10th Annual SECA Workshop Pittsburgh, PAJuly 14-16, 2009

Integrated Gasification Fuel Cell Performance and Cost AssessmentPerformance and Cost Assessment

Presented by Phil DiPietro, Division Director

Situational Analysis and Benefits DivisionSituational Analysis and Benefits Division

Office of Systems Analyses and Planning, NETL

• Co-analystsK i ti G d– Kristin Gerdes

– Dale KeairnsDick Newby– Dick Newby

– And help and advice from Eric Grol and Jan Thijssen

2

Summary Points

• Paradigm change: Fuel cells offer higher efficiency and lower capital

• Percent CO2 capture matters: At $50/mtCO2, 100% CO2 capture saves 0.5 cents/kWh compared to 90%

3

Objective: evaluate a power plant based on fuel cell conversion of syngas as an investment optiony g p

• Scope: central station, baseload duty cycle• Assess atmospheric and pressurized fuel cell stacks• Assume DOE goals for cost and performance of the fuel

cell block• Use unit operation cost data from IGCC studiesUse unit operation cost data from IGCC studies• Include cost of CO2 storage, emissions• Quantify water use/consumptiony p

4

Configurations of Advanced Coal-Based Power PlantsIntegrated Gasification Fuel CellIntegrated Gasification

Catalytic G ifi

Oxygen plant

Integrated Gasification Fuel Cell

Slurry Oxygen

Integrated Gasification Combined Cycle

Gasifier

Syn gas cleaning

plantyGasifier

Syn gas l i

plant

cleaning

Expander

Fuel cell

cleaning

Combustion

Selexol CO2

Fuel cell

Oxy-combustion

Combustion turbine

Steam cycle

Air

Steam cycle / Expander

cycle

Power

5

CO2 Power

Sub-system Technology

Sub-system IGCC IGFC (atm) IGFC (press)

Gasifier Slurry Fed Catalytic

Gas Cleaning Dry Dry Humid

Syngas Advanced “F” Fuel cell Fuel cellSyngas Conversion

Advanced F Turbine

Fuel cell, 20 psia

Fuel cell, 270 psia

Steam Cycle Subcritical Subcritical Noney

Carbon Capture Selexol (90%) Oxy-combustion of anode off-gas (~99%)

6

Performance and Cost Summary

Conventional IGCC

IGFC (Atm SOFC)

IGFC (Press SOFC)

Efficiency (%, HHV) 32.5 49.4* 56.2**

CO EmissionsCO2 Emissions (kg CO2/MWh net) 90 6 6

Water Usage (gal/MWh net) 570 240 170(gal/MWh net)

Capital Cost (2007$/kW) 2,400 2,000 1,800

LCOE(cents/kWh) 10.2 8.8 7.9

* The efficiency without CO2 compression is 52 6%

7

The efficiency without CO2 compression is 52.6%** The efficiency without CO2 compression is 60.1%

Fuel Cell Performance Assumptions

SOFC Parameter SOFC (atm) SOFC (press)

Inlet/Outlet Temperature 650 / 800 CInlet/Outlet Temperature 650 / 800 C

Fuel Single Pass Utilization 70%

C D i 500 A/ 2Current Density 500 mA/cm2

Outlet Pressure 20 psia 270 psia

Nernst Potential* 0.84 0.92

Stack Overpotential 40 mV 50 mV

Degradation Rate 0.1% / 1,000 hrs 0.1% / 1,000 hrs

8

* Nernst calculated based on SOFC exit conditions that includes operating pressure and gas composition

Fuel Cell Cost Assumptions

• 700 $/kW AC output from the stack ($2007)I t ll d t– Installed cost

– Consistent with DOE cost targetIncludes associated heat exchangers blowers– Includes associated heat exchangers, blowers, controls and DC-to-AC rectifier

• Replacement cost assumed to be $100/kW AC output from the stack ($2007)

