Systems and Industry Analyses Studies

Table of Contents


DOE/NETL possesses strong systems analysis and policy-support capabilities. Systems analysis in support of the Gasification Systems Program consists of conducting various energy analyses that provide input to decisions on issues such as national plans and programs, resource use, environmental and energy security policies, technology options for research and development programs, and paths to deployment of energy technology.

Cost and Performance Baseline for Fossil Energy Power Plants Studies

The Cost and Performance Baseline for Fossil Energy Power Plants studies establish up-to-date estimates for the cost and performance of combustion and gasification based power plants as well as options for co-generating synthetic natural gas and fuels, all with and without carbon dioxide capture and storage. Several ranks of coal are being assessed in process configurations that are based on technology that could be constructed today such that the plant could be operational in the 2010 - 2015 timeframe. The analyses were performed on a consistent technical and economic basis that accurately reflects current market conditions.

Volume 1 - Bituminous Coal and Natural Gas to Electricity

 

 

 

Updated Costs (June 2011 Bases) for Selected Bituminous Baseline Cases

Establishes performance and cost data for fossil energy power systems, specifically integrated gasification combined cycle (IGCC) plants fueled with bituminous coal, pulverized coal (PC) plants fueled with bituminous coal, and natural gas combined cycle (NGCC) plants all with and without carbon capture and sequestration.

Revision 2, November 2010

DOE/NETL-2010/1397

August 2012

DOE/NETL-341/082312

Volume 2 - Coal to Synthetic Natural Gas and Ammonia (Various Coal Ranks)

Establishes performance and cost data for coal fueled plants producing synthetic natural gas and ammonia. The plants are based on a dry-feed entrained-flow gasifier and include cases using bituminous, sub-bituminous, and lignite coals. All configurations were studied with and without carbon sequestration. The analyses were performed on a consistent technical and economic basis that accurately reflects current market conditions for plants starting operation in 2012. This is believed to provide the most comprehensive set of cost and performance data available in the public literature to date. The cost and performance data were compiled from published reports, information obtained from vendor quotes and users of the technology, and data from designing and building projects.

July 2011

DOE/NETL- 2010/1402

Volume 3a: Low Rank Coal to Electricity: IGCC Cases

Establishes performance and cost data for fossil energy power systems, specifically integrated gasification combined cycle (IGCC) plants all with and without carbon capture and sequestration.

May 2011

DOE/NETL-2010/1399

Volume 3b: Low Rank Coal to Electricity: Combustion Cases

Establishes performance and cost data for fossil energy power systems, specifically pulverized coal (PC) and circulating fluidized bed combustor (CFBC) plants all with and without carbon capture and sequestration.

March 2011

DOE/NETL-2011/1463

Cost and Performance Baseline for Fossil Energy Plants - Volume 3c: Low Rank Coal to Electricity: NGCC Cases

This study establishes performance and cost data for fossil energy power systems, specifically integrated gasification combined cycle (IGCC), combustion, and natural gas combined cycle (NGCC) plants all with and without carbon capture and sequestration. Most of the coal fired plants are studied using both Rosebud Montana Powder River Basin Coal (PRB) at a Montana site at an elevation of 3,400 feet and North Dakota Lignite (NDL) at a mine-mouth North Dakota site at an elevation of 1,900 feet. NGCC plants are also studied at both locations.

March 2011

DOE/NETL-2010/1396

Volume 4 - Bituminous Coal to Liquid Fuels with Carbon Capture

Publication scheduled for 2012

 

 

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Gasification Systems Program's Systems and Industry Analyses Studies

Life Cycle Analysis: Integrated Gasification Combined Cycle (IGCC) Power Plant

This report examines the Life Cycle Analysis of an Integrated Gasification Combined Cycle plant. It develops an Inventory of emissions results, and calculates Life Cycle costs for the plant with and without CCS.

June 2013

NETL/DOE-2012/1551

Life Cycle Analysis: Integrated Gasification Combined Cycle (IGCC) Power Plant Presentation

Presentation for life cycle analysis compilation of the power LCA reports. Develops an inventory of emissions results, and calculates life cycle costs for each plant with and without CCS.

June 2013

 

Quality Guideline for Energy System Studies: Fuel Prices for Selected feedstocks in NETL Studies

The purpose of this guideline is to estimate the delivered market price of select fuels commonly used as feedstock in the energy system studies sponsored by the National Energy Technology Laboratory (NETL). Specifically this includes four coals and natural gas delivered to three regions.

February 2013

NETL/DOE-341/11212

Quality Guideline for Energy System Studies: Capital Cost Scaling Methodology

The purpose of this Quality Guidelines Guideline for Energy System Studies is to provide a standard basis for scaling capital costs, with specific emphasis on scaling exponents. The intention of having a standardized document is to provide guidelines for proper procedures to increase consistency between studies.

February 2013

NETL/DOE-341/013113

Production of Zero Sulfur Diesel Fuel from Domestic Coal: Configurational Options to Reduce Environmental Impact

The conversion of domestic resources such as coal and biomass into diesel fuel is a near-term technology pathway to address the energy security, economic sustainability, and climate change concerns which currently face our nation. This study evaluates the economic viability and environmental impact of producing diesel fuel via Fischer-Tropsch (FT) synthesis. Two facility design approaches – focused on fuels production and the co-production of fuels and electricity, respectively – were evaluated for the conversion of domestic resources such as coal or a mixture of coal and biomass.

