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The main addressed objectives of this paper are: underline advantages and disadvantages of the techincal
alternatives of coal and natural gas plant; evaluate the capital costs and revenues of these two alternatives;
emphasize that by now coal fired units emissions are approaching the emissions of the combined cycle, but
in the near future with the coming of the zero emission technology any difference could be removed.
Finally, this paper will discuss what could be the position of an investor today in respect to the development
and opportunities of the CCS (Carbon Capture Sequestration) technologies.
T
alle opportunit offerte dalle tecnologie CCS (Carbon Capture Sequestration).
he economic development of one coun- higher capital cost required for the con-
try is dependent upon the ability of the struction of coal fired units;
authorities to set up a highly suitable, halt in 1988, after a referendum, of all nucle-
competitive and reliable electricity sector. ar construction, shut of the existing reac-
It is well known that Italy, where in 2010 more tors and their decommission from 1990
than 56% of electricity will be produced by (the only country in the world).
natural gas, is the European country having Recent reduction of natural gas supply within
the most expensive and unbalanced fuel mix the 2005 and 2006 winters and political crisis
in the electricity production sector. among Russia and its nearby countries con-
The main disadvantages for Italy from this cerning the gas prices, pushed Enel to increa-
unbalanced fuel mix are: se its investments in new or retrofitted coal
higher electricity cost in respect to other fired units, but also Italian IPPs started to take
western countries; this high Italian kWh in due consideration the coal alternative.
cost reduces the competitiveness of many Within this framework IPG finalized a feasibi-
energy intensive industry productions; lity study on behalf of a new Italian IPP intere-
potential risk of electricity shortage in case sted to compare for its brown field site a
of interruptions of natural gas supply from natural gas combined cycle plant with a coal
one of the three main Italians suppliers fired unit preparing also technical documents
(Algeria, Libya and Russia). for the debate with local and government
The main reasons of this fuel natural gas authorities and with green associations so to
oriented policy in Italy have been: obtain the permits required by the Italian
strong opposition to the conventional coal laws.
fired units from the green associations and The main addressed objectives of this paper are:
from the local authorities, asserting that coal underline advantages and disadvantages of
is more polluting in respect to natural gas; the above mentioned alternatives that is
Note: US gas turbines have DLN systems capable of operating at less than Note: this value could be reduced in case of a
5 to 8 ppm NOx and catalyst must be used in addition to attain limits. too quick increase of natural gas consumption
All triple-pressure US HRSGs are equipped with SCR and CO catalyst beds.
In Italy green associations and local authori- mines they are replacing.
ties are opposing the coal choice, basing on Figures 1 and 2 indicate, rispectevely, the natu-
the fact that coal is dirty and its environmen- ral gas and coal price trends from 1995 to
tal impact is more dangerous in respect to 2005 (Cif = cost + insurance + freight).These
natural gas. For this reason in Italy combined figures show that the gas prices rise more
cycles provide also base load power and in quickly in respect to coal prices.
2010 more than 56% of electricity will be pro-
duced by natural gas.
A chapter of this paper will be dedicated to 1.2 Fuel Transportation
compare the emissions of the natural gas Fuel transportation costs are also an impor-
combined cycle with the emissions of the coal tant factor in the utility fuel selection. These
fired conventional units and IGCC plants. costs can vary significantly by plant location,
Due to the improvements of the exhaust gas utility ability to promote inter-carrier compe-
purification technologies coal fired conventio- tition and distance between fuel source and
nal plants emissions start today to approach in plant. The cost to transport coal is ranging
Europe the combined cycle emissions, on the from $ 0.60 to 0.85/million BTU for long
contrary the emissions of the coal fired IGCC distances. But due to the dispersion of coal
can be today also lower of the cc emissions. reserves, coal transport costs are usually less
Unlike natural gas, coal is not suitable for than these amounts and are ranging between
dispersed on-site use. Coal can be used most $ 0.10 to 0.30/million BTU. Gas pipeline tran-
effectively where it permits the user to enjoy sport costs also vary widely depending upon
the economics of scale of large units and coal distance and location. They can range from $
delivery by ship, barge, unit train or conveyor 1.50/million BTU to $ 2,5/million BTU or
(for a mine mouth plant). higher and have an impact ranging from 30%
The differences between coal and natural gas up to 50% on the total gas price.
alternatives for new electric generation capa-
city decisions are reported in table 1.
