Chemical Looping Combustion Coal Power Technology

Development Prototype

CO2 Capture Technology ConferenceUS DOE/NETL, Pittsburgh

24-26 March 2009

Herb Andrus

Alstom Chemical Looping Development – March 24-26, 2009 - P 2© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Chemical Looping Development

• Project Overview

• Technology

• Project Objectives

• Project Methodology

• Future Plans

Alstom Chemical Looping Development – March 24-26, 2009 - P 3© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

N°1 worldwidein turnkeypower plants

N°1 worldwidein environmentalcontrol systems

N°1 worldwidein hydroelectric

N°1 worldwidein services forelectricity utilities

N°1 worldwidein high speed and very high speed

N°2 worldwidein urban transport(metro and trams)

Alstom makes 1 metro in 4 and 1 tram in 3

The Alstom Group – Two main activitiesEquipment & services for power generation & rail transport

> 76,000 staff in > 70 countriesTotal orders 2007/08 :

€23.5 bn

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Project Overview

• US DOE Program:Plants Capture and Emissions Program

• Funding: $6.3MM– Cooperative Agreement: September 2008– US DOE: 80%– Alstom: 20%

• Performance dates:– Budget Period 1: Sept ’08 - Sept ’09– Budget Period 2: Oct ’09 - Mar ‘11

• Project Participants:– Alstom

• PEMM Corp• Univ. of British Columbia

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Overall Objective:

Develop, test and commercialize a limestone-based chemical looping system for existing and new pulverized coal-fired power plants, for the following performance:

• Over 90% CO2 capture from Coal

• Less than 20% increase in COE for Existing Coal-fired Plant

• Capital cost – 20% lower than Conventional Boiler Island for new plant (not including CO2 compression)

• Less than $20/ton, avoided cost of CO2 capture (with CO2 compression)

Chemical Looping: a way to Capture CO2 Efficiently, at Low Cost

Alstom Chemical Looping Development – March 24-26, 2009 - P 6© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Chemical Looping ProgramDevelopmental Status

Fuel and Limestone

Prep

PC/CFBSteam

Generator

Power BlockST / GTGas Clean Up

ChemicalLooping

CO2 RecoveryOption

Standard Equipment

DevelopmentalEquipment

Replace:

Ash Disposal Switch Yard

Alstom Chemical Looping Development – March 24-26, 2009 - P 7© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Chemical Looping Development

• Project Overview

• Technology

• Project Objectives

• Project Methodology

• Future Plans

Alstom Chemical Looping Development – March 24-26, 2009 - P 8© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Chemical Looping ConceptWhy do it?: Lowest Cost Option for Capturing CO2 from Coal

What is it?: Oxy-Firing without Oxygen PlantSolid Oxygen Carrier Circulates between Oxidizer and Reducer

Oxygen Carrier: Carries Oxygen, Heat and Fuel Energy

Carrier picks up O2 in the Oxidizer, leaves N2 behind

Carrier Burns the Fuel in the Reducer

Heat produces Steam for Power

Oxygen Carrier:Metal Oxide: Fe, Ni, Mn, Cu…Ores or on Substrates

Limestone-based carriers

Metal Oxides:Process Development: CHALMERS UNIVERSITY

Equipment Development: ALSTOM

Limestone-based: ALSTOM

Steam Ox

ReMe MeO

Air

Fuel CO2 + H2O

N2 + O2Ox

RedMe MeO

Air

Fuel CO2 + H2O

N2 + O2

Air reactor (Oxidizer)

Fuel reactor (Reducer)

METAL OXIDE

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Chemical Looping Concept

Chemical Looping FlexibilityOption 1: Chemical Looping Combustion

Excess Air-to-Fuel

Product Gas is CO2

Heat Produces Steam for Power

Option 2: Chemical Looping Gasification

Excess Fuel-to-Air

Product gas is SynGas

No Inherent CO2 Capture

Option 3: Hydrogen Production

Add CaO – CaCO3 Loop to Option 2

Add Calciner

Product Gas is Hydrogen

Calciner Off-Gas is CO2Oxidizer

Reducer

Calciner

Hot Solids

Cold Solids

CaCO3 CaO

CaS

Hydrogen

Coal,Steam

CO2

Air

CaCO3

Depleted Air, Ash,CaSO4

OxidizerReducer

Calciner

Hot Solids

Cold Solids

CaCO3 CaO

CaS

CaSO4CaSO4

Product Gas

Coal,Steam

CO2

Air

CaCO3

Depleted Air, Ash,CaSO4

Steam toPower Cycle

Limestone-based

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Chemical Looping Options and Applications

• Lowest Cost CO2 Capture Option• Competitive with or without CO2 Capture

• CO2 Capture - PC/CFB Retrofit• CO2 Capture - Ready Power Plant• Advanced Steam Cycles