May 2012

DOE/NETL-2012/1542

Power Systems Life Cycle Analysis Tool

Power Systems Life Cycle Analysis Tool (Power LCAT) is a high-level dynamic model that calculates production costs and tracks environmental performance for a range of electricity generation technologies: natural gas combined cycle (NGCC), integrated gasification combined cycle (IGCC), supercritical pulverized coal (SCPC),existing pulverized coal (EXPC), nuclear, and wind (with and without backup power). All of the fossil fuel technologies also include the option of carbon capture and sequestration technologies (CCS). The model allows for quick sensitivity analysis on key technical and financial assumptions, such as: capital, O&M, and fuel costs; interest rates; construction time; heat rates; taxes; depreciation; and capacity factors. Power LCAT is targeted at helping policy makers, students, and interested stakeholders understand the economic and environmental tradeoffs associated with various electricity production options.

May 2012

DOE/NETL-2012/1566

QGESS: Technology Learning Curve (FOAK to NOAK)

This report summarizes costing methodologies employed by NETL for estimating future costs of mature commercial Nth-of-a-kind (NOAK) power plants from initial first-of-a-kind (FOAK) estimates for use in costing models and reports. It defines the specific steps and factors which can be used in such estimation calculations. The methodology within is based on knowledge of major plant component costs for various technologies.

March 2012

NETL/DOE-341/042211

QGESS: CO2 Impurity Design Parameters

This section of the Quality Guidelines provides recommended impurity limits for CO2 stream components for use in conceptual studies of CO2 carbon capture, utilization, and storage systems. These limits were developed from information consolidated from numerous studies and are presented by component. Impurity levels are provided for limitations of carbon steel pipelines, enhanced oil recovery (EOR), saline reservoir sequestration, and cosequestration of CO2 and H2S in saline reservoirs.

March 2012

NETL/DOE-341/011212

QGESS: Process Modeling Design Parameters

The purpose of this section of the Quality Guidelines is to document the assumptions most commonly used in systems analysis studies and the basis for those assumptions. The large number of assumptions required for a thorough systems analysis make it impractical to document the entire set in each report. This document will serve as a comprehensive reference for these assumptions as well as their justification.

March 2012

NETL/DOE-341/081911

QGESS: Specifications for Selected Feedstocks

This document provides recommended specifications for various feedstocks that are commonly found in NETL-sponsored energy system studies. Adhering to these specifications should enhance the consistency of such studies. NETL recommends these guidelines be followed in the absence of any compelling market, project, or site-specific requirements in order to facilitate comparison of studies evaluating coal-based technologies.

March 2012

NETL/DOE-341/011812

Recommended Project Finance Structures for the Economic Analysis of Fossil-Based Energy Projects

In this update to the 2008 report, the financial parameters to be used in economic analysis studies are updated and the issue of technology risk premium is revisited. Profiles for distributing Total Overnight Costs over various Capital Expenditure Periods (e.g. 3 and 5 years) and project financing costs that are representative of actual energy projects are also re-evaluated.

September 2011

DOE/NETL-2011/1489

Tracking New Coal-Fired Power Plants

This study establishes the cost and performance for a range of carbon dioxide (CO2) capture levels for new supercritical pulverized coal and integrated gasification combined cycle power plants. Cost of avoiding CO2 emissions is calculated and utilized to find the optimum level of CO2 capture for each plant type.

July 2011

 

Cost and Performance of PC and IGCC Plants for a Range of Carbon Dioxide Capture

This study establishes the cost and performance for a range of carbon dioxide (CO2) capture levels for new supercritical pulverized coal and integrated gasification combined cycle power plants. Cost of avoiding CO2 emissions is calculated and utilized to find the optimum level of CO2 capture for each plant type.

May 2011

DOE/NETL-2011/1498

QGESS: Cost Estimation Methodology for NETL Assessments of Power Plant Performance

This paper summarizes the cost estimation methodology employed by NETL in its assessment of power plant performance. A clear understanding of the methodology used is essential for allowing different power plant technologies to be compared on a similar basis. Though these guidelines are tailored for power plants, they can also be applied to a variety of different energy conversion plants (e.g., coal to liquids, syngas generation, hydrogen). This document is part of the Office of Program Planning and Analysis’s Quality Guidelines for Energy Systems Studies (QGESS) series.

April 2011

DOE/NETL-2011/1455

Analysis of Natural Gas Fuel Cell Plant Configurations

This report presents the results of a Pathway Study for natural gas fueled, fuel cell (NGFC) power systems with carbon capture and sequestration (CCS). The results quantify the performance and cost benefits for a series of projected gains made through the development of advances in the component technologies or improvements in plant operation and maintenance. The design and cost bases for this pathway study closely follows the bases applied in the NETL, 2010, Bituminous Baseline report so that direct performance and cost comparisons can be made with the conventional fossil-fuel power plant results estimated in that report. Performance and cost projections for a baseline integrated gasification combined cycle (IGCC) power plant, a baseline natural gas combined cycle (NGCC) power plant, and prior coal-based integrated gasification fuel cell (IGFC) pathways, are compared with the results for the NGFC pathways. The results represent the potential future benefits of NGFC technology development. They also provide DOE with a basis to select the most appropriate development path for NGFC, and to measure and prioritize the contribution of its R&D program to future power systems technology.

March 2011

DOE/NETL-2011/1486

Analysis of Integrated Gasification Fuel Cell Plant Configurations

This report presents the results of a Pathway Study for coal-based, integrated gasification fuel cell (IGFC) power systems with carbon capture and sequestration (CCS). The results quantify the performance and cost benefits for a series of projected gains made through the development of advanced technologies or improvements in plant operation and maintenance. The results represent the potential future benefits of IGFC technology development. They also provide DOE with a basis to select the most appropriate development path for IGFC, and to measure and prioritize the contribution of its R&D program to future power systems technology. The IGFC plants in this study apply advanced, planar, solid oxide fuel cell (SOFC) technology with separate anode and cathode off-gas steams, and incorporate anode off-gas oxy-combustion for nearly complete carbon capture. The SOFC simulations utilize the expected operating conditions and performance capabilities of this solid oxide fuel cell technology, operating initially at atmospheric-pressure. The power plant cost and performance estimates reflect performance projections based on the current state of SOFC development, as well as projecting a pathway of SOFC technology development advances.

