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Atmospheric Iron-Based Coal Direct Chemical Looping Process for Power Production

Luis G. Velazquez-Vargas FE-0009761

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Project Objectives Phase I Project objectives: 2012 -2013

Evaluate commercial viability of OSU’s coal-direct chemical looping process for power production with CO2 capture.

Perform a techno-economic evaluation of the commercial design. Phase II Project Objectives

Reduce technology gaps identified in Phase I by conducting laboratory testing and small pilot-scale testing.

Re-evaluate the CDCL technology and identify development pathway for commercialization in year 2025.

Update design and cost performance of the commercial 550 MWe CDCL power plant

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Project Participants

Federal Agencies: •DOE/NETL

Project participants: •The Babcock & Wilcox, PGG •The Ohio State University •Clear Skies Consulting

Industrial Review Committee: •Consol Energy •First Energy •Duke Energy •Ohio Development Service Agency

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Outline

CDCL Concept

Current Status of the CDCL Technology

Phase I Commercial Design

CDCL Comparison with other CO2 Capture Technologies

Techno-Economic Analysis

Small-Pilot Design

Conclusions

Future Work

Acknowledgments

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Chemical Looping Concept

Reducer

Fe + FeO

Fe2O3

CO2 + H2O

Coal

Air In

Combustor

Heat out

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Reducer Reactor Concept

6

H2/CO

CO2/H2O/CO/H2

Reducer Fluidized Bed Moving Bed

Operation Regime

Bubbling, turbulent, fast fluidized, or spouted bed

Moving packed, or multistage fluidized bed

Gas Solid Contacting Pattern

Mixed/Cocurrent Countercurrent

Particle Attrition High Low

Maximum Iron oxide Conversion

11.1% ( to Fe3O4) >50% (to Fe &

FeO)

Solids circulation rate High Low

Ash Separation Technique Separate Step In-Situ

Subsequent Hydrogen Production

No Yes

Particle size, μm 100-600 1000-3000 Reducer gas velocity*, m/s <0.4 >1.0

Reactor size for the same fuel processing capacity

Large Small

The Babcock & Wilcox Power Generation Group Proprietary and Confidential

Fluidized Bed Moving bed

Fe2O3

Fe/FeO H2/CO

CO2/H2O

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CDCL Moving Bed Reactor Concept

Volatiles

Bottom Section

Top Section

Char

Volatilization

Coal

CO2

Fe/FeO Enhancer

Fe2O3

H2O+CO2 (Ash, Hg, Se, As)

Bottom Section* C + CO2 2 CO 2 CO + Fe2O3 Fe + FeO + 2 CO2

* Reactions not balanced

Top Section* CxHy + Fe2O3 Fe + FeO + CO2 + H2O CO + Fe2O3 Fe + FeO + CO2 H2 + Fe2O3 Fe + FeO + H2O

Coal Volatilization* Coal C + CxHy (Volatiles)

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Outline

CDCL Concept

Current Status of the CDCL Technology

Phase I Commercial Design

CDCL Comparison with other CO2 Capture Technologies

Techno-Economic Analysis

Small-Pilot Design

Conclusions

Future Work

Acknowledgments

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Commercialization Path

OSU’s Laboratory

Scale

Scal

e

OSU’s Sub-Pilot 25 kWth

B&W’s Pilot

3 MWth

Demo 50 MWth

Commercial 100 - 550 MWth

2004 2008 2014 2020 2016 2025

Time

Work performed under this

award

B&W’s Phase I

Phase II B&W’s 250

kWth

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Commercial Fe2O3 Oxygen Carrier Particles

Commercial Fe2O3 particles lose reactivity within a few cycles

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Composite Fe2O3 particles sustain multiple redox cycles without significant loss in activity

Composite Fe2O3 Oxygen Carrier Particles

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25 kWth Sub-Pilot Demonstration

• Fully assembled and operational • >680 hours of operational

experience • >200 hours continuous successful

operation • Smooth solids circulation • Confirmed non-mechanical gas

sealing under reactive conditions • 17 test campaigns completed

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Fuel Feedstock Type Fuel Flow (lb/hr) Enhancer

