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Advancements in Clean Coal Technology,Wisconsin Joint Legislative Council Special Committee on Nuclear Power Madison Wisconsin Tom HewsonEnergy Ventures Analysis IncArlington VirginiaNovember 15 2006,Energy Ventures Analysis Inc,New Coal Capacity Required to Meet Growing US Power Need,NGCC,Coal,Nuclear,Renewable,Energy Ventures Analysis Inc,Coal Generation Demand by 2025,122,800 MW EVA Fuelcast Long Term Outlook 200687,000 MW: DOE Annual Energy Outlook 2006,Energy Ventures Analysis Inc,Most States Have Announced Coal Project(s),Highly Likely,Applied for Permits & Financing,Studied- No Final Decision,No known new Coal projects,Energy Ventures Analysis Inc,Clean Coal Technologies,Generation TechnologiesEnvironmental Control Technologies,Energy Ventures Analysis Inc,Clean Coal Generation Technologies,Pulverized Coal Fluid Bed CombustionIntegrated Coal Gasification Combined Cycle,Energy Ventures Analysis Inc,Pulverized Coal Accounts for Most of the 92,033 MW Announced New Clean Coal Projects,150 Projects as of 10/06,Energy Ventures Analysis Inc,Clean Coal Pulverized Coal Combustion,Dominate coal generation technology Two types: subcritical & supercriticalMost energy efficient coal technology in US today84 announced new coal projects Low technology risk, competitive cost40 Supercritical projects (31,420 MW)-Weston#4, Elm Road #1-220 Subcritical projects (10,252 MW)- Columbia EnergyAdvancements in materials, controls and temperature mixing led to improved performance and reliability,Energy Ventures Analysis Inc,PULVERIZED COAL BOILER LAYOUT,Source: Supercritical Boiler Technology Matures Richardson et al 2004 (Hatachi),Energy Ventures Analysis Inc,Subcritical vs. Supercritical,Source: Supercritical Plant Overview Ron Ott, Black & Veatch 2/04,Energy Ventures Analysis Inc,Pulverized Coal Technology,Source: Supercritical Plant Overview Ron Ott, Black & Veatch 2/04,Energy Ventures Analysis Inc,Fluid Bed Combustion,Source: US DOE,Energy Ventures Analysis Inc,Fluid Bed Combustion,Conventional technology 104 Boilers-8,900 MW in operation33 Projects- 12,897 MW of announced projects- including Mantiwoc and Nelson DeweyUp to 320 MW size range offeredGreater fuel flexibility(waste coals, pet coke, fuels,.)Lower heatrate efficiency vs. pulverized coalInherent low NOx rates from lower combustion temperatures (0.370.07#NOx/MMBtu),Energy Ventures Analysis Inc,Fluid Bed Combustion Technology Changes,Fluid Bed SizeBoiler size designs have been expanding increasing unit output (up to 320 MW)Improved sulfur capture performanceImproved mixing to lower Ca:S ratios and increased bed capture rate (up to 97%)Some designs added FGD controls to further decrease emissions (0.13-0.15#SO2/MMBtu)Increase steam cycle pressure,Energy Ventures Analysis Inc,Fluid Bed Combustion Technology Sizes Have Been Increasing,Energy Ventures Analysis Inc,Integrated Gasification Combined Cycle,117 plants with 385 Gasifiers in operation in 2004. These facilities produce mostly chemicals (37%), gas (36%) or power (19%) Multiple Gasification process technologiesEntrained flow (Shell, GE (Texaco)- Polk Co, Conoco-Phillips (Dow/Destec)- Wabash River)Fixed bed (Lurgi, EPIC)- Dakota Gasification CorpFluidized bed (Southern Co- Staunton, KRW-Pinon Pine)Current IGCC power technology applications focus on producing CO rich syngas that can be burned in turbines. Future IGCC technologies maybe developed to produce hydrogen rich syngas with maximum carbon capture (aka “zero emission” IGCC). 