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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Tailoring Cementitious Materials Towards Value-Added Use of Large CO 2 Volumes

Hydraulic cements with alternative chemistries were developed for large-volume and value-added use of carbon dioxide. The hydraulic cements were processed using the energy-efficient mechanochemical technique at room temperature and atmospheric pressure. Carbon dioxide was captured directly from combustion emissions during processing. For this purpose, mechanochemical processing of hydraulic cements was accomplished under a flow of combustion emissions prior to the release of emissions to the atmosphere. The process removed a significant fraction of carbon dioxide from combustion emissions. The hydraulic cements captured carbon dioxide at about 10% of their weight. Two hydraulic cement chemistries were developed, and their mechanochemical processing was successfully scaled-up. The characteristic feature of one chemistry was its relatively low (near-neutral) pH where the integration of carbon dioxide yielded clear value. The second cement chemistry was based on alkali activation of industrial wastes. This chemistry could make value-added use of carbon dioxide, but it had to be refined to control the pH drop caused by CO 2 integration. These two cements render binding effects upon hydration by forming a combination of stable carbonates and aluminosilicates or phosphates. Efforts to develop cement chemistries based solely on carbonates were not successful. The mechanochemical process was found to integrate carbon dioxide into the alternative cement chemistries in the form of disordered and metastable carbonates. During hydration reactions, the disordered/metastable carbonates are either transformed into stable carbonate phases with desired binding efforts, or carbonates get integrated into the primary inorganic binders (hydrates). When compared with mechanochemical processing in pure carbon dioxide, mechanochemical processing in combustion emissions produced hydraulic cements with improved engineering properties. The mechanochemical process was scaled-up, and its variables as well as the raw materials formulations were optimized for implementation at pilot scale. Scale-up was found to enhance the carbon capture potential and the engineering qualities of the resulting hydraulic cements. This was because scale-up raises the intensity of mechanical energy input to raw materials. Certain mechanochemical phenomena cannot be induced, irrespective of the cumulative mechanical energy input, unless the intensity of impact is raised above a minimum level that cannot be achieved in laboratory-scale implementation of the process. Due to this effect, the duration of the mechanochemical process as well as its energy demand could be reduced significantly (by an order of magnitude) upon transition from laboratory to pilot scale, with the hydraulic cements produced at pilot scale offering engineering properties that were superior to those realized in laboratory-scale mechanochemical processing. The hydraulic cements produced at pilot scale via mechanochemical processing under a flow of combustion emissions were thoroughly characterized. They were found to meet standard requirements for ‘General Use’ hydraulic cements. They were compatible with the industrial-scale concrete production and construction practices that are used with the currently prevalent hydraulic cements. The new hydraulic cements with integrated carbon dioxide were found to offer distinct advantages over the currently prevalent Portland cement in terms of net carbon footprint and energy content. The combined raw materials and energy costs of the new hydraulic cements are competitive, and major cost savings can be realized because of the simplified production process that significantly lowers the capital investment in cement production plants. Mechanochemical processing of the new hydraulic cements under a flow of combustion emissions can be implemented using some existing components of cement manufacturing plants; this facilitates adoption of the technology by the cement industry.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Mixing-Controlled Combustion of Ethanol Enabled by Prechamber Ignition (PC-MCC): A Preliminary Experimental Demonstration

This experimental study presents preliminary investigations of prechamber-enabled mixing-controlled combustion (PC-MCC) at −2 bar brake mean effective pressure (BMEP) and 2200 rpm with fuel-grade ethanol (E98). Experimental results are conducted on a prechamber retrofitted single-cylinder Caterpillar C9.3B test engine. First, a series of prechamber-only experiments were conducted with a motored engine to evaluate the salient combustion trends in response to relevant prechamber operating parameters. Under firing conditions, the prechamber operating strategy was assessed with respect to the impact on ignition assistance of direct-injected E98 and overall engine performance. The preliminary results indicate the jet-induced ignition process is robust and prompts diffusion combustion of E98 at diesel-like boundary conditions. Here, the effect of external exhaust gas recirculation (EGR) on the residual tolerance of the prechamber combustion process was also investigated and showed stable combustion in both the main chamber and prechamber up to 30% EGR. Experiments were also conducted with the stock diesel engine for baseline comparison. At matched combustion phasing, mixing-controlled combustion of ethanol enabled by prechamber ignition was able to achieve heightened gross thermal efficiency while simultaneously reducing NOx and practically eliminating smoke emissions relative to diesel combustion. In addition, the covariance of load and standard deviation of combustion phasing was diesel-like and less than 2% and 1 CAD, respectively.

