IEA MOST Workshop: Advances in deployment of fossil fuel technology Beijing June 25, 2014
US DOE National Carbon Capture Center Power Systems Development Facility (PSDF) started combustion testing June 1996 and gasification September 1999. In May 2009, PSDF transitioned to the National Carbon Capture Center (NCCC). Existing facilities used to support development of precombustion CO 2 capture and gasification technologies. Additional facility, the Post-Combustion CO 2 Capture Center (PC4) built and started testing March 2011. Located at adjacent power plant, Alabama Power s Plant Gaston, which provides commercially representative flue gas for testing (hot ESP, SCR, and wet FGD).
Project Facts Performance Period 10/01/2008 to 09/30/2014 Total Project Value $251M DOE $201M Non-DOE $50M Award Number DE-NT0000749 Performance Period 5/01/2014 to 04/30/2019 Total Project Value $188M DOE $150M Non-DOE $38M Award Number DE-FE0022596
Coal-based Technology Development Directly Resulting from DOE/Southern Company R&D Partnership Research < 0.1 MWe Development 1-10 MWe Demonstration 10-100+ MWe Commercial 250 MWe + SCR systems Crist Clean Coal Project 1992-1995 9 MW SEI Birchwood 1996 250 MW 100,000 MW 11,000 MW FGD systems Scholz 1978 23 MW Yates Clean Coal 1992 100 MW Low NOx burners Smith Clean Coal 1992 180 MW Hammond Clean Coal 1991 500 MW 18,000 MW 8,000 MW 325,000 MW 22,000 MW Baghouse w/ activated carbon Miller 1995 1 MW Gaston 2&3 1996 & 2001 2*250 MW 8,000 MW* 1,600 MW Carbon Dioxide (Capture & Storage) Daniel 2009 SECARB II 3000 tons National Carbon Capture Center Barry 500 tpd 2011-2014 25MW Citronelle 2009-2020 SECARB III 100k tpy Confidential and Proprietary Citronelle 2009-2023 SECARB III 1M tpy Kemper 3 MM tpd 2014-2054 584MW 500 MW Industry Southern Denotes estimate provided by EPRI
National Carbon Capture Center (NC3) Post-Combustion CO 2 Capture Gasification Pre-Combustion CO 2 Capture
Progress to Commercialization Role of NCCC Lab Scale Component Validation Process Development Unit Large Pilot Demonstration Commercial Role of NCCC Full deployment Tech transfer to power plant slipstream unit e.g. Plant Barry Fundamental R&D Time
Pre-Combustion Facilities Gas Analyzer Building Original SCU OSU Chem Looping Parr Rx Control Room MTR small CO2 and H2 membranes MTR 230 kg/hr CO2 membrane Syngas Conditioning Module Testing: Tech Dev 1 TDA SRI International Clariant JM WPI MPT
Pre-Combustion CO 2 Capture Site Overview Gasification Process Transport Gasifier Syngas Conditioning Unit 50 lb/hr 10 lb/hr Syngas Cooler High Temp Mercury Sorbent CO 2 Batch Reactor Syngas Cooler 50 lb/hr WGS Reactor Cooling & Cleaning System Low Temp Polymeric CO 2 & H 2 Membranes Particulate Filter Syngas Take-Off 500 lb/hr 50 lb/hr Desulfurization Reactors Cooling & Cleaning System CO 2 Membrane & Solvent High Temp Carbon-Based H 2 Membrane Atmospheric Syngas Combustor 50 lb/hr WGS Reactor Desulfur -ization Reactor COS Hydrolysis Reactor High Temp Pd- Based H 2 Membrane High Temp CO 2 Sorbent To Stack
Post Combustion Carbon Capture Center (PC4)
Post Combustion Carbon Capture Center (PC4) Bench-Scale Test Bays Pilot-Scale Test Bays 3 2 1 1. Akermin solvent 2. MTR membrane 3. SRI International sorbent 4. DOE sorbent 5. SSTU solvent 1. 0.6-MW PSTU solvent 2. 1.2-MW BASF/Linde solvent 3. 1.2-MW MTR membrane Eight Test Bays for Technologies from 0.01 MW to 1.2 MW
Expanded PC4 Testing Capability
Codexis Lab Scale Component Validation Process Development Unit Large Pilot Demonstration Commercial Carbonic anhydrase enzyme with MDEA 65% capture Rate of capture 25 times > than MDEA No apparent effect of trace metals or elevated process temperatures Enzymes
Accomplishments PC4 Lab Scale Component Validation Process Development Unit Large Pilot Demonstration Commercial Immobilized Carbonic anhydrase enzyme with Potassium Carbonate Up to 90% capture 7 fold increase in flow Established low solvent loss, demonstrated aerosol emissions below the detection limit Enzymes
Accomplishments PC4 Lab Scale Component Validation Process Development Unit Large Pilot Demonstration Commercial Polymeric Polaris membrane, 1 st and 2 nd generation 2 modules, cross flow and countercurrent-swept 1 ton/day data being used for scale-up Membranes
Accomplishments PC4 Lab Scale Component Validation Process Development Unit Large Pilot Demonstration Commercial Novel carbon sorbent Free flowing, resistant to attrition, low heat of reaction Demonstrated 90% capture Significant improvement in gas/sorbent disengagement Sorbents
Accomplishments PC4 Lab Scale Component Validation Process Development Unit Large Pilot Demonstration Commercial 0.25 MW Mobile Test Unit 2,400 hours of operation Successfully evaluate reductions in solvent and degradation emissions from absorber Solvent Process
Accomplishments PC4 Lab Scale Component Validation Process Development Unit Large Pilot Demonstration Commercial Nominal 1000 hours of operation Target 90% capture Parametric tests up to 100 conditions Solvent degradation, emissions, regeneration energy, corrosion, metal accumulation Solvents
