futuregen 2.0 update

© 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

© 2011 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. 2

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


• 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


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


GS

GS

GS


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

7


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.

8


Meredosia Plant

6

4

1 2 3 5

1 2 3

4 7

Boilers & Turbines

9


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

10


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

11


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

12


• 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

13


• 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

14

Main Fuel

• Illinois #6 • 10,500 Btu/lb (24,423 kJ/kg) • 3.2 % sulfur, 0.12% chlorine


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

15


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

16


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

17


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

18


~ 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


Boiler

Coal Bunkers

Ash Silo Gypsum Pile

CPU

ASU

PJFF

Recycle Heater

(Airheater)

WFGD

DCCPS PR Fans

ID Fans

SR Fans


Boiler & GQCS

ASU

CPU

Stack

Boiler

WFGD

DCCPS

PJFF

Steam Turbine Building

1

1

2

2

3

4

5

3 4

5

21


Boiler Sectional Side View


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)


1. • 99.99% removal of 2 microns or larger

Pulse Jet Fabric Filter (PJFF)


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


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


• 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


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)


Thank You! Questions?

futuregen 2.0 update

Documents