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O F F I C E O F F O S S I L E N E R G Y • U . S . D E P A R T M E N T O F E N E R G Y
COAL & POWER
SYSTEMS
STRATEGIC PLAN &
MULTI-YEAR PROGRAM PLANS
E X E C U T I V E S U M M A R Y
CLEAN, LOW-COST ENERGY BUILDING ON A SUCCESSFUL
FOR A STRONG ECONOMY TRACK RECORD
EXECUTIVE
A N D H E A LT H Y E N V I R O N M E N T
SUMMARY C&PS-supported RD&D has already
returned substantial benefits to con-
The availability of affordable energy is sumers and taxpayers. These returns
now, and will continue to be, essential include affordable, cleaner, and more
The Fossil Energy Coal and Power Systems (C&PS) Program is committed to ensuring that,
to our Nation’s economic strength. efficient powerplants that are now in
as America enters the 21st century, we will continue to have the cleaner, more
WITH A LONG-TERM Even with great advances in renewable use throughout the world. The poten-
affordable, and secure energy needed to keep our economy growing strong and to pro-
energy use, energy forecasts agree that tial for future returns is even greater as
vide valuable jobs for many generations to come. To achieve this vision, Fossil Energy’s
fossil fuels will be the dominant energy technologies that are nearly through
C&PS program plan focuses on developing advanced fossil energy technologies aimed at STRATEGIC FOCUS, THE
source for the foreseeable future. By the RD&D pipeline enter the market-
improving the biosphere and continuing the economic competitiveness of our Nation.
2020, we will rely on fossil fuel for place. Building on this successful track
The plan is structured to meet our short-term, mid-term, and long-term needs for low-
COAL AND POWER SYSTEMS 90% of our energy needs. The aim of record of partnerships with industry,
cost, reliable electricity and transportation fuels, culminating in the creation of a new
the Coal and Power Systems (C&PS) the C&PS program is developing very
fleet of energy facilities called Vision 21. This document contains the current C&PS
Program is to see that this occurs in the clean electric power generation tech-
Strategic Plan and the Multi-Year Program Plans of each product line.
PROGRAM PURSUES R&D most efficient manner and without nologies that will be much more effi-
The C&PS program will create significant public benefits in the evolving energy market. harm to our environment. Our Nation cient than powerplants in use today.
It supports the U.S. Department of Energy’s (DOE’s) mission and its strategic goals to is blessed with abundant natural gas The long-term strategic vision of the
develop and promote secure and competitive energy systems that minimize impacts on the ESSENTIAL TO MEETING and coal resources that can be used to program is to create the ability to use
U.S. and the global environment, and to deliver critical scientific understanding and tech- maintain and increase our productivity coal and natural gas to produce trans-
nological innovations. The following pages outline program strategy and identify the issues, and economic well being while meeting
OUR NATION’S ENERGY portation fuels and valuable chemicals
priorities, challenges, major activities, and projects required to attain goals and objectives. environmental protection goals. jointly with electric power in a way
The plan has been developed by the Office of Fossil Energy and the Federal Energy The C&PS program of the U.S. Depart- that produces little or no pollutants
Technology Center, utilizing stakeholder input. It is linked with DOE’s Integrated Natural NEEDS WELL INTO THE ment of Energy (DOE), Office of Fossil and achieves efficiencies of up to 90%.
Gas Strategic Plan through discussions of gas-powered generation. Energy, develops advanced power gen- Powerplant efficiency matters: one
eration and alternative fuel technology golf-ball-sized lump of coal can pro-
2 1 S T C E N T U R Y. in partnership with industry. Increased duce enough electricity to light a 100-
Comments on the C&PS plan should be addressed to the Of fice of Fossil Energy,
1000 Independence Avenue, S.W., Washington, D.C. 20585. efficiency, low-pollutant emissions, watt light bulb for 75 minutes using a
reduced cost for power generation, and typical powerplant in operation today
ultra-clean transportation fuels from to make the electricity, 90 minutes
coal, natural gas, and biomass are key using advanced units nearly ready to
CONTENTS
goals of the program. enter the marketplace, and 140 minutes
using the high-efficiency technology in
EXECUTIVE SUMMARY 1 use when this vision is realized. It’s not
just that less fuel will be used to light
STRATEGIC PLAN 4
a room; using less fuel reduces the
MULTI-YEAR PROGRAM PLANS 24 amount of pollutants, solid waste, and
TECHNOLOGIES FOR EXISTING PLANTS 26 greenhouse gases (carbon dioxide) that
NEAR- AND MID-TERM DEVELOPMENT AND DEMONSTRATION 33
are produced when the light bulb is
used. When efficiency is combined with
DISTRIBUTED GENERATION 56
advances in environmental controls, the
VISION 21 64 result is a very clean, environmentally
CARBON SEQUESTRATION RESEARCH 74 responsible means to generate electric
power using fossil fuels. This is the
ADVANCED RESEARCH 80
Coal and Power Systems Program
INTERNATIONAL 84 Vision 21.
1
E X E C U T I V E S U M M A R Y E X E C U T I V E S U M M A R Y
Ultimately, the returns realized by this DOE supports the development of tech- Carbon sequestration is an element of FUTURE PROGRAM BENEFITS
program will extend far beyond U.S. nologies meeting public-sector needs, the program critical to the sustained or
borders. Energy to fuel continued technologies that would otherwise E N E R G Y F O R T R A N S P O R TA T I O N
expanded large-scale use of fossil fuels Future benefits of the C&PS program
SELECTED PROGRAM BENEFITS
growth will come primarily from fossil emerge far more slowly, if at all. Cur- with current generation technology. include low-cost energy, superior envi-
TO DATE Net oil imports, which now account
fuels, particularly in rapidly develop- rently, private industry is limiting its To substantially reduce total world ronmental protection, long-range fuel
Cumulative SO 2 scrubber costs for 46% of U.S. consumption, are
ing nations, such as China and India, own long-term energy R&D largely greenhouse gas emissions, new CO2 supply security, economic competitive-
reduced by $50 billion through projected to increase to 65% by
that are rich in coal reserves. Exporting because of uncertainty related to future sequestration technologies are needed. ness, and high-value jobs.
1995, and overall SO 2 emissions 2020. Growing dependence on
cleaner, more efficient technologies will regulations, the perceived need to min- Research targets longer-term solutions,
down by 40% since 1970, even imports, particularly from politically • Between 2000 and 2015, 70%
not only benefit the U.S. economy, but imize long-term capital investments, including CO 2-recycling, enhanced
though coal use increased 85% unstable regions, threatens our reductions are projected for SO 2 ,
will help satisfy growing global and risks relating to deregulation of the natural sinks for carbon, and geologic
during this period. national energy security and con- NO X , and HAPs emissions from
demand and improve living standards electric power industry. sequestration.
tributes to a negative U.S. trade existing powerplants.
Low-NO X burners and postcombus- while reducing greenhouse gas emis- Through co-investment with industry Advanced research pursues the under-
balance. High-quality transportation • Environmental compliance cost
tion controls that satisfy emissions- sions and preventing pollution. in promising technologies, DOE miti- lying technology base for more efficient
liquids from coal, natural gas, and reductions for meeting existing and
reductions requirements installed The Coal and Power Systems Program gates R&D risks. Active participation use of fossil resources. Efforts are focused
biomass resources can offset these future regulations are expected to
in 50% of U.S. coal-fired capacity is addressing key environmental con- by DOE and industry partners in such on such areas as novel materials, bio-
effects. average over $5 billion/year
at a small fraction of the cost of cerns, while being responsive to DOE R&D positions the U.S. as a leader processing, coal utilization science,
previously available technologies. through 2010, and could exceed $7
strategies enhancing scientific under- in growing global markets for clean university research, advanced hybrid
billion/year after 2010.
Clean atmospheric fluidized-bed standing and promoting secure, effi- energy technologies. processes and cycles, and smart sys-
technology commercially deployed cient, and competitive energy systems. tems, all of which will help achieve • By 2010, savings in the cost of
with $8 billion in sales. Vision 21 goals. electricity are expected to increase
the cumulative Gross Domestic Prod-
More than 600 MW in integrated In the near- and mid-term, develop- Development of strategic international
PURSUING THE VISION uct (GDP) by $137 billion, generat-
gasification combined-cycle (IGCC) ment of a new generation of advanced partnerships is also an important part
ing more than 1.4 million job years.
plants installed in commercial power and fuel-producing systems will of the program. They foster environ-
service with: FEDERAL mental cooperation and facilitate global • Cost-competitive advanced technolo-
be completed. The efficiency of these
The Coal and Power Systems Program sales of U.S. energy technologies. gies can by 2020 capture potential
• 10% to 20% improvement in systems ranges from 40% to a potential
GOVERNMENT’S ROLE builds toward Vision 21. Each element international sales of over $235 bil-
efficiency 70%. Systems under development Systems studies shape the framework
has specified goals that align with the lion, creating almost 500,000
include technologies—such as and scope of program strategy and pro-
• 98% reduction in SO 2 emissions target of achieving market availability jobs/year. Domestic sales are
advanced gas turbines and combined vide information to stakeholders on
• 80% lower NO X emission rate DOE, in partnership with the private for Vision 21 technologies in the 2010 expected to bring $65 billion, and
gasification/fuel-cell systems—that vital energy and environmental issues.
than current requirements. sector, invests in energy research to to 2015 time frame. generate over 100,000 jobs/year.
will become part of Vision 21 plants
protect the Nation against risks to Near-term goals include development
• 20% lower CO 2 emissions of the future. • A coal-conversion industry will
energy supplies and damage to the of improved technologies for existing
Another element of the program is reduce dependence on foreign oil,
Three coal-processing plants initi- environment. These Federal invest- plants, concentrating on cost-effective increasing oil security while helping
ated that convert low-rank Western ments are carefully focused on areas directed toward clean and reliable dis-
advanced environmental compliance reduce the U.S. energy trade deficit
coal and high-sulfur Eastern coal where there are large potential public- tributed generation systems. Modular
for the Nation’s current coal-fired and capturing a share of what may
into a product that meets environ- sector benefits; but financial rewards, construction and flexible siting make
powerplants. These technologies will be the largest new job-creating
mental standards. given the significant risks involved, are these systems desirable in specific
also increase the efficiency of existing sector of the economy.
not adequate to attract sufficient levels market segments. Internationally, and
New technologies have been plants so that they can provide more
of private-sector investment. in Alaska, distributed systems will be • By 2020, deployment of more effi-
demonstrated that improve the economical power.
well-suited to applications in the many cient power systems globally could
environmental performance of
areas not served by an electrical trans- reduce greenhouse gas emissions by
steel and cement processes.
mission and distribution grid. nearly 150 million metric tonnes
Cost reductions realized by con- (MMT) per year of carbon. The goal
sumers because of these accom- set for FE-sponsored sequestration
plishments are important to the options is to be able to offset all
U.S. economy. The Nation will con- growth in U.S. carbon emissions
tinue to reap these benefits well beginning in 2015.
into the future. The overall eco-
nomic value of even a small
reduction in the cost of electricity
is huge, considering that domestic
electricity sales are forecast to
total 3,877 billion kilowatt-hours
2 3
in 2010.
STRATEGIC PLAN
C O N T E N T S
MISSION 6
VISION TO 2015 6
SITUATION ANALYSIS 6
STRATEGIC GOALS—
PLANNING HORIZON 2015 11
PERFORMANCE INDICATORS 13
PROGRAM STRATEGIES 18
COAL AND POWER SYSTEMS TECHNOLOGY 19
PROGRAM BENEFITS 22
S T R A T E G I C P L A N S T R A T E G I C P L A N
S I T U A T I O N A N A LY S I S THE ROLE OF AN EFFICIENT AND
ENERGY CONSUMPTION BY FUEL TYPE
CLEAN FOSSIL ENERGY CYCLE
MISSION All countries desire adequate energy
PRESENT SITUATION resources for current needs and future Today, the 5.9 billion people in the
The mission of the Coal and Power
World
Systems (C&PS) Research and Devel- The U.S. has the lowest unsubsidized generations. For the U.S., fossil energy Gas 20% world use more than 400 quads of energy
Nuclear 6%
opment (R&D) Program is to foster electricity rates in the world. Gas and remains a major resource (greater than per year. Fossil fuels provide 75% of the
Hydro, Solar,
the development and deployment of coal prices are lower than in most of 85%) in the country’s mix of energy Coal 22% Wind, Geo 6%
world’s energy.
advanced, clean, affordable fossil- the world. The U.S. also has one of the use. The challenge is to improve the
Biomass 13%
based power and alternate fuels sys- most energy-intensive economies, con- efficiency of the fossil energy cycle
in a clean, environmentally friendly Oil 33%
tems. Fuel-flexible power generation suming a quarter of the world’s total
and conversion technologies will be energy, while producing a quarter of manner.
developed to efficiently utilize coal, the world’s GDP. One half of U.S. oil United States
Gas 24%
gas, and opportunity fuels. The long- consumption is from imported oil.
Nuclear 8%
term focus is on utilization of coal— According to the Energy Information
Coal 22% Hydro, Solar,
our Nation’s most abundant energy Administration (EIA), U.S. energy
Wind, Geo 5%
resource. Through internal govern- expenditures for 1996 were $291 billion Biomass 3%
ment research and external partner- for petroleum products and $214 billion
Oil 38%
ships with industry and academic for electric power. Within the electric-
organizations, we will promote U.S. generation sector, fossil fuels provide
68% of the overall domestic need. Coal This graph shows the world’s primary
global leadership in coal fuels and
power-systems technology, creating accounts for 55% of electricity needs energy supply for the past 150 years.
U.S. dependence on low-cost energy. STRATEGIC ISSUES Environmental compliance with
U.S. jobs and contributing to a and is expected to continue to fuel the The most noticeable feature is the 20-fold
The continued strength of the U.S. AND DRIVERS domestic regulations. Given potential
stronger economy. majority of electric power production.
increase in energy use between 1850 and economy depends on the availability of regulatory requirements for NOX, SO 2,
Increased competition in the domestic
The U.S. trade balance for oil and natu-
1990. The energy mix has also changed. low-cost energy. The demand for elec- power-generation industry. Transform- HAPs, ozone, fine particulates, and
ral gas was a negative $63 billion in
VISION TO 2015 In 1850, biomass—wood—was the primary tricity and transportation fuels will ing a regulated power-generation solid and liquid wastes, the Nation
1996. This amount is approximately
continue to grow. Fossil fuels will meet industry into one that is market-driven must find cost-effective ways to
Clean production of low-cost electric- equal to the top three export commodities energy source. In 1990, fossil fuels—coal,
much of this demand. creates uncertainties. As a result, implement environmental protection
ity and low-cost fuels from coal will (chemicals, agricultural products, and oil, and natural gas—are the primary
Changes in electricity prices have sig- industry is reluctant to risk major, regulations.
raise global living standards for manufactured goods). energy sources.
future generations. nificant effects on the economy. For long-term investments in generation Energy R&D trends and funding
example, an increase in the cost of elec- facilities, especially those associated constraints. R&D investments, includ-
As the leader in developing ultra-
HISTORY OF WORLD ENERGY MIX tricity of 0.5 cents per kilowatt-hour with advanced technologies having ing energy R&D, help drive economic
high-efficiency energy technologies
(about a 7% increase in delivered price) higher capital costs, even if they show growth and job creation, and are one
with near-zero emissions, the United
leads to the same inflationary impact as improved environmental performance. of the most important foundations for
States will benefit from plentiful, 500
a 30-cent-per-gallon rise in gasoline Effective means are needed to over- U.S. economic competitiveness and
low-cost electricity supplies and alter-
price (about a 25% increase in delivered come market entry barriers to these international leadership. However,
nate fuel sources. The United States
price). Therefore, low-cost electricity is advanced technologies. investments from both the private
will produce a significant share of 400
Biomass essential to economic growth. sector and the Federal government
the products and services being used Economic competitiveness. Because
Nuclear
However, Americans want secure other governments provide assistance have declined significantly; this trend
in the fast-growing world energy Hydro
energy supplies, and the associated to their industries, the Federal govern- is expected to continue. Consequently,
market while enhancing its trade 300
Gas government resources must be lever-
Quads/yr
balance, and creating highly skilled, economic benefits, achieved in an ment must strive to ensure that U.S.
environmentally responsible manner. industries are able to compete in the aged with private-sector funds to
well-paying jobs.
The goal of affordable energy that global market, and must support activi- achieve identified goals within the
200
does not harm the environment can ties that effectively secure a “level envisioned time frame.
Oil
be achieved by the use of advanced, playing field” for domestic suppliers.
100 more efficient power generation and
conversion systems.
Coal
0
1850 1870 1890 1910 1930 1950 1970 1990
6 7
S T R A T E G I C P L A N S T R A T E G I C P L A N
protect the environment as part of the become targets for reduced funding. expected to follow. The drivers are
FUNDING HISTORY
Clean Air Act Amendments (CAAA) Congress’ concerns also extend to the (1) reduced cost of electricity to con-
implementation. Further reduced stan- effects of unfunded mandates, includ- sumers and (2) the desire to retain
Funding for C&PS is declining. Closer
dards on NO X emissions (as a precur- ing added costs for compliance with current jobs and encourage future
300 sor to ground-level ozone), lower caps increasingly stringent regulations, on investments in their States.
288 collaboration with private and public stake-
279 on SO 2 emissions, tightened fine the future domestic economy.
holders has facilitated progress toward particulate emission requirements, and Other considerations
250
Internal DOE. Given the present fund-
240 240 243 program goals. the introduction of new limits on haz- ing constraints, the Energy Resources International Energy Agency (IEA).
ardous air pollutants (e.g., mercury) Business Line of DOE has competing The 23 countries that comprise the IEA
210
200 200 are expected. priorities. Administration policy seek to create conditions in which the
178
Dollars, Millions
Federal Energy Regulatory Commission drivers for DOE focus on investments energy sectors of their economies can
150 (FERC). FERC recently issued Orders to improve and protect the environ- make the fullest possible contributions
888 and 889 on equal access to the ment, maintain energy security, and to sustain economic development, the
transmission of electricity as a way to promote the economic well-being of the well-being of their people, and a high-
100
increase competition. These orders, in Nation. DOE is dedicated to ensuring quality environment. Establishing free
effect, started a restructuring of the that R&D is well-focused, and that it and open markets is a priority. Energy
50 power industry. will return lasting public benefits many security and environmental protection
times greater than the initial invest- are also emphasized through diversifi-
Other government agencies ments. DOE also has a stake in ensur- cation of energy supply, cleaner and
0
1991 1992 1993 1994 1995 1996 1997 1998 U.S. Congress. Congress is expected to ing that advanced technologies arising more efficient use of energy, and
debate the Administration’s Compre- from R&D are effectively deployed to energy conservation. The IEA countries
hensive Electricity Competition Plan reap these public benefits. recognize the reality of global energy
Energy security. World and U.S. oil S TA K E H O L D E R C O N S I D E R A T I O N S projected, especially in developing and to consider the uncertainties that State and local governments. Several interdependence and promote the effec-
demand continues to grow while U.S. and transitional economies, and there increased competition will bring. As State governments have already tive operation of international energy
Public markets.
oil production declines. This, coupled is intense global competition for Congress seems determined to main- enacted legislation that supports
with the reality that a large percentage The public’s concerns include energy this market. tain projected balanced budgets, gov- increased competition in the power-
of oil resources are found in politically costs, system reliability, and the protec- ernment investments in R&D may generation industry. Much more is
With few units contemplated domesti-
uncertain regions, means that the tion of health and the environment.
cally, and facing subsidized competi-
Nation must position itself with technolo- tion abroad, U.S. vendors and suppliers
gies that use domestic resources to pro- Utilities and other electricity generators
are unable to invest in longer-term
duce transportation fuels to ensure its TRENDS IN ENERGY, ELECTRICITY, AND GDP
Utilities are concerned about proposed R&D to develop improved systems
long-term energy and national security. tougher environmental regulations. without Federal government help.
Response to global climate concerns. They are also concerned about the Energy is the vehicle of economic
International concerns over the future treatment of assets in which they Industry sector 5
development. In developed countries,
impacts of greenhouse gases produced invested as a “regulated” industry.
The industry sector wants to be able to electric consumption grows at the
by anthropogenic activities have led to In preparation for competition, some
rely on stable energy prices and reli-
are providing other energy services, same rate as GDP. 4
an international consensus that cost- able supplies. Electricity-intensive
effective measures to reduce the growth shedding assets, or entering into joint
industries see deregulation as a way to Electricity
of greenhouse gas emissions are pru- ventures, while others continue to Consumption
reduce their production costs. They are
operate as low-cost producers. 3
Index,1970 = 1
dent. Some Nations remain concerned also concerned about availability, relia-
about the uncertainties of potential bility, price stability, and power quality.
longer-term (2100 and beyond) impacts. Equipment suppliers and energy GDP
Domestic and international sources are service companies 2
Regulatory agencies and
also pressing for large absolute reduc- Domestic growth in demand for elec- oversight bodies Energy
Consumption
tions in the near-term. Technologies tricity will be low. Thus, equipment
Environmental Protection Agency 1
being developed to allow the use of suppliers see limited opportunities for
(EPA). The EPA is implementing more
domestic resources must address new baseload capacity in the U.S. over
stringent environmental standards,
these concerns. the next 10 years. However, a large
intended to improve human health and 0 History Projection
international market for electricity is 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015
8 9
S T R A T E G I C P L A N S T R A T E G I C P L A N
Developing countries. Developing FUTURE TRENDS The dependence of the U.S. on
U.S. POWER GENERATION
countries include energy as a high- Increased U.S. reliance on fossil fuels. imported fuels can be reduced through
priority need along with food, clean The DOE Energy Information Adminis- changes in the mode of transportation
water, and health and medical care. tration (EIA) projects that U.S. reliance and the production of alternate fuels Fossil fuels currently are used to produce
Many developing countries would like on fossil fuels will rise from the present from coal or other sources. 2500
68% of the Nation’s electricity. That figure is
assistance with electrification. They level of 85% to 90% by 2020 under cur- Increased world energy demand. On
expected to rise to 83% by 2020.
believe they can benefit from a better rent trends of price and usage. The EIA a world scale, oil demand is expected
understanding of advanced fossil sys- also projects that the use of fossil fuels to reach about 97 million barrels per 2000
tems, e.g., clean coal technologies. to produce electricity will rise from the day by 2010, or about 37% higher Coal
Generation, Billion kw-hr
In addition to technical assistance and current 68% to 83% by 2020. Approxi- than today.
technology transfer, developing coun- mately 225,000 MW of new electricity
1500
Economic growth, largely in develop-
tries also want assistance in infrastruc- generating capacity will be required by ing countries, will fuel these increases
ture development. Underdeveloped 2010. Of this, 50% will be gas-fired Other
in energy demand for oil. 1000
financial and regulatory systems often peaking units, and 40% will be gas
increase project risk in these countries. Decline in longer-range R&D funding.
combined cycle.
This means project financing by public- Longer-range energy R&D, funded
Natural Gas
U.S. oil and gas imports. The United solely by private-sector entities, is 500
and private-sector organizations is
States is a declining oil producer and expected to continue its decline as
challenging. In general, newly industri-
imports one-half of the 18.4 million companies focus more on near-term
alized nations present unparalleled Petroleum
barrels of oil consumed every day. research (6 months to 1 year) because 0
opportunities for applying U.S. exper-
The U.S. is also a net importer of natu- 1993 1996 1999 2002 2005 2008 2011 2014 2017 2020
tise (resulting in U.S. sales) to build of increasing competition.
ral gas. By 2020, it is expected that the
clean, reliable, and economical electric
Nation will import about 65% of its oil,
power systems.
a total of 16 million barrels per day,
and 15% of its gas.
STRATEGIC GOALS — production and use, while maintain- ral gas, and over 85% in combined
ing the availability and affordability heat and power applications.
PLANNING HORIZON 2015 of fossil fuels. •During the 2003–2010 period, make
•Security. Ensure the availability of available technologies for existing
secure, affordable liquid fuels. coal and power plants that will signif-
GROWTH OF WORLD ENERGY USE AND POPULATION
DOE STRATEGIC ENERGY GOALS icantly lower the cost of meeting more
Meeting these goals will yield sus-
The Coal and Power Systems (C&PS) tained public benefits from the use of stringent environmental regulations.
Population is perhaps the most important Program is an integral part of the Fossil our abundant fossil resources. •During the 2005–2015 period, make
factor in determining the future of energy 12 1200 Energy Strategic Plan and derives its available a suite of cost-effective
World Energy goals and objectives from the goals of
use. Population is predicted to grow Consumption options with increasingly large carbon
10 1000
that plan. The Fossil Energy Strategic COAL AND POWER SYSTEMS sequestration capacity.
from 5.9 billion to 8 to 12 billion by 2100.
Plan in turn supports a key DOE strate- PROGRAM GOALS
This expanded world population will con- World gic energy goal: promoting secure, Security
Population Coal and Power Systems Program goals
sume three times as much energy as we 8 800 competitive, and environmentally
support the Fossil Energy environmen- •Provide the Nation with large, less-
People, Billions
consumed in 1970. responsible energy systems that serve
tal and security goals in the following polluting alternative sources of liquid
Quad/yr
6 600 the public’s needs. The C&PS program
ways: transportation fuels that are cost-
is also responsive to similar goals of
competitive with equivalent petroleum
the Comprehensive National Energy
4 400 Environment products, for deployment beginning
Strategy.
•By 2010, make available cost-effective around 2010.
