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The operations of an existing pulverized coal (EXPC) power plant with or without carbon capture and sequestration (CCS) on the basis of 1MWh electricity output. To access the model referenced in the report, please visit https://www.netl.doe.gov/energy-analysis/details?id=4EDA9298-2B77-4320-B48E-DEE007352794
Presented by NETL at EUEC 2018, 03/18
Presented by NETL at Power Gen International, 12/7
The Power Systems L-CAT is a high-level dynamic model that calculates levelized production costs and tracks environmental performance for a range of electricity generation technologies: natural gas combined cycle (using either imported (LNGCC) or domestic natural gas (NGCC)), integrated gasification combined cycle (IGCC), supercritical pulverized coal (SCPC), existing pulverized coal (EXPC), nuclear, and wind. All of the fossil fuel technologies also include an option for including carbon capture and sequestration technologies (CCS). The model allows for quick sensitivity analysis on key technical and financial assumptions, such as: capital, O&M, and fuel costs; interest rates; construction time; heat rates; taxes; depreciation; and capacity factors. The fossil fuel options are based on detailed life cycle analysis reports conducted by the National Energy Technology Laboratory (NETL). For each of these technologies, NETL's detailed LCAs include consideration of five stages associated with energy production: raw material acquisition (RMA), raw material transport (RMT), energy conversion facility (ECF), product transportation and distribution (PT&D), and end user electricity consumption. The goal of the NETL studies is to compare existing and future fossil fuel technology options using a cradle-to-grave analysis. The NETL reports consider constant dollar levelized cost of delivered electricity, total plant costs, greenhouse gas emissions, criteria air pollutants, mercury (Hg) and ammonia (NH3) emissions, water withdrawal and consumption, and land use (acreage).
Alstom’s Limestone Chemical Looping (LCL™) process has the potential to capture CO 2 from new and existing coal-fired power plants while maintaining high plant power generation efficiency. This new power plant concept is based on a hybrid combustion- gasification process utilizing high temperature chemical and thermal looping technology. This process could also be potentially configured as a hybrid combustion-gasification process producing a syngas or hydrogen for various applications while also producing a separate stream of CO 2 for use or sequestration. The targets set for this technology is to capture over 90% of the total carbon in the coal at cost of electricity which is less than 20% greater than Conventional PC or CFB units. Previous work with bench scale test and a 65 kWt Process Development Unit Development (PDU) has validated the chemistry required for the chemical looping process and provided for the investigation of the solids transport mechanisms and design requirements. The objective of this project is to continue development of the combustion option of chemical looping (LCL-C™) by designing, building and testing a 3 MWt prototype facility. The prototype includes all of the equipment that is required to operate the chemical looping plant in a fully integrated manner with all major systems in service. Data from the design, construction, and testing will be used to characterize environmental performance, identify and address technical risks, reassess commercial plant economics, and develop design information for a demonstration plant planned to follow the proposed Prototype. A cold flow model of the prototype will be used to predict operating conditions for the prototype and help in operator training. Operation of the prototype will provide operator experience with this new technology and performance data of the LCL-C™ process, which will be applied to the commercial design and economics and plan for a future demonstration plant.
One of the more significant issues related to carbon capture retrofits pertains to the reduction in net power output (derate) due to the large parasitic power load required for appreciable levels of carbon capture. Post-combustion capture (PCC) has been shown to reduce the net plant efficiency of an equivalent plant without capture by 20 percent or more. Yet, post-combustion amine scrubbing is anticipated to be the most viable near-term technology for reducing carbon dioxide (CO 2 ) emissions from existing coal plants. This study attempts to quantify auxiliary load replacement options for existing pulverized coal (PC) boilers to reduce the effects caused by steam and power requirements of the CCS systems and the resulting derated output of the existing plant. While individual retrofit options are highly plant-specific and, therefore, subject to unique optimization pathways, each of the proposed cases in this study attempts to examine the most promising configurations for each repowering technology.
The United States Environmental Protection Agency (EPA) issued updated effluent limitation guidelines (ELGs) and standards for the steam electric power generation point source category in November 2015 to strengthen controls on wastewater discharges. Many of the public comments discussed concerns about reliability, and whether Best Available Technology Economically Achievable (BAT) has been adequately demonstrated under a variety of conditions; however, discussion of the cost of electricity (COE) impact of installing the technology on existing coal units was limited. To address the COE impact of installing processes to achieve compliance for wet flue gas desulfurization (FGD) wastewater at existing pulverized coal (PC) plants, this study focused on developing cost and performance estimates of multiple commercial technologies in various configurations, including alternative (non-BAT) compliance processes (e.g., zero valent iron) and overcompliance processes (e.g., brine concentration with fly ash conditioning). Exhibit ES-1 provides the net plant efficiency (η) and COE estimated for each of the selected process configurations in this study. Case 0 is the reference subcritical PC plant, which represents an existing unit discharging wet FGD wastewater to surface water. It is assumed that all existing capital assets are fully depreciated, such that any capital costs reflect only the cost of the wet FGD wastewater treatment systems and plant upgrades required to accommodate the retrofits.
TDA Research, Inc. has developed a novel sorbent based post-combustion CO 2 removal technology. This low cost sorbent can be regenerated with low-pressure (ca. 1 atm) superheated steam without temperature swing or pressure-swing. The isothermal and isobaric operation is a unique and advantageous feature of this process. The objective of this project was to demonstrate the technical and economic merit of this sorbent based CO 2 capture approach. Through laboratory, bench-scale and field testing we demonstrated that this technology can effectively and efficiently capture CO 2 produced at an existing pulverized coal power plants. TDA Research, Inc is developing both the solid sorbent and the process designed around that material. This project addresses the DOE Program Goal to develop a capture technology that can be added to an existing or new coal fired power plant, and can capture 90% of the CO 2 produced with the lowest possible increase in the cost of energy. .
uelCell Energy, Inc. (FCE) has developed a novel system concept for separation of carbon dioxide (CO2) from greenhouse gas (GHG) emission sources using an electrochemical membrane (ECM). The salient feature of the ECM is its capability to produce electric power while capturing CO2 from flue gas, such as from an existing pulverized coal (PC) plant. Laboratory scale testing of the ECM has verified the feasibility of the technology for CO2 separation from simulated flue gases of PC plants as well as combined cycle power plants and other industrial facilities. Recently, FCE was awarded a contract (DE-FE0007634) from the U.S. Department of Energy to evaluate the use of ECM to efficiently and cost effectively separate CO2 from the emissions of existing coal fired power plants. The overarching objective of the project is to verify that the ECM can achieve at least 90% CO2 capture from flue gas of an existing PC plant with no more than 35% increase in the cost of electricity (COE) produced by the plant. The specific objectives and related activities planned for the project include: 1) conduct bench scale tests of a planar membrane assembly consisting of ten or more cells of about 0.8 m2 area each, 2) develop the detailed design for an ECM-based CO2 capture system applied to an existing PC plant, and 3) evaluate the effects of impurities (pollutants such as SO2, NOx, Hg) present in the coal plant flue gas by conducting laboratory scale performance tests of the membrane. The results of this project are anticipated to demonstrate that the ECM is an advanced technology, fabricated from inexpensive materials, based on proven operational track records, modular, scalable to large sizes, and a viable candidate for >90% carbon capture from existing PC plants. In this paper, the fundamentals of ECM technology including: material of construction, principal mechanisms of operation, carbon capture test results and the benefits of applications to PC plants will be presented.
Material inputs for retrofitting an existing pulverized coal (EXPC) power plant with carbon capture and sequestration (CCS). To access the model referenced in the report, please visit https://www.netl.doe.gov/energy-analysis/details?id=03FD6C0E-5DA6-4455-9374-78A247D946BB
This report summarizes the carbon capture research and development conducted by The State University of New York at Buffalo (UB), University of South Carolina (USC), GTI Energy (GTI), and Rensselaer Polytechnic Institute (RPI) for U.S. Department of Energy (DOE) project DE-FE0031730 titled “Transformational Molecular Layer Deposition Tailor-made Size-Sieving Sorbents for Post-Combustion CO 2 capture.” The objective of this project was to develop a transformational molecular layer deposition (MLD) tailor-made size-sieving sorbent integrated with a pressure swing adsorption (PSA) cycle schedule that can be installed in new or retrofitted into existing pulverized coal (PC) power plants for CO 2 capture with a cost of electricity at least 30% lower than a supercritical PC power with CO 2 capture, or approximately $\$$30 per tonne of CO 2 captured, and with it being ready for demonstration by 2030.
With increasing demand placed on power generation plants to reduce carbon dioxide (CO2) emissions, processes to separate and capture CO2 for eventual sequestration are highly sought after. Carbon capture processes impart a parasitic load on the power plants; it is estimated that this would increase the cost of electricity from existing pulverized coal plants anywhere from 71-85 percent [1]. The National Energy and Technology Lab (NETL) is working to lower this to below a 30 percent increase. To reach this goal, work is being done not only to accurately simulate these processes, but also to leverage those accurate and detailed simulations to design optimal carbon capture processes. The major challenges include the lack of accurate algebraic models of the processes, computationally costly simulations, and insufficiently robust simulations. The first challenge bars the use of provable derivative-based optimization algorithms. The latter two can either lead to difficult or impossible direct derivative-free optimization. To overcome these difficulties, we take a more indirect method to solving this problem by, first, generating an accurate set of algebraic surrogate models from the simulation then using derivative-based solvers to optimize the surrogate models. We developed a method that uses derivative-based and derivative-free optimization alongside machine learning and statistical techniques to generate the set of low-complexity surrogate models using data sampled from detailed simulations. The models are validated and improved through the use of derivative-free solvers to adaptively sample new simulation points. The resulting surrogate models can then be used in a superstructure-based process synthesis and solved using derivative-based methods to optimize carbon capture processes.
Increasing the competitiveness of the existing pulverized-coal utility fleet in the United States may be achieved by decreasing heat rate, via increases in steam cycle efficiency through upgraded steam temperatures and use of latest technology available in steam turbine and blading design. The average net plant efficiency of the US coal-fired fleet is approximately 33% (HHV). Plant efficiency increases to approximately 41.4% (HHV) at 1,350°F (732°C) steam temperature. However, achieving these Advanced Ultra-Super Critical (AUSC) steam conditions requires the use of advanced high-temperature materials. While there has been a significant amount of DOE-funded materials R&D, most of the related design work has focused on new (greenfield) units, rather than on opportunities to retrofit this advanced technology to the existing utility fleet. If technology, based upon the advanced materials required for AUSC steam conditions, may be applied to the existing fleet, using an economically viable retrofit, a higher capacity factor can be expected as a result of the increased plant competitiveness. The Electric Power Research Institute (EPRI) was awarded a project by the US Department of Energy to examine the technical and economic feasibility of a series of steam cycle upgrades to the two most prevalent types of U.S. coal power plants: 2,400 psig (16.6 MPa) subcritical and 3,500 psig (24.1 MPa) supercritical pulverized coal units. The nine upgrade options that were originally being considered included increasing the main and reheat steam temperatures from 1,000°F (538°C) to 1,100°, 1,200°, and 1,350°F (593°C, 649°C, and 732°C) while holding the steam pressures constant at their original design values, and cases where just the main steam or reheat steam temperatures were increased. The objective was to minimize the modifications required to the existing power plant while still providing a significant improvement in heat rate. The upgrade options assumed that the boiler enclosure envelope remained unchanged from each base case, and that all applicable OEM design guidelines for normal commercial units were imposed. For the highest temperature supercritical case, an option of using a low-pressure molten salt loop to transfer heat from the furnace to the steam was examined. The first major task of the work scope was designed to examine the technical feasibility of various upgrade options, while the subsequent work determined economic viability of the technically feasible upgrade options. Prior to evaluating the effect of these increased temperatures, a “base case” model of a subcritical and supercritical PC boiler was created, which was used for comparative purposes. Upgrade options were evaluated at full-load, part-load and dynamic transient conditions. Once the technical feasibility of each upgrade option was evaluated, the economic value of the heat rate improvement of each feasible option was determined by detailed modeling of unit dispatch in several regional power markets. The dispatch model was used to estimate the amount of revenue from power sales the upgraded unit would receive in comparison to a non-upgraded version of the same power plant. As a parallel task to the dispatch analysis, the capital cost of implementing the upgrades was estimated. The capital cost estimates were then compared to the increased revenue estimated by the dispatch modeling to determine the economic attractiveness of each upgrade option. Several upgrade options were determined to be technically feasible. The net present value (NPV) of the costs for steam cycle upgrades considered in this study ranged from approximately $\$$111 to $\$$130 million. The economic modeling results show that the unit dispatch changes resulting from steam cycle upgrades are relatively small, due largely to heat rate (and operating cost) changes being relatively small. Additionally, the cost of each upgrade exceeds the net revenue increases associated with the upgrade case. Note that the breakeven values are higher for subcritical retrofits, but the capital costs for the subcritical upgrades are also slightly higher. In typical new pulverized coal plants, fuel accounts for approximately 25% of the cost of electricity (COE), while capital costs represent around 50% of the COE. Therefore, in order to improve the heat rate by 4% one can only afford to increase the capital cost by 2%, at the same cost of electricity. The conclusion of this study is that without a cost for emitting CO 2 , it will be difficult to pay for significant efficiency improvements on plants firing low cost coals.
The goal of this project is to develop a near-zero emissions flue gas purification technology for existing PC (pulverized coal) power plants that are retrofitted with oxy-combustion technology. The objective of Task 2 of this project was to evaluate an alternative method of SOx, NOx and Hg removal from flue gas produced by burning high sulfur coal in oxy-combustion power plants. The goal of the program was not only to investigate a new method of flue gas purification but also to produce useful acid byproduct streams as an alternative to using a traditional FGD and SCR for flue gas processing. During the project two main constraints were identified that limit the ability of the process to achieve project goals. 1) Due to boiler island corrosion issues >60% of the sulfur must be removed in the boiler island with the use of an FGD. 2) A suitable method could not be found to remove NOx from the concentrated sulfuric acid product, which limits sale-ability of the acid, as well as the NOx removal efficiency of the process. Given the complexity and safety issues inherent in the cycle it is concluded that the acid product would not be directly saleable and, in this case, other flue gas purification schemes are better suited for SOx/NOx/Hg control when burning high sulfur coal, e.g. this project's Task 3 process or a traditional FGD and SCR.
The goal of this project was to develop a near-zero emissions flue gas purification technology for existing PC (pulverized coal) power plants that are retrofitted with oxycombustion technology. The objective of Task 3 of this project was to evaluate an alternative method of SOx, NOx and Hg removal from flue gas produced by burning low sulfur coal in oxy-combustion power plants. The goal of the program was to conduct an experimental investigation and to develop a novel process for simultaneously removal of SOx and NOx from power plants that would operate on low sulfur coal without the need for wet-FGD & SCRs. A novel purification process operating at high pressures and ambient temperatures was developed.
For a secure and sustainable energy future, the United States (U.S.) must reduce its dependence on imported oil and reduce its emissions of carbon dioxide (CO{sub 2}) and other greenhouse gases (GHGs). To meet these strategic challenges, the U.S. wiU have to create fundamentally new technologies with performance levels far beyond what is now possible. Developing advanced post-combustion clean coal technologies for capturing CO{sub 2} from existing coal-fired power plants can play a major role in the country's transition to a sustainable energy future, especially when coupled with CO{sub 2}-enhanced oil recovery (CO{sub 2}-EOR). Pursuant to these goals, NRG Energy, Inc. (NRG) submitted an application and entered into a cost-shared collaboration with the U.S. Department of Energy (DOE) under Round 3 of the Clean Coal Power Initiative (CCPI) to advance low-emission coal technologies. The objective of the NRG W A Parish Post-Combustion CO{sub 2} Capture and Sequestration Demonstration Project is to establish the technical feasibility and economic viability of post-combustion CO{sub 2} capture using flue gas from an existing pulverized coal-fired boiler integrated with geologic sequestration via an enhanced oil recovery (EOR) process. To achieve these objectives, the project will be executed in three phases. Each phase represents a distinct aspect of the project execution. The project phases are: • Phase I. Project Definition/Front-End Engineering Design (FEED) • Phase ll. Detailed Engineering, Procurement & Construction • Phase III. Demonstration and Monitoring The purpose of Phase I is to develop the project in sufficient detail to facilitate the decision-making process in progressing to the next stage of project delivery. Phase n. This report provides a complete summary of the FEED study effort, including pertinent project background information, the scope of facilities covered, decisions, challenges, and considerations made regarding configuration and performance of the facility, along with the conceptual design and estimate results. The findings of this report should be considered conceptual in nature and are conditioned on the statements contained herein. The cost of preparing this report (including the FEED study described herein) was funded in part by a $167-million grant provided by the U.S. DOE.
Presentation for life cycle analysis compilation of the Power LCA Reports. Develops an inventory of emissions results, and calculates life cycle costs for each plant with and without CCS.
SRI International (SRI), in collaboration with Stanford University, OLI Systems (OLI), Politecnico de Milano (PoliMi), and Aqueous Systems Aps (ASApS) performed a 45-month effort to develop a promising Mixed-Salt Process (MSP) for carbon dioxide capture. The MSP combines existing ammonia and potassium-carbonate technologies with improved absorption steps for rate enhancement and ammonia emission reduction and a novel selective regeneration process with a high-pressure CO 2 product to introduce a new and advanced transformational solvent-based technology. The striking advantages of the SRI MSP include: low heat of reaction, high loading of CO 2 , high-pressure regeneration of > 99% pure dry CO 2 , low sensitivity to impurities, low process cost, use of a non-degradable low-cost solvent with a very low carbon footprint for its production, low emissions, and reduced water use compared to the state-of-the-art ammonia-based and amine technologies. The overall objective of the project was to develop and test a solvent-based CO 2 capture technology that can capture CO 2 from existing or new pulverized coal (PC) power plants at low cost. Our specific goal was to test SRI’s newly developed MSP at the large bench-scale level to demonstrate that the process could capture CO 2 at high efficiency (> 90%) with very high CO 2 loading (> 10 wt.%), require less than 2 GJ/tonne for solvent regeneration, and produce a CO 2 stream at high pressure with a purity > 95 vol.%. This 45-month MSP development program was designed to conduct (1) extensive test campaigns with different process flowsheet variants, and (2) detailed thermodynamic, kinetic, and process modeling. These tests and models were very important to identify any issues associated with the process in the early stages and then resolve them before moving into the next scale-up (> 1 MWe scale) testing. The technology development plan consisted of balanced experimental and process modeling activities as shown in Figure i. Such an approach reduces the risks associated with the process operability at large scales and provides capital and operating expenditure (CAPEX/OPEX) predictions with improved accuracies. Under the MSP development program at SRI, we performed an aggressive testing campaign with individual subsystems as well as integrated CO 2 capture and regeneration system to identify the best operating conditions. The project was carried out in two budget periods (BP1 & BP2).