NETL/FE technologies for value-added applications in a deeply decarbonized economy

David Lyons Acting Technology Manager Gasification and Coal/Coal-Biomass to Liquids November 16, 2016

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NETL Core Competencies

Computational Science &

Engineering

High Performance Computing

Data Analytics

Materials Engineering & Manufacturing

Structural & Functional

Design, Synthesis &

Performance

Geological & Environmental

Systems

Air, Water & Geology

Knowledge & Mitigation

Energy Conversion Engineering

Component &

Device

Design & Validation

Systems Engineering & Analysis

Process & System

Optimization, Validation & Economics

Effective Resource Development • Efficient Energy Conversion • Environmental Sustainability

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NETL Coal Program Technology Thrusts Advanced Energy Systems

• Efficient Energy Conversion • Zero-Emissions Power Production • Minimize Water Use and Discharge

Carbon Capture

• Cost-Effective Capture Systems • Minimize Energy Penalty for Capture and Compression • Smaller Capture System Footprint

Carbon Storage

• Safe, Effective, Long-term Storage • Monitoring, Verification, Accounting, and Assessment • Demonstrate Storage Infrastructure

Crosscutting Research & Analysis

• High-performance Materials • Sensors and Controls • Enabling Technologies

STEP (Supercritical CO2)

• High-efficiency Power Cycle • Reduced Water Consumption and Air Emissions • Reduced Power Cycle Footprint

Rare Earth Elements

• Efficient Rare Earth Element (REE) Recovery • Cost-Competitive Domestic Supply of REEs • Coal Byproduct Utilization

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Advanced Energy Systems Advanced Combustion Systems

• Oxy-Combustion • Chemical Looping

Combustion • Enabling

Technologies/Innovative Concepts

Coal and Coal-Biomass to Liquids • Biomass Feed and

Gasification • Reactor Engineering Design • Advanced Fuels Synthesis • Site-Specific Coal Conversion

Gasification Systems • Air Separation • Reactor Engineering Design • Site-Specific Coal Conversion • Novel Technologies to

Advance Conventional Gasification

STEP (Supercritical CO2) • Turbomachinery • Recuperators • Advanced Concepts for Direct-Fired

Cycles • Systems Integration and

Optimization Solid Oxide Fuel Cells

• Cell Technology • Core Technology • Systems Development

Advanced Turbines • Advanced Combustion Turbines • Turbomachinery for sCO2 Power

Cycles • Pressure Gain Combustion

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NETL Oil & Natural Gas Technology Thrusts

Unconventional Oil & Gas

Developing technologies to maximize recovery and reduce environmental impact from unconventional oil & gas development.

Transmission & Delivery

Developing technologies and practices to mitigate emissions from natural gas transmission, distribution, and storage facilities.

Methane Quantification Assessing current methane emissions data and addressing data gaps.

Methane Hydrates Unlocking the mysteries of methane hydrates and developing ways to tap their massive energy potential.

Offshore Minimizing the environmental impacts of deepwater and ultra-deepwater oil and natural gas production.

Advancing Technologies to Ensure Safe and Prudent Oil & Gas Development

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NETL Supported Power Generation Technologies

2nd-Generation Transformational Bio-Gasification

AUSC Steam Cycles

Integrated Gasification Fuel Cells (IGFC)

Direct Power Extraction

Chemical Looping

Supercritical CO2 Cycles

Transformational CO2 Separation

Transformational H2 Production

Pressurized Oxy-Combustion

Pressure Gain Combustion

65% LHV Combustion Turbines

Atmospheric Oxy-Combustion

Radically Engineered Modular Systems (REMS)

Warm Syngas Cleanup

Oxygen Production

Pre-Combustion CO2 Capture

High-Pressure Dry Feed

Combustion Turbine

Components

DG SOFC

ASPECTS ALSO APPLICABLE TO HYDROGEN

Gasif

icat

ion

Com

bust

ion

Sensors & Controls

Simulation-Based Engineering

Water Management

High-Performance Materials

Post-Combustion CO2 Capture

Oxygen Production

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Solving Technology Challenges • Hydrogen combustion with low single digit NOx

• Solved for 2,650 oF turbine inlet temperature (TIT) (TRL 1 -> 7) • UTSR essentially identified & solved the basic science needed to

understand ignition delay for H2 combustion • Adv. mfg. applied to realize the design required by the physics • Approach will revolutionize low NOx combustion for H2 & natural gas!