The C&PS program supports the fol-
2 200 power systems, with negligible emis-
Population of lowing primary goals of the Fossil
Developed Countries sions of conventional pollutants and
Energy Strategic Plan:
significantly reduced CO 2, that
0 0 •Environment. Eliminate environmen-
1900 2050 2100
achieve generating efficiencies greater
1950 2000
tal issues as a barrier to fossil fuel than 60% using coal, 75% using natu-
10 11
S T R A T E G I C P L A N S T R A T E G I C P L A N
In addition, the C&PS program has the Vision 21 •Near-zero pollutants to meet more
A VISION 21 FLEET FOR THE 21ST CENTURY
goals of: The ultimate integration of the C&PS stringent emissions standards (less
•Promoting the export of U.S. fossil goals is a concept called Vision 21, than one-tenth of New Source Perfor-
technology products, equipment, and which builds on the C&PS technology mance Standards [NSPS] for criteria Vision 21 technologies are intended to
services to create U.S. jobs, reduce the development portfolio. Vision 21 pro- pollutants) at a lower cost Electricity and Electricity and Electric Industrial Hydrogen
Fuels Company Process Heat Company Energy and Electric support customer choice through a fleet of
trade deficit, and reduce local, vides the technology for a new fleet of •Options for no net CO 2 emissions Company Company Company
competitive plants. These highly efficient,
regional, and global environmental cost-competitive plants of varying sizes •Fuel flexibility (coal, natural gas, and near-zero-emissions systems can be opti-
impacts. with ultra-high efficiency, near-zero opportunity fuels)
pollutants, and fuel-flexible features. mized for a variety of private-sector needs.
•Helping to ensure the reliability of •A set of flexible, integrated modules
environmentally acceptable energy Some of these plants will be capable of For example, an electric company Vision 21
Electricity Electricity
configured to meet a range of market
supplies by managing the regulatory integrating power generation with the plant would be configured to optimize the
applications and sizes, and capable of
review, as required by law, of certain production of a high-value slate of
producing electric power and an production of electricity; an industrial energy
export/import activities related to transportation fuels and chemicals
array of high-value commodities Process Liquids/ company would be configured to produce
electricity. for the market. Vision 21 plants will Heat Gas
(such as chemicals, high-quality
also have the option of using carbon electricity and high-value liquids and gases,
steam, liquid fuels, and hydrogen) at
sequestration systems to address and a self-generator’s system would be con-
competitive prices in a free market
global climate change issues.
figured as a competitive source of electric-
Specific objectives for the Coal and
The distinguishing features of the
Power Systems Program elements in Natural Gas ity, heat, and perhaps hydrogen. Distributed
Vision 21 fleet are:
support of the goals are identified in generators could provide the same services
Synthesis Gas Hydrogen
•Production of low-cost electricity at the table on pages 14 and 15. in remote areas or alternative choices to
stand-alone efficiencies of more than Distributed Generation
60% for coal and over 75% using Electricity customers in developed areas and also
Electricity
natural gas Conventional Steam provide peaking capacity to the grids.
Fuels
FOSSIL-BASED POWER AND ENERGY UTILIZATION P U B L I C , C U S T O M E R , A N D S TA K E - Industrial Boiler Owners, and the Gas An example of a specific benefit would
HOLDER OUTREACH GOALS Turbine Association; from State agen- be the compliance cost savings resulting
DOE’s outreach efforts are increasing cies; and from advisory groups such as from the deployment of advanced envi-
Conventional new powerplants operate at
public awareness of the importance of the National Coal Council. These ronmental-control devices to reduce
100 35% to 37% efficiency. The Clean Coal Tech-
Vision 21
clean, low-cost fossil energy to sustain strong outreach activities will improve powerplant emissions, including SO2
nology Program has already demonstrated the acceptance of fossil fuel, particu- and NO X. The benefit would be lower
a high quality of life now and for
plants with 38% to 40% efficiency. “Nth”- future generations. larly coal, as an environmentally electricity cost. The overall economic
75
of-a-kind CCT units will improve to the 45%
acceptable source of energy. value of even a small reduction in the
Advanced A goal of these outreach efforts is to
Central cost to produce electricity is huge con-
Efficiency (HHV), %
System to 50% level. Vision 21 powerplants will be seek input from the public and other
(Coal) ATS (Gas) sidering that domestic electricity sales
capable of 60% to 65% efficiency using stakeholders in order to properly fash-
50 are forecast to total 3,877 billion kilo-
PC CCT ion a program that meets their needs.
Conventional coal, 75% efficiency using gas, and 85% watt-hours in 2010.
These efforts highlight fossil energy’s
efficiency in combined heat and power PERFORMANCE INDICATORS Achievement is the number of target
contribution to improved environmen-
25 applications. tal quality, strong economic health, and goals reached and the degree to which
continued national security. they are achieved. An example is the
DEFINITION OF OUTCOME- achievement of cost and performance
Recommendations and suggestions on ORIENTED METRICS
0
targets of systems and technologies
program emphasis and direction con-
Coal Clean Coal Advanced Advanced Coal-Based Natural Gas Gasification/ Benefits are the overall value to the within a planned time frame.
IGCC, PFBC, Gas Hybrid FC/Turbine Combustion tinue to be received from customer and
LEBS, and Turbines Hybrids Coproduction public resulting from the program
IFC (HIPPS) Fuel Utilization stakeholder groups, such as the Coal
investment in R&D. Types of benefits
Utilization Research Council, the Coal
include lower-cost energy, cleaner
Industry Strategy Forum, the Gasifica-
environment, and increased jobs.
tion Technology Council, the Council of
12 13
S T R A T E G I C P L A N S T R A T E G I C P L A N
ÃC&PS OBJECTIVES BY PROGRAM ELEMENTS
Time Frame Objectives Time Frame Objectives
Technologies for Existing Plants Carbon Sequestration Research
2000 Complete the development, demonstration, and dissemination of technical, economic, and environmental results for 1999 In conjunction with the Office of Energy Research, the Office of Fossil Energy will develop a science and technology roadmap that will
environmental-control systems needed to meet Title IV requirements of the Clean Air Act. describe various sequestration pathways.
2000 Develop a technology roadmap that leads to improved powerplant efficiency and performance through systems integration, advanced- 2005 to 2010 Develop moderate-cost technology options for CO2 management, which would include capture, separation, use, and
combustion and emission-optimization control systems, and other techniques. disposal.
2005 Promote the enhancement of the technical performance of environmental-control systems to meet pending environmental regulations, 2010 to 2015 Develop effective technologies to integrate capture and sequestration of CO2 with advanced power systems, and develop technological
including those associated with PM2.5, NOX reduction for ozone attainment, and HAPs. approaches that enhance the performance and efficiency of natural sinks.
2010 Foster the development of new, cost-effective advanced environmental-control technologies for achieving near-zero 2015 Develop technology options based on novel concepts, such as artificial photosynthesis, to achieve near-zero greenhouse gas
emissions of SO2, NOX, particulates, and HAPs, and for minimizing solid and liquid wastes. emissions from fossil fuels, at low cost.
2010 Develop plant efficiency and performance enhancement techniques that can be used domestically and internationally for direct reduc- Advanced Research
tion of CO2 emissions and that will improve coal-fired powerplant competitiveness.
Ongoing Continue to seek technology breakthroughs by pursuing research performed under University Coal Research, Small
Near- and Mid-Term Development and Demonstration Business Innovative Research, and Historically Black Colleges and Universities/Other Minority Institution programs.
2001 Complete the Low-Emissions Boiler System Development Program and disseminate the results to prospective customers. 2005 Extend the materials, bioprocessing, and coal utilization science technology base by conducting evolutionary support research for the
technical modules and product lines.
2005 Complete the demonstration projects conducted under the Clean Coal Technology Demonstration Program.
2010 Develop revolutionary technologies and processes that can substantially improve and advance power, environmental, and fuel
2005 Foster development of advanced gas turbine systems that use natural gas and are also capable of operating with coal- or biomass-
systems. This new portfolio of advanced technologies will contribute to the achievement of Vision 21.
derived fuel, to be introduced into commercial operation by 2010.
2015 Develop a series of “leapfrog” technologies (e.g., advanced CO2-management schemes, advanced hybrid processes and cycles, and
2010 Complete the development of a suite of power systems, including pressurized fluidized-bed combustion, integrated gasification
smart systems).
combined cycle, indirect fired cycles, and gasification/fuel cell combined cycles for market readiness and as power modules for
Vision 21. International
2010 Complete the technology base necessary to ensure commercial viability of technologies that produce transportation fuels at a cost Ongoing Introduce coal-intensive or coal-importing developing countries to advanced power systems technologies that reduce
competitive with conventional petroleum products and with 20% less CO2 emissions than current petroleum-process technologies. CO2 and other emissions.
2010 Ensure the commercial viability of technologies needed to convert solid feedstocks into finished fuels, chemicals, Ongoing Assist U.S. industries in maintaining world leadership in fossil fuel technologies, consistent with sustainable development, climate and
feedstocks, and carbon products at a competitive price and with minimal environmental impact. environmental goals, and U.S. economic competitiveness.
Distributed Generation Ongoing Promote U.S. goods and services in the international market.
2000 Perform the systems, market, and cost analyses necessary to establish a strategic technology roadmap. Ongoing Ensure transparency in energy trade.
2005 Complete demonstration of the domestic and international commercial viability of new distributed power-generation technologies that Ongoing Provide the appropriate regulatory framework for effective international trade.
use fossil fuels, including advanced fuel cells, heat engines, hybrids, and integrated heat and power systems.
Technical, Economic, and Environmental Systems Studies
2010 Enhance the technical, economic, and environmental performance of distributed power-generation technologies, and extend fuel
The Technical, Economic and Environmental Systems Studies support all of the other seven key elements in the Coal and Power
capability to biomass and other CO2-neutral fuels to compete in the restructured power-generation market.
Systems Program. A strategic goal is to generate information from systems studies that shape the framework and scope of the C&PS
Vision 21 strategic plan and provide insight on important energy and environmental issues to DOE management and stakeholders.
2005 to 2010 Further develop existing gasification, gas cleanup, combustion, turbine, fuel cell, and coproduction technology to meet efficiency goals 2000 Complete assessments of pending environmental regulations, State and Federal utility restructuring legislation, and other policy,
greater than 60% for coal-fired units and 75% for gas-fired units, with near-zero SO2, NOX, and particulate emissions. regulatory, and legislative issues that arise, to determine their effect on coal and power systems deployment.
2005 to 2010 Complete development of advanced materials, components, catalysts and sorbents, computational sciences, and other 2005 Develop a C&PS strategy consistent with the national strategy on greenhouse gas emissions.
fundamental technologies required to support integration of modules into the Vision 21 fleet of energy plants.
2010 Ensure that specific enabling technologies have been identified, are available, and are market-ready to achieve the benefits of
Vision 21.
14 15
S T R A T E G I C P L A N S T R A T E G I C P L A N
A specific achievement could be the ACCOMPLISHMENTS The technical, environmental, and
CLEAN COAL TECHNOLOGY DEMONSTRATION PROGRAM MILESTONES
number of advanced technologies, Lower-cost and more effective SO 2- operational database for commercial-
products, and services resulting from control technologies for coal-fired scale utility atmospheric fluidized-bed
the R&D program (e.g., clean coal tech- combustion (AFBC) was developed FY 1998 1999 2000 2001 2002 2003 2004 2005
powerplants have been developed in
nologies) developed for commercial partnership with industry, producing under the cost-shared FE-industry
Power Systems
readiness. an installed base of 77 gigawatts, one- program. As a result of this 110-MWe
Wabash River Final Report
Effectiveness is the extent of the fourth of all U.S. capacity. The cumula- repowering demonstration, the vendor
Tampa Electric Final Report
impacts made in achieving the target tive building and operating costs for was able to introduce a commercial Sierra Final Report
goals. An example is effectiveness in these scrubbers through 1995 were line of AFBC boilers 3 years earlier Alaska IDEA Start Operation Final Report
assisting U.S. industry to compete in reduced by $50 billion because of this than expected. Coal Diesel Start Construction Start Operation Final Report
the international market. research. Typical emissions of SO 2 from In the first utility-scale demonstration McIntosh 4A Start Construction Start Operation Final Report
a 500-MWe powerplant have dropped of pressurized fluidized-bed combus- Jacksonville Start Construction Start Operation Final Report
Awareness is the degree and extent to
Clean Energy Start Construction Start Operation Final Report
which changes in public perception of from 70,000 tons per year in 1970 to tion (PFBC), a 70-MW plant achieved
McIntosh 4B
coal and fossil power are realized 20,000 tons per year in 1995. over 11,000 hours of operation and Start Construction Start Operation Final Report
through the dissemination of fact-based A new generation of low-NO X combus- successfully demonstrated 90% to 95%
Environmental
SO 2 removal and NO X emissions in the Systems
information. tors and postcombustion devices has
been developed by the Office of Fossil range of 0.15-0.33 lb/10 6 Btu. This joint SCS-WF Final Report
FE-Ohio Power Company project’s EER-SI Final Report
Energy (FE) in partnership with indus-
successful operation is the basis for a PS Colorado Final Report
try. Burner sales to date exceed $750
EER-WF Final Report
million, and will approach $4 billion by project that will demonstrate a second-
LIFAC Final Report
2000. Similar NO X reductions would generation PFBC at twice this scale.
CHIYODA Final Report
have been more costly using previously NYSE&G Final Report
attainable control technology. Sales of Micro Reburn Final Report
postcombustion technologies (like
selective catalytic reduction) are pro- Coal Fuels and
Industrial Systems
jected at over $2.5 billion by 2000.
AAB CE-Expert Final Report
Previously, this technology had cost
Rosebud Final Report
twice as much as today’s version. LPMEOH Final Report
Bethlehem-Cl Final Report
CPICOR Final Report
Start Construction Start Operation
Over 600 MWe in integrated gasifica- projects under the cost-shared CCT furnace granular-coal injection technol-
tion combined-cycle (IGCC) power is program. Both processes produce a ogy demonstrated that 40% of the coke
now in commercial service in the U.S. stable coal product having low mois- can be replaced with coal injected
at three locations. The technology being ture content, low sulfur content, and a directly into a blast furnace. This pro-
demonstrated is 10% to 20% more effi- heating value of 12,000 Btu/lb. One cess reduces the coke production
cient than conventional pulverized coal process also produces a liquid product requirement with the attendant reduc-
plants, achieves up to 98% SO 2 removal, equivalent to No. 6 fuel oil. The prod- tion in SO 2, NO X, and HAPs emissions.
and reduces NO X emissions to approxi- ucts from these two projects are being Numerous awards have been presented
60% EFFICIENCY mately 0.1 lb/10 6 Btu. This achieve- sold to utility and industrial consumers. to projects conducted under the FE-
ment was the result of the cost-shared The technologies are being marketed industry cost-shared CCT program for
government/industry Clean Coal actively worldwide, particularly advancing coal-based technologies.
COAL ELECTRICITY
Technology (CCT) Program partnership. in Asia. Five Powerplant of the Year Awards
NATURAL GAS FUELS
BIOMASS CHEMICALS A barrier to using the Nation’s vast The environmental acceptability of have been presented by Power Magazine
low-sulfur, low-energy-density western industrial coal use is being addressed since 1991 to projects demonstrating
coal resources is being addressed under FE-industrial partnership advanced flue gas desulfurization,
through two advanced, coal-upgrading demonstrations. For example, blast PFBC, and IGCC technologies.
16 17
S T R A T E G I C P L A N S T R A T E G I C P L A N
PROGRAM STRATEGIES informed decisions. This requires an Strategic partnering. Partnering with COAL AND POWER systems integration, (2) advanced
effective coordinated outreach effort. industry and other key public- and combustion technology, (3) advanced
Examples of outreach tools include private-sector stakeholders is essential SYSTEMS TECHNOLOGY optimization and boiler control systems, S TA K E H O L D E R F E E D B A C K
conferences, workshops, regional to achieve program goals. Partnership and (4) reduced parasitic power con-
The underlying strategic principle is to • Continue emphasis on power
forums, educational programs and arrangements with stakeholders sumption associated with environmental
build on the technological successes generation R&D
materials, speaking engagements, include: controls.
already achieved by the Coal and The strategic focus of the C&PS pro-
• Pursue R&D on retrofitable emission
Power Systems Program in order to multimedia presentations, and the •Cost-sharing or cost participation gram is on implementing eight key The goal is to make these systems
control systems
develop very clean advanced electric Internet. Feedback from various stake- with industry and other organizations elements aimed at developing and flexible so they can be incorporated
power generation and transportation holders, customers, users, and interest deploying technology options for the into existing powerplants as well as • Pursue R&D on coal fuels
•Establishing diverse sources (includ-
fuel production technologies. Three groups helps measure the benefits and ing Historically Black Colleges and changing energy landscape over the integrated into future plant designs. • Pursue R&D on environmental
basic program strategies used to imple- effectiveness of the outreach strategy. Universities/Other Minority Institu- next two decades. These program aspects of coal production
ment this principle are customer focus, Optimizing resources. Scarce fiscal tions) of collaborative and coordinated elements are described below. technology
resource optimization, and strategic resources must be used wisely and research and development activities NEAR- AND MID-TERM DEVELOPMENT
Four guiding principles are used to • Solicit stakeholder input on R&D
partnering. effectively. The focus is on optimizing aimed at achieving the program objec- AND DEMONSTRATION
develop each key element: priorities for carbon sequestration
Focusing on the customer-stakeholder. resource use by leveraging existing tives within required time frames Clean Coal Technology demonstrations.
1. Build on past R&D successes and • Pursue industry-government-
A primary strategy is to listen to the funds through cost participation with •Establishing feedback mechanisms, The strategy is to demonstrate highly
experiences. university partnerships in carbon
customers’ needs and incorporate them other stakeholders, and making use of such as industry forums, to assess efficient, low-emission, advanced coal
2. Build an essential portfolio of sequestration research
into the program’s goals, objectives, relevant and applicable results from progress and direction technologies for electric power genera-
other research programs through col- technologies including advanced, tion, environmental control, production
and activities. To accomplish this, cus-
With respect to cost-sharing and repay- revolutionary, and “leapfrog”
tomer forums are established, utilizing laborative efforts. of clean fuels, and industrial applica-
ment arrangements with industry, technologies.
mechanisms such as regional meetings, An analysis of the potential return on tions. Commercial-scale demonstration
appropriate terms depend on the
joint studies, and co-sponsorship of the research investment will be used to 3. Provide timely and effective projects will be concluded delivering
maturity of the technology and reflect
events. establish funding priorities. In addi- dissemination of technology results. operational, technical, environmental,
the sharing and management of risks.
tion, multi-year cost profiles (as well as and economic performance know-how
Customers need easy access to accu- 4. Use analysis as a guiding tool
cost-sharing profiles) are used to plan to industry.
rate, reliable, usable, and relevant in R&D.
information to enable them to make investment requirements. High-efficiency, ultra-clean coal- and
natural-gas-power systems. The strat-
TECHNOLOGIES FOR egy is to foster the development of (1)
EXISTING PLANTS ultra-high-efficiency, environmentally
superior, and cost-competitive advanced
Cost-effective advanced environmental
gas turbine systems for baseload
compliance. Strategies are to pursue the
applications; (2) low-emissions boiler
development of technologies to reduce
Demonstrating the success of converting systems to provide reliable, efficient,
emissions of SO X, NO X, and fine partic-
coal to high-value, low-emission feedstocks, and environmentally superior alterna-
ulates from powerplant flue gases;
the innovative ENCOAL process plant near tives to current technologies; and (3)
develop controls for hazardous air pol-
technically, economically, and environ-
Gillette, Wyoming, now supplies industry lutants; reduce the quantity of solid
mentally superior pressurized flu-
with both solid and liquid fuels of superior
waste generated; and improve disposal
idized-bed combustion, integrated
practices and promote the economic
quality. With a goal of 1,000 tons of coal gasification combined cycle, indirect
utilization of solid waste to meet
processed per day, ENCOAL has supplied fired cycle, and gasification/fuel cell
existing and emerging environmental
combined systems.
5 million gallons of coal-derived liquid to regulations for the utility sector.
The potential efficiency of these sys-
eight industrial customers. It has delivered Improved plant efficiency and
tems ranges from 40% to nearly 70%.
17 unit trains of process-derived fuel, a low- performance. The program will invest
The challenge is to achieve these per-
in approaches that improve the effi-
sulfur, high-Btu solid product, to six major formance levels while providing elec-
ciency and performance of the existing
utilities. A large-scale commercial plant is tricity at a cost that is 10% to 20%
fleet of over 300 gigawatts of coal-fired
now under development. lower than current generation plants.
power generation through (1) improved
18 19
S T R A T E G I C P L A N S T R A T E G I C P L A N
Advanced fuels production. The pro- DISTRIBUTED GENERATION VISION 21 The success of Vision 21 also depends INTERNATIONAL TECHNICAL, ECONOMIC, AND
gram will seek the development and This effort will foster the development Develop technology to enable Vision 21. on significant innovation in supporting The strategy is to advance the coal and E N V I R O N M E N TA L S Y S T E M S S T U D I E S
demonstration of technologies capable and deployment of clean, reliable base- Vision 21 is a set of flexible, high- technology areas, including materials power industry worldwide by working Analyses will be performed to shape
of (1) providing fuels, chemicals, and load power generation alternatives, efficiency modular systems of varying and components, catalysts and sor- with U.S. and foreign partners to: the framework and scope of the
carbon products for use in all sectors of such as fuel cells and heat engines, that sizes that can be integrated and bents, computational sciences, and C&PS program, and provide insight
•Maximize export opportunities sup-
the economy and (2) converting raw can be integrated into systems capable tailored to produce electricity and advanced controls and sensors. to FE stakeholders on energy and
porting domestic energy project
solids into utility and boiler fuels and of providing both heat and power for high-value, fossil-based commodities environmental issues.
developers in expanding international
tailored feedstocks to produce chemi- industrial and commercial customers. for domestic and international markets. sales of energy technology by facili- Among the most significant issues are
cals and carbon products. The aim is to Vision 21 systems will (1) be capable of CARBON SEQUESTRATION RESEARCH
These systems are characterized by tating new market entry, expanding (1) potential impacts of implementing
provide the Nation with the capability producing electricity at an efficiency of The goal is to provide a suite of cost-
their range of sizes to meet distributed existing markets, and encouraging the Clean Air Act Amendments of 1990
to economically produce transportation over 60% with coal and 75% with gas at effective options that capture and
applications, high efficiencies of 50% to private investments, while removing Title IV (production of SO 2 and NO X)
fuels, chemicals, and feedstocks from a cost that is 10% to 20% less than cur- sequester CO 2 emissions from fossil-
70%, and extremely low pollutant emis- potential barriers to investments. This and Title I (reduction of NO X to attain
coal, natural gas, oil shale, biomass, rent systems, (2) offer choices for the fueled powerplants. This research
sions. The aim is to provide systems includes the introduction of advanced ozone National Ambient Air Quality
and other carbonaceous resources. economical production of fuels and focuses on (1) capture, separation, use,
that can compete in the domestic utility power technologies that reduce car- Standards [NAAQS]); (2) pending
Technologies to produce hydrogen will chemicals, (3) have near-zero SO 2, NO X, and/or disposal of CO 2 before it enters
market in areas where transmission is bon dioxide and other emissions into revisions of the NAAQS for fine partic-
also be pursued through cooperative and particulate emissions, (4) provide the atmosphere; (2) enhancement of the
expensive or restricted, or where relia- coal-intensive economies. ulates (PM 2.5) and ozone; (3) reduction
efforts with other offices in DOE. options that will have no net CO2 performance and efficiency of natural
bility is absolutely required. There is •Provide leadership in international of hazardous air pollutants particularly
also potential for a significant market emissions, and (5) be fuel-flexible. CO 2 sinks; and (3) novel techniques, mercury; (4) climate change strategies;
organizations. All activities are
in developing countries. R&D will focus on new enabling tech- such as artificial photosynthesis and and (5) electricity-restructuring
driven by and support U.S. foreign
nologies such as low-cost oxygen- and other biotechnologies. legislation.
policy objectives related to energy,
hydrogen-separation membranes and This element of the program involves environment, economic prosperity,
high-temperature heat exchangers, as supporting science, as well as technol- and national security. Focus is on
well as improving the performance and ogy development and proof of concept expanding international demand for
integration of gasifiers, advanced gas verification. U.S. coal and U.S. technologies.
cleanup systems, advanced-combustion
•Establish effective partnerships that
systems, hybrid systems, turbines, and
increase bilateral and multilateral
coproduction technologies. ADVANCED RESEARCH
R&D efforts; promote U.S. interna-
The program will seek new and inno- tional technology transfer; support
vative scientific approaches that are environmental cooperation; and
essential to achieving C&PS strategic encourage environmentally friendly
goals. Advanced research pursues (1) development. This strategy will be
evolutionary supporting research for accomplished through training and
A Clean Coal Technology project demon-
product lines being developed, (2) rev- by providing information on clean
strates advanced electric power generation: olutionary and innovative concepts power systems.
two slagging coal combustors will burn that produce significant technological
pulverized coal in a Healy, Alaska, plant.
improvements in product lines, and (3)
leapfrog or breakthrough technological
concepts that respond to grand techni-
cal challenges (i.e., those challenges
that, if overcome, can result in major,
accelerated advancements toward
achieving program goals).
Chris Arend
20 21
S T R A T E G I C P L A N S T R A T E G I C P L A N
PROGRAM BENEFITS Emission and cost reductions. Between Capturing U.S. and global markets.
