Jeffrey Phillips, Electric Power Research Institute (EPRI) - Speaker at the marcus evans Generation Summit held in Dallas, TX, February 25-26, 2013, delivered his presentation entitled 21st Century Coal Power: Recent Developments in Coal Power Generation Technology

1. 21st Century Coal Power
Recent Developments in Coal Power Generation Technology
Dr. Jeffrey N. Phillips
Senior Research Manager
Generation Summit
February 25, 2013

2. Presentation Outline
• Some fossil power plant basics
• A History Lesson
• 21st Century coal power plants
• What to do about CO2?
© 2013 Electric Power Research Institute, Inc. All rights reserved. 2

3. Conventional Coal Plant
12 MW 39 % Efficiency
(HHV basis)
88 MW 2.5 MW own use
100 MW 39 MW
41.5 MW
46.5 MW
© 2013 Electric Power Research Institute, Inc. All rights reserved. 3

4. Gas Turbine “simple cycle”
100 MW
65 MW
35 MW
35% Efficiency
(HHV basis)
© 2013 Electric Power Research Institute, Inc. All rights reserved. 4

5. Combined Cycle
27 MW 100 MW
Fuel
38 MW
65 MW
17 MW 35 MW
17 + 35 = 52 MW
21 MW to 52% Efficiency!
condenser (HHV basis)
© 2013 Electric Power Research Institute, Inc. All rights reserved. 5

6. A History Lesson
(the original Dr. Phillips)
© 2013 Electric Power Research Institute, Inc. All rights reserved. 6

7. History of Steam Conditions for
Fossil Fired Power Plants
1500
1400
750
• During 1st 60 years of the
1300
Eddystone 1 700 20th century, steam turbine
1200 650 temperatures rose from
Temperature, Degrees F
Temperature, Degrees C
1100 Philo 6 600
500°F to 1200°F
1000 550
900
500 – Thermal efficiency rose
800
450 from 4% to 40% (HHV)
400
700
350
• Eddystone experienced
600 300 several materials issues
500 250
200
– Derated from 1200°F to
400
1900 ’10 ’20 ’30 ’40 ’50 ’60 ’70 ’80 ’90 2000 ’10 1140°F
Year
Maximum Steam Turbine Inlet
• No improvements for 50+
Temperature History years!
© 2013 Electric Power Research Institute, Inc. All rights reserved. 7

8. A Different Story for Gas Turbines!
(Note: Pentagon has funded R&D for jet engines for many years)
Gas Turbines Steam Turbines
3000
2500
Max. Turbine Inlet Temp. (Deg F)
2000
1500
1000
500
1930 1940 1950 1960 1970 1980 1990 2000 2010
Year
© 2013 Electric Power Research Institute, Inc. All rights reserved. 8

9. Emissions History of US Coal Power Plants (Dates
represent year plant began operating)
90 3000
80
2500
SOx & NOx, lb/MWhr
70
CO2, lb/MWhr
60 2000
50 SO2
1500
40 NOx
30 1000 CO2
20
500
10
0 0
1921 1960 2008 NGCC
Natural Gas has a natural advantage when it comes to CO2 emissions
© 2013 Electric Power Research Institute, Inc. All rights reserved. 9

10. 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
© 2013 Electric Power Research Institute, Inc. All rights reserved. 10

11. 21st Century Coal Power Plants
© 2013 Electric Power Research Institute, Inc. All rights reserved. 11

12. Increasing Steam Temperature and Pressure Increases
Thermal Efficiency and Decreases Emissions
2 Percentage Point Efficiency Gain = 5% CO2 Reduction
Subcritical Plant Range
Supercritical
Plant Range
Commercial
Advanced Ultra-
Supercritical
Plant Range
1000°F 1400°F
Note: HHV Basis
“Least Regrets” Strategy for CO2 Reduction?
© 2013 Electric Power Research Institute, Inc. All rights reserved. 12

13. Acknowledgements: U.S. Department of Energy (US DOE)
/ Ohio Coal Development Office (OCDO) A-USC Steam
Boiler and Turbine Consortia
© 2013 Electric Power Research Institute, Inc. All rights reserved. 13

