www.inl.gov Paris, France, Paris, 2013 5, April NEA/IAEAWorkshopExpert Nuclear,ofApplications TechnicalEconomicand Non of Assessment 01 526 208 [email protected] Dr. MichaelG. ProcessApplications Heat and Economics Next Generation NuclearPlant Industrial

- 1346

McKellar

- Electric Electric

Outline • Objectives • Advantages of HTGR Process Heat • Assumptions • Process Heat Applications • Hybrid Energy Systems • Conclusions

1 Objectives • The Next Generation Nuclear Plant (NGNP) Project, led by Idaho National Laboratory, is part of a nationwide effort under the direction of the U.S. Department of Energy to address a national strategic need identified in the Energy Policy Act of 2005—to promote the use of nuclear energy and establish a technology for hydrogen and electricity production that is free of greenhouse gas (GHG) emissions. • This presentation is a summary of analyses performed by the NGNP project to determine whether it is technically and economically feasible to integrate high temperature gas-cooled reactor (HTGR) technology into industrial processes.

2 Advantages of HTGR High-Temperature Process Heat • Reducing CO2 emissions by replacing the heat derived from burning fossil fuels, as practiced by a wide range of chemical and petrochemical processes, and co-generating electricity, steam, and hydrogen. • Generating electricity at higher efficiencies than are possible with current nuclear power generation technology • Providing a secure long-term domestic energy supply and reducing reliance on offshore energy sources • Producing synthetic transportation fuels with lower life cycle, well-to- wheel (WTW) greenhouse gas (GHG) emissions than fuels derived from conventional synthetic fuel production processes and similar or lower WTW GHG emissions than fuels refined from crude oil

3 Advantages of HTGR High-Temperature Process Heat

• Producing energy at a stable long-term cost that is relatively unaffected by volatile fossil fuel prices and a potential carbon tax, a price set on GHG emissions • Extending the availability of natural resources for uses other than a source of heat, such as a petrochemical feedstock • Providing benefits to the national economy such as more near-term jobs to build multiple plants, more long-term jobs to operate the plants, and a reinvigorated heavy manufacturing sector.

4 Assumptions: Process Models

• No heat loss in piping between HTGRs and process applications except with SAGD • Natural gas composition based on information published by Northwest Gas Association • Natural gas standard volume flow: 15.56°C (60°F) • Ambient inlet water temperature: 15.56°C (60°F) • Ambient inlet air temperature: 21.11°C (70°F) • Ambient pressure: Sea level (1 atmosphere absolute) • High-efficiency compressors and turbines: 80– 90% efficient • Steam generators: 25°C minimum temperature approach • Process heat exchangers: 10°C minimum temperature approach (except when demonstrated industrial experience indicates differently) • Intermediate heat exchanger: 25°C minimum approach temperature

5 Outputs and Assumptions: HTGR-Integrated Technology

• Energy products: electricity, process heat, and/or hydrogen • Power generation efficiency: 41–48% (calculated) • Temperature Difference across core ~ 375°C to 400°C • Heat output: 600 MW(t) • Primary circulator: 80% efficient 6 Assumptions: Economic Analyses • Plant economic life: 30 years (excludes construction time) • Construction period – Fossil plant: Three years – HTGR plant: Three years per reactor with 6 months stagger between reactor • Start-up assumptions for “nth-of-a-kind” HTGR – Operating costs: 120% of estimated operating costs – Revenues: 65% of estimated revenue • Plant availability: 90% • Internal rate of return (IRR): 12% • Inflation rate: 3% • Interest rate on debt: 8% • Repayment term: 15 years • Reactor capital cost assumptions for HTGR modules: – $2,000/kW(t) for plants with one or two modules

– $1,400/kW(t) for plants with three or more modules 7 Assumptions: Economic Analyses

• Tax basis assumptions

– Effective U.S.

income tax rate: 38.9%

– U.S. state tax: 6%

– U.S. federal tax:

35%

• MACRS depreciation:

15-year plant life

• Simplified business model in which a

single entity owns and

operates the industrial

and associated HTGR plants

8 High Temperature Gas-cooled Reactors – Application Beyond Electricity Reactor Temperature Range Covering Applications Evaluated To-date

Up to 850°C

High Temperature Reactors can provide energy production that supports wide spectrum of industrial applications including the petrochemical and petroleum industries Power Production

10 Hydrogen Production: High Temperature Steam Electrolysis

Natural Gas

Natural Natural Gas Gas

Water Sulfur Steam Removal System Water

Plant Water Exhaust Cooling Steam Water Towers Treatment Natural Water Gas

Water

Shift & Syngas Reformer H -Rich Syngas H 2 Conditioning 2

Exhaust CO2

11 Hydrogen Production: High Temperature Steam Electrolysis

12 Coal to Gasoline Production

N2

Gasoline Air Air Separation DME Synthesis DME Synthesis

Crude Crude O MTG 2 MeOH Products

Coal Milling & Methanol Gasoline Coal Coal Gasification Syngas Gasoline Drying Synthesis Purification