ÃBENEFITS SUMMARY OF FOSSIL ENERGY’S COAL AND POWER SYSTEMS PROGRAM
the years 2000 and 2015, 70% reduc- Cost-competitive advanced technolo-
tions are projected for SO 2, NO X, and gies will equip U.S. manufacturers to 2001–2005 2006–2010 2011–2015 2016–2020
Investments made in C&PS by govern- HAPs emissions from existing power- capture a significant share of U.S. and
Domestic Power System New Capacity—Coal & Gas (GW/5yr) 93 56 84 57
ment and industry are projected to reap plants, while environmental compliance global markets for power generation
Commercialization of Power Systems ($mm/5 yr) 19,958 11,226 19,297 14,108
enormous environmental, economic, cost reductions for meeting existing equipment. For the 20 years leading up
Jobs Created (job years/year) 163,656 92,055 158,235 115,686
and energy security benefits. The C&PS and future regulations are expected to to 2020, domestic sales are expected to
program is projected to result in the average about $5 billion per year through have an economic impact of about $65 Foreign Power System Capacity (GW/5 yr) 214 230 272 256
creation of over 700,000 jobs per year 2010 and could exceed $7 billion per billion and generate over 100,000 jobs Commercialization of Power Systems ($mm/5 yr) 48,587 54,522 66,777 67,522
and about $335 billion in new domestic year between 2010 and 2020. per year. During this same time period, Jobs Created (job years/year) 383,746 432,413 532,904 539,013
economic benefits through 2010. Tables Boost to the U.S. economy. Savings in international sales could potentially Cumulative Production Capacity—Coal Liquids (mm bbl/day) 0 0 0.15 0.54
containing a detailed summary of these the cost of electricity would have a bring in revenues of over $235 billion Commercialization of Coal Liquids Technology ($mm/5 yr) 0 0 1,158 4,316
projected benefits are shown below and beneficial effect on the U.S. economy. and could support about 500,000 jobs Jobs Created (job years/year) 0 0 1,586 5,914
on the next page. Over the first 10 years (through 2010), per year.
Macroeconomic Benefit of Lower Priced Electricity
the Gross Domestic Product (GDP) is Contribution to GDP ($mm/5 yr) 59,143 78,450 Unknown Unknown
expected to increase by slightly over Jobs Created (5 Year Average Change from Base) (job years/year) 117,404 165,856 Unknown Unknown
$137 billion, generating roughly
Direct Employment in C&PS R&D Program
140,000 jobs per year.
Dollars Invested in R&D ($mm/5 yr) 4,986 4,986 4,986 4,986
Jobs Created (job years/year) 40,882 40,882 40,882 40,882
ÃDERIVED PUBLIC BENEFITS FROM COAL AND POWER PROGRAM Environmental Compliance Cost Savings Due to R&D
Dollars Saved ($mm/5 yr) 19,800 33,000 36,500 36,500
Time Frame Program Drivers Public Benefits
TOTAL IMPACT OF FE C&PS PROGRAM
Near Term (2000–2004) Environmental Improvement Meet existing environmental standards with lower-cost
Economic ($mm/5 yr) 152,474 182,184 128,717* 127,432*
environmental technology (CCT) ($25B total savings) and
Jobs Created (job years/year) 705,689 731,207 733,608* 701,495*
higher efficiency system (ATS)
* Benefit estimates appear to decline from 2011 through 2020 because the macroeconomic benefits of lower-priced electricity have not been
Greenhouse Gas/Climate Change GHG reduction (through efficiency increase >60% with ATS
forecast, since they are unknown. If those benefits had been estimated, the benefits may not have declined from 2010.
and fuel cells and biomass cofiring) “voluntary contributions”
Mid Term (2005–2010) Environmental Improvement Achieve pending new environmental standards for existing
plants with new/improved/low-cost environmental
Reduced dependence on foreign oil. Reduced greenhouse gas emissions.
technologies ($6B/yr)
A U.S. coal-conversion industry could By 2020, deployment of more efficient
Greenhouse Gas/Climate Change and Deployment of first wave of new advanced powerplants reduce dependence on foreign oil sup- power systems globally could reduce
Environmental Impact (e.g., LEBS at 42% efficiency; 29% CO2 reduction) can plies, thus increasing the Nation’s oil greenhouse gas emissions by nearly 150
replace the aging fleet of powerplants (3,500 plants over 30 security while helping reduce the U.S. million tonnes (MMT)/year of carbon.
years old in 1998); replacement potential with other energy trade deficit, and capturing a The goal set for FE-sponsored seques-
advanced power systems is 70% of the current 300-GWe coal share of what could be the largest new tration options is to be able to offset all
capacity by 2010; 34-GWe new additions with coal by 2015; job-creating sector of the economy. growth in CO 2 emissions from U.S.
CO2 rate reduction of 42% through efficiency increase,
If, for example, domestic production of power generation after 2010.
incremental improvements in pollutant reduction of 1/4 to
liquid fuels could be increased by just
1/10 NSPS
1 million barrels per day, the balance of
Energy Security Energy security and reduced emissions in transportation sector payments would be reduced by $250
through use of enhanced diesel fuel billion over the period 2015 to 2030.
Long Term (2011–2015) Environmental Improvement Additional $6B/yr savings in environmental compliance;
These savings can be achieved through
reduced emissions and increased efficiency in fuel use
successful strategic R&D investments
in transportation sector
in advanced liquefaction, as well as
domestic enhanced oil-recovery
Climate Change Reduced rate of CO2 emissions via increased efficiency (clean
technologies.
coal, ATS, fuel cells); established viability of CO2 sequestration
with coal and other fossil fuels as energy source for power/fuels
22 23
MULTI-YEAR
PROGRAM PLANS
C O N T E N T S
TECHNOLOGIES FOR EXISTING PLANTS 26
NEAR- AND MID-TERM DEVELOPMENT
AND DEMONSTRATION 33
DISTRIBUTED GENERATION 56
VISION 21 64
CARBON SEQUESTRATION RESEARCH 74
ADVANCED RESEARCH 80
INTERNATIONAL 84
T E C H N O L O G I E S F O R E X I S T I N G P L A N T S
TECHNOLOGIES FOR
EXISTING PLANTS INTRODUCTION address ozone concerns in the eastern
U.S. will lead to State requirements for
COST-EFFECTIVE most eastern U.S. coal-fired power-
PROGRAM AREAS
SOLUTIONS FOR E N V I R O N M E N TA L C O N C E R N S A R E plants to significantly reduce NO X
Advanced Environmental- THE DRIVING FORCE emissions (to 0.15 pound per million
TODAY’S FLEET Btu) by 2003. Utilities are already
Compliance Technologies The environmental drivers influencing
ordering hardware for compliance.
• Advanced Control Systems the operation of existing coal-fired
On the other hand, western U.S. power-
powerplants over the next decade are
• Ambient Air Quality Monitoring plants are not subject to these regula-
being defined today. Key environmen-
tions, but may need similar reductions
tal regulations have been proposed or
• Air Toxics to meet future regional haze or fine
promulgated over the past year estab-
particulate matter (PM 2.5) standards in
• Combustion By-Products lishing a basis for new technology
the 2007 to 2015 time frame. Because
Utilization needed to comply with them:
most of these regulations on the hori-
•Revised National Ambient Air Quality zon are not yet finalized, and because
Improved Plant Efficiencies Standards (NAAQS) for fine particu- the timing of implementation of the
and Performance late matter and ozone. regulations has not yet been clearly
• Repowering •Instructions to revise State Implemen- articulated, judgment must be used
tation Plans to address ozone con- in estimating the effectiveness and
• Advanced Computer-Based cerns in the eastern U.S. timing of needed technologies.
Controls •Petitions by northeastern States for
Objectives being pursued in this
program element are:
DOE IS DEVELOPING the Environmental Protection Agency
(EPA) to require upwind States to •Develop and demonstrate extremely
reduce emissions of nitrogen oxides low NO X burner technologies (aug-
TECHNOLOGIES TO HELP (NO X) from powerplants. mented by advanced computer-based
controls) intended to provide the
•Requirements for States to address
lowest-cost option for use on dry-
regional haze.
EXISTING POWERPLANTS bottom boilers, by October 2000.
•Proposals to regulate mercury
•Further refine high-efficiency NO X
emissions from powerplants.
reduction technologies, such as
M E E T E N V I R O N M E N TA L The cost to comply with these regula-
selective catalytic reduction (SCR),
tions is expected to be several billion
to reduce compliance costs for wet-
dollars per year; the research challenge
S TA N D A R D S , I N C R E A S E bottom boilers, by October 2000.
is to find improved technologies that
•Develop and demonstrate technolo-
dramatically reduce these costs and fill
gies to address mercury emissions
EFFICIENCY, AND technology gaps.
by 2004.
•Develop a database in partnership
IMPROVE OVERALL STRATEGIES AND TIMING with other public- and private-sector
organizations on the sources and
It is imperative that needed technolo-
receptors of ambient fine particulate
gies be developed through cost-shared
PERFORMANCE. matter in support of NAAQS attain-
collaboration between government
ment/non-attainment determinations
and industry quickly enough to allow
and State implementation strategies.
for demonstration and deployment
prior to regulatory deadlines. Some •Develop and transfer to industry
of these regulations are already pro- the technology base for the cost-
mulgated and their requirements must effective and environmentally accept-
be met soon. For example, instructions able utilization of coal-combustion
to revise State Implementation Plans to by-products.
27
T E C H N O L O G I E S F O R E X I S T I N G P L A N T S T E C H N O L O G I E S F O R E X I S T I N G P L A N T S
BENEFITS TO THE NATION •Develop and transfer to industry •Postcombustion NO X control technol- •A suite of mercury-control technolo- •Determining the formation, transport, 640-megawatt (MW) coal-fired unit
operational, performance, and cost ogy that is capable of meeting NOX gies that remove all forms of mercury and chemical composition of ambient located at the Cardinal power station
information on advanced repowering, emission standards for ozone mitiga- from coal-combustion flue gas will be fine particulate matter in order to in Ohio. This is a first-of-a-kind
Environmental and economic
cofiring, and advanced computer- tion at a cost 25% to 50% less than developed and demonstrated by 2005. better understand the relationship demonstration of this technology on
security. Advanced technologies
based control systems. stand-alone SCR will be available •Technologies for repowering steam between anthropogenic emissions an electric-utility boiler of this size.
for improved plant performance
by 2003. powerplants will be viewed as a pre- of SO X, NO X, and PM and ambient Utilities are considering SNCR systems
and environmental compliance
•Postcombustion control technology ferred way to utilize existing power- air quality. to meet the emission reductions that
will yield benefits to human
ACHIEVEMENTS TO DATE that is capable of increasing the over- plant assets by 2010. • Improving the collection efficiency of will be required under the proposed
health as well as to the environ-
AND IN THE FUTURE all collection efficiency of primary particulate-control technology, espe- NO X emission regulations to address
ment, and will result in cheaper,
The U.S. electric utility industry has fine particulates to 99.9%, especially cially fine particles in the submicron- summertime ozone.
more efficient electric power.
made major strides in reducing emis- for small particles in the 0.1 to 1.0 size range, including both retrofits to
Essential reductions in emissions.
sions of SO 2, NO X, and particulates micron range, will be developed and conventional emissions-control hard-
Specific benefits to the U.S. by AMBIENT AIR QUALITY MONITORING
since passage of the 1970 Clean Air Act demonstrated by 2005. A D V A N C E D E N V I R O N M E N TA L – ware, such as electrostatic precipita-
2010 will include reduction of
and its subsequent amendments. Emis- • Technologies that increase the utiliza- tors (ESPs), and the development of In response to the PM2.5 National
emissions of SO2, NOX, and primary
sions of SO 2 have been reduced from tion of high-volume coal-combustion COMPLIANCE TECHNOLOGIES advanced systems. Ambient Air Quality Standards, DOE
particulate matter from coal-based
1980 levels of 10.9 million to 5.3 million by-products (fly ash and scrubber Projects in Advanced Environmental is also collaborating with EPA, EPRI,
power systems to levels determined
tons. NO X emission rates from utility sludge) as well as create high-value Control Systems involve DOE-industry and the utility industry in the operation
necessary to address human health
boilers are 40% below 1990 levels, from uses of solid materials generated from ADVANCED CONTROL SYSTEMS collaborations. Working with American of several ambient monitoring sites to
and environmental concerns. Such
an average of 0.65 lb/mm Btu to an advanced coal combustion systems The Advanced Environmental Control Electric Power, several other utilities, collect information critical to under-
concerns include ozone, PM2.5,
average of 0.39 lb/mm Btu. Particulate will be available by 2000. Effective Systems subprogram focuses on the and the Electric Power Research standing the impact of coal-based
visibility impairment, acidification,
emissions from the utility sector have use of the solid by-products from coal development of cost-effective environ- Institute (EPRI), DOE is field-testing power systems on air quality.
and eutrophication.
decreased by nearly one-third since combustion will be considered to be a mental control technologies and sys- an SNCR NO X-control system on a
Energy security. Electric power 1988. “common business practice.” tems that are able to meet current and
from indigenous coal resources
DOE-industry partnerships developing future restrictions on the emissions of
will continue to be an integral
technologies needed for existing plants SO X, NO X, and particulate matter (PM)
component of the Nation’s overall
are expected to accomplish these goals: from the electric utility sector. It pro-
energy mix, thereby ensuring that
vides the scientific underpinning neces-
the U.S. maintains a position of Coal combustion by-products are proving sary to identify control technology needs
energy independence and security.
useful for such applications as the and research priorities and to foster
Continued value of investments. informed decision making. This part of In DOE’s Upper Ohio River
construction of this cattle lot.
The existing infrastructure at older the Coal and Power Systems Program
Valley Project, an air sam-
fossil-energy powerplants will be helps to ensure that our indigenous
maintained using repowering and pler in Greene County,
coal resources are utilized in an envi-
cofiring technologies. ronmentally sound manner, so that Pennsylvania, verifies that
Lower-cost electricity. Improve- they can continue to be an integral PM 2.5 standards are met
ments in the efficiency and envi- component of the Nation’s overall and collects representative
ronmental and operating perfor- energy mix.
samples for detailed
mance of existing powerplants will Areas of focus are:
information on the chemical
result in a lower cost of electricity.
• Developing postcombustion control
In fact, the U.S. could save up to composition of fine parti-
technology—such as SCR, SNCR, and
$7 billion per year because of culate matter in outdoor air.
advanced reburning—capable of
lower-cost environmental-control
achieving significant NOX reductions
technologies to meet new standards.
in response to environmental issues
such as ozone transport, ambient
fine particulates, acid rain, and
eutrophication.
28 29
T E C H N O L O G I E S F O R E X I S T I N G P L A N T S T E C H N O L O G I E S F O R E X I S T I N G P L A N T S
In the Upper Ohio River Valley Project, upstream of a particulate-control and improving existing technologies
HOT WINDBOX REPOWERING
four monitoring sites will be located device, such as an ESP or baghouse, for environmentally beneficial utiliza-
in the tri-state area around Pittsburgh, enhanced removal across a lime- or tion of coal-combustion by-products
Pennsylvania. These sites will offer a limestone-based wet scrubber, and from power systems. The emphasis is The hot windbox repowering approach,
comparison of ambient PM2.5 in rural and novel, stand-alone technology. on by-products whose supply has
Existing Equipment where hot turbine exhaust replaces the air
urban settings, providing an under- For example, the Advanced Emissions- traditionally far outpaced utilization Air Flue Gas
to Stack entering the boiler, increases generating
standing of local and regional pollutant Control Development Project is focused capacity (flue-gas desulfurization Gas Turbine Boiler
Electricity capacity up to 25%, and increases effi-
transport issues. DOE is also participat- on evaluating and developing cost- [FGD] sludge and high-carbon fly ash)
ing in ambient PM2.5 monitoring and effective strategies for controlling and the by-products from advanced ciency by as much as 15%.
Steam Electricity
characterization studies with the mercury from electric-utility boilers power systems developed under DOE’s
Generator
Tennessee Valley Authority in Great and making maximum use of existing Clean Coal Technology Program. Steam
Smoky Mountain National Park and Coal Turbine
emissions-control systems such as wet This issue is addressed through out-
with Southern Company Services in Natural Turbine Exhaust Generator
scrubbers, ESPs, and fabric filters. reach activities that include facilitating Gas 1,000 °F
the Atlanta, Georgia, area. Under the Carbon-Based Sorbent Injec- technology transfer of data from DOE-
Feed-
tion for Mercury Control Project, jointly sponsored coal combustion by-product water
Heaters Extraction
funded by DOE and EPRI, Public Ser- (CCB) utilization projects to State regu- Steam
AIR TOXICS vice Company of Colorado is evaluat- lators and CCB users. Field-scale
Air toxics research promotes the devel- ing the mercury-capture effectiveness demonstrations are under way that use
opment of postcombustion control of various carbon-based sorbents. large volumes of FGD material and fly Condenser
options for mercury, particularly vapor- ash to reduce surface subsidence and
phase mercury. The emphasis is on acid mine drainage and produce aggre-
augmenting the effectiveness of exist- COMBUSTION BY-PRODUCTS gate for transportation and other con- DOE is implementing a CCB con- means of transforming older, underper- The cost of new generating capacity,
ing control technologies to enable UTILIZATION struction materials. The subprogram sortium managed by West Virginia forming plants into cleaner, lower-cost combined with the difficulty in obtain-
capture of all chemical forms of mer- also includes product development for University to form partnerships with producers of electricity. ing permits and developing new plant
Combustion by-products utilization
cury. The control approaches being fly ash that contains large amounts the utility industry, other Federal sites, makes repowering an attractive
focuses on developing new technologies
investigated include sorbent injection of carbon. and State agencies, universities, and option. Repowering existing coal-fired
special-interest groups to enhance the REPOWERING steam-generating units can boost gen-
use of CCBs. The consortium will lever- The in-place fleet of fossil electric- erating capacity, improve efficiency,
age Federal funds to initiate research generating plants continues to wear and reduce CO 2, SO 2, NO X, and parti-
REPOWERING
projects, from feasibility studies through and age, with many units reaching 40 culate emissions—all at competitive
demonstration field tests, that have and 50 years of service. The U.S. power costs. The additional capacity and the
Repowering with a high-efficiency clean the potential to increase the options industry is being restructured and typically low production cost of a
Air coal power system leads to an increase in available to coal producers and users deregulated into a competitive market, highly efficient, coal-fired, advanced
Gas Turbine for disposition of CCBs. with electricity being sold as a bulk power system translates into high-
Electricity net power capacity and net relative plant
commodity. Demand is for the lowest capacity factors and a steady revenue
efficiency.
cost of electricity. Many existing plants stream. By comparison, life extension
will reach a point where they are worn provides no major improvements in
Generator Gas Turbine
Heat Recovery Steam Generator out, are too inefficient to compete, face generating capacity or production cost.
IMPROVED PLANT significant costs to upgrade emission One common option is hot windbox
to Stack
controls, or must contend with any repowering. In this approach, hot
Fuel
EFFICIENCIES AND combination of these factors. Options exhaust from a gas turbine replaces
Existing Steam
Gas Equipment Electricity include extensive refurbishment to the air entering an existing boiler,
PERFORMANCE extend the life of these units, retirement eliminating the need for forced-draft
of aging units, replacing them with fans, increasing generating capacity up
Steam Generator new capacity, or repowering them. to 25%, and increasing efficiency by as
Turbine
Improving the efficiency and perfor- Repowering uses existing equipment in much as 15%. Generally suitable for
Coal Char
mance of the existing fleet of over 300 the plant while integrating new tech- newer units larger than 300 MW, hot
Coal
to Stack
gigawatts of coal-fired powerplants nology, such as gas turbines, to allow windbox repowering can be a low-cost
Pyrolyzer Boiler Low-Temperature with new equipment and technology the plant to produce more electricity option.
Heat Recovery Steam Generator could be one of the most cost-effective than the original design.
30 31
T E C H N O L O G I E S F O R E X I S T I N G P L A N T S
NEAR- AND MID-TERM
Feedwater heating is another low-cost One of these artificial intelligence DEVELOPMENT AND
repowering option. In this approach, systems—the Generic NOX Control
A N E N V I R O N M E N TA L S U C C E S S
heat from the exhaust of a gas turbine Intelligent System (GNOCIS™)—was DEMONSTRATION
STORY: LOW-NOX BURNERS
is used to heat feedwater for the exist- demonstrated at Georgia Power Com-
POWER AND FUELS
ing boiler. The benefits are a capacity pany’s Plant Hammond Unit 4 (a 550-
A quarter of the coal-fired capacity in
increase of up to 30% and an efficiency MW opposed wall-fired unit), where it PRODUCTION FOR
the U.S. today uses low-NO X burners
improvement of 5% to 10%. is fully operational and has achieved
developed through DOE investment, THE FUTURE
Repowering is made even more an efficiency improvement of 0.5%, a
significantly reducing emissions of one
attractive because a suite of flexible 3% reduction in the unburned carbon
of the chief pollutants responsible for
advanced power system technologies content of the unit’s fly ash, and a 15%
smog and ozone buildup.
developed through DOE sponsorship reduction in NO X emissions at full
A portfolio of cost-effective NO X - load. This performance would allow a
are available, allowing an optimum
control technologies suitable for the typical eastern U.S. powerplant rated at
repowering strategy to be developed
full range of existing boilers is now 1,000 MW to reduce its coal consump-
for site-specific situations. By repower-
available. Three major new low-NO X tion by up to 25,000 tons per year.
ing with clean, efficient power systems,
burners are now widely marketed, ,
GNOCIS™ developed jointly by DOE,
such as a pressurized fluidized-bed
and sales of these will reach $4 EPRI, PowerGen, Radian International,
combustor, integrated gasification
billion in the next couple of years. Southern Company, and the U.K.
combined cycle, or high-performance
Gas reburning has also been success- Department of Trade and Industry, is
power system, net power capacity
fully demonstrated on a number of designed to operate on units burning
increases from 20% to 175% and net
different boilers, reducing NO X by gas, oil, or coal and is available for all
relative plant efficiency increases of
over 65%. This process breaks down combustion firing geometries. To date,
over 30% can be achieved.
NO X into environmentally benign 20 coal-fired plants have installed ADVANCED COAL
gases by using natural gas or finely .
GNOCIS™ Adding these plants to the
ground micronized coal to reburn the 15 powerplants that are in preliminary
ADVANCED COMPUTER-BASED AND POWER SYSTEMS
residues of coal-firing. The Generic stages of applying this system of
CONTROLS
NO X Control Intelligent System is the advanced computer-based controls sug-
latest innovation to lead the way to Improving the way that existing plants
gests that by 2000 there will be 20,000 WILL ENABLE CLEANER,
the zero-NO X plants of the future. are operated is an effective way to
MW of power-generating capacity
improve their environmental perfor-
The costs of reducing NO X emissions garnering the benefits of GNOCIS™.
mance, reduce cost, and increase
by retrofitting powerplants are now MORE EFFICIENT USE
efficiency.
up to 90% lower than they would
have been without the Federal Modern control systems have signifi-
cantly improved the operating perfor- OF DOMESTIC FOSSIL
government’s research investment.
mance—in terms of both cost and
environmental performance—of coal-
fired powerplants. However, the com-
ENERGY RESOURCES
plexity of the optimization problem has
limited the benefits achieved by con-
FOR GENERATING LOW-
ventional systems. This complexity
can be overcome by embedding artifi-
cial intelligence or other advanced COST ELECTRICITY AND
computer-based approaches in a
powerplant’s digital control system.
PRODUCING LIQUID
AND SOLID FUELS,
AND CHEMICALS.
32
D E V E L O P M E N T A N D D E M O N S T R A T I O N D E V E L O P M E N T A N D D E M O N S T R A T I O N
INTRODUCTION •Develop high-performance power The U.S. will also realize economic A domestic industry based on convert- CLEAN COAL TECHNOLOGY
system (HIPPS) designs for large benefits from exporting clean energy ing coal into 2 million barrels per day
commercial plants, prototype plants, technologies resulting from DOE pro- of liquid fuels would provide, by 2030, DEMONSTRATION PROGRAM
PROGRAM AREAS
RESPONDING TO NEW and repowering applications. grams. International opportunities for more than 660,000 high-paying jobs in
Clean Coal Technology MARKETPLACE REALITIES •Remove technological limitations on advanced fossil energy technology coal mining, manufacturing, and man-
Demonstrations hot-gas filtration to achieve the full exports are enormous. It is estimated agement, as well as jobs in indirect The Clean Coal Technology Demon-
DOE programs developing coal and
performance potential of fluidized- that the annual worldwide demand for supporting labor, and would attract as stration Program was implemented
• Advanced Electric power systems are responding to dra-
bed combustion (FBC) plant designs energy will reach 542 quadrillion Btu much as $100 billion in new invest- through a series of five nationwide
matic changes occurring in the energy
Power Generation by 2002. by 2015, 1.6 times the current level. ments. Further, coal-derived fuels competitive solicitations conducted
marketplace. Energy industry deregula-
Coal is expected to account for about could “cap” imported oil prices. A $1 over a 10-year period. The first solici-
• Environmental Control Devices tion could create intense cost-reduction •Extend the superior environmental
25% of this demand. The total world- savings in the price per barrel of oil tation selected technologies to balance
pressures on power producers; DOE performance of integrated gasification
• Coal Processing for programs are geared to provide these
wide market for new powerplants will could yield a $6-billion-per-year benefit the goals of expanding coal use and
combined-cycle (IGCC) systems
Clean Fuels be approximately $2 trillion between to our economy. minimizing environmental impact.
producers with cost-competitive solu- beyond electric power generation to
2000 and 2030. The U.S. has the poten- Coal-derived liquid transportation The next two solicitations favored tech-
tions to environmental challenges. At production of market-based energy
• Industrial Applications tial of capturing a large portion of this nologies to mitigate potential impacts
the same time, gas, electric, and oil and chemical products. fuels provide significant environmental
market—more than $480 billion in rev- benefits. Fuels such as Fischer-Tropsch of acid rain from existing coal-fired
Power Systems companies are merging into larger
•Reduce the cost of producing coal- enues, supporting 600,000 U.S. jobs powerplants. The fourth and fifth
business entities that are investing less diesel or dimethyl-ether-derived diesel
• Advanced Turbine derived transportation fuels from $30 over three decades. solicitations addressed post-2000
in research. Therefore, DOE programs could enable the design of modified
to $21 per barrel. energy supply-and-demand issues: the
Systems (ATS) must leverage limited private-sector Programs to produce liquid fuels diesel engines with improved efficiencies
research dollars more effectively than •Enable coproduction of power, liquid from coal could also yield substantial and up to 47% reduction in emissions. capping of sulfur dioxide (SO2) emis-
• Low-Emissions Boiler fuels, and premium carbon products economic and energy security benefits. sions in the Clean Air Act Amendments
ever. Deregulation is also creating new
System (LEBS) markets for energy products, like from coal and fuels containing Increasing production of liquid fuels by of 1990, the increased need for electric
Vision 21 plant concepts that will use biomass or solid waste. 1 million barrels per day using lique- power, and the need to alleviate con-
• High-Performance Power cerns over global climate change.
gas, coal, and biomass fuels to generate These strategies are yielding measur- faction technologies would reduce our
Systems (HIPPS) Nation’s balance of payments by $130
a mix of products that include electric- able benefits to the U.S. economy and Now that more than half of the result-
• Fluidized-Bed Combustion ity, liquid fuels, and chemicals, with environment. As the CCT program is billion between 2015 and 2030. ing projects have been completed, the
(FBC) virtually zero environmental impact. being completed, for example, it is value of the program is clear.
making readily available to industry a
• Integrated Gasification compendium of operational, technical,
Combined Cycle (IGCC) STRATEGIES FOR SUCCESS environmental, and economic perfor-
Specific strategies for the near- and mance data and experience on advanced,
Fuels mid-term development and demonstra- highly efficient fossil power technolo-
tion program are to: gies. The results will demonstrate to
• Transportation Fuels PERFORMANCE OF NEAR- AND MID-TERM COAL AND POWER TECHNOLOGIES
developers and users that these
•Conclude commercial-scale demon-
• Solid Fuels and Feedstocks advanced power technologies provide Cost Performance Environmental Performance
stration projects in the Clean Coal
benefits that far outweigh the risks
Technology (CCT) Demonstration Program Target COE Capital Efficiency SO X NO X CO 2 Particulate
often associated with new technology
Program by 2005. Area Year [Note 1] [Note 2] [Note 3] [Note 4] [Note 4] [Note 5] [Note 6]
investments.