Accomplishments PC4 Lab Scale Component Validation Process Development Unit Large Pilot Demonstration Commercial Membranes Solvent Process
Cost Reduction for Carbon Capture - example Develop 2nd-Generation technologies that: Are ready for demonstration in the 2020 2025 timeframe (with commercial deployment beginning in 2025) Achieve capture costs of approximately $40/tonne of CO 2 captured MTR Membrane 1 TPD Unit 9000 hrs of operation 20 TPD Unit Starting this year Improved performance (permeance) - Coating application thinner - Coating materials Module cost - Low cost components - Membrane casting improvements - Production automation - Use of multi-insert module vessels Change in COE (%) 100 90 80 70 60 50 40 30 MTR membrane process assuming $50/m 2 1 st Generation Polaris 2 nd Generation Polaris MEA (DOE Case 10) Advanced Polaris DOE Target 100 1,000 10,000 Membrane CO 2 permeance (gpu) Pilot Testing of a Membrane System for Post-Combustion CO2 Capture at NCCC, DOE-NCCC Review Meeting, March 12, 2014
Accomplishments Designed and built unique R&D facility and assembled a world class staff Hosted 20 developers testing 24 different technologies Tested innovative technologies emerging from NETL and ARPA-E development programs, as well as developers worldwide funded internationally Provided reliable data to support continued development of their technologies. For pre-combustion/gasification In last five years, 12 gasification test runs for 8,700 hours on coal More than 20,000 hours combined testing of technologies For post-combustion tested more than 22,800 hours of testing
International CCS Test Center Network Accelerate carbon capture technology development by sharing lessons learned between the world s leading test centers SaskPower Boundary Dam Build confidence with targeted groups outside the CCS community by sharing positive stories from its research efforts Experts sharing knowledge in a private fashion Knowledge sharing among a core group of participants that operate large, technologyindependent test centers Established knowledge sharing techniques NCCC TCM - Mongstad
Principals Clear outcomes The network will focus on solving problems in a collaborative way. Analysis and problem solving should be the focus of the network, not data collection. We will clearly identify knowledge gaps and specific areas of focus. Practical approaches will be taken to information sharing The network will share non-confidential information We will leverage the large amounts of public information already available. Digital technology for better connectivity The network will use digital technologies for international knowledge sharing. Financial sustainability Through common digital technologies and by collecting non-confidential information only the costs for running the network will be manageable.
Criteria for Joining Criteria Participant Type Operating a capture facility connected to a coal or gas fired power plant or an industrial plant Core Organization X Participating Organization Participating Individual Willing to provide fee payments as described below. X Willing to host visitors for a site tour as its site facility (restrictions to be communicated by the test center) X Aiming to be as neutral as possible in technology decisions X X Willing to share non-confidential knowledge and jointly work together to solve joint problems X X X Has appropriate subject matter expertise X X X Will sign off on appropriate procedures for knowledge sharing X X X
Topics for Knowledge Sharing Description Priority Health, safety & environment Sharing good practice in health, safety and environment. High Laboratory methods Monitoring & instrumentation Waste management Establishing recognized methods for sampling and analysis Sharing experience with measurement, monitoring and instrumentation. Sharing experience with reclaimer units and the removal and / or treatment of waste. High High High Benchmarking Scale-up The definition of standard methods necessary and proper key performance indicators, such as energy consumption per tonne of CO 2 captured. Will apply to currently tested processes only Risks and lessons learnt regarding challenges around scaling up a test center High / Medium Medium
Topics for Knowledge Sharing Technology verification Harmonization of requirements Description Verifying that the technology being tested does as is claimed Accelerating technology development through harmonization of testing requirements. This is rated as low priority as harmonization of requirements across test centers is unlikely to be achieved. Priority Medium / Low Low Operational experience Sharing experience with common equipment such as pumps, compressors and heat exchangers. Low Regulations Technology Screening studies Sharing experience with legislation and regulatory framework conditions. Assessing what companies are leading in capture technology and should be used as potential candidates for technology testing. Screening studies have been defined as technologies that have the potential to be implemented in future (beyond 5 years) Low Low