Ibrahim Gulyurtlu

1. SIXTH INTERNATIONAL CONFERENCE ON CLEAN COAL TECHNOLOGIES CCT2013 Clean Coal Technologies - What roadmap for R&D Ibrahim Gulyurtlu 12-16 MAY 2013, THESSALONIKI GREECE

2. Clean Coal Technologies - What roadmap for R&D • Introduction • CO2 considerations • CoalutilisationtechnologiesandResearchareas for furtherdevelopment • CO2 sequestrationoptionsinthelong-term • Some examples • Programmesof US, Japan , andEurope • Future conceptsofpowerplants • 9. Conclusions

3. Clean Coal Technologies - What roadmap for R&D Introduction

4. Clean Coal Technologies - What roadmap for R&D Coal continues to be the most abundant fossil fuel in the world but its wider use, particularly in developed countries heavily relies on technological developments for clean coal utilization in the energy market. Clean coal technologies (CCTs) developed in the last 40 years have been developed with the objective being deployed reduce the environmental consequences of the use of coal with particular attention on SO2, NOx, particulate matter and very recently on mercury.

5. Clean Coal Technologies - What roadmap for R&D Clean coal technologies (CCTs) developed in the last 40 years have been developed with the objective being deployed reduce the environmental consequences of the use of coal with particular attention on SO2, NOx, particulate matter and very recently on mercury. Short-term objective is basically to ensure that the existing fleet of power plants respect with the present and emerging regulations through cost-effective measures to have the most adequate environmental control.

6. Clean Coal Technologies - What roadmap for R&D • Roadmap objectives, scope and structure, in IEA document on technology roadmap, were summarised in three principle ways with the aims to reduce emissions of CO2 from coal-fired power plants, in addition to improved demand-side energy efficiency: • Deploy and further develop high efficiency and low emissions (HELE) coal technologies, i.e. use more efficient technology and continue to develop higher-efficiency conversion processes. • Deploy CCS; recent demonstration projects show that CCS is technically viable and, in fact, essential to achieving long-term CO2 reduction targets. • Switch to lower-carbon fuels or to non-fossil technologies as a means of reducing generation from coal.

7. Clean Coal Technologies - What roadmap for R&D However, facts about the present situation could be summed up as: − Technologies presently in operation for clean coal utilisation do really not meet the requirements for near-zero emissions or carbon management − The strategy employed by far for incremental improvements are not adequate to meet future requirements − Based on the strategy mentioned above, the policy applied up to now has involved adding on new equipment to existing plants to meet incremental improvements but this is generally a complex & costly procedure.

8. Clean Coal Technologies - What roadmap for R&D It is required to implement policies to make the transition to new technologies most effective and successful because − 60% of available U.S. capacity 20-40 years old while in Europe, it is even higher for older fleet of power stations fired with coal and the situation in Japan is not much different. In countries with large consumption of coal for power like China, India new fleet is getting in operation but the technologies used are not suitable for efficient carbon management. − It is essential to get new technologies on the commercial stage in the next 10-15 years to be able to substitute retiring power stations. − This transition must be accompanied without any disruptions in meeting the demand for power.

9. Clean Coal Technologies - What roadmap for R&D Coal reserves by region and type

10. Clean Coal Technologies - What roadmap for R&D Electricity generation from different sources

11. Clean Coal Technologies - What roadmap for R&D It is clear that the future of coal utilisation depends on the issue of CO2 is resolved in a cost effective manner for coal to be a vaible alternative. One aspect that is also highly important for the future is that any new technology developed should be able to deal with any type of coal and not specific to the nature of coal used. The current technologies are very much dependent on the nature of coal.