•Perform technology readiness and ATS (gas) 2002 10% lower 10% lower 60% (LHV) <10 ppm 67% less
full-scale testing for two alternative LEBS 2002 10% lower lower 45% 0.1 0.1 23% less 0.01
natural-gas utility-scale Advanced
HIPPS 2008 20% lower 10% lower 55% 0.06 0.06 36% less 0.003
Turbine System (ATS) concepts
by 2002. FBC 2008 $0.045 $950 52% 0.06 0.06 33% less 0.003
•Demonstrate proof-of-concept for IGCC 2008 $0.045 $1000 52% 0.06 0.06 33% less 0.01
a low-emission boiler system (LEBS), Notes
advanced pulverized-coal-fired 1—Cost of electricity (COE) in $ per kilowatt-hour. Lower refers to comparison with today’s technology.
powerplant by 2003. 2—Capital cost in $ per kilowatt. Lower refers to comparison with today’s technology.
3—Efficiency based on higher heating value unless noted otherwise.
4—Values as pounds-per-million Btu unless noted otherwise.
5—Reduction of CO2 emitted compared to a 35% efficient coal plant.
6—Particulates as pounds-per-million Btu unless noted otherwise.
34 35
D E V E L O P M E N T A N D D E M O N S T R A T I O N D E V E L O P M E N T A N D D E M O N S T R A T I O N
BENEFITS TO THE NATION Results are benefiting existing plants New power generation systems vali- ADVANCED ELECTRIC COAL PROCESSING FOR
as well as next-generation systems. dated through the program include POWER GENERATION CLEAN FUELS
Today, for example, NO X reduction circulating fluidized-bed technology, Approximately 56%, or about $3.2 bil- Five projects that create clean fuels by FIVE POWERPLANT AWARDS
Economic security. A major benefit
technologies demonstrated through pressurized fluidized-bed combustion lion, of total available government CCT coal-processing, valued at nearly $520 PRESENTED TO CCT PROJECTS
of near- and mid-term power
CCT projects are being retrofitted to (PFBC), and integrated gasification funds has been earmarked for advanced million, represent a diversified portfo- BY POWER MAGAZINE
technologies is low-cost electricity
over 25% of the Nation’s coal-fired combined-cycle systems. These systems electric power generation systems, to lio of technologies. Three of them
for citizens and industries. • Tidd PFBC Demonstration Project
capacity. These technologies can are now in or near commercial-scale enhance their efficiency, environmental involve the production of high-energy-
Because electricity expense is a (The Ohio Power Company)—1991
achieve not only existing regulated operations that demonstrate their performance, and reliability. Over 900 density solid compliance fuels for
major factor in the cost of provid-
emissions levels, but also those pro- strong potential as electric power gen- • Advanced Flue Gas Desulfurization
ing products and services, sustain- megawatts (MW) of new capacity and utility or industrial boilers; one also
posed by the Environmental Protection eration and coproduction plants of the Demonstration Project (Pure Air on
ing a low-electricity production over 800 MW of repowered capacity are produces a liquid for use as a chemical
Agency (EPA) for 2000. The program next century. the Lake, L.P.)—1993
cost is critical for U.S. industry’s represented by 11 advanced electric feedstock. One project is demonstrating
has also demonstrated several advanced power generation projects. Projects a new methanol production process. • Demonstration of Innovative Appli-
competitiveness in the world
technologies that have significantly include four IGCC systems, five PFBC Another has developed an expert com- cations of Technology for the CT-121
market. Energy technology pro-
improved the economic and environ- or circulating fluidized-bed combustion puter software system that enables a FGD Process (Southern Company
vides the foundation for competi-
mental performance of SO2 controls. (CFBC) systems, and two advanced utility to predict the operating perfor- Services, Inc.)—1994
tive alternatives needed to meet
varying marketplace situations. Furthermore, CCT technologies are combustion/heat-engine systems. mance of coals not previously burned • Wabash River Coal Gasification
being used to transform low-rank and These projects will provide environ- in its boiler. Repowering Project (CINergy
Reduced balance-of-trade deficit.
noncompliance coals to useful, environ- mentally sound, more efficient, and less Corp/PSI Energy Inc.)—1996
Because U.S. industry is de-empha-
mentally superior coal-based fuels for costly electric power generation, while
sizing longer-term research as part • Tampa Electric Integrated Gasifica-
use by domestic utility and industrial providing a demonstrated technology INDUSTRIAL APPLICATIONS
of short-term survival strategies, tion Combined-Cycle Project (Tampa
coal users, and are being considered for base necessary to meet new capacity Four projects with industrial applica-
federally sponsored technology Electric Company)—1997
major projects abroad. In addition, requirements in the 21st century. tions have a combined value of nearly
development is critical to sustain-
coal-based industrial processes are $1.3 billion. They include the substitu-
ing U.S. industry’s competitive-
gaining significant environmental and tion of coal for 40% of the coke used in
ness in the world marketplace.
economic benefit from the demonstra- E N V I R O N M E N TA L C O N T R O L D E V I C E S iron making, integration of a direct
Energy technologies being devel-
tion of these advanced technologies. Valued at more than $700 million, 19 iron-making process with the produc-
oped address rapidly expanding
global-market demands and are, The Clean Coal Technology Demonstration environmental-control projects include tion of electricity, reduction of cement
therefore, central to U.S. respon- seven NO X emissions-control systems kiln emissions and solid-waste genera-
Program reached a significant milestone in
siveness to export opportunities installed on over 1,700 MW of utility- tion, and demonstration of an efficient,
1997 with the completion of 21 of 39 active
that translate into high-paying generating capacity, five SO 2 emissions- industrial-scale combustor.
projects. Several demonstrated technolo- control systems installed on about 770
U.S. jobs.
gies, including fluidized-bed and gasification MW, and seven combined SO 2/NO X
Energy security. Providing tech-
technology, are now being successfully
emissions-control systems installed
nologies that use our abundant
on about 700 MW of capacity. The
indigenous resources as a commercialized.
operating experience of most of these
significant component of our
environmental-control devices was
Nation’s fuel mix is critical to
CCT PROJECTS documented by the end of 1997.
maintaining energy independence
and security. Number of Market Number
Environmental acceptability. Projects Segment Completed
These technologies offer the means 11 Advanced Electric Power Generation 2
to produce energy from abundant,
19 Environmental Control Devices 15
low-cost fossil fuels without
detriment to the environment. 5 Coal Processing for Clean Fuels 2
Lower carbon dioxide emissions. 4 Industrial Applications 2
Because of high-efficiency
energy conversion, these advanced
technologies will greatly reduce
the release of carbon dioxide into
the atmosphere as they replace less
efficient technologies.
36 37
D E V E L O P M E N T A N D D E M O N S T R A T I O N D E V E L O P M E N T A N D D E M O N S T R A T I O N
POWER SYSTEMS required under New Source Perfor- Pressurized Fluidized-Bed Combustion for developing advanced turbine sys-
UTILITY-SCALE ATS PERFORMANCE
mance Standards (NSPS). Incorporating (PFBC) technology moves coal combus- tems. FE supports the utility-scale sys-
POWER SYSTEMS IN
supercritical boiler technology, the tion to a new plateau of performance tem development, industry/university
60% (LHV) system efficiency
THE MID-TERM A key strategic goal of the Office of design will boost thermal efficiencies to with efficiencies for initial systems consortium, materials research for
<10 ppm NOX emissions
Fossil Energy is to develop progres- 42% compared with today’s 33% to 35%. approaching 45%, and SO 2 and NO X advanced alloys, ATS applications for
• By 2002, technology readiness and
sively higher-efficiency power systems. More than 73% of the final phase’s $127 removals at levels one-fifth that coal fuels, and the Federal Energy 10% reduction in cost of electricity
validation testing will be performed
In the long term, these systems are to million costs will be provided by the required under the NSPS. Improve- Technology Center (FETC) in-house Reliability, availability, and maintainability
for two competing natural gas utility-
produce near-zero levels of pollutants private sector and State government. ments could raise efficiencies to more R&D. EE supports the industrial-scale of current combined-cycle products
scale advanced turbine system
while simultaneously reducing electric- High-Performance Power Systems than 55% and emission levels to one- system development, materials research
generation concepts.
ity costs by 10% to 20%. Several (HIPPS) are based on the indirectly tenth the NSPS limits. on thermal barrier coatings, ceramic
• By 2003, proof-of-concept will be advanced systems are near completion: retrofit engine development, and ATS Utility-scale ATS
fired combined cycle, a cycle that is Integrated Gasification Combined
demonstrated for a LEBS advanced applications for biomass fuels.
The Advanced Turbine Systems (ATS) particularly attractive because of its Cycle (IGCC) is a key system in the Utility-scale ATS concepts are being
pulverized-coal-fired powerplant.
program is close to commercializing a very high thermal efficiency and capa- Vision 21 plant concept. The goal is to Program benefits include (1) commer- developed by General Electric Company
• By 2002, technological limitations prototype utility gas turbine with bility to handle a wide range of fuels, improve efficiencies, costs, and envi- cialization of utility-scale ATS concepts *
and Westinghouse Electric Corporation.
on hot-gas filtration will be solved remarkable improvements in efficiency including “opportunity” fuels (such as ronmental performance for power, as the cleanest, most efficient com- Both will complete evaluation of their
to achieve the full performance and environmental performance. Over petroleum coke or sawdust) and fuels, and chemical production. bined-cycle powerplant available by combustion, heat transfer, and aero-
potential of FBC plant designs. the next two years, testing will be “wastes.” Efficiencies of 47% to 50% 2002; (2) reduced cost of electricity to dynamic design concepts under actual
• By 2010, DOE will run a pioneer completed for full-scale components can be achieved with gas turbines consumers, thereby preserving compet- operating conditions by December
coproduction IGCC plant and, by and subsystems, as will manufacturing available today. With turbines expected ADVANCED TURBINE SYSTEMS itiveness of U.S. industry in world mar- 2000.
2015, a full-scale plant will deliver capability for the first test engines. to be available when HIPPS is de- The DOE Office of Fossil Energy (FE) kets; (3) sustained U.S. global
ployed in about a decade, efficiencies technology leadership; and (4) major * Westinghouse Electric Corporation was
market-based energy and chemical Site preparation will begin for critical and the Office of Energy Efficiency
purchased by Siemens on August 20, 1998,
products that cost less than those full-speed engine tests scheduled for the of 55% will be possible. and Renewable Energy (EE) share reductions in NO X and CO 2 emissions.
and was renamed Siemens Westinghouse
from any other sources. final phase of this program. responsibility with industrial partners Power Corporation.
The Low-Emissions Boiler System
(LEBS) is in its final phase. An 80-MW
proof-of-concept facility, scheduled to
UTILITY ADVANCED GAS TURBINE SYSTEMS
be on-line in 2001, will reduce SO 2 and
NO X to less than one-sixth the levels
Outstanding environmental
performance and improved Heat Recovery
Steam Generator
economics in both natural-
Air to Stack
gas-fired and coal-fired
Gas Turbine
applications are promised
by advanced turbine systems. 1 Hot Cold
2 Reheat Reheat
In the near term, natural C T
gas will play an increasing
Generator
role in electric generation.
Closed-Loop
The third IGCC plant to become operational Natural-gas units are more Steam Cooling 5
efficient and less capital-
in the United States, the 100-MW Sierra
intensive, have lower non-
Pacific Piñon Pine project near Reno,
fuel costs, are more rapidly
Fuel Gas 3 4 6
Nevada, demonstrates a KRW air-blown constructed, and remain LP/IP HP
gasifier with in-bed sulfur capture, economical in small sizes. Condensate
Combustor Generator Steam Steam
advanced hot-gas cleanup, and General However, in the mid-term, Turbine Turbine
advanced coal systems will
Electric power generation. With an antici- 1 Compressor Technology 4 Combustor Technology
replace or reduce natural- 2 Gas Turbine Technology 5 Coolant Fluid Testing
pated efficiency of over 43%, the plant will gas feed as gas systems 3 Integrated Gasification and Biomass 6 Combined Cycle Integration
Condenser
deliver more efficient, less costly, and become relatively more
cleaner electricity. expensive than coal.
38 39
D E V E L O P M E N T A N D D E M O N S T R A T I O N D E V E L O P M E N T A N D D E M O N S T R A T I O N
General Electric Company. General Westinghouse Electric Corporation. Other ATS program developments Materials development. Projects
Electric is conducting compressor tests Westinghouse has introduced the 501G transferred to the 501G design are new include (1) single-crystal complex-cored INDUSTRY/UNIVERSITY CONSORTIUM SUCCESSES
for the 7H ATS system. The compressor ATS gas turbine, featuring an aero- thermal barrier coatings that permit airfoil technology to attain higher tur-
University of California at Berkeley Probe for in-situ measurements of fuel/air ratio
is the first stage of the turbine and dynamic design incorporating the higher turbine blade temperature. bine inlet temperatures and (2) depend-
Syracuse University Computer code to optimize turbine design
increases the pressure of large volumes latest computer models and turbine- able thermal barrier coatings to enable
of air needed for combustion of natural component design. Use of a computer Technology base research increased turbine inlet temperatures Georgia Institute of Technology Process for producing thermal barrier coatings
gas or other fuels. High-temperature model has resulted in reduced turbine and development while maintaining airfoil substrate tem- Control strategy for eliminating combustion instability
tests have verified effective cooling of component thickness and increased Critical technology barrier issues for peratures at levels that meet ATS life
hot turbine components by steam to efficiency without increased manufac- ATS include development of advanced goals. Emphasis is being placed on
achieve ATS turbine temperatures. turing costs. materials, low-emissions combustion, cost-effective casting of single-crystal
sensor development, noise measure- Energy and Research Development Center,
Casting of the largest advanced single- The piloted-ring combustor is a lean, advanced turbine cooling, and components.
ments in combustors, and combustor contracted universities perform applied
crystal turbine components in the premixed, multistage design that pro- advanced component design methods. In-house R&D. FETC’s combustion dynamics and control. research specific to the needs of major
world was also completed, a critical duces ultra-low pollutant emissions group, collaborating with university ATS developers in combustion, aerody-
Industry/university consortium. DOE
step toward commercializing the ATS while maintaining stable turbine investigators, conducts laboratory tests namics, materials, and heat transfer.
supports applied research for 95 U.S.
gas turbine. Single-crystal materials, operation. to evaluate novel concepts for low-
universities, including workshops and
much stronger than the polycrystalline To solve efficiency losses caused by emissions-combustor modeling, mixing
student internships at industry facilities.
materials now used to produce blades, leakage around the ATS internal parts, sensor development, heat-transfer
Under the direction of the South Carolina
are better able to resist conditions pre- Westinghouse has developed brush and
sent in the ATS. Technology develop- abradable coating seals for the station-
ment for the H program has already ary sections of the turbine. These seals ROADMAP FOR ATS PROGRAM
yielded many side benefits to U.S. have already been incorporated into
industry. Turbine component develop- the Westinghouse 501G turbine design. FY 1995 1996 1997 1998 1999 2000 2001 2002
ment, which deals with manufacturing
turbine blades, has improved with the Utility System Development
and Demonstration
use of advanced processes for casting
complex, single-crystal metallurgical Component Design
and Testing
turbine parts.
Complete subscale testing
Full-Scale Component/Subsystem Testing
Complete full-scale component tests
Full-Scale, No-Load System Testing
Complete Complete
prototype prototype
Industrial System Development design testing
General Electric’s utility- and Demonstration
scale advanced turbine Ceramic Retrofit 4,000-Hour Engine Test (EE)
Complete component development Complete prototype testing
Component Design and Testing
Complete subscale testing
CONCEPTS Full-Scale Component/Subsystem Testing (EE)
Complete full-scale component tests
General Electric Developing two systems: a 9H (50 Hz) Industrial System Demonstration (EE)
Complete Complete
system, and a 7H (60 Hz) system prototype prototype
Technology Base Development design testing
Westinghouse Developing and testing 501G
air-cooled engine as the precursor Industry/University Consortium
to an ATS design Materials (FE & EE)
FETC In-House Research
Westinghouse’s utility-scale
advanced turbine Coal Applications
Biomass Applications
EE: Office of Energy Efficiency and Renewable Energy
FE: Office of Fossil Energy
40 41
D E V E L O P M E N T A N D D E M O N S T R A T I O N D E V E L O P M E N T A N D D E M O N S T R A T I O N
To date, the consortium has conducted After nearly five years of systems HIGH-PERFORMANCE
51 projects that include combustion to
ROADMAP FOR LEBS PROGRAM analysis, engineering development, LEBS PERFORMANCE POWER SYSTEMS
improve fuel utilization and minimize FY 1997 1998 1999 2000 2001 and testing, three cost-shared industry Efficiency 42% to 45% The key to developing an indirectly
environmental effects, heat transfer and Phase II teams delivered 400-MW commercial fired cycle is learning how to transfer
NOX emissions 0.1 lb/106 Btu
aerodynamics to upgrade turbine blade Engineering Development plant designs and proposed proof-of- heat from combustion to the turbine air
and Subsystem Testing SO2 emissions 0.1 lb/106 Btu
life and performance, and materials to concept approaches. In September 1997, in a high-temperature air furnace
Complete preliminary
extend life and withstand higher oper- design of proof-of-concept the team led by DB Riley was chosen to Particulate emissions 0.01 lb/106 Btu (HITAF). This requires both innovative
Phase III test facility and test plan
ating temperatures for more efficient Revised Design of
construct an 80-MW LEBS plant at engineering and advanced materials.
systems. Commercial Plant Elkhart, Illinois, adjacent to the Turris To realize high system efficiency, the
Complete revised design
Humid air turbine (HAT) combustion of commercial plant
Coal Company mine, which produces HITAF must operate at higher tem-
Phase IV
testing. FETC and its industrial Illinois #5 high-sulfur coal. The plant The furnace will use staged combustion peratures than conventional coal-fired
POCTF Detail Design,
partner, United Technology Research Construction, Operation will use a low-NO X, U-fired furnace and a concept called “reburning” to steam boilers.
Downselect from Initiate construction of developed under the LEBS program. reduce NO X pollutants. Flue gas leav-
Center, are identifying combustor three contractors to proof-of-concept facility Two industry teams, led by Foster
configurations to efficiently burn high- one contractor A 10-MW test module for the moving- ing the boiler can be further cleaned
Wheeler Development Corporation and
moisture, high-pressure gas/air mix- bed copper-oxide flue-gas cleanup pro- of NO X and SO 2 in the copper-oxide
United Technologies Research Center,
tures, resulting in low emissions for cess will also be built and operated. process. Ammonium sulfate fertilizer
have been developing different ver-
systems where injected moisture can Nearly all coal ash is converted by the will be produced from the by-product
sions of HIPPS. When fully developed,
boost both power and efficiency. U-fired furnace into a glass-like slag streams.
both versions are to be capable of
LOW-EMISSIONS BOILER SYSTEM power-cycle technology at the lowest by-product that can be used in the
Computer models are being developed achieving efficiencies of 55%. Less
The low-emissions boiler system (LEBS) possible cost. construction industry. The volume of
to aid in the design of combustion advanced configurations of HIPPS
systems that operate with humidified is a highly advanced pulverized-coal- LEBS can be adapted to specific user slag is only one-third that of the fly ash technology, available now, can be used
air. In-house testing of new combustor fired powerplant being developed requirements, such as limits on fuel produced in a conventional coal boiler, to repower existing coal-fired plants
components is under way. Test data will under an industry-DOE/Fossil Energy availability, local regulations, and significantly reducing solid-waste- to increase both their power output
be compared to computer models for partnership. Its innovative design inte- site conditions. It is positioned for handling requirements. and efficiency.
design of full-scale engine combustors. grates components to maximize bene- ready acceptance by the electric power
fits achieved from advances in low- industry at home and overseas.
NO X combustion, flue gas cleanup, and
LOW-EMISSIONS BOILER SYSTEM
ROADMAP FOR HIPPS PROGRAM
FY 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
LEBS performance offers dramatic improve-
Complete design of
Claus Phase II prototype HIPPS plant
Plant ments over conventional coal-fired power-
Sulfur By-Product Engineering Development
plants. Higher thermal efficiency will cut CO 2 and Testing
Complete commercial Complete
Condensate plant design revisions technical report
Regenerator Heater emissions by 15% to 20% over today’s new
CH4 Phase III
plants. Emissions of acid gases (SO 2 and Construct and Operate
U-Fired Boiler CuO Fabric Low-Temperature Prototype HIPPS
Absorber Air Heater Filter Heat Recovery NO X ) will be one-sixth or lower and particu- Downselect from Complete Complete Complete
Flue two contractors to detail design construction tests
Gas
Stack one contractor
late matter emissions one-third of current
Coal Air
NSPS limits. Significantly, this is to be
Fly Ash Recycle
achieved along with a reduction in the cost
Vitrified Slag
of electricity.
Advanced, low-NOX, Copper-oxide flue- Heat recovery to Fabric Air heater recovers
U-fired boiler produces gas cleanup system air, condensate filter for heat from flue gases
environmentally removes 96%-99% of particulate for increased efficiency
benign inert slag SO2 and, if needed, collection
99% of NOX
42 43
D E V E L O P M E N T A N D D E M O N S T R A T I O N D E V E L O P M E N T A N D D E M O N S T R A T I O N
and a limestone utilization model will A number of composite-type ceramic Sulfur/alkali removal
HIGH-PERFORMANCE POWER SYSTEM be developed to optimize sulfur cap- and iron aluminide-type filter elements Alkali in hot-gas streams can limit gas
ture and minimize the volume of solid are also undergoing development. turbine life and reliability. The severity
In the HIPPS indirectly fired cycle, air is by-products. Filter cost can be reduced by 25% of the alkali problem must be deter-
Air
heated in a coal-fired, high-temperature air Net operating costs and landfill require- through optimized design of the sys- mined. Gas turbine tolerance to alkali,
Gas Turbine
Electricity ments will be reduced by expanding tem; filter vessel cost is about 75% of the amount of alkali released, the effect
furnace (HITAF) to a temperature approach-
markets for FBC by-products. FBC ash the total system cost. of filter-cake characteristics, and the
ing the gas turbine inlet temperature. Natural
will be characterized for conventional ability to control alkali will be assessed.
gas or a clean-coal-derived fuel can be used Heat Recovery applications, such as agriculture, mine Solids transfer Also, experiments to determine sulfur
Generator Steam Generator
to reach inlet temperature. This hot air is remediation, and structural fill, and Cost reduction and reliability improve- removal and trace-contaminant levels
Turbine Exhaust
to Stack high-value uses of solid by-products ment can be achieved by improved in the gas stream during integrated
expanded in the turbine, producing over half
Natural Gas Burner to Stack from FBC systems will be developed. handling of hot-solids material—feed demonstration will be conducted.
the system’s power output. Heat recovered
CH4 and withdrawal, flow control, and fines
from turbine exhaust and from the HITAF flue Hot-gas filtration
Steam Flue Gas removal. A feasibility study of a rotary
gas is used to raise steam for the steam Emission Control
Filter element durability, filter-ash high-pressure dry-solids feeder will
Flue Gas
turbine, to create more power. HIPPS will Electricity bridging, and system costs are critical evaluate the system’s potential for
achieve an efficiency of 55% and has drawn development issues being addressed. reducing capital and operating costs.
Steam
Turbine The challenge of producing candle- An advanced system for simpler and
potential as a key combustion-based tech-
Generator filter elements able to operate for more reliable transfer of hot char from
nology module for Vision 21. Coal more than three years is being met the carbonizer to the fluid-bed combus-
by enhancing monolithic filter elements tor will be tested for its ability to
High-Temperature Condenser made of various materials, such as
Air Furnace (HITAF) decrease materials flow and handling-
clay-bonded silicon-carbide, porous- related downtime by at least 50%.
FLUIDIZED-BED COMBUSTION Results from system studies will Topping combustor/turbine sintered metal, and alumina-mullite
Advanced fluidized-bed combustion guide future R&D. Optimum turbine- Developing and demonstrating a oxide.
