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