 Stainless

316L Stainless

304L Stainless

Results of Initial 120-hour TestsTest 1 Test 2

Alloy Average Mass Loss, milligrams

Vapor Phase Water Bath Vapor Phase Water Bath

Alloy 20 0.2 0.4 0.7 0.9

AL-6XN 0.2 0.4 0.4 0.6

347 SS 0.2 0.4 0.6 0.9

321 SS 0.5 0.8 1.0 1.2

316L SS 0.2 0.4 0.3 0.6

304L SS 0.1 0.4 0.5 0.6

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CORROSION STUDIES (CONT.)1000-HOUR TESTS TO DATE

• Testing at 50°C

• 260 hours 520 hours

• Testing at 90°C

• 260 hours 520 hours

GASIFIER SELECTION

No. Gasifier Name Co

mm

erci

al

Rea

din

ess

Op

erat

ion

al

His

tory

wit

h

Lig

nit

e

Ap

pli

cab

ilit

y to

L

ign

ite

No

tio

nal

Co

st

Th

erm

al

Inte

gra

tio

n

Sys

tem

Rel

iab

ility

Total Score Ran

k

1 SCGP 4.6 1.7 3.4 1.5 4.3 3.5 18.9 102 SFG 4.3 1.5 3.6 1.8 4.3 3.8 19.2 83 OMB Slurry 4.8 1.0 1.3 4.8 2.8 4.3 18.9 94 OMB Dry 3.6 2.0 3.5 4.5 4.0 4.3 21.9 45 MHI 2.4 0.7 3.2 3.0 3.3 2.0 14.6 186 Prenflo 3.3 1.2 3.0 2.5 4.0 3.3 17.3 117 GE 4.7 0.8 1.3 2.8 2.3 3.4 15.2 158 E-GAS 4.1 0.8 1.2 3.0 2.5 3.5 15.1 179 E-STR 1.8 1.2 3.5 3.0 3.3 3.0 15.9 1410 GTI 1.4 1.0 2.8 3.0 3.5 2.0 13.7 1911 HT-L 3.7 0.0 1.0 3.0 2.7 2.0 12.3 2012 MCSG 4.0 0.0 1.0 3.0 2.0 2.0 12.0 2113 OSEG 3.3 0.0 1.3 3.0 2.0 2.0 11.7 2214 TPRI 3.0 1.0 3.7 3.5 3.3 2.0 16.5 1215 U-GAS 3.4 2.4 3.8 3.1 3.1 3.5 19.4 716 HTW 3.3 3.2 3.7 2.8 3.1 3.7 19.8 617 TRIG 3.0 2.6 4.6 3.4 3.1 3.7 20.3 518 AFB 2.3 2.0 3.1 3.2 2.9 2.8 16.2 1319 KRW 1.7 1.3 3.7 3.0 3.5 2.0 15.2 1620 BGL 3.9 3.9 4.8 3.3 3.8 3.3 23.0 321 Lurgi 4.9 5.0 4.9 3.8 2.1 4.0 24.6 122 SEDIN 5.0 4.5 4.7 5.0 2.0 3.0 24.2 2

The team ranked 22 gasification systems and narrowed the list down to nine.(selected systems highlighted in yellow)

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DETAILS OF SELECTED SYSTEMS

• The team will perform further down-selection of gasification systems based on additional criteria.– Actual costs– Commercial guarantees– Sodium impacts– Overall system efficiency

Gasifier Name VendorVendor

Headquarters System Type Feed AshCurrent Rank

Lurgi Air Liquide Germany Fixed Bed Dry Nonslagging 1

BGL Envirotherm Germany Fixed Bed Dry Slagging 2

SE ECUST/Sinopec China Entrained Flow Dry Slagging 3

TRIG KBR/Southern Company USA Fluid Bed Dry Nonslagging 4

HTW ThyssenKrupp Uhde Germany Fluid Bed Dry Nonslagging 5

U-GAS SES USA Fluid Bed Dry Agglomerated 6

SFG Siemens Germany Entrained Flow Dry Slagging 7

SCGP Shell Netherlands Entrained Flow Dry Slagging 8

Prenflo ThyssenKrupp Uhde Germany Entrained Flow Dry Slagging 9

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IMPURITY REMOVAL• The EERC has completed initial testing of the 8 Rivers DeSNOx process.