27 Proposed IGCC power projects17,296 MWIncluding Elm Road #3,Energy Ventures Analysis Inc,IGCC Overview,Energy Ventures Analysis Inc,IGCC Heatrate Penalty vs. Fuel Type,Energy Ventures Analysis Inc,Energy Ventures Analysis Inc,Availability Comparison,Energy Ventures Analysis Inc,Current Economics of New Baseload Generation,Energy Ventures Analysis Inc,Integrated Gasification Combined Cycle,Air vs. oxygen blown gasifiers potential to save Air separation unit costs, reduce onsite power consumptionDry vs. slurry fuel feed Improve energy efficiency by 2.6%Hot syngas clean-up Improve energy efficiency 1.0-1.5%Improve gasifier reliability to save redundancyGas turbine advancements new turbine classes (FB-H 2.2% improvement), hydrogen rich fuel combustion for carbon regulation worldShift reactor technology to maximize syngas CO2 capture and hydrogen production for carbon regulation Syngas mercury capture,Energy Ventures Analysis Inc,Flue-Gas Desulfurization to ReduceSulfur Dioxide Emissions,Selective Catalytic ReductionTo Reduce NOx Emissions,Activated Carbon Injection withCOHPAC to Reduce Mercury,MEA Scrubber to captureCarbon Dioxide Emissions,Energy Ventures Analysis Inc,Flue Gas Desulfurization,Large amounts of FGD retrofits required to meet comply with environmental requirements under both Acid Rain program and Clean Air Interstate Rule 100,603 MW of post 2005 announced FGD retrofits39,017 MW more FGD retrofits required by 2025All new coal units,Energy Ventures Analysis Inc,Flue Gas Desulfurization,Duct injection vs. FGD Regenerative vs. Non-regenerative reagents Wet vs. Dry Improved reagent reactivity Improved mixing designs to lower Ca:S ratios Larger reactor vessels Design removals steadily improving. Up to 98%Avg FGD emission rate- 0.34#SO2/MMBtuWeston #4 SCPC permit limit- 0.09#SO2/MMBtuElm Road SCPC#1-2 permit limit- 0.15#SO2/MMBtuElm Road IGCC draft limit- 0.03#SO2/MMBtu,Energy Ventures Analysis Inc,Selective Catalytic Reduction,EPA SIP Call and Clean Air Interstate Rule Require more NOx reductions. 24,080 MW of announced SCR Retrofits post 2005 (116,600 MW total retrofits when completed)Will need 100,000 MW more retrofits over next 10 years. Will continue to grow to 137,000 MW in 15 yearsAll new PC coal plants,Energy Ventures Analysis Inc,Selective Catalytic Reduction,Catalyst improvements Larger catalyst beds Cost vs. performance tradeoffs Fuel quality issues affecting SCR performanceDesign removals steadily improving. Up to 90% SCR designsAvg SCR rate 0.08#NOx/MMBtuWeston #4 permit limit- 0.06#NOx/MMBtuElm Road #1-2 permit limit- 0.07#NOx/MMBtuElm Road IGCC draft limit- 0.06#NOx/MMBtu,Energy Ventures Analysis Inc,Mercury Control,Mercury speciation Varies significantly by coal quality Oxidized mercury water soluble, high removal with FGDElemental mercuryNon-water soluble, not removed by most existing control configurations Particulate mercury Removed by existing particulate controls,Energy Ventures Analysis Inc,Mercury Removal Performance,Source: UARG Jan 2005,Energy Ventures Analysis Inc,2010 Coal-Fired Mercury Emissions,Energy Ventures Analysis Inc,Mercury Control R&D,Improve oxidized mercury capture rateFGD AdditivesIncrease oxidized mercury shareFuel additivesElemental mercury removalActivated carbon injectionNovel sorbent use Flue gas temperature control to improve adsorption,Energy Ventures Analysis Inc,Mercury Policy Issues,Some states have set very strict mercury emission rate targets that exceed current demonstrated technology capability. Fuel quality issues Some waste fuels have higher mercury contentsIncremental removal vs. overall removalTransport/deposition characteristicsWeston #4 permit limit- 1.7#Hg/TBtu or 88% controlElm Road #1-2 permit limit- 1.12#Hg/TBtu or 90% controlElm Road IGCC draft limit 5.6#Hg/TBtu or 95% control,Energy Ventures Analysis Inc,CO2 Control Alternatives,Improved energy efficiencyCo-fire/switch to lower carbon fuelsPre-Combustion Strip CO2 from IGCC syngas (FutureGen would convert CO rich syngas to hydrogen and CO2 improving overall system CO2 removal efficiency) Strip nitrogen gas from inlet combustion air (Oxyfuel) to lower flue gas volume Strip carbon dioxide from flue gas exhaust using absorption (MEA scrubber)- 4 US plants Research on using alternative scr

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