12. Clean Coal Technologies - What roadmap for R&D CO2 considerations

13. Clean Coal Technologies - What roadmap for R&D CO2 With human-related activities currently producing about 27 billion tonnes of CO2 emissions each year world-wide, it’s important to know not just how much CO2 can be captured using CCS, but for how long it will remain in storage. While any CO2 captured will remain stored indefinitely (?), estimates indicate CCS could capture and store the equivalent of between 70 and 450 years of man’s current global annual CO2 emissions. European Technology Platform for Zero Emission Fossil Fuel Power Plants (ZEP)

14. Clean Coal Technologies - What roadmap for R&D

15. Clean Coal Technologies - What roadmap for R&D Source: IPCC (2007)

16. Clean Coal Technologies - What roadmap for R&D Source: IPCC (2007)

17. Clean Coal Technologies - What roadmap for R&D Source: National CO2 Emissions from Fossil-Fuel Burning, Cement Manufacture, and Gas Flaring: 1751-2008. Emissions by Country

18. Clean Coal Technologies - What roadmap for R&D CO2 Other industrial processes e.g. fuels, chemicals, plastics, etc Carbon capture and compression To the electricity grid Sequetration -Capture Coal fired plant Gas fired plant Industry e.g. cement Storage Low carbon energy Oil to Industry Coal and biomass Transport Gas Injection Imperial College London/ Grantham Institute for Climate Change Saline aquifer Gas field Oil field Enhanced Oil Recovery

19. Clean Coal Technologies - What roadmap for R&D Options that include CO2-enhanced oil recovery and CO2-enhanced coal bed methane production, are particularly attractive because injection costs are offset by increased fossil fuel production.

20. Clean Coal Technologies - What roadmap for R&D The issue is that not all storage locations are close to the sources of CO2 emissions IEA publication

21. Clean Coal Technologies - What roadmap for R&D In the global transition desired to have a fully low-carbon economy, the Carbon Capture and Storage (CCS) technology has emerged, in recent years, the key way to achieve a desirable equilibrium between rising demand for fossil fuels for energy and the objective of reducing the greenhouse gas emissions. There is a great doubt that this aim to control the global temperature can be achieved. This is because the use of CCS as a large scale technology that could be employed commercially feasible for large scale deployment is put in question by many report. EU has already considered CCS not of the first priorities of further R,D &D.

22. Clean Coal Technologies - What roadmap for R&D • The International Panel on Climate Change (IPCC) states that “Retrofitting existing plants with CO2 capture is expected to lead to higher costs and significantly reduced overall efficiencies than for newly built power plants with capture. The cost disadvantage of retrofitting may be reduced in the case of some relatively new and highly efficient existing plants or where a plant is substantially upgraded and built.” Most other studies agree with these conclusions. The main reasons are: • Higher investments • Shorter lifespan • Efficiency penalty • Standstill cost

23. Clean Coal Technologies - What roadmap for R&D • For EU, the aim for the future is low carbon energy mix. EU has encouraged projects that could advance CCS from research projects to commercial demonstration projects with the objective of reducing cost, showing the safe geological storage of CO2, build on the knowledge and then pass this information with low-risk to investors. There have been considerable efforts to take the leading role on CCS development, all the demonstration projects funded by EU with complete CCS are located outside EU and even the promising suffer delays because of: • Lack of business case • Public awareness and acceptance • Legal framework • CO2 storage and infrastructure • International cooperation

24. Clean Coal Technologies - What roadmap for R&D At present, CCS-equipped power plants could not produce electricity at costs that would make them profitable. This is because the cost of avoiding CO2 emissions using the current CCS technology is higher than the price paid for emitting CO2. The first CCS demonstration projects would operate in the red oval in the chart (right) and face a ‘financing gap’ of at least € 25 - € 55 per tonne CO2. It is estimated that with continuous technological improvements, the costs can be halved by 2020. This should ensure that CCS plants can in the future operate within commercially feasible parameters in an environment governed by a robust CO2 price (blue oval in the chart). EU publication

25. Clean Coal Technologies - What roadmap for R&D Coal utilisation Technologies and Research areas for further development

