Dr. Jeffrey N. Phillips
Senior Research Manager
Generation Summit
February 25, 2013
21st Century Coal Power Recent Developments in Coal Power Generation Technology
2 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Presentation Outline
• Some fossil power plant basics
• A History Lesson
• 21st Century coal power plants
• What to do about CO2?
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Conventional Coal Plant
100 MW
12 MW
88 MW
41.5 MW
46.5 MW
39 % Efficiency (HHV basis)
2.5 MW own use
39 MW
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Gas Turbine “simple cycle”
100 MW
35 MW
65 MW
35% Efficiency (HHV basis)
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Combined Cycle
100 MW
Fuel
35 MW 17 MW
65 MW
27 MW
21 MW to
condenser
38 MW
17 + 35 = 52 MW
52% Efficiency! (HHV basis)
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A History Lesson
(the original Dr. Phillips)
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1500
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1900 ’10 ’20 ’30 ’40 ’50 ’60 ’70 ’80 ’90 2000 ’10
Year
Tem
pera
ture
, D
eg
rees F
Tem
pera
ture
, D
eg
rees C
Eddystone 1
Philo 6
History of Steam Conditions for Fossil Fired Power Plants
• During 1st 60 years of the
20th century, steam turbine
temperatures rose from
500°F to 1200°F
– Thermal efficiency rose
from 4% to 40% (HHV)
• Eddystone experienced
several materials issues
– Derated from 1200°F to
1140°F
• No improvements for 50+
years! Maximum Steam Turbine Inlet
Temperature History
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A Different Story for Gas Turbines! (Note: Pentagon has funded R&D for jet engines for many years)
500
1000
1500
2000
2500
3000
1930 1940 1950 1960 1970 1980 1990 2000 2010
Year
Max. T
urb
ine In
let
Tem
p. (D
eg
F)
Gas Turbines Steam Turbines
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Emissions History of US Coal Power Plants (Dates
represent year plant began operating)
0
500
1000
1500
2000
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3000
0
10
20
30
40
50
60
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80
90
1921 1960 2008 NGCC
CO
2, lb
/MW
hr
SO
x &
NO
x,
lb/M
Wh
r
SO2
NOx
CO2
Natural Gas has a natural advantage when it comes to CO2 emissions
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US Generation Capacity (Source: U.S. Energy Information
Administration, www.eia.doe.gov)
Most coal power plants in the US are more than 30 years old
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21st Century Coal Power Plants
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nc
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2 Percentage Point Efficiency Gain = 5% CO2 Reduction
Su
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2 Percentage Point Efficiency Gain = 5% CO2 Reduction
Increasing Steam Temperature and Pressure Increases
Thermal Efficiency and Decreases Emissions
Note: HHV Basis
1400°F 1000°F
“Least Regrets” Strategy for CO2 Reduction?
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Acknowledgements: U.S. Department of Energy (US DOE)
/ Ohio Coal Development Office (OCDO) A-USC Steam
Boiler and Turbine Consortia
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Highlights of the Boiler Consortium Work
IN740 Pipe Extrusion Weld Development
Steamside Oxidation Fireside Corrosion
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Major Step: Code Case 2702 (Inconel®740H)
now Approved for Use in Section I
• Approved: Sept. 26, 2011
• Maximum Use Temperature: 800°C (1472°F)
• Rules for:
– Chemistry
– Heat-treatment
– Welding
– Post-weld heat-
treatment
– Cold-forming
– Weld strength reduction
factors
Approved for B31.1 in September 2012
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What is gasification?
• Similar to combustion (burning) but with less than half the
amount of oxygen needed to fully burn the coal
• Combustion: excess air
• Gasification: excess fuel (by a lot!!)
