the potential of advanced technologies to reduce igcc ...advanced technologies pathway for igcc with...
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GTC Conference, Colorado Springs, CO, October 7, 2009
The Potential of Advanced Technologies
to Reduce IGCC Carbon Capture Costs
Kristin GerdesAnalyst
2
Advanced Technologies Pathway for IGCC
with Carbon Capture
• Today CCS adds >30% to cost of IGCC
• Successful R&D can enable improved performance
and reduction in cost for IGCC with CCS
Incorporation of advanced technologies over time
25%
30%
35%
40%
45%
50%
Efficiency(HHV)
CaptureNon-Capture Reference
1,000
1,500
2,000
2,500
3,000
Total Plant Cost(2007$/kW)
4
6
8
10
12
Levelized Cost of Electricity
(2007¢/kWh)
3
IGCC Non-Capture Reference Plant
• Technology– Illinois #6 Bituminous coal
– Single-stage slurry-fed entrained radiant gasifier
– Cryogenic air separation unit
– Adv F-class gas turbine
– Solvent-based acid gas removal
– Steam Cycle 1800 psig/1050°F/1050°F
– Process simulation software
• Economics– 2007 dollars (constant)
– Capital costs from Parsons, vendor sources
• Owner’s costs excluded
– 17.5% capital charge factor
– Coal price $1.80/MMBtu
– Greenfield, midwestern USA, 0 ft elevation
– 80% capacity factor
4
Today’s CCS Adds 30% to COE of IGCC
Added for CCS Baseline (90% CO2 capture)
– Two-stage water-gas-shift reactors
– Additional physical solvent stage for CO2 separation
– CO2 compression
– Transportation, storage and monitoring (TS&M) of CO2
IGCC
Baseline
IGCC with
CCS*Delta
Net Plant Efficiency
(HHV)38.2% 32.5% -6% pt
Total Plant Cost**
($/kW, 2007$)1,800 2,400 +$600/kW
20-year levelized COE
(¢/kWh, 2007$)7.80 10.3 +30%
* 90% CO2 capture
** TPC excludes owner’s costs
Oxygen
Production
Gasifier
and Syngas
Cooling
Gas
Cleanup
Power
Island
Coal
Feed
O2
Air
Air
H2 Fuel
CO2
Compression
CO2
CO2
Separation
Water Gas
Shift
N2
5
Advanced Technology Progression
Technology Advancements
Coal Feed System Slurry Feed Dry Coal Feed Pump
Oxygen Production Cryogenic Air Separation Ion Transport Membrane
Gas Cleanup Cold Gas Cleanup Warm Gas Cleanup
H2 Turbine Advanced F Adv H2 Turbine Next Gen Adv Turb
CO2 Separation Physical Solvent H2 Membrane
Capacity Factor 80% 85% 90%
Oxygen
Production
Gasifier
and Syngas
Cooling
Gas
Cleanup
and Shift
Hydrogen
Turbine
Steam
Bottoming
Cycle
Coal
FeedRaw
Syngas
O2
Air Air
Hot
Flue
Gas Flue Gas
To Stack
H2 Fuel
N2
CO2
Compression
CO2CO2
Separation
CO2
Transport,
Storage and
Monitoring
6
Advanced Technologies Pathway
• Advanced technologies introduced in approximate
order of development
• Evaluate cumulative COE benefits over time
4
6
8
10
12
Leve
lize
d C
ost
of
Ele
ctri
city
(2
00
7¢/
kWh
)
Today's IGCC with CCS
Approximate development of advanced technologies over time
Non-capture Reference
7
25%
30%
35%
40%
45%
Ref
eren
ce
Co
al P
um
p
Efficiency(HHV)
1,000
1,500
2,000
2,500
3,000
Ref
eren
ce
Co
al P
um
p
Total Plant Cost(2007$/kW)
4
6
8
10
12
Ref
eren
ce
Co
al P
um
p
Levelized Cost of Electricity
(2007¢/kWh)
Non-Capture Reference
Coal Feed Pump
• Increased gasifier cold gas efficiency with
elimination of slurry
• Reduced coal feed, auxiliary load, and net power
+ 1%pt
8
4
6
8
10
12
Ref
eren
ce
Co
al P
um
p
85
% C
F
Levelized Cost of Electricity
(2007¢/kWh)
Non-Capture Reference
Reliability, Availability and Maintainability
• Current materials and instrumentation limited life in harsh environment
• Advanced materials and instrumentation
– Corrosion and erosion resistant materials
– In-situ repair techniques
– Real-time measurement
• 5% capacity factor improvement to 85% provides 4% COE reduction
9
25%
30%
35%
40%
45%
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
Efficiency(HHV)
1,000
1,500
2,000
2,500
3,000
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
Total Plant Cost(2007$/kW)
4
6
8
10
12
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
Levelized Cost of Electricity
(2007¢/kWh)
Non-Capture Reference
Warm Gas Cleanup (WGCU)
• Warm transport desulfurization process replaces cold gas desulfurization– Eliminates sour water stripper and improves heat recovery
– Estimated capital costs similar for each technology
+ 1%pt
- $60/kW - 2% COE
10
25%
30%
35%
40%
45%
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
Efficiency(HHV)
1,000
1,500
2,000
2,500
3,000
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
Total Plant Cost(2007$/kW)
4
6
8
10
12
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
Levelized Cost of Electricity
(2007¢/kWh)
Non-Capture Reference