February 2011

DOE/NETL-2011-1482

Current and Future Technologies for Gasification-Based Power Generation:  Volume 2 -- A Pathway Study Focused on Carbon Capture Advanced Power Systems R&D Using Bituminous Coal

The impact of a portfolio of advanced technologies in DOE's Clean Coal R&D Program were evaluated in gasification-based power plant configurations with carbon capture and sequestration (CCS) resulting in power plants that are significantly more efficient and affordable than today's fossil energy technologies. In the IGCC process, the study estimates that a 7 percentage point efficiency improvement over conventional gasification technology is possible. With fuel cell technology, process efficiency improvements of 24 percentage points are potentially achievable. Furthermore, successful R&D for the advanced technologies evaluated results in capital costs and cost of electricity that is more than 30% below that of conventional IGCC technology with CCS.

November 2010, Revision 1

DOE/NETL-2009/1389

Life Cycle Analysis: Power Studies Compilation Report

The compilation of the power LCA reports develops an inventory of emissions results, and calculates life cycle costs for each plant with and without CCS.

October 2010

DOE/NETL-2010/1419

Estimating Freshwater Needs to Meet Future Thermoelectric Generation Requirements

Future freshwater withdrawal and consumption from domestic thermoelectric generation sources were estimated for five cases, using AEO 2010 regional projections for capacity additions and retirements. Results demonstrate that carbon capture technologies could increase the water demand of thermoelectric power plants and indicate that consumption is expected to increase in all cases.

September 2010

DOE/NETL-400/2010/1339

Life Cycle Analysis: Integrated Gasification Combined Cycle (IGCC) Power Plant Appendix: Process Modeling Data Assumptions and GaBi Modeling Inputs

This report contains appendix information of Life Cycle Analysis of an Integrated Gasification Combined Cycle plant. It also develops an Inventory of emissions results, and calculates Life Cycle costs for the plant with and without CCS.

August 2010

DOE/NETL-403/110209

Assessment of Hydrogen Production with CO2 Capture, Volume 1: Baseline State of the Art Plants

This study establishes performance and cost data for state-of-the-art fossil energy hydrogen production plants with carbon dioxide capture and storage. Both natural gas and bituminous coal feedstocks are assessed. Future volumes will examine the cost and performance benefit when DOE-funded advanced technologies are incorporated into a coal-based hydrogen production plant with CO2 capture.

August 2010

DOE/NETL-2010/1434

Production of High Purity Hydrogen from Domestic Coal: Assessing the Techno-Economic Impact of Emerging Technologies

This report assesses the improvements in cost and performance of hydrogen production from domestic coal (with carbon capture) when employing emerging technologies funded by DOE. This analysis specifically evaluates replacing conventional gas cleanup and hydrogen separation with warm gas cleanup and a high temperature membrane.

August 2010

DOE/NETL-2010/1432

Investment Decisions for Baseload Power Plants

This report, prepared by ICF International, provides an identification and discussion of factors considered for investment decisions for base load power generation in the U.S.(for example levelized cost of electricity, design and construction lag, fuel cost and variability, technology performance risk, initial capital outlay, water use, future cost of carbon emissions) and discusses their relative importance in investment decisions. There is a detailed discussion on current and advanced power plant technologies, including ultra-supercritical coal power, coal power with carbon dioxide capture and storage, and nuclear power. In addition, there is a detailed description and analysis of two case studies from actual power plant projects to substantiate the identified objective functions from the above items.

January 2010

402/012910

Assessment of Power Plants That Meet Proposed Greenhouse Gas Emission Performance Standards

Technoeconomic assessment of western U.S. coal-fired power plants (greenfield IGCC and supercritical PC, and existing subcritical PC) each with three CO2 capture levels: 0%, 90%, and a level appropriate to meet California's standard of 1,100 lb CO2/MWh.

November 2009

DOE/NETL-401/110509

Integration of H2 Separation Membranes with CO2 Capture and Compression

A core mission of the U.S. Department of Energy's (DOE) Carbon Storage Program is to foster the development of commercially-ready technologies for CO2 capture and sequestration. R&D supported by the U.S. DOE is investigating alternatives to absorption for capturing CO2 that may achieve program goals. Membrane gas separation has a number of advantages, in that they are usually compact, have no moving parts, have low maintenance, and are highly reliable. In this assessment, alternative flowsheets incorporating membranes that may out-perform current technologies for CO2 capture were investigated. An initial screening study identified several novel integrations of membranes for IGCC applications.

November 2009

DOE/NETL- 401/113009

Estimating Freshwater Needs to Meet Future Thermoelectric Generation Requirements: 2009 Update

Future freshwater withdrawal and consumption from domestic thermoelectric generation sources were estimated for five cases, using AEO 2009 regional projections for capacity additions and retirements. Results demonstrate that carbon capture technologies could increase the water demand of thermoelectric power plants and indicate that consumption is expected to increase in all cases.

September 2009

DOE/NETL-400/2009/1339

Evaluation of Alternate Water Gas Shift Configurations for IGCC Systems

This report investigates the cost and performance effects of a range of carbon capture goals, by varying the amount of CO converted to CO2 in the water gas shift step of an IGCC plant.

