Sustainable Coal for our Grandchildren?

Australian Institute of Energy

Dr John Topper
Managing Director of IEA Clean Coal Centre and Operating Agent for the IEA Greenhouse Gas R&D Programme Melbourne, 30 April 2010

IEA Clean Coal Centre

www.iea-coal.org.uk

Italy Germany CEC Canada Austria Australia GCCSI

Japan

Poland

Rep. of Korea Spain UK USA Anglo Coal ESKOM Netherlands Group Schlumberger Eletrobras

IEA CCC MEMBERS

Beijing Research Inst Coal Chemistry Banpu Coal Assoc NZ Danish Power Group Swedish Ind Group Suek

BHEL

IEA Clean Coal Centre

www.iea-coal.org.uk

IEA GHG MEMBERSHIP

Contents

Coal Demand to 2030 The roadmap for sustainable use of coal and other fossil fuels State of the Art in coal fired power plant Up grading and replacing old coal fired power plant Routes for carbon capture Current status of carbon capture
IEA Clean Coal Centre www.iea-coal.org.uk

World primary energy demand in the Reference Scenario: this is unsustainable!

IEA WEO 2008

Mtoe

18 000 16 000 14 000 12 000 10 000 8 000 6 000 4 000 2 000 0 1980 1990 2000 2010 2020 2030

Other renewables Hydro Nuclear Biomass Gas Coal Oil

World energy demand expands by 45% between now and 2030 an average rate of increase of 1.6% per year with coal accounting for more than a third of the overall rise

The continuing importance of coal in world primary energy demand

IEA WEO 2008 Increase in primary demand, 2000 - 2007
Mtoe 1 000 900 800 700 600 500 400 300 200 100 0 Coal Oil Gas Renewables Nuclear 2.2% 20% 0.8% 0% Non-OECD OECD 1.6% 60% 4.8% 100% % = average annual rate of growth 80%

Shares of incremental energy demand Reference Scenario, 2006 - 2030

Coal All other fuels

2.6%

40%

Demand for coal has been growing faster than any other energy source & is projected to account for more than a third of incremental global energy demand to 2030

Global electricity generation (450 ppm Scenario)

100%

1% 1% 18% 16% 15% (1%)

9% 4% 5% 22%

40%

75%

Wind Hydrogen Other Renewables Biomass & Waste

20%
50%

6%

18% 18%

Hydro Nuclear Gas Oil Coal

25%

41%

2% 21%

0% 2006 2030

World Energy Outlook 2008, IEA

Renewables and nuclear power will increase. The share of renewables would achieve 40%. The share of coal halves to 21%, coal will remain one of the largest electricity sources.

People without access to electricity in IEA WEO Reference Scenario (millions)

World population without access to electricity 2008: 1.5 billion people 2030: 1.3 billion people
$35 billion per year more investment than in the Reference Scenario would be needed to 2030 equivalent to just 5% of global power-sector investment to ensure universal access

TOP DOWN CCS ROADMAP

IEA Clean Coal Centre

www.iea-coal.org.uk

The ETP BLUE Map Scenario

OECD/IEA 2009

CCS deployment in the BLUE Map Scenario

Number of Projects

There is an ambitious growth path for CCS from 2010 to 2050

MtCO2/year Captured

A Global Challenge

CCS will be required in all regions of the world in power, industry and upstream

An ambitious growth pathway

MtCO2/year Captured OECD regions must lead in demonstrating CCS, but the technology must quickly spread to the rest of the world

CCS is not just a clean coal

Coal power only makes up around 40% of stored emissions in 2050

Demonstration to Commercial

New build projects

Expanded collaboration on CCS R&D and technology transfer will be critical

Coal Fired Power Plant State of the Art

IEA Clean Coal Centre

www.iea-coal.org.uk

Recent Plant State-of-the-Art Conditions

G8 Case study plants Studstrup (DK) 540/540 Maatsura 1 (J) 538/566

610

Esbjerg (DK) 560/560

Max SH Steam Temperature, C

600 590 580 570

Ultrasupercritical

Schwarze Pumpe (D) 547/565 Maatsura 2 (J) 593/593 Haramachi 2 (J) 600/600 Nordjylland (DK) 580/580/580 Boxberg (D) 545/581 Tachibanawan 1 (J) 600/610

