atmospheric iron-based coal direct chemical looping process for power production · 2015-07-13 ·...

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Atmospheric Iron-Based Coal Direct Chemical Looping Process for Power

ProductionPittsburgh, PA. Jun 26. 2015

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Project ObjectivesPhase 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:2013-2016 Reduce technology gaps identified in Phase I by conducting

laboratory testing and small pilot-scale testing.

Update design and cost performance of the commercial 550 MWeCDCL power plant

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

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Project ParticipantsFederal Agencies:

•DOE/NETL

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

Industrial Review Committee:•American Electric Power•Consol Energy•Dayton Power & Light•Duke Energy•First Energy•Ohio Development Service Agency

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Outline Commercialization Path

Phase I: CDCL Concept and Techno-Economic Analysis

Phase I: Technology Gaps

Phase II: Pilot Design

Phase II: Laboratory Testing and Studies

Project Schedule

Conclusions and Acknowledgments

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Commercialization Path

OSU’s Laboratory

Scale

Scal

e

OSU’s Sub-Pilot25 kWth

B&W’s Pilot

3 MWth

Demo50 MWth

Commercial100 - 550 MWth

2004 2008 2014 20202016 2025

Time

Work performed under this

award

Phase IIB&W’s 250

kWth

B&W’s Phase I

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Outline Commercialization Path

Phase I: CDCL Concept and Techno-Economic Analysis

Phase I: Technology Gaps

Phase II: Pilot Design

Phase II: Laboratory Testing and Studies

Project Schedule

Conclusions and Acknowledgments

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Chemical Looping Concept

Reducer

Fe + FeO

Fe2O3

CO2 + H2O

Coal

Air In

Combustor

Heat out

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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 CO2 CO + Fe2O3 Fe + FeO + 2 CO2

* Reactions not balanced

Top Section*CxHy + Fe2O3 Fe + FeO + CO2 + H2OCO + Fe2O3 Fe + FeO + CO2H2 + Fe2O3 Fe + FeO + H2O

Coal Volatilization*Coal C + CxHy (Volatiles)

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Outline Commercialization Path

Phase I: CDCL Concept and Techno-Economic Analysis

Phase I: Technology Gaps

Phase II: Pilot Design

Phase II: Laboratory Testing and Studies

Project Schedule

Conclusions and Acknowledgments

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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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Modular Loop Design

Reducer

Combustor

Riser

Distributor

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CDCL Technology Comparison

BasePlant

MEAPlant

CDCLPlant

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 Commercialization Path

Phase I: CDCL Concept and Techno-Economic Analysis

Phase I: Technology Gaps

Phase II: Pilot Design

Phase II: Laboratory Testing and Studies

Project Schedule

Conclusions and Discussion

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CoalReducer

Combustor

Riser

Distributor

Air Air

To Convection pass Reducer

• Coal Injection and distribution• Char residence time• Ash Separation/ Enhancer Gas• Fate of alkali• Fate of S, Hg, and N

Combustor• In-bed Heat exchanger• Auto-thermal Operation

Technology Gap Analysis

Particles• Max. op. temp.• Attrition• Reactivity• Deactivation

Operation• Start up• Shut down• Turn down – Idle• Hazardous Op

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CDCL Technolgy GapsDesign/Technology Issues Ongoing/Past Mitigation Planned Mitigation Future Mitigation

ParticlesManufacturing Cost Under OSU’s SOW Particle ManufacturerAttrition NCCC Lab 2” BFB / Envergex High Temperature Resistance TGA TGA

Reducer DesignCoal Injection & Distribution OSU’s Sub-Pilot Small-pilot Unit 3 MWth-PilotChar Residence Time OSU’s Sub-Pilot TGA, Small-pilot UnitAsh Separation / Enhancer Gas OSU’s Sub-Pilot Small-pilot UnitPressure Drop Phase I (Calculation) Small-pilot UnitCO2 Purity Phase I (Calculation) Small-pilot UnitSulfur, NOx, Hg Emissions OSU’s Sub-Pilot Small-pilot Unit 3 MWth-Pilot

Alkaline Management 2” BFB (Preliminary) 2” BFB 3 MWth-PilotCombustor Design

Heat Exchanger surface B&W’s CFB Technology 3 MWth-PilotAuto-thermal Operation Phase I (Calculation) Small-pilot Unit 3 MWth-Pilot

SystemOperation NCCC Small-pilot Unit 3 MWth-PilotStart up/Shut down NCCC Small-pilot Unit 3 MWth-Piot

Safety NCCC Small-pilot Unit 3 MWth-Pilot

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Outline Commercialization Path

Phase I: CDCL Concept and Techno-Economic Analysis

Phase I: Technology Gaps

Phase II: Pilot Design

Phase II: Laboratory Testing and Studies

Project Schedule

Conclusions and Acknowledgments

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Pilot Unit Design

Physical Specifications•Materials: Refractory lined Carbon Steel •Overall Height: 32 ft•Footprint = 20’ x 20’

Process Specifications•Thermal rating: 250 kWth•Coal Feed Rate: 70 lb/hr•Coal size: Pulverized coal•Max Operating Temperature: 2012 oF•Oxygen Carrier: Iron based•Reducer : Counter-current moving bed•Combustor : Bubbling bed•Particle tranport: Pneumatic

Oxygen Carrier Specifications•Active metal: Iron based•Size: 1.5 mm

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CDCL 250 kWth PilotCoal residence time

Controling coal and particle flow rate

Ash separationControling enhancer gas flow rate; Material (ash) balance.