PC-MCC↗
DOE OSTI2022

DNS Of the ignition process of n-heptane/air premixed combustion with low-temperature chemistry in turbulent boundary layer

In the present work, three-dimensional direct numerical simulation (DNS) of n-heptane/air premixed combustion in turbulent boundary layer was performed to explore the near-wall ignition process with low -temperature chemistry. A reduced chemical mechanism with 58 species and 387 elementary reactions for n-heptane combustion was used in the DNS. The general characteristics of the ignition process near the wall were examined. Here, it was found that low-temperature ignition (LTI) dominates the upstream region, and high -temperature ignition (HTI) appears in the downstream region. The ignition process and the low-temperature chemistry pathways of the DNS are compared with those of a corresponding laminar case. It was found that the ignition process was affected by turbulence, which results in thickened reaction zones. However, the carbon flow analysis of low-temperature chemistry showed that turbulence rarely affects the low-temperature chemistry pathway. The combustion modes of various regions were scrutinized based on the budget terms of species transport equations and the chemical explosion mode analysis (CEMA). It was shown that the reaction term of RO 2 is significant during the LTI process of the upstream region, and the reaction terms of CH 2 O and CO 2 are evident in the downstream region, indicating the occurrence of HTI. It was also shown that auto-ignition is dominant in the upstream region. With increasing streamwise distance, the contribution of flame propagation increases, which takes over that of auto-ignition in the near-wall region.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Tailored Bioblendstocks with Low Environmental Impact to Optimize MCCI Engines

The overall objective of the project is to develop and demonstrate a microalgae bio-blendstock with greater than 60% greenhouse gas reduction potential relative to petroleum diesel, that can reduce sooting propensity, increase cetane number and improve engine thermal efficiency relative to a baseline diesel engine operating on conventional fuel. Specific objectives include: (1) development of a new framework for both LCA and TEA that explicitly considers temporal variation in productivity and the frequency of crop loss; (2) determination of how fuel compounds that can be produced from the algal biomass can be ‘bio-tailored’ based on the species composition and biological production process, and subsequent processing via HTL to biocrude, and upgrading of the biocrude; (3) execution of a feedback loop (algae production  biocrude refining  combustion optimization  feedback to refining stage), for optimization of fuels for MCCI combustion; (4) optimization of MCCI combustion and emissions performance, accounting first for the biological processes that dictate the chemical composition of biocrude oil, and second for the subsequent chemical processes that comprise mixing controlled compression ignition combustion; (6) simulation of MCCI engine combustion processes to demonstrate the incorporation of relevant fuel chemistry that captures the specific impacts of optimized algal fuels.

09 BIOMASS FUELS↗
DOE OSTI2020

TAILORED BIOBLENDSTOCKS WITH LOW ENVIRONMENTAL IMPACT TO OPTIMIZE MCCI ENGINES

The overall objective of the project is to develop and demonstrate a microalgae bio-blendstock with greater than 60% greenhouse gas reduction potential relative to petroleum diesel, that can reduce sooting propensity, increase cetane number and improve engine thermal efficiency relative to a baseline diesel engine operating on conventional fuel. Specific objectives include: (1) development of a new framework for both LCA and TEA that explicitly considers temporal variation in productivity and the frequency of crop loss; (2) determination of how fuel compounds that can be produced from the algal biomass can be ‘bio-tailored’ based on the species composition and biological production process, and subsequent processing via HTL to biocrude, and upgrading of the biocrude; (3) execution of a feedback loop (algae production  biocrude refining  combustion optimization  feedback to refining stage), for optimization of fuels for MCCI combustion; (4) optimization of MCCI combustion and emissions performance, accounting first for the biological processes that dictate the chemical composition of biocrude oil, and second for the subsequent chemical processes that comprise mixing controlled compression ignition combustion; (6) simulation of MCCI engine combustion processes to demonstrate the incorporation of relevant fuel chemistry that captures the specific impacts of optimized algal fuels.

