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Doe/Netl-401/110907 Carbon Dioxide Capture from Existing Coal-Fired Power Plants DOE/NETL-401/110907 Final Report (Original Issue Date, December 2006) Revision Date, November 2007 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 therein 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 therein do not necessarily state or reflect those of the United States Government or any agency thereof. Carbon Dioxide Capture from Existing Coal-Fired Power Plants DOE/NETL-401/110907 Final Report (Original Issue Date, December 2006) Revision Date, November 2007 NETL Contact: Jared P. Ciferno Office of Systems Analysis and Planning Division Prepared by: Massood Ramezan, Project Manager Timothy J. Skone, Project Engineer Research and Development Solutions, LLC Nsakala ya Nsakala, and Gregory N. Liljedahl, Project Co-Leaders Alstom Power Inc. With Support From: Loren E. Gearhart, Principal Investigator ABB Lummus Global, Inc. Rolf Hestermann, Principal Investigator Alstom Power Generation AG Barry Rederstorff, Host Site Advisor American Electric Power National Energy Technology Laboratory www.netl.doe.gov This Page Intentionally Left Blank Carbon Dioxide Capture from Existing Coal-Fired Power Plants, Final Report TABLE OF CONTENTS TABLE OF CONTENTS ............................................................................................................................ i LIST OF TABLES .....................................................................................................................................iii LIST OF FIGURES ................................................................................................................................... vi ACRONYMS AND ABBREVIATIONS.................................................................................................. ix ACKNOWLEDGMENTS ......................................................................................................................... xi EXECUTIVE SUMMARY ........................................................................................................................ 1 1 INTRODUCTION................................................................................................................................ 1 1.1 Background......................................................................................................................................2 1.2 Current Study ..................................................................................................................................3 1.2.1 CO2 Capture Level Sensitivity Study...............................................................................................4 1.2.2 Solvent Regeneration Energy Sensitivity Study - A Look To The Future:...................................5 2 STUDY UNIT DESCRIPTION AND BASE CASE PERFORMANCE.......................................... 9 2.1 Study Unit Description ....................................................................................................................9 2.2 Base Case Performance Analysis .................................................................................................12 2.2.1 Calibration of the Boiler Computer Model....................................................................................12 2.2.2 Overall System Description and Material and Energy Balance (Base Case).................................13 2.2.3 Boiler Analysis Results (Base Case)..............................................................................................16 2.2.4 Steam Cycle Performance (Base Case)..........................................................................................17 2.2.5 Flue Gas Desulfurization System Analysis (Base Case) ...............................................................21 3 THE SENSITIVITY OF PLANT PERFORMANCE AND ECONOMICS TO CO2 CAPTURE LEVEL............................................................................................................. 23 3.1 Study Unit Modifications and Definition of the Amine-Based CO2 Capture Systems..................23 3.1.1 Design Basis for CO2 Capture Systems Retrofit Equipment and Performance Calculations (Cases 1-5) .....................................................................................................................................24 3.1.2 Boiler Island Modifications and Performance (Cases 1-5)............................................................32 3.1.3 Design and Performance of Advanced Amine CO2 Removal Systems (Cases 1-4)......................37 3.1.4 Process Description - CO2 Removal, Compression, and Liquefaction System (Cases 1-4) ..........37 3.1.5 Case 5/Concept A: Design and Performance of Kerr-McGee/ABB Lummus Amine CO2 Removal System ............................................................................................................................75 3.1.6 Steam Cycle Modifications, Performance, and Integration with Amine Process (Cases 1-5).......96 3.1.7 Project Construction Schedule (Cases 1-5)..................................................................................111 3.2 Summary and Comparison of Overall Plant Performance and Carbon Dioxide Emissions (Cases 1-5) ...................................................................................................................................113 3.2.1 Auxiliary Power and Net Plant Output ........................................................................................114 3.2.2 Net Plant Heat Rate and Thermal Efficiency...............................................................................115 3.2.3 CO2 Emissions .............................................................................................................................116 3.2.4 Steam Cycle Performance............................................................................................................118 3.2.5 Boiler Performance ......................................................................................................................119 3.3 Cost Analysis ...............................................................................................................................120 3.3.1 Cost Estimation Basis ..................................................................................................................120 3.3.2 Carbon Dioxide Separation and Compression System Costs ......................................................122 i Carbon Dioxide Capture from Existing Coal-Fired Power Plants, Final Report 3.3.3 Boiler Modification Costs............................................................................................................132 3.3.4 Flue Gas Desulfurization System Modification Costs.................................................................132 3.3.5 Let Down Steam Turbine/Generator Costs..................................................................................133 3.3.6 Charges for Loss of Power During Construction.........................................................................133 3.3.7 Summary of Total Retrofit Investment Costs ..............................................................................133 3.4 Economic Analysis ......................................................................................................................136 3.4.1 Economic Study Scope and Assumptions....................................................................................136 3.4.2 Economic Analysis Results..........................................................................................................140 4 ADVANCES IN POST COMBUSTION CO2 CAPTURE TECHNOLOGIES .......................... 147 5 SENSITIVITY OF PLANT PERFORMANCE AND ECONOMICS TO SOLVENT REGENERATION ENERGY .............................................................................. 149 5.1 Performance Analysis ...............................................................................................................150 5.1.1 Steam Cycle Modifications and Performance with Reduced Solvent Regeneration Energy.......154 5.2 Cost Analysis ...............................................................................................................................157 5.3 Economic Analysis ......................................................................................................................157 6 REPLACEMENT POWER DISCUSSION ................................................................................... 159 7 CONCLUSIONS AND RECOMMENDATIONS FOR FUTURE WORK ................................ 161 8 BIBLIOGRAPHY ............................................................................................................................ 164 9 APPENDICES ..................................................................................................................................A-1 9.1 Appendix I – Plant Drawings (Cases 1-5) ...................................................................................A-2
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