Carbon Dioxide Strategies by Chris Trayhorn, Publisher of mThink Blue Book, April 1, 2003 The Kyoto Protocol would have required the United States to commit to a 7 percent reduction in carbon emissions from the 1990 level by 2010. This paper will examine the strategies, technologies, and costs that could be tried to reduce emissions within the power sector. According to the Energy Information Administration (EIA), the actual emissions from the power sector in 1990 were 507 million metric tons (mmt) of carbon, or 1,859 mmt of CO2. The estimated 2000 emissions were 2,352.5 mmt of CO2. Using the EIA’s projected power growth rate of 1.7 percent per year, and assuming most new generation plants are natural gas, the estimated 2010 emissions are 712 mmt of carbon, or 2,603 mmt of CO2. Compliance with Kyoto would require the power sector, which represents about a third of the total U.S. carbon emissions, to limit emissions to 472 mmt of carbon, thus yielding a reduction of 240 mmt by 2010. It is a daunting challenge. Achieving that result would be equal to replacing one-third of existing coal-fired plants with a zero-CO2 emission technology such as nuclear. We’ll look at a variety of approaches and their costs, including plant replacement and sequestration. New Plants Aging coal-fired power plants could be replaced with new, cleaner plants that emit less or no CO2, including: • Pulverized-coal-fired plants with a supercritical steam cycle (PCSC) • Natural-gas-fired combined cycle plants (NGCC) • Integrated coal-gasification combined cycle plants (IGCC) • Nuclear power plants CO2 scrubbing can be done using post-combustion or pre-combustion technologies. A pulverized-coal plant would require post-combustion scrubbing. Natural gas and coal-gasification plants would require pre-combustion scrubbing. Post-combustion of coal-fired boiler flue gas has been performed on a small scale. In this technology, the flue gas is cooled by water spraying and then treated in an amine scrubber, where CO2 is stripped. The CO2 collected from the amine regenerator is compressed and liquefied for export. Pre-combustion scrubbing can be implemented on a natural gas plant or a coal gasification plant before the fuel is combusted in the gas turbine. In this technology, fuel gas is converted to hydrogen and carbon dioxide through steam reforming (natural gas only) and water shift conversion. Carbon dioxide is then stripped out by an acid gas removal system (such as amine scrubbing), and hydrogen is left as the fuel for gas turbine. Slack Demand Industrial and commercial uses of CO2 are limited compared with the amount emitted from power plants. The total industrial use of CO2 in the United States is less than 50 million tons per year, which is less than 1 percent of the approximately 6 billion tons emitted annually from fossil fuel combustion. The largest single use of CO2 is for enhanced oil recovery (EOR); other uses of CO2 include carbonated drinks, freeze drying, and food packaging, but these usage rates are minimal. Potential industrial uses of CO2 are also small compared with man-caused emissions of CO2. Assuming that CO2 is substituted for fossil fuel feedstock in all plastics production in the United States (there is no suggestion that this is feasible), less than 200 million tons of CO2 per year would be required, or about 3 percent of the total CO2 produced in the United States. Use of CO2 in fuel making (converting syngas to methanol, for example) has been suggested. However, methanol or its derivative, MTBE, is not considered suitable fuel for motor vehicles. Another potential industrial use involves creating urea by combining ammonia with carbon dioxide. But this use, too, has a very limited potential because the annual amount of fertilizers produced is two orders of magnitude smaller than the amount of CO2 available annually. A thorough review of beneficial uses of CO2 shows that its potential is very limited. Figure 1: Economic Analysis Notes (1) For each technology, the plant output for cases with CO2 removal is lower than output without CO2 removal by the amount of energy used for CO2 scrubbing. (2) For plants without CO2 removal, the number shown is the amount of CO2 avoided by replacing an existing subcritical plant emitting 850 kg of CO2 per megawatt. For plants with CO2 removal, the amount shown is based on 90 percent removal on total tonnage basis, but adjusted for reduced net plant output. As an example for the PCSC plant without CO2 removal, which emits 800 kg/mwh, the CO2 avoided is 50 kg/mwh (850-800). However, for the same plant with 90 percent CO2 removal, the CO2 removed is 960 kg/mwh [0.90 x 800 kg/mwh divided by 600 mw/800 mw]. Sequestration CO2 sequestration can be accomplished either by an offset (indirect sequestration) or by reduction in emissions from the generation facility (direct sequestration). Indirect sequestration can be done by removing CO2 from the atmosphere by terrestrial uptake (e.g., sequestering CO2 in soil, forests, and other vegetation) or