Supercritical
560 550 540 530 1980 1985 1990 1995 2000 2005 2010

Avedore (DK) 580/600 Niederaussem (D) 580/600 Hekinan (J) 568/593 Isogo (J) 600/610 Yunghung 566/576 Genesee 3 580/570 Hitachinaka (J) 600/600

Year
IEA Clean Coal Centre

Torrevaldaliga (I) 600/610 Huyan (China)

www.iea-coal.org.uk

Nordjylland 3, Denmark
USC, tower boiler, tangential corner firing, int. bituminous coals, cold sea water

Most efficient coal-fired plant Operating net efficiency 47% LHV, power only mode/44.9% HHV (not annual) High steam conditions 29 MPa/582C/580C/580C at boiler by early use of new materials (P91) Large number of feedwater heating stages Double reheat has prevented LP blade erosion Very low emissions and full waste utilisation NOx abatement Combustion measures and SCR Particulates removal ESP Desulphurisation Wet FGD
IEA Clean Coal Centre www.iea-coal.org.uk

Niederaussem K, Germany
USC, tower boiler, tangential wall firing, lignite of 50-60% moisture, inland

Most efficient lignite-fired plant Operating net efficiency 43.2% LHV/37% HHV High steam conditions 27.5 MPa/580C/600C at turbine; initial difficulties solved using 27% Cr materials in critical areas Unique heat recovery arrangements with heat extraction to low temperatures complex feedwater circuit Low backpressure: 200 m cooling tower, 14.7C condenser inlet Lignite drying demonstration plant being installed to process 25% of fuel feed to enable even higher efficiency NOx abatement Combustion measures Particulates removal ESP Desulphurisation Wet FGD
IEA Clean Coal Centre www.iea-coal.org.uk

E On 50% efficient plant

50 plus by using new nickel alloy superheater tubing at 700C Location Efficiency Capacity Investment Start of operation Wilhelmshaven 50 % 500 MWe 1 billion ++ 2014? 2010? Material development Request for proposal 2014?

2007 Size of plant Search for location

IEA Clean Coal Centre

Construction Start of operation

www.iea-coal.org.uk

CO2 emission reduction pathways

Average worldwide 30.0% 1116 gCO2/kWh gCO2/kWh 38% 881 gCO2/kWh 45% 743 gCO2/kWh 50% 669 gCO2/kWh Advanced R&D State-of-the art PC/IGCC

EU average

but deep cuts only by

CCS

adapted from VGB 2007; efficiency HHV,net

<2020

Energy Efficiency makes big change but deep cuts of CO2 emission can be done only by Carbon Capture and Storage (CCS)

Potential for CO2 emissions reductions by adopting state of the art

Coal-fired power and CHP plants worldwide account for ~25% of total CO2 production

Replacement potential - ~300 GW Upgrade potential - up to 200 GW Replacement or upgrade of some units under progress or already planned Globally 1.35 - 1.7 billion ton/annum of CO2 reduction possible by moving to current state of the art pc-plants about 5% of global anthropogenic emissions

OECD/IEA 2008

Upgrading of low value coals

Why upgrade low value coals?
Lignite drying Niederaussem K

to improve coal quality: e.g. reduced moisture content, ash content and increased heating value to suppress low-temperature oxidation/self-heating during transport and storage to improve the consistency of coal properties

How to upgrade?

washing drying dry separation ultra-clean coal processes briquetting and pelletising

Ultra clean coal UCG Ltd Australia

IEA Clean Coal Centre

www.iea-coal.org.uk

Carbon capture and storage

Three Options; Post-combustion Pre-combustion Oxyfuel Three Options; Coal seams, 40 Gt CO2 Oil and gas fields, 1,000 Gt CO2 Deep saline aquifers up to 10,000 Gt CO2

Two Options; Pipelines Ships

Capture

Transport

Storage

IEA Clean Coal Centre

www.iea-coal.org.uk

Post Combustion Capture by Solvents

courtesy Vattenfall

IEA Clean Coal Centre

www.iea-coal.org.uk

Chinas 1st Post Combustion CO2 Capture Pilot Plant

The design parameters are: Flue gas flow to unit 2000-3000 Nm3/h Steam consumption 3GJ/tonne CO2 Solvent consumption < 1.35 kg/tonne CO2 Owners: Huaneng CSIRO assisted
IEA Clean Coal Centre www.iea-coal.org.uk

Vattenfall Oxy Fuel Technology

(Courtesy Vatenfall)

