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Projected Costs of Generating Electricity - OECD Nuclear Energy ...

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The impurities contained in coal are released during combustion. In addition, nitrogen oxides (NO X )<br />

are formed by the combustion process itself by reactions with nitrogen contained in the coal and in the<br />

combustion air. Toxic by-products found in combustion gases include sulphur dioxide, nitrogen oxides,<br />

halogens, unburned hydrocarbons and metals. Ash remains from the non-combustible portion <strong>of</strong> coal feed<br />

and unburned carbon. Typically half is collected in the bottom <strong>of</strong> the boiler and the remainder is carried<br />

along in the combustion gases as fly ash. Various environmental control systems must be incorporated into<br />

the plant design to limit the formation <strong>of</strong> pollutants (nitrogen oxides) or remove them from flue gases.<br />

Pollution control systems<br />

The pollutants controlled from coal-fired plants and the levels to which they are controlled are key cost<br />

factors. The tighter the emissions limits, the more expensive the pollution control systems will cost to<br />

build and operate, and the more energy they will consume. All the coal-fired plants in this study meet<br />

national pollution control requirements, which vary from country to country. The IEA (1997) summarises<br />

major pollution control standards for coal-fired power plants within IEA member countries. The pollutants<br />

controlled and environmental protection measures associated with coal combustion are nonetheless<br />

similar for all the plants in this study. The major pollutants <strong>of</strong> concern are airborne emissions <strong>of</strong> sulphur<br />

dioxide, nitrogen oxides and particulate matter.<br />

Sulphur dioxide is controlled in all cases presented in this report, except Brazil and India, by flue gas<br />

desulphurisation systems. The predominant wet scrubber design consists essentially <strong>of</strong> a reaction vessel<br />

in which the sulphur dioxide is absorbed from the flue gas stream by a slurry <strong>of</strong> limestone or other reagent.<br />

Sulphur removal efficiencies <strong>of</strong> 95% or more are possible. This type <strong>of</strong> desulphurisation system is<br />

expected to be installed on most new coal-fired power plants. Other configurations are possible, including<br />

spray dryer systems, dry sorbent injection and regenerable systems (Soud and Takeshita, 1994).<br />

The energy needed to operate a wet scrubber system consumes up to 1% <strong>of</strong> plant output. The system<br />

also adds up to 100-250 USD/kWe to plant capital cost (Takeshita, 1995), and also adds to operating and<br />

maintenance costs. <strong>Energy</strong> consumption and costs are closely related to the permissible level <strong>of</strong> sulphur<br />

dioxide emissions from the plant.<br />

Nitrogen oxides are controlled by modifications to the coal combustion system itself, to minimise their<br />

formation, and post-combustion removal. Staging air within the combustion zone (overfire air) and the<br />

use <strong>of</strong> low-NO X burners are the two primary combustion techniques which result in an immediate<br />

reduction in NO X production <strong>of</strong> up to 60% compared to uncontrolled coal combustion. Low-NO X burners<br />

are standard or the minimum NO X control requirement in many countries. Capital costs for these burners<br />

are not a significant cost element: typically 10-30 USD/kWe. If NO X emissions must be reduced below<br />

levels obtainable using combustion modifications, dedicated NO X removal systems must be installed.<br />

Generally selective catalytic reduction (SCR) systems are used for coal-fired stations. These involve the<br />

injection <strong>of</strong> ammonia or urea into the flue gas and the catalytically enhanced reaction <strong>of</strong> the reagent with<br />

NO X to form nitrogen and oxygen. SCR is the most effective NO X control technology, but is relatively<br />

expensive. All the flue gas must pass through catalyst beds. The catalyst reactor adds some<br />

50-90 USD/kWe to the capital cost and induces higher plant electrical consumption. The catalyst itself<br />

must be periodically replaced at some expense. Half <strong>of</strong> the conventional coal-fired plants in this study in<br />

<strong>OECD</strong> member countries are fitted with SCR. None <strong>of</strong> the plants in non-member countries have postcombustion<br />

NO X control. Soud and Fukusawa (1996) describe developments in control <strong>of</strong> NO X emissions.<br />

The third major airborne pollutant from coal-fired stations is particulate matter. This is essentially<br />

the ash carried along with the combustion gases. Control <strong>of</strong> particulate matter has been incorporated<br />

in nearly all coal-fired power stations in <strong>OECD</strong> member countries for many years. One <strong>of</strong> two basic<br />

systems is included in all plants <strong>of</strong> this study. Electrostatic precipitators function by drawing particulate<br />

matter to electrically charged plates along the flue gas path. Fabric filters, installed in “baghouses,”<br />

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