潘偉平 Wei-Ping Pan

Taipei, Taiwan

October 23-26, 2016

CLEAN COAL TECHNOLOGY FOR

THE POWER INDUSTRY

26th Modern Engineering & Technology Seminar 2016

主要內容

Contents

• Coal may be challenged, but Coal is not

dead!

• Solution for Cleaning Coal Power

Legislation & Regulation

Implementation

Using & Optimization (Performance Improvement:

efficiency, reliability, availability)

Monitoring Continuously

美國煤炭現狀

Current Coal Status in the U.S.

51% 38%

9%

2%

2012年

美國煤炭探明儲量2372億噸

煙煤 bituminous

次煙煤

subbituminous coal

褐煤 lignite

無煙煤 anthracite

燃煤发电

钢铁

建材

生活

化学产品

美國煤炭消費中

有約94%都用於發電

燃煤發電

Coal-fired Power

Generation

鋼鐵

Iron and Steel

建材

Building materials

化學產品

Chemicals

生活

Life

% Share of Power Source Coal Deposited in USA

Source: U.S Energy Information Administration, http://www.eia.gov/coal/data.php#consumption

美國燃煤、燃油電廠分佈

Location of Coal and Oil Power Plants in USA

能源價格對美國電力行業的影響 Impact of Energy Prices on the U.S Power Industry

2005-2015年美國能源價格

Do

llar

per

to

n

Do

llar

per

Mcf

D

oll

ar p

er b

arre

l

Source: 1.U.S Energy Information Administration. COAL DATA BROWSER. Market average price, annual.

2.U.S Energy Information Administration. U.S. Natural Gas Wellhead Price. https://www.eia.gov/dnav/ng/hist/n9190us3a.htm

3.U.S Energy Information Administration .U.S. Crude Oil First Purchase Price.

https://www.eia.gov/dnav/pet/hist/LeafHandler.ashx?n=PET&s=F000000__3&f=A

美國發電量及其能源結構分佈 U.S. Energy Generation and Distribution Structure

美國電力產業

U.S. Electrical Power Industry

33.77%

32.91%

19.14%

5.93%

4.38%

1.02%

2.84%

煤

coal

天然氣

natural gas

核能

nuclear

水電

hydropower

風能

wind energy

太陽能

solar

其它

other

38.33%

27.86% 19.48% 6.40%

4.41%

1.02% 2.84%

44.70%

23.93% 19.56%

6.38% 0.00%

2.82%

2015 2014 2010

Source: U.S Energy Information Administration, Electric Power Monthly. Net Generation for all sectors monthly,

http://www.eia.gov/electricity/data/browser/.

2015 電力來源百分比份額 2015 Percentage share of power source

美國，中國以及台灣電力產業

U.S., China and Taiwan Electrical Power Industry

Source: 1. U.S Energy Information Administration, Electric Power Monthly. Net Generation for all sectors monthly, http://www.eia.gov/electricity/data/browser/.

2. 《2016-2022年中国电力行业运行态势及投资战略研究报告》

3. Provided by Prof. Hsu Heng-Wen, Natural Resources Technology Division, Green Energy and Environment Research Lab, Industrial Technology Research Institute

世界電力行業能源結構預測

Prediction of Energy Structure in the World

World net electricity generation by fuel (trillion kilowatthours)

Source: 1. U.S Energy Information Administration, International Energy Outlook 2013.

1. U.S Energy Information Administration, International Energy Outlook 2016.

40%

36%

22%

24%

Prediction in 2013 Prediction in 2016

29%

28%

40%

22%

美國電力控制污染排放環保政策的制定 U.S. Power Plants to Develop Pollution Control Environmental Policy

Sources of Mercury Emissions in the U.S.

Industrial

Category

1990

Emissions

tons per year

(tpy)

2005

Emissions

(tpy)

Percent

Reduction

Power Plants 59 53 10%

Municipal Waste

Combustors 57 2 96%

Medical Waste

Incinerators 51 1 98%

臭氧

Ozone

細顆粒物

PM2.5

'08 '09 '10 '11 '12 '13 '14 '15 '16 '17

Beginning

CAIR Phase I

Seasonal

NOx Cap

HAPs MACT

proposed

rule

Beginning

CAIR Phase

II Seasonal

NOx Cap

Revised

Ozone

NAAQS

Begin

CAIR

Phase I

Annual

SO2 Cap

Beginning CAIR

Phase II Annual

SO2 & NOx Caps

Next PM-

2.5

NAAQS

Revision

Next Ozone

NAAQS Revision

SO2 Primary

NAAQS

SO2/NO2

Secondary

NAAQS

NO2

Primary

NAAQS

二氧化硫/

氮氧化物

SO2/NO2

New PM-2.5 NAAQS

Designations

CAMR &

Delisting

Rule vacated

汞/有害空氣污染物

Hg/HAPS

Final EPA

Nonattainment

Designations

PM-2.5

SIPs due

(‘06)

