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Advanced Technologies towards Zero Emissions (ZETs) from coal fired plant and

their introduction in EU Member States

John TopperManaging Director, IEA Clean Coal Centre

Energy Policy and Strategy of Sustainable Development for Central and Eastern European Countries until 2030

Warsaw, Poland, 22-23 November

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IEA Clean Coal Centre Members Today

UK

USA

Japan

Anglo S Africa

Eskom S Africa

NIGBHEL India

BRICC China

Austria

Canada

CEC

Italy

Sweden

ACIC Australia

CANZ N Zealand

Danish Power Group

http://www.iea-coal.org.ukhttp://www.iea-coal.org.uk

Rep. of Korea

BG Group UK

Germany

Eletrobras, Brazil

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Background and Content

• This presentation uses material from Towards zero emissions coal-fired power plants, an IEA CCC report recently issued, author Dr Colin Henderson

• Which is the third of a group of three - the first two were Clean coal technologies and Clean coal technologies roadmaps

• Will discuss targets for ZETs, the main technologies and development pathways

• And give examples of policies being followed in Germany and UK and by the European Commission.

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Current plant emissions and suggested ZETs targets (stack gas concentrations at 6% O2, dry)

Techn’gy SO2

mg/m³NOx as NO2

mg/m³Particlesmg/m³

Mercury CO2

kg/kWh

PCC +FGD 100-400(to 98%)

100-200(SCR)

10-50 710-920

CFBC As PCC <200-400 <50

PFBC As PCC 120-400 <50

IGCC 98-99% removal

<75 <1

NGCC Negligible <30 (SCR)-300 0 ~370

PCC as ZETs

<100 (interim)<30 (eventual)

<100 (interim)<50 eventual)

<10 90% removal >80% removal

IGCC as ZETs

<25 <25 <1 90% removal >80% removal

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Technologies as possible bases for ZETs

• Starting point is current technologies: PCC, CFBC, PFBC and IGCC

• CO2 capture over-riding in setting ZETs plant designs

• As platforms for CO2 capture, supercritical PCC and IGCC most valuable

• PCC: large commercial base and experience of flue gas scrubbing for CO2 capture

• IGCC: good emissions performance and possible less efficiency loss for CO2 capture

• Both needed to allow for different drivers and policies in different countries

• CFBC will have a niche role

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CO2 capture systems for PCC - ZETs

Air and coal CO2 to storage

N2, excess O2, H2O, etc

Oxygen and coal

CO2 to storage

Oxy-coal combustion

BoilerAmine

scrubbing

Boiler Moisture removal

Recycle combustion gases

De-NOx, FGD, ESP

Flue gas scrubbing

Contaminants removal

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Technologies - PCC-ZETs … (1)

CO2 capture - flue gas chemical scrubbing:

• Based on methods established on reducing gases using amines

• Experience on flue gas flows up to equivalent of 50 MWe

• Flue gas introduces issues like corrosion, solvent degradation

• Energy consumption high but being reduced (new solvents and integration improvements)

• Around a ~9% points efficiency penalty looks achievable

• Other work: inorganic absorbents; membrane contactors; physical separation

• Will need to consider how to integrate with SOx, NOx, particulates controls and possibly mercury removal

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Technologies - PCC-ZETs … (2)

CO2 caputre – oxygen firing with recycle flue gas (oxy-

coal firing):

• Demonstrated for power generation from coal only in pilot test rigs

• Feasibility study for retrofit 30 MWe coal unit in Australia

• Large pilot plant planned by Vatenfall next to Schwarze-Pumpe power station in Germany

• Efficiency penalty appears similar to chemical scrubbing

• New oxygen production technology would reduce penalty

• Potential issues: corrosion, deposition, in-leakage of air

• Co-disposal with other captured pollutants may allow close to true zero emissions

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Possible pathway to PCC-ZETs to 2025

2025

S/C PCC

Hg activities:removal methodscharacterisation

First commercial salesPCC-ZETs

retrofits and new Advanced PCC-ZETs

2005 2015

SO2, NOx, particulatescontrol: reduce cost

of systems

CO2 capture:Large plant

chemical scrubbing demo

CO2 capture R&D activities:New solvents, heat integration

Other absorbentsMembrane contactors

AdsorptionOxy-coal test programmes

Advanced USC PCC demonon-CO2 capture

Advanced USC PCCcommercial

non-CO2 capture

ITM oxygenplants commercial

Oxy-coal demo

Oxy-coal large plant demo

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R&D needs – PCC and PCC-ZETs

• Ferritic materials and nickel alloys for higher steam conditions• Widen range of deep SO2 removal systems• Develop SCR for deep NOx removal from coal-fired plants• Develop mercury removal and measurement systems• CO2 capture by flue gas scrubbing - new solvents• CO2 capture from flue gas using membrane contactors and

adsorption techniques

• Oxy-coal: develop NOx removal from CO2 disposal stream• Oxy-coal: develop mercury removal from CO2 disposal stream• Oxy-coal combustion: explore process implications of co-disposal• Oxy-coal: testing of materials for high steam parameters• Scale up ion transport membranes for oxygen production

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CO2 pre-combustion capture for IGCC - ZETs

