atmospheric iron-based coal direct chemical looping

© 2016 The Babcock & Wilcox Company. All rights reserved. Proprietary and Confidential .1

Atmospheric Iron-Based Coal Direct Chemical Looping Process for Power

Production: Phase II

Pittsburgh, PA. August 12, 2016


Project Objectives

Phase I Project objectives: 2012 -2013 • Evaluate commercial viability of OSU’s coal-direct chemical looping

process for power production with CO2 capture.

• Perform a techno-economic evaluation of the commercial design.

Phase II Project Objectives: 2013-2017 • Conducting laboratory testing and small pilot-scale testing to

reduce technology gaps identified in Phase I.

• Update design and cost performance of the commercial 550 MWe CDCL power plant

• Re-evaluate the CDCL technology and identify development pathway for commercialization in year 2025.


Project Participants Federal Agencies:

• DOE/NETL State Agency:

• Ohio Development Service Agency Project participants:

• The Babcock & Wilcox • The Ohio State University • Clear Skies Consulting

Industrial Review Committee: • American Electric Power • Dayton Power & Light • Dover Light & Power • Duke Energy • First Energy • Consol Energy


Outline Commercialization Path

Phase I: CDCL Concept and Techno-Economic Analysis

Phase I: Technology Gaps

Phase II-A: Laboratory Testing and Studies

Phase II-B: 250 kWth Pilot Design and Construction

Project Schedule

Conclusions and Acknowledgments


Commercialization Path

OSU’s Laboratory

Scale

Scal

e

OSU’s Sub-Pilot 25 kWth

B&W’s Pilot

10 MWth

Demo 50 MWth

Commercial 100 - 550 MWth

2004 2008 2014 2020 2016 2025

Time

Work performed under this

award

Phase II B&W’s 250

kWth

B&W’s Phase I







Project Schedule



Chemical Looping Concept

Reducer

Fe + FeO

Fe2O3

CO2 + H2O

Coal

Air In

Combustor

Heat out


CDCL Moving Bed Reactor Concept

Volatiles

Bottom Section

Top Section

Char

Volatilization

Coal

CO2

Fe/FeO Enhancer

Fe2O3

H2O+CO2 (Ash, Hg, Se, As)

Bottom Section* C + CO2 2 CO 2 CO + Fe2O3 Fe + FeO + 2 CO2

* Reactions not balanced

Top Section* CxHy + Fe2O3 Fe + FeO + CO2 + H2O CO + Fe2O3 Fe + FeO + CO2 H2 + Fe2O3 Fe + FeO + H2O

Coal Volatilization* Coal C + CxHy (Volatiles)


CDCL Commercial Plant Design and Engineering


CDCL Technology Comparison

Base Plant

MEA Plant

CDCL Plant

Coal Feed, kg/h 185,759 256,652 205,358

CO2 Emissions, kg/MWhnet 801 111 31

CO2 Capture Efficiency, % 0 90 96.5

Net Power Output, MWe 550 550 550

Net Plant HHV Heat Rate, kJ/kWh (Btu/kWh)

9,165 (8,687)

12,663 (12,002)

10,084 (9,558)

Net Plant HHV Efficiency, % 39.3 28.5 35.6

Cost of Electricity, $/MWh 80.96 132.56 102.67

Increase in Cost of Electricity, % - 63.7 26.8







Project Schedule



Coal Reducer

Combustor

Riser

Distributor

Air

To Convection pass

Reducer • Coal Injection and distribution • Char residence time • Ash Separation • Enhancer Gas • Fate of alkali & Agglomeration • Fate of S, Hg, and N

Combustor • In-bed Heat exchanger

Technology Gap Analysis

Operation • Start up, shut down, turn down

Particles • Attrition • Reactivity • Deactivation







Project Schedule



Alkaline Agglomeration Test

-2-101234567

850 900 950 1000 1050D

P (in

H2O

)Temperature (oC)

9.10% after oxidized

9.10% in air

Alkaline injection test inn BFB

Particles aglomerate at very high alkaline content : ~9.1wt.%

Heater

CO2 Flow

DP


Paraticle Regeneration

(b)

Agglomerated particle caused by alkaline can be regenerated in the combustor.