Syngas CO/H2 0.1-1.71 N/A Coal volatile/ Natural Gas CH4 0.1-0.4 N/A

Coal char Lignite 0.7-2.0 CO2/H2O Metallurgical Coke 0.05-3 CO2/H2O

Coal

Sub-Bituminous 0.05-7.38 (25 kWth) CO2/H2O Bituminous 0.05-3 CO2/H2O Anthracite 0.2-0.7 CO2/H2O

Lignite 2.84-6.15 (20 kWth) CO2

Biomass Wood pellets 0.1 CO2 Coke Petroleum Coke 1.98 – 5.95 CO2/H2O

• 680 hours of sub-pilot CDCL operational experience • Successful results for all coal / coal-derived feedstock tested

Fuel Feedstock Study

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Reducer Carbon Conversion Profile

Reducer Gas Concentration Profile

0%

1%

2%

3%

4%

5%

90%91%92%93%94%95%96%97%98%99%

100%

0 50 100 150 200

Con

cent

ratio

n C

O, C

H4,

O2

(%)

Con

cent

ratio

n C

O2

(%)

Time (min)

CO2

CO

CH4

CH4

CO2

CO

0%10%20%30%40%50%60%70%80%90%

100%

10 60 110

Car

bon

Con

vers

ion

(%)

Time of reaction (min)

00.050.10.150.20.250.30.350.40.450.5

0

2

4

6

8

10

2 4 6 8 10 12 14 16 18

Con

cent

ratio

n (%

) CO

, CH

4, C

O2

Con

cent

ratio

n (%

) O2

Time (min)

CO2O2COCH4

Combustor Gas Concentration Profile

CH4

CO CO2

O2

Sample Data: PRB Process Performance • Continuous steady carbon conversion

from reducer throughout all solid fuel loading (5- 25kWth)

• <0.25% CO and CH4 in reducer outlet = full fuel conversion to CO2/H2O

• <0.1% CO, CO2, and CH4 in combustor = negligible carbon carry over, nearly 100% carbon capture

200-hour Sub-Pilot Continuous CDCL Demonstration

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Outline

CDCL Concept

Current Status of the CDCL Technology

Phase I Commercial Design

CDCL Comparison with other CO2 Capture Technologies

Techno-Economic Analysis

Small-Pilot Design

Conclusions

Future Work

Acknowledgments

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Fuel converter

Combustor

Pump

Coal Prep. Coal

CO2 Compressor

Bag House FGD Stack

CO2 Sequestration

LP IP HP

Air

Fe2O3

Cooling Tower

ID Fan

Water

ID Fan

H2O

CO2+H2O

Enhancer Gas Recycle Fan

Electricity

Carrier Particle Makeup (Fe2O3)

Fly Ash and Carrier Particle Fines

FGD

Spent Air

Steam

Water Steam Cycle

FeO/Fe

Commercial Plant Design: 550 MWe

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CDCL Commercial Plant Design and Engineering

OSU’s experimental data was converted into a commercial 550 MWe CDCL power plant.

• Material and Energy Balance • Process Flow Diagrams • Equipment Drawings • Arrangement Drawings • Plant layout Drawings • 3-D Models

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Outline

CDCL Concept

Current Status of the CDCL Technology

Phase I Commercial Design

CDCL Comparison with other CO2 Capture Technologies

Techno-Economic Analysis

Small-Pilot Design

Conclusions

Future Work

Acknowledgments

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CDCL Technology Comparison

Base Plant

MEA Plant

CDCL Plant

Coal Feed, kg/h 185,759 256,652 205,358

CO2 Emissions, kg/MWhnet 801 111 31

CO2 Capture Efficiency, % 0 90 96.5

Net Power Output, MWe 550 550 550

Net Plant HHV Heat Rate, kJ/kWh (Btu/kWh)

9,165 (8,687)

12,663 (12,002)

10,084 (9,558)

Net Plant HHV Efficiency, % 39.3 28.5 35.6

Cost of Electricity, $/MWh 80.96 132.56 102.67

Increase in Cost of Electricity, % - 63.7 26.8

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Outline

CDCL Concept

Current Status of the CDCL Technology

Phase I Commercial Design

CDCL Comparison with other CO2 Capture Technologies

Techno-Economic Analysis

Small-Pilot Design

Conclusions

Future Work

Acknowledgments

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Acc. No.