The size of the plant is about 30 MWth Operational since late 2008 Located at Schwarze Pumpe in Germany Trials withlignite and hard coals

IEA Clean Coal Centre

www.iea-coal.org.uk

Alstom Hitachi Babcock IHI Alstom / AL CIUDEN CIUDEN ENEL HP Oxyfuel

Schwarze Pumpe Schwarze Pumpe Callide Lacq El Bierzo CFB Facility El Bierzo PC Facility Brindisi Test Facility

2008 2010 2011 2009 2011 2011 2012

30MWth 30MWth 30MWe 30MWth 30MWth 20MWth 48MWth

Lignite Lignite Coal Gas/Oil? Coal Coal Coal

Vattenfall - Janschwalde (PC -250MWe) KEPCO/KOSEP - Yongdong (PC - 100MWe) Black Hills Power - Wyoming (PC - 100MWe) FW/Praxair HBPW Michigan (CFB - 78MWe) Endesa/CIUDEN - El Bierzo (CFB - 300MWe)

2009 Lacq Worlds first 30MWt retrofitted Oxy-NG boiler 2008 Worlds FIRST 30 MWt full chain demonstration at Schwarze Pumpe Pilot Plant 2007 2003 - 2005 B&W CEDF (30MWt) large scale burner testing started

2011 Callide Worlds first 30MWe retrofitted Oxy-coal power plant

Target : Commercialised by 2020

By 2014-2018 Demonstration of 50 300MWe full scale power plant.

2011 CIUDEN Worlds first 30MWt Oxy-CFB Pilot Plant

1990 - 1995

Vattenfall (ENCAP ++) 1998 2001 CS Energy / IHI Callide Project CANMET US DOE Project / B&W / Air Liquide

1980s

EC Joule Thermie Project - IFRF / Doosan Babcock / Intl Combustion NEDO / IHI / Jcoal Project First large scale 35MWt Oxy-Coal Burner Retrofit Test done by International Combustion

By the end of 2010/2011, Users (i.e. Power Plant Operators) will have 6 burner manufacturers fully demonstrating Utility Size Large Scale Burners which should give a high level of confidence toward demonstration

ANL/Battelle/EERC completed the first industrial scale pilot plant

B&W Alstom Doosan Babcock

CEDF Alstom CE DBEL - MBTF

2008 30MWth Coal 2010 15MWth Coal 2009 40MWth Coal

Updated by S. Santos (05/09/09)

Development of IGCC by RWE Power

RWE Power will develop a zero-CO2 lignite-fired IGCC in Germany Plant will be commissioned with CO2 transport and storage if market and regulatory conditions are appropriate
Capacity: Net efficiency (target): CO2 storage: Commissioning:
IEA Clean Coal Centre

450 MWgross, 360 MWnet 40% 2.6 million tonnes per year in depleted Gas reservoir or saline aquifer 2014
www.iea-coal.org.uk

Green Gen The first Chinese IGCC

Near Tiajin, southeast of Beijing. The first phase of GreenGen is expected on line in 2011, generating 250MWe, expanding to 650 megawatts in later phases.
IEA Clean Coal Centre www.iea-coal.org.uk

Power Generation CCS projects worldwide Main projects (>100MW)

Power Generation CCS projects worldwide Emerging CCS world

CCS activities using low rank coals - Projects and proposals

IEA Clean Coal Centre

www.iea-coal.org.uk

OECD roadmapping PCC

Current position (2009)
COMMERCIAL USC TO 25-30 MPa/600C/620C 46% NET, LHV, BITUM COALS, INLAND, EU, EVAP TOWER COOLING, (44%, HHV). ON HIGH MOISTURE LIGNITE 43% NET, LHV, SIMILAR CONDITIONS (37%, HHV) Emissions on bitum coals: Particulates 5-10 mg/m3 SO2 <20 mg/m3 NOx 50-100 mg/m3 dry systems can give lower emissions

From IEA Clean Coal Centre Report ccc152

2009-2015
COMMERCIAL USC TO 25-30 MPa/600C/620C

2015-2017
COMMERCIAL USC TO 25-30 MPa/600C/620C 700C DEMOS

2017-2020
COMMERCIAL USC TO 35 MPa/700C/720C

2020-2025
COMMERCIAL CCS USC TO 35 MPa/700C/720C (scrubbing only for 700C technology) COMMERCIAL OXYCOAL USC TO 30 MPa/600C/620C