August 2009

DOE/NETL-401/080509

NEMS CO2 Market Model Development Documentation Report

This report details the development and results of a modified version of EIA's National Energy Modeling System (NEMS) model that directly represents potential CO2 transfer between alternative supply sources and regional EOR-CO2 production capability as represented by the NETL supply and demand curves. A new module was developed and added to the NEMS system to equilibrate CO2 supply and demand and establish regional CO2 transfer prices between CO2 sources and EOR/sequestration entities. The project methodology, NEMS' modifications, and specified model results are comprehensively detailed in this report. Appendices containing NEMS coding and result tables are provided in a separate document.

April 2009

DOE/NETL-402/043009

NEMS CO2 Market Model Development Documentation Report Appendices

This document contains the Appendices for the report titled "NEMS CO2 Market Model Development Documentation Report" that details the development of a modified version of EIA's National Energy Modeling System (NEMS) model and directly represents potential CO2 transfer between alternative supply sources and regional EOR-CO2 production capability. These Appendices contain NEMS coding and result tables.

April 2009

DOE/NETL-402/043009

Affordable, Low-Carbon Diesel Fuel from Domestic Coal and Biomass

This study evaluates the use of domestic resources to meet national objectives of energy security, economic sustainability, and the mitigation of global climate change. Specifically, feasibility of these objectives is reviewed relevant to the transportation sector's needs and the unconventional fuels by which this sector can operate. The findings of the report indictate that CTL fuel is compatible with our current fuel distribution infrastructure, can be used directly in existing diesel vehicles, and would be economically competitive with petroleum-derived diesel when the crude oil price (COP) is equal to or above $86 per barrel (bbl).

January 2009

DOE/NETL-2009/1349

Current and Future IGCC Technologies:  A Pathway Study Focused on Non-Carbon Capture Advanced Power Systems R&D Using Bituminous Coal -- Volume 1

The impact of a portfolio of advanced technologies in DOE’s Clean Coal R&D Program were evaluated in gasification-based power plant configurations (without carbon capture and sequestration) resulting in power plants that are significantly more efficient and affordable than today’s limited set of fossil energy technologies.  In the IGCC process alone, the study estimates that an 11 percentage point efficiency improvement over conventional gasification technology is possible. With fuel cell technology, process efficiency improvements upwards of 24 percentage points are potentially achievable.  Capital cost reductions result not only from less expensive technology alternatives such as warm gas cleanup and ITM air separation, but also from increased power generation brought about by advanced technology such as syngas turbines – resulting in cumulative total plant cost reductions by as much as $700/kW.  Improvements in process efficiency, reductions in capital and operating expense, and increase in capacity factor all contribute to decreased cost of electricity (COE), projecting an overall decrease by more than 3 cents/kW-hr – or a decrease of 35 percent. Pittsburgh Coal Conference Presentation [PDF-318KB]

October 2008

DOE/NETL-2008/1337

Recommended Project Finance Structures for the Economic Analysis of Fossil-Based Energy Projects

This analysis develops a set of market validated financial assumptions, including the required internal rate of return for the equity portion of the investment (IRROE), cost of debt, and the financing structure (debt/equity ratio) needed to conduct comparative economic analyses of commercial and advanced coal-based power and fuel systems. These inputs are necessary to perform technical and economic analyses of coal-to-power, coal-to-liquids (CTL), coal-to-synthetic natural gas (CTG), natural gas to liquids (GTL) and natural gas to power technologies.

September 2008

DOE/NETL-401/090808

Impact of Cost Escalation on Power Systems R and D Goals - Report

This report recommends updates to goals for three technology areas in the Clean Coal R&D Program: Advanced Power Systems (APS); Carbon Sequestration (CS); and Fuel Cells (FC) to account for cost escalation, and it contains a definition of the baseline used to set these goals.

August 2008

DOE/NETL-2008/1308

An Engineering-Economic Analysis of Syngas Storage

This investigation examines whether an IGCC facility that operates its gasifier continuously but stores the syngas and produces electricity only when daily prices are high may be more profitable than an IGCC facility with no syngas storage. The goal of this study is to generate an initial examination of whether storing syngas can increase the profitability of IGCC plants, rather than to perform a plant design.

July 2008

DOE/NETL-2008/1331

Deployment of Advanced Coal Power in the U.S. under a Range of Carbon Tax Scenarios

The National Energy Modeling System (NEMS) was exercised to forecast market penetration for advanced coal power with CO2 capture under a range of CO2 emission tax scenarios, considering market-based incentives for low carbon emission power and improved technology performance consistent with the DOE/FE research portfolio.

January 2008

 

Independent Assessment of the Potential of Chemical-Looping in the Context of a Fischer-Tropsch Plant

Simulations of an integrated coal to Fischer-Tropsch (F-T) liquids process, including a chemical looping scheme, under development by Ohio State University, were performed and the technical results from this analysis were then compared to a conventional coal-to-liquids (CTL) system. Results of the comparative technical analysis between the chemical looping scheme and the conventional CTL scheme indicate that the chemical looping case increased liquid production from the same coal feed by about 10% and the total carbon emissions per barrel produced is about 19% less for the proposed chemical looping system compared to the conventional CTL configuration.

December 2007

DOE/NETL-2008/1307

Alaska Coal Gasification Feasibility Studies - Healy Coal-to-Liquids Plant

This study evaluates the feasibility of building a relatively small coal-to-liquids plant in central Alaska to provide a clean diesel product to Alaska’s refineries. The study concludes that the establishment of a 14,640 barrel per day F-T plant, using 4 million tons per year of coal, could be economic provided the price per barrel of the F-T product is at least $64 per barrel.

July 2007

DOE/NETL-2007/1251

Preliminary Feasibility Analysis of RTI Warm Gas Cleanup (WGCU) Technology

This report provides a preliminary techno-economic assessment of RTI’s warm gas cleanup (WGCU) technology. Conceptual IGCC plant designs with the WGCU for high temperature H2S removal were developed and then compared with the results of a conventional acid gas removal (AGR) technology.

