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National Carbon Capture Center at the Power Systems Development Facility
Every day, every job, safely.
Kerry Bowers, Director, National Carbon Capture Center RECS 2011
About Us
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Challenge of CO2 Capture = Cost
Source: Data from Cost and Performance Baseline for Fossil Energy Plants, volume 1: Bituminous Coal and Natural Gas to Electricity, Final Report; NETL, May 2007
Post-Combustion Capture Cost
4%
5%
9%
4%
9%
2%
4%
0%
5%
10%
15%
20%
25%
30%
35%
40%
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Trans., Stor. & Monit.
Compression capital
Capture capital
Capture operating
Capture steam
Capture aux. pow er
Compression pow er
Parasitic Power ↑COE by 17%
Operating Cost ↑COE by 4%
Capital Cost ↑COE by 15%
Tota
l CO
E in
crea
se (%
)
Pre-Combustion Capture Cost
Parasitic Power loss is more than ½ of the incremental cost of CO2 capture...
...while incremental Capital adds another ¼ to the incremental cost.
Carbon Capture Terminology
• Post-combustion
• Pre-combustion
• Oxy-combustion
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§ Cooperative Agreement with DOE; managed by NETL.
§ Scope of Work involves all 3 major areas of CO2 capture:
Post-combustion
• Build test infrastructure at Plant Gaston
• Partner with solvent and process developers for evaluation
• Move technology forward to demonstration phase
Pre-combustion
• Utilize and expand existing syngas infrastructure
• Provide test site for syngas CO2 capture technology evaluation
• Use data in engineering of full-scale systems
Oxy-combustion
• Scoping / screening studies of new pressurized oxy- combustion process.
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National Carbon Capture Center
Goals of the NCCC § Offer a unique flexible testing facility where processes can be tested on coal
derived gas at various scales
§ Serve as a technology development facilitator by providing facilities for technology scale-up
§ Solicit and incorporate activities and projects from a wide variety of participants and partners. Find “Best-in-class” Technology.
§ Deliver innovation through a cross-cutting, collaborative project that provides an accelerated pathway to cost-effective CO2 capture technology for coal fueled power production
Pre-combustion Post-combustion Oxy-combustion
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Prog
ress
to C
omm
ercia
lizat
ion à
Technology Development Time Scale à
Basic R&D - Lab Scale
Commercial Demonstration
Focus of NCCC Technical Program
Transfer laboratory work to more realistic conditions
Sub-system or component testing at larger-scale
Small Pilot Unit
Large Pilot Unit
Commercial CO2 Capture Deployment
SoCo MHI 25 MW Test at Plant Barry
Fundamental science & laboratory development
Integrated CO2 capture system testing
Pre-Combustion CO2 Capture
Sensor Development
Feed System Development
Fuel Flexibility Syngas Cleanup/CO2 Capture
Particulate/Ash Removal
Transport Gasifier
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Alabama Power Plant E.C. Gaston Wilsonville, Alabama
Location of Post-Combustion Facility
Confidential and Proprietary
FGD
Stack
ID Fan
Pilot Solvent Test Unit (PSTU)
Bench Scale Test Units
Post-Combustion Carbon Capture Center (PC4) Plant Gaston
#1
#2
Pilot Test Unit #2
#3
#4
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Pilot Solvent
Test Unit
Plant Gaston
Bench Scale
Post-Combustion CO2 Capture
Pilot Scale Module
Site Preparation
PSTU modular fabrication
PSTU module delivery and installation Post-Combustion CO2 Capture
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PSTU Commissioning
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-‐ Emergency Ac/on Plans
-‐ Environmental Guidelines
-‐ Opera/ng Procedures
-‐ Training
-‐ Walk-‐downs -‐ Hang Valve Tags -‐ Rota/ng Equipment Checkouts
-‐ Hydro Tests
-‐ Process Controls Configura/on
-‐ Controls Graphics -‐ Data Collec/on System Configura/on
-‐ Loop Checks -‐ Func/onal Control Checks
-‐ Ini/al Test with Flue Gas
-‐ Baseline Test with MEA
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• Operated as an air-blown combustor at the PSDF from 1996 to 1999
• Excellent results – High throughput, nearly complete carbon conversion, low NOx, low SOx
• Key attributes: – Very high solids circulation rate – Robust mechanical design – Solids cooler – Pressurized operation
Ø Transport Oxy-Combustion (TROC™)
O2
Transport Combustor
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Typical Oxy-Combustion
Fan
Gas Heater
Low-pres CO2 Compr.
Coal Prep
Comb. Boiler
Hg capture
High-pres CO2 Compr.
coal
CO2
water steam
byproduct
airoxygen
CO2 Purification
vent gas (incl. CO2)
Cooling Drying
ash
Arrow thickness is proportional to the mass flow.
recycle CO2
water
FGDID FanESP or baghouse
airinfiltration
Hgash
sorbent
Cryo. ASU
Fan
primary gas
secondary gas
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Coal Prep
TROC w/ Solids Cooler
Flue Gas Cooler PCD Hg
Capture
High-pres CO2 Compr.
coal
CO2
water steam
ash
airCryo. ASU
oxygen
CO2 Purification
vent gas (incl. CO2)
Cooling Drying
recycle CO2
Pressur. Feed
sorbent
O2 Pres.
water steam
ash
Arrow thickness is proportional to the mass flow.
recycle CO2
waterHg
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Transport Oxy-Combustion
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Steam Generator TROC™
Amine CO2 Capture
Steam Turbine
Steam Turbine
CO2-CPU
ASU-O2
Repowering Retrofit Study
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BOP
FGD
SCR
Baghouse
BOP
Benefits of NCCC for CO2 Capture R&D
à Accelerating CO2 capture technology commercialization
• Serve as centralized R&D facility – Reduce redundancy of multiple test facilities – Leverage existing R&D infrastructure and people
• Make available realistic syngas and flue gas for process
verification – Flexible in capacity & process conditions – Compare different technologies
• Offer Southern’s expertise in process engineering and Power
plant O&M – Identify critical issues – Assist in scaling up technologies
• Provide independent data acquisition and analysis
– Validate laboratory performance in real industrial settings – Enable simulation, modeling and economic assessments
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