National Energy Technology Laboratory

DrivingInnova+on♦DeliveringResults

NathanWeiland,WallyShelton,TravisShultz,CharlesWhite

September20th,2016

ReviewofNETL’sSupercri?calCO2(sCO2)Techno-economicAnalyses

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WhySupercri?calCO2(sCO2)PowerCycles?•  Applicabletomul?pleheatsources

(nuclear,solar,fossil,wasteheat)forindirecthea?ng

•  Poten?alforhigherefficiencyrela?vetotradi?onalpowercycles–  Highthermalrecupera6onrejects

lessheattotheenvironment–  Singlephasefluidheattransfer–  Reducedcyclecompressionpower

neartheCO2cri6calpoint•  Reducedturbomachinerysizesdue

tohigherworkingfluiddensity•  CO2isgenerallystable,abundant,

inexpensive,non-flammable,andlesscorrosivethanH2O

SourceofFigures:V.Dostal,M.J.Driscoll,andP.Hejzlar,ASupercri?calCarbonDioxideCycleforNextGenera?onNuclearReactors,ReportMIT-ANP-TR-100,March2004.

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sCO2CyclesforFossilEnergyApplica?ons

Indirectly-heatedcycle•  Applicabletoadvancedcombus?onboilers

•  Incumbenttobeat:USC/AUSCboilers•  Highfluiddensity,lowpressurera?oyields

compactturbomachinery•  Ideallysuitedtoconstanttempheat

source•  Adaptablefordrycooling

Directly-heatedcycle•  ApplicabletoIGCCandNGCC

•  Incumbenttobeat:Adv.F-,H-,orJ-classCombinedCycle(NGCCorIGCC)w/CCS

•  Fuelflexible:coalsyngasorNG•  100%CO2captureatstoragepressure•  Netwaterproducerifaircooled

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•  sCO2PowerCyclesBaseProgram–  Implementedthroughmul6pleFossilEnergyprograms–  Combina6onofextramuralprojectsandinternalNETLresearchand

analy6calcapabili6es•  Turbomachinery•  Recuperators•  Oxy-fuelCombus6on

•  DOEsCO2CrosscutIni?a?ve(STEP)–  Collabora6onbetweenFossil,Nuclear&RenewableDOEOffices–  Mission:Addresstechnicalissues,reducerisks,andmature

technologytoacceleratecommercializa6on–  Objec6ve/goal:Design,build,andtest10MWepilotsCO2facility

(STEP)•  Conceptualdesignstudiescomplete•  $100Million,6yearbuildandtestprogramtostartin2016

•  sCO2HeaterIntegra6on•  Materials&Fundamentals•  SystemsAnalysis

U.S.DOEFossilEnergysCO2PowerCycleR&DEfforts

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NETLResearchandInnova?onCenterCoreCompetencies

Computa?onalScience&Engineering

High-Performance

Compu?ng

DataAnaly?cs

MaterialsEngineering&Manufacturing

Structural&Func?onal

Design,Synthesis&Performance

Geological&Environmental

Systems

Air,Water&Geology

Understanding&

Mi?ga?on

EnergyConversionEngineering

Component&

Device

Design&Valida?on

SystemsEngineering&

Analysis

Process&System

Op?miza?on,Valida?on&Economics

ProgramExecu?on&Integra?on

StrategicPlanning

Project

Management

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MajorsCO2SystemsAnalyses

•  Techno-economicEvalua?onofU?lity-ScalePowerPlantsBasedontheIndirectsCO2BraytonCycle–  Finalreportunderrevision

•  PerformanceofanIntegratedGasifica?onDirect-FiredSupercri?calCO2PowerCycle–  Plantcostes6matenearingcomple6on

•  DevelopmentofadynamicsCO2plantmodeltoassesscontrolmechanismsandtransient/partloadperformanceofthe10MWeSTEPdemosCO2plant–  Preliminaryanalysescomplete,modelrefinementsongoing

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U?lity-ScaleIndirectsCO2PlantsOverview•  Earlyworkshowsthatthenarrowtemperatureaddi?on

windowofarecompressionsCO2BraytonCyclerestrictsboilerselec?on–  ModifiedOxy-CFBboilerswithCCSchosenforanalysis

•  Reference:Oxy-Coal-FiredCFBRankineCycleswithCCS(24.1MPa/600°C/620°C)

•  Oxy-Coal-FiredCFBsCO2BraytonCycleswithCCS:(620°C&760°C)–  Recompressioncyclewithreheatand/ormaincompressorintercooling

(4combina6onsx2temperatures)

•  PerformanceComparisons•  EconomicComparisons&Sensi?vityofCOEtoTPC•  Poten?alforImprovedEfficiency–AlternateCycles

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Oxy-Coal-FiredCFBRecompressionsCO2BraytonCycle

MAC Cryogenic ASU

Ambient Air

Oxy-Circulating

Fluidized Bed Combustor

Forced Draft Fan

Primary Air Fan

Coal

BottomAsh

IDFans

BagHouse

LP CO2Compressor w/

Intercooling

CO2 Drying

Infiltration Air

Knockout Water

CO2 Product

Fly Ash

Note: Block Flow Diagram is not intended to represent a complete process. Only major process streams and equipment are shown.