2025-2030
COMMERCIAL CCS USC TO 35 MPa/700C/720C RANGE OF CAPTURE SYSTEMS

Post-2030
COMMERCIAL CCS USC ROUTINELY BEYOND 35MPa/700C/720C ALL CAPTURE SYSTEMS ALL COALS, ALL FIRING CONFIGURATIONS 45%+ NET, LHV, INC CO2 CAPTURE, ALL COALS

R&D, PILOT TESTS Materials, cycles CO2 capture

R&D materials Side-stream CCS

R&D Materials Novel post-comb Oxy-coal materials 700C

FULL FLOW CCS DEMOS ON USC 600C PLANTS

ADVANCED FULL FLOW CCS DEMOS (scrubbing only for 700C technology)

OXY-COAL CCS DEMO 700C TECHNOLOGY

>700C/720C DEMOS, ALL WITH CCS, VARIOUS TYPES R&D materials

Full environmental controls at at least 2009 state-of-theart emissions

Near-zero emissions all coals: Particulates <1 mg/m3 SO2 <10 mg/m3 NOx <10 mg/m3 99% mercury removal 90% CO2 capture

R&D Oxy-coal materials 700C

Emissions on all coals: Particulates 1 mg/m3 SO2 10 mg/m3 NOx 10 mg/m3 90% mercury removal

2015-2017: 500 MWe 700C PCC demo in Europe should be supplemented with other demos. Sidestream CO2 capture needed 2017-2020: 700C plants should be offered commercially, supported by continuing materials dev/testing Full-flow CO2 scrubbing demo should be designed on a 700C plant for this period and oxy-coal material tests should be conducted at these steam temperatures Demonstration of 700C technology with oxy-firing would follow in 2020-2025, commercialisation later IEA Clean Coal Centre www.iea-coal.org.uk

OECD roadmapping IGCC

Current position (2009)
5 DEMOS/EX- DEMOS OPERATE, 250-300MWe VARIOUS ENTRAINED GASIFIERS ON VARIOUS COALS 600 MWe COMMERCIAL PLANTS UNDER CONSTRUCTION. HIGHER CAP. COST THAN PCC BUT COST W. CAPTURE COMPETITIVE. 40-43% NET, LHV, 46% NEW PLANTS (LATEST F-TURBINES) ON BITUMINOUS COALS

From IEA Clean Coal Centre Report ccc152

2015-2017
85% AVAILABILITY COMMERCIAL PLANTS WITH LATEST F- AND W-CLASS GTs. SOME WITH PARTIAL CAPTURE COMMERCIAL OP OF NEW WATER QUENCH GASIFIERS

2009-2015
CONSTRUCT , OPERATE COMMERCIAL PLANTS WITH LATEST F AND W TURBINES

2017-2020
HGH AVAILABILITY COMMERCIAL PLANTS OPERATING WITH LATEST F- AND WCLASS GTs VARIOUS GASIFIER TYPES

2020-2025
COMMERCIAL PLANTS OPERATING WITH HOR J-GTs ABLE TO BURN HIGH HYDROGEN FULL CO2 CAPTURE AVAILABLE CAPITAL COST COMPARABLE WITH PCC FOR NON-CAPTURE SYSTEMS EFFICIENCY 50%+ LHV BASIS ON ALL COALS (NO CO2 CAPTURE)

2025-2030
90% AVAILABILITY COMMERCIAL IGCC WITH H- OR J-CLASS GTSs WITH ULTRA-LOW NOx ON HYDROGEN FUEL

Post-2030
CO2 CAPTURE AS STANDARD USING GAS SEPARATION MEMBRANES CAPITAL COST LOWER THAN PCC WITH CCS 45%+, LHV, INC CO2 CAPTURE, ALL COALS ITM OXYGEN AS STANDARD WITH ITMOPTIMISED H2 GT DRY GAS CU INCL MERCURY FUEL CELLS IN SOME PLANTS EVENTUALLY OTHER SYSTEMS WITH CO2 GTs CO2/H2O GTs

Emissions: Particulates <1 mg/m3 SO2 <20 mg/m3 NOx <50 mg/m3; SCR will allow lower levels Mercury capture demonstrated