An overview of the coal market in Italy indi- 1.3 The Technology Choices and
cates that coal supply is safer in respect to the Their Costs (excluding CCS)
other fuels for the following reasons (table 2): Plant capital costs are significantly different
coal reserves are abundant and distributed between the coal and the natural gas fired
in more than 100 countries, while oil and gas power generation options.
reserves are concentrated within few coun- Natural gas based technologies have lower
tries and many of these countries are politi- capital costs than coal based technologies and
cally instable; this difference is also depending from the
high availability of coal extraction, transpor- technology selected for coal generation option.
tation, storage and handling systems on wor- This capital cost advantage of the NG plants is
ldwide basis. ranging between $ 500 to $ 1000/kW depen-
Abundant coal reserves in many countries can ding upon the assumptions used that is fuel
be mined well into the next century at costs source, required by authorities environmental
(in constant $s) very close to todays produc- limitations, selected technology for the coal
tion costs. The best evidence for this is that fired plant, major equipment redundancy, plant
new coal mines are and will continue to be site location and labor cost on the plant site.
added at a very full production cost very The main technologies that are competing
close to the production costs of the existing today on the market are the following.
Fig. 1 Cost trends of natural gas from 1995 to 2005 Fig. 2 Costtrends of coal from 1995 to 2005
US Dollars per million
1.3.1 Natural Gas Combined Cycle plants 36-38% efficiency, a sea water cooled
The combined cycle is the basic gas-fired supercritical plant can readily achieve 45% on
technology that consists of gas turbines an LHV basis.
discharging hot exhaust gases into recovery Recently EON announced they will build the
boilers producing high pressure steam which worlds most innovative coal-fired power
operates a steam turbine. Both the gas turbi- plant by 2014 with an efficiency of more than
ne and the steam turbine move one or two 50% and with superheater temperatures up
electrical generators which generate electricity. to 700 C, using nickel-based alloys, instead of
For example a large 800 MWe plant of this conventional steel for the key components of
technology costs around 600 $/kW. boiler and steam turbine. Increasing efficiency
The gas fired combined cycle is the most effi- is one of the best strategies to reduce coal
cient commercial technology with heat rates consumption, but it is also the way for zero
(LHV) of only 5880 BTU/kWh (58% efficien- emission plants.
cy), but further improvements are expected
in the near future. However, the natural gas
heat rate is sensitive to unit operations and 1.3.3 Integrated Gasification Combined
can decline to a lower energy efficiency if Cycle Plants (IGCC)
operated at loads of 50% of the rated capaci- Coal gasification is a process that converts
ty.At low loads emissions also increase, becau- solid coal into a synthetic gas composed main-
se the dry low NOx combustion systems is not ly of carbon monoxide and hydrogen. Coal can
in operation. be gasified in various ways by properly con-
trolling the mix of coal, oxygen or air, and
steam within the gasifier. Manufacturers offer
1.3.2 Conventional Pulverized Coal several technology options for controlling the
Fired Plant flow of coal in the gasification section (e.g.
The key components of a conventional coal fixed bed, fluidized bed, and entrained-flow
fired plant are the steam generator and the systems). Most gasification processes being in
steam turbine that are interconnected by the commercial operation use oxygen as the oxi-
thermal cycle, where the water coming from dizing medium.
the condenser is heated in dedicated feedwa- IGCC combines a fossil fuel gasification system
ter heaters supplied by steam extracted from with a combined cycle. Depending on the level
the steam turbine. The two main options are of integration of the various processes, IGCC
the subcritical and the supercritical cycles. was achieving 40 to 42% efficiency.