by ocean uptake (e.g., ocean fertilization). Direct sequestration requires separation and capture of CO2 emissions from the generation facility, transportation, and long-term storage in geological formations or in the ocean. Carbon dioxide can be compressed and/or liquefied as necessary for export. For long-distance hauling, it is desirable to liquefy the gas to make it a cold liquid. CO2 can be transported at low pressure in insulated tank trucks at -30°C. Artificial photosynthesis is another approach for CO2 fixation under ambient conditions. Microalgae systems present the best biological technology for the direct capture and utilization of CO2 emitted by power plants. These microscopic plants would be grown in large, open ponds, wherein power plant flue gas or pure CO2 would be introduced as small bubbles. The estimated mitigation cost for this type of process can be as high as $100 per metric ton of CO2 recycled. A pond of about 50 to 100 square kilometers (12,250 to 24,500 acres) would be needed for a 500 megawatt power plant. The biomass would be harvested as a fossil fuel replacement. Considerable opportunities exist for improving these systems. The estimated cost of afforestation — using forests to absorb the gas — is in the range of $3 to $10 per metric ton of CO2. This cost does not include land or forest management. Isolation Direct CO2 sequestration technologies include: • Injection into oil and gas reservoirs • Injection into deep, unmineable coal seams • Injection into saline aquifers • Injection of liquid CO2 into the deep ocean Geological formations such as oil and gas fields, coal beds, and saline aquifers are likely to provide the first large-scale opportunity for CO2 sequestration. During 1998, oil field operations pumped about 43 million tons of CO2 into about 70 wells for oil recovery. Many additional candidates exist for EOR. CO2 disposal in depleted oil and gas reservoirs is possible today, but the ability to dispose of the extremely large quantities that may be required is uncertain. A much greater opportunity for storing large volumes of CO2 injection lies in geologic formations. Confined saline aquifers, rock caverns, and salt domes have the potential to sequester millions and possibly billions of tons of CO2, but many technical, safety, liability, economic, and environmental issues remain unresolved. Disposal of CO2 in deep, unmineable coal beds may offer the advantage of displacing methane from the coal beds for enhanced coal bed methane recovery. A pilot program of CO2-assisted coal bed methane production has been in operation since 1996. Four million cubic feet per day of pipeline-fed CO2 from a natural source is injected daily. Full field development of the process could boost recovery of in-place methane by 75 percent. Sequestration in deep saline formations or in oil and gas reservoirs can be achieved by a combination of three mechanisms: displacement of the natural fluids by CO2, dissolution of CO2 into the fluids, and chemical reaction of CO2 with minerals present in the formation to form stable compounds like carbonates. Deep aquifers may be the best long-term underground storage option. Such aquifers are generally saline and are separated hydraulically from more shallow aquifers and surface water supplies used for drinking water. The spatial match between storage locations and CO2 sources is better for deep aquifers than for gas and oil reservoirs. A study has estimated that 65 percent of CO2 captured from U.S. power plants can be injected into deep aquifers without the need for long pipelines. The ocean holds an estimated 40,000 gigatons of carbon (compared with 750 gigatons in the atmosphere) and is considered to be a potential sink for very large-scale CO2 sequestration. Two basic methods are used for ocean sequestration: direct injection of CO2 into the deep ocean; and indirect sequestration in which the net natural CO2 uptake is increased via the use of micronutrients in areas of the ocean where CO2 could be absorbed by an increase in plankton growth. For ocean sequestration to be effective, the CO2 must be injected below the thermocline, the layer of ocean between approximately 100 and 1,000 meters, in which temperatures decrease dramatically with depth. The thermocline is a stable stratification due to the large temperature and density gradients, thus inhibiting vertical mixing and slowing the leakage of CO2. The water beneath the thermocline may take centuries to mix with surface waters, and CO2 below the boundary will be effectively trapped. CO2 could be dissolved at moderate depths (1,000 to 2,000 meters) to form a dilute solution or could be injected below 3,000 meters (the depth at which CO2 becomes negatively buoyant) to form a CO2 lake. Subsea pipelines to 1,000-meter depths are expected to cost on the order of $1.2 million per kilometer or more. As indicated by the material presented previously, considerable research and development would be needed to find cost-effective ways to sequestrate CO2, or