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Title: Engineering and Economic Analysis of an Advanced Ultra-Supercritical Pulverized Coal Power Plant with and without Post-Combustion Carbon Capture Task 7. Design and Economic Studies

Abstract

This report evaluates the economics and performance of two A-USC PC power plants; Case 1 is a conventionally configured A-USC PC power plant with superior emission controls, but without CO 2 removal; and Case 2 adds a post-combustion carbon capture (PCC) system to the plant from Case 1, using the design and heat integration strategies from EPRI’s 2015 report, “Best Integrated Coal Plant.” The capture design basis for this case is “partial,” to meet EPA’s proposed New Source Performance Standard, which was initially proposed as 500 kg-CO 2/MWh (gross) or 1100 lb-CO 2/MWh (gross), but modified in August 2015 to 635 kg-CO 2/MWh (gross) or 1400 lb-CO 2/MWh (gross). This report draws upon the collective experience of consortium members, with EPRI and General Electric leading the study. General Electric provided the steam cycle analysis as well as v the steam turbine design and cost estimating. EPRI performed integrated plant performance analysis using EPRI’s PC Cost model.

Authors:
 [1];  [2];  [2];  [3]
  1. Electric Power Research Inst. (EPRI), Palo Alto, CA (United States)
  2. General Electric, Schenectady, NY (United States)
  3. Hendrix Engineering Solutions, Inc., Calera, AL (United States)
Publication Date:
Research Org.:
Energy Industries Of Ohio Inc., Independence, OH (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1243059
DOE Contract Number:
FE0000234
Resource Type:
Other
Country of Publication:
United States
Language:
English
Subject:
54 ENVIRONMENTAL SCIENCES