Item Description CDCL Cost, $k

1 Coal & Sorbent Handling $ 45,930 2 Coal & Sorbent Prep and Feed $ 21,772 3 Feedwater & Misc. BOP Systems $ 95,364 4 Boiler/CDCL Equipment $ 554,053 5 Flue Gas Cleanup $ 154,402

5B CO2 Removal & Compression $ 87,535 6 Combustion Turbine/Accessories - 7 HR, Ducting & Stack $ 44,799 8 Steam Turbine Generator $ 146,288 9 Cooling Water System $ 44,951

10 Ash/Spent Sorbent Handling System $ 15,256 11 Accessory Electric Plant $ 61,392 12 Instrumentation & Controls $ 25,903 13 Improvements to Site $ 16,394 14 Buildings & Structures $ 66,362 Total Plant Cost $1,380,401

Total Plant Cost

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Cost of Electricity

Base Case, $k CDCL, $k

Total Overnight Capital Cost 1,348,350 1,725,172 Fixed O&M 38,829 48,769 Variable O&M 10,986 13,916 Consumables 20,742 13,743 Fuel 104,591 114,807 Oxygen Carrier - 15,581

Total Production Cost 1,523,498 1,931,989

Cost of Electricity, $/ MWh 80.96 102.67

Increase in COE, % 26.8%

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Technology Gap Assumption Target Relative Increase in COE with respect to

DOE’s base plant CDCL Designed Case 26.8%

Residence Time 100% 33% reduction 24.7%

CO2 Credit 0% Credit 6.5% at $20/ton 20.9%

CO2 Credit 0% Credit 96.5% at $20/ton 0.64 %

Sensitivity Analysis

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Outline

CDCL Concept

Current Status of the CDCL Technology

Phase I Commercial Design

CDCL Comparison with other CO2 Capture Technologies

Techno-Economic Analysis

Small-Pilot Design

Conclusions

Future Work

Acknowledgments

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Experimental CDCL Small-Pilot Design

• Thermal Input: 250 kWth. • Height: 30’ • Footprint: 10’ x 10’ • Location: B&W’s Research

Center. Barberton Ohio.

Objective: Obtain representative reducer performance under autothermal system conditions.

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Outline

CDCL Concept

Current Status of the CDCL Technology

Phase I Commercial Design

CDCL Comparison with other CO2 Capture Technologies

Techno-Economic Analysis

Small-Pilot Design

Conclusions

Future Work

Acknowledgments

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Development of suitable oxygen carrier capable of >100 redox cycles Moving bed design enhances carbon and particle conversion and enhances process efficiency

Continuous 200-hour feasibility demonstration of CDCL at 25 kWth scale

•High coal conversions achieved in the reducer •High CO2 purity with low carbon carryover to the combustor •Various types of coals successfully tested

Techno-economic analysis shows that increase in COE is <27% for CDCL plant when compared to PC plant with no carbon capture

Small Pilot unit designed to resolve technology gaps identified in Phase I with emphasis on autothermal system operation.

Conclusions

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Outline

CDCL Concept

Current Status of the CDCL Technology

Phase I Commercial Design

CDCL Comparison with other CO2 Capture Technologies

Techno-Economic Analysis

Small-Pilot Design

Conclusions

Future Work

Acknowledgments

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Future Work: 3MWth Pilot Scale Demonstration

• Thermal Input = 3 MW • Height = 90 feet • Footprint = 40’ x 40’ • Location: B&W’s Research

Center. Barberton Ohio.

Objective: Investigate coal distribution and system performance at commercial-scale conditions.

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Outline

CDCL Concept

Current Status of the CDCL Technology

Phase I Commercial Design

CDCL Comparison with other CO2 Capture Technologies

Techno-Economic Analysis

Small-Pilot Design

Conclusions

Future Work

Acknowledgments

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Acknowledgments

This material is based upon work supported by the Department of Energy under Award

Number DE-FE0009761