• Existing equipment at the EERC was used to generate an Allam Cycle flue gas from lignite coal and to test the process.

• The DeSNOx process uses only water in a packed spray column to remove sulfur and nitrogen species through oxidation reactions.

• Test results show that high levels of SOx

and NOx removal have been achieved:

– SOx: >99% removal

– NOx: ~95% removal

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DESNOX PERFORMANCE

0

20

40

60

80

100

120

140

160

15:0

015

:03

15:0

715

:10

15:1

415

:17

15:2

015

:24

15:2

715

:31

15:3

415

:38

15:4

115

:45

15:4

815

:51

15:5

515

:58

16:0

216

:05

16:0

916

:12

16:1

516

:19

20:5

320

:57

21:0

021

:04

21:0

721

:11

21:1

421

:17

21:2

121

:24

21:2

821

:31

21:3

521

:38

21:4

121

:45

21:4

821

:52

21:5

521

:59

22:0

222

:05

22:0

922

:12

22:1

622

:19

22:2

322

:26

22:2

922

:33

22:3

622

:40

22:4

322

:47

22:5

022

:54

22:5

7

Co

nce

ntr

atio

n,

pp

m

Time

NO and SO2 Concentration on 5/9/16

NO

SO2

Sampling at DeSNOx Inlet

Sampling at DeSNOx Outlet

Moved Analyzer

SO2 Not Detectable, Has Already Oxidized

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DESNOX OPTIMIZATION• The pH in the process drops as NOx and SOx form nitric and sulfuric acid.

• The EERC is developing data to maintain pH around 3, which will help to ensure consistent removal.

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

0

5

10

15

20

25

30

35

40

5/9/16 5/10/16 5/11/16 5/12/16 5/13/16 5/14/16

pH

Wa

ter

Ad

d R

ate

(lb

/hr)

Date

Water Exchange Rate & pH

H2O Exchange Rate (lb/hr)pH

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SYNGAS COMBUSTION

• ASPEN PLUS modeling was completed.

– Range of syngas compositions modeled for testing on a 5-MWth prototype test combustor.

• Design considerations:

– Swirl-stabilized diffusion flame injector.

– Primary zone temperature of 3600°F.

– Equivalence ratio of 0.99.

– Uniform dilution zone exit temperature of 2100°F.

• Design completed.

– 5-MWth combustor.

– Including instrumentation.

– Validate the combustor.

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FUTURE WORK

• Corrosion

– Additional 1000-hr tests.

– Focus on hot-side corrosion.

• Gasifier selection

– Continued modeling with lignite performance data.

• Impurity removal

– Additional pre- and postcombustion technology evaluations.

• Syngas combustion

– Demonstration of combustion unit.

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TECHNOLOGY DEVELOPMENT ROAD MAP

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PROJECT TEAM AND INDUSTRY SPONSORS

• State of North Dakota

• ALLETE (MP and BNI)

• Basin Electric (Basin and DGC)

• 8 Rivers Capital

• Ceramatec

• EERC

PATHWAY TO LOW-CARBON LIGNITE

UTILIZATION

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CONTACT INFORMATION

Energy & Environmental Research CenterUniversity of North Dakota15 North 23rd Street, Stop 9018Grand Forks, ND 58202-9018

www.undeerc.orgTelephone (701) 777-5114Fax (701) 777-5181

Jason Laumb, Principal [email protected]

supercritical co production · 2018-04-17 · gasifier name vendor vendor headquarters system type...

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