Investigation of Liquid CO2 (LCO2) / Coal Slurry for ... · Jose Marasigan, EPRI Prof. John Dooher, Adelphi University (Dooher Institute of Physics & Energy) Harvey Goldstein, WorleyParsons

Jose Marasigan, EPRI

Prof. John Dooher, Adelphi University (Dooher Institute of Physics & Energy)

Harvey Goldstein, WorleyParsons Group, Inc.

2013 Gasification Technologies Conference

Wednesday, October 16, 2013

Investigation of Liquid CO2 (LCO2) / Coal Slurry

for Feeding Low Rank Coal to Gasifiers

2 © 2013 Electric Power Research Institute, Inc. All rights reserved.

Presentation Outline

• Background

• Project scope

– Objectives

– Tasks

• Evaluation results summary

• Comparison with previous published analyses

• Technology development roadmap


Background Liquid CO2 and H2O (Theoretical)

Liquid CO2 Compared to

H2O

Expected Performance

Impact

Viscosity Lower Higher solids loading at

same slurry viscosity

Heat of Vaporization 75-80% Lower Less oxygen needed to

achieve given gasifier

temperature

Atomization Finer Better carbon conversion at

same gasifier temperature

Previous studies have shown significant IGCC performance improvement with liquid CO2 slurry.


Project Scope Objectives

Overall objective

• Reduce cost, improve

efficiency of IGCC with

CCS by utilization of

captured CO2

Specific objective

• Gain greater understanding

and confirm potential

advantages of using

LCO2/Low rank coal

slurries

Liquid CO2 Slurry for Feeding Low Rank Coal to Gasifiers U.S. DOE Award DE-FE0007977


Project Scope Tasks

• Task 1 - Conduct laboratory tests and evaluations

• Task 2 - Develop LCO2 slurry preparation system design

• Task 3 - Perform plant-wide techno-economic analyses

• Task 4 - Draft technology development roadmap

Leverage findings of initial tasks to support subsequent tasks.


Project Summary Teaming structure

DOE/NETL

Jenny Tennant Dr. Arun Bose

EPRI Jose Marasigan

WorleyParsons Group, Inc.

Harvey Goldstein

Dooher Institute of Physics and

Energy Prof. John Dooher

Columbia University

Prof. Marco Castaldi

ATS Rheosystems Steven Colo

Phillips 66

Tom Reynolds


Task 1: Conduct Lab Tests & Evaluations Summary

Task scope

• Coal characterization and preparation

– Montana Rosebud Powder River Basin (PRB)

– North Dakota Freedom Lignite

• Rheology tests

– All coals

– LCO2 and water slurries

• Slurry data analyses


Task 1: Conduct Lab Tests & Evaluations Conclusions

• Higher coal concentrations verified in LCO2

– PRB test, 68 wt% (LCO2) vs. 55 wt% (water)

– Estimate 75 wt% (LCO2) in commercial application

• Lower viscosities verified in LCO2 at same solids loading

– ~factor of 10 lower than comparable water slurry

– Estimate:

• <100 centipoise in commercial application

• LCO2/coal slurry atomizes to finer spray drop sizes

• “Slurryability” of coal in LCO2 relatively insensitive to coal

properties


Task 2: Develop LCO2 Slurry Prep System Summary

Task scope

• Design slurry preparation system that will function for all

design coals

– Batch system

– Continuous flow system

– Estimate capital and O&M cost of each system

• Conduct industry search and survey

– Related concepts/technologies applicable to LCO2 slurry

applications


IGCC Plant Configuration with Full CO2 Capture

Gasifier

Liquid CO2 /

Coal Feed

System

Air

Separation

Unit

CO2

Removal

Shift

Reactors

Gas

Cooling

and

Cleanup

Gas

Turbine

Class 7F

Pressure

Ratio 18:1

CO2 To Sequestration

or Beneficial Use

~2200 psig

Syngas

HRSG

Stack

Steam

Turbine

Heat Sink

Electric

Power

To Grid

~520 MWe

Transformer

Transformer

450 psig

Compress Intercool Compress

450 psig

Coal

Pile


Batch Process System Design Basis

• Slurry is 75% coal and

25% LCO2 by weight

• Minimize flashing of

LCO2 during mixing

• Use pressure vessel

to mix LCO2 and coal

• 250 psig (17 bar)

• -10°F (-23°C)

• Maximize use of

commercially

available equipment

CO2 SlurryCO2 Available


Coal

Preparation

(Grind/Dry)

Pressure

Boost/Feed

Heat Sink

Commercial

Refrigeration

Heat

Exchanger Heat

Exchanger

Coal/CO2

Mixing

Vessel

LCO2 / Coal Slurry Batch Prep/Feed System

From CO2

Compressor

To Gasifier

Coal

Pile

850 psig (59 bar)