Hydrogen Membrane for CO2 Separation
+ 3%pt
- $400/kW- 13% COE
• Mixed conducting ceramic membrane separates hydrogen at
pressure and temperature
– Reduces CO2 compression load and regeneration steam requirements
• Target costs of membrane significantly less than solvent
separation, coupled with increase in net power
11
25%
30%
35%
40%
45%
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
Efficiency(HHV)
1,000
1,500
2,000
2,500
3,000
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
Total Plant Cost(2007$/kW)
4
6
8
10
12
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
Levelized Cost of Electricity
(2007¢/kWh)
Non-Capture Reference
Advanced Hydrogen Turbine (AHT-1)
+ 2%pt
- $190/kW - 7% COE
• Higher pressure ratio, firing temperature and design for H2-rich fuels improve turbine performance– Allows air integration reducing ASU auxiliary power
– Increases steam cycle temperature improving steam cycle efficiency
• Increase in power rating has economy of scale benefit
12
25%
30%
35%
40%
45%
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
ITM
Efficiency(HHV)
1,000
1,500
2,000
2,500
3,000
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
ITM
Total Plant Cost(2007$/kW)
4
6
8
10
12
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
ITM
Levelized Cost of Electricity
(2007¢/kWh)
Non-Capture Reference
Ion Transport Membrane (ITM)
- $130/kW- 5% COE
• ITM replaces cryogenic ASU system for oxygen production– ASU is 15% of capital costs, consumes 10-15% of power
• Anticipated capital cost reductions drive COE benefit
13
25%
30%
35%
40%
45%
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
ITM
AH
T-2Efficiency
(HHV)
1,000
1,500
2,000
2,500
3,000
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
ITM
AH
T-2
Total Plant Cost(2007$/kW)
4
6
8
10
12
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
ITM
AH
T-2
Levelized Cost of Electricity
(2007¢/kWh)
Non-Capture Reference
Next Generation Adv H2 Turbine (AHT-2)
+ 1.5%pt
25%
30%
35%
40%
45%
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
ITM
AH
T-2Efficiency
(HHV)
1,000
1,500
2,000
2,500
3,000
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
ITM
AH
T-2
Total Plant Cost(2007$/kW)
4
6
8
10
12
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
ITM
AH
T-2
Levelized Cost of Electricity
(2007¢/kWh)
Non-Capture Reference
- 10% COE- $240/kW
- 1% COE
• Further turbine advancements increase pressure ratio, firing temperature, stage efficiencies and power rating– Reduction to single train has competing economy of scale
impacts
- $20/kW
14
Reliability, Availability and Maintainability
• Further advancements in
materials, sensors and
incorporation of advanced
controls as well as
operating experience has
potential to push availability
higher
• 5% capacity factor
improvement to 90%
provides 3% COE reduction
4
6
8
10
12
Ref
eren
ce
Co
al P
um
p
85
% C
F
WG
CU
H2
Mem
b
AH
T-1
ITM
AH
T-2
90
% C
F
Levelized Cost of Electricity
(2007¢/kWh)
Non-Capture Reference
15
Summary of Pathway Potential
Technology Addition Impact
Efficiency
Increase*
(% points)
TPC
Reduction*
(2007$/kW)
COE
Reduction*
(2007¢/kWh)
Coal feed pump Increase cold gas efficiency 0.8 -10 -0.1
Gasifier materials and
instrumentation
Increase capacity factor to
85%0.0 0 -0.4
Warm gas cleanup
and hydrogen
membrane
Eliminates cold gas cleanup
thermal penalties and
reduces capital cost3.7 -450 -1.4
Advanced H2 turbineIncreases power output and
allows air integration1.8 -190 -0.7
Ion transport
membraneReduces capital cost 0.3 -130 -0.4
Next generation
advanced H2 turbine
Increases power output,
efficiency1.5 -20 -0.1
Advanced sensors
and controls
Increases capacity factor to
90%0.0 0 -0.2
IGCC with CCS Pathway Impact +8.0% pts -$800/kW -3.3¢/kWh
* Incremental increase over preceding case with initial comparison to baseline IGCC with conventional CCS technology
16
Conclusions
Advanced technologies offer pathway to CCS at
significantly lower cost and better performance
than conventional IGCC with CCS
♦ 8 percentage points improvement in efficiency
♦ > 30% ($800/kW) reduction in total plant cost
♦ > 30% (3.3 ¢/kWh) reduction in levelized COE
17
Acknowledgements
• NETL
– Julianne Klara, Senior Analyst
– Gary Stiegel, Gasification Technology Manager
– Richard Dennis, Advanced Turbines Technology
Manager
– Sean Plasynski, Sequestration Technology Manager
• Noblis (modeling and analysis)
– John Plunkett, David Gray, Charles White, Sal
Salerno, Glen Tomlinson
Additional information available at:
http://www.netl.doe.gov/energy-analyses