Today supercritical components reached very Most of the IGCC plants use entrained gasi-
good availability so these cycles are the most fiers (e.g. Texaco-GE, Krupp Uhde and Shell
adopted by the utilities also due to their higher technologies).
efficiency in respect to subcritical cycles. Many companies including IPG [1, 2] presen-
These new conventional coal-fired steam ted interesting improvements of the existing
electric generating plants employ advanced IGCC processes, but these improvements had
pollution controls to meet very strict envi- not success up to now, because the efficiency
ronmental requirements for particulates, sul- increase to around 46%-47% do not justify
fur dioxide, mercury and NOx. The capital the higher cost of this technology.
cost of new conventional coal-based techno- IGCC cost projections range from US$1800
logy was in 2003 approximately $1200/kW.As to $2100/kW; 20 to 30% higher than for the
well known the boiler market situation resul- pulverized coal plants equipped with wet
ted mainly in Europe in the nineties in the scrubbers and DeNOx. It is also important to
bankruptcy of important manufacturers. This note that about 50% of IGCC is chemical
big crisis loomed over this sector up 2004, plant, on which the electric utilities operation
forcing the surviving boiler makers to reduce staff do not have experience and that finally
their manpower and costs in order to get out IGCC has higher O & M costs in respect to
from this downturn. Due to the very high the pulverized coal plants.
demand in 2006 coal fired boiler prices IGCC was indicated within the nineties the
moved up and a shortage of critical materials technology of choice due to the opportunity
contributed also to this increase of boiler pri- of high removal of SO2 (e.g. 99% or higher)
ces and to the extension of their delivery and of all other coal pollutants.
times. For example prefabricated P92 pipes Today the removal efficiency of the De-SOx
delivery moved during 2006 from 12 to 22 and De-NOx systems improved and the emis-
months.Today the capital cost of a new conven- sions of new pulverized coal plants are lowe-
tional is in Europe around $1400 - 1600/kW. ring day by day.
Compared to the conventional subcritical An interesting opportunity could be offered
Table 3: Operating data of a combined cycle equipped with dry air cooled condenser
Table 4: Operating data of a Supercritical unit equipped with dry air cooled condenser
Fig. 4 - Preliminary
660 MWe unit layout
In addition the IGCC commissioning period is coal fired conventional supercritical unit;
quite longer of that of the conventional plants definition of the capital and operating cost
and the IGCC availability is lower mainly of the cc versus the conventional unit;
during the first years of life of these plants. comparison of the emissions of the cc ver-
IGCC availability is low also due to poor plant sus the coal fired conventional unit;
standardization that could be improved stan- comparison of the COE of the cc versus the
dardizing an IGCC plant on EU basis. conventional unit.
3. An Italian Case: the IPG Feasibility 3.1 Preliminary Design on this Site of a
Study 800 MWe Natural Gas Combined Cycle
The site of this plant is located in the North The power island is equipped with two gas
of Italy at about 20 km from the sea side.This turbines, two heat recovery steam generators
site has been selected due to its local facili- and one steam turbine.
ties, including an existing transportation The operating performances of this plant are
system of coal from a nearby harbour and a indicated in the table 3.
large area suitable for this plant and not usual This plant is rigged with a direct dry air coo-
in this Italian mounting region. led condenser equipped with 20 modules.
This study has been split into the following The maximum electrical power consumption
phases: of this condenser is expected to range from
preliminary design on this site of a 800 MWe 2,5 to 3 MWe.The water consumption inclu-
natural gas combined cycle and of a 660 MWe ding the auxiliary evaporation towers, the
thermal cycle makeup and minor additional standards request NOx emissions lower of
requirements is ranging from 50 to 55 t/h. 200 mg/Nm3, but Enel agreed with Italian local
authorities to reduce NOx emissions under
100 mg/Nm3. And the coal fired units emis-
3.2 Preliminary Design on this Site sions are referred to a 6% O2 content in the
of a 660 MWe Coal Fired Conventional flue gas on dry basis.