• IGCC with Downstream CO2 Capture• Industrial SynGas• Coal-to-Liquid Fuels

• CO2 Capture - PC/CFB Power Plant• CO2 Capture - Ready PC/CFB Power Plant• Advanced Steam Cycles• IGCC with CO2 Capture• Fuel Cell Cycles• Industrial Hydrogen, CO2

Option 3 – Hydrogen with CO2 Capture

Option 2 – Syngas with no CO2 Capture

Reducer Oxidizer

CaSO4 CaS

N2

AirCoalCaCO3

Ash, CaSO4To Disposal

CO2Steam

Option 1 – Combustion with CO2 Capture

Reducer Oxidizer

CaSO4 CaS

N2

AirCoalCaCO3Steam Ash, CaSO4

To Disposal

SyngasCO2, N2

Calciner CO2

Reducer Oxidizer

CaSO4 CaS

N2

AirCoalCaCO3Steam Ash, CaSO4

To Disposal

H2

Applications

Alstom Chemical Looping Development – March 24-26, 2009 - P 11© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

CO2 Capture in Power PlantsRelative Economics

Chemical Looping CO2 Avoided Cost: $11-13/ton of CO2

4.00

5.00

6.00

7.00

8.00

9.00

0 10 20 30 40 50 CO 2 Allowance Price ($/Ton CO2 Emitted)

(Cents/

kWhr

)

IGCC H Class (E-Gas) with Capture- SpareIGCC H Class (E-Gas) with Capture

6-Regenerative Carbonate Cyclewith Capture10-Advanced O2 Fired CFB withCaptureOxygen Transport Membrane CFB

14-Ammonia Scrubbing

4-Chemical Looping Combustionwith Capture (Metal Oxides)3-Chemical Looping Combustionwith Capture (CaS)1-Chemical Looping Gasification7FA with Capture (CaS)Air Fired PC w/o Capture(3915/1085/1148)

Advanced MEA

4.00

5.00

6.00

7.00

8.00

9.00

0 10 20 30 40 50 CO 2 Allowance Price ($/Ton CO2 Emitted)

Comparable range of costs for conventional technologies

4-Chemical Looping Combustionwith Capture (Metal Oxides)3-Chemical Looping Combustionwith Capture (CaS)1-Chemical Looping Gasification7FA with Capture (CaS)Air Fired PC w/o Capture(3915/1085/1148)

Chemical Looping cases Reference casecases Reference case

Basis: • Plant size 400 MWe • Steam conditions 3915 psia/1085 degF/1148 degF/2.5in Hga • Cost basis 2006, $US • Coal cost 1.5 $/MMBtu • Levelized capital charge 13.8% • Capacity factor 85%

Cost

of E

lectri

city

cent

s/Kw-

hr

Reference: DOE GHG Phase I, Bozzuto, et.al, Alstom Power, 2003

2006 $’s

Alstom Chemical Looping Development – March 24-26, 2009 - P 12© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Chemical Looping Equipment Comparison

Building Volume 100% 48%Boiler/Gasifier Weight 100% 65%

220’ 127’

Significant Volume & Weight Reduction

Air Fired CFB

183’ 140’

Chemical Looping Plant

Alstom Chemical Looping Development – March 24-26, 2009 - P 13© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Chemical Looping Technology

Pulverized Coal Power Plant - Retrofit Concepts

Existing Steam

TurbinePower Block

Steam

Feed WaterGenerator

Air

Fluegas

ExistingPC Boiler

ExistingCoal

Pulverizer

CoalLimestone

(CaCO3)

Reducer Oxidizer

CaSO4 CaS

N2 to Stack

AirAsh, CaSO4to DisposalCalcinerCO2

H2CO2- free

Boiler fuel(H2)

Steam

Concept 1 – Chemical Looping – CO2 Free Fuel; Minimum Boiler Modification-

Concept 2 – Chemical Looping Oxidizer Replaces / Modifies Boiler

Feed Water

ExistingSteam

TurbinePower Block

Steam

Generator

ExistingCoal

Pulverizer

CoalLimestone(CaCO3)

Reducer Oxidizer

CaSO4 CaS

N2 to Existing Stack

Air

Ash, CaSO4to Disposal

CO2

Steam

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• Designed and Built by Alstom

• Allows Testing of Individual Loops and Processes

• 3 Year Successful Test Program – Completed

• All Chemistry/Rates Verified

• Phase 3 - Pilot Plant− Two Exhaust Fans/Stacks− Automatic Solids Transport Controls

AshCoolers (6)

SolidsHeater

SealpotControlValves (2)

2-StageCyclones (2)

SprayCoolers &Filters (5)

ReducerOxidizer

ProductGasBurner

Chemical Looping Pilot PlantAlstom’s Chemical Looping Pilot Facility (65 kWt)

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Cold Flow Model – Flow Stability, Scale-up

15 Foot Model

Figure 6-6 Laser Solids Velocity Probe.

