COAL AND CLEAN COAL TECHNOLOGIES FOR THE FUTURE

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COAL AND CLEAN COAL TECHNOLOGIES FOR THE FUTURE

• Dr Andrew Minchener
• (Member of EC POWERCLEAN Thematic Network)

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WHAT IS POWERCLEAN?

• Thematic network funded under the EC FP5 Fossil
  Energy RD programme
• Members from EU industry, research institutes and
  universities
• To encourage exchange between EC supported
  research projects, particularly coal
• To propose an RTD strategy for future clean
  fossil energy power generation activities
• To help communication between national and EC
  activities
• To improve dissemination of results

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THEMATIC LINKAGES
Gas Turbine Power Plants
PowerClean

• Coal and Other Solid Fuels
• Ultra-supercritical pf
• Circulating fluidised bed
• Pressurised fluidised bed
• Gasification combined cycle
• Hybrid cycles

Fossil Fuel Power Plant Technologies
CO2 Capture and Storage
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SCOPE OF PRESENTATION

• Introduction
• energy demand, energy reserves, generating
  capacity, technology choices
• Coal-fired power generation technology options
  for Europe
• pf technology
• fluidised bed combustion systems
• IGCC
• advanced cycles
• R,DD needs

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KEY ENERGY CONSIDERATIONS WITHIN THE EUROPEAN
UNION (1)

• Security of fuel supply at the European level on
  a competitive basis.
• Need to meet stricter environmental limits
• Need to ensure that the EU is a world leader in
  low emissions power plants.
• Must take into account the enlargement of the EU.
• Need for a long-term technology vision and
  roadmap.

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FUTURE ENERGY NEEDS
1500
IEA projection of world fuel supply
900
EU Energy demand and supply (Green Paper)
Reserves-to-production ratios
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NEW POWER CAPACITY NEEDS IN EUROPE (VGB)
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TECHNOLOGY CHOICE

• Energy Policy (near-zero emissions)
• Fuel Type and Availability
• Local Circumstances
• Technology Maturity and Reliability
• Cost
• Efficiency
• Environmental Performance

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Technology options
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TECHNOLOGIES OF INTEREST TO EUROPE

• Advanced ultra-supercritical pf combustion
• CFBC, incorporating an advanced supercritical
  steam cycle
• IGCC

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PROPOSED STRATEGY FOR TECHNOLOGY DEVELOPMENT AND
DEPLOYMENT (1)

•  
• CCTs need to be competitive in a near to medium
  scale in terms of improved environmental
  performance and better economics (10-15 years)
• Likely timescale for near zero emissions
  technology deployment is medium to long term (gt20
  years)

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PROPOSED STRATEGY FOR TECHNOLOGY DEVELOPMENT
AND DEPLOYMENT (2)

•  The near zero emissions technologies will be
  based on the CCT variants currently being
  established.
• The more appropriate variants are not necessarily
  those currently favoured by EU industry for
  nearer term application.
• There needs to be appropriate consideration and
  support for those technology variants that offer
  the best prospects for associated CO2 capture.

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State-of-the-art pf technology Best
installations world-wide
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Best reference plant Tachibana-Wan, 2x1050 MWe
Emissions (mg/Nm3 _at_ 6 O2) NOx 90 SO2
140 Dust 10
STACK
Steam 600/610C, 250 bar
BOILERS
GGH
COAL STORAGE
ESP
WFGD
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TRENDS FOR PF USC WITHIN EUROPE
Thermie AD700 325 bar, 700C/700C ? 5055
(Net, LHV)
COST 522 300 bar, 630/650C
Today
2010-2015
soon
600 MW reference design 300 bar,
600/620C Achievable ? 4547 (Net, LHV)
Reduced capital costs Novel layouts
Yesterday
Vertical or spiral wound furnace 250 bar,
540/560C ?lt 40 (Net, LHV)
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State-of-the-art CFBC technology Best
installations world-wide
600
500
Lagisza (PL)
Jacksonville (USA)
400
Sulcis (I)
AES Puerto Rico
Seward (USA)
Gardanne (F)
Baima (China)
Gross electrical output, MWe
Turow (PL)
300
Turow (PL)
Gilbert (USA)
Red Hills (USA)
200
Tonghae (Korea)
Can (Turkey)
Tha Toom (Thailand)
100
0
1994
1996
1998
2000
2002
2004
2006
2008
2010
Year plant commissioned
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BEST REFERENCE PLANTLagisza power station, 460
MWe

• Total output 460 MWe
• SH steam conditions
• flow rate 360 kg/s
• temperature 560 C
• pressure 27.5 MPa
• RH steam conditions
• flow rate 307 kg/s
• temperature 580 C
• pressure 5.46 MPa
• Efficiency (gross, LHV) 43
• Commercial operation 2007

