Clean Coal Technology Developments & the move towards CO2 Capture

Dr John TopperIEA Clean Coal Centre, London

STEP-TREC Programme,Trichy, December, 2013

Membership status of the IEA Clean Coal Centre at October 2013

Italy JapanRepublic of Korea

UK

Glencore Xstrata

BHEL

Anglo American Thermal Coal

USA

S Africa

Austria

Canada

GermanyCEC

Beijing Research Institute of Coal

Chemistry

Australia

Coal Association

NZ

Eletrobras

SuekElectric Power Planning & Engineering Institute of China

Banpu

Poland

A centre of excellence for all aspects of clean coal knowledge

transfer

1. Coal Supply and Demand to 2035

2. Examples of Best Practice Today in Coal Fired Power

3. Efficient Clean Power Tomorrow?

4. Status of Carbon Capture

World Energy OutlookPublished by IEA November 2012

All views expressed are the speaker’s and not necessarily the IEA’s

IEA WEO 2012Incremental world primary energy demand

by fuel, 2001-2011

Total non-coal Coal

Mto

e

0

250

500

750

1 000

1 250

1 500

1 750

Oil

Naturalgas

Renewables

Since the start of the 21st century, coal has dominated the global energy demandpicture, alone accounting for 45% of energy demand growth over 2001-2011

IEA WEO 2012World primary energy demand by fuel

0

1 000

2 000

3 000

4 000

5 000

Oil Coal Gas Renewables Nuclear

Mto

e 2010

2035

Fossil fuels account for 60% of the overall increase in demand,remaining the principal sources of energy worldwide

3 000 4 000 5 000 6 000TWh

2 000

IEA WEO 2012A power shift to emerging economies

The need for electricity in emerging economies drives a 70% increase in worldwide demand, with China & India accounting for over half of the global growth

Change in power generation, 2010-2035

-1 000 0 1 000

Japan

European Union

United States

China

TWh

Coal Gas Nuclear Renewables

India

Countries with the largest populationwithout access to electricity in 2010

0

50

100

150

200

250

300

350

Indi

a

Bang

lade

sh

Nig

eria

Ethi

opia

Indo

nesia

DR C

ongo

Paki

stan

Tanz

ania

Keny

a

Uga

nda

Mill

ion

0%

10%

20%

30%

40%

50%

60%

70% Developing Asia

Sub-Saharan Africa

Cumulativeshare of globaltotal (right axis)

Over 95% of those without electricity are in developing Asia or sub-Saharan Africa & nearly two-thirds are in just ten countries (IEA WEO 2012)

Best Practice Today

Torrevaldaliga Nord

3 units at 660MWe = 1980MWe stationLow conventional emissions (NOx <100 mg/m3, sulphur oxides <100 mg/m3,

particulates 15 mg/m3, at 6% O2, dry); full waste utilisationHighest steam conditions: 604C/612C at turbine: 25 MPaOperating net efficiency >44.7% LHV Wet scrubber based limestone/gypsum FGDNOx abatement SCRParticulates removal Bag filtersNew sea port for coal deliverySolids handling all enclosed

USC, boilers supplied by Babcock Hitachi , using bituminous coal

Niederaussem K, Germany

Highly efficient lignite-fired plantOperating net efficiency 43.2% LHV/37% HHV High steam conditions 27.5 MPa/580C/600C at turbine; initial difficulties

solved using 27% Cr materials in critical areasUnique heat recovery arrangements with heat extraction to low

temperatures – complex feedwater circuitLow backpressure: 200 m cooling tower, 14.7C condenser inletLignite drying demonstration plant being installed to process 25% of fuel

feed to enable even higher efficiencyNOx abatement Combustion measuresParticulates removal ESPDesulphurisation Wet FGD

USC, tower boiler, tangential wall firing, lignite of 50-60% moisture, inland

Isogo New Units 1 & 2, Japan – highlights

Near zero conventional emissions (NOx 20 mg/m3, sulphur oxides 6 mg/m3, particulates 1 mg/m3, at 6% O2, dry); full waste utilisation

Highest steam conditions: 25.0 MPa/600C/610C at turbine: ASME CC 2328 steels in S/H; P122 for main steam pipework

Operating net efficiency >42% LHV/40.6% HHVEfficiency tempered slightly by 21C CW, fewer FW heating stages Dry regenerable activated coke FGD (ReACT)NOx abatement: Combustion measures and SCRParticulates removal: ESPIsogo New Unit 2 uses ReACT specifically for multi-pollutant control,

including mercury

USC, tower boiler, opposed wall firing, international bituminous coal and Japanese

coals, warm sea water

Huaneng Yuhuan 4x 1000MWe USC coal fired power plant

Sasan UMPP, Madhya Pradesh

Reliance Power, 6 x 660 MW supercritical units. 24.7 MPa/565/593

Plant connected to the grid in September 2012

HELE coal-fired power generation

What are HELE technologies? (HELE=high Efficiency Low Emissions)

Reduce non-GHG emissions Reduce CO2 emissions *Efficiency improvement*

Efficiency improvement reduces specific fuel consumption and also reduces specific pollutant emissions.

HELE CCS

Age distribution of existing power plants

0

50

100

150

200

250

300

Before1950

1951-60

1961-70

1971-80

1981-90

1991-2000

2001-10

European Union

GW

0

50

100

150

200

250

300

Before1950

1951-60

1961-70

1971-80

1981-90

1991-2000

2001-10

United States

GW

010

20

30

40

50

60

70

Before1950

1951-60

1961-70

1971-80

1981-90

1991-2000

2001-10

India

GW

0

100

200

300

400

500

600

Before1950

1951-60

1961-70

1971-80

1981-90

1991-2000

2001-10

China

GW

Coal Oil Natural gas Nuclear Hydro Biomass and waste Wind Other renewables

Ageing infrastructure is the challenge in many OECD countries. Emerging economies have a growing demand for electricity.