26. Clean Coal Technologies - What roadmap for R&D • Issues • What are the next steps with existing technologies • What are the new technologies that could offer the optimised carbon management as performance capabilities could vary depending on application

27. Clean Coal Technologies - What roadmap for R&D Technologies presently utilised are not the most suited to face the future for our energy needs. They are based on up to 100 year-old concept improved over the years with add-on equipment and retrofitting to mostly address the environmental issues as they emerged. The existing technology was conceived to produce power to satisfy the rapidly industralisation of the Western world without too much concern to be ultra clean and to minimise greenhouse gas emissions such as CO2. new integrated system designs.

28. Clean Coal Technologies - What roadmap for R&D There are several potential paths to satisfy the long-term need for near-zero emission coal plants. Advanced combustion technology can use pure oxygen instead of air, thus making it easier to capture CO2. Gasification could lead to producing several end products such as electricity and transportation fuels and could handle flexibility in the fuel available. There are also for exploration the hybrid concepts combining combustion and gasification or making simultaneous use of power generation options such as fuel cells and combustion turbines, thus achieving high system efficiencies with very much reduced greenhouse gas emissions..

29. Clean Coal Technologies - What roadmap for R&D Emissions Control - Existing Plants Current technology could handle − Meeting existing regulations for NOx, PM, Hg, and by-product, however targets for using fresh water use my need to be re-evaluated Further technology requirements for improvement − Low-NOx combustion, low-cost catalysts, improved gas filtration and electrostatic separation, sorbent systems, multi-pollutant controls, dry cooling

30. Clean Coal Technologies - What roadmap for R&D Projects are underway for advanced environmental control technology and ancillary systems in the following areas: A) advanced NOx emissions control, B) mercury emissions control, C) particulate-matter emission control, D) coal utilization by-products, E) air quality research, and F) energy-water interface. Field demonstrations (utilizing up to 600 MW scale plants) are being carried out in the areas of innovative NOx, mercury and particulate control technologies as well as exploring opportunities for by-product utilization.

31. Clean Coal Technologies - What roadmap for R&D (USA roadmap for existing plants)

32. Clean Coal Technologies - What roadmap for R&D Current situation regarding emissions Roadmap technology publication of IEA

33. Clean Coal Technologies - What roadmap for R&D Advanced Combustion • TechnologyNeeds for whichfurther R&D required • - Cofiring, • CFB (circulatingfluid-bed) scale-up, • Advancedboilertube & steam turbine materials, • Coal-oxygencombustion, • Oxygen“carriers, • Sensors& controls

34. Clean Coal Technologies - What roadmap for R&D Combustion technology needs are focused on three areas: advances that allow the effective use of existing plant assets (e.g., use of expert system techniques to improve emissions control; repowering technology to increase plant capacity, increase efficiency, and meet environmental requirements), advances to current plant concepts that will bridge to future plants, (e.g., ultra-supercritical steam to achieve higher efficiency), and future plant designs that have near-zero emissions including CO2.

35. Clean Coal Technologies - What roadmap for R&D Fuel flexibility and ultra-low NOx combustion are near-term objectives to enhance existing plant capability and performance. The capability to achieve operation with ultra-supercritical steam allows for increased plant efficiency. This capability will benefit plants built in 2010 and be available for integration in future near-zero emission plant concepts. Nitrogen-free combustion includes innovative concepts that include oxygen combustion and concepts that utilize chemical oxygen carriers.