Light Fuel LPG Slag Gas Sour Gas CO Sulfur Plant CO 2 CO 2 Compression 2 Nuclear Heat Nuclear Power for Tail for Electrolysis Electrolysis and General Plant Support Gas (700°C) Gas Compression Power Water Cooling Sulfur Production Treatment Towers HT Steam H O 2 Electrolysis O2 & H2 General Plant Support Gasoline Light Fuel DME Synthesis DME Gas for Synthesis Power Water Cooling Topping Heat Production Treatment Towers Crude Crude MeOH MTG Products

Coal Milling & Methanol Gasoline Coal Coal Gasification Syngas Gasoline Drying Synthesis Purification

Nuclear Power Nuclear Power for for Syngas H2S Removal LPG Slag Compressors Sour Gas CO2 Sulfur Plant CO2 CO2 Tail Compression Gas

Sulfur Nuclear Power for CO2 Compressors

Nuclear Heat Integration 13 Nuclear Power Integration Coal to Gasoline Production

14 Gas to Gasoline Production

N2

Gasoline DME Synthesis DME Synthesis Air Air Separation O2

Crude Crude Steam MTG MeOH Products

Natural Sulfur Natural Natural Gas Methanol Gasoline Syngas Gasoline Gas Removal Gas Reforming Synthesis Purification

General Plant Support

LPG Nuclear Power Water Cooling Power for Production Treatment Towers Light Fuel Gas ASU and Gas

N2 Compression

General Plant Support Gasoline DME Synthesis DME Synthesis Power Water Cooling Air Air Separation O2 Production Treatment Towers Crude Crude Exhaust MTG MeOH Products

Natural Sulfur Natural Natural Gas Methanol Gasoline Syngas Gasoline Gas Removal Gas Reforming Synthesis Purification

Nuclear Power for Syngas Steam LPG Compressors Nuclear Heat for Reforming Fuel Gas (700°C)

Nuclear Heat Integration 15 Nuclear Power Integration Gas to Gasoline Production

16 Coal to Diesel Production

Plant Cooling Water Towers Treatment

HRSG Exhaust Power Air Air Separation O 2 Production

Tail Tail Gas Gas N2

Gasification & Product LPG Coal Milling & Syngas Fischer-Tropsch FT Coal Coal Syngas Upgrading & Naphtha Drying Cleaning & Synthesis Liquids Refining Conditioning Diesel

CO2 Slag

Sulfur Plant Sour Gas (Claus) and CO2 Sulfur CO2 CO2 Tailgas Sulfur Tail Compression Reduction Gas

HTGR HTGR Plant Power Cooling 850°C ROT 700°C ROT Water Production Towers Heat Generation Power Gen. Treatment

Nuclear Heat (He 825°C) He Return

High Power Temperature Tail Gas H O O & H 2 Electrolysis 2 2 Recycle Units Tail Gas

Coal Gasification & Product LPG Coal Milling & Fischer-Tropsch FT Coal Syngas Syngas Upgrading & Naphtha Drying Synthesis Liquids Air Conditioning Refining Diesel

CO2 CO2 Slag Recycle

Sulfur Plant Sour Gas (Claus) and CO Sulfur CO 2 Nuclear Heat Integration Tailgas Sulfur 2 Compression Reduction Tail Gas Nuclear Power Integration 17 Coal to Diesel Production

18 Gas to Diesel Production

N2

Tail Gas Air Air Separation O 2 Recycle

Tail Tail Gas Gas

Preforming & Product LPG Natural Sulfur Gas Fischer-Tropsch FT Autothermal Syngas Upgrading & Naphtha Gas Removal Mix Synthesis Liquids Reforming Refining Diesel

Steam Plant Power Cooling Water Production Towers Treatment

N2

Nuclear Heat Integration

Air Air Separation O2

Tail Gas Recycle Tail Gas Gas CO2 Removal, LPG Mix Preforming & Product Natural Hydrotreating Fischer-Tropsch FT Autothermal Syngas Upgrade & Naphtha Gas and Sulfur Synthesis Liquids Reforming Refining Removal Hot He Diesel

Steam Plant Nuclear Heat Hot He Water (He 675°C) Treatment

HTGR Power Cooling 850°C ROT Production Towers Heat Generation

He Return 19 Gas to Diesel Production

20 Ammonia Production: Gas to Ammonia To EOR or Sequestration Natural Urea Gas

CO2 Urea To UAN-32 CO2 Urea Natural Synthesis Synthesis Gas CO2 Stack Water Gas Natural NH3 Sulfur Gas Removal Syngas Ammonia Syngas NH Conditioning Synthesis 3 Ammonium Nitrate Natural Gas NH NH Fuel Gas 3 3 Ammonium Air Nitrate Exhaust Primary Reformer Ammonium Syngas General Plant Nitric Acid Nitric General Plant Support Steam Water Nitrate Nuclear Heat for Support Synthesis Acid Synthesis Natural Gas Preheat To EOR or Water Power Cooling (> 350°C) Sequestration Syngas Treatment Production Towers Power Nitric Nuclear Power for Production Acid CO2 Compressors CO2 Secondary Air CO2 Reformer Urea Synthesis Water Cooling Natural To UAN-32 Nuclear Power for Urea Treatment Towers Gas Synthesis CO2 Urea Granulator Stack Water Fans Gas Urea NH Sulfur 3 Removal Syngas Ammonia Syngas NH Conditioning Synthesis 3 Ammonium Air Nitrate Natural Gas NH NH Fuel Gas 3 3 Ammonium Nuclear Power for Nitrate Exhaust Ammonia Synthesis Primary Compressors and Ammonium Reformer Refrigeration Unit Nitric Acid Nitric Steam Water Nitrate Syngas Synthesis Acid Synthesis

