Advanced Power Plant Development and Analyses Methodologies. Semi-Annual Report

Advanced Power Plant Development and Analyses Methodologies.
Semi-Annual Report - August 1, 2005 to January 31, 2006.

List of Tables							7
List of Illustrations							9
Introduction							10
1.	Results and Discussion – Phase 1						12
	1.1	Sub-System Selection					12
	1.2	Screening Analysis					14
		1.2.1	Natural Gas Cases				15
		1.2.2	Coal Based Cases				15
	1.3	Detailed Analysis					15
		1.3.1	Design Basis				16
		1.3.2	Natural Gas Based SOFC / HAT Hybrid				16
			1.3.2.1			Process Description	16
			1.3.2.2			Performance Estimates	17
		1.3.3.	Coal Based Advanced Transport Reactor (ATR) Gasification SOFC Hybrid				18
			1.3.3.1			Process Description	18
			1.3.3.2			Performance Estimates	20
			1.3.3.3			Cost Estimates	20
		1.3.4	Coal Based “Zero Emission” Plant with Vision 21 Technology				21
			1.3.4.1			Process Description	21
			1.3.4.2			Performance Estimates	23
		1.3.5	Coal Based H₂ Coproduction with CO₂ Capture				23
			1.3.5.1			Process Description	23
			1.3.5.2			Performance Estimates	26
		1.3.6	Nontechnical Issues				61
			1.3.6.1			The Role of Trading Groups	63
2.	Results and Discussion – Phase 2						65
	2.1	Task 1 – Efficient Recovery of CO2 in Current State-of-the-art Plants					65
		2.1.1	Gasifier				65
			2.1.1.1			GE Gasifier versus Shell Gasifier	65
			2.1.1.2			GE Gasifier versus E-Gas Gasifier	65
		2.1.2	Power Block and Heat Recovery				68
			2.1.2.1			Solid Oxide Fuel Cell	68
			2.1.2.2			Gas Turbines	68
			2.1.2.3			Air Separation Unit	70
			2.1.2.4			Slurry Options	72
			2.1.2.5			NOx Emission Control	73
			2.1.2.6			Acid Gas Removal	73
			2.1.2.7			Metal Carbonyls	74
			2.1.2.8			Mercury, Arsenic, Cadmium, and Selenium	75
		2.1.3	Coal Based Near Zero Emission / H₂ Coproduction Plant with Selexol™.				75
			2.1.3.1			Process Description and Flow Diagrams	75
			2.1.3.2			Performance Estimates	86
			2.1.3.3			Cost Estimates	86
		2.1.4	Coal Based Near Zero Emission / H₂ Coproduction Plant with CO₂LD Sep^(SM)				86
			2.1.4.1			Process Description and Flow Diagrams	86
			2.1.4.2			Performance Estimates	87
			2.1.4.3			Cost Estimates	88
	2.2	Task 2 – Efficient Recovery of CO₂ in Intermediate Level Technology					88
		2.2.1	Process Description and Flow Diagram				88
		2.2.2	Performance Estimates				90
		2.2.3	Cost Estimates				90
	2.3	Task 3 – Efficient Recovery of CO₂ In Advanced Technology Plant					91
		2.3.1	Process Description and Flow Diagram				91
		2.3.2	Performance Estimates				93
		2.3.3	Cost Estimates				93
3.	Results and Discussion – Phase 3						117
	3.1	Task 1 – Advanced Turbine and Turbine Systems Assessment					117
		3.1.1	Gas Turbine Technology				117
			3.1.1.1		Gas Turbine Firing Temperature		119
			3.1.1.2		Gas Turbine Pressure Ratio		119
			3.1.1.3		Combustor Developments		120
			3.1.1.4		IGCC Applications		121
			3.1.1.5		Novel Cycles		125
4.	Conclusions						132
	4.1	Phase 1					132
	4.2	Phase 2					135
	4.3	Phase 3					138
5.	References						140
6.	Appendix A – Analysis Tools						143
	6.1	APSAT					143
		6.1.1	SOFC Model				143
		6.1.2	Gas Turbine				144
		6.1.3	Humidifier Model				144
		6.1.4	Compressor and Steam Turbine Models				145
	6.2	SOAPP					145
	6.3	References					145
7.	Appendix B – Screening Analysis						150
	7.1	Natural Gas Based Cases					150
		7.1.1	High Pressure SOFC Integrated with High Pressure Ratio Intercooled Gas Turbine				150
		7.1.2	High Pressure SOFC Integrated with HAT				151
		7.1.3	Atmospheric Pressure MCFC Integrated with Intercooled Gas Turbine				151
		7.1.4	O2 Breathing High Pressure SOFC Integrated with HAT Cycle				152
		7.1.5	Advanced Ranking Cycle Combusting H₂ with O₂				152
	7.2	Coal Based Cases					153
		7.2.1	Integrated Gasification SOFC / GT Hybrid Systems				153
		7.2.2	Integrated Gasification SOFC / HAT Hybrid Systems				154
		7.2.3	Advanced Transport Reactor Gasifier				155
		7.2.4	Partial Gasification Hybrid Systems				156
	7.3	References					157
8.	Appendix C – Base Cases						170
	8.1	Coal Based IGCC Plant Without CO₂ Recovery					170
		8.1.1	Process Description				170
		8.1.2	Performance and Cost Estimates				170
	8.2	Coal Based IGHAT Plant With CO₂ Recovery – “Zero Emission” With Nearer Term Technology					171
		8.2.1	Process Description				171
9.	Appendix D – Economic Analysis Methodology						174
	9.1	Basis of Economic Analysis					174
		9.1.1	Organization and Start-Up Costs				174
		9.1.2	Working Capital				174
		9.1.3	Land Costs				174
		9.1.4	Operating and Maintenance Cost Estimates				174
			9.1.4.1	Fixed Operating Costs			174
			9.1.4.2	Variable Operating Costs			175
			9.1.4.3	By-Product Credit			175
			9.1.4.4	Operating and Maintenance Costs			176
			9.1.4.5	Fuel Cost			176
10.	Appendix E – Gas Turbine Development Needs						179
	10.1	Potential Paths					180
		10.1.1	Aero Frame				180
		10.1.2	Intercooled Aeroderivative				181
	10.2	Development Plans					182
	10.3	References					182