09 BIOMASS FUELS↗
DOE OSTI2025

Process and environmental safety of thermochemical conversion of biomass

Biomass presents a promising opportunity for converting waste into valuable energy, fuels, and chemicals through various thermochemical processes, including hydrothermal carbonization, hydrothermal liquefaction, pyrolysis, gasification, and combustion. However, these processes operate under extreme conditions, introducing significant safety hazards that necessitate meticulous management to prevent accidents. This review discusses potential hazards, risk mitigation strategies, and safety management practices, emphasizing the importance of integrated safety measures into the design and operation of these processes. It also highlights the critical need for robust safety engineering and environmental management strategies tailored to each thermo-chemical process. As these processes transition from laboratory to industrial scale, there is an imperative to develop a clear and concise pathway for emerging industries to achieve regulatory compliance, achieve safety certification, and enable effective stewardship of potential fugitive emissions. By addressing safety and environmental concerns, stakeholders can optimize economic benefits, rural development, and achieve sustained domestic energy generation benefits offered by biomass conversion technologies. Further research on plant design optimization, operational safety, environmental evaluation standardization, and innovative waste management solutions will support the safe and effective scaling of these technologies, ultimately contributing to sustainable management and resource recovery.

09 - BIOMASS FUELS↗
DOE OSTI2024

Field-Scale Testing of a High-Efficiency Membrane Reactor (MR)—Adsorptive Reactor (AR) Process for H2 Generation and Pre-Combustion CO2 Capture

The study objective was to field-validate the technical feasibility of a membrane- and adsorption-enhanced water gas shift reaction process employing a carbon molecular sieve membrane (CMSM)-based membrane reactor (MR) followed by an adsorptive reactor (AR) for pre-combustion CO2 capture. The project was carried out in two different phases. In Phase I, the field-scale experimental MR-AR system was designed and constructed, the membranes, and adsorbents were prepared, and the unit was tested with simulated syngas to validate functionality. In Phase II, the unit was installed at the test site, field-tested using real syngas, and a technoeconomic analysis (TEA) of the technology was completed. All project milestones were met. Specifically, (i) high-performance CMSMs were prepared meeting the target H2 permeance (>1 m3/(m2.hbar) and H2/CO selectivity of >80 at temperatures of up to 300 °C and pressures of up to 25 bar with a <10% performance decline over the testing period; (ii) pelletized adsorbents were prepared for use in relevant conditions (250 °C < T < 450 °C, pressures up to 25 bar) with a working capacity of >2.5 wt.% and an attrition rate of <0.2; (iii) TEA showed that the MR-AR technology met the CO2 capture goals of 95% CO2 purity at a cost of electricity (COE) 30% less than baseline approaches.

42 ENGINEERING↗
DOE OSTI2020

Ability of Particulate Matter Index to describe sooting tendency of various gasoline formulations in a stratified-charge spark-ignition engine

This study investigates the ability of Particulate Matter Index (PMI) to describe the sooting behavior of various gasoline formulations in a stratified-charge (SC) spark-ignition engine. Specifically, the engine was operated at 2000 rpm with an intake pressure of 130 kPa where soot formation is known to primarily occur in the bulk gases. Exhaust soot emissions were measured for nine test fuels at various exhaust gas recirculation levels. A comparison between measured soot levels and PMI shows that PMI is a relatively poor predictor of the sooting tendency of the tested fuels under lean SC combustion. Among the fuels, three fuels, namely the diisobutylene blend, High Olefin, and E30 fuels exhibit measured soot behavior opposite of that predicted by PMI. Optical diagnostics were utilized to further investigate the in-cylinder phenomena for these three fuels. Analysis of natural luminosity and diffused back-illumination extinction imaging suggests that fuel-induced differences in the amount of soot formed are responsible for a majority of the discrepancy in measured versus predicted sooting tendency. Fuel-induced differences in soot oxidation and spray development seem to play minor roles. Because the combustion and air-fuel mixing processes for lean SC combustion are different from conventional stoichiometric operation it is hypothesized that the PMI correlation needs to be modified to account for differences in stoichiometric air-fuel ratio and level of oxygenation between fuels. Furthermore, the role of fuel volatility in PMI possibly needs to be de-emphasized for SC operation with fuel injection into compression-heated gases.