(FBC) technology offers a viable power compressor configuration and opera- topping combustor with suitable fuel
generation option for the post-2000 tion of first-generation PFBC are being flexibility, flame stability, and NO X-
time frame. Commercial FBC units studied. Optimum configurations of emissions characteristics is critical to
operate at competitive efficiencies, cost second-generation PFBC for Vision 21 commercializing second-generation SECOND-GENERATION PFBC SYSTEM
less than today's units, and have NOX concept plants with fuel cells and CO2 PFBC systems. Tests of a multi-annular
and SO 2 emissions below levels man- sequestration options will be devel- swirl burner (MASB) have demon-
oped. Gas turbine studies will be per- In a second-generation PFBC system, the
dated by Federal standards. strated good flame stability and NOX
Air
formed on gas compositions and heat performance. Systems testing of the
feed is partially gasified in a pressurized
FBC comprises three technology varia- Gas Turbine
capacities specific to PFBC, which can MASB was performed at the Wilsonville Electricity fluidized-bed carbonizer. The carbonizer pro-
tions: atmospheric FBC, first-generation
lead to higher allowable turbine blade Power Systems Development Facility
pressurized FBC or PFBC, and second- duces a low-Btu gas and a char. The char is
temperatures. (PSDF) during 1998, and integration of
generation PFBC. Second-generation burned in a PFBC. Both gases are cleaned
the MASB into ATS designs will occur Heat Recovery
PFBC systems include a carbonizer Generator Steam Generator
Advanced FBC systems by hot-gas filtration, and the pyrolyzer gas
reactor and topping combustor to after the turn of the century.
demonstration to Stack is burned in a topping combustor to heat the
increase efficiency levels.
Two CCT projects are providing valu- Combustion by-products Topping Combustor PFBC flue gas. The hot gas drives a gas
Researchers in seven FBC subprograms Steam
able information: one at Lakeland, utilization turbine to generate power. The flue gas
are demonstrating advanced features Flue Gas Steam
Florida, demonstrating commercial- FBC economics improve as combustion
of FBC and providing R&D to lower Electricity generates steam in a heat recovery steam
scale advanced pressurized FBC tech- by-products are reduced or high-value
capital and production costs. Thrusts generator, which is used to generate addi-
nology by 2002; and the other at uses are found. The goal is to reduce
include simplification of FBC systems Air
Jacksonville, Florida, demonstrating solid by-products from FBC systems
tional power. At the Wilsonville Power Sys-
and components, incorporation of Fuel Generator
circulating atmospheric FBC by 2000. Gas Steam
without compromising sulfur capture Turbine tems Development Facility (PSDF), a highly
alternative feed and withdrawal sys- Coal
or producing in-bed sintering. Variabil- Char advanced second-generation PFBC now
tems, and incorporation of advanced Sorbent
Coal
subsystems and steam cycles. ity of limestone will be assessed as a Steam demonstrates high efficiency at pilot scale.
factor in the volume of solid by-products,
Carbonizer PFBC
44 45
D E V E L O P M E N T A N D D E M O N S T R A T I O N D E V E L O P M E N T A N D D E M O N S T R A T I O N
capital cost must be reduced, and relia- Gasification. Advanced gasification
ROADMAP FOR FBC PROGRAM bility and capacity utilization must be technologies, such as the transport
FY 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 IGCC MARKETS
improved. The use of natural-gas com- gasifier, are being developed through a
bined cycle today could be beneficial coordinated program. Researchers are
Clean Coal • Domestic and international
CCT Commercial Operation for IGCC tomorrow, because as natural also developing fluid dynamic data and
Technology Projects 300 MW APCFBC sited JEA begins LW&E begins 300 MW APCFBC baseload power
AFBC sited at LW&E construction construction AFBC testing testing begins
gas prices rise, gasification units can be advanced computational fluid dynamic
at JEA begins • Domestic repowering readily installed to replace natural gas. models to support the development of
Power Systems • Refinery cogeneration these advanced gasifiers. Investigations
Development Facility Shakedown Shakedown Carbonizer Integrated Advanced Vision 21 Vision 21 Gasification systems technology are being conducted to develop
MASB PFBC shakedown APCFBC filter(s) component testing begins • Pulp and paper
testing begins testing begins installation The IGCC program strategy empha- improved refractory materials and
• Steel and aluminum advanced instrumentation to enhance
Advanced PFBC sizes capital and operating and mainte-
System Development • Coproduction of fuels nance (O&M) cost reductions, increased gasifier performance, reliability,
Continued MASB LW&E support Release Continue filter, efficiency, and
testing and tests as needed FW Livingston environmental improvement and control.
development reports
and chemicals efficiencies, feedstock and product flex-
ibility, and near-zero emissions of pol-
Advanced
High-Efficiency lutants and carbon dioxide to meet
Initiate Start Foster Start-up
First-Generation feasibility detailed construction future energy market demands and
PFBC study design
INTEGRATED GASIFICATION break the barriers to global commercial
Vision 21 System COMBINED-CYCLE SYSTEMS acceptance of gasification-based tech-
and Component R&D Begin Vision 21 Initiate bench- Fuel cell First component Adaptation of
IGCC air separator
nologies. To achieve these goals, the
system studies scale testing adaptation design for PSDF The integrated gasification combined-
technology to PFBC strategy focuses on research and devel-
cycle (IGCC) process provides industry
opment of gasification system tech-
with low-cost, highly efficient options
nologies, the conduct of engineering
for meeting a wide spectrum of market
analyses, and the integration of
applications.
advanced technologies from other
Cofiring of biomass and IGCC is one of the most efficient and programs, where appropriate.
industrial by-products environmentally friendly of today’s
commercial and advanced coal tech-
Existing fluidized beds are suitable for
nologies. Gasification technology can
cofiring, but, to date, only 8 of the 100
process all carbonaceous feedstocks,
units in the U.S. cofire material. Cofiring
including coal, petroleum coke, resid-
of biomass and industrial by-products
ual oil, biomass, and municipal and
could evolve into a standard practice as
hazardous wastes, and is the only
a near-term means to reduce CO 2 emis-
advanced power-generation technology
sions. R&D data on heavy metals are
capable of coproducing a wide variety
needed so that environmental approval The Power Systems Devel-
of commodity and premium products
and permits for cofiring projects are opment Facility provides a
to meet future market requirements.
not any more difficult to obtain than
critical bridge between
for single-fuel solid-combustion units. IGCC technology is applicable to both
domestic and international baseload research- and commercial-
and repowering applications. Industrial scale demonstrations of
markets also include the production of
IGCC technology.
environmentally superior transporta-
tion fuels, premium chemicals, and
commodity products. IGCC systems are
Filter element durability, as it translates into also very effective in converting haz-
ardous industrial wastes into valuable,
useful performance life, is a critical factor
benign products.
for reducing FBC operating costs. Long-term
Coal gasification processes must
studies of various types of hot-gas filters
compete economically with natural-gas
are being performed to study durability and combined cycle technologies. Therefore,
performance.
46 47
D E V E L O P M E N T A N D D E M O N S T R A T I O N D E V E L O P M E N T A N D D E M O N S T R A T I O N
Researchers are also investigating novel are being developed to enhance IGCC cogeneration of power, steam, and
ROADMAP FOR IGCC PROGRAM hydrogen separation technologies that plant revenues and minimize waste hydrogen, and the coproduction of
FY 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
are capable of operating at high tem- disposal costs. These technologies will power, fuels, and chemicals. Through
peratures and pressures for use in con- be particularly important when co- the use of advanced engineering design
Gasification junction with fuel cells to improve feeding coal with alternative feedstocks concepts for heat integration, equip-
Technology Systems
overall IGCC plant efficiency. Tolerance such as municipal waste and biomass. ment sizing, and construction, and the
Gasification
Initiate advanced Shakedown Initiate Refractory Begin O2-blown Test high- Begin co-feed Complete dynamic
to chemical and particulate contami- Processes are also being developed for use of market-based costs, this study
materials/ transport alternative coupon transport gasifier temperature testing (PSDF) gasifier model nants, the ability to conduct reactions the direct production of elemental sul- will provide the lowest-cost, highest-
instrument gasifier feedstocks testing (PSDF) measure-
development (PSDF) R&D ment of carbon monoxide with water (the fur from the waste streams produced efficiency IGCC systems. This study,
Gas Cleaning/ water-gas shift reaction) for the pro- by the gas cleanup technologies. In together with other engineering analy-
Conditioning
Begin ultra- Startup Initiate HT Add PSDF Complete Begin ultra- HT filter
clean gas GPDU particulate desulfurizer GPDU clean gas testing (PSDF) duction of additional hydrogen, and addition, work will also focus on ses, will be used to identify future
program removal reactor technologies the ability to concentrate CO2 are criti- the integration of fuel cell and fuel R&D efforts to further reduce material
(Vision 21) analysis scale-up
Gas Separation cal issues that must be addressed to cell/turbine hybrid systems. cost, consumables, and total plant cost.
Begin air Initiate H2 Begin Begin IGCC Scale up Scale up H2 Air separation H2 membrane Commercial meet the goals of Vision 21. Other In addition, these studies will be used
separation membrane CO2 CO2 capture gas separation membrane integrated integrated offering of air
R&D manufacturing hydrate demon- technology demonstration demonstration separation novel concepts for concentrating CO2 Systems analysis/product integration to increase plant efficiency and prof-
R&D R&D stration membranes
from various IGCC process streams are Economic analyses, process perfor- itability and to reduce emissions
Product/By-Product
Utilization
Initiate Begin Ash/slag Begin single-step Initiate Initiate co-feed
being investigated. mance assessments, and market studies through integration of advanced gasifi-
ash/slag DSRP technology sulfur recovery fuel cell ash/slag quality cation system, power generation, and
quality testing demonstration (PSDF) integration R&D Product/by-product utilization. This are planned to provide sound engineer-
improvement (PSDF) (PSDF)
area focuses on developing technolo- ing and economic guidance for future synthesis gas conversion technologies.
Systems Analyses/ gies that can improve the utilization of R&D initiatives and to support commer- The IGCC program, together with the
Product Integration
process and waste streams to generate cialization activities, both domestically Fuels program, is embarking on a cost-
Systems Engineering
Complete Initiate Complete Begin evaluation Update CO2 Evaluate
value-added marketable products and and internationally. shared feasibility study of an advanced
CO2 life-cycle Vision 21 design of advanced integration/ co-feeding to minimize waste disposal costs. Tech- coproduction plant, called the Early
analysis concept optimization gas cleaning economic integration Systems engineering. An IGCC opti-
definition technologies evaluations economics nologies that improve the quality and mization study is being performed for Entrance Coproduction Plant (EECP).
Market Analyses/ marketability of gasifier slag and ash
Outreach
Initiate gasification Complete Complete Complete Complete initial
baseload power applications, the
database development economic domestic international Vision 21 market
evaluation market market strategy
study strategy strategy
Technology Integration/ CCT Commercial Operation
Demonstration Complete EECP feasibility Complete Complete EECP EECP Begin EECP INTEGRATED GASIFICATION COMBINED-CYCLE SYSTEM
Wabash completed Piñon Pine Tampa detailed construction/ operation
testing testing testing design startup
IGCC systems are ideally suited to deliver a
suite of energy products to meet future mar- Air
Gas Turbine
ket requirements. IGCC systems use a gasi- Electricity
fier to convert carbon-based feedstocks into
Alternative feedstocks such as petroleum supply of ultra-clean gas for fuel cell Gas separation. Advanced gas separa-
synthesis gas (a mixture of carbon monoxide
coke, biomass, and municipal waste in integration, to enable the catalytic con- tion technologies are being developed Generator
Heat Recovery
and hydrogen). The gases are cleaned of Steam Generator
conjunction with coal are being evalu- version of synthesis gas to fuels and that have potential for reducing capital
ated as feedstocks for power and chemicals, and to enable advanced and operating costs, improving plant particulates, sulfur, and other contaminants to Stack
coproduction applications in existing processes to effectively separate carbon efficiency, and concentrating and cap- before being combusted in a high-efficiency Combustor
and advanced gasifiers. dioxide. Advanced sorbents are being turing carbon dioxide. New air separa-
combined-cycle gas and steam turbine sys- Air Coal Gas
Gas cleaning/conditioning. Research in explored and novel technologies are tion technologies that use mixed- Electricity
tem to produce electricity, or are catalyti-
this area is intended not only to reduce being developed to achieve near-zero conducting ceramic membranes and
emissions of particulates, sulfur and that have potential for significant cost cally converted to high-value transportation Air Separation Unit
capital and O&M costs and increase the
efficiency of IGCC systems, but also to nitrogen oxides, and hazardous air pol- reductions and efficiency improvements fuels or chemicals. In addition, hydrogen
Steam Generator
meet more stringent gas quality lutants, and to minimize consumables are being developed. Oxygen Turbine
and steam can be produced. Particulate Hot-Gas
requirements for cogeneration and and waste products. A wide range of Cleanup Cleanup
coproduction applications. These new process conditions are being considered
Coal Steam
technologies are needed to ensure the in order to meet specific downstream
processing requirements. Gasifier
48 49
D E V E L O P M E N T A N D D E M O N S T R A T I O N D E V E L O P M E N T A N D D E M O N S T R A T I O N
It is intended that the results of this Technology integration/demonstration. FUELS T R A N S P O R TA T I O N F U E L S producing transportation fuels and
program and supporting R&D will lead Two key components of the IGCC The Energy Information Administration chemicals from coal and other carbona-
to the construction and operation of a program are the Power Systems Devel- (EIA) predicts that, by 2020, U.S. ceous, non-petroleum domestic
DEMONSTRATED
first-of-a-kind Vision 21 plant. opment Facility (PSDF) in Wilsonville, Coal and natural gas are versatile fuels petroleum imports, already represent- resources. Specifically, research is
SUCCESS FOR IGCC
Market analysis/outreach. A detailed Alabama, and the Gas Processing Devel- and feedstocks. Improved solid fuels ing over 50% of consumption, will rise focused on developing clean fuels that
Through cost-shared efforts by the opment Unit (GPDU) in Morgantown, (1) are environmentally superior to
analysis of the market potential of and economically competitive transporta- to 65% and increase our negative bal-
Department of Energy and industry West Virginia. These two facilities pro- those derived from conventional
IGCC technologies in conventional and tion fuels from gas and coal are expected ance of payments. Total worldwide oil
partners, the promise of gasification vide the critical link between R&D and petroleum-based fuels; (2) can satisfy
niche market applications, both domes- near-term products of DOE programs. demand will double, creating a very
has been demonstrated in three coal- commercial-scale demonstrations. the liquid fuel requirements of our
tically and internationally, is being con- A key emphasis in transportation-fuels competitive market for imports from
based IGCC plants that now provide Through cost-sharing industrial part- Nation’s transportation infrastructure;
ducted. Using the results of this study, development is the production of high- sources that are likely to be politically
reliable commercial service and a nerships, these facilities will provide and (3) will help engine and vehicle
a commercialization strategy will be quality, clean-burning diesel fuels from unstable. From an environmental per-
proving ground for IGCC technology. the means for performing integrated manufacturers achieve higher perfor-
formulated for use in the next decade. both natural gas and coal. The solid spective, vehicles currently account for
A unique combination of gasification, This, together with a technology system and component testing at a fuels and feedstocks program examines a large portion of urban air pollution, mance with significantly lower
gas cleanup, and advanced turbine database currently undergoing devel- scale of operation relevant to industry. the environmental and economic benefits including carbon monoxide, nitrogen emissions in both conventional and
technologies, IGCC systems offer an opment, will provide important infor- The four CCT IGCC demonstration pro- of blending biomass and waste feed- oxides, volatile organic compounds, advanced systems.
attractive approach for providing mation to both the public and private jects, Tampa Electric, Wabash River, stocks with coal, develops tailored feed- and particulates. The transportation Many years of public investment in
clean, affordable electricity as well as sectors for future decision making. Piñon Pine, and Clean Energy, are also stocks for making premium carbon sector also contributes about one-third coal liquefaction and power systems
other valuable products. IGCC plants key elements of the IGCC program. products, and provides the means to of U.S. greenhouse gas emissions. RD&D have resulted in major advances,
operated by the Sierra Pacific Power These projects are currently confirming remove trace contaminants from coal. Further limits on emissions are likely including reduced costs and mitigation
Company, Tampa Electric Company, process scale-up, evaluating process and will be difficult to meet with of environmental impacts. Continued
Through Vision 21, advanced technolo-
and PSI Energy, Inc., now serve elec- performance, and providing data on conventional fuels. investments can provide the U.S. with
gies for coproducing power and fuels
tricity customers with low-cost, envi- reliability, availability, and maintenance. technology options critical to our
will enable our Nation to use its plenti- The coal liquefaction technology pro-
ronmentally friendly power. In the DOE will maintain an active role in future energy security and economic
ful fossil resources to fulfill a broader gram response to these environmental,
future, as a key integral unit in Vision these projects by providing technical strength.
range of energy and chemical feedstock energy security, and economic chal-
21 plants, IGCC units like these will assistance and supporting R&D to needs while reducing impacts to the lenges is to provide the technical basis
supply synthesis gas, steam, trans- enhance their success. environment. for a clean fuels industry capable of
portation fuels, chemicals, and The Tampa Electric IGCC system, built
hydrogen, in addition to power.
as a greenfield site, is one of the cleanest
By converting carbonaceous feed-
and most efficient coal-fired powerplants EIA—PROJECTED U.S. CRUDE OIL PRODUCTION AND CONSUMPTION
stocks such as coal and biomass to
in the world.
high-value and commodity products
as well as to baseload power, IGCC Coal-derived transportation fuels can be an
can meet diverse national and inter- 25
important element in the overall strategy to
national energy market needs. Copro-
Consumption decrease our Nation’s reliance on foreign oil.
duction of energy products maximizes
returns on investment in these facili- 20 Currently, the United States uses 18 million
ties while minimizing waste and barrels per day (bbl/day) of crude, over 50%
environmental impact. Net Imports of which is imported. Rising oil imports will
15 65%
Million bbl/day
Thanks to investments in energy R&D 50% worsen the balance of trade. Last year, the
by the Federal government and indus-
U.S. paid over $60 billion for imported oil;
try partners, U.S.-based companies are
10 this amount could more than double (in con-
well-positioned to apply IGCC systems
at home and to capture a healthy Production stant dollars) by 2020.
share of what promises to be a multi-
5
billion-dollar export market for clean
power-generation technologies.
0 History Projection
1975 1985 1995 2005 2015 2020
50 51
D E V E L O P M E N T A N D D E M O N S T R A T I O N D E V E L O P M E N T A N D D E M O N S T R A T I O N
COAL-DERIVED FUEL COSTS D I R E C T L I Q U E FA C T I O N
Preliminary economic analyses indicate that In a direct route from
coal to transportation
1970s Technology: $50/bbl liquid fuels can be coproduced at a cost
liquids, coal’s large,
equivalent to crude oil at $21 per barrel. Product
complex structure is
Refining
These low costs can be achieved because broken down and con- Aromatic Feedstocks
Current Baseline: $34/bbl
of savings associated with integrating Early verted into distillate Coal Jet Fuel
Hydrogenation
Entrance Coproduction Plants with existing
crude. During this pro- Hydrogen Oxygenated Fuels/Chemicals
Continued R&D: $25/bbl cess, hydrogen is added Coal Carbon Products
petroleum refining facilities and using coal
Early Entrance Plants: $21/bbl to the coal, raising the
Wastes Coal Liquid Gasoline
combined with low-cost feedstocks, such as hydrogen-to-carbon
petroleum coke and wastes. ratio to a level compa-
rable with that of
petroleum crude.
Because of its interest in the production Early Entrance Coproduction economic and environmental require-
Coal-derived liquid transportation fuels privately funded design, construction, levels of pollutant-producing sulfur
of high-quality diesel fuel through the Plant activities ments. This information will enable the
could also provide significant environ- and operation by 2007 of a first-of-a- and nitrogen than those of typical
Fischer-Tropsch indirect liquefaction To facilitate an industry-led effort to teams to pursue private-sector financ-
mental benefits. Diesel fuels such as kind commercial facility that copro- petroleum crude.
process, DOE’s Office of Transportation demonstrate advanced liquefaction ing for detailed design, construction,
Fischer-Tropsch and high-cetane liquid duces multiple products—some com- R&D will pursue process improvements Technologies is an important partner technologies, the government will cost- and operation of their plants. One
oxygenates would enable the design bination of power, fuels, and chemicals. in the direct hydrogenation of coal— with the Office of Fossil Energy in devel- share feasibility studies, R&D, and likely strategy would be to coproduce
of modified engines with improved Technologies are being developed in alone and in combination with petro- oping fuels and transportation systems. preliminary designs of first-of-a-kind electricity, transportation fuels, and
efficiencies and up to 50% lower total a time frame consistent with FE’s mid- leum residuals and waste material—
commercial Early Entrance Coproduc- chemicals by integrating IGCC with
emissions than conventional fuels. term Early Entrance Coproduction including the development of more effi-
tion Plants. These activities will help indirect liquefaction. Feedstocks could
To meet these research objectives and Plant strategy. Through cost-shared cient reactors, more active and robust include petroleum coke, wastes, and
industry teams to refine their strate-
establish the foundation for a U.S. coal partnerships, program resources will slurry catalysts, and methods that pro- biomass in addition to coal.
gies, reduce technical risks, and define
conversion industry by 2010, the pro- be leveraged to provide the Nation duce hydrogen more economically and
gram has developed strong partner- with the capability to produce signifi- reduce its consumption during lique-
ships with industry, academia, National cant quantities of coal-derived trans- faction. Multiple feeds will be studied
Laboratories, and other government portation fuels, chemicals, and carbon to reduce the production of greenhouse A D V A N C E D S Y N T H E S I S G A S C O N V E R S I O N T O T R A N S P O R TA T I O N F U E L S A N D C H E M I C A L S
organizations to reduce the technical products after 2010. gases. Early commercial entry of direct
and environmental risks associated liquefaction technology would most
with commercial deployment. An Technology status and direction likely involve coprocessing heavy Coal can also be con-
example is the Early Entrance Copro- With current technology, the cost of residual oil at a refinery. verted to liquid form
Three-Phase
duction Plant initiative, part of Vision producing direct liquids in stand-alone Novel three-phase slurry reactor tech- by an indirect route. Slurry Reactor
Technology
21, that is scheduled for implementa- Tail Gas Ultra-Clean Transportation Fuels
plants would be about $30 per barrel. nology is also being developed to cost- Clean synthesis gas
F-T Diesel
tion in FY 1999 as a joint effort with the The cost can be reduced to the $21-per- effectively produce premium fuels, an (hydrogen and carbon DME/Methanol
IGCC program. Preliminary studies barrel target by coprocessing coal with excellent diesel-fuel blending compo- monoxide) is produced Liquid DME Derivatives
show that integrating technologies such low-cost feedstocks. Research has nent, or high-value chemicals using by gasifying coal with Water
Hydrocarbons Chemicals
as coal-based power and fuel produc- shown that these liquids can then be syngas produced from natural gas steam and oxygen. The Methanol
tion at one facility can offer economic upgraded, at lower cost than crude or coal. synthesis gas is then Steam DME
and environmental benefits when com- oil, using conventional petroleum reacted over catalysts to Acetyl Chemicals (VAM/MMA)
Synthesis Gas F-T Chemicals (Olefins/Naphtha)
pared with stand-alone plants. Teams refining technologies to produce high- form premium refinery (derived from
carbonaceous
will be pursuing industry-government octane gasoline, jet fuels, and valuable feedstock. feedstocks)
Feed Gas
cost-shared research and engineering chemicals. These fuels have much lower
studies that will be directed toward
52 53
D E V E L O P M E N T A N D D E M O N S T R A T I O N D E V E L O P M E N T A N D D E M O N S T R A T I O N
Systems engineering and analyses reduce the laboratory R&D needed to production of environmental solid fuels Solid Fuels and Feedstocks Program for power production from coal,
Engineering and economic analyses are effect process improvements. In addi- and tailored carbon feedstocks. The key activities will result in new tech- biomass, and waste and the other for
needed to define and prioritize future tion, R&D will examine innovative “Environmental Solid Fuels” activity is nology for: (1) precombustion control the precombustion removal of contami-
R&D initiatives and to support com- hydrogen production technologies that developing advanced technologies to of potentially hazardous air pollutant nants from pulverized coal at utility
mercialization activities, both domestic have the potential to provide for both enable the efficient use of coal, emissions from coal by 2005; (2) con- powerplants. Work will also continue
and international. A major emphasis is sequestration of CO2 and significant biomass, and waste fuels, while verting one billion tons of impounded on the development of a national coal
on performing life-cycle environmental reductions in manufacturing costs. addressing existing and future environ- coal to clean fuel and the avoidance of quality database on trace elements and
analyses on CO 2 emissions that arise mental regulations and concerns associ- the formation of new coal waste ponds cooperation with a broad-based, utility-
from mining, transport, handling, con- ated with hazardous air pollutants, by 2005; (3) facilitating 8 gigawatts of sector consortium for coal utilization
version, and product utilization. SOLID FUELS AND FEEDSTOCKS greenhouse gas emissions, and waste coal/biomass cofiring by 2010; and (4) research.