June 2007

 

Metal sorbents for high temperature mercury capture from fuel gas

The paper “High temperature metal sorbents for mercury capture from fuel gas” was accepted for publication in the Elsevier Journal - Fuel.  It was found that palladium can adsorb large quantities of mercury from simulated syngas upon extended exposures, whereas platinum captured somewhat less mercury.  Sorbents with palladium concentrations of between 2 and 9% by weight on alumina were exposed to simulated syngas at temperatures of 204 oC – 371 oC.  X-ray diffraction analysis of the used palladium sorbents exposed at 204 oC suggests the formation of a mercury-palladium alloy, with concentrations of 12.0 - 14.4 atom percent mercury.  The large capacity for mercury by palladium sorbents bodes well for its commercial prospects in gasification systems.

May 2007

 

Power Plant Water Usage and Loss Study

The objective of this study is to prepare a source of information from which valid comparisons can be made for the water loss between the various fossil fuel power plants such as IGCC, PC , and NGCC. Previous estimates of water usage or water loss for conceptual power plant configurations have used water impacts of technology options as the basis for comparison .  However, these previous estimates were made using available flow sheet data that were generally not complete, and as a result have generated potentially misleading comparisons. It is important that any comparison be made using data from complete water balances for the flow sheets and that all uses, makeup streams, discharges, internal generation and losses be accounted for in the balance and assessment of water streams in order to establish credible conclusions. By providing the following:
(1) an account of water usage throughout the power plant and a credible methodology that can be used for future studies,
(2) a baseline set of cases and water loss data for assessing potential improvements and evaluating R&D programs, and
(3) a basis for comparing water usage in various types of advanced power systems,
this report serves as a tool for reviewing design assumptions, technology capabilities, system performance, etc. and identifying areas where new technology approaches or gasifier designs could lead to substantially lower water requirements.

May 2007

 

Industrial Size Gasification for Syngas, Substitute Natural Gas and Power Production

This feasibility study was performed to evaluate the technical and economic viability of coal-derived syngas and substitute natural gas (SNG) using gasification technology fueled with an Eastern bituminous coal and a PRB coal. Results of the study show that there is a need for an industrial size coal gasification system to take advantage of the abundant, price stable coal resources in the U.S. to provide a coal-derived substitute natural gas to U.S. Industries.

April 2007

DOE/NETL-401/040607

Baseline Technical and Economic Assessment of a Commercial Scale Fischer-Tropsch Liquids Facility

This report examines the technical and economic feasibility of a commercial 50,000 barrel per day  coal-to-liquids (CTL) facility in the Illinois coal basin. The facility employs gasification and Fischer-Tropsch (F-T) technology to produce commercial-grade diesel and naphtha liquids from medium-sulfur bituminous coal. The scope of the study includes conceptual design development, process analysis, component descriptions, capital and operating cost estimates, and a comparative financial analysis.

April 2007

DOE/NETL-2007/1260

Technical and Economic Assessment of Small-Scale Fischer-Tropsch Liquids Facilities

This report examines the technical and economic feasibility of a small-scale coal-toliquids (CTL) facility in southwestern West Virginia. The facility employs gasification and Fischer-Tropsch (F-T) technology to produce commercial-grade diesel and naphtha liquids from a high-sulfur bituminous coal. The scope of the study includes conceptual design development, process analysis, component descriptions, capital and operating cost estimates, and a comparative financial analysis.

February 2007

DOE/NETL-2007/1253

Beluga Coal Gasification Feasibility Study - Phase I Final Report

This report summarizes the investigation of an IGCC system for a potential industrial setting on the Cook Inlet, in Nikiski, Alaska. Faced with an increase in natural gas price and a decrease in supply, local industry is investigating alternatives to natural gas as a feed stock for their process plants. This study evaluated a gasification plant that would supply syngas to meet the chemical needs of a local application and would also co-produce power to meet on-site demand, and possibly other byproducts for local use. The results of the study verified that conversion of a plant from natural gas to syngas is technically and economically feasible.

July 2006

DOE/NETL-2006/1248

CMC Bench Scale Material Test Plan Topical Report

This test plan document describes the technical work to be performed at the Department of Energy research laboratories at Oak Ridge National Laboratory in Oak Ridge, TN and the National Energy Technology Laboratory materials research facility in Albany, OR.

June 2006

DE-FC26-04NT42237

Comparison of Pratt and Whitney Rocketdyne IGCC and Commercial IGCC Performance

This report compares the performance and cost of commercial Integrated Gasification Combined Cycle (IGCC) plants using General Electric Energy (GEE) and Shell gasifiers with conceptual IGCC plant designs using the Pratt & Whitney Rocketdyne (PWR) compact gasifier. The PWR gasifier is also compared with the GEE gasifier in hydrogen production and carbon capture mode. With the exception of the PWR gasifier, the plants are designed with commercially available equipment to be operational in approximately 2010. All results should be considered preliminary and dictated in large part by the selected design basis.

June 2006

DOE/NETL-401/062006

Conceptual Design of an Ultra-Dense Phase Injector and Feed System Topical Report

This document describes the technical work performed on the ultra-dense phase multi-element injector and feed system between May 2005 and Mar 2006.

April 2006

DE-FC26-04NT42237

PWR Gasifier Peer Review Report, Attachment 1, Attachment 2

This report presents the findings from the January 24, 2006, peer review that was performed to review the work that Pratt and Whitney Rocketdyne (PWR) has done to date, their technical approach for future development, and to assess the potential benefit of the PWR gasifier and feed system technologies over state-of-the art coal gasification. It also presents the peer reviewers' findings related to the DOE analysis of the PWR refractory, and a DOE system study comparing the performance and economics of the PWR gasifier to the GE and Shell gasifiers.