Citation Formats

Booras, George, Powers, J., Riley, C., and Hendrix, H. Engineering and Economic Analysis of an Advanced Ultra-Supercritical Pulverized Coal Power Plant with and without Post-Combustion Carbon Capture Task 7. Design and Economic Studies. United States: N. p., 2015. Web.
Booras, George, Powers, J., Riley, C., & Hendrix, H. Engineering and Economic Analysis of an Advanced Ultra-Supercritical Pulverized Coal Power Plant with and without Post-Combustion Carbon Capture Task 7. Design and Economic Studies. United States.
Booras, George, Powers, J., Riley, C., and Hendrix, H. Tue . "Engineering and Economic Analysis of an Advanced Ultra-Supercritical Pulverized Coal Power Plant with and without Post-Combustion Carbon Capture Task 7. Design and Economic Studies". United States. doi:. https://www.osti.gov/servlets/purl/1243059.
@article{osti_1243059,
title = {Engineering and Economic Analysis of an Advanced Ultra-Supercritical Pulverized Coal Power Plant with and without Post-Combustion Carbon Capture Task 7. Design and Economic Studies},
author = {Booras, George and Powers, J. and Riley, C. and Hendrix, H.},
abstractNote = {This report evaluates the economics and performance of two A-USC PC power plants; Case 1 is a conventionally configured A-USC PC power plant with superior emission controls, but without CO2 removal; and Case 2 adds a post-combustion carbon capture (PCC) system to the plant from Case 1, using the design and heat integration strategies from EPRI’s 2015 report, “Best Integrated Coal Plant.” The capture design basis for this case is “partial,” to meet EPA’s proposed New Source Performance Standard, which was initially proposed as 500 kg-CO2/MWh (gross) or 1100 lb-CO2/MWh (gross), but modified in August 2015 to 635 kg-CO2/MWh (gross) or 1400 lb-CO2/MWh (gross). This report draws upon the collective experience of consortium members, with EPRI and General Electric leading the study. General Electric provided the steam cycle analysis as well as v the steam turbine design and cost estimating. EPRI performed integrated plant performance analysis using EPRI’s PC Cost model.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Tue Sep 01 00:00:00 EDT 2015},
month = {Tue Sep 01 00:00:00 EDT 2015}
}
  • This topical report presents the techno-economic evaluation of a 550 MWe supercritical pulverized coal (PC) power plant utilizing Illinois No. 6 coal as fuel, integrated with 1) a previously presented (for a subcritical PC plant) Linde-BASF post-combustion CO 2 capture (PCC) plant incorporating BASF’s OASE® blue aqueous amine-based solvent (LB1) [Ref. 6] and 2) a new Linde-BASF PCC plant incorporating the same BASF OASE® blue solvent that features an advanced stripper interstage heater design (SIH) to optimize heat recovery in the PCC process. The process simulation and modeling for this report is performed using Aspen Plus V8.8. Technical information frommore » the PCC plant is determined using BASF’s proprietary thermodynamic and process simulation models. The simulations developed and resulting cost estimates are first validated by reproducing the results of DOE/NETL Case 12 representing a 550 MWe supercritical PC-fired power plant with PCC incorporating a monoethanolamine (MEA) solvent as used in the DOE/NETL Case 12 reference [Ref. 2]. The results of the techno-economic assessment are shown comparing two specific options utilizing the BASF OASE® blue solvent technology (LB1 and SIH) to the DOE/NETL Case 12 reference. The results are shown comparing the energy demand for PCC, the incremental fuel requirement, and the net higher heating value (HHV) efficiency of the PC power plant integrated with the PCC plant. A comparison of the capital costs for each PCC plant configuration corresponding to a net 550 MWe power generation is also presented. Lastly, a cost of electricity (COE) and cost of CO 2 captured assessment is shown illustrating the substantial cost reductions achieved with the Linde-BASF PCC plant utilizing the advanced SIH configuration in combination with BASF’s OASE® blue solvent technology as compared to the DOE/NETL Case 12 reference. The key factors contributing to the reduction of COE and the cost of CO 2 captured, along with quantification of the magnitude of the reductions achieved by each of these factors, are also discussed. Additionally, a high-level techno-economic analysis of one more highly advanced Linde-BASF PCC configuration case (LB1-CREB) is also presented to demonstrate the significant impact of innovative PCC plant process design improvements on further reducing COE and cost of CO 2 captured for overall plant cost and performance comparison purposes. Overall, the net efficiency of the integrated 550 MWe supercritical PC power plant with CO 2 capture is increased from 28.4% with the DOE/NETL Case 12 reference to 30.9% with the Linde-BASF PCC plant previously presented utilizing the BASF OASE® blue solvent [Ref. 6], and is further increased to 31.4% using Linde-BASF PCC plant with BASF OASE® blue solvent and an advanced SIH configuration. The Linde-BASF PCC plant incorporating the BASF OASE® blue solvent also results in significantly lower overall capital costs, thereby reducing the COE and cost of CO 2 captured from $147.25/MWh and $56.49/MT CO 2, respectively, for the reference DOE/NETL Case 12 plant, to $128.49/MWh and $41.85/MT CO 2 for process case LB1, respectively, and $126.65/MWh and $40.66/MT CO 2 for process case SIH, respectively. With additional innovative Linde-BASF PCC process configuration improvements, the COE and cost of CO2 captured can be further reduced to $125.51/MWh and $39.90/MT CO 2 for LB1-CREB. Most notably, the Linde-BASF process options presented here have already demonstrated the potential to lower the cost of CO2 captured below the DOE target of $40/MT CO 2 at the 550 MWe scale for second generation PCC technologies.« less
  • Post-combustion CO 2 capture (PCC) technology offers flexibility to treat the flue gas from both existing and new coal-fired power plants and can be applied to treat all or a portion of the flue gas. Solvent-based technologies are today the leading option for PCC from commercial coal-fired power plants as they have been applied in large-scale in other applications. Linde and BASF have been working together to develop and further improve a PCC process incorporating BASF’s novel aqueous amine-based solvent technology. This technology offers significant benefits compared to other solvent-based processes as it aims to reduce the regeneration energy requirementsmore » using novel solvents that are very stable under the coal-fired power plant feed gas conditions. BASF has developed the desired solvent based on the evaluation of a large number of candidates. In addition, long-term small pilot-scale testing of the BASF solvent has been performed on a lignite-fired flue gas. In coordination with BASF, Linde has evaluated a number of options for capital cost reduction in large engineered systems for solvent-based PCC technology. This report provides a summary of the work performed and results from a project supported by the US DOE (DE-FE0007453) for the pilot-scale demonstration of a Linde-BASF PCC technology using coal-fired power plant flue gas at a 1-1.5 MWe