Particle Characterization

Photograph of TGA Analyzer

Gas Delivery System

31.50

32.00

32.50

33.00

33.50

34.00

34.50

35.00

35.50

36.00

0 200 400 600 800 1000 1200

Wei

ght (

mg)

Time (min)

particles 100 cycles 1200 C

Recyclability Test


Particle Reduction Studies

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

1.2

495 495.5 496 496.5 497 497.5 498 498.5 499

Degr

ee o

f oxi

datio

n (0

= F

e, 1

=Fe2

O3)

Time during 3rd cycle (min)

850 C850 C1000 C1000 C1000 C1150 C1150 C

Gas and fines

Particles

Bottom Moving Bed

Top Moving Bed

Combustor

Coal + CO 2

CO 2

Air

Riser

1150 C

850 C


Particle Oxidation Studies

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

489 489.5 490 490.5 491 491.5 492

Degr

ee o

f oxi

datio

n (0

= F

e, 1

=Fe2

O3)

Time during 3rd cycle (min)

850 C

850 C

1000 C

1000 C

1000 C

1150 C

1150 C

Gas and fines

Particles

Bottom Moving Bed

Top Moving Bed

Combustor

Coal + CO 2

CO 2

Air

Riser

1150 C


Coal Flow Model Tests: Fines entrainment


Char & Ash Residence Time in Moving Bed

0.6

0.7

0.8

0.9

1

1.1

1.2

1.3

1.4

1.5

0.5

0.6

0.7

0.8

0.9

1

1.1

1.2

0 50 100 150 200 250

Pres

sure

dro

p (in

of w

ater

)

Time (s)

dp1 (inH2O)

dp3 (inH2O)

dp4 (inH2O)

dp2 (inH2O)

Fines Residence Time

5CFM, 160g flint clay


25 kWth Sub-Pilot Demonstration

• > 800 hours of operational experience

• > 200 hours continuous successful operation

• Smooth solids circulation • Complete ash separation in

reducer. • Achieve nearly pure CO2 from

reducer outlet • 17 test campaigns completed


Reducer Carbon Conversion Profile

Reducer Gas Concentration Profile

0%

1%

2%

3%

4%

5%

90%91%92%93%94%95%96%97%98%99%

100%

0 50 100 150 200

Con

cent

ratio

n C

O, C

H4,

O2

(%)

Con

cent

ratio

n C

O2

(%)

Time (min)

CO2

CO

CH4

CH4

CO2

CO

0%10%20%30%40%50%60%70%80%90%

100%

10 60 110

Car

bon

Con

vers

ion

(%)

Time of reaction (min)

00.050.10.150.20.250.30.350.40.450.5

0

2

4

6

8

10

2 4 6 8 10 12 14 16 18

Con

cent

ratio

n (%

) CO

, CH

4, C

O2

Con

cent

ratio

n (%

) O2

Time (min)

CO2

O2

CO

Combustor Gas Concentration Profile

CO CO2

O2

Sample Data: PRB Process Performance • Continuous steady carbon conversion

from reducer throughout all solid fuel loading (5- 25kWth)

• <0.25% CO and CH4 in reducer outlet = full fuel conversion to CO2/H2O

• <0.1% CO and CO2 in combustor = negligible carbon carry over, nearly 100% carbon capture

200-hour Sub-Pilot Continuous CDCL Demonstration







Project Schedule



Pilot Unit Design

Physical Specifications •Materials: Refractory lined Carbon Steel •Overall Height: 32 ft •Footprint = 20’ x 20’ Process Specifications •Thermal rating: 250 kWth •Coal Feed Rate: 70 lb/hr •Coal size: Pulverized coal •Max Operating Temperature: 2012 oF •Oxygen Carrier: Iron based •Reducer : Counter-current moving bed •Combustor : Bubbling bed •Particle tranport: Pneumatic

Oxygen Carrier Specifications •Active metal: Iron based •Size: 1.5 mm







Project Schedule



Project Schedule

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

Task 1. Project Management and Planning

Project Management and Planning

Task 2. Laboratory Testing

Large Scale Particle ManufacturingOxygen Carrier (Particle) Characterization

Task 3. Pilot Facility Design, Construction and Testing

Pilot Plant Facility Design Test Facility Cost Estimate

Pilot Plant Facility ConstructionPilot Plant Facility Commissioning & Testing

Task 4.Data Analysis and Update of Commercial Plant Economic Analysis

Data Reduction and Analysis Commercial Plant Design and Cost Analysis

Update Next Scale Pilot Plant Design

Task 5. Phase II Final Report

Final Report and Close out Documents

2017Phase II 2015 2016







Project Schedule



Conclusions

• CDCL offers a cost-effective alternative for coal-based power generation with carbon capture

• The commercial CDCL modular design is ideal for commercial deployment of the technology

• Cold flow model and laboratory testing is confirming assumptions and design features of the 250 kWth pilot unit and the commercial design

• The design of 250 kWth pilot plant has been completed, the unit is under construction and we are moving soon towards the comissioning and testing phase


Acknowledgments

This material is based upon work supported by the Department of Energy under Award

Number DE-FE0009761 and The Ohio Coal Development Office under Award Number

OER-CDO-D-15-02.