Supercritical Unit
The unit rating and steam conditions have been
chosen according to Italian standardization. 4.2 Sulphur Dioxide Emissions
This unit will be equipped with: SO2 gas turbines emissions are not measured
two pass balanced boiler arranged for pulve- in the gas turbine exhaust gas, but often natu-
rized coal firing; ral gas holds sulphur compounds.
advanced De NOx SCR systems with 85% With reference to coal fired power plants EU
efficiency; standards request SO2 emissions lower of 200
advanced fabric filters with a 99,9% efficiency; mg/Nm3, but Enel agreed with Italian local
advanced humid limestone/gypsum De SOx authorities to reduce SO2 emissions under
with a 97% efficiency; 100 mg/Nm3.
coal stock system equipped with two geo-
desic domes designed for a capacity of
about 35,000 m3 each that means the ope- 4.3 Carbon Monoxide and Carbon
ration of this unit for about ten days. The Dioxide Emissions
coal shall be delivered to this dome through Combined cycle CO emissions are ranging
a fully closed belt conveyor system. from 15 to 20 mg/Nm3, while the CO emis-
direct dry air cooled condenser equipped sions of conventional units are negligible. But
with 45 modules. The maximum electrical US Authorities impose to reduce CO emis-
power consumption of this condenser is sions of large combined cycles at 1 ppm using
expected to range from 5 to 5,6 MWe. catalyst.
The operating performances of this plant are CO2 is not a pollutant, but has an impact on
indicated in the table 4. the greenhouse gases.
The water consumption including the auxilia- CO2 emissions are tied to the efficiency of the
ry evaporation towers, the thermal cycle power plant and are respectively about 0,38
makeup, gypsum washing, scrubber make up t/MWh for new combined cycles and about
and minor additional requirements is ranging 0,80 t/MWh for conventional advanced coal
from 150 to 160 t/h. fired units.
The preliminary layout of this supercritical
unit is indicated in figure 4. This layout has
been subsequently modified to obtain a bet- 4.4 Particulate Emissions
ter fitting with the site. Also particulate emissions are not usually
measured in gas turbine exhaust gases, but
recent investigations confirm that gas turbi-
4. Combined Cycle Versus Supercritical nes exhaust gases can hold PM10, PM5 and
Coal Fired Unit Emissions: as Today PM2,5 mainly during plant start up and low
The main pollutants of the electrical thermal load.
power plants are NOx, SO2, CO and particu- When the gas turbine operates at high load
late. and in steady state conditions, the combu-
stion process, specifically DLN, is highly effi-
cient and therefore usually do not produce
4.1 Nitrogen Oxide Emissions PM emissions.
European gas turbines manufacturers usually In effect, gas turbines and combined cycles
guarantee NOx emissions < 25 ppm using DLN exhaust gases may hold particulates coming
combustion systems in steady state conditions from:
with load ranging from 50% to 100%. inert solids within fuel gas supply; usually, but
It is interesting to note that US gas turbines not always gas turbines manufacturers
manufacturers produce 9 ppm combustion impose to filter natural gas at plant battery
systems for the US market. But US Authorities limits ;
impose to reduce NOx emissions at 3 ppm metallic rust and oxidation products (pre-
using SCR. sent also in the gas transportation piping, in
The gas turbines NOx emissions are referred to the cc inlet and exhaust equipment inclu-
a 15% O2 content in the flue gas on dry basis. ding the heat recovery steam generator). It
With reference to coal fired power plants EU is important to note that gas travel for
Combined cycles: Combined cycles: Coal fired unit: Coal fired unit:
Pollutant content Pollutant content Pollutant content Pollutant content
mg/Scu-meter mg/Scu-meter related mg/Scu-meter mg/Scu-meter
@ 15% O2 v/v dry, @ 3.5% O2 v/v dry, @ 3.5% O2 v/v dry, @ 6% O2 v/v dry,
during premixing (from during premixing (from also at low loads also at low loads
50% to 100% load) 50% to 100% load)
NOx 25 73 118 or lower 100 or lower
SOx perhaps negligible, but perhaps negligible, but 118 or lower 100 or lower
not measured in Italy not measured in Italy
Particulates not measured in Italy not measured in Italy 15 15
CO 20 58 Negligible Negligible
Table 5 : Combined
cycle emissions
in respect to the coal thousand kilo-meters inside not previously and gas well locations and characteristics,
cleaned steel piping ; from the type of used transportation system
fire unit emissions
formation of aromatic compounds or PM10, and from the length of journey from the fuel
in Europe
PM5 & PM2,5 during natural gas combustion, source to the power plant.
