Abstract Process Economics Program Report 180C ADVANCED CARBON CAPTURE (December 2009)

Transcription

1 Abstract Process Economics Program Report 180C ADVANCED CARBON CAPTURE (December 2009) ABSTRACT A great deal of attention has been paid in recent years to the issue of carbon emissions and their effect on climate change. Because of this, considerable effort has been made in the area of carbon capture and sequestration as applied to coal-fired power plants. In previous PEP reports and reviews we have examined integrated gasification and combined cycle (IGCC) and oxycombustion. In this report we examine the technology and economics of electric power generation using supercritical pulverized coal combined with scrubbing of the flue gases and compression of CO 2. We present three carbon capture processes. First, we examine the use of generic, modern (30 wt%) monoethanolamine (MEA) scrubbing. Second, we examine an advanced amine process as exemplified by the Mitsubishi Heavy Industries Kansai Electric KM- CDR process which uses the proprietary hindered amine KS-1. Finally, we look at the chilled ammonia process which has been jointly developed by Alstom, the Electric Power Research Institute (EPRI), and SRI International. We have conducted all of our analyses using new plant construction (the issue of retrofits is beyond the scope of this study) at 550 MW net power output. Our efforts are centered around the development of independent cost analyses tied to the basis of comparison laid out in the US Department of Energy s report, Cost and Performance Baseline for Fossil Energy Plants, DOE/NETL-2007/1281, revised October, We have found that on a levelized cost basis with 90% CO 2 capture and compression, MEA scrubbing adds 4.5 /KWh to the cost of power generation via supercritical pulverized coal. The advanced amine and chilled ammonia processes show similar overall economics, each adding 4.1 /KWh. SRI Consulting PEP Report 180C

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3 SRIC agrees to assign professionally qualified personnel to the preparation of the Process Economics Program s reports and will perform the work in conformance with generally accepted professional standards. No other warranties expressed or implied are made. Because the reports are of an advisory nature, neither SRIC nor its employees will assume any liability for the special or consequential damages arising from the Client s use of the results contained in the reports. The Client agrees to indemnify, defend, and hold SRIC, its officers, and employees harmless from any liability to any third party resulting directly or indirectly from the Client s use of the reports or other deliverables produced by SRIC pursuant to this agreement For detailed marketing data and information, the reader is referred to one of the SRI Consulting programs specializing in marketing research. THE CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS PROGRAM covers major hydrocarbons and their derivatives on a worldwide basis. In addition the SRIC DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States, Western Europe, Canada, and East Asia, South America and Mexico.

4 CONTENTS 1 INTRODUCTION SUMMARY PURPOSE OF THIS STUDY TECHNICAL AND ECONOMIC ISSUES A CONTROVERSY OVER ENERGY OF REGENERATION PARASITIC LOADS AND CAPITAL COSTS SUPERCRITICAL PULVERIZED COAL-FIRED POWER GENERATION MONOETHANOLAMINE SCRUBBING KM-CDR PROCESS USING KS-1 SOLVENT CHILLED AMMONIA PROCESS NGCC EMISSIONS EQUIVALENCE - CALIFORNIA EMISSIONS STANDARD COST ESTIMATES PLANT PERFORMANCE CONFIDENCE LEVELS AND UNCERTAINTIES INDUSTRY STATUS SUPERCRITICAL PULVERIZED COAL POWER GENERATION WITH CARBON CAPTURE VIA MONOETHANOLAMINE SCRUBBING CHEMISTRY CORROSION AND HEAT STABLE SALTS PROCES REVIEW PROCESS DESCRIPTION Supercritical Pulverized Coal without Carbon Capture Carbon Capture Case: MEA Scrubbing Carbon Capture Case: CO 2 Compression Natural Gas Emissions Equivalent Case SRI Consulting iii PEP Report 180C