Proposed CAIR

Replacement

Rule Expected

HAPS MACT

final rule

expected

CAIR

Vacated

HAPS MACT

Compliance 3 yrs

after final rule

CAIR

Remanded

空氣

Air

Begin

CAIR

Phase I

Annual

NOx Cap

PM-2.5

SIPs due

(‘97)

316(b) proposed

rule expected

316(b) final rule

expected

316(b) Compliance

3-4 yrs after final rule Effluent

Guidelines

proposed rule

expected

水Water

Effluent Guidelines

Final rule expected Effluent Guidelines

Compliance 3-5 yrs

after final rule

Begin Compliance

Requirements under

Final CCB Rule

(ground water

monitoring, double

monitors, closure,

dry ash conversion)

灰Ash

Proposed

Rule for CCBs

Management

Final

Rule for

CCBs

Mgmt

Final CAIR

Replacement

Rule Expected

Compliance with

CAIR

Replacement Rule

二氧化碳

CO2

CO2

Regulation

Reconsidered

Ozone

NAAQS

美國電力控制污染排放環保政策的制定 U.S. Power Plants to Develop Pollution Control Environmental Policy

(Legislation & Regulation)

污染物排放控制政策及規定 Emission Policies and Regulations for Pollutants Control

Regulation/Policy

Emission limits

(mg/Nm3)

SO2 NOx PM Mercury (Hg)

United States EPA 2013 113 181 10 MACT

(90% removed)

China

GB13223-2011 50 100 20 0.03

Plan for energy-

saving and

emission-

reduction in coal-

fired power plants

(2014-2020)

35 50 10 —

Near Zero

Emission 2014 35 50 5 —

Taiwan Existing 172 144 20 0.005

New-built 86 62 10 0.002

CO2

Capture

Low-NOx

Burner

OFA

Urea

Injection Stack

CO2

Compressed for transport and storage SO2 & Hg

Scruber

ESP/ FF

PM & Hg

Capture

Activated

Carbon

or

Fly ash

SCR

DeNOx

BOILER

(~90%)

(~??.?%)

(~95%)

燃煤電廠清潔燃燒的解決途徑 Solutions and Opportunities for Cleaning Coal Power

WESP

Low Temperature Economizer

蒸汽循環技術發展 Technology Development of Steam Cycles

(Performance Improvement)

煤電機組效率提高方法

Improving Coal-Burning Unit Efficiency

T h e t h e o r e t i c a l b a s i s o f

thermodynamic cycle in coal-

burning unit——Rankine cycle

The improving method of coal-

burning unit efficiency：

• Capacity expansion reforming

• Main steam / reheat steam temperature improving retrofit

• Subcritical unit upgraded to supercritical/Ultra-supercritical unit

鍋爐 Boiler

• Conventional flow path retrofit

• Main steam / reheat steam temperature improving retrofit

• Subcritical unit upgraded to supercritical/Ultra-supercritical unit

汽輪機Turbine

發電機相關技術改造

Generator related reformation

輔助系統相關技術改造

Auxiliary System related reformation

Reheating cycle Regenerative cycle

𝜼 =𝑾𝒏𝒆𝒕

𝒒𝟏≈𝒉𝟏 − 𝒉𝟐𝒉𝟏 − 𝒉𝟑

= 𝟏 −𝒉𝟐 − 𝒉𝟑𝒉𝟏 − 𝒉𝟑

中國煤電機組平均供電煤耗

The Average Coal Consumption Rate of Power Supply in China

The average coal consumption rate of power supply in China: 315g/kWh (2015)

Unit: g/kWh

1000MWe

Ultra-

supercritical

660MWe

Ultra-

supercritical

600MWe

Supercritical

350MWe

Supercritical

600MWe

Subcritical

300MWe

Subcritical

Water

cooling unit 282 289 300 310 312 324

Air cooling

unit 305 307 320 323 330 340

0

5

10

15

20

25

Quantity of Ultra-supercritical unit in China

1000MWe 660MWe

Source: Jianxiong Mao, Development of Utra-supercritical Technology for Power Generation, Paper presented at the Chinese Society

of Power Engineering Annual Conference on Ultra-Supercritical Technology 2015, January 13-15, 2016, Nanjing, Jiangsu, China.