The Solid Fuels and Feedstocks (SFF) disposal/land reclamation issues. It producing cost-effective premium car-
Proof-of-concept testing Program is developing and commer- includes the preparation and utilization bon materials from coal by 2015. Tailored Carbon Feedstocks
cializing advanced technologies for of coal/biomass/waste composite fuels Premium carbon feedstocks and
Proof-of-concept (POC) evaluations to
processing carbon-based solid materials to permit a greater percentage of Environmental Solid Fuels products are being developed by an
produce Fischer-Tropsch and other
that will (1) maintain U.S. industrial renewables to be utilized in new and Research in this area is developing industry-led, cost-shared consortium
premium, high-performance fuels will
competitiveness, (2) contribute to effi- existing power production systems to innovative methods for recovering use- that will develop, demonstrate, and
provide optimum processing strategies
cient power production, and (3) pro- reduce CO 2 emissions by 10% or more. able fuels from materials that otherwise commercialize technologies for
and sufficient quantities of materials
mote environmental quality. A number New approaches are also being devel- would be discarded at coal cleaning nonfuel uses of coal, such as: The Solid Fuels and Feedstocks Program
for engine and vehicle tests. All coal-
of significant successes have already oped to improve the recovery and plants or utility power stations. Pro- investigates making premium carbon prod-
fuels R&D, which culminates in POC • High-value premium carbon and
been achieved by the program. For handling of fine coal from existing jects address the estimated 2 to 3 bil-
activities and fuel testing, is focused, graphite products ucts from coal, such as high-quality graphite
example, the Microcel ® flotation col- production and waste coal ponds lion tons of coal fines that lie in waste
and will continue to focus, on develop- • High-strength, lightweight materials electrodes. (Courtesy of the Carbide/Graphite
umn developed with DOE support has and piles. impoundments at coal mines and wash-
ing fuels that assist the transportation for improving fuel efficiency/reduc- Group, Inc., Pittsburgh, PA.)
sector in meeting its future emissions had significant commercial success in The “Tailored Carbon Feedstocks” ing plants around the country, the
ing weight of vehicles
requirements. To this end, partnerships coal and minerals applications, with activity is concentrated on advanced approximately 30 million tons of coal
over 50 units in use worldwide. Other technologies for the development of that is currently being wasted into •Advanced feedstocks to reduce
have been created with other Federal
successes include development of the premium carbon products from coal ponds each year by active mining oper- hazardous air pollutants, such as
organizations and their stakeholders to
Micro-Mag ® heavy-medium cycloning and the preparation of specially ations, and the millions of tons of mercury
facilitate commercial deployment of
these advanced, alternative fuels. process for coal cleaning and the designed (tailored) feedstocks for the unburned carbon found in powerplant • Improved rechargeable batteries
GranuFlow ® process for improved coal production of advanced transportation fly ash landfills. Technologies are also
• Fuel cell applications
Novel R&D in coal liquefaction fines handling. fuels and chemicals from coal, biomass, being developed that combine coal and
and waste feeds. biomass or municipal solid waste into • Chemically tailored carbon molecular
Computational chemistry techniques Based on the results of two successful
clean-burning fuels. A method for sieves
will be used to more efficiently develop workshops held to acquire stakeholder
input, the Solid Fuels and Feedstocks removing mercury from coal before it is •Adsorbents for water and air
kinetic models of coal conversion pro-
Program is focused on activities to burned, preventing the mercury from pollution control
cesses, which will in turn greatly
develop advanced technologies for the being released to form a hazardous air
•Specialty chemicals and coke
pollutant, is also being developed.
• Materials for heat-resistant
Other research in this area that will
applications
result in the more efficient use of solid
ROADMAP TO COMMERCIAL DEPLOYMENT fuels includes proof-of-concept (POC)- The Solid Fuels and Feedstocks Pro-
scale testing of a selective agglomera- gram uses engineering, market, and
FY 1995 2000 2005 2010 2015 2020 2025 2030 tion process that uses a new mixing economic evaluations to understand
device (tubular processor); pilot-scale how energy efficiency is improved and
Commercial Plants
testing of an electrostatic separation greenhouse and other gas emissions are
Early Entrance process for dry, fine-size coal; and reduced by new technology options for
Plants Design/Construct Operate
POC-scale testing of an advanced flota- the production of metallurgical and
Process Verification foundry coke.
Testing tion control system. Industrial-scale
Lab/Bench Testing testing of two advanced technologies
will also be conducted—one for the
production of carbonized slurry fuels
54 55
D I S T R I B U T E D G E N E R A T I O N
DISTRIBUTED
GENERATION INTRODUCTION Distributed generation systems will be
used largely in markets not served by
OPTIONS FOR PROGRAM AREAS
centralized power. Some requirements
BOTH BASELOAD AND DISTRIBUTED for distributed generation systems to
TOMORROW’S
• Fuel Cells GENERATION ARE NEEDED achieve their full market potential
ENERGY MIX include:
• Advanced Gas Engines As the U.S. moves to competitive util-
ity markets, decisions on alternate •Low cost. In the U.S., technology
• Combined Heat and Power power generation technologies will be selection will be based in large part
based in large part on system costs and on cost. Fuel cells and advanced heat
capital outlays. Distributed generation engines are being designed to offer
has many advantages to offer the cost-effective energy solutions.
energy industry. Distributed generation •Very high reliability. Distributed
could augment the traditional central generation systems must be robust
station grid system in relatively remote because they will be used and main-
locations where upgrading the existing tained by companies that are not as
transmission grid would be more costly experienced as powerplant operators
than installing a distributed generation and engineers in central power sta-
system; and at sites requiring 100% tion facilities. Fuel cell systems have
availability (such as hospitals and already performed reliably for long
industrial or commercial facilities periods of time without complex or
where cogeneration loads can help time-consuming repairs.
DISTRIBUTED make distributed generation economi-
•Flexible size configurations. Avail-
cal). A report prepared by the Gas
ability in a variety of sizes from
Research Institute estimates that gas-
kilowatts (kW) to tens of megawatts
GENERATION SYSTEMS fueled distributed generation capacity
is a key attribute of distributed
could be as high as 6,000 megawatts
generation technologies.
(MW) per year for baseload fuel cells
OFFER POWER in 2010. •Modular construction. The modular-
ity of distributed generation technolo-
gies increases their flexibility to meet
PRODUCERS EASE changes in demand as efficiently
as possible.
OF SITING, MODULAR •Environmental acceptability. Since
many distributed generation systems
may be located in communities near
CONSTRUCTION demand centers or in remote, envi-
ronmentally pristine areas, their
environmental performance must be
OPTIONS, ENVIRON- extremely high.
•Rapid startup. Some distributed gen-
M E N TA L B E N E F I T S , eration technology can meet peaking,
intermediate load, and load following
needs.
A N D H I G H E F F I C I E N C Y.
•Power quality. Distributed generation
offers many ancillary benefits includ-
ing voltage control, reactive power
control, and regulatory control.
57
D I S T R I B U T E D G E N E R A T I O N D I S T R I B U T E D G E N E R A T I O N
BENEFITS TO THE NATION STRATEGIES FOR SUCCESS •Demonstrate distributed generation Maintaining U.S. leadership in the
FUEL CELL DIAGRAM
The Distributed Generation Program is technologies, such as advanced fuel technology race is crucial in capturing
based on extensive participation with cells and heat engines, in cogenera- world fuel cell markets. It is important
Industrial and commercial
the private sector and other govern- tion and district heating/cooling to maintain the current technological A basic fuel cell consists of two
growth. Growth of U.S. industry
ment agencies (such as DOE's Office applications with overall system edge in significant technologies and electrodes, an anode, where the Fuel Gas
will be supported by maintaining
of Energy Efficiency and Renewable efficiency reaching 85%. U.S. ownership and intellectual prop- fuel is introduced, and a cathode, Anode
distributed generation technical Electrolyte DC Power
Energy) for the development of fuel erty rights in critical areas. This is separated by an electrolyte. It
rights and ownership, and by Air Cathode
cells and advanced heat engines for being accomplished through the estab- produces DC power that is easily
forming engineering and manufac-
stationary applications. Cogeneration lishment of engineering and manufac- converted to common AC power Fuel Cell Water
turing infrastructures for dis-
and district heating are important turing infrastructures in the United by an inverter, and hot water for
CO2
tributed generation technologies
elements of the program. FUEL CELLS States for new fuel cell industries. use in buildings or industrial pro-
within the U.S. Domestically
manufactured goods can then be The program implements RD&D The Fuel Cells Program focuses on the cesses. Fuel cell types are charac-
sold to world markets. that promotes timely demonstration development of highly efficient, envi- terized by their electrolyte and
of fuel cell systems, focusing first on Fuel cells generate electricity and heat ronmentally benign, high-temperature corresponding operating tempera-
Reduced electricity costs.
resolving technical issues, including using an electrochemical process fuel cell power generation technologies, ture. For example, MCFCs use a
Distributed generation systems
cost reduction and packaging. Particu- superior to that of a battery. A fuel such as molten carbonate fuel cells mixture of carbonate salts as the
will result in reduced costs for
lar emphasis is placed on conducting cell continuously produces power as (MCFCs) and solid oxide fuel cells electrolyte, which is a liquid at
electrical and heating/cooling
the appropriate basic research and long as a fuel, such as natural gas, (SOFCs). It includes the integration of the fuel cell operating tempera-
systems expansion, as they do
technology transfer to assist in and an oxidant (air) are supplied. components for proof-of-concept testing, ture of about 650°C. In contrast,
away with the need to transport
commercialization. Present systems can exceed 50% elec- customer tests of subscale integrated SOFCs use a ceramic electrolyte
electricity or heat and allow
trical efficiency, based on the fuel's systems, and eventual commercial that remains solid at their
expansion of existing facilities in Having established a consortium of
lower heating value. Next-generation demonstration of full-scale systems. 1,000°C operating temperature.
small increments. U.S. engine manufacturers, engine
systems are expected to achieve over
Increased reliability. Power qual- users, and research institutions to
70% and, eventually, greater than 80%
ity and reliability will be increased evaluate developmental needs for
efficiencies.
because distributed generation an advanced gas engine, DOE is
determining its role in cooperative The Fuel Cell Program is being driven,
systems are not subject to trans-
research programs required to address in part, by the emergence of dis-
mission line and network voltage
public needs. tributed generation approaches and
fluctuations, and because they are DISTRIBUTED POWER GENERATION
deregulation of the electric power
installed near end-use markets.
industry. Fuel cells offer greater cus-
tomer choice; greater siting flexibility; Distributed generation will offer utilities the
FUTURE ACHIEVEMENTS FOR
DISTRIBUTED GENERATION
the capability to use “opportunity opportunity to match the electricity demand
fuels,” such as gas produced in land- Existing of individual customers by providing reliable
Measurable goals for DOE and indus- Central Transmission
fills; reduction of capital investment Station Substation on-site generation. In this example, electric-
try partnerships are to:
and risk; a highly efficient, reliable, and
•Yield commercial offerings of fuel cell environmentally benign source of elec- ity is being produced at distributed genera-
powerplants in the 200-kW to 3-MW tricity; and elimination of transmission tion substations located near electricity users.
range. and distribution problems. Transmission Transmission These distributed sources of electric power
Substation Substation
•Lower fuel cell powerplant costs may, but are not required to, be connected
to under $1,500 per kW by 2003.
to the central electrical transmission lines.
Distribution Distribution Distribution
•Achieve fuel cell electrical conversion Substation Substation Substation
efficiencies of between 50% and 60%.
•By 2010, commercialize U.S.-manufac-
Cogeneration
tured advanced gas engines with 20% Applications
higher brake efficiency, 75% lower
NO X emissions, and lower cost com- Industrial, Commercial, and Residential Loads
pared to current engine technology.
58 59
D I S T R I B U T E D G E N E R A T I O N D I S T R I B U T E D G E N E R A T I O N
FUEL CELL REBATE
SOLID OXIDE FUEL CELL POWERPLANT LAYOUT
FUEL CELL PROGRAM PROGRAM
ACCOMPLISHMENTS Recuperator
• Over 160 phosphoric acid fuel cell Exhaust stack With fuel cells, as with most other
Instrumentation and controls products, increased manufacturing
(PAFC) units manufactured and
Inlet air filter
operating worldwide. volume lowers cost, increasing market
Fuel supply skid
penetration. To help increase market
• 250 kW and 2 MW molten carbonate
Power conditioning penetration, the Fuel Cell Rebate Pro-
fuel cell (MCFC) product development
gram (also called the Climate Change
tests completed. 300 kW to 1 MW
Fuel Cell Program) was begun in
demonstration planned. Intercooler
Switchgear 1996 using funds provided by the
• 100 kW solid oxide fuel cell (SOFC) Department of Defense (DOD), Office
demonstration being conducted. of Deputy Under Secretary of Defense
Additional 100 kW to 1 MW for Environmental Security.
SOFC module
demonstrations planned.
Rebates are given to organizations
• Fuel cells and fuel cell/turbine Startup blower installing a fuel cell manufactured in
hybrids are enabling technologies To produce a usable quantity of electric power, individual cells are assembled into a "stack" of
Power turbine the U.S., with priority given to power-
for Vision 21 concepts. electrically interconnected repeating components. This MCFC stack developed by Energy plants placed on DOD installations.
Research Corporation is made up of around 300 cells, with an area of 8 square feet.
Rebate program status:
A fuel cell powerplant consists of one or more stacks integrated into a power section, which
• In 1996, 33 grants of $1,000/kW
is then linked to a fuel processor and a power conditioner to convert the power from direct (or a maximum of one-third of pro-
current (DC) to alternating current (AC). ject costs) were awarded, resulting
in sales of 42 fuel cell powerplants
(200 kW) representing a crosscut of
market potential.
• In 1997, 53 grants were awarded.
ROADMAP FOR FUEL CELLS PROGRAM
• In 1998, an additional $5 million
FY 1997 1998 1999 2000 2001 2002 2003 was provided for awards to be
announced in 1999.
Phosphoric Acid
Market Entries Commercial Use, Private Sector
Molten Carbonate
Production Improvement
and Cost Reduction Initial powerplant Commercial demos
Market Entries (Gas) field demos tested Commercial Use & Coal Demos
Solid Oxide/
Advanced Concepts
Production Improvement
and Cost Reduction Begin 100 kW Class Commercial demos
Market Entries (Gas) generator test Commercial Use & Coal Demos
Advanced Research
Future Concepts
and Critical Areas
60 61
D I S T R I B U T E D G E N E R A T I O N D I S T R I B U T E D G E N E R A T I O N
ADVANCED GAS ENGINES COMBINED HEAT AND POWER These benefits are being demonstrated ECONOMICAL, RELIABLE,
by the Fuel Cell Program in a small
100-kW district-heating program in AND CLEAN ON-SITE
the Netherlands, and at the Miramar
As the need for distributed power Cogeneration is the simultaneous pro-
Naval Air Station in Southern Califor- POWER GENERATION
generation emerges, continued global duction of heat or cool air and electri-
nia. The Fluidized-Bed Combustion
market growth is projected for gas- cal power in a single process or from
(FBC) Program has also worked with
reciprocating engines and industrial- a single piece of equipment. The heat- A compact phosphoric acid fuel cell has
Alaskan Native groups to investigate
scale gas turbines. Advanced ing or cooling produced can then be been supplying reliable electric power to a
the adaptation of coal-fired FBC cogen-
industrial-scale turbines are being used in industrial processes or district- hotel in Spokane, Washington, for over a
eration and district heating in remote
developed under the Advanced heating systems that distribute steam, year, demonstrating the high efficiency
villages.
Turbine Systems (ATS) Program. temperature-controlled water, or air to and ease of installation of fuel cell power
multiple sites or buildings. Currently, Developing cost-effective cogeneration generation. This 200-kW ONSI unit was
Projected growth in natural gas use
district heating or cooling is provided and district-heating technologies is the first commercial fuel cell installation
will increase the Nation's need for
by cogenerating plants or facilities closely allied with DOE’s efforts to in the northwestern United States. Over
efficient and clean gas-reciprocating
designed specifically for this service. improve the overall efficiency and 160 units have been manufactured so far,
engines. Orders for natural-gas-recipro-
environmental performance of fossil- and the technology is speeding through
cating engines were 38% higher in 1996 By the end of the next decade, environ-
based power generation, both conven- the initial stages of commercialization.
than in 1995. Assuming this market mental requirements for all power
tional pulverized-coal and advanced Worldwide deployment of the phosphoric
growth trend continues, improving the systems may create significant opportu-
systems. acid fuel cell (PAFC) is expected within
efficiency and reducing the cost of nities for cogeneration and district
these engines will have significant heating. Electricity generators could the next five years, as the need for high-
environmental and consumer benefits. reduce emissions while achieving efficiency power technologies with low
the greatest return on investment and emission rates increases. Concerns about
Environmental constraints continue
the highest efficiencies (about 85% potential climate change from CO 2 emis-
to become more stringent as policies
higher heating value) by using high- sions will boost sales of fuel cells, as they
to reduce greenhouse gas emissions
tech cogeneration and district-heating can reduce CO 2 emissions by as much as
and as regulations for non-attainment
systems. Capital costs associated with 60% over those of today's coal plants.
areas become more restrictive. Devel-
opment of advanced gas-reciprocating cogeneration and district-heating The power generation system of choice
engines would provide cost-effective systems continue to be the main in distributed generation scenarios, the
products to enable engine users to impediment to their use. All DOE PAFC is currently being sold with standard
comply with possible new climate advanced fossil-power systems can warranties. It is particularly well-suited for
change and air emissions standards. be adapted to cogeneration and use in hospitals, hotels, and computer
district-heating operations. center, where its quiet, self-contained
U.S. manufacturers today are at a
Fuel cells, advanced gas turbine sys- operation can be installed in modules to
disadvantage with respect to foreign
tems, and integrated gasification match individual customer demand.
manufacturers. Foreign products are
combined-cycle systems will have less DOE-sponsored R&D led to the fuel cell's
more efficient, less polluting, and
impact on the environment if coupled launch on the market, and DOE is now
cheaper. Developing advanced
with cogeneration applications. helping to implement its commercializa-
gas-reciprocating engines would
tion through the phosphoric acid fuel
provide U.S. manufacturers with a
cell program and supporting research to
competitive edge in the global
lower its capital costs.
engine market.
As in Spokane, where the PAFC supplies
DOE is organizing workshops and
a flexible source of supplemental power
meetings to evaluate the need for a
to baseload electricity, Fuel cells are an
cooperative research program to
ideal component of a diversified portfolio
develop advanced gas engines.
for U.S. power suppliers.
62 63
V I S I O N 2 1
VISION 21
INTRODUCTION •Assure the availability of affordable
MEETING ENERGY
transportation fuels. Vision 21
NEEDS OF THE assures the U.S. of the availability of
PROGRAM AREAS
NEXT CENTURY WHY VISION 21 IS A NECESSITY liquid transportation fuels that are
* Enabling Technologies Vision 21 is a new approach to 21st- cost-competitive with equivalent
century energy production from fossil petroleum products. Our national
* Supporting Technologies
fuels. It will integrate advanced con- security is increased because reliance
* Systems/Market Analyses cepts for high-efficiency power genera- on imported oil is reduced. Our inter-
tion and pollution control into a new national balance of trade is improved
* Vision 21 Plant Design
class of fuel-flexible facilities capable of because oil imports can be reduced
producing electric power, process heat, and also because the availability of
and high-value fuels and chemicals alternative sources of transportation
with virtually no emissions of air pol- fuels tends to stabilize oil prices.
lutants. These plants will be designed •Continue U.S. leadership role in clean
using a variety of configurations to energy technology. By a recently
meet differing market needs. published account, world trade in
This concept is a vision of the way environmental controls has surpassed
electricity needs to be generated in the trade in armaments. Vision 21 would
21st century in order to meet environ- create the U.S. technology and know-
mental requirements and keep energy how to promote the export of fossil
costs affordable and consistent with energy technology, equipment, and
robust economic growth. An aggressive services. U.S. fossil energy/environ-
ENERGY FOR THE
industry cost-shared Vision 21 mental industries would expand and
Program would: new industries would be created,
21ST CENTURY WILL providing local, regional, and
• Remove environmental barriers to
national benefits.
fossil fuel use. The technological
innovations produced by the Vision
B E S U P P L I E D B Y H I G H LY
21 Program would allow use of a bal-
anced mix of fossil fuels for our elec-
EFFICIENT MODULAR tricity and transportation fuels needs.
Environmental barriers, including
smog- and acid-rain-forming pollu-
FA C I L I T I E S T H A T C O U L D tants, would be effectively removed.
Concerns over global climate change
would be mitigated by carbon dioxide
BE CONFIGURED TO emission reductions as great as 50%
resulting from thermal efficiency
improvements. Net CO 2 emissions
COPRODUCE ELECTRICITY, could be reduced to zero, if needed,
through sequestration.
H E A T , T R A N S P O R TA T I O N
FUELS, AND CHEMICALS,
WITH ALMOST NO AIR
P O L L U TA N T S , S O L I D
WASTE, OR CO2 EMISSIONS. 65
V I S I O N 2 1 V I S I O N 2 1
BENEFITS TO THE NATION Vision 21. The Vision 21 Program O X Y G E N - S E PA R A T I O N T E C H N O L O G I E S investment of $114 per kilowatt, a 2.9%
VISION 21 CONCEPT TECHNOLOGY MODULES
is also related to the Carbon Seques- Oxygen is a key ingredient in many increase in thermal efficiency, a 6.5%
tration Research Program, focusing Vision 21 modules. It is required for decrease in the cost of electricity, and a
High standard of living. Clean pro-
on cost-effective, high-efficiency combustion, gasification, and effective 500-fold decrease in SO 2 emissions.
duction of low-cost electricity and
technologies in configurations well- concepts for limiting CO2 production. Although these benefits are substantial,
transportation fuels from coal will Integrated Energy Plants suited to CO 2 sequestration; and the Using pure oxygen rather than air formidable obstacles must be overcome
maintain or raise living standards for
Fuel Office of Fossil Energy (FE) Materials allows CO 2 to be more easily concen- to develop this technology. These chal-
future generations. Modules Modules Modules
Feed R&D Program is an essential partner
Stock … … … Power trated for sequestration because the lenges are being addressed in a three-
Energy security. The availability of a in the development of the new
Combustion/ Separation/ Fuels/Chemicals large quantities of nitrogen found in phase program spanning about seven
clean, efficient fleet of powerplants Gasification Conversion Power materials required to pursue these air are no longer present. Successful years. The first phase addresses high-
for the 21st century will offer the Heat
new technologies. technology options need low-cost risk materials development, membrane
…
U.S. the security of knowing that it Modules Modules Other Useful Products
… … air-separation technologies capable of fabrication, membrane performance,
can use its largest domestic resource
making high-purity oxygen. and engineering issues related to pro-
to produce most of its energy needs. Fuels/
Gas Cleanup Products
A novel class of dense ceramic materi- cess integration. Subsequent phases
Fuel flexibility increases security by
als called ion transport membranes will focus on scale-up of the mem-
allowing the use of biomass and Modules Modules ENABLING TECHNOLOGIES
(ITMs) have the potential to meet this branes and fabrication techniques, eval-
opportunity fuels. … …
need. uation of full-scale modules, process
Economic security. The ultra-efficient CO2 Steam/ integration, and validation of process
Sequestration Cogen
use of resources in Vision 21 plants A recent study quantified the impact of
Enabling technologies allow the Vision engineering and economic models.
will support the continued strength advanced membrane technology on
21 modules to meet efficiency, environ-
of the U.S. economy, which is depen- integrated gasification combined-cycle
CO2 to Disposal/Reuse mental-performance, and cost targets.
dent on the availability of low-cost (IGCC) technology. The initial results
Some needed enabling technologies are
energy. Coproduction of high-value showed a 31% decrease in the cost of
described below.
commodities will boost the economy Discrete technology modules offer Vision 21 plant designers maximum flexibility in their choice oxygen, a decrease in total capital
further. of products, feedstocks, and environmental controls. Planners can select modules according
Competitive market position. Tech- to the feedstock supply and product demands of an individual region.
ION TRANSPORT MEMBRANE
nologies developed under the Vision
21 Program will ensure that the U.S.
The rapidly changing domestic and Partnerships and linkages are being
will continue to lead the field in New low-cost air-separation technologies are an
international situation (i.e., climate created with industry, universities,
ultra-high-efficiency energy tech- essential factor in realizing Vision 21. Producing
change, oil security, environmental reg- private and public R&D laboratories, Air
nologies with near-zero emissions.
ulation, electric utility restructuring, and Federal and State agencies. The high-purity streams of oxygen will reduce capital
Lower-cost electricity. Vision 21 aging U.S. energy infrastructure, global Vision 21 Program includes enabling costs and increase efficiency, and separating
plants will produce 10% to 20% trade competition and privatization, technologies, supporting technologies,
hydrogen for sale will increase profitability signifi-
cheaper electricity due to increased and declining R&D budgets) requires systems integration and market analy-
efficiency, the use of a variety of low- cantly. Pure oxygen is also required by technolo-
that more be done. Vision 21 combines ses, and Vision 21 plant design. The
cost feedstocks, and the coproduc- electricity- and fuel-producing subsys- product of a Vision 21 Program would gies that concentrate CO 2 for sequestration.
tion of high-value fuels and tems in a way that seeks to maximize be the design basis for commercial- DOE-sponsored R&D has identified a novel class
chemicals. thermal efficiency, minimize emissions scale Vision 21 plants.
of dense ceramic materials called ion transport
Consumer choices. Vision 21 technol- of traditional pollutants, and minimize Significant near-term benefits may be membranes, which use mixed-conducting ionic
ogy will offer people in the U.S. the cost, and yet is readily compatible with realized by the Nation as Vision 21
ceramics to conduct both oxygen ions and elec- O2
opportunity to choose the energy carbon dioxide sequestration. follows its technology roadmap toward
products best suited to their regional its ultimate goal. For example, high- trons through the membrane wall. No external
markets, economies, and geographies. efficiency fuel cell/turbine cycles using electric circuit is required to move electrons
LINKAGE TO OTHER STRATEGIC natural gas would be developed for the through the membrane, so the process produces
PROGRAMS distributed-power-generation market.
virtually pure oxygen at far less cost than N2
Vision 21 is seen as a long-range, cost- Technology improvements that produce
alternatives.
shared, industry-driven R&D program fuels or chemicals from coal and other
designed to produce public benefits solid hydrocarbon feedstock would be
from the present to 2030 and beyond. available for other applications besides
66 67
V I S I O N 2 1 V I S I O N 2 1
H Y D R O G E N - S E PA R A T I O N molecules through the membrane wall The materials available today limit the
ROADMAP FOR VISION 21 PROGRAM
TECHNOLOGIES at high temperatures and pressures. maximum temperatures in steam tur-
One solution to global climate change is A second approach centers on the bine plants to about 1,050° F to 1,100° F.