it will become a technology barrier for implementing CO2 removal technologies. Direct CO2 sequestration cost estimates vary from as low as $5 to higher than $50 per metric ton because of limited industry operating experience. Cost varies with the volume to be disposed of, distance to the sequestration point, and sequestration technology. CO2 sequestration in deep wells appears to be a feasible technology. The cost of transportation and injection is estimated at $10 per metric ton. However, if some other disposal method is used, such as fixing the CO2 in carbonate material for disposal, the cost of sequestration is estimated at $30 per metric ton. For this paper, a sequestration cost of $20 per metric ton has been assumed. Economics Table 1 shows assumed values of the major technical parameters (plant size, heat rate, capital cost, and capacity factor) for the new plants under consideration, both without and with CO2 removal and sequestration. The major financial assumptions are: • Plant economic life is 30 years • Discount rate is 10 percent • Equity share is 30 percent • Debt tenor is 18 years • Interest on debt is 8 percent • General inflation is 2.5 percent per year • Return on equity (after tax) is 16 percent • First-year COE is stated in 2002 dollars • Fuel cost is $1.19/GJ ($1.25/million Btu) for coal, $3.80/GJ ($4.0/million Btu) for gas, and $0.47/GJ ($0.50/million Btu) for nuclear Other plant data such as construction duration and plant operations and maintenance cost is per industry norms. Note that many of these variables are site, fuel, ambient conditions, customer, and dispatch specific, so the assumed number can vary 10 to 15 percent or more. As stated earlier, nuclear — from a CO2 emissions reduction viewpoint — is ideal. Public acceptance, however, continues to be a barrier for nuclear. Kyoto Protocol versus Bush Initiative The United States has the lowest electricity rates among the developed countries, predominantly due to inexpensive fossil-fuel-based generation. Because of the strong link (which may be loosening if not already broken) between economic growth and electricity demand (and hence greenhouse gas emissions), a rapid reduction in emissions would be costly and would threaten U.S. economic growth. Consequently, in February 2002 U.S. President George W. Bush announced a new initiative, which would reduce the greenhouse gas (GHG) intensity — defined as metric tons of carbon (mtc) emissions per million dollars of gross domestic product — by 18 percent in the next 10 years. In 2002, the GHG intensity stands at 183 million mtc. Based on the current GDP of $10 trillion, total emissions are 1,830 mtc. Using the projected GDP growth of 2.9 percent per year, the GDP in 2010 would be $12.55 trillion. With the Bush initiative of 1.8 percent average reduction in GHG intensity, the target GHG intensity in 2010 would be 157.4 mtc (prorated from 151 mtc in 2012). This equals total emissions of 1,975 million mtc in year 2010. Since the power sector accounts for one-third of total emissions, the power sector CO2 reduction goal by 2010 is 48 million mtc. This goal is 20 percent of the 240 million mtc reduction under the Kyoto protocol. Another salient difference of the Bush initiative is that stabilization and, ultimately, reversal of GHG emissions are anticipated to occur in 25 to 30 years as opposed to 12 to 15 years under Kyoto. As expected, the increase in COE is much lower under the Bush initiative than under the Kyoto Protocol. This is because the bulk of existing coal-fired generation (which is responsible for lower COE in the United States) is still maintained. Conclusions • Strictly from a capacity addition viewpoint with the assumed price for coal as $1.19/GJ ($1.25/MMBtu) and gas as $3.8/GJ ($4/MMBtu); coal is competitive with gas (a natural gas plant). For a coal gasification plant and nuclear to be competitive, the gas price must increase beyond $4.4/GJ ($4.6/MMBtu). • Removal and direct sequestration of CO2 are very expensive, especially for a pulverized coal plant technology. Considerable R&D is needed to develop cost-effective technologies. Until then, indirect sequestration is a more pragmatic approach for the United States. • If CO2 removal and sequestration become a priority, nuclear and other CO2 neutral technologies become attractive options. • The Bush initiative, while less burdensome for the U.S. economy, will take about 15 years longer than the Kyoto Protocol to stabilize and eventually reverse the GHG emissions trend. Filed under: White Papers Tagged under: Utilities About the Author Chris Trayhorn, Publisher of mThink Blue Book Chris Trayhorn is the Chairman of the Performance Marketing Industry Blue Ribbon Panel and the CEO of mThink.com, a leading online and content marketing agency. He has founded four successful marketing companies in London and San Francisco in the last 15 years, and is currently the founder and publisher of Revenue+Performance magazine, the magazine of the performance marketing industry since 2002.