Status of Coal Utilization and Its Future Direction: A US Perspective

Jeffrey N. Phillips (jphillip@epri.com) Senior Program Manager Advanced Generation Tokyo, Japan September 7, 2011

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Coal Capacity Additions by Year Source: NETL “Tracking New Coal-Fired Power Plants”, Jan. 2011

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Proposed and Forecasted Coal-Fired Capacity Source: NETL “Tracking New Coal-Fired Power Plants”, Jan. 2011

4 © 2011 Electric Power Research Institute, Inc. All rights reserved.

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1900 ’10 ’20 ’30 ’40 ’50 ’60 ’70 ’80 ’90 2000 ’10 Year

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Eddystone 1

Philo 6

Materials for A-USC Coal Power Plants – U.S. Department of Energy (DOE) and Ohio Funded Project

• During 1st 60 years of the 20th century, steam turbine temperatures rose from 250°C to 650°C – Thermal efficiency rose

from 4% to 40% (HHV) • Eddystone experienced

several materials issues – Derated from 650°C to

615°C • No improvements for 50

years!

Maximum Steam Turbine Inlet Temperature History

DOE Goal

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Participants: U.S. DOE / Ohio Coal Development Office A-USC Steam Boiler and Turbine Consortia

Federal – State – National Laboratory Non Profit – For Profit

Cost Sharing Consortium

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U.S. DOE – OCDO Advanced USC Project Accomplishments

General design studies show favorable economics

Welding Technology Developments

Fabrication Processes

Fireside Corrosion (High-Sulfur Coal & In-Plant Testing)

Steam-Side Oxidation

HP Turbine Concept

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News on A-USC Materials Development (hot off the press)

• In April 2011, at their works in Houston, Wyman-Gordon successfully extruded a ∼7.2-tonne ingot of Inconel 740 into a pipe section 0.38-m OD, 10.5-m long with 0.0.076-m wall thickness

• Tests are in progress to determine the properties on the extruded material

8

U.S. Dept. of Energy CCS Projects Locations & Cost Share

Southern Company Kemper County IGCC Project

IGCC-Transport Gasifier w/Carbon Capture

~$2.67B – Total $270M – DOE

NRG W.A. Parish Generating Station Post Combustion CO2 Capture

$339M – Total $167M – DOE

Summit TX Clean Energy Commercial Demo of Advanced

IGCC w/ Full Carbon Capture ~$1.7B – Total $450M – DOE

HECA Commercial Demo of Advanced

IGCC w/ Full Carbon Capture ~$2.8B – Total $408M – DOE

FutureGen 2.0 Large-scale Testing of Oxy-Combustion w/ CO2 Capture and Sequestration in Saline Formation

Plant: $737M – Total; $590M – DOE Trans. & Storage: $553M – Total; $459M– DOE

Project: ~$1.3B – Total; ~$1.0B – DOE

CCPI FutureGen 2.0 ICCS Area 1

Archer Daniels Midland CO2 capture from Ethanol plant CO2 stored in saline reservoir

$208M - Total $141M - DOE

Air Products CO2 capture from Steam Methane Reformers

EOR in eastern TX oilfields $431M - Total $284M - DOE

Leucadia Energy CO2 capture from Methanol plant

EOR in eastern TX oilfields $436M - Total $261M - DOE

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• Kemper County, MS • 582 MWe (net) IGCC: 2 KBR Transport

Gasifiers, 2 Siemens Combustion Turbines, 1 Toshiba Steam Turbine

• Mississippi Lignite Fuel • ~67% CO2 capture (Selexol® process)

3,000,000 tons CO2/year • EOR Sequestration site TBD (Start 2014) • Total Project: $2.4 Billion DOE

Share: $270 Million (13%)

Southern Company Services, Inc. CCPI-2 Advanced IGCC with CO2 Capture

Project Awarded – Jan 2006 Project moved to MS – Dec 2008 Construction – July 2010 NEPA ROD – August 2010 Operations – May 2014

• Status – NEPA Record of Decision on

August 19, 2010 – Construction initiated on

July 16, 2010

Kemper County IGCC Construction Update

Kemper County IGCC Construction Update

12

FutureGen 2.0 Oxy-Combustion w/CO2 Sequestration

• Meredosia, IL and Morgan Co., IL • 200 MWe Gross oxy-combustion

repowering of Ameren’s Meredosia Unit 4 steam turbine (Start 2016)

• 90% CO2 capture (cryogenic separation) 1,300,000 tons CO2 /year

• Deep saline sequestration in Mt. Simon formation

• Total Project: $1.3 Billion DOE Share: $1.05 Billion (81%)

• Status – Pre-FEED in progress – Sequestration site characterization and

validation – NEPA in progress, public scoping

meetings 2nd Quarter CY2011

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