Decrease generation from subcritical Install CCS* on plants over supercritical

Increase generation from high-efficiency technology (SC or better)

Glo

bal c

oal-f

ired

elec

trici

ty

gene

ratio

n (T

Wh)

Supercritical

HELE Plants with CCS*

USC

Subcritical

*CCS (Post-combustion, Oxyfuel, Pre-combustion CO2 capture)

IGCC

Improve efficiency, then deploy CCS

* CCS fitted to SC (or better) units.

Three processes essential to achieve a low-carbon scenario

Shar

e of

CCS

(1=1

00%

)

Efficiency improvement

CO2

abatement by CCS

Share

of C

CS

Ave

rage

CO

2 in

tens

ity fa

ctor

in 2

DS

(g

CO

2/kW

h)

33% 34% 37% 42% 43%

Raising efficiency significantly reduces the CO2/kWh emitted.

Efficiency in 2DS

Impact of efficiency improvement on CO2 abatement

Data for hard coal-fired power plants from VGB 2007; data for lignite plants from C Henderson, IEA Clean Coal Centre; efficiencies are LHV,net

CO2 emission reduction by key technologies

Energy Efficiency makes big change but deep cuts of CO2 emission can be done only by Carbon Capture and Storage (CCS)

>2030

but deep cutsonly by CCS

Average worldwidehard coal

33%1015 gCO2/kWh

38%881 gCO2/kWh

EU av hard coal

47%711 gCO2/kWh

State-of-the artPC/IGCC hard coal

50%669 gCO2/kWh

Advanced R&DHard coal

gCO

2/kW

h

Latrobe Valley lignite (Australia)

28-29.0%

1400 gCO2/kWh EU state-of-the-art lignite

43-44%

930 gCO2/kWh

55%

740 gCO2/kWh

Advanced lignite

The challenge of advanced USC

Nickel-based super-alloys will enable plant components to withstand temperatures of 700ºC and beyond.

Boiler tube/piping Steam turbine

rotor/shaft

Generator

~Boiler Steam turbine

700-760°C

700°C/ 30 - 35MPa 700-760°C

- Nickel-based super-alloys

- Ferrite/Austenitic alloys

Current state of A-USC technology

National programme

Steam temperature

Efficiency (LHV, net )

Programme start date

Demonstration plant operational by (size) Also includes:

EU 700ºC >50% 1998 2021 (500 MWe) Coatings, biomass co-firing, cycling

USA 760ºC 45-47% (HHV, net) 2000 2021 (600 MWe) Oxyfuel, coatings, high

sulphur coalJapan 700ºC >50% 2008 2021 (600 MW) Biomass co-firingChina 700ºC 46-50% 2011 2021 (660 MWe) -India 700ºC >50% 2011 2017 (800 MWe) -

India

China

Japan

USA

EU

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

2019

2020

2021

Timeline showing duration between programme start date and the planned date for an operational demonstration plant

The steam cycle is optimised for maximum efficiency.

Advanced lignite pre-drying in pulverised coal combustion

RWE Power Vattenfall

Moisture reduction important for some coals

Drax is a pioneer in biomass direct injection technologyNew 500MW co-firing facility is largest in the worldCapacity to co-fire >1.5m tonnes pellets per year

24

Drax Power in UK - 500MW Co-firing Facility

Puertollano IGCC power plant and pilot plant location

PRENFLO Gasifier

Coal preparation

Sulphur Recovery

Combined Cycle

New CO2 capture pilot

plant

ASU

Pilot plant general view

IGCC power plant general view

PSE-CO2 project : CO2 Capture Pilot Plant

Courtesy of Elcogas

http://www.globalccsinstitute.com/get-involved/in-focus/2013/10/global-status-ccs-2013

Number of global large-scale integrated CCS projects drops in 2013 10/11/2013 The number of global large-scale integrated carbon capture and storage projects (LSIPs) dropped from 75 to 65 in 2013, according to a report from the Global Carbon Capture and Storage Institute. The institute monitors the number of LSIPs as a method of tracking the progress of CCS developments and defines LSIPs as “projects considered to be at a suffi ciently large scale to be representative of commercial-scale process streams.” The report states 13 LSIPs have been removed from the institute’s list since 2012, with five of those being canceled, seven put on hold and one downscaled. Three LSIPs were added to the list, however, reducing, bringing the total number to 65. According to the institute, four projects have commenced operation since 2012, making a total of 12 CCS projects in operation, and two projects have commenced construction since 2012, making a total of eight projects under construction. Of the 65 projects identified by the institute, the U.S. has the most with 20, with Europe second with 15 and China third with 12. The U.S. Environmental Protection Agency recently proposed a new rule that would limit CO2 emissions from new coal-fired units to 1,100 pounds of CO2 per megawatt-hour, which would require advanced emissions controls such as CCS. http://www.power-eng.com/articles/2013/10/number-of-global-large-scale-integrated-ccs-projects-drops-in-2013.html

GCCSI – Report 2013As reported in Power Engineering magazine

GCCSI – Summary Report 2013Contribution of CCS to CO2 emissions reduction

GCCSI - Summary Report 2013Costs of CO2 avoided in Power Sector

GCCSI – Summary Report 2013LSIPS Progress since 2010

THE ENDTHANK YOU ALL FOR LISTENING

john.topper@iea-coal.org