供電凈效率與材料成本

Net Power Supply Efficiency and Material Cost

Ultra-Supercritical unit (28-31MPa/600℃/600℃)

Ultra-Supercritical unit (28-31MPa/600℃/620℃)

High Ultra-Supercritical unit (33-35MPa/640℃/650℃)

High Ultra-Supercritical unit (40MPa/700℃/700℃) Further improve efficiency:

600℃→700℃

Approximation to the Carnot cycle

Net

po

wer

su

pp

ly e

ffic

ien

cy, %

Steam temperature, ℃

Improve

thermodyn

amic design

of power

plant Development of high-temperature

material technology

700℃ double-reheat USC (after 2025)

600℃ double-reheat USC (2015)

600℃ single-reheat USC (2006 - present)

影響燃煤電廠能效水平的主要因素 Principal Factors Influencing the Energy Efficiency of Power Plant

Influencing Factors

Impact on the coal

consumption amount

(g/kWh)

1 Poor Performance of Turbine 5-12

2 Operation in Low Load 3-7

3 Poor Performance of Cold End(low vacuum) 0.5-5

4 Low Efficiency of Boiler 1-3

5 Large Quantity of Desuperheater Spray of Boiler 0.5-2

6 Valve Internal Leakage of Thermodynamic System 0.5-3

7 Frequently Starting and Stopping of Unit 0.5-1.5

8 Main/Reheat Steam Temperature & Pressure <1

9 Poor Heat-Retaining Capacity <0.2

10 Poor Performance of Boiler Feed Pump Turbine 0.5-1

煤質調節：酵素技術及其收益 Coal Conditioning : Enzyme Technology and Benefits

Enzyme

Dilution

Spray

Coal Preparation

Stilling Combustion

optimization

超低排放改造技術路線 Technology Route for Ultra-Low Emission Retrofitting

Low NOx Burner

Boiler -- 353oC ---- 350oC ----- 117oC ------- 90oC ---------- 89oC --------- 50oC ---------------------- >80oC

Flue Gas Temperature

ESP,FGD,WESP細顆粒物質量分佈 Fine PM Mass Distribution in ESP, FGD and WESP

吸附劑注射汞捕集方法起源 Genesis of Sorbent Injection for Mercury Capture

Hg0 Hg2+ Hgp

Contact Conversion Capture

Particles Surface Pores

• Major issues with

measurement of Hg

at these low levels in

actual flue gas.

(OHM)

• Development of Hg

control technologies

in laboratory and

pilot scale.

1990s

• Hg measurement

improvements and

options expanded.

(OHM, CEM &30B)

• Field studies with

halogen-treated

sorbents (AC and

non-carbon

sorbents)

2000s

• Measurement still

challenging and high

maintenance.

• Specific application

challenges (SO3, concrete,

compatibility &

corrosion)

• compliance at 1.2 lb/Tbtu,

using ACI considered as

maximum achievable

control technology and

best available control

technology

2016

飛灰基汞控制系統

Fly Ash-base Mercury Control System

07:3

0:0

0

08:3

0:0

0

09:3

0:0

0

10:3

0:0

0

11:3

0:0

0

12:3

0:0

0

13:3

0:0

0

14:3

0:0

0

15:3

0:0

0

16:3

0:0

0

1

2

3

4

5

6

7

experiment 3experiment 2

Me

rcu

ry c

on

ce

ntr

atio

n（

ug

/m3） baseline experiment 1

SCR

ESP

FGD

燃煤電廠產生的煙氣中，二氧化碳所佔比例僅15%左右，所以碳捕集過程中最大的花費是如何提高二氧化碳的濃度。

CO2 separation:

~ $50-100 / ton carbon

& energy intensive

CO2 disposal:

~ $4-8 / ton carbon

CO2 separation:

~ $100-200 / ton carbon

& energy intensive

碳捕集的技術：挑戰 CO2 Sequestration Technologies – Technical Obstacles

燃燒后 捕集

IGCC燃燒前 捕集

富氧燃燒

CO2 separation:

~ $35 / ton carbon

& energy intensive

Chemical

MEA

Caustic

Ammonia

Others

Adsorber beds

MOF

Zeolite

Active carbon

Tire char

Chicken waste

Others

Regeneration

method

(Vacuum) Pressure swing

Temperature swing

Washing

Open system

Close system

Gas separation

Polyphenyleneoxide

Polydimethylsiloxane

Gas absorption

Polypropelene

Ceramic based

systems

Oxygen Carriers

Cu based

Ni based

Fe based

碳分離和捕集的技術：解決方法 CO2 Separation and Capture

Absorption

Cryogenics

Microbial/

Algal

Systems

Membranes Oxy-

Combustion

Chemical

Looping

Combustion

Adsorption

碳酸氫銨CO2捕集技術中試實驗 Pilot-scale of CO2 Capture by Ammonium Bicarbonate Technology

碳酸氫銨CO2捕集技術中試實驗 Pilot-scale of CO2 Capture by Ammonium Bicarbonate Technology

Steam

from

turbine

Condensate

return

SaskPower Clean Coal Project:

Cansolv Amine-base SO2&CO2 Integrated System

Flue gas

Steam

from

turbine Condensate

return

Lean

SO2

Amine

Rich

SO2

Amine

Lean

CO2

Amine

Rich

CO2

Amine

10% CO2 Storage

90% CO2 Enhanced Oil Recovery

SO2

converted

to Sulfuric

Acid

傳統CCS技術的花費 Current Costs for Conventional CCS options

Post Combustion Capture $65/t CO2 or another $65/MWh added to a new Supercritical PC unit + WFGD + SCR

Oxy-combustion $54/t CO2 or another $54/MWh added to a new Sub-Critical PC unit + WFGD + SCR

Pre-Combustion Capture with IGCC $41/t CO2 or another $41/MWh added to a new IGCC

Chemical Looping Combustion Potential $19/t CO2 to $35/t CO2 or another $19/MWh to $35/MWh added to a new Circulating

Fluidized Bed Combustor

Only if the coat for capturing CO2 can be reduced to a cost less than the

CO2 can be sold for beneficial uses like Enhanced Oil Recovery (EOR)

-- i.e. < $35/t CO2

Only if processes can be developed to convert the CO2 into high value

liquid fuels and chemicals while paying for the CO2 at >$35t/ CO2

不依靠碳捕集&儲存技術，未來電廠能否符合CO2排放標準？ Can Future Coal Plants Meet CO2 Emission Standards Without Carbon Capture & Storage?

US EPA “New source performance standard” (August 3, 2015, court pending) :

new coal power plant : 636kg/MWh of CO2 emission Current state-of-art coal-fired power plant with USC steam conditions above 593℃ , emit

approximately 800kg/ MWh.

IGCC plant: 700kg/MWh

Advanced USC with 12.5% Steam utilization (high efficiency combined heat-and-power

applications): 636kg/MWh

IGCC plant with high quality coal: 627kg/MWh

Development of gasifiers integrated with solid oxide fuel cells, with combined cycle plants

having firing temperatures for the combustion turbine approaching 1700℃ : ~ 500kg/MWh

為何煤電？

Why Coal Power ?

If not Coal then what ?

Wind & Solar Ok - availability

Hydro Ok - location

Gas & Oil Ok - cost

Nuclear Ok – waste / base

Coal – Clean Coal ??

Clean Coal is not a silver bullet, however, we

will almost surely have to burn more coal

for a few decades.

“If your only tool is a hammer – then your solution is very likely to be a nail”

電廠潔淨煤技術 Clean Coal Technology for the Power Industry

The USA, China and Taiwan will continue to rely on coal for about 30% of their power

generation needs. This is because of the lower cost and abundance of the resource.

由於費用低廉和資源豐富，美國、中國、臺灣30%以上的電力依然將依賴於燃煤。

However, the challenge is to reduce the amount of pollution and green gas emitted

during coal combustion. The increase in power efficiency through Ultra supercritical

unit (such as Subcritical unit upgraded to Supercritical /Ultra-supercritical

unit)with ultra-low emission technologies (the combined application of lower

temperature economizer, retrofitted SCR, ESP, FGD and WESP) is the most effective

way to continue to use coal.

由於燃煤過程中產生污染物和溫室氣體，超臨界（例如亞臨界升級為超臨界/超超臨界）和超低排放技術（例如採用低溫省煤器、濕式電除塵，對SCR、ESP、FGD改造升級）是燃煤發電持續發展最有效的措施。

Ultimately, cost and emissions are issues for thermal energy, space is an issue for wind energy

and safety is an issue for nuclear energy.

根本上，費用和排放是燃煤發電的關鍵，空間限制是風電的關鍵，安全性是核電的關鍵。

The most important criteria for establishing energy policy will have to be based on each

countries energy resources, economic security and energy security.

能源政策的建立要依賴于能源資源、經濟性和安全性。