Advanced Turbine Program • Adv. combustion turbines for H2 fuels (IGCC, NGCC) – 1 of 3 Key

Technology Areas • CC eff. ~ 65 % (LHV, NG bench mark), TIT of 3,100 oF • Components Approach TRL ~ 3 --- > TRL 6 - 7 • Delivers transformational performance benefits by 2025 for coal

based IGCC with CCS (ready for full-scale demonstration) • Delivers another $20/T reduction in CO2 capture cost

2nd Generation targets met (H2 Turbine Program) • COE reduction of ~15% and cost of capture reduction of

~$19/tonne • Eff. improvements of 3% pts. (4.3% pts. vs. 2003 IGCC with 7FA)

Advanced Turbines How H2 is Playing a Role

Turbine Improved aerodynamics, longer airfoils for a larger annulus / higher mass flow and improved internal cooling designs to minimize cooling flows while at higher temperatures

Combustor Combustion of hydrogen fuels with single digit NOx, no flashback, and minimal combustion instability

Compressor Improved compressor

efficiency through three- dimensional aero dynamics for higher pressure ratio

Rotor Increase rotor torque for higher power output and the potential for lowering capital cost ($/kW)

Materials Improved TBC, bond coats and base alloys for higher heat flux, thermal cycling and aggressive conditions (erosion, corrosion and deposition) in IGCC applications

Leakage Reduced leakage at tip and wall interface and reduced recirculation at nozzle/rotating airfoil interface for higher turbine efficiency and less purge Photo courtesy of Siemens Energy

Exhaust Diffuser

Improved diffuser designs for higher temperature exhaust, lower pressure drop with increased mass flow

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Fuel

Air

Power out

Power to grid

Exhaust

Balance-of-Plant

Balance-of-Plant Fuel Cell Stacks Module

Solid Oxide Fuel Cells provide many benefits ….. Environmentally friendly

• Intrinsic carbon capture (CCS) capability • Meet (without CCS) EPA Carbon Pollution Standards

- Natural gas fueled: 1,000 lb. CO2/MWh-gross - Coal fueled: 1,400 lb. CO2/MWh-gross

• Near-zero SOx and NOx • Minimal water consumption, ~1/3 of the amount

relative to combustion processes High efficiency

• >60% (HHV) electrical • >85% (HHV) combined heat and power

Fuel Flexible • Natural gas, syngas, propane, biogas, logistics fuels,

hydrogen Modular

• Incremental capacity additions • Ideally suited for distributed generation applications

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Enabling Gasification-based Technology

WATER

COAL

OXYGEN

BIOMASS

POWER

LIQUID FUELS

FERTILIZER

CHEMICALS HYDROGEN

GAS CLEANUP/

GAS SEPARATION

GASIFIER

CO2 (for reuse/storage)

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Coal

Particulate Removal

Gas Cleanup

Shift Reactor

Synthesis Gas Conversion Transportation Fuels

and Chemicals

Carbon Dioxide Utilization & Storage

Hydrogen

Gasifier

Generator

Electric Power

Electric Power

Heat Recovery Steam Generator

Steam

Steam Turbine

Stack

Steam

Combustor

Fuel Cells

Gas Turbine

Air Separator

Oxygen

Slag By-product

Sulfur By-product

Fly ash By-product Gaseous Constituents

Solids

Hydrogen Separation

Generator

Feed Pump

Syngas Cooler

Gasification Systems/CBTL H2:CO ~2:1

90%

Coal-Biomass Mixtures

Compressed Air

Co-Production Particulates

Technology Components

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Products that can be made from syngas

Molecules of H2 and CO contained in synthesis gas are building blocks that can be used to synthesize a wide variety of complex hydrocarbons & organic compounds

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Utilization of CO2 as a Raw Material

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Mineralization

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Chemical Looping Combustion Benefits • Transformational cost reduction potential • No need for O2 production • High CO2 concentration in exhaust • Uses conventional materials and fabrication

techniques • Leverages large-scale CFB experience,

especially with limestone carriers

Fuel Reactor

Oxygen Carrier (reduced)

CO2 (w/ H2O)

Coal

Air Reactor

Air

Vitiated Air

(Heat) Oxygen Carrier (oxidized)

R&D Activities • Limestone-based chemical looping combustion • Iron-based chemical looping combustion • Chemical looping combustion with oxygen

uncoupling • Pressurized chemical looping • H2 production from syngas • Chemical looping coal gasification • Chemical looping oxygen carrier development

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Chemical Looping Gasification – OSU

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Chemical Looping Gasification – Alstom

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Chemical Looping Gasification – GE

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Hydrogen Production and Use NETL Mission Space

NETL Mission Space

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Solutions for Today…Options for Tomorrow

For More Information www.netl.doe.gov