Nuclear Heat for Nitric Nuclear Power for Primary Reformer – Syngas Nuclear Power for Acid Prill Tower Fans Replaces Natural Gas Compander Combustion (700°C)

Secondary Air Reformer Nuclear Power for Nuclear Heat Integration Air Compressor Nuclear Power Integration 21 Ammonia Production: Gas to Ammonia with HTSE To EOR or Sequestration Natural Urea Gas

CO2 Urea To UAN-32 CO2 Urea Natural Synthesis Synthesis Gas CO2 Stack Water Gas Natural NH3 Sulfur Gas Removal Syngas Ammonia Syngas NH Conditioning Synthesis 3 Ammonium Nitrate Natural Gas NH NH Fuel Gas 3 3 Ammonium Air Nuclear Power for Urea Nitrate H2O Granulator Fans Exhaust Primary Ammonium Reformer Nitric Acid Nitric Natural Gas CO2, CO2 Urea Steam Syngas General Plant Water Nitrate Natural Gas Synthesis Acid Burner H2O Purification Support Synthesis Syngas Urea To UAN-32 Power Nitric O Urea 2 Synthesis Synthesis Production Acid Topping CO2 O Heat for Secondary 2 Nuclear Power for Air HTE Reformer Ammonia Synthesis O2 Compressors and Water Cooling NH3 Treatment Towers Refrigeration Unit HT Steam Ammonia Water H H NH Electrolysis 2 2 Synthesis 3 Ammonium H2 Nitrate Nuclear Power Nuclear Heat NH for Compander NH Hydrogen 3 3 Ammonium For Electrolysis Air (700°C) Burner Nitrate N2 Nuclear Power H O, 2 Ammonium for Electrolysis N Nitric Acid Nitric 2 Water Nitrate Synthesis Acid Synthesis Nuclear Heat Integration Separation Nuclear Power Integration Water Nitric Nuclear Power for Acid Prill Tower Fans General Plant Support

Power Cooling Water Production Towers Treatment 22 Ammonia Production

For this study ammonia was converted to UAN-32 fertilizer 23 Ammonia Production

24 Seawater Desalination: Reverse Osmosis

25 Seawater Desalination: Multi-stage Flash Distillation

26 Seawater Desalination: Multi-Effect Distillation

27 Steam Assisted Gravity Drainage

28 Oil Shale

29 Bitumen Upgrading

30 Hybrid Energy Systems Process Integration

Optimized Analysis – System Integration

Process Modeling, Life-Cycle, and Economic Assessments

Wind Farm SMR-Renewable-Biomass HES Dynamic System Modeling Wind Farm

Wind Farm Shannon

ROT Diana

Lee Variable Power Generation SMR- 1. NuScale LWR a Grid 2. GE Prism MSR 3. Electricity

RIT GW-hr Battery Storage Tom Bob (with Rick) Hydrogen Production H2 Gas Reforming

Gases

Drying & Energy Systems Dynamics Fast Pyrolysis Hyrdotreatment Biomass Torrefaction Storage (450 - 500 C) Upgrading Research & Testing (200 - 300 C) Bio-Oils HES Example: Nuclear Hybrid System to Offset Fluctuations in Wind or Solar Power

Wind energy

heat Steam turbine power generators Nuclear energy Reliable base or intermediate power

fuel Steam steam Methane Methanol generation reforming synthesis carbon Synfuel Natural gas Hybrid Energy Systems Integrate Via • Energy sources • Storage • Industrial Processes • Power Production • Process Heat 32 • Instrumentation and Control Conclusions • Integration NGNP HTGRs with process heat applications greatly reduces greenhouse gas emissions • HTGRs produce electricity at higher thermal efficiencies (less heat loss, less water usage) than LWRs • Many HTGR integrated process heat applications are economically feasible (i.e. SAGD, GTL (Methanol path), GTL (Fischer Tropsch path) • A reactor outlet temperature of 850 C is ideal for many process heat applications • Imposed carbon taxes would help promote HTGR integrated process heat applications • Hybrid Energy Systems provides a means to effectively integrate renewable energy, nuclear energy, and process heat applications through storage, process heat, power production, instrumentation and control.

33 HTGR Process Heat Integration Team • Rick Wood, INL • Anastasia Gandrik, INL • Larry Demick, NGNP Alliance • Eric Robertson, INL • Michael McKellar, INL • Mike Patterson, INL • Lee Nelson, INL

34