Today 2005 2010 2015
to develop a hydrogen economy based development of dense ceramic mem- For more efficient plants, high-
Vision 21
efficiency heat exchangers are needed Pulverized Coal Low-Emission Advanced Ultra-Critical
on renewable energy resources such as branes that conduct hydrogen as pro- Combustion Boiler Systems Steam Systems
biomass or the photovoltaic splitting of tons (proton transfer membranes) to superheat and reheat steam to tem-
High Performance
water. In such an economy, the trans- through the membrane wall in much peratures of 1,300° F or higher. The Power Systems
portation sector would use hydrogen as the same way as an ion transfer mem- Advanced Materials Program is meet-
Advanced Gas Hybrid Power Systems
a fuel, and electricity would be pro- brane (ITM). Both approaches focus ing this need by developing advanced Separation/Purification
duced using hydrogen in high-effi- R&D efforts on the water-gas shift alloys that have both high-temperature
Integrated Gasification Fuel Flexible IGCC
ciency fuel cells. In this scenario, there reaction to produce hydrogen. strength and corrosion resistance for Combined Cycle
would be no net CO 2 emissions, a result use in heat exchangers. When these Pressurized Advanced Pressurized
improved alloys are available, conven- Fluidized Bed Fluidized Bed
that would stabilize or decrease the
concentration of CO 2 in the atmosphere. HIGH-TEMPERATURE
tional powerplants with efficiencies of Advanced Fuel Cells
HEAT EXCHANGERS
45% to 50% will become possible and
An alternative path to a hydrogen
Vision 21 plants with 60% efficiency Gas Turbine Fuel Flexible
economy could use carbonaceous fuels One way to increase efficiency in a Gas Turbine
will be achievable.
as a source of hydrogen, with the powerplant is to operate at higher Emissions Control Advanced
Emissions Control
sequestration of CO2. However, no temperatures. The efficiency of a steam
commercial technologies exist today turbine (Rankine cycle) increases with Fuel Preparation Coproduction
that can accomplish the separation of the temperature of the steam entering
hydrogen from other gases (for exam- the turbine, and the efficiency of a gas Fuels Synthesis CO2 Capture
ple, N 2, CO 2, CO) at high temperatures turbine (Brayton cycle) increases with
and pressures. Ceramic membranes the temperature of gases at the turbine
Carbon Carbon
could accomplish the desired separa- inlet. High-temperature heat exchangers Sequestration Sequestration
tion economically. The first approach are key to achieving these higher
being pursued is to concentrate on fab- temperatures.
ricating membranes (molecular sieves)
that have sufficiently small pores to
permit only the passage of hydrogen
HIGH-TEMPERATURE AIR FURNACE FUEL-FLEXIBLE GASIFICATION •Evaluating alternative feedstocks in ADVANCED HOT-GAS CLEANUP
The Vision 21 concept depends on the existing gasification facilities such as Key to achieving Vision 21 goals of
ability to use the fuels, including waste Clean Coal Technology projects and high efficiencies, near-zero emissions,
A team led by United Technologies Research in developmental units.
materials, that are available at lowest and low cost, is the cleaning and condi-
Radiant Convective
Air Heater Air Heater Center is developing a high-temperature air cost in the area where the plant is •Developing novel gasification concepts tioning of gasification and combustion-
Top View End View
furnace (HITAF) for heating turbine air in located. This capability is being created that can lower costs and improve effi- product gases. Product gases must be
Air Slag/ high-performance power systems, a type of by the development of advanced gasifi- ciency, feedstock flexibility, and mod- cleaned of all particulate matter, all
Tubes Refractory
cation technology to process a variety ularity. Such technologies may include sulfur- and nitrogen-containing com-
indirectly fired cycle. The HITAF uses
Coal of feedstocks. catalytic gasification, the use of novel pounds, and all traces of other haz-
Air advanced materials and a highly innovative
Air at
Investigations are focusing on: ceramic membrane approaches, and ardous compounds that may affect
1300°F
design that prevents hot heat exchanger the use of CO 2 instead of steam as the downstream operations or be emitted
Combustion
at 2800°F Air at •Defining the availability and cost of
800°F tubes from contacting corrosive coal- diluent for oxygen feed to the gasifier into the atmosphere.
from Compressor alternative feedstocks and identifying
Air at 1700°F NOX in systems that capture CO 2 for
to Duct Burner Destruction combustion products. Such design concepts obstacles to achieving technical success.
and Gas Turbine Zone
sequestration.
1800°F and approaches will be needed in Vision 21
Flue Gas Recirculation
plants.
Slag
Screen
Slag Ash
68 69
V I S I O N 2 1 V I S I O N 2 1
Gases must be cleaned at temperatures developed under the Advanced Turbine SUPPORTING TECHNOLOGIES MATERIALS AND COMPONENTS visually “walk” through a three-
and pressures close to gasifier/combus- Systems (ATS) Program will provide New materials and components are dimensional rendition of a new design
A ROADMAP OF VISION 21
tor operating conditions and those of the cleanest, most efficient natural gas being developed to address the special for a plant and simulate its operation in
Integral to the Vision 21 concept of
TECHNOLOGY
downstream operations. Research turbine combined-cycle powerplant on needs of Vision 21. The ceramic materi- different situations would be invaluable
clean and cost-effective use of fossil
activities are focusing on: the commercial market. als required for novel membrane appli- for identifying opportunities, steering
Vision 21 provides a technology fuels is directed research on materials,
•Developing high-efficiency, high- Vision 21 demands that these achieve- cations and special alloys for high- supporting research, and confirming
roadmap for progressively cleaner components, controls, sensors, com-
temperature particulate filters that ments be extended to other fuels, temperature heat exchangers are exam- the performance of the design.
and more efficient energy produc- puter modeling, and other supporting
tion. The roadmap brings together operate in either an oxidizing or a including fuel gas produced from coal technologies that cut across existing ples of products of this activity that are The Vision 21 concept provides maxi-
enabling technologies, such as reducing environment. and hydrogen. This goal is being product lines and provide support to critical to the timely deployment of mum flexibility with respect to prod-
advanced, low-cost hydrogen and •Investigating new classes of catalysts pursued through the development of achieve program goals. These technolo- Vision 21 plants. ucts, feedstocks, and environmental
oxygen separation and advanced gas or sorbents capable of decomposing advanced-cycle configurations with gies are also applicable to other FE and controls. Individual modules could be
cleaning, that are needed to realize and/or removing chemical contami- increased pressure ratios, advanced DOE research and technology develop- linked together in many different com-
performance targets of efficiency nants at high temperatures. alloys and ceramic materials, and ment programs. Much of this work is VIRTUAL DEMONSTRATIONS binations to create Vision 21 plants.
and cost. It integrates and builds on combustion technology that could jointly defined and co-sponsored by a Virtual demonstrations—the use of The only way to demonstrate all of
advanced technologies now in the advance gas turbines to higher levels diverse group of industrial partners. computer models and simulations to these combinations is by using virtual
R&D and demonstration phase, such ADVANCED COMBUSTION SYSTEMS
of performance at reduced cost. develop, test, and evaluate the design demonstrations. In addition, virtual
as those in the Clean Coal Technol- of new concepts—are critical to speed demonstrations could be used in a
Highly efficient, clean advanced com-
ogy Program. progress and reduce the cost of making predictive fashion to prioritize combi-
bustion systems are being developed
COPRODUCTION
Vision 21 plants a reality. Virtual nations of modules for a Vision 21
Additional process improvements for Vision 21. These systems focus on
Coproduction integrates IGCC power demonstrations are already being used plant for a specific site, based on feed-
will be achieved through such sup- the indirectly fired cycle because this
production and indirect liquefaction to in other industries, e.g., aircraft design stock availability, population density,
porting technologies as advanced cycle is inherently fuel flexible and
produce both electricity and fuels or and manufacturing, as a cost-effective environmental goals, and markets for
materials and components, improved highly efficient. A key characteristic of
chemicals in a single plant. Both IGCC tool to reduce scale-up, construction, coproducts.
catalysts, environmental-control tech- the indirectly fired cycle is that com-
nologies, sensors and controls, and bustion products do not contact the and indirect liquefaction are now prac- and operational risks. The ability to
virtual demonstrations. Careful cost turbine, thereby avoiding potentially ticed commercially, but not together.
and market analyses will be pursued serious corrosion problems that may One driver that could make coproduc-
tion in a Vision 21 facility attractive is POWERPLANT EFFICIENCY MATTERS
concurrently with technology devel- arise from the use of sulfur- and ash-
opment to ensure that resultant containing fuels and expanding the CO 2 management.
technologies achieve market types of fuel that can be used. The basic IGCC process gasifies car- One golf-ball-size lump of coal
acceptance. bonaceous feed at high temperatures to would produce enough electricity
produce synthesis gas—a mixture of
to light a 100-watt bulb for 75
FUEL CELL HYBRIDS carbon monoxide and hydrogen. The
minutes in a conventional power-
The Vision 21 concept is expanding the gas is then cleaned of contaminants
and fed to a gas turbine/generator plant, 90 minutes in plants in
possibilities for advanced power gener-
ation systems to work together to and steam-bottoming cycle. In the the CCT program, 100 minutes in
achieve efficiencies that could not be coproduction mode, a portion of the “nth” of a kind CCT units, and
attained in a single system. When a synthesis gas is directed to a reactor
140 minutes in Vision 21 plants
fuel cell and advanced gas turbine are that catalytically converts the gas
into premium diesel fuels, gasoline, (which also produce steam,
integrated in a Vision 21 concept, the
efficiency of the system is expected to or chemicals. chemicals, heat, and other
exceed 70%. Many types of fuel cell The novelty of coproduction in a by-products).
hybrids are being studied to under- Vision 21 facility is integration of a
stand their potential. highly efficient power cycle with fuel
production in a way that facilitates
the capture and sequestration of
FUEL-FLEXIBLE TURBINES substantially all CO2 produced.
By 2002, advanced materials, combus-
tion systems, and cooling techniques
70 71
V I S I O N 2 1 V I S I O N 2 1
ADVANCED CONTROLS AND Modular design and construction VISION 21 PLANT DESIGN
VISION 21
SENSOR SYSTEMS would maximize shop fabrication,
With the advent of advanced power- minimize expensive field construction,
generation and fuel-conversion tech- and maintain flexibility in the design The Vision 21 Program will produce
nologies such as those proposed for and deployment of Vision 21 plants. engineering-level designs for prototype
Vision 21, a new generation of (small commercial) and large commer-
advanced controls and sensors must cial plants. The major products of the
be developed. The new controls and program are:
sensors will be compact, modular, •Component/subsystem designs. The
inexpensive, and easy to maintain. S Y S T E M S / M A R K E T A N A LY S E S
development of enabling technologies
They will maximize the operational provides the building blocks for
efficiency of advanced fossil-fueled integration into Vision 21 systems.
processes while reducing emissions. Systems analysis is a critical part of the
Vision 21 Program and serves to guide •Prototype plant designs. Designs of
Electricity
all activities. The key role of systems prototype plants of varying complex-
Feedstocks
analysis is to develop Vision 21 system ity will be produced. The plants will Opportunity Products
MODULARIZATION Coal, Gas, Biomass,
configurations that meet program utilize a range of feedstocks and Opportunity Fuels Clean Fuels, Chemicals
Most large industrial and utility fossil produce various products.
objectives, and to define performance
fuel plants are designed on a site-by-
targets for individual subsystems and •Commercial plant designs. The best of
site basis. Vision 21 plants will be built
supporting technology needs. the prototype plants will serve as the
from modules available in several
Market analyses will be concurrently basis for designs of large, commercial
fixed-size ranges. Systems Dynamic
performed to determine the acceptabil- plants of varying complexity and Engineering Response
and Control
ity of the most promising systems in product slates. Systems
Integration
Little or No
both national and international mar- Current Effort Cycle Cost/Market Industrial
kets. The results of market and system Analysis Analysis Ecology
analyses will be used to ensure that
Vision 21 closely meets market Modular Design Virtual
and Manufacturing Demonstration
requirements. Supporting
Research
High-Performance Process Sensors and
Materials Intelligent Control Systems
Some Work
in Progress
Carbon Fuel Cell/
Sequestration Turbine Hybrids
A VISION 21 CONCEPT
Hydrogen and Oxygen Multi-Feedstock
Separation Membranes Gasification
Enabling
Technologies
Existing
Program Robust Catalysts for High-Temperature
Fuels/Chemicals Synthesis Turbines
Fuel Syngas Power
Processing $2.77-$4.37/MMBTU with sequestration Generation $0.0325-$0.0447/kWh with sequestration
Coal $2.37/MMBTU without sequestration $0.03/kWh without sequestration
$1/MMBTU High-Temperature Gas Stream Advanced
H2 Heat Exchangers Ultra-Purification Combustion
$3.12-$4.72/MMBTU with sequestration to Distributed Power/Chemicals/Transportation Fuel
$2.72/MMBTU without sequestration
Technology
Power Environment Fuels Base
CO2 Sequestration
$10-$50/ton of carbon
72 73
C A R B O N S E Q U E S T R A T I O N R E S E A R C H
CARBON SEQUESTRATION
RESEARCH INTRODUCTION The Greenhouse Gas Sequestration
portfolio concentrates on innovative
PURSUING MID- sequestration concepts for longer-term
PROGRAM AREAS
NEW AND IMPROVED TECHNOLOGIES solutions. It includes sequestration
AND LONG-TERM
• System Studies and AT THE CORE OF DOE’S APPROACH technologies for integration with Vision
SOLUTIONS Assessments 21 plants at an energy facility site and
No single issue is as complex, or holds
approaches to remove carbon dioxide
• Enhanced Natural Sinks/ as many implications for the world’s
from the atmosphere by the enhance-
inhabitants, as global climate change.
Offsets ment of natural sinks to create
One of the primary environmental
greenhouse gas reduction credits.
• Capture and Separations concerns of the 21st century, response
to climate change could dictate funda- The program addresses novel and
Technology
mental changes in the ways in which advanced concepts for:
• Geologic/Ocean Storage we generate and use energy. Such mea- •Cost-effective CO 2 capture and
sures as increasing energy efficiency, separation processes
• Chemical and Biological
forest management options, and renew-
Fixation/Reuse •Geologic storage options, including
able energy applications are potentially
those that recycle carbon back to its
important methods for reducing global
source in natural formations
greenhouse gas emissions in the short
to medium term. •Enhancement of natural processes in
terrestrial and ocean sinks to comple-
For the longer term, when much larger
ment point-source sequestration that
reductions may be sought, it is clear
is directly associated with energy
CONCERNS ABOUT that additional technologies, including
production
carbon sequestration, could be essen-
tial. The importance of carbon seques- •Chemical or biological fixation
GLOBAL CLIMATE tration research has been underscored or reuse
by the President’s Committee of Advi- A recent study by the Massachusetts
sors on Science and Technology Institute of Technology evaluated and
CHANGE DRIVE THE
(PCAST) report, Federal Energy Research prioritized research needs for the cap-
and Development for the Challenges of the ture, use, and storage of CO2 from
NEED TO DEVELOP Twenty-First Century, November 1997. fossil-fuel-fired powerplants (Herzog,
The PCAST report recommends Drake, Adams—CO 2 Capture, Reuse,
increasing the U.S. Department of and Storage Technologies for Mitigating
LEADING-EDGE Energy’s (DOE’s) R&D for carbon Global Climate Change, January 1997).
sequestration. Specifically, the report Based upon current assessments, the
recommends: “A much larger science- potential for sequestration is quite
TECHNOLOGIES FOR based CO 2 sequestration program high but largely unexamined. In the
should be developed.... The aim should United States, very little research and
be to provide a science-based assess- development has been done on
COST-EFFECTIVE
ment of the prospects and costs of CO 2 promising options that might address
sequestration. This is very high-risk, these pathways.
CARBON SEQUES- long-term R&D that will not be under-
taken by industry alone without strong
incentives or regulations, although
TRATION AND REUSE. industry experience and capabilities
will be very useful.”
75
C A R B O N S E Q U E S T R A T I O N R E S E A R C H C A R B O N S E Q U E S T R A T I O N R E S E A R C H
BENEFITS TO THE NATION STRATEGIES FOR SUCCESS nical, and environmental research Further workshops on specific areas of SYSTEM STUDIES AND ENHANCED NATURAL
The overall goal of the program is to using domestic and international cost- sequestration research, such as geologic
develop a set of sequestration options shared collaborations with industry, sequestration, are being conducted ASSESSMENTS SINKS/OFFSETS
Energy security. Effective carbon
with potential to offset all new growth universities, and other governments during FY 1999.
sequestration and reuse technolo-
in greenhouse gas emissions beginning (e.g., the International Energy Agency The challenge for the future is to expand
gies will enable the U.S. to depend
in the year 2015, and to verify the [IEA] Greenhouse Gas R&D Pro- the current collaborative industry- A wide variety of activities are used to The annual exchange of CO2 between
upon its vast and inexpensive
environmental acceptability, technical gramme, the Climate Technology university-government R&D partner- identify and assess promising novel the atmosphere and the combined
domestic resources of coal, which
feasibility, and cost-effectiveness of a Initiative of the Framework Convention ships that result in cost-effective, and advanced concepts for sequestra- ocean and terrestrial biosphere is
now provide 55% of all electricity
sequestration capacity sufficient for on Climate Change [Working Group 3], innovative technologies to complement tion technologies and the evolving extremely large compared to total
produced, and still satisfy
wide-scale implementation starting and other agreements). In addition, the and enhance natural sequestration technologies necessary to support annual anthropogenic emissions. This
environmental concerns.
in 2015. Offices of Fossil Energy and Energy processes. them. Activities include system studies; suggests that small increases in the net
Growth of U.S. industry. Develop- Research (ER) have established a formal exploratory research; technical, eco- absorption of CO 2 in the global carbon
ment of a portfolio of innovative, During the 2005 to 2015 time period, a The program emphasizes competitive,
working group to coordinate carbon- nomic, and environmental assessments; cycle could have a significant effect on
cost-effective sequestration tech- suite of cost-effective options with cost-shared solicitations to create
management science and sequestration full fuel-cycle analyses; expert work- changes in atmospheric greenhouse gas
nologies will keep energy prices increasingly large carbon sequestration partnerships. The first of these compet-
technology research. DOE’s program shops; and outreach activities to seek concentration.
low and thus help the U.S. to capacity will be made available. The itive solicitations, issued in FY 1998,
has also received considerable input promising new ideas and to communi-
program will seek to develop even selected 12 innovative novel concepts Dissolved CO2 in the oceans is removed
remain a world economic leader. from industry, government, and aca- cate findings and results to industry,
lower-cost options by 2020, capable of for the control of atmospheric emissions by the growth of phytoplankton, with
Market competitiveness. Develop- demic stakeholders via expert work- academia, and the public.
sequestering carbon at a cost of $10/ton. of CO2, methane (CH4), and nitrous plant decay products settling to the
ment of sequestration technologies shops held during the summer of 1998.
The strategy for achieving this goal is oxide (N 2O). Sequestration-related top- deep ocean or ocean bed. When carbon
will also enable the U.S. to com- is thus removed, it is ultimately
to build upon ongoing scientific, tech- ics are included in the Department’s
pete in, and likely lead, a new replaced by CO 2 drawn from the atmo-
Small Business Innovation Research,
global market for an entirely novel sphere. Numerous concepts have been
University Coal Research, and Small
class of technologies. proposed for enhancing oceanic uptake
Business Technology Transfer Program
solicitations. of atmospheric CO 2.
DOE’s CO 2 sequestration portfolio aims to remove CO 2 efficiently from fossil fuel production
and use and to store it for geologic time. Higher-efficiency powerplants will emit less CO 2 ;
cost-effective Vision 21 plants will emit no net CO 2 . Point-source sequestration and distributed
sequestration, including enhancement of natural processes, will reduce CO2 emissions and
atmospheric concentrations.
COMBINED PORTFOLIO BENEFITS
A TIMELINE TO ACCOMPLISH THE GOAL
CO2
F Y 1 9 9 8 . Feasibility investigations of 12 F Y 1 9 9 9 . Comprehensive CO 2 sequestration B y 2 0 1 0 . In partnership with industry and
novel concepts for greenhouse gas seques- research roadmapping is being completed. international partners, DOE will establish
High-Efficiency Vision 21 tration were initiated. International collabo- The second phase of novel concepts investi- the viability of a large capacity of seques-
Power
rative research in ocean sequestration gations—to obtain the required engineering tration approaches suitable for deployment
Enhanced CO2 Point Source Products activity is under way with Japan and and economic data to proceed to proof-of- by industry in the longer-term (post-2015)
Natural Sinks Removal/
Geologic Norway. An industry-government partnership concept—is scheduled to begin. time frame.
Sequestration
addressing sequestration in deep, unmine-
CO2 able coal seams was initiated in collabora-
tion with the IEA Greenhouse Gas R&D
Forests Unmineable Coal Seams Programme. A comprehensive update of the
Soils Deep Saline Aquifers assessment of research needs for CO 2
Ocean Depleted Oil Wells sequestration was completed.
Deep Ocean
76 77
C A R B O N S E Q U E S T R A T I O N R E S E A R C H C A R B O N S E Q U E S T R A T I O N R E S E A R C H
An important component of terrestrial opportunities. However, to achieve C A P T U R E A N D S E PA R A T I O N S GEOLOGIC/OCEAN STORAGE CHEMICAL AND BIOLOGICAL
uptake of CO 2 is tree and plant growth. potential benefits, barriers to the appli-
Trees can remove carbon from the cation of advanced forest-management TECHNOLOGY FIXATION/REUSE CHEMICAL AND BIOLOGICAL
atmosphere and sequester it in forests technologies must be overcome. Another set of promising concepts for PA T H W A Y S F O R C A R B O N
and forest products, whereas deforesta- Carbon sequestration in soils is also a reducing CO 2 concentrations pertain to SEQUESTRATION
tion reduces the amount of carbon key part of the carbon cycle. In this Sequestration from large point sources its storage in geologic formations. It is Advanced chemical and biological
sequestered. Through improved forest- area, research is needed to develop requires cost-effective capture of car- believed that CO 2 could be cost-effec- sequestration is aimed at permanent,
management technologies, substantial practical and economic technology bon, whether it is CO 2 or C, and its tively sequestered in these formations. stable sequestration and at recycling • Conversion of CO to new
increases can be made in carbon approaches to increasing soil organic separation from other constituents not carbon to create new fuels, chemical carbon-based products
Options for geologic storage of CO2
sequestration by (1) halting deforesta- matter and to inexpensively monitor destined for sequestration. Capture and feedstocks, and other products.
include sequestration in depleted or • Chemical sequestration as a
tion, (2) expanding forests and reforest- changes in it. separation technology is available but Research is being conducted to develop
depleting oil or gas wells, coal seams, carbonate mineral
ing areas, and (3) increasing the stocks is costly and inefficient. novel concepts to convert CO2 , CO, or
or deep underground saline forma- • Direct conversion of CO 2 into
of carbon in existing forests. C into environmentally benign, eco-
The focus of this program area is the tions. Statoil of Norway is currently methanol or other products
A recent study by the IEA Greenhouse development of innovative concepts to sequestering CO 2 in a deep saline nomically useful products. The major
Gas R&D Programme has confirmed advantage of these technologies is that • Decarbonization of fossil fuels with
address improvements in the technical reservoir under the North Sea, the first
that there are potentially large, they produce economically valuable the capture of excess carbon
and economic performance of existing practical project of this method of
cost-effective, forest sequestration technologies. sequestering CO 2. Critical research products for the global economy while • Microalgae sequestration
questions center on understanding the meeting a global environmental goal.
• Biomimetic fixation of carbon
effects of CO 2 on the chemical and All concepts for these technologies are
physical properties of storage sites, at an early research stage. Better under-
CARBON SEQUESTRATION
environmental impacts, total potential standing of the basic processes and
storage capacity, and the economics of new chemistry and bioprocessing
Carbon sequestration is the separation and various candidate sites. approaches is needed before practical,
Geologic achievable technology performance or
Storage capture of CO 2 for either geologic storage, Similar carbon storage has already
cost levels can be estimated.
enhancement of natural sinks, or chemical taken place for over a decade at more
Ocean
Sequestration and biological fixation/reuse. It includes dis- than 70 enhanced oil recovery sites
around the world, where CO 2 injection
posal either as CO 2 or as some other form of
is used to augment traditional oil
carbon. More than just storage, it includes
recovery technologies.
Use as both existing and new commercial uses of
Research is being conducted to answer
Feedstock
CO 2 , CO, and C. the most critical technical questions
about the feasibility of and capacity for
ocean storage of CO 2 captured from
combustion processes.
C/CO2
CO2-Enhanced
Photosynthesis
Advanced Carbon
Products
Capture from
Atmosphere
78 79
A D V A N C E D R E S E A R C H
ADVANCED RESEARCH
INTRODUCTION BIOPROCESSING
THE FOUNDATION
PROGRAM AREAS
FOR INNOVATIVE The major goal of the Advanced Primarily fundamental research, this
SYSTEMS • Materials and Advanced Research Program is to develop, by program area includes research into the
Metallurgical Research 2015, a series of advanced materials, chemistry, biochemistry, microbiology,
subsystem technologies, and break- and engineering of bioprocessing tech-
• Bioprocessing through process concepts that are nologies and focuses on the biological
• Coal Utilization Science essential to the success of Vision 21. production and processing of fossil
fuels, wastes, and biomass.
• University Coal Research
• Historically Black Colleges and
Universities/Other Minority
MATERIALS AND ADVANCED
Institutions COAL UTILIZATION SCIENCE
• Small Business Innovation M E TA L L U R G I C A L R E S E A R C H
Research
The Coal Utilization Science (CUS)
• Advanced Clean Fuels Program activities focus on developing Program supports research to develop
Research a technology base in advanced materi- technologies for clean, efficient power
als synthesis, processing, life-cycle anal- generation from coal and other fossil
ysis, and performance characterization. fuels. Emphasis is placed on producing
F O R G I N G T H E PA T H
The program funds exploratory fundamental information by perform-
research on new materials that could ing experimental research and theoreti-
FROM BASIC RESEARCH improve the performance or reduce the cal investigations on processes and
cost of existing fossil fuel technologies, mechanisms that form technological
and the development of materials for barriers. Novel processes that address
TO REALIZATION OF new systems. Partnering and cost-shar- environmental issues as well as power
ing with industry are central elements. generation are included.