14. Highlights of the Boiler Consortium Work
IN740 Pipe Extrusion Weld Development
Steamside Oxidation Fireside Corrosion
© 2013 Electric Power Research Institute, Inc. All rights reserved. 14

15. 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
© 2013 Electric Power Research Institute, Inc. All rights reserved. 15

16. 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
© 2013 Electric Power Research Institute, Inc. All rights reserved. 16

17. 100MW Net Coal to Power:
28 + 20 – 9 = 39%
(HHV basis)
19MW
9MW
15MW 79MW
51MW
20MW 28MW
47MW
IGCC schematic from US DOE
27 MW
© 2013 Electric Power Research Institute, Inc. All rights reserved. 17

18. 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
© 2013 Electric Power Research Institute, Inc. All rights reserved. 18

19. CO2 Capture in Coal Power Systems
© 2013 Electric Power Research Institute, Inc. All rights reserved. 19

20. 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
© 2013 Electric Power Research Institute, Inc. All rights reserved. 20

21. SECARB Transport & Storage Project Overview
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
© 2013 Electric Power Research Institute, Inc. All rights reserved. 21

22. SECARB Geology Overview
• 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
Confining
Zone
seals and confining
Injection
units above the Paluxy
Zone (at least 5)
• Structural dome has
Rodessa
Formation
proven four-way
closure
© 2012 Electric Power Research Institute, Inc. All rights reserved. 22

23. CO2 Injection Started 21-Aug-2012
• Current CO2 injection rates and wellhead pressures
• 500 tonnes/d (9.64 MMscf/d)
• 9.06 MPa (1,314 psig)
CO2 capture at Plant Barry CO2 booster pump at wellhead (maximum
delivery pressure 22.8 MPa (3,300 psig)
More than 50,000 tons of CO2 already stored
© 2012 Electric Power Research Institute, Inc. All rights reserved. 23

24. Oxy-Combustion Capture of CO2
© 2012 Electric Power Research Institute, Inc. All rights reserved. 24

25. Oxy-Combustion Overview
© 2013 Electric Power Research Institute, Inc. All rights reserved. 25

26. © 2013 Electric Power Research Institute, Inc. All rights reserved. 26

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
Status
 Phase 1 (Pre-FEED) completed
Key Dates
 Initial sequestration site
 Complete FEED: Sep 2013 characterization completed
 Construction: Sep 2014  Phase 2 (NEPA, Design and
 Commercial Operation: Sept 2017 Permitting) initiated February 1, 2014
27

28. Pre-Combustion Capture of CO2
© 2013 Electric Power Research Institute, Inc. All rights reserved. 28

29. Dakota Gasification Substitute Natural Gas
(SNG) Production Facility
Lignite
CO2 to
“Syngas” Enhanced Oil
CO2 Pipeline Recovery
~3 million tons CO2/yr
CO2 SNG to
Production & Methanation pipeline
Removal
H2-rich
syngas
Gasification & Heat
Recovery
Supplies natural gas power
Owned by Dakota plants (approx 1000 MW)
Gasification connected to NG pipeline grid
© 2013 Electric Power Research Institute, Inc. All rights reserved. 29

30. Southern Company Services, Inc. CCPI-2
Advanced IGCC with CO2 Capture
• Kemper County, MS Plant Site
• 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%) Status
• Total estimated plant cost: ~ $3 Billion  Plant construction >50% complete;
>4,000 construction workers on site
Key Dates  CO2 off-take agreements signed
 Project Awarded: Jan 30, 2006  Lignite mine under development
 Project moved to MS: Dec 5, 2008  Subsystems (water treatment, cooling
 NEPA Record of Decision: Aug 19, 2010 towers) to begin pre-commissioning
 Initiate excavation work: Sept 27, 2010  Combustion turbine startup: Jul 2013
 Operations: May 2014  Gasifier heat-up: Dec 2013
30

31. 31

32. Together…Shaping the Future of Electricity
© 2013 Electric Power Research Institute, Inc. All rights reserved. 32