due to poor premixing during DLN combu-
stion and/or oxygen scarcity at low loads in
some combustor zone or due also to the 4.6 Main Emissions During the
heavier molecules existing in the gas [5]. Upstream of the Natural Gas Life Cycle
In the case of natural gas we must take in due
4.5 Comparison consideration mainly:
Table 5 is comparing the combined cycle emis- gas flaring (gas combustion on the well area)
sions in respect to the coal fire unit emissions. and venting (release of gas to atmosphere
Gas turbines manufacturers usually obtain the also on the well area), referred to the gas
above indicated guaranteed emissions at stea- that cannot be used locally or transported.
dy state loads from 50% to 100% and if the During the World Bank-IMF Spring meetings
combustors are well adjusted. to tackle issues such as the impact of clima-
The reduction of NOx is obtained also to the te change and the efficient use of clean
detriment of an increase of CO emissions. energy, the Global Gas Flaring Reduction
As indicated in this table 5 it is important to partnership issued a statement April 23,
note the NOx gas turbine emissions are 2006 estimating that over 150 bcm of natu-
referred to a 15% O2 content, while the stan- ral gas are being flared and vented annually.
dard emissions of a conventional power plant That is the equivalent of the combined
are referred to a 6% O2 content, but in effect annual gas consumption of Germany and
the O2 content is around 3.5%. France. And the 40 bcm of gas flared in
In this table 5 both the cc and the conventio- Africa is equivalent to half of the continen-
nal units emissions are also referred at a 3.5% t's power consumption;
O2 content. gas purification near the extraction area to
In addition, basing on the fact that the flue reduce CO2 (that can reach also from 20%
exhaust gas temperatures at chimney outlet up to 30% in volume) and H2S content.
are ranging from 95 C to 100 C for cc and These CO2 and H2S are usually vented to
from 120 C to 125 C for conventional units, atmosphere;
the upward lift of the cc flue exhaust gas is gas leakages during its transportation and
lower and so the pollutants emitted by the cc CO2 emitted by the gas turbines moving
may be discharged nearby the plant mainly in the pipeline gas compressors and by the
case of thermal inversion. LNG ships motors.
This comparison between coal and natural
gas on environmental basis must take also in
due consideration their emissions during 4.7 Main Emissions During the
their extraction, mining, treatment and tran- Upstream of the Coal Life Cycle
sportation steps up to the power plant In the case of coal we must take in due con-
(upstream emissions) [8]. sideration mainly:
A comparison between coal and gas upstream natural gas (including in some cases up to 90%
emissions is not easy on quantitative basis, of methane) leakages from the coal mining
because it is dependent from the coal mining during coal extraction: this gas, that must be
removed during coal extraction mainly for must be reduced to very low values (prelimina-
safety reasons, is or flared or vented or con- ry studies indicate also 0,01%), the future emis-
veyed through pipelines to the natural gas sions in case of the adoption of CCS post com-
users (power generation, home heating etc). bustion technologies both for CC and conven-
This gas coming from coal-bed formations is tional plants could be as follows.
including a 2 micron coal dust (mean particle
size) that quickly coats gas filters, and it is
tough to remove when it builds up in dehy- 5.1 Nitrogen Oxide and CO Emissions
dration, processing, and lubricating liquids; Gas turbines would use also in Europe the 9
dust formation from coal during its tran- ppm combustion technologies now requested
sportation and storage : but now are used by the US Authorities and always referred to
covered geodesic domes for storing coal a 15% O2 content in the flue gas on dry basis.
and coal is transported for example from Additional reduction to about 3 ppm will be
the ships to the boiler coal bunkers through obtained through catalysts.
a fully closed belt conveyor system, so dust The NOx emissions of the coal fired units will
dispersion to the environment is approa- be reduced to 20 ppm or lower as referred to
ching to zero; a 6% O2 content in the flue gas on dry basis,
wastewater discharges: the cleaning of all combining at their best low NOx burners,
coal handling machinery is usually made BOFA (boosted overfire air), Selective auto-
using water that after its use is conveyed to catalytic reduction (SACR), NOx Selective
water purification systems. Catalytic Reduction (SCR) [6].