Australian brown coal R&D - projects and technologies. Dr Phil Gurney APEC Expert Group of Clean Fossil Energy Thursday February 23, 2012

Transcription

1 Australian brown coal R&D - projects and technologies Dr Phil Gurney APEC Expert Group of Clean Fossil Energy Thursday February 23, 2012

2 Outline Australian Brown Coal considerations Issues, Challenges and Opportunities for utilisation of brown coal Brief History of R&D Setting the scene BCIA s role and activities Current programs and activities Project examples High Efficiency Power from Brown Coal Chemical looping combustion Reducing cost of CO2 absorber columns

3 Australian Brown Coal Resources

4 World proven recoverable reserves, 2008 Germany, 3.9% India, 5.8% China, 10.9% Rest of world, 41.8% Russia, 15.0% USA 22.7% Australia, 7.3% Black Brown Black Coal, 53.80% Other, 2.20% Oil, 1.00% Hydro,4.60 Gas, 15.90% Brown Coal, 22.50% Fuels for Australian Electricity

5 Australian Brown Coal Characteristics 25% of global resource Primarily located in Latrobe Valley 60+% Water energy penalty for moisture reduction Weight / flammability Uneconomic to transport wet coal Current use primarily local Electricity generation Briquettes (0.4MT/a) Soil additives

6 Major Brown Coal Power Stations Hazelwood Hazelwood Power Station (1675MW) built between 1964 and 1971 Morwell Open cut mine - ~18MT coal per annum Yallourn Yallourn W Power Station (1480MW) built between 1974 and 1982 Open-cut mine ~18MT coal per annum (~4MT overburden) LoyYang LoyYang A Power Station (2200MW) built between 1977 and 1988 LoyYang B Power Station (1050MW) built between 1985 and 1993 Open-cut mine ~30MT coal per annum (~3-4MT overburden)

7 Other Brown Coal Power Generation Angelsea (Aluminium production) Power Station 150MW, Built ~ Open cut mine ~1.1MT EnergyBrix (Briquettes) Power Station 170MW, Built ~ Coal from Yollourn and LoyYang mines South Australia (Power) Northern Power Station 520MW, Built Playford B Power Station 240MW, Built Leigh Creek coal mine, ~2.5MT pa

8 Recent history of research SECV / Coal Corporation of Victoria ( ) Research arm acquired by HRL in 1994 CRC for New Technologies for Power Generation from Low Rank Coal ( ) properties and characteristics of low-rank coals, ash and deposit formation and combustion, gasification CRC for Clean Power from Lignite ( ) properties and characteristics of lignite, the chemistry and physics of coal processing, coal drying. CRC for Greenhouse Gas Technologies ( present) carbon dioxide (CO2) capture and geological storage

9 ETIS Projects: Coal Research, Development and Demonstrations Victorian Government funded research (to 2009) Coal Utilisation Steps Strategic Research & Development Applied Pilot Demonstration Large Scale Deployment Coal Prep Combustion Gasification Monash Uni: Lignite for Waste-water Clean-up CSIRO: Modelling of Dried Brown Coal Combustion Aquex: Brown Coal Dewatering HRL: Advanced flaw detection Boiler Optimisation Advanced materials assessment Monash Uni: Advanced gasification Oxy-fuel Combustion MTE Coal Drying IP: Advanced Dried Brown Coal Combustion HRL: IDGCC CCS Loy Yang Power/CO2CRC: Post Combustion Capture CO2CRC: Pre Combustion Capture IP: Advanced dried Brown Coal Combustion Otway Basin Carbon Storage Trial ETIS 2 CCS $110m over 6 years

10 BCIA established December 2009 Private, member based company Focus on environmentally sustainable uses of Australia s Brown Coal Funding Programs for Improved efficiency of Energy Generation Carbon capture technologies Low-emissions alternate uses of Coal (CTX, etc) Skills development for future technology International linkages Communication of outcomes

11 How does BCIA deliver a Brighter Future? ~$21M funding secured from Governments, Members invested into Research and Development (Grants and commissioned activities) Skills for future applications of brown coal Networks and linkages to bring together expertise and delivery Communication of outcomes and benefits of Brown Coal Focus on early stage and pilot R&D issues and technologies 5-20 years out Primarily cost reduction and practicalities, rather than breakthroughs

12 2011/12 Research Program Reducing Emissions (Improving Efficiency) of Coal for Power Direct Injection Coal Engine (CSIRO, Exergen Pty Ltd and Ignite Energy Resources Pty Ltd.) Next Generation Lower Emissions Gasification Systems (HRL, Monash, CO2CRC) Entrained Flow Gasification for power, fuel and chemicals* (Monash University, Mitsubishi Heavy Industries) * ANLEC brown coal node project

13 2011/12 Research Program Improving CO2 capture Pilot-Scale Oxy-Fuel Combustion of Victorian Brown Coal* (Monash University and partners) Chemical looping for fuels production and CO2 capture (Monash University, TRUenergy, CSIRO) Low cost flue gas treatment and CO2 removal* (Loy Yang Power, CSIRO) Solvent-Based Carbon Capture Technology (CO2CRC, GDF Suez International Power, Process Group) Reducing cost of CO2 absorber columns* (Process Group, WES, CO2CRC) * ANLEC brown coal node project