scale in Wilsonville, AL at the National Carbon Capture Center (NCCC). Following a project kick-off meeting in November 2011 and the conclusion of pilot plant design and engineering in February 2013, mechanical completion of the pilot plant was achieved in July 2014, and final commissioning activities were completed to enable start-up of operations in January 2015. Parametric tests were performed from January to December 2015 to determine optimal test conditions and evaluate process performance over a variety of operation parameters. A long-duration 1500-hour continuous test campaign was performed from May to August 2016 at a selected process condition to evaluate process performance and solvent stability over a longer period similar to how the process would operate as a continuously running large-scale PCC plant. The pilot plant integrated a number of unique features of the Linde-BASF technology aimed at lowering overall energy consumption and capital costs. During the overall test period including startup, parametric testing and long-duration testing, the pilot plant was operated for a total of 6,764 hours out of which testing with flue gas was performed for 4,109 hours. The pilot plant testing demonstrated all of the performance targets including CO 2 capture rate exceeding 90%, CO 2 purity exceeding 99.9 mol% (dry), flue gas processing capacity up to 15,500 lbs/hr (equivalent to 1.5 MWe capacity slipstream), regeneration energy as low as 2.7 GJ/tonne CO 2, and regenerator operating pressure up to 3.4 bara. Excellent solvent stability performance data was measured and verified by Linde and BASF during both test campaigns. In addition to process data, significant operational learnings were gained from pilot tests that will contribute greatly to the commercial success of PCC. Based on a thorough techno-economic assessment (TEA) of the Linde-BASF PCC process integrated with a 550 MWe supercritical coal-fired power plant, the net efficiency of the integrated power plant with CO 2 capture is increased from 28.4% with the DOE/NETL Case 12 reference to 30.9% with the Linde-BASF PCC plant previously presented utilizing the BASF OASE® blue solvent [Ref. 4], and is further increased to 31.4% using a Linde-BASF PCC plant with BASF OASE® blue solvent and an advanced stripper interstage heater (SIH) configuration. The Linde-BASF PCC plant incorporating the BASF OASE® blue solvent also results in significantly lower overall capital costs, thereby reducing the cost of electricity (COE) and cost of CO 2 captured from $147.25/MWh and $56.49/MT CO 2, respectively, for the reference DOE/NETL Case 12 plant, to $128.49/MWh and $41.85/MT CO2 for process case LB1, respectively, and $126.65/MWh and $40.66/MT CO 2 for process case SIH, respectively. With additional innovative Linde-BASF PCC process configuration improvements, the COE and cost of CO 2 captured can be further reduced to $125.51/MWh and $39.90/MT CO 2 for a further optimized PCC process defined as LB1-CREB. Most notably, the Linde-BASF process options assessed have already demonstrated the potential to lower the cost of CO 2 captured below the DOE target of $40/MT CO 2 at the 550 MWe scale for second generation PCC technologies. Project organization, structure, goals, tasks, accomplishments, process criteria and milestones will be presented in this report along with highlights and key results from parametric and long-duration testing of the Linde-BASF PCC pilot. The parametric and long-duration testing campaigns were aimed at validating the performance of the PCC technology against targets determined from a preliminary techno-economic assessment. The stability of the solvent with extended operation in a realistic power plant setting was measured with performance verified. Additionally, general solvent classification information, process operating conditions, normalized solvent performance data, solvent stability test results, flue gas conditions data, CO 2 purity data in the gaseous product stream, steam requirements and process flow diagrams, and updated process economic data for a scaled-up 550 MWe supercritical power plant with CO 2 capture are presented and discussed in this report.« less
  • The dramatic improvement in pulverized coal fired (PC) plant boiler flue gas emissions over the past 15 to 20 years in response to the concerns for a {open_quotes}Green Environment{close_quotes} is frequently overlooked. For example, during this time period systems and equipment have been installed on PC`s that reduce SO{sub 2} emissions by 85% and even to more than 95% and NO{sub x} emission reductions by about 50%.
  • The first part of this report presents a comparison of the conceptual designs of a large (570 MW(e)) pulverized coal (PC) steam generator equipped with a wet limestone flue gas desulfurization (FGD) system and two equivalent sized atmospheric fluidized bed (AFB) steam generators including balance of plants for electric-power generation. The reader is cautioned that this portion of the report compares a zero generation AFB technology to pulverized coal technology which has been operationally and economically optimized for the past half-century. This comparison is intended to be indicative of whether further development of the AFB concept as a viable alternativemore » to the PC/FGD concept for electric-power generation is merited. In the second part, the load-following capability of a once-through subcritical atmospheric fluidized bed boiler is analyzed. Digital computer simulation predictions of the plant's response to open loop step changes in firing rate, feedwater flow, governor valve, unit load demand, etc, are made. The predicted response of throttle pressure, steam temperature, unit load, etc, are compared to the response of a conventional coal-fired, once-through, subcritical unit. The load-following capability is assessed through this qualitative comparison. Additional model response predictions are also presented for which no test data are presently available.« less
  • The objectives of this report are to present: the facility description, plant layouts and additional information which define the conceptual engineering design, performance and cost estimates for the pulverized coal fired (PCF) power plant which utilizes high-sulfur coal as fuel, and a spray dryer/fabric filter flue gas desulfurization (FGD) system; an assessment of the impact of using low-sulfur coal on the results of the base case conceptual engineering studies, plant layouts and cost estimates. Following the introductory comments, the results of the study of the PCF power plant with a spray dryer/fabric filter FGD system are summarized in Section 2.more » In Section 3, the high-sulfur coal case steam cycle heat balance, a performance and operating data summary and an availability assessment are provided. Sections 4 and 5 present the high-sulfur coal case power plant and FGD system descriptive information and costs, respectively. In Section 6, an assessment of the impacts of using low-sulfur coal as fuel is presented. Appendix A is the power plant and FGD system major equipment list. The design and cost estimate classification chart referenced in Section 5 is included as Appendix B. 5 references, 18 figures, 29 tables.« less