Interstage Cooling

CO2 Purification

Compression/Pumping

CO2 Compression, Drying, and Purification Unit

Interstage Knockout

CO2 TURBINE

MAIN CO2 COMPRESSOR

CO2 COOLER

HIGH TEMPERATURE RECUPERATOR

Limestone LOW TEMPERATURE RECUPERATOR

Bypass CO2 Compressor

FLUE GAS RECUPERATOR

FLUE GAS COOLER

Knockout Water

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OverallPlantEfficiencies(%HHV)

IndirectsCO2PlantPerformance

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IndirectsCO2SummaryandConclusions

•  Objec?ve-ComparesCO2RecompressionBraytonCycle(s)toaSOASteamRankineCycle.

•  Performancedeterminedforfourconfigura?ons,allshowingperformanceimprovement.

•  At620°Cturbineinlettemperature,thereheatedandintercooledsCO2caseshowsa~2percentagepointsimprovementinplantefficiencycomparedtothesteamRankinecase.

•  Atthehighertemperature(760°C),thecomparisontotheSteamRankineCycle(620°C)improvesinoverallefficiencyto~6percentagepoints.

•  Furtherop?miza?onsoftheconfigura?onsconsideredmayberequiredtodemonstratedaneconomicadvantage.–  CondensingCO2cycles–  Par6alCoolingsCO2Cycle

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DirectsCO2CycleAnalyses

•  Direct-firedsCO2powercyclesareajrac?veduetotheirhighefficiencyandinherentabilitytocaptureCO2atstorage-readypressures

•  Highpressuresleadtohighpowerdensityandreducedfootprint&cost

•  StudyObjec?ves:–  Developaperformance

baselineforasyngas-fireddirectsCO2cycle

–  Analyzesensi6vityofperformanceandcostindicatorstosCO2cycleparameters

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Coal-firedDirectsCO2PlantBlockFlowDiagram

DryerIllinoisNo.6Coal

LockHoppers

ShellGasifier WHB Quench

ScrubberCOSHyd Sulfinol

Oxy-Combust

LPASU

N2

O299.5%O2

Turbine

Recuperator

H2O

CPU

CO2 ComprRecycleCO2

CO2 toSequestration

SteamPlant

SyngasComprH2O ClausSulfur

SyngasRecycle

Air

~

CO2

SGC SGC

Vent•  Shellgasifierchosenfordryfeedingandwasteheatrecoveryop?ons

•  Gasifiertrainsyngascoolersmodifiedtoincludesyngasprehea?ngandsCO2hea?ng

•  HighpurityO2limitsimpuri?esthatreducedirectsCO2cycleefficiency

•  Syngasoxy-combus?onwithinthesCO2cycle

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DirectsCO2ConclusionsandFutureWork

•  Conclusions:–  Directcoal-firedsCO2

cycledevelopedshowsimprovedperformancerela6vetoIGCCandotherreferencecases

–  CapitalcostsareexpectedtobelowerthanIGCCduetoreplacementofgasturbineandsteamboeomingcycle

–  Sensi6vitystudiesprovideguidelinesforimprovingperformanceandreducingcosts

•  FutureWork–  Incorporatetheeffectsofturbineblade

coolingflows(completed)–  Developcostes6matefortheimproved

baselinecase(nearingcomple6on)–  Extendanalysestodevelopmentofnatural

gas-fireddirectsCO2cycles

Parameter IGCC sCO2Cycle

EPRIsCO2Cycle2

Netpoweroutput(MWe) 497 595 583Netplantefficiency(HHV%) 31.2 39.8 39.6Carboncapturefrac6on(%) 90 98 99CapturedCO2purity(mol%CO2) 99.99 99.44 98.1

31,2 32,635,2

39,3 39,8

05101520253035404550

Plan

tefficien

cy(%HHV

)

CoalFiredPlantswithCCS

5Na?onalEnergyTechnologyLaboratory(NETL).(2010,November2).CostandPerformanceBaselineforFossilEnergyPlantsVolume1:BituminousCoalandNaturalGastoElectricity.PiWsburgh,Pennsylvania.6Weiland,N.,andShelton,W.W.“SystemsAnalysesofDirectPowerExtrac?on(DPE)andAdvancedUltra-Supercri?cal(AUSC)PowerPlants,”Crosscu^ngResearch&RareEarthElementsPor`oliosReview,PiWsburgh,PA,April18th,2016.7Shelton,W.W.,Weiland,N.,White,C.,PlunkeW,J.,andD.Gray.Oxy-coal-firedCircula?ngFluidBedCombus?onwithaCommercialU?lity-sizeSupercri?calCO2PowerCycle.The5thInterna?onalSymposium-Supercri?calCO2PowerCycles.SanAntonio,Texas.March2016.

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OtherCurrentandFuturesCO2WorkwithinSEA•  Pre-ScreeningofIndirectsCO2CycleIntegra?on

Opportuni?es(complete)–  Evaluatedtheop6onsforsCO2cycleintegra6onwithchemicallooping

combus6on,magnetohydrodynamics,andfuelcellsystems.

•  ProcessSystemsEngineeringResearchTeam–  Pressure-drivenAspenPlusDynamicsmodelofa10MWIndirectsCO2

RecompressionBraytonCycle–  Developmentofamul6-stageradialsCO2compressorinAspen

CustomModeler

•  Developmentofa1-DsCO2recuperatorsizing/cos?ngmodel–  Enablesrecuperatorcos6ngasafunc6onofapproachtemperature,

pressuredrop,andmaterialsofconstruc6on

It’sAllAboutaClean,AffordableEnergyFuture

Formoreinforma+ononoursCO2efforts,contact:Nathan.Weiland@netl.doe.gov,412-386-4649(NETLResearch)Rich.Dennis@netl.doe.gov,304-285-4515(DOEsCO2Program)

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