February 2006

 

Gasification Plant Cost and Performance Optimization Task 3 - Final Report

This study evaluates the application of Gas Technology Institute’s (GTI) fluidized bed U-GAS® gasifier at an industrial application. The first of the three subtasks in this study examines the use of the gasifier for an upstate New York industrial setting using a Southeastern Ohio coal. Both air-blown and oxygen-blown gasifier schemes are evaluated for this subtask. The next subtask of the study is to develop an advanced design for an air-blown case based on the first subtask. The third subtask of the study investigates the GTI gasifier in a stand-alone lignite-fueled IGCC power plant application, sited in North Dakota.

May 2005

DE-AC26-99FT40342

Polygeneration of SNG, Hydrogen, Power, and Carbon Dioxide from Texas Lignite

The intent of this study is to investigate the feasibility of siting a lignite conversion plant in Texas at the mine mouth of the Wilcox lignite deposit. The concept is to coproduce at least three products: electric power, hydrogen or substitute natural gas (SNG), and carbon dioxide. The electric power would be sold to the grid, the hydrogen would be sent by pipeline to the Gulf Coast petroleum refineries, the SNG would be sold as a natural gas supplement, and the carbon dioxide would be pipelined to the West Texas oil fields for enhanced oil recovery.

December 2004

DE-AM26-99FT40465

Potential Application of Coal-Derived Fuel Gases for the Glass Industry: A Scoping Analysis

The objective of this study is to explore the economic viability of producing coal-derived fuel gases for use in the glass manufacturing industry as an alternative to natural gas. In this study small-size gasification systems that suffer adversely from economics of scale were not considered. Instead, full-scale commercial gasification systems were analyzed that could produce enough fuel gas and electric power for several manufacturing plants. The possibility exists to gather a number of large manufacturers in a geographically centralized location in an Industrial Gasification Island (IGI) complex so that a central coal gasification plant could economically provide fuel and power to all of these industries.

December 2004

 

Final Report: Coal-Based Integrated Coal Gasification Combined-Cycle: Market Penetration Recommendations and Strategies

This report analyzes IGCC's potential market penetration under different environmental, technology, natural gas price, and policy incentive scenarios. In each scenario, the study identifies key findings that highlight IGCC's advantages and challenges. These findings show that IGCC is applicable in many future scenarios.

September 2004

 

Current and Future IGCC Technologies: Bituminous Coal to Power

In order to evaluate the benefits of the ongoing R&D, 15 IGCC configurations that produce electric power from bituminous coal were analyzed in this report. Twelve cases do not have carbon capture, and 3 cases capture carbon. The results show that there are potentially significant improvements that could result from continuing research development and demonstration (RD&D) in advanced IGCC systems with and without sequestration, provided that the RD&D achieves the performance and cost levels assumed in this analysis. These improvements include reduced capital costs and improved plant efficiency resulting in a 35 percent reduction in COE compared to current IGCC and sequestration technologies.

August 2004

DE-AM26-99FT40465

Deploying IGCC in this Decade with 3Party Covenant Financing

This report, divided into two volumes, describes a 3Party Covenant financing and regulatory proposal (3Party Covenant) aimed at reducing financing costs and providing a technology risk tolerant investment structure to stimulate initial deployment of 3,500 MW of Integrated Gasification Combined-Cycle (IGCC) coal generation power plants in this decade. The 3Party Covenant is an arrangement between the federal government, state utility commission, and equity investor that serves to lower IGCC cost of capital by reducing the cost of debt, raising the debt/equity ratio, minimizing construction financing costs, and allocating financial risk.

    • Volume I [PDF-768KB] (July 2004) describes the 3Party Covenant financing and regulatory program to stimulate near-term IGCC deployment, and how the 3Party Covenant improves the economics of IGCC technology to make it competitive. 

    • Volume II [PDF-635KB] (July 2004) provides a detailed legal analysis of the federal and state authorities and regulatory mechanisms for implementing the 3Party Covenant.

July 2004

 

Tampa Electric Integrated Gasification Combined-Cycle Project - Project Performance Summary

Tampa Electric Company successfully completed a five year demonstration of a 250-MWe integrated gasification combined-cycle power plant based on Texaco's pressurized, oxygen-blown, entrained flow gasifier. This project is part of DOE's Clean Coal Technology Demonstration Program related to coal use.

June 2004

DOE/FE-0469

Final Report: An Analysis of The Institutional Challenges To Commercialization and Deployment of IGCC Technology in The U.S. Electric Industry

This report identifies and prioritizes the institutional (i.e., non-technical) challenges to the rapid commercialization and deployment of coal gasification technologies in the U.S. electric power sector and provides recommendations for overcoming them. It focuses on Integrated Gasification Combined-Cycle technology, the most successful method of producing electric power utilizing coal gasification. The report recommends a number of regulatory, legislative, executive and policy initiatives, at both the federal and state levels, for achieving those objectives.

March 2004

 

Gasification Plant Cost and Performance Optimization Task 1 and 2 - Final Report

This project developed optimized designs and cost estimates for several coal and petroleum coke IGCC co-production projects that produced hydrogen, industrial grade steam, and hydrocarbon liquid fuel precursors in addition to power.  The as-built design and actual operating data from the DOE sponsored Wabash River Coal Gasification Repowering Project was the starting point for this study that was performed by Bechtel, Global Energy and Nexant under Department of Energy contract. This final report includes the results from Tasks 1 and 2.