14 2011/12 Research Program Alternate Uses of Coal Hydrogen supply chain development (HRL Developments Pty Ltd, Kawasaki Heavy Industries Limited) Coal derivatives to improve soil carbon (Monash University, partners including LawrieCo; Exergen Pty Ltd and Environmental Clean Technologies) Improved handling of lignite-based products (Monash University, Environmental Clean Technologies Ltd, LawrieCo, Keith Engineering (Australia) Pty Ltd) Carbon materials from Victorian brown coal for CO2 capture** (KEPCO, Monash University) Catalytic steam gasification and assessment of Dimethyl Ether** (KEPCO, Monash University) Blast furnace coke from lignite** (KEPCO, Monash University) ** Project transferred from DPI

15 Member focused programs Members access to programs in: Research and Skills specifically for members PhD sponsorships Research Fellows Community skills programs Commissioned reports specifically for members Reports developed for members in specified focus areas Linkages and networks Seminars, conferences, international linkage programs Communications Results, benefits of brown coal

16 High Efficiency Power from Brown Coal - DICE? Victorian coals Coal processing CWF Diesel engine generation hydrothermal, partial drying-slurry, de-sanding Exergen Ignite Energy Resources JGC, Evergreen

17 Thermal efficiency (% HHV, delivered) Efficiency - coal to delivered electricity DCFC MSD* LSD** GT CCG IGC USC DICE * Medium speed ** Low speed Centralised Decentralised Distributed Unit capacity (MWe)

18 GGE (kg CO 2 /MWh delivered) Efficiency - coal to delivered electricity MSD* LSD** IGCC USC DICE * Medium speed ** Low speed 600 DCFC GT 400 CCGT Distributed Decentralised Centralised Unit capacity (MWe)

19 DICE research objectives Assess a range of process combinations to produce suitable fuel for direct injection coal engines assess on a common life cycle basis, coal -> delivered electricity Identify technologies for preparing Victorian coal for use in adapted large diesel engines identify and pilot test technologies for desanding Victorian coals develop fuel specifications with large engine manufacturers for engine development Develop a business case and engineering for a demonstration at the 10 MW scale by 2015

20 Chemical Looping Combustion of Victorian Brown Coal First such study using brown coal The research program is aimed at addressing critical technical aspects of chemical looping process relevant to the brown coal processing and conversion: Key objectives Development of high performance oxide carrier with long stability amenable to brown coal combustion/gasification Kinetics of reaction and oxygen transfer rate to the fuel from oxygencarrier, including ash mineral-oxygen carrier interaction Identify the optimum process variant and reactor design configuration exclusively for Victorian brown coal with low cost/energy penalties. Design and construction of a bench scale rig and a ~2kg/hr looping rig Preparing a comprehensive technology status report on chemical looping combustion of coal-derived syn gas and coal

21 Project partners : University Industry partnership TRUenergy CSIRO Chalmers University Technical University of Darmstadt Monash University Project Leader Two PhD students and several undergraduate students trained Publications so far International Journal of Hydrogen Energy Energy & Fuels Fuel International Coal Science and Technology Conference Clearwater conference

22 Hazelwood CO 2 Capture Plant Reducing the cost of CO2 absorber columns Plant Details: Hazelwood Power Station Inlet flow untreated gas: 20,770 Am 3 /h CO 2 content untreated gas:13 mol% (wet basis) CO 2 content product gas: 95 mol% (wet basis) Solvent: proprietary amino acid Absorber diameter:1.5 m Reboiler Duty: 3 MW Footprint: 20 x 34 m (incl. liquefaction) CO 2 capture rate: 50 tpd Future Work Conventional absorber internals will be removed and replaced with WES internals to enable a direct comparison

23 CO2CRC Solvent Pilot Plant Location: Originally installed at HRL Mulgrave Coal Gasification Pilot Plant, Victoria. Will be relocated to Hazelwood Power Station. Start up: April 2012 Plant Details: CO 2 capture rate: ~ 1 tpd Solvent circulation rate: 1.5 m 3 /h Solvent: Various (MEA, carbonate, amino acid, etc.) Skid dimensions: 5.5 x 2.5 x 7.3 m (LxWxH) Modifications for BCIA funded Project: - Convert from pre-combustion to post combustion flue gas operation - Add a WES absorber in parallel to conventional absorber to enable direct comparison

24 Conlcusions Australian Brown Coal Issues, Challenges and Opportunities Long history of R&D Today s focus on environmentally sustainable uses High Efficiency Power from Brown Coal Cost-effective capture processes Alternate uses of coal - CTX

25 For more information on Brown Coal Innovation Australia Level 27, 101 Collins Street Melbourne VIC 3000 Australia Tel Fax phil.gurney@bcinnovation.com.au