Pressure dropPressure balance on the system

CO2 Purity; Sulfur, NOx emissionsGas analysis through out the reactor

Autothermal operationSteady-state operation without primary burner

System OperationStart up and shutdown,HazOp, JSA and other operation protocols

Gas and fines

ParticlesGas sample #1

Gas sample #2

Bottom Moving Bed

Top Moving Bed

Combustor

Coal + CO2

CO2

Air

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Outline Commercialization Path

Phase I: CDCL Concept and Techno-Economic Analysis

Phase I: Technology Gaps

Phase II: Pilot Design

Phase II: Laboratory Testing and Studies

Project Schedule

Conclusions and Acknowledgments

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Coal Flow Model Tests: Fines entrainment

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Fines Residence Time in Moving Bed

0.6

0.7

0.8

0.9

1

1.1

1.2

1.3

1.4

1.5

0.5

0.6

0.7

0.8

0.9

1

1.1

1.2

0 50 100 150 200 250

Pres

sure

dro

p (in

of w

ater

)

Time (s)

dp1 (inH2O)

dp3 (inH2O)

dp4 (inH2O)

dp2 (inH2O)

Fines Residence Time

5CFM, 160g flint clay

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0

50

100

150

200

250

300

350

400

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

mig

ratio

n tim

e co

nsta

nt (s

)

superficial velocity (m/s)

iron100, mass ratio = 0.01

iron100, mass ratio = 0.02

iron100, mass ratio = 0.04

iron325, mass ratio = 0.01

iron325, mass ratio = 0.02

iron325, mass ratio = 0.04

Clay 300, mass ratio = 0.04

Clay 300, mass ratio = 0.01

Clay 300, mass ratio = 0.02

Ash and Fines residence time (τr)

Flint clay

Iron 325

Iron 100

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Particle Characterization

Photograph of TGA Analyzer

Gas Delivery System

0

100

200

300

400

500

0 100 200 300 400 500 600

Gas f

low

rate

(scc

m)

Time to reach 50% conversion (s)

t50%

Time to reach 50% conversion as a function of gas flow rate

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Particle Reduction Studies

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

1.2

495 495.5 496 496.5 497 497.5 498 498.5 499

Degr

ee o

f oxi

datio

n (0

= F

e, 1

=Fe2

O3)

Time during 3rd cycle (min)

850 C850 C1000 C1000 C1000 C1150 C1150 C

Gas and fines

Particles

Bottom Moving Bed

Top Moving Bed

Combustor

Coal + CO2

CO2

Air

Riser

1150 C

850 C

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Particle Oxidation Studies

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

489 489.5 490 490.5 491 491.5 492

Deg

ree

of o

xida

tion

(0 =

Fe,

1=F

e2O

3)

Time during 3rd cycle (min)

850 C

850 C

1000 C

1000 C

1000 C

1150 C

1150 C

Gas and fines

Particles

Bottom Moving Bed

Top Moving Bed

Combustor

Coal + CO2

CO2

Air

Riser

1150 C

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Particle Integrity Studies: Carbon formation

2 CO

Carbon

CO2

Iron-based Oxygen Carrier

CO2 Evalution after carbon formation on oxygen carrier particles

Above 900 oC there is no carbon formation

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Alkaline Agglomeration Test

-2-101234567

850 900 950 1000 1050D

P (in

H2O

)Temperature (oC)

9.10% after oxidized

9.10% in air

Alkaline injection test inn BFB

Particles aglomerate at very high alkaline content :

~9.1wt.%

Heater

CO2 Flow

DP

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Particle Regeneration

(b)

Agglomerated particle caused by alkaline can be regenerated in the combustor.

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Outline Commercialization Path

Phase I: CDCL Concept and Techno-Economic Analysis

Phase I: Technology Gaps

Phase II: Pilot Design

Phase II: Laboratory Testing and Studies

Project Schedule

Conclusions and Acknowledgments

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Project Schedule

4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10

Pilot Plant DesignPilot Plant Cost EstimatePilot Plant Construction

Pilot Plant Testing

Task 1. Project Management and Planning

Task 2. Laboratory Testing and Oxygen Carrier Characterization

Task 3. Pilot Facility Design, Construction and Testing

Task 4.Data Analysis and Update of Commercial Plant Economic Analysis

Task 5. Phase II Final Report

2014 2015 2016

Phase II

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Outline Commercialization Path

Phase I: CDCL Concept and Techno-Economic Analysis

Phase I: Technology Gaps

Phase II: Pilot Design

Phase II: Laboratory Testing and Studies

Project Schedule

Conclusions and Acknowledgments

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Conclusions

• CDCL offers a cost-effective alternative for coal-based power generation with carbon capture

• The commercial CDCL modular design is ideal for commercial deployment of the technology

• Cold flow model and laboratory testing is confirming assumptions and design features of the 250 kWth pilot unit and the commercial design

• The design of 250 kWth pilot plant has been completed and we are moving soon towards the construction and testing

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Acknowledgments

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

Number DE-FE0009761