5 CONTENTS (Continued) PROCESS DISCUSSION Choice of Design Bases Plant Performance Summary COST ESTIMATES Capital Costs Production Costs SUPERCRITICAL PULVERIZED COAL POWER GENERATION WITH CARBON CAPTURE VIA MITSUBISHI HEAVY INDUSTRIES PROCESS (KS-1 SOLVENT) 5-1 CHEMISTRY PROCES REVIEW PROCESS DESCRIPTION Natural Gas Emissions Equivalent Case PROCESS DISCUSSION Choice of Design Bases Carbon Capture and Compression Parasitic Loads Plant Performance Summary COST ESTIMATES Capital Costs Production Costs SUPERCRITICAL PULVERIZED COAL POWER GENERATION WITH CARBON CAPTURE VIA CHILLED AMMONIA SCRUBBING CHEMISTRY PROCES REVIEW PROCESS DESCRIPTION PROCESS DISCUSSION Choice of Design Bases Plant Performance Summary SRI Consulting iv PEP Report 180C

6 CONTENTS (Concluded) COST ESTIMATES Capital Costs Production Costs APPENDIX A: PATENT SUMMARY TABLES... A-1 APPENDIX B: CITED REFERENCES... B-1 APPENDIX C: PROCESS FLOW DIAGRAM... C-1 SRI Consulting v PEP Report 180C

7 ILLUSTRATIONS 4.1 Supercritical Pulverized Coal Power Generation No Carbon Capture Process Flow Diagram... C Supercritical Pulverized Coal Power Generation Carbon Capture via Monoethanolamine Scrubbing Process Flow Diagram... C Supercritical Pulverized Coal Power Generation Carbon Capture via Monoethanolamine Scrubbing Process Flow Diagram... C Supercritical Pulverized Coal Power Generation Carbon Capture via Mitsubishi Heavy Industries Process (KS-1 Solvent) Process Flow Diagram... C Supercritical Pulverized Coal Power Generation Carbon Capture via Mitsubishi Heavy Industries Process (KS-1 Solvent) Process Flow Diagram... C Supercritical Pulverized Coal Power Generation Carbon Capture via Chilled Ammonia Scrubbing Process Flow Diagram... C Supercritical Pulverized Coal Power Generation Carbon Capture via Chilled Ammonia Scrubbing Process Flow Diagram... C-19 SRI Consulting vi PEP Report 180C

8 TABLES 2.1 Cost of CO2 Removed/Avoided Cost of CO2 Removed/Avoided California Standard Cases Plant Performance Summaries, KWE Supercritical Pulverized Coal Power Generation Carbon Capture via Scrubbing by MEA, MHI (KS-1), Ammonia Plant Performance Summaries, KWE Supercritical Pulverized Coal Power Generation Carbon Capture via Scrubbing by MEA, MHI (KS-1), Ammonia NGCC Emissions Equivalence Cases Physical Properties of Monoethanolamine Typical Reclaimer Bottoms Composition Typical Filter Residue Composition Supercritical Pulverized Coal Power Generation Carbon Capture via Monoethanolamine Scrubbing Design Bases Design Coal Specification Supercritical Pulverized Coal Stream Flows Supercritical PC Major Equipment List (without CO 2 Capture) Supercritical Pulverized Coal Power Generation Carbon Capture via Monoethanolamine Scrubbing Design Bases Supercritical Pulverized Coal with Carbon Capture via Monoethanolamine Scrubbing Major Stream Flows Supercritical PF Major Equipment List (with CO 2 Capture) Carbon Capture via Monoethanolamine Scrubbing Carbon Capture and Compression Major Equipment Supercritical Pulverized Coal Power Generation Carbon Capture via Monoethanolamine Scrubbing NGCC Emissions Equivalence Case CO 2 Compressor Interstage Pressures Plant Performance Summaries, KW E Supercritical Pulverized Coal Power Generation Carbon Capture via Monoethanolamine Scrubbing SRI Consulting vii PEP Report 180C