Gasification and solids removal

Acid gas removal system

CO2 to storage

Hydrogen to gas turbine

ShiftCoal plus oxygen

Hydrogen sulphide to sulphur recovery

Steam

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IGCC - ZETs

CO2 capture – pre-combustion:

• For CO2 capture, syngas would be shifted to CO2 plus additional H2, CO2 separated and the H2 burnt in the gas turbine

• CO2 in relatively high concentration, capture with lower efficiency penalty compared with PCC plant

• Experience of E-class GTs on 95% H2. F-turbines under development

• Syngas shift requires steam - quench gasifier simplifies and reduces cost

Integrating enhanced abatement of conventional emissions:

• SO2 - already very low levels. Capture of CO2 can be integrated• NOx - SCR or future ultra low-NOx combustion systems• Co-disposal with CO2 could lower costs• Particulates emissions already virtually nil• Mercury emissions depend on the gasifier

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Possible pathway to 2025 for IGCC-ZETs

IGCCcommercial

scaledemos

Early full flow IGCC ZETsdemonstrations

Advanced IGCCZETs plants

various technologiesmulti-products

CO2 capture:physical scrubbing demo

ITM oxygenplants commercialCO2 capture R&D:

membrane separationmembrane reactors

PSA

HGCU R&D:particulatesSO2, NH3

mercury, CO2

Further large demonstrationnon-CO2 capture

IGCC plants

20252005 2015

Commercialnon-CO2 capture

IGCC plants

F-class hydrogen turbinedevelopment

and commercialisation(other markets)

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R&D needs - IGCC and IGCC-ZETs

• Develop improved refractories• Improve gas coolers• Feed systems for low-rank coals• Hot gas clean‑up developments• Syngas tests on new turbine designs• Mercury removal and measurement systems

• CO2 separation technologies (physical solvents, membranes, adsorption)

• Membrane reactors• Scale up ion transport membranes for oxygen production• Demonstrate hydrogen turbines in F-class• Ultra low-NOx burners for syngas and hydrogen

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Why we need both technologies!

Uncertainty in R & D – not sure of outcomes and associated costs for ultra-supercritical PCC and IGCC

IGCC looks more suitable when CO2 Capture is involved but it is currently higher risk and will take 15-20+ years to see market penetration

Construction policy in China and India favours PCC – where most “new build” will occur

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China – Future Ordering Patterns

-

5

10

15

20

25

30

2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017

New Orders to meet IEA/Interfax/McCoy/China Energy ForecastThermal Capacity 2020 Prediction = 720GW

GW

10

20

30

40

43

No.600MWUnits

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European Roadmaps

Referat IX A 8

Federal Ministryof Economy and Labour

C O O R E T E C : Roadmap

2050

2020

2015

Pote

ntia

l of U

tilis

atio

n on

Tim

e Sc

ale

2010

2005

Risk of R&Dhighlow medium

Vision

Steam PP =50%Gas PP >60%

Steam PP =55%Gas pp =65%

Hybrid-Power Plant

Zero-Emission

Power Plant

Capture with

Membranes

Oxyfuel-Demo

IGCCDemo

CO2-Wash

CO2-Reservoirs

CO2/H2-Turbine

Materials

Materials 700°C

Procedures Protection Systems

Materials800°C

Min. Leaks

Strategielinie: Effizienz Strategielinie:CO2-Capture/ Storage

CarbonReduction

Time

`Increased Efficiency`Trajectory

`Zero Emissions`Trajectory

Near-term Mid-term Long-term

Zero emissions will need the most efficient plant

Key issue will be value of CO2

CAT Options are complementary

CCS Timeline

20202004 20122008 2015

CCS operational

Commence build

Demooperational

CommenceDemo

Immediate Issues to be Addressed :-• Design Studies• Performance Standards• Monitoring & Verification• Legal/Regulatory

Directorate General for ResearchDirectorate General for Research- P Dechamps- P Dechamps – Nov 2004 – Nov 2004 - - 2121

CO2 C+S R&D Policy

A Priority in Long Term Energy R&D in FP6 (2002-2006)

Capture and sequestration of CO2, associated with cleaner fossil fuel plants.

Targets: reduce the cost of CO2 capture from 50-60 € to 20-30 € per tonne of CO2 captured, whilst aiming at achieving capture rates above 90%, and assess the reliability and long term stability of sequestration.

Directorate General for ResearchDirectorate General for Research- P Dechamps- P Dechamps – Nov 2004 – Nov 2004 - - 2222

Components of FP7? Continued focus on Carbon Capture and

Storage

Re-introduction of Clean Coal Technology in recognition of the drive for greater efficiency whilst CCS is developed and deployed

Technology Platform to advise on strategy and direction of these two elements

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Conclusions

• ZETs needed to maintain power security

• Targets are suggested for emissions of conventional pollutants and mercury as well as for CO2 for ZETs

• As platforms for ZETs, supercritical PCC and IGCC most likely to dominate future markets

• Incentives needed for conventional IGCC demonstrations also as a foundation for IGCC-ZETs

• Concentrate on increased efficiency and lower emissions of conventional pollutants whilst developing and deploying CCS technologies

• Does Poland and other Central European states need to become more engaged in the drive towards ZETs?