Ethylene Glycol Loop

~250 psig

(17 bar)


Task 3: Plant-wide Techno-Economic Analysis Summary

• Evaluate 4 cases:

–Montana Rosebud PRB, water slurry feed

–Montana Rosebud PRB, LCO2 slurry feed

–ND Freedom Lignite, water slurry feed

–ND Freedom Lignite, LCO2 slurry feed

• Performance models based on ASPEN Plus

–E-Gas™ performance provided by Phillips 66 (now

CB&I)

• Economic analyses conform to design basis


Performance, Cost and LCOE Results 90% CO2 Capture

Case 1 Case 2 Case 3 Case 4

Coal PRB Lignite

Slurry H2O CO2 H2O CO2

Coal In (lb/hr) 679,576 672,160 976,416 912,612

Gross MW 741 718 822 762

ST Output (MW) 277 254 358 298

GT Output @ ISO (MW) 232 232 232 232

Aux. Load (MW) 204 213 246 245

Net Plant Power 537 504 577 517

Net Plant Heat Rate

(Btu/kWh, HHV) 10,836 11,420 11,210 11,680

Total Plant Cost (TPC)* $1,876 $1,890 $2,177 $2,107

COE, $/MWh 125.26 133.92 138.90 149.09

* Cost in million 2012 US dollars


LCO2 vs. Water Slurry for Low Rank Coals Evaluation Results Summary

• Reduced plant output and higher heat rate for PRB and for

ND lignite at 90% CO2 capture

– Shift steam requirement

– Parasitic load

– Reduced feedstock enthalpy

• Nominal change in capital cost of complete IGCC plant

• Increased COE for PRB and ND lignite

• No benefit for E-Gas™-based IGCC with 90% CO2 capture

– Incidental benefits in improved CGE are more than offset

by higher overall costs, increased complexity and

reduced output and efficiency


Comparison of Results with Previous Analyses

* Includes specific power consumption of ASU, Selexol and CO2 compression train only

ASPEN Analysis EPRI1

(2010)

MIT2

(2012)

DOE

S4B3 EPRI/WP

Gasifier GE GE-Radiant Quench E-Gas™ E-Gas™

Coal PRB PRB Lignite PRB PRB Lignite

Slurry H2O CO2 H2O CO2 H2O CO2 H2O H2O CO2 H2O CO2

Slurry bone dry

solids wt% 48.3 55 51 58 48 54 48.7 53 55.7 47 48

CGE (%HHV) +7 63 75 60 72 70 74.4 76 67.8 71.4

Aux. Power as % of

gross power 31 28.9 28* 26* 31* 27* 29.2 27.5 29.7 28 30.4

% Reduction of O2

with CO2

13 13 17 2.4 6.2

Net efficiency (%) 29.8 32.6 26.5 29 24.2 28.4 30.4 31.5 29.9 30.4 29.2

1 EPRI Technical Update 1021333, Program on Technology Innovation: Liquid CO2 Coal Slurry for

Feeding Coal to Gasifiers, June 2010. 2 Botero, C., Field, R., Brasington, R., Herzog, H., Ghoniem, A., “Performance of an IGCC Plant with

Carbon Capture and Coal-CO2-Slurry Feed: Impact of Coal Rank, Slurry Loading, and Syngas Cooling

Technology”, Industrial & Engineering Chemistry Research, ie3018093, 2012. 3 National Energy Technology Laboratory (NETL). “Cost and Performance Baseline for Fossil Energy

Plants Volume 3a: Low Rank Coal to Electricity: IGCC Cases”, DOE/NETL-2010/1399, May 2011.


Technology Development Roadmap Identify Pathway to Resolve Fundamental Issues

Source: John Dooher, Adelphi University


Acknowledgment and Disclaimer

Acknowledgment This material is based upon work supported by the Department of Energy National Energy

Technology Laboratory under Award Number DE-FE0007977.

Disclaimer This report was prepared as an account of work sponsored by an agency of the United

States Government. Neither the United States Government nor any agency thereof, nor

any of their employees, makes any warranty, express or implied, or assumes any legal

liability or responsibility for the accuracy, completeness, or usefulness of any information,

apparatus, product, or process disclosed, or represents that its use would not infringe

privately owned rights. Reference herein to any specific commercial product, process, or

service by trade name, trademark, manufacturer, or otherwise does not necessarily

constitute or imply its endorsement, recommendation, or favoring by the United States

Government or any agency thereof. The views and opinions of authors expressed herein

do not necessarily state or reflect those of the United States Government or any agency

thereof.


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Investigation of Liquid CO2 (LCO2) / Coal Slurry for ... · Jose Marasigan, EPRI Prof. John Dooher, Adelphi University (Dooher Institute of Physics & Energy) Harvey Goldstein, WorleyParsons