9 TABLES (Continued) 4.15 Plant Performance Summaries, KW E Supercritical Pulverized Coal Power Generation Carbon Capture via Monoethanolamine Scrubbing NGCC Emissions Equivalence Case SCPC Power Generation Without Carbon Capture Total Capital Investment SCPC Power Generation With MEA Scrubbing Total Capital Investment SCPC Power Generation With MEA Scrubbing (NGCC Equivalent Emissions) Total Capital Investment SCPC Power Generation With MEA Scrubbing Battery Limits Investment SCPC Power Generation With MEA Scrubbing (NGCC Equivalent Emissions) Battery Limits Investment SCPC Power Generation Without Carbon Capture Production Costs SCPC Power Generation With Carbon Capture via MEA Scrubbing Production Costs SCPC Power Generation With MEA Scrubbing (NGCC Equivalent Emissions) Production Costs Supercritical Pulverized Coal Power Generation Carbon Capture via Mitsubishi Heavy Industries Process (KS-1 Solvent) Design Bases Design Coal Specification Supercritical Pulverized Coal with Carbon Capture via KS-1 Scrubbing Stream Flows Carbon Capture via Mitsubishi Heavy Industries Process (KS-1 Solvent) Carbon Capture and Compression Major Equipment List Supercritical Pulverized Coal Power Generation Carbon Capture via Mitsubishi Heavy Industries Process (KS-1 Solvent) NGCC Equivalent Emissions Design Bases CO 2 Compressor Interstage Pressures Plant Performance Summaries, KW E Supercritical Pulverized Coal Power Generation Carbon Capture via Mitsubishi Heavy Industries Process (KS-1 Solvent) SRI Consulting viii PEP Report 180C

10 TABLES (Continued) 5.8 Plant Performance Summaries, KW E Supercritical Pulverized Coal Power Generation Carbon Capture via Mitsubishi Heavy Industries Process (KS-1 Solvent) NGCC Emissions Equivalence Case SCPC Power Generation with Scrubbing via KM-CDR Process with KS-1 Total Capital Investment SCPC Power Generation with Scrubbing via KM-CDR Process with KS-1 (NGCC Emissions Equivalence Case) Total Capital Investment SCPC Power Generation with Scrubbing via KM-CDR Process with KS-1 Battery Limits Investment SCPC Power Generation with Scrubbing via KM-CDR Process with KS-1 (NGCC Emissions Equivalence Case) Battery Limits Investment SCPC Power Generation with Scrubbing via KM-CDR Process with KS-1 Production Costs SCPC Power Generation with Scrubbing via KM-CDR Process with KS-1 (NGCC Emissions Equivalence Case) Production Costs Supercritical Pulverized Coal Power Generation Carbon Capture via Chilled Ammonia Scrubbing Design Bases Design Coal Specification Supercritical Pulverized Coal with Carbon Capture via Chilled Ammonia Scrubbing Stream Flows Carbon Capture via Chilled Ammonia Scrubbing Carbon Capture and Compression Major Equipment List Supercritical Pulverized Coal Power Generation Carbon Capture via Chilled Ammonia Scrubbing NGCC Equivalent Emissions Design Bases CO 2 Compressor Interstage Pressures Supercritical Pulverized Coal Power Generation Carbon Capture via Chilled Ammonia Scrubbing Summary of Refrigeration Loads Plant Performance Summaries, KW E Supercritical Pulverized Coal Power Generation Carbon Capture via Chilled Ammonia Scrubbing SRI Consulting ix PEP Report 180C

11 TABLES (Concluded) 6.9 Plant Performance Summaries, KW E Supercritical Pulverized Coal Power Generation Carbon Capture via Chilled Ammonia Scrubbing NGCC Emissions Equivalence Case SCPC Power Generation with Chilled Ammonia Scrubbing Total Capital Investment SCPC Power Generation with Scrubbing via Chilled Ammonia Scrubbing (NGCC Emissions Equivalence Case) Total Capital Investment SCPC Power Generation with Chilled Ammonia Scrubbing Battery Limits Investment SCPC Power Generation with Chilled Ammonia Scrubbing (NGCC Emissions Equivalence Case) Battery Limits Investment SCPC Power Generation with Chilled Ammonia Scrubbing Production Costs SCPC Power Generation with Chilled Ammonia Scrubbing (NGCC Emissions Equivalence Case) Production Costs SRI Consulting x PEP Report 180C