36. Clean Coal Technologies - What roadmap for R&D CO2 intensity factors and fuel consumption values

37. Clean Coal Technologies - What roadmap for R&D The share of supercritical and ultrasupercritical capacity in major coal consuming countries

38. Clean Coal Technologies - What roadmap for R&D Roadmap technology publication of IEA

39. Clean Coal Technologies - What roadmap for R&D Future emissions levels expected with more advanced system Roadmap technology publication of IEA

40. Clean Coal Technologies - What roadmap for R&D Advanced Gasification • Technology Needs for which further R&D required • More efficient, lower cost gasifier designs (transport & others), • Improved refractory materials, • Air separation, • More efficient & reliable feed systems

41. Clean Coal Technologies - What roadmap for R&D Integrated gasification combined cycle (IGCC) plants are the cleanest coal-based power systems available today and represents an effective means of capturing carbon dioxide for sequestration. The capital cost and reliability, availability and maintainability (RAM) of gasification processes are two key drivers in determining the commercial deployment of gasification technology.

42. Clean Coal Technologies - What roadmap for R&D IGCC could become a dominant technology in the power industry because of the following advantages: • Ability to handle almost any carbonaceous feedstock; • Ability to efficiently clean up product gas to achieve near-zero emissions of criteria pollutants, particulates, and mercury at substantially lower costs and higher efficiencies; • Flexibility to divert some syngas to uses other than turbine fuel for load following applications; • High efficiency because of the use of both gas turbine and steam turbine cycles; • Ability to cost effectively recover CO2 for sequestration, if required; • Ability to produce pure H2, if desired; • Greater than 50% reduction in the production of solid by-products; and, • Substantial reduction in water usage and consumption. Gary J. Stiegel, et. Al. NETL

43. Clean Coal Technologies - What roadmap for R&D Integrated Gasification Combined Cycle (IGCC) Roadmap technology publication of IEA

44. Clean Coal Technologies - What roadmap for R&D The major IGCC projectsintheworld Spain USA USA Holland JAPAN 250 MW Nakoso DEMO PLANT Presentation by Yoshikazu IKAI, Japan Coal Energy Centre

45. Clean Coal Technologies - What roadmap for R&D Integrated Gasification Fuel Cell Roadmap technology publication of IEA

46. Clean Coal Technologies - What roadmap for R&D Gasifier concepts are being investigated to lower the plant capital cost. Higher throughput designs; improved refractory life; the development of low-cost, reliable dry feed technology; and increased carbon conversion (98% target) are projected to contribute approximately 10% reduction in plant cost and approximately 5 percentage point increase in plant efficiency. Advanced air separation technology is projected to contribute a 5-7% reduction in the capital cost. The next generation air separation technologies require efficient thermal integration with the gasifier and the energy conversion technology (e.g., gas turbine).

47. Clean Coal Technologies - What roadmap for R&D • GasCleaning • TechnologyNeeds for whichfurther R&D required • Multi-pollutantcontrol, • Filtermaterials & systems, • Regenerablesorbents, • Sensors& instrumentation

48. Clean Coal Technologies - What roadmap for R&D Gas cleaning basically removes gas-phase contaminants and particulates to avoid corrosion, erosion or deposition in downstream energy conversion equipment and involves both environmental and process considerations. They are particularly stringent for coal-fired power plants. In future coal-fired systems, equipment can include combustion turbines, fuel cells, catalytic reactors to convert syngas to fuels, separations technologies for capturing CO2 or separating H2, and heat transfer equipment.

49. Clean Coal Technologies - What roadmap for R&D Gas cleaning involves many pollutants and any cleaning process has to be specific for the downstream unit operations to be employed. The requirements will differ for reliable operation of membrane separation technology, fuel cells, turbines, and other component designs. Representative requirements for fuels or chemicals production include total sulfur <60 ppb, total halide < 10 ppb, NOx < 100 ppb as well as specifications for other trace chemicals.

50. Clean Coal Technologies - What roadmap for R&D The approach for gaseous contaminant control is usually to employ sorbents. Sorbent performance, cost, regenerability and attrition resistance are common barriers. One of the challenges is how to design a system to meet the multi-pollutant control needs that is simple, low cost and reliable. The design of the gas cleaning system have to integrate well both process control and operation procedures – e.g. compatibility in operating temperature and pressure transients during turndown, start-up or shut-down.