40 Foot Model

Laser Solids Velocity Probe

Chemical Looping Cold Flow Model

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Chemical Looping Kinetics

Chemical Looping - Kinetics Summary

1.E-011.E+001.E+011.E+021.E+031.E+041.E+051.E+061.E+071.E+08

7 8 9 10

1/Temp (degK * 10^4)

k's

(%/s

ec-a

ta),

exce

ptk(

wgs

) (%

/sec

-ata

^2)

Pitt 8 Carbon Gasification

Charcoal Gasification

CaSO4 Reduction (FBHE ash)

CaSO4 Reduction (FBHE ash w/ SA

CO2 Capture (FBHE ash)

CO2 Capture (FBHE ash w/ SA)

Water Gas Shift (FBHE ash)

Water Gas Shift (FBHE ash w/ SA)

CaS Oxidation

1400 degF2000 degF

Kinetic Rates exceed Design Requirements

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US DOE Phase I, II, III - Accomplishments

Chemical LoopingPilot Plant Development

• All Milestones Successfully Completed – On-time, On-budget• Pilot Testing (65 kWt) – Successfully Complete• 15-foot Cold Flow Model testing completed – Stable Solids Transport

achieved• 40-foot Cold Flow Model – Stability achieved, Scaleup verified• Internal and ASME/US DOE Peer Reviews Successfully completed• Alstom’s Phase IVA - Prototype (3 MWt):

US DOE Cooperative Agreement - Sept, 2008

Alstom Chemical Looping Development – March 24-26, 2009 - P 18© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Chemical Looping Development

• Project Overview

• Technology

• Project Objectives

• Project Methodology

• Future Plans

Alstom Chemical Looping Development – March 24-26, 2009 - P 19© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Chemical Looping PrototypePhase IVA

Chemical Looping 3 MWt Prototype Facility Preliminary Concept

• 1000 lb/hr coal flow• 1st Integrated Operation• 1st Autothermal Operation

Phase IV Objective:Obtain the engineering and operating informationrequired to build and operate a reliable, commercial-sizedemonstration plant.

Alstom Chemical Looping Development – March 24-26, 2009 - P 20© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Chemical Looping Development

• Project Overview

• Technology

• Project Objectives

• Project Methodology

• Future Plans

Alstom Chemical Looping Development – March 24-26, 2009 - P 21© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

• Prototype Location – Alstom Power, Windsor, CT.– All Equipment Necessary for Viable Demo Design– 1000 lb coal / hr – Combustion, Syngas, Hydrogen– Design, Construction, Operation, Maintenance, Modification by Alstom

N2 Rich Fluegas

OxidizerReducer

Process Steam

Limestone

CombustionAir

Solids Drain

Coal

Stack

Medium-Btu Gasto Cooler and

Fuel Compression

AshCooler

Calciner

TubularAir

Heater

CO2CO2 rich product to Gas Processing System

MBHE

SolidsReturn

CaS

HotSolids

CaSO44

MBG (H2)

CaCO33

CaOOxygen TransportChemical Loop

CarbonateChemical Loop

CalcinerThermal Loop

Phase IVA – Prototype Concept

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Chemical Looping Development - Phase IVASolids Transport Testing

• Prototype Cold Flow Model (CFM)– Startup and operating methods

– Identify/Solve critical technical aspects

– Improve plant arrangement

– Assist cost study

• High Solids Load Tests in 40-ft CFM– Solids/gas Transport design tool

– Quantify the key parameters in this region

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Chemical Looping Development – Phase IVADesign/Build/Test Program

• Small-scale Cold Flow Modeling– Vessels scaled from the Prototype plant design

– Control and distribution of solids/gas flow

– Startup procedures

– Identify critical areas (e.g. erosion, control) for the prototype plant design

– Prototype operator training

– Prototype solids transport problem solving

• Design/Test Prototype plant – Complete the design tools for the prototype plant

– Complete the prototype sizing and selections for all vessels

– Prototype Operation/Testing/Modification/Development

– Update commercial economics analysis and specs recheck

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Prototype Schedule

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Chemical Looping Development

• Project Overview

• Technology

• Project Objectives

• Project Methodology

• Future Plans

Alstom Chemical Looping Development – March 24-26, 2009 - P 26© ALSTOM 2008. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Chemical Looping DevelopmentPhases IV, V, VI

Prototype (1000 lb/coal/hr)

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Chemical Looping Development Plan

• Demonstration Plant – Phase V: – Objective: Demonstrate Reliability and Performance

– Electric Utility Sponsor/Existing site – locate during Phase IV

– 50 to 100 MWe

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