42 ENGINEERING↗
DOE OSTI2021

Achieving Runtime State Verification Assurance in Critical Cyber-Physical Infrastructures

Industrial Cyber-Physical Systems (ICPS) are an essential backbone of national critical infrastructures. They help monitor and control crucial cyber-enabled services such as energy generation. Commonly ICPS monitors the physical process through Supervisory Control and Data Acquisition (SCADA) systems. The SCADA ecosystem takes critical real-time and future system operational decisions based on the runtime state behavior of field sensors. Traditional SCADA systems use legacy and insecure communication protocols such as the Modbus protocol that lack adequate security mechanisms to provide robust runtime state behavior assurance of constrained field sensors. Therefore, constrained field sensors are commonly vulnerable to standard semantic attacks that gradually change the behavior state of infected devices. This paper discusses process integrity assurance techniques necessary to enhance the security of behavior-based protocols such as the Modbus protocol. The Runtime State Verification (RSV) protocol proposed in this paper aims to address semantic attacks in the SCADA ecosystem by integrating behavior-based Mandatory Results Automata (MRA) and a Hyperledger Fabric (HLF) network. The RSV protocol provides high process integrity assurance through enhanced behavior-based MRA suitable for the constrained field devices. A proof of concept of the RSV protocol has been evaluated in an emulated water-tube boiler. Preliminary evaluations of the RSV protocol aimed to measure the efficiency of the proposed protocol by monitoring an Combustion Efficiency (CE) process necessary to preserve optimal combustion, thus minimizing costs and future maintenance of water-tube boilers. We analyze the overall network overhead and latency of the proposed RSV protocol by evaluating the HLF network performance and comparing the proposed RSV protocol with the state-ofart BloSPAI protocol. Through the preliminary evaluations of the proposed RSV protocol, this paper demonstrates that the proposed RSV protocol overcomes the shortcomings and network overhead of the BloSPAI protocol by integrating behavior-based authentication through novel MRAs and HLF networks.

Rivera, Abel Gomez↗
DOE OSTI2024

Functional Data Analysis in Wearable Body Sensor Networks

Improving response time of indirect room-size calorimeters is still an outstanding problem in metabolic research. Accurate estimates of instantaneous rates of gaseous exchange require numerical differentiation of measured gaseousgas concentrations. We propose a new method to estimate the instantaneous gaseousgas exchange rates in indirect calorimetry. In contrast to the previously developed techniques, the method addresses the problem of differentiation of gaseous concentrations as an ill-posed problem. By applying the method of regularization, the problem of differentiation is converted into a well-posed problem resulting in smooth and consistent gaseous exchange rates. The validity of the method is tested on a large dataset of calorimeter experiments which included 313 human experiments along with 231 alcohol combustion experiments. It is demonstrated that the method is able to reliably differentiate between the “unphysiological” process of alcohol combustion and physiological variations produced by human metabolism. The method also allowed unraveling the previously unreported relative kinetics of O2 consumption and Respiratory Quotient (RQ) in humans. It was found that the kinetics of oxidative fuel selection lags behind the energy expenditure in humans exhibiting some sort of oxidative inertia. The time lag varies from 2-3 min up to 30 min, depending on particular individual. No such lag was found in alcohol combustion experiments. In addition to the relative kinetics of substrate oxidation, two statistical indexes reflecting variability of minute-by-minute RQ were estimated. The indexes were the RQ’s standard deviation and RQ’s first-order derivative. Both indexes showed statistically significant difference between human experiments and alcohol combustion experiments. We conclude that the proposed method can consistently extract physiologically-relevant information from noisy calorimetry data and the aforesaid information can provide additional insights into the mechanism of metabolic fuel selection in humans.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Functional Data Analysis in Wearable Body Sensor Networks