9

Catalytic Gasifier

• Good match with the fuel cellC l O– Consumes less O2

• ~ 0.25 kg O2 per kg coal versus ~ 0.7 for slurry fed

– Makes methaneMakes methane• 17 vol% in syngas versus ~ 0 vol% for slurry

– Uses steam

• Large area of technology risk is in catalyst recovery/regenerationy g– We use Exxon assumption of 2/3 recovery – Adds estimated 0.20 cents/kWh O&M cost

10

Oxy-combustion of Anode Off-gas

• Utilizes remaining fuel value and raises steam qualityquality

• Eliminates water gas shiftEliminates water gas shift

• Avoids “touching” CO2, enables near 100% capture

• Un-reacted oxygen in effluent is an area for future t dstudy

11

Design for High SOFC Capacity Drives System EfficiencyDrives System Efficiency

2.5

1.5

2

hr

Gas Turbine or Expanders

1

W/lb

coa

l/h Steam Turbine

SOFC

0

0.5kW Auxiliary

IGCC IGFC with atm SOFC

IGFC with press SOFC

-0.5

12

atm SOFC press. SOFC

Cost Assessment of IGFC

• Cost Approach– Fuel cell system installed

$2,500

et

IGCC with CCSFuel cell system installed

cost of $700/kW AC output from stack (2007 dollars)

– Other major unit costs $1,500

$2,000

Cos

t, $/

kW n

e IGFC (atm) with CCSIGFC (press) with CCS

$12scaled from range of studies– O&M costs and financial

parameters consistent with NETL Bituminous Baseline

$500

$1,000

Tota

l Pla

nt

$8

$10

$12

net

IGFC (atm) with CCSIGFC (press)

IGCC with CCS

NETL Bituminous Baseline Report (August 2007)

• High efficiency of IGFC and

$0

$4

$6

LCO

E, $

/kW

h

IGFC (press) with CCS

• High efficiency of IGFC and ease of CO2 capture drives down capital costs and LCOE relative to today’s IGCC t h l

$0

$2

13

technology

IGCC and IGFC Capital Costs, $/kW

IGCC IGFC Adv IGFC

Drivers of Cost DifferencesRelative to IGCC

• Catalytic Gasification (Low Temp Oxygen) (-)Gasification, ASU 1,085 620 550

Catalytic Gasification (Low Temp, Oxygen) ( )• Catalyst/Ash Handling and Coal Prep (+)• System Efficiency (-)

G Cl i 235 175 220• Sulfur Polishing (+)

H id G Cl i (Ad IGFC l ) ( )Gas Cleaning 235 175 220 • Humid Gas Cleaning (Adv IGFC only) (+)• System Efficiency (-)

Power Island 455 770 610 • Fuel Cell System (+) • Parasitic Load ( )• Parasitic Load (-)

CO2 Capture 245 135 125 • Oxycombustion v Selexol (-)• System Efficiency (-)

Balance of Plant 370 285 235 • System Efficiency (-)

Total 2 390 1 985 1 740

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Total 2,390 1,985 1,740

IGCC and IGFC with CCS LCOE

IGCC IGFC (atm)

Adv IGFC

Drivers of Cost DifferencesRelative to IGCC

Total Plant Costs ($/kW) 2,390 1,985 1,740

Variable O&M (cents/kWh) 0.8 1.1 1.1

• Stack Replacement (+)• Gasifier Catalyst, Sorbents (+)(cents/kWh) y ( )• System Efficiency (-)

Fixed O&M, $/kW/yr 44 47 45 • Plant Size (+) • System Efficiency (-)

Fuel Cost, cents/kWh 1.9 1.2 1.1 • System Efficiency (-)

CO2 Transport and 0 35 0 25 0 20 • System Efficiency (-)Storage Cost, cents/kWh 0.35 0.25 0.20 • Percent CO2 captured (+)