Research is currently being conducted
T H E V I S I O N 2 1 C O N C E P T,
by the Advanced Research and Tech-
nology Development Materials Pro-
ADVANCED RESEARCH gram at Oak Ridge National Laboratory,
the Advanced Metallurgical Research
Program at Albany, Oregon, as well as
CONCENTRATES ON materials-related activities at the Fed-
eral Energy Technology Center (FETC).
TECHNOLOGIES AND
PROCESSES THAT ENABLE
INNOVATIVE SYSTEMS.
81
A D V A N C E D R E S E A R C H A D V A N C E D R E S E A R C H
UNIVERSITY COAL RESEARCH H I S T O R I C A L LY B L A C K ADVANCED CLEAN FUELS This cutting-edge research program BENEFITS TO THE NATION
provides the basis for new technologies
AN ADVANCED RESEARCH COLLEGES AND RESEARCH by serving as a bridge between basic
High-efficiency power. Develop-
SUCCESS STORY: NEW CERAMICS Grants are provided by the University and applied fuels research. The program
ment of advanced materials
Coal Research (UCR) Program to U.S. UNIVERSITIES/OTHER is exploring novel concepts for the
A lightweight ceramic hot-gas filter will enable the production of
universities in order to support funda- Coal-derived substitutes for traditional production of new fuels from coal and
material developed by the Advanced advanced, high-efficiency power
mental research and develop improved MINORITY INSTITUTIONS petroleum products have the potential mixtures of coal and other resources.
Research Program is now widely used systems that better utilize fossil
fossil energy technologies. Novel and to provide the secure supply of trans- Research is done in concert with
to remove hot-gas particulates in fuel resources.
innovative approaches are sought to portation fuels that is critical to all sec- industry, academia, and other govern-
fossil-fueled power generation and Domestic liquid fuels. Production
solve national and global environmen- The Historically Black Colleges and tors of our economy. Development of a ment agencies and laboratories at the
industrial systems, vastly improving of non-petroleum-based liquid
tal and energy-related issues. This Universities/Other Minority Institu- synthetic fuels industry will positively national and State levels.
their efficiency and productivity. fuels with low environmental
research sustains U.S. global pre- tions (HBCU/OMI) Program was affect our balance of payments and cre-
Developed as part of an industry-DOE eminence in the areas of fossil fuel established to provide a mechanism ate high-paying jobs, while addressing impact will give the U.S. an alterna-
cost-shared collaboration, the filter science and engineering by supporting for cooperative research between his- the projected decline in petroleum pro- tive source of transportation fuel.
material is now sold commercially, fossil energy research at our Nation’s torically black institutions and other duction and the concomitant increase Energy security. Maintenance of
with a potential international market universities. The result is a developing minority institutions with U.S. indus- in demand after 2015. In addition, these coal as the primary source of
of $7 billion over the next 10 years. and expanding knowledge base in tries and Federal agencies. This pro- fuels will be more environmentally energy for electricity production
The U.S. market alone is forecast to disciplines relevant to fossil fuels. gram strives to support the education friendly than any petroleum-based will provide Americans with a
reach $200 million annually by the of scientists and engineers and spon- products, while using our vast domes- dependable domestic source of
end of the century. sors research in support of the Office tic coal resources to provide a level of power.
of Fossil Energy’s (FE’s) product lines. energy security not seen for decades. Economic security. Reductions in
The HBCU/OMI program has empha- energy costs resulting from
sized improving the environmental advanced technologies will ensure
compatibilities of advanced coal, oil, continued economic well-being for
gas, and environmental technology U.S. citizens.
concepts.
Environmental acceptability.
Advanced materials and processes
are critical to meeting both tighter
AN ADVANCED RESEARCH SUCCESS STORY: SUPER 9 CHROME ALLOY emissions standards and future
Today Super 9 Chrome, an extremely strong steel alloy, is the worldwide industry restrictions on greenhouse gases.
SMALL BUSINESS
standard for safer and more reliable coal-fired powerplants. Developed by the Reduction of emissions will
U.S. Department of Energy (DOE) advanced materials program, the new alloy is improve human health and the
INNOVATION RESEARCH/
now used for superheater tubes, pipes, and forgings, allowing an increase in environment.
SMALL BUSINESS powerplant operating steam temperature from 1,005°F to 1,075°F.
The higher operating temperatures have allowed powerplants to boost efficien-
TECHNOLOGY TRANSFER cies and to save on fuel costs. The greater reliability afforded by Super 9
Chrome parts and the improved stability of equipment incorporating the new
alloy have also served to reduce maintenance charges, thereby improving the
FE’s Small Business Innovation economic performance of the powerplant fleet overall.
Research/Small Business Technology
Transfer (SBIR/STTR) programs make
competitive grants to small businesses
for fossil-related technology research
projects that interest small businesses
while advancing the mission of FE.
Research supports FE goals of obtain-
ing clean fuels and energy from fossil
sources.
82 83
I N T E R N A T I O N A L P R O G R A M
INTERNATIONAL
PA R T N E R S H I P S I N INTRODUCTION • Maximize export opportunities. The
U.S. is the world leader in the devel-
EMERGING GLOBAL
opment of clean fossil-power tech-
PROGRAM AREAS
MARKETS TA C K L I N G G L O B A L E N E R G Y I S S U E S nologies. The International Program
• Brazil OF THE 21ST CENTURY works to ensure that U.S. companies
get a share of the global market for
• India Worldwide, the demand for power is
clean power systems, thereby secur-
increasing exponentially. The global
• Ukraine market for electric power systems has
ing jobs, driving economic growth for
the U.S., and contributing to global
• Poland been estimated at $2,279 billion (1993
environmental protection.
dollars) between 1995 and 2010, and
•ª Middle East over half this investment will be for • Establish effective partnerships.
coal-fired units. At the same time, the Partnerships play an important role
energy sectors of many countries are in overcoming barriers facing U.S.
undergoing major transformations. companies pursuing export opportu-
Increasingly stringent environmental nities. Such barriers include trade,
regulations, growing international finance, inadequate understanding of
concerns over global climate change, U.S. clean power systems, and unfair
and increased competition among fuels competitive trade practices. Through
drive the need for advanced power its partnerships, the program facili-
technologies that deliver electricity tates business solutions to remove
efficiently, cleanly, and economically. these barriers.
WORKING TO These trends offer great opportunities • Facilitate electricity transactions
for clean coal technologies and across international borders. The
advanced power generation systems, International Program ensures relia-
ENSURE A CONTINU- the wide-scale adoption of which bility and open-access transmission
would protect local, regional, and global through border systems. The Office
environments and support the Adminis- authorizes exports of electricity,
ING AND GROWING
tration’s environmental goals. collects and analyzes information on
international electricity trade, con-
STRATEGIES FOR SUCCESS ducts country-specific studies on
WORLD MARKET FOR
electric power systems and the con-
The International Program in the
struction of international transmission
U.S. Department of Energy’s (DOE’s)
U.S. TECHNOLOGIES, lines, and provides electric power
Office of Coal and Power Systems has
regulatory assistance.
four major strategies:
DOE’S INTERNA- •Provide leadership in international
organizations. Office of Fossil Energy
(FE) staff have leadership roles in
TIONAL PROGRAM several international organizations:
the International Energy Agency,
Latin America Energy Organization,
HELPS PROMOTE Asia Pacific Economic Cooperation’s
Regional Energy Cooperation Work-
ing Group, United Nations Economic
ADVANCED POWER
Commission for Europe Clean Coal
Technology Initiative, and the World
GENERATION Energy Council.
SYSTEMS ABROAD.
85
I N T E R N A T I O N A L P R O G R A M I N T E R N A T I O N A L P R O G R A M
ONGOING ACHIEVEMENTS BRAZIL INDIA The Greenhouse Gas Pollution Preven- •Additional training on the merits BENEFITS TO THE NATION
Through membership in international tion Project, initiated in 1995, is funded and operating characteristics of
organizations, FE staff in the Interna- by USAID and the Indian government Advanced Biomass Cogeneration
A stronger economy. Increased
tional Program influence policies to at a total of about $30 million. The powerplants at Indian sugar mills.
The International Program, through Since 1982, the Federal Energy Technol- international technology sales will
help support U.S. foreign policy and Efficient Coal Conversion component •Monitoring, to world standards, of
FE’s Office of Coal and Power Import ogy Center (FETC) has managed six improve the U.S. economy and
energy, environmental, economic, and of this project seeks to improve the the Advanced Biomass Cogeneration
and Export (ImEx), has sponsored sev- coal-related projects in India for the increase the number of high-skill
national security objectives. Such poli- efficiency and environmental perfor- demonstration projects when they
eral conferences and workshops to pro- U.S. Agency for International Develop- jobs for Americans.
cies can enhance opportunities for U.S. mance of existing Indian coal-fired become operational, to develop
mote technology advances in Brazil’s ment (USAID). The total value of these
powerplants, while the Advanced Market competitiveness. The pro-
firms to expand into international mar- coal mining and power generation projects, including contributions from a database on Indian conditions.
Biomass Cogeneration component gram improves the U.S. techno-
kets. International agreements are exe- sectors. In addition, it has sponsored the various Indian partners, is about •Assessment of advanced DOE tech-
seeks to promote year-round cogenera- logical advantage and U.S.
cuted with counterparts in key foreign trade missions for industry and gov- $80 million, with about $15 million of nologies (e.g., fuel cells, pressurized
tion in Indian sugar mills with power competitiveness in the interna-
countries that support FE’s RD&D ernment where Brazilian participants the total brought to FETC for direct fluidized-bed combustion) and recom-
export to the grid while using only tional market.
objectives, and foreign partners are have benefited by face-to-face discus- implementation. mendations to USAID-India to pro-
supported in an advisory capacity as biomass fuels. Energy security. By promoting
sions of common areas of interest Two of these projects have been com- vide cost-shared pre-feasibility study
they pursue private power reforms. with U.S. business entities. Projections strategic international collabora-
pleted recently: (1) Program for Accel- funding.
indicate that coal-fired electricity gen- tion and supporting high-effi-
To ensure that U.S. companies get a eration of Commercial Energy Research •Continued championing of three inte-
MAJOR EVENTS TO COME ciency use of fuel resources, the FE
share of the global market for clean eration in Brazil could increase sub- (PACER), which was funded at grated gasification combined-cycle International Program increases
fossil power systems, bilateral efforts stantially and require billions of dollars •Additional efficiency demonstration
$356,000, and (2) U.S.-Asian Environ- (IGCC) projects that are under vari-
of investment by 2015. The United testing at several State Electricity U.S. energy security.
are ongoing in seven regions: Africa, mental Partnership’s (USAEP’s) Indo- ous stages of development in India
Eastern Europe, the Pacific Rim, Russia States is Brazil’s largest trading partner Boards’ coal-fired powerplants to Environmental security. A priority
U.S. Coal Preparation and Beneficiation with USAID and the World Bank/
and the Newly Independent States, and DOE’s efforts in the energy field increase awareness of greenhouse of the program is to mitigate the
Project, which was funded at $382,000. International Finance Corporation.
South Asia and Near East, Western help maintain this position. gas reduction opportunities and global environmental impact of
The PACER project included engineer-
other benefits. •Support of a coal-gasification-based increased fossil fuel usage by
Europe, and Western Hemisphere. In ing and economic analyses by FETC to
plant, possibly with coproduction of overcoming the obstacles to using
each region, countries are assisted with support development of commercial •Selection of three or four additional
chemicals and power. clean fossil power systems.
adapting their power sectors to meet coal washeries in India. This project Advanced Biomass Cogeneration
local demands and environmental has helped open the Indian coal prepa- demonstration projects for funding. Expanded markets. Facilitating
pressures. This assistance facilitates ration market, which has been valued both new market entries and
dialogue between financial institutions at over $4 billion, to U.S. companies expansion in existing markets, the
and U.S. companies. and technologies. program develops international
The second project supported deploy- markets for U.S. energy-related
ment of an advanced coal-cleaning technologies, services, and energy
circuit, based on U.S. technology sup- resources.
ported by DOE, at the first commercial
non-coking-coal washery in India. The
objective of this project is to demon-
strate production of coal with less than
Through a recently completed agreement with
30% ash in the 2.5-million-ton-per-year
commercial washery. Two U.S. firms, USAID-India, FETC supported demonstration of a
Spectrum Technologies and CLI, have U.S. advanced coal cleaning technology at the
taken equity positions in the commer- commercial Bilaspur Coal Washery in Madhya
cial washery, and CLI, a U.S. coal Pradesh. This 2.5-million-ton/yr washery is
preparation design company, has been
being built through a joint venture among
awarded a $12-million engineer,
Spectrum Technologies of New York, CLI Corpo-
procure, and construct contract and
ration of Pennsylvania, and Bombay Suburban
a $4-million-per-year operation and
maintenance contract. Electricity Supply of India. Additional site-
specific cost-benefit studies have been con-
ducted to support establishment of other coal
beneficiation plants in India with U.S. partners.
86 87
I N T E R N A T I O N A L P R O G R A M I N T E R N A T I O N A L P R O G R A M
UKRAINE a low-grade anthracite having an ash by washing and for use in a large-scale
CUMULATIVE WORLDWIDE ELECTRIC POWER INVESTMENTS BY REGION (1995–2010) content in the range of 18% to 20%. test burn in a 2.5 MWt CFB boiler at
(IN BILLIONS OF DOLLARS, 1993)
They have operated recently with coal Babcock & Wilcox Company’s R&D
Investment North Latin Western China OECD East South Central Newly Middle Africa World that contains 30% to 37% ash. About Center in Alliance, Ohio. Tests with
In 1994, a U.S.-Ukraine Clean Coal
Type America America Europe Pacific Asia Asia and East Indep, East Total 30% of the calorific feed to the boilers washed and unwashed coal in a
Rim Europe States
Technology Task Force was established
must be supplied by oil or gas to com- pulverized-coal combustor at FETC
to develop a cost-effective approach to
Generation pensate for the poor coal and deterio- confirmed the benefits of using cleaned
upgrading an anthracite-burning
Solid Fuel 94 22 102 222 51 100 71 19 24 2 27 734 rated boiler equipment. coal for improving boiler performance
powerplant in Eastern Ukraine,
Several approaches were used in devis- and reducing the need for support fuel.
Natural Gas 32 23 89 1 14 41 13 10 33 27 15 298 Lugansk GRES. Members of the Task
ing a plan for upgrading Lugansk GRES. The CFB test showed that coal could
Oil 1 8 1 0 0 1 1 7 2 2 6 29 Force were drawn from the FE Office,
An engineering services company eval- be combusted acceptably with no
FETC, the Ukrainian Ministry of
Nuclear 6 3 8 18 39 21 6 3 26 0 0 129
uated the plant and designed several support fuel.
Energy, and the Ukrainian Academy
Hydro/Renewal 17 52 15 67 5 6 48 5 13 3 5 235 of Sciences. alternative approaches for rehabilitat- Economic and financial analyses of sev-
Subtotal 149 108 215 308 108 169 139 44 98 34 54 1,426 ing the existing boilers, including one eral approaches to refurbishing existing
The plant uses eight 200-megawatt
that would increase power output boilers and installing new CFB boilers
Other (MW) slagging pulverized-coal com-
above the nameplate capacity to 230 were prepared, and several supporting
Transmission 14 42 20 31 10 28 23 3 14 4 12 200 bustors that were installed in the 1960s.
MW. In addition, they described how studies by U.S.-Ukrainian teams evalu-
While the units have been heroically
Distribution 54 36 78 84 39 61 60 11 30 10 19 480 twin 60-MW circulating fluidized-bed ated coal and coal-waste sourcing, and
maintained by plant staff with few
General 14 17 20 43 10 17 21 6 14 5 7 173 (CFB) boilers could be installed in the coal-cleaning plants available to
resources, the equipment is well
existing space to use low-quality coal Lugansk GRES. The option of shutting
Subtotal 82 94 118 159 59 105 103 19 58 18 38 854 beyond its design life and is worn out.
without support fuel. down Lugansk GRES and bringing in
The boilers have been derated to 145
Total 231 202 333 467 167 275 242 63 156 52 91 2,279 power from other areas was evaluated
MW. In addition, coal quality has dete- A shipment of 160 tonnes of Ukrainian
Annual Average 15 13 22 31 11 18 16 4 10 3 6 152 anthracite was sent to the U.S. to test and found to be uneconomic.
riorated since the units were put on
line. They were designed for use with schemes for improving its quality
Source: Resource Dynamics Corp. estimates based on EIA’s 1995 World Energy Outlook, Capacity Constraints Scenario, base case.
•Continued technical assistance for FE has also supported creation of a
Advanced Biomass Cogeneration bilateral Coal Advisory Group, com-
DOE has conducted a cooperative project
activities, including an anticipated posed of coal and coal technology
with the government of Ukraine and with
interest in bagasse gasification for associations and academics, to advise
power or liquid fuel production. the Indo-U.S. Bilateral Consultations funding from USAID to strengthen the coun-
•Technical assistance and training to on issues relevant to the coal industry. try’s thermal power sector. The project at
foster “climate-friendly” policies This group has the charter to identify
Lugansk GRES developed a cost-effective
and combat “climate change in cities” topics of interest and propose joint
approach to upgrading an anthracite-burning
in India, two new USAID-India efforts to address those issues. Princi-
pal topics of interest include fly powerplant. The incentive was first to aid
initiatives.
ash utilization, coal cleaning, and Ukraine in providing alternative sources of
powerplant efficiency improvements. power to the nuclear station at Chernobyl,
Secondary issues include coal mine
and second to help Ukraine reduce the
fires and coal-bed methane collection
and utilization. amount of imported oil and gas it needs
for cofiring with poor-quality anthracite
at Lugansk GRES, easing its balance-of-
payments problem with Russia.
88 89
I N T E R N A T I O N A L P R O G R A M I N T E R N A T I O N A L P R O G R A M
POLAND Almost all of the companies have Emissions have declined substantially. solution that is being proposed by the any potential disruption of service.
secured local Polish partners and Particulate matter has been reduced by University of Cairo is the use of U.S.- Discussions have been initiated
formed joint ventures, which are 3,924 metric tons per year, SO 2 by 884 developed fuel cells, which can provide between Texaco and Destec in the
A NEW ENERGY AND ENVIRON-
expected to lead to the establishment metric tons per year, NO X by 183 met- high-efficiency power generation with U.S., the Israel Electric Corporation,
M E N TA L T E C H N O L O G Y C E N T E R I N In 1989, President Bush pledged that
of permanent businesses after the ric tons per year, and carbon monoxide no environmental problems. and Israel Refineries, Ltd. An IGCC
BEIJING the U.S. government and U.S. compa-
cooperative agreements are completed. by 1,330 metric tons per year. In Israel, a proposal has been submit- market study is under way and a trade
China will by 2015 replace the U.S. as nies would help the government and
Technologies that are being pursued ted to the U.S.-Israel Science and Tech- mission to the U.S. is being scheduled.
holder of the dubious honor of being people of Poland to reduce severe air
pollution in and around the Polish city include boiler-modification and mod- nology Commission, administered by
the largest emitter of greenhouse gases
of Krakow, the former capital. ernization equipment, novel separators the Department of Commerce, to inves-
during energy conversion. Coal today
Krakow’s monuments and other his- that remove particulate matter, use of tigate the efficacy of cofiring coal with
provides 75% of China’s energy needs MIDDLE EAST
toric structures were being ravaged cleaned and graded coal for stoker municipal and industrial waste. This
and is projected to continue supplying
by pollution from uncontrolled coal boilers, district-heating extension, approach has the potential advantage
at least 60% through 2050.
burning. district-heating controls, briquettes of both providing additional power
As a move both to help reduce global for home stoves, a micronized-coal- Several coal and power systems pro- and eliminating an environmental
CO 2 emissions and to enhance the Since then, DOE FETC has headed the
combustion system, and automated jects are planned and under way in the problem, because the waste is currently
adoption of U.S. environmentally supe- Krakow Clean Fossil Fuels and Energy
boiler-combustion controls. Middle East. In Egypt, assistance is being landfilled at high cost in areas of
rior technologies in China, the U.S.- Efficiency Program, designed to
Financially, the program has been being provided to Cairo University and high alternative-use value.
China Energy and Environmental upgrade boiler houses that provide
highly successful. To date, $11 million the Ministry of Power in their efforts to Additionally, Israel has expressed inter-
Technology Center in Beijing was insti- industrial, commercial, and residential
spent on cooperative agreements has prepare a proposal to the U.S.–Egypt est in IGCC for the gasification of refin-
tuted in November 1997. Backed by heat, as well as small stoves that fire
leveraged $12 million from U.S. partici- Science and Technology Joint Fund. ery residuals and for coal gasification
joint DOE and Environmental raw coal for home heating and cooking.
pants and their Polish counterparts. The proposal will look at possible alter- backup to new natural-gas-fired power-
Protection Agency funding, it demon- This usage, combined with low stack
native solutions to a lack of adequate plants being built on the Mediterranean
strates a long-term relationship, build- heights at district-heating and indus- In addition, the program has helped to
power. Egypt identifies two problem coast. The new powerplants would
ing on trust, mutual benefits, and trial plants, has caused substantial sul- establish three permanent joint ven-
areas, which they refer to as areas of derive their fuel from a natural gas
goodwill. fur dioxide (SO 2), nitrogen oxides tures and one licensing agreement, to
“chaotic growth” and “touristic vil- pipeline from Egypt, and the IGCC
(NO X), and particulates pollution. realign the Eastern European opera-
Activities are jointly implemented by lages,” that are not adequately served would provide security backup to
The Krakow program, valued at $20 mil- tions of a major U.S. firm, and to
the U.S. and Chinese governments and by the electricity grid. One possible
lion, originally considered five different expand two Polish manufacturing sites.
conducted by a bi-national team. A
approaches to pollution reduction: Coal-fired operations have been
Web database already contains more
upgraded and environmental perfor-
than 1,000 U.S. firms with energy and •Conservation and extension of
mance has been greatly improved. For
environmental technology and equip- central-station district heating
example, because updated controls Eight U.S. companies have had opportunities
ment that can serve the Chinese mar-
•Replacement of coal- and coke-fired were installed on five boilers, fuel con-
ket. The Center is now conducting joint to market their environmental technologies
boilers with natural-gas-fired boilers sumption in one boiler house decreased
expert studies on coal liquefaction,
by 25%. Thirty-seven core separators, and establish businesses in Poland thanks
•Replacement of coal-fired home-
IGCC for retrofit and repowering, coal
heating stoves with electric heating which have high efficiencies in captur- to the DOE-led Krakow Clean Fossil Fuels
preparation, and superfine coal appli-
appliances ing particulates, have been installed, and Energy Efficiency Program. The program
cations, with plans to investigate
and 16 more are in the process of being
applications for fuel cells. One recent •Reduction of emissions from boilers also gathered fundamental information on
installed across Poland and elsewhere
agreement negotiated by the Center is using coal and coke pollutant emissions and reduction strategies
in Central Europe. A local district-
between HTI, a New Jersey company, •Reduction of emissions from coal-
heating system has been modernized for small-scale Polish boilers and home
and China’s Central Coal Research Insti- fired stoves in private homes
and expanded, resulting in 41 MW of stoves, making this information available
tute to conduct a feasibility study
Eight U.S. organizations are participat- coal-fired boilers being retired and
on direct liquefaction, an area in to organizations in the U.S., Poland, and
ing through cost-shared cooperative coal consumption being reduced by
which U.S. technology competes with Central Europe. Building upon their suc-
agreements that introduce clean coal more than 1,300 metric tons per year.
Japanese and German suppliers.
technologies and upgraded equipment cesses in Krakow, some U.S. businesses
In supporting the new center in to the Polish marketplace. The U.S. have already made additional sales worth
China, DOE’s International Program is government contribution is, at most, several millions of dollars in Poland, Central
advancing national goals of energy 50%. In some cases, funding comes
and environmental security and in- Europe, and Russia.
from third parties or Polish partners.
creasing opportunities for clean coal
technologies in the global marketplace.
90 91
F O S S I L E N E R G Y
W O R L D W I D E W E B N E T W O R K
U.S. DEPARTMENT OF ENERGY
www.fe.doe.gov
INTRODUCING
THE
FUTURE...
T H E O F F I C E O F F O S S I L E N E R G Y I S I M M E D I A T E LY A C C E S S I B L E O N T H E W O R L D W I D E W E B .
L I N K S F R O M T H E M A I N F O S S I L E N E R G Y H O M E PA G E TA K E Y O U T O P R O J E C T S A T F I E L D
SITES, TO CONTRACT AWARD NOTICES, OR TO TECHNICAL REPORTS. WEB LINKS GIVE YOU
I N S TA N T I N F O R M A T I O N A B O U T N E W T E C H N O L O G I E S , B U D G E T S , O R C U R R E N T H O T E N E R G Y
ISSUES, AND CAN TELL YOU HOW TO SUBMIT UNSOLICITED PROPOSALS OR PROMOTE
TECHNOLOGIES IN GLOBAL MARKETS.
WHETHER YOU WANT INFORMATION ON THE LATEST FUEL CELL DEVELOPMENT, OR A FULL
LISTING OF OIL RESERVOIR DEMONSTRATIONS, OR JUST WANT TO KNOW MORE ABOUT
G L O B A L WA R M I N G , Y O U C A N G E T T H E R E B Y S TA R T I N G A T H T T P : / / W W W. F E . D O E . G O V
FOR MORE INFORMATION,
PLEASE CONTACT:
Office of Fossil Energy
U.S. Department of Energy
1000 Independence Avenue
Washington, DC 20585
(202) 586-4410
Federal Energy
Technology Center (FETC)
U.S. Department of Energy
Morgantown Location:
P.O. Box 880
Morgantown, WV 26507-0880
(304) 285-4764
Pittsburgh Location:
P.O. Box 10940
Pittsburgh, PA 15236-0940
(412) 892-4687
www.fetc.doe.gov
JANUARY 1999
C PRINTED ON RECYCLED PAPER
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