September 2003

DE-AC26-99FT40342

Gasification Plant Cost and Performance Optimization Task 2 Topical Report Coke/Coal Gasification With Liquids Co production Volumes 1 and 2

This report describes Task 2 of a Department of Energy sponsored study (DOE contract DEAC26- 99FT40342) that extended the investigation of petroleum coke and coal fueled IGCC power plants to those that co-produce liquid transportation fuel precursors using Fischer- Tropsch hydrocarbon synthesis technology.  Task 2 was divided into three subtasks.  These subtasks dealt with converting two of the optimized plants developed during Task 1 into IGCC power plants with liquid fuels co-production. The results of Task 2 showed that adding hydrocarbon liquids co- production to an IGCC power plant can be cost effective when oil prices are relatively high.

September 2003

DE-AC26-99FT40342

Topical Report: IGCC Plant Cost Optimization Task 1

The "Gasification Plant Cost and Performance Optimization" project examines current state-of-the-art coal gasification to provide baseline optimized design cases from which the Department of Energy can measure future progress towards commercialization of gasification processes and achievement of the Vision 21 program goals. This optimization focus or metric was to minimize the cost of electric power produced by IGCC plants primarily by reducing the plant capital cost, increasing the efficiency, increasing the overall system availability, coproducing products, and reducing the operating and maintenance costs.

August 2003

DE-AC26-99FT40342

Refinery Technology Profiles - Gasification and Supporting Technologies

This report includes an overview of refinery gasification and supporting technologies and a description of the methodology used in the analysis. A comparison of this newly developed data with the current performance of the technology and the research goals of DOE’s fossil energy programs is provided. The profiles are consistent with existing refinery based gasification plants constructed and operated since 1996. The information contained in this report was used to generate the following tables for implementation in the Petroleum Marketing Module within NEMS.

September 2003

 

Capital and Operating Cost of Hydrogen Production from Coal Gasification

Due to wide differences in reported cost for capital and the need to provide a baseline cost for hydrogen production, prior plant designs and cost estimates for producing hydrogen from coal gasification utilizing commercial technology have been reviewed and updated. The key benefit of utilizing commercial technology is obtaining credible cost estimates for the plant with a minimum of process contingency. The results of the effort are intended to prepare a basis from which to utilize individualized financial parameters in the U. S. Department of Energy Integrated Gasification Combined-Cycle Cost Estimating Model to arrive at a selling price for hydrogen. From a common thermal gasifier throughput, plant gate costs for hydrogen produced from coal gasification from two coals, Pittsburgh #8 bituminous and Wyodak Powder River Basin sub-bituminous, were determined from two plant designs for hydrogen production, based on currently available process technology, and meeting current permitting regulations for environmental compliance. These baseline plants will not capture CO2. These cost estimates were prepared to quantify the differing plant characteristics associated with bituminous coal or sub-bituminous coal.

April 2003

DE-AM26-99FT40465

Eastman Chemicals from Coal Complex

This Topical Report provides publicly available technical data on the Eastman chemicals-from-coal complex in Kingsport, including the removal of mercury within the gasification section. The chemicals-from-coal complex continues to be a commercially viable operation for the production of acetyl chemicals from coal.  The project involves the operation of a 260 short tons per day, or 80,000 gallons per day, methanol unit utilizing coal-derived syngas from Eastman’s integrated coal gasification facility.
Other specific data on the operation of the Eastman guard bed to protect methanol synthesis catalyst and the wastewater treatment system are provided. Species of arsenic and sulfur from the Rectisol syngas clean-up plant are present at parts-per-billion by volume concentrations, and a catalyst guard bed has been in service to further reduce these concentrations prior to the introduction of the primary syngas feed (Balanced Gas) to either the fixed-bed methanol plant or the Liquid Phase Methanol Demonstration Unit.

March 2003

DE-FC22-92PC90543

Removal of Trace Contaminants from Coal-Derived Synthesis Gas

This topical report examines the identification of potential catalyst poisons and their effects on catalyst performance, the selection of suitable adsorbents to be used in a fixed catalyst guard bed configuration for the removal of targeted catalyst poisons, and the implementation and evaluation of the performance of the adsorbents in the Liquid Phase Methanol Demonstration Unit.  The project involves the operation of an 80,000-gallons-per-day (260-short-tons-per-day (sT/D)) methanol unit utilizing coal-derived syngas from Eastman’s integrated coal gasification facility.

March 2003

DE-FC22-92PC90543

Feed System Innovation For Gasification of Locally Economical Alternative Fuels (FIGLEAF)

The goal of the project was to identify and evaluate low-value fuels that could serve as alternative feedstocks and to develop a feed system to facilitate their use in integrated gasification combined-cycle and gasification coproduction facilities. The feasibility study undertaken for the project consisted of identifying and evaluating the economic feasibility of potential fuel sources, developing a feed system design capable of providing a fuel at 400 psig to the second stage of the E-Gas (Destec) gasifier to be cogasified with coal, performing bench- and pilot-scale testing to verify concepts and clarify decision-based options, reviewing information on high-pressure feed system designs, and determining the economics of cofeeding alternative feedstocks with the conceptual feed system design.

February 2003

DE-FC26-00NT40904

Process Screening Analysis of Alternative Gas Treating and Sulfur Removal For Gasification

This report updates a 1987 SFA Pacific, Inc. report to the Electric Power Research Institute that dealt with acid gas treating and sulfur recovery for integrated gasification combined-cycle (IGCC) power generation. Not only are the emission regulations more stringent than those prevailing at the time of the first report, but there is now sufficient commercial experience in IGCC that points the way to the processes that will meet current and potential future regulations.