• Combustion: produces heat
• Gasification: produces “syngas” and some heat
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15MW 79MW
28MW 51MW
47MW
20MW
9MW
Net Coal to Power:
28 + 20 – 9 = 39% (HHV basis)
19MW
100MW
IGCC schematic from US DOE 27 MW
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Duke Edwardsport IGCC – In Start-up Phase
• Edwardsport, IN
• 618 MW
• Consumes coal from Indiana
• Uses GE Energy gasification
technology and gas turbines
• Construction Began: March
2008
• First firing of gas turbine on
natural gas: March 2012
• First gasification of coal:
October 2012
Courtesy of Duke Power
EPRI will hold technical meeting & tour here in June 2013
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CO2 Capture in Coal Power Systems
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CO2 Storage – Main Focus is Injection Into
Geological Formations
• Saline reservoirs
– 100’s of years capacity
– Little experience
• Economical, but lesser
capacity options
– Depleted oil & gas
reservoirs / enhanced oil
recovery
– Unmineable coal
beds/enhanced coal-bed
methane recovery
Courtesy of Peter Cook, CO2CRC
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Project Goals
• Construct and operate a 19
km (12 mile) CO2 pipeline that
will transport CO2 from Plant
Barry to the Citronelle Dome in
Alabama USA
• Inject 100,000–300,000
metric tons of CO2 into the
Paluxy Formation (saline)
• Conduct monitoring activities
before (8 mos), during (2 yrs)
and after (3 yrs) injection
• Close out the site
SECARB Transport & Storage Project Overview
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• Target reservoir is the Lower Cretaceous Paluxy Formation (2,865 –3,200 m; 9,400–10,500 ft)
• Massive 335 m (1,100 ft) interval of stacked fluvial sands and confining units
• Numerous reservoir seals and confining units above the Paluxy (at least 5)
• Structural dome has proven four-way closure
SECARB Geology Overview
Injection Zone
Confining Zone
Rodessa Formation
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CO2 Injection Started 21-Aug-2012
CO2 booster pump at wellhead (maximum
delivery pressure 22.8 MPa (3,300 psig)
• Current CO2 injection rates and wellhead pressures
• 500 tonnes/d (9.64 MMscf/d)
• 9.06 MPa (1,314 psig)
More than 50,000 tons of CO2 already stored
CO2 capture at Plant Barry
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Oxy-Combustion Capture of CO2
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Oxy-Combustion Overview
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27
FutureGen 2.0 Oxy-Combustion w/ CO2 Sequestration
• Meredosia, IL & Morgan Co., IL
• 167 MWe gross oxy-combustion
repowering of Ameren’s Meredosia
Unit 4 steam turbine
• 90% CO2 capture (cryogenic
separation) 1,000,000 tons CO2 /year
• Deep saline sequestration in Mt.
Simon formation ~30 miles east of
power plant
• Total Project: $1.65 Billion
DOE Share: $1.05 Billion
Key Dates
Complete FEED: Sep 2013
Construction: Sep 2014
Commercial Operation: Sept 2017
Status
Phase 1 (Pre-FEED) completed
Initial sequestration site
characterization completed
Phase 2 (NEPA, Design and
Permitting) initiated February 1, 2014
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Pre-Combustion Capture of CO2
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Dakota Gasification Substitute Natural Gas
(SNG) Production Facility
CO2 to
Enhanced Oil
Recovery
SNG to
pipeline
Gasification & Heat
Recovery
CO2
Production &
Removal Methanation
“Syngas”
H2-rich
syngas
CO2 Pipeline
Supplies natural gas power
plants (approx 1000 MW)
connected to NG pipeline grid Owned by Dakota
Gasification
Lignite
~3 million tons CO2/yr
30
Southern Company Services, Inc. CCPI-2 Advanced IGCC with CO2 Capture
Plant Site Plant Site
Status
Plant construction >50% complete;
>4,000 construction workers on site
CO2 off-take agreements signed
Lignite mine under development
Subsystems (water treatment, cooling
towers) to begin pre-commissioning
Combustion turbine startup: Jul 2013
Gasifier heat-up: Dec 2013
Key Dates
Project Awarded: Jan 30, 2006
Project moved to MS: Dec 5, 2008
NEPA Record of Decision: Aug 19, 2010
Initiate excavation work: Sept 27, 2010
Operations: May 2014
• Kemper County, MS
• 582 MWe (net); 58 MWe duct firing; 2 TRIGTM
gasifiers, 2 Siemens combustion turbines, 1
Toshiba steam turbine
• Fuel: Mississippi lignite
• ~67-69% CO2 capture (Selexol® process);
3,000,000 tons CO2/year
• EOR; Denbury Onshore LLC, Treetop
Midstream Services LLC
• Total DOE Project: $2.01 Billion;
DOE Share: $270 Million (13%)
• Total estimated plant cost: ~ $3 Billion
31
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