Improving response time of indirect room-size calorimeters is still an outstanding problem in metabolic research. Accurate estimates of instantaneous rates of gaseous exchange require numerical differentiation of measured gaseousgas concentrations. We propose a new method to estimate the instantaneous gaseousgas exchange rates in indirect calorimetry. In contrast to the previously developed techniques, the method addresses the problem of differentiation of gaseous concentrations as an ill-posed problem. By applying the method of regularization, the problem of differentiation is converted into a well-posed problem resulting in smooth and consistent gaseous exchange rates. The validity of the method is tested on a large dataset of calorimeter experiments which included 313 human experiments along with 231 alcohol combustion experiments. It is demonstrated that the method is able to reliably differentiate between the “unphysiological” process of alcohol combustion and physiological variations produced by human metabolism. The method also allowed unraveling the previously unreported relative kinetics of O2 consumption and Respiratory Quotient (RQ) in humans. It was found that the kinetics of oxidative fuel selection lags behind the energy expenditure in humans exhibiting some sort of oxidative inertia. The time lag varies from 2-3 min up to 30 min, depending on particular individual. No such lag was found in alcohol combustion experiments. In addition to the relative kinetics of substrate oxidation, two statistical indexes reflecting variability of minute-by-minute RQ were estimated. The indexes were the RQ’s standard deviation and RQ’s first-order derivative. Both indexes showed statistically significant difference between human experiments and alcohol combustion experiments. We conclude that the proposed method can consistently extract physiologically-relevant information from noisy calorimetry data and the aforesaid information can provide additional insights into the mechanism of metabolic fuel selection in humans.

60 - APPLIED LIFE SCIENCES↗
DOE OSTI2023

Surface Roughness Effects from Additive Manufacturing in High Efficiency Gas Turbine Combustion Systems

In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $ \$ $6B annually (at $ \$ $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year), and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE) missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.

42 ENGINEERING↗
DOE OSTI2023

Surface Roughness Effects from Additive Manufacturing in High Efficiency Gas Turbine Combustion Systems

In the past, clean combustion systems were characterized by high system development costs due to growing complexity and escalating manufacturing costs from conventional manufacturing processes. As a result, high efficiency concepts are difficult to design and more difficult to be cost-effectively manufactured. In recent years, with the introduction of additive manufacturing (AM) technologies, the rapid prototyping and mass production processes of clean combustion systems are promising to be significantly simplified with significant reduction in terms of engine manufacturing cost and engine energy cost. Compared with conventional manufacturing built parts, the AM process enabled a simpler design to be adopted for the nozzle, reducing the number of required braze and weld joints from twenty-five to just five. The resulting nozzle was 25% lighter and five times more durable and contributed to a 15% reduction in fuel burn in comparison with the previous model produced. Applying these improvements to a fleet of 5,000 turbofan engines at 150 kN thrust would result in fuel cost savings of $6B annually (at $5/gallon Jet-A fuel price, 700 gallon/hour fuel consumption rate, and 2,300 operational hours per year),and reduce CO2 emissions by more than 25 million tons per year. These advances support core Department of Energy (DOE)missions in energy efficiency, improving productivity, and environmental sustainability. Maximizing the benefit of these new capabilities will require high prediction capability of high speed turbulent flow with wall modeled Large Eddy Simulation (LES). GE Aviation maintains that advanced simulation technology and supercomputing is required in order to provide the appropriate boundary conditions to realize the maximum potential of AM and Ceramic Matrix Composite to reduce cooling flow, a first order penalty on the Brayton cycle. The algorithm developed using the ANSYS/Fluent software would provide the foundation for entirely new avenues of research and development with potential multi-billion dollar impact to the US economy, and significant reduction in carbon based emissions across the aerospace and power generation industries. The formulation of this iWLES (integral wall model for LES) is generic and allows to capture the changes in flow dynamics that have a significant impact on the wall bounded flow characteristics, such as swirler effective area, bulk swirl number, local pressure distribution, exit velocity profile, and turbulence kinetic energy profile. A periodic channel flow with rough flat plate is simulated using LES (Wall-Adapting Local Eddy-viscosity) model to verify the implementation of iWLES in the Fluent User Defