Clean Coal Combustion:Meeting the Challenge of Environmental and Carbon Constraints

A.R. Ericson

2 3

Our Vision for New Coal PowerPortfolio of Clean Technologies

CO2 Capture And

SequestrationCOAL

PARTIAL COMBUSTION

Fuel Cell

PETROCHEMICAL O2

water shift

CO2 Scrubbing

IGCC

Air

AIR BLOWN IGCC

IGCC

H2H2 GT

CO22

CFB USC CFB

O2 Oxygen Fired CFB or PC

PC USC PC

COMPLETE COMBUSTION

AirPost-

combustion capture

CO22

ConcentratedCO2

Carbonate looping

CO22

Near-zero emissions Carbon Free Power

CHEMICALLOOPING

3

Presentation Roadmap

Market Realities

Environmental Performance – Mission Critical

Advanced Cycle Designs

Coal Generation in a Carbon Constrained World

Outlook for New Ultra Clean Coal Capacity

4

Drivers for New CapacityNorth America

Our economies continue to driveelectricity demand growth

Source: NERC 2006 Long TermReliability Assessment

5

Existing US Coal FleetExpanding output to meet demand

1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005Year

5456586062646668707274

Cap

acity

Fac

tor

%

Equivalent to 45 GW of new coal capacity

6

Drivers for New Coal BuildNorth America

Base Energy needs versus Peaking Capacity

Base load demand expected to increase at roughly GDP

Economics Fuel Cost End User price shocks driving

demand for low cost energy

Coal availability and prevalence

200+ Years of Reserves in North America

Advent of OTC (over the counter) markets for coal and emissions

Environmental regulations drive new clean plants

Fuel diversity

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1

2

3

4

5

6

7

8

9

19

98

20

00

20

02

20

04

20

06

20

08

20

10

20

12

20

14

Delivered Price

US

$/M

M B

TU

Natural Gas

Steam Coal

Source: U.S. EIA

7

New Coal CapacityFaces Challenges

Economics Utilization of all low cost domestic coals …and opportunity fuels Competitive costs

Operations Highest reliability and commercial availability Operating parameters to meet demands of grid

Environmental Near zero emissions … and a carbon strategy

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Meeting the Goals for Coal Based Power - Emissions

9

Source: Energy Velocity database ( EPA CEMS 2005 data )

SubBit. PC

IGCC (operating)

Bit. PC

CFB

PC and CFB Clean Coal technologies have

demonstrated the lowest emissions :

Exceed Requirements Cost Effectively Reliably

2005 Wtd Avg NOx Emissions - US Coal Units

0.000.010.020.030.040.050.060.070.08

Lb

s/M

MB

tu

Top 20 - Lowest NOx emitters

2005 Wtg. Avg SO2 Emissions - US Coal Units

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

Lb

s/M

MB

tu

Top 20 - Lowest SOx emitters

Operating Coal Combustion – Best in Class Emissions

10

Ultra Clean Coal CombustionEmissions Control Capability

Today’s state-of-the-art NOx >95% reduction with optimized firing systems and SCR

SO2 >99% capture with Wet FGD and DBA Particulates 99.99% capture Hg 80- 95% capture (coal dependent)

Next steps Continued improvements Integrated Multi-pollutant systems to reduce costs High Hg capture on all coals (without reliance on ACI) Introduction of CO2 capture

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12

Karlshamn Power Plant

Unit 3 Power capacity:

3 x 340 MW

Fuel:

Heavy fuel oil(max. 3.5% S)

13

FLOWPACKarlshamm Performance Levels

Inlet Gas Conditions (at ESP outlet) English Metric

Flue Gas Flow ~ 870,000 acfm 1,080,000 Nm3/hr

Flue Gas Temp 270°F 130°C

Particulate Matter (PM) 0.025 lb/MMBTU 30 mg/Nm3

Outlet Gas Conditions (at stack)

SO2 (>99% w/ no additives) < 19 ppmv < 55 mg/Nm3

SO3 (~70% removal) < 1 ppmv < 2 mg/Nm3

PM (>60% removal -oil soot) < 0.01 lb/MMBTU < 2 mg/Nm3

Sulfur Content in the Fuel: 2.5%

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Additives: Halogen(s) Powdered Activated Carbon Halogenated Powdered Activated

Carbon

= Potential additive injection points

When Additional Control is Needed -Mercury Capture Technologies

15

Multi-pollutant APC Systems

Integrated APC systems based around commercially proven and reliable technologies

Use readily available reagents Produces reusable byproduct(s)

– No impact on fly ash Superior cost/performance ratio:

– Extremely compact design Reduces capital costs for equipment, erection

and BOP– Fewer moving parts reduces maintenance costs – Superior environmental performance

Reduced permitting schedule/cost Avoided cost for SO2 credits

Targeted emissions levels:– SO2: 0.02 lb/MMBTU (> 99.5%)– Hg: 1.0 lb/TBTU (> 90%)– PM: 0.01 lb/MMBTU (99.99%)– NOx: 0.05 lb/MMBTU w/SCR

• “Polishing” (Level TBD) w/o SCR

Controls SOx, PM10/PM2.5 Mercury & NOx

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Meeting the Challenge -Advanced Cycles

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Increased Value for Efficiency

Compared to 34% subcritical efficiency, 11,000 BTU/lb coal, 80% capacity factor

0

24

68

10

1214

16

20 25 30 35 40 45 50

Efficiency

Coal Price USD/Short Ton

500 MW Unit

Annual Fuel Savings, MUSD

42%

40%

38%

36%

~$6.5M/yr~$10M/yr

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Efficiency – Critical to emissions strategy

Coal w/ 10%

co-firing biomass

100% Coal

Existing US coal fleet @ avg 33%

Commercial Supercritical

Net Plant Efficiency (HHV), %

Source: National Coal CouncilFrom EPRI study

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0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

2000 2001 2002 2003 2004 2005

Supercritical PC Subcritical PC CFB

Worldwide orders for new coal generation

Clear Trend to Supercriticalfor Global Steam Power

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147 GW, 230 Supercritical Coal Fired Boilers Ordered Since 1990

0

10

20

30

40

50

60

70

80

<1050 For

unknown

1050 F -1110 F

>=1110 F0

20

40

60

80

100

120

<1050 For

unknown

1050 F -1110 F

>=1110 F

Maximum of SH or RH Temp Maximum of SH or RH Temp

Number of UnitsGW

Clear Trend to Advanced Supercritical Cycles

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SupercriticalFlexible for power grid needs

Operating PerformanceTurndown – Supercritical PC/CFB units have

– Flexibility to rapidly change load– Turndown to lower minimum loads during off peak– Maintain efficiency when operating at part loads

Excellent startup ramp rates to meet grid demand

0

50

100

150

200

250

First Fire to Turbine Synch, Minute with Bypass System

Hot Start Up, after 2 hr shutdown

Warm Start Up, after 8 hr shutdown

Cold Start Up, after 36 hr shutdown

Supercritical Drum

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Progression of Plant Efficiency via Advanced Steam Conditions and Plant Designs

1960 1980 2000 2020

Material Development

-Efficiency (net) HHV-Typical Steam Parameters

35-37%

37-38

41%- 43%

TARGET48 - 50 %

Ni-based Materials

T91

Mature Supercritical

AdvancedAustenitic Materials

3480/1005/1050 (psi/°F/°F)

2400/1005/1005167/540/540

Up to5400/1300/1325(psi/°F/°F)

4000/1110/1150(psi/°F/°F)

4000/1075/1110 (psi/°F/°F)

38-41%

SubcriticalTechnology

Commercial State of Art Supercritical

UltraSupercritical

Advanced USC

2010

SlidingPressure

Supercritical

US-DOE :Ultra-Supercritical Boiler Project Operating Target: 1400°F/5500 psig

European Thermie Project Operating Target: 1292°F/ 4500 psig

US-DOE :Ultra-Supercritical Boiler Project Operating Target: 1400°F/5500 psig

European Thermie Project Operating Target: 1292°F/ 4500 psig

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0

10

20

30

40

50

POLK/WABASHIGCC

Target for NewIGCC*

SCPC Today USC Target Next Gen IGCCPla

nt

Eff

icie

ncy

% (

HH

V B

asis

)

Meeting the Goals for Coal Based Power - Efficiency

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Meeting the ChallengeCO2 Reduction

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CO2 Mitigation Options – for Coal Based Power

Increase efficiency Maximize MWs per lb of carbon processed

Fuel switch with biomass

Partial replacement of fossil fuels = proportional reduction in CO2

Then, and only then ….Capture remaining CO2 for EOR/Sequestration

= Logical path to lowest cost of carbon reduction

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CO2 Capture

Innovative options continue to emerge and develop

Post Combustion Capture Adsorption Absorption Hydrate based Cryogenics / Refrigeration based

Oxy-fuel Firing External oxygen supply integrated membrane-based Oxygen carriers (chemical looping)

Decarbonization reforming (fuel decarbonization) carbonate reactions (combustion decarbonization)

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GBoiler

CO2liquid

M

Stripper

MEA CO2Absorber

CO2 Compressor

Steam Turbine

MEA

Amine-Based Absorption - CO2 Capture

MEA has demonstrated performance on coal based flue gas

Work required to address:

Regeneration power

Compression ratio

Cost of solvent

SHADY POINT, OKLAHOMA, USA An AES CFB power plant with

MEA CO2 separation

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Advancements Absorption Stripping CO2 Capture

Ionic Liquids “designer solvents”

“Piperazine” - alternative solvent

Process integration and improvement has driven cost down from 70 to 40-50 $/ton CO2 --- further progress expected

With industry focus on improvements, advanced amines likely to be competitive solution for post combustion capture

Amine scrubbing continues to develop

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CO2 Capture Innovations Chilled Ammonia System

Flue GasCoolingSystem

EnergyRecovery

EnergyRecovery

CO2

Tower

EnergyRecovery

ExistingSO2 Scrubber

Flue Gas

Ammonia reacts with CO2 and water and forms ammonia carbonate or bicarbonate

Moderately raising the temperature reverses the above reactions – producing CO2

Regeneration at high pressure

CO2 Lean

CO2 Rich

CO

2 A

bso

rpti

on

T

ow

er

ExistingStack

ConcentratedCO2 to SequestrationEnergy

Recovery

Energy Recovery

Flu

id

Re

ge

ne

rati

on

Flu

e G

asC

oo

ling

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Advantages of Chilled Ammonia

High efficiency capture of CO2

Low heat of reaction

High capacity for CO2 per unit of solution

Easy and low temperature regeneration

Low cost reagent

No degradation during absorption-regeneration

Tolerance to oxygen and contaminations in flue gas

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We Energies Pleasant Prairie Host Site Location for 5MW Pilot

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Carbon Free PowerAdvanced Combustion

Innovative Combustion Options for 2010 and Beyond

Oxygen Firing – Direct concentration of CO2 to >90% for reduced capture costs

Chemical Looping –Leapfrog technology with potential to achieve significantly lower costs than PC/CFB/IGCC

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Compressor

Air SeparationUnit (ASU)

N2

BoilerO2

O2, N2

Air in-leakageFuel

Condenser

H2O

CO2 Recycle

Oxygen Firing to produce concentrated CO2 stream

CO2

3 MWt pilot CFB

Oxygen Firing – Direct concentration of CO2 to >90% for reduced

capture costs

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30 MWth Oxy-fired PC Pilot Plant – Vattenfall

Location of pilot plant in the Industrial Park Schwarze Pumpe

2020approx. 4-5

Commercial Plant approx. 1000 MWel

2015Realisation with CO2 sequestration,

1:20Demo Plant 600 MWth

Vattenfall..., ALSTOM, others

2008Test of the oxyfuel process chain

1:60Pilot Plant 30 MWth

CEBra, BTU Cottbus, Vattenfall, ALSTOM

2005Fundamentals of oxyfuel combustion with flue gas recirculation

1:50Test Plant 500 kWth

Universities (Stuttgart, Chalmers, Dresden)

Vattenfall, ALSTOM..

2004

2005

Fundamentals of oxyfuel combustion

Laboratory Tests 10 / 55 kWth

PartnersComObjectiveScale-up Factor

Development Steps

2020approx. 4-5

Commercial Plant approx. 1000 MWel

2015Realisation with CO2 sequestration,

1:20Demo Plant 600 MWth

Vattenfall..., ALSTOM, others

2008Test of the oxyfuel process chain

1:60Pilot Plant 30 MWth

CEBra, BTU Cottbus, Vattenfall, ALSTOM

2005Fundamentals of oxyfuel combustion with flue gas recirculation

1:50Test Plant 500 kWth

Universities (Stuttgart, Chalmers, Dresden)

Vattenfall, ALSTOM..

2004

2005

Fundamentals of oxyfuel combustion

Laboratory Tests 10 / 55 kWth

PartnersComObjectiveScale-up Factor

Development Steps

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OxidizerReducer

Calciner

Cold Solids

CaCO3 CaO

CaS

CaSO4

Hydrogen

Coal,Steam

CO2

Air

CaCO3

Depleted Air, Ash,CaSO4

OxidizerReducer

CaS

CaSO4

CO2 & H2O

Coal,Limestone Air

Depleted Air, Ash,CaSO4

Chemical Looping Combustion

Chemical Looping Gasification

Future Technologies for CO2 CaptureChemical Looping

Hot Solids

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0

2

4

6

8

10

SCPCIG

CC

SCPC w/M

EA

Oxyfir

ing w

CO2

SCPC adv

amin

es

IGCC F

turb

ine

SCPC NH3

USCPC adv C

O2

IGCC H

turb

ine

w adv

CO2

Lev

eliz

ed C

OE

cen

ts/K

wh

rMultiple Paths to CO2 ReductionInnovations for the Future

No CO2 Capture ------------------------------With CO2 Capture---------------------------

Technology Choices Reduce Risk and Lower Costs

Note: Costs include compression , but do not include sequestration – equal for all technologies

‘Hatched’ Range reflects cost variation from fuels and uncertainty

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Conclusions

New coal fired power plants shall be designed for highest efficiency to minimize CO2 and other emissions

Lower cost, higher performance technologies for post combustion CO2 capture are actively being developed, and more are emerging

There is no single technology answer to suit all fuels and all applications

The industry is best served by a portfolio approach to drive development of competitive coal power with carbon capture technology

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