December 2002

739656-00100

Updated Cost and Performance Estimates for Fossil Fuel Power Plants with CO2 Removal

This report presents updated results of a study on the potential cost of electricity produced in both conventional and innovative fossil-fueled power plants that incorporate CO2 removal for subsequent sequestration or use. Baseline cases are natural gas combined-cycle and ultra-supercritical pulverized coal plants with and without post-combustion CO2 removal, and integrated gasification combined-cycle plants with and without pre-combustion CO2 removal.

December 2002

 

Major Environmental Aspects of Gasification-Based Power Generation Technologies - Final Report

This report provides a comprehensive reference resource for gasification-based power generation technologies that examines both environmental performance and regulatory topics affecting the siting and operation of commercial plants. It presents an evaluation of the environmental performance of Integrated Gasification Combined - Cycle (IGCC) power generation technology and compares IGCC environmental performance with other competing coal-based technologies.

December 2002

DE-AT26-99FT20101

Forecasting the Benefits of DOE Programs for Advanced Fossil-Fuel Electricity Generating Technologies: The EIA High Fossil Electricity Technology Case

Each year the DOE Energy Information Administration (EIA) produces forecasts of U.S. energy activities for the next twenty to twenty-five years. The forecasts are generated with the EIA's National Energy Modeling System and are published in the EIA's Annual Energy Outlook (AEO) report. The AEO report is based on a business-as-usual forecast, called the Reference case, of what is most likely to happen given existing legislation and known trends for economic, technological, and demographic growth. After producing the Reference case forecast, the EIA reruns the Reference case with selected changes in the assumptions. These reruns, called "alternate" cases, selectively vary assumptions for economic growth, fuel supplies, and rates of improvements in energy technologies.

October 2002

 

An Environmental Assessment of IGCC Power Systems

This paper presents an evaluation of the environmental performance of IGCC power generation technology and compares IGCC environmental performance with other competing coal-based technologies. Information presented is extracted from a DOE report entitled "Major Environmental Issues Affecting Implementation and Operation of Gasification-Based Technologies Utilized For Power Generation."

September 2002

 

Gasification-based Power Generation with CO2 Production for Enhanced Oil Recovery

This paper examines the expected economic and CO2 emission performance of two fossil-based technologies for providing new electric generating capacity in the State of California in the time frame 2010-2030 are compared.  The two technologies are state-of–the-art natural gas combined-cycle and coal-based integrated gasification combined-cycle.

September 2002

 

The Cost of Mercury Removal in an IGCC Plant - Final Report

This report estimates the cost of mercury removal for applying a carbon bed filter to an IGCC plant. The carbon filter bed is assumed to achieve 99 percent reduction of mercury emissions, with outlet levels less than 1 ppbw. The cost format was based on the methodology used in the EPA Mercury Study Report to Congress while the cost estimate (capital and O&M) was based on Parsons on-site data and experience. The costs of mercury removal by a carbon bed in an IGCC are found to be much lower than from a utility boiler with carbon filter beds.

September 2002

 

Hydrogen from Coal

This report examines current and advanced technologies to produce hydrogen from coal. The performance and economics of these technologies are analyzed including configurations for carbon sequestration. For comparison, the economics of producing hydrogen from natural gas and photovoltaic water electrolysis are included.

July 2002

DE-AM26-99FT40465

Wabash River Coal Gasification Repowering Project -Project Performance Summary

This project, part of DOE's Clean Coal Technology Demonstration Program, pioneered commercial introduction of integrated gasification combined-cycle (IGCC) power generation technology. In 1992, the resultant Wabash River Coal Gasification Repowering Project Joint Venture embarked on a demonstration of Global Energy's E-Gas ™ gasification technology in an IGCC mode at 262-MWe scale - then, the world's largest single-train IGCC.

July 2002

DOE/FE-0448

Gasification Markets & Technologies - Present and Future: An Industry Perspective

This report presents industry's views of technologies, market opportunities, and both long-term and short-term research needs deemed critical to improving the economics and performance of gasification technologies. The principal findings are the result of confidential interviews with "expert teams" from 22 prominent organizations across a wide span of the U.S. gasification industry, all of which are identified as having a direct influence on current and future technology trends.

July 2002

DOE/FE-0447

Benchmarking Biomass Gasification Technologies for Fuels, Chemicals & Hydrogen Production

The overall objective of this paper is to survey and benchmark existing-commercial or near-commercial biomass gasification technologies for suitability to generate syngas compatible with commercial or near-commercial end-use technologies for fuels, chemicals and hydrogen manufacture.  This study considered the specific fuel and chemical applications: Fischer-Tropsch fuels, methanol, hydrogen, and fuel gas.

June 2002

 

Novel Gas Cleaning/ Conditioning for Integrated Gasification Combined Cycle Base Program Final Report

This report describes the Base Program experimental activities completed to identify candidate sorbents and suitable operating conditions for each of the two stages of the Ultra-Clean process. Commercial process performance and economics are also estimated for this novel gas cleaning process.

August 2001

DE-AC26-99FT40674

Novel Gas Cleaning/ Conditioning for Integrated Gasification Combined Cycle Volume 1 – Conceptual Commercial Evaluation Optional Program Final Report

Siemens Power Generation, Inc. conducted a program with the Gas Technology Institute (GTI) to develop a Novel Gas Cleaning process that uses a new type of gas-sorbent contactor, the “filter-reactor”. This report describes and presents a commercial evaluation of this process. 

August 2001

DE-AC26-99FT40674

Novel Gas Cleaning/ Conditioning for Integrated Gasification Combined Cycle Base Program Final Report Test Plan Topical Report

This report describes the test plan for selection of candidate sorbent materials and evaluation of the sorbents in the laboratory–scale units to provide the necessary data to verify the technical and economical feasibility of the Ultra-Clean Gas Cleanup Process.

April 2000

DE-AC26-99FT40674

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