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CFBC TRENDS Developments of compact CFBC design
(Lurgi)

• Volume 70 of conventional designed CFB
• 500 MWe design

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R, DD REQUIREMENTS TO OPTIMISE PERFORMANCE OF
EXISTING CCTs (1)

• Ultra-supercritical pc combustion
• Achieve very high efficiency with advanced
  ultra-supercritical steam cycles while ensuring
  that the novel components using new, materials of
  construction can achieve acceptable reliability
  at economic cost.
• Establish materials for the advanced steam cycle
  components
• Modify and improve the overall design leading to
  compact, less capital intensive systems where the
  advanced materials are minimised.
• Implement demonstration of a commercial prototype

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R, DD REQUIREMENTS TO OPTIMISE PERFORMANCE OF
EXISTING CCTs (2)

• Circulating fluidised bed combustion
• Establish designs for larger, 600-800 MWe, units
  incorporating advanced supercritical steam cycles
  
• Ensure the designs can avoid thermal cracking of
  refractories in the furnaces and the cyclones
• Establish the integration of a 20 substitution
  of coal by renewables (biomass), which can reduce
  CO2 emissions by a further 20-25.
• Implement demonstration of advanced design

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R, DD REQUIREMENTS TO ESTABLISH THE MORE
PROMISING NEAR-ZERO EMISSIONS VARIANTS FOR
COMBUSTION TECHNOLOGIES

• Develop less energy intensive removal schemes
  compared to the use of chemical scrubbing using
  amines.
• Determine whether oxy-fuel combustion to
  establish a more concentrated stream of CO2 can
  be attractive technically and economically.
• Develop lower cost, less energy consuming oxygen
  separation systems (also applicable to IGCC).
• Integrate the combustion process with the CO2
  capture stage in order to minimise efficiency
  losses and potential plant flexibility/availabilit
  y problems
• Demonstrate at significant scale the removal of
  CO2 from a pc and/or CFBC plant

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State-of-the-art IGCC technology Best
installations world-wide
At least 163 commercial gasification plants in
operation, construction, planning or design
stage Currently only 15 major IGCC plants using
coal, petroleum coke and refinery residues as
feedstock
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Best referencePuertollano IGCC plant, 300 MWe
Emissions (mg/Nm3 _at_ 6 O2) NOx 150 (lt100) SO2
25 (lt20) Dust 8 (lt2)
Efficiency 42 (net, LHV basis)
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R, DD REQUIREMENTS TO OPTIMISE PERFORMANCE OF
EXISTING CCTs (3)

• IGCC/ MULTI-FUNCTION IGCC
• Gasifier component development, including
  improved materials of construction for
  refractories and HRSGs, improved feeding and
  handling systems.
• Gas turbine combustor development to ensure the
  efficient use of hydrogen rich fuels.
• Ancillary component development, including lower
  cost air separation units.
• Complementary design and optimisation studies,
  including full integration of CO2 capture.
• Establish a demonstration of multi-function IGCC

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ASSOCIATED STUDIES

• Level playing field techno-economic studies of
  all three technology variants, both for CCT and
  near zero emissions applications, taking into
  account the global market possibilities.

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SUMMARY OF PRIORITY R, DD NEEDS (1)

• Implement an ultra-supercritical pf combustion
  demonstration power plant, building on the
  approach established by EU industry within the AD
  700 project.
• Establish a state of the art CFBC utility scale
  unit using advanced supercritical steam
  conditions (building on the AD 700 experience)
  incorporating the co-firing of coal and biomass.
• In both cases, if appropriate, continue the
  technical RD necessary to optimise and integrate
  the CO2 capture systems appropriate to establish
  near zero emissions variants of these
  technologies.

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SUMMARY OF PRIORITY R, DD NEEDS (2)

• Establish an integrated RD programme for
  multi-function IGCC development appropriate to H2
  and power production. This will include component
  development, the optimised integration of CO2
  capture and the provision of a gas turbine H2
  combustion system. In addition, it will be
  necessary to determine and implement the most
  appropriate approach to demonstrate this
  multi-function concept.
• In all cases, the R,DD activities need to be
  supported by level playing field techno-economic
  analyses in order to determine the likely market
  penetration for each of these more promising
  technology options

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CONCLUSIONS

• Inevitable demand for improved and new coal-based
  generating plant
• New requirements to limit emissions to air, land
  and water
• Clean Coal Technologies are available and under
  development which are capable of meeting the
  demands
• Need to combine experience and capabilities to
  exploit the full potential of clean coal
  technologies