R&D AND PILOT REDUCE CAP COST INCREASE AVAILABILITY EXTEND RANGE OF COALS GAS TURBINE DEVELOPMENTS OPTIMISE IGCC BLOCKS DEVELOPMENT OF DRY SYNGAS CLEANING NON-CRYOGENIC AIR SEPARATION, e.g. ITM

PROVE ABOVE OPERATE ON HIGH HYDROGEN FUELS WITH SATISFACTORY NOx EMISSIONS SO CAPTURE COMPATIBLE
REDUCE COST EXTEND RANGE OF COALS ITM DEMO IGCC PARTIAL FLOW DEMOS OF HGCU SIDESTREAM GAS CU+FUEL CELL

DEVELOP H-CLASS IGCC GT DEVELOP GT FOR ITM CYCLES DEVELOP NOVEL GASIFIER DESIGNS NEW POWER CYCLES PILOT GAS CLEANING+ FUEL CELLS TESTS

COMMERCIAL SCALE DEMO OF DRY GAS CLEANUP DEMONSTRATE ITM O2 IN IGCC WITH ITM-OPTIMISED GT

DEMONSTRATE ITM OXYGEN SUPPLY IN IGCC

DEVELOP CO2 GTs DEMONSTRATE LARGE FUEL CELLS ON SYNGAS DEMONSTRATE ULTRA-DEEP SYNGAS CLEANING FOR FUEL CELLS

DEMONSTRATE NON-CRYOGENIC AIR SEPARATION

SLIPSTREAM TEST OF FUEL CELL ON ULTRA-CLEAN SYNGAS

FULL FLOW PRECOMB CCS DEMOS USING SHIFT+SCRUBBING

ADVANCED CCS DEMOS

Emissions: Particulates 0.1 mg/m3 Emissions of SO2 and NOx <10 mg/m3 90% mercury removal

Near-zero emissions, all coals: Particulates 0.1 mg/m3 SO2 <10 mg/m3 NOx <10 mg/m3 99% mercury removal

Full emissions controls at at least 2009 state-of-the-art

IEA Clean Coal Centre

www.iea-coal.org.uk

CCS Barriers and Hurdles

Barriers and Hurdles are primarily non-technical Real Political will global agreement lacking Regulation Finance Social acceptability of Transport Routes and Storage WHAT IS PLAN B?
IEA Clean Coal Centre www.iea-coal.org.uk

CONCLUSIONS
Even if ambitious targets for achieving 450ppmCO2 are achieved, the world will still be using very substantial amounts of coal Coal use will be increasingly in developing countries where pressures to maintain economic growth and increase living standards could take precedence. Decarbonising power and industrial use requires thousands of projects, will cost around $3.5 trillion and will encompass, coal and gas fired power, large industrial use of fossil fuels and after 2030 be very dependent on actions in non-OECD countries Immediate action is required for sustainability and much of it to address non-technical issues
IEA Clean Coal Centre www.iea-coal.org.uk

THE END
Thank you for Listening John.topper@iea-coal.org +44 20 8780 2111 www.iea-coal.org.uk
IEA Clean Coal Centre www.iea-coal.org.uk

Geological Storage Options

Unminable Coal Seams 30 Gt CO2

Able to store <2 Years of 2030 Emissions

Depleted Oil & Gas Fields 930 Gt CO2

Able to Store 50 Years of 2030 Emissions

Deep Saline Aquifers 400-10 000 Gt CO2

Able to store 20 - 530 Years of 2030 Emissions

Largest CO2 Storage Projects

Snohvit capturing and injecting 0.7Mt/y CO2 since 2008

Rangeley injecting 0.8 Mt/y CO2 since 1980s

Sleipner capturing and injecting 1Mt/y CO2 since 1996

Total Anthropogenic CO2 captured Weyburn capturing and injected currently 5 Mt/y
and injecting 1.6 Mt/y CO2 since 2000 In-Salah capturing and injecting 0.8 Mt/y CO2 since 2004

Sleipner CO2 injection

Time-lapse seismic data

1994

2001
Utsira Fm.

CO2 plume in map view

2008

2008-1994

How Does the CO2 Stay Underground?

Structural Trapping
CO2 moves upwards and is physically trapped under the seals
Dissolution of CO2

Residual storage

Dissolution

CO2 becomes stuck between the pore spaces of the rock as it moves through the reservoir CO2 dissolves in the formation Residual trapping of CO2 water The CO2 can react with minerals in the rock forming new minerals
Mineral trapping of CO2

Mineralisation