LCOE (20-yr), cents/kWh 10.2 8.8 7.9

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No

CCS

tical

CCC

SNo

CS

Subc

rit PC

N CCCC

So CS

IGCC

m)

No CCCC

SS

IGFC

(atm

s)

Gasifier WGSFGD

No

CCS

CCS

IGFC

(pre

s s FGDBFWCool Tower

0 200 400 600 800 1,000 1,200 1,400Raw Water Withdrawal

(gal/MWh net)

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Effect of net CO2 emissions on LCOE

Coal Use Net CO2 Variable Cost Variable Cost

of CO2Platform Coal Use,

Btu/kWh Emissions, kgCO2/MWh

for Fuel, cents/kWh

Emissions @ $50/mtCO2, cents/kWh

IGCC 10,500 90 1.9 0.5

IGFC (Atm) 6,910 6 1.2 0.03

IGFC (Press) 6,070 6 1.1 0.03

PC (no capture) 9,280 860 1.6 4.3

PC (90% capture) 13,720 130 2.3 0.7

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LCOE in a Carbon IGCC CCS IGCC no CCSIGFC (atm) CCS IGFC (atm) no CCS

Constrained Scenario

16

IGFC (atm) CCS IGFC (atm) no CCSIGFC (press) CCS IGFC (press) no CCS

IGCC, CO2 capture becomes economically preferable to no capture at

12

14

ts/k

Wh)

preferable to no capture at $30/mt CO2

Fuel cells reduce the cross 8

10

LCO

E (c

ent

over to $20/mt CO2

6

8

20-y

r

40 20 40 60 80 100

Cost for Emitted CO2, $/mt

18

2, $

Conclusions

• IGFC platforms, based on a fuel stack that meets the program goals offers both a step change inprogram goals, offers both a step change in efficiency and reduced capital cost per kW and higher percent CO2 capture and reduced water use

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Advanced IGFC with Atmospheric SOFC and DGCNominal 50% Efficient System

air

HeatRecovery

stackgas

coal

Coal Catalyst

AshCatalyst

Separation

ash & carbon lossBlower

Dry Gas Cleaning

Particulateand Low-temp

CoolingAnode

Cathode

SOFCExpander

Oxy-Combustor

oxygen

CO2HRSG

g

Selexoland

CatalyticGasifier

HeatRecovery

steam

Treatment Separation

ash & catalyst

MercuryRemoval

Scrubbing Cooling

HeatRecovery

anodeoff-gas

Polishingoxygen

ASU

G Recovery

N2

oxy-comb O2

steam

Removal

anoderecycle gas

eductor

syngassteam addition

Recovery

air

gas

• Catalytic gasifier

O b t• Oxy-combustor

• Recycle gas eductor

20

coal

High Performance IGFC SystemNominal 60% Efficient System

Coal Catalyst

Treatment

AshCatalyst

Separation

ash & carbon loss airHeat

RecoverystackgasHRSG

Expander

CatalyticGasifier

HeatRecovery

Humid Gas Cleaning

steamAnode

Cathode

SOFC

Expander

Oxy-Comb

oxygen

CO2HRSG

expanderParticle& HCl

removal

SulfurRemoval

and

Hg & Trace

removal

oxygen

ASUN2

oxy-comb O2

steam anoderecycle

gas

polishing

eductor

air

eductorgas

• Catalytic gasifier

• Humid gas cleaning

• Pressurized SOFC

• Oxy-combustor

• Recycle gas eductor

21

y g

Atm SOFC - no CCS Atm SOFC - with CCS

10

10.5

Pres SOFC - no CCS Pres SOFC - with CCSReported Results

9

9.5

10

ts/k

Wh)

8

8.5

LCO

E (c

en

6 5

7

7.5

20-y

r

6

6.5

0.00% 0.20% 0.40% 0.60% 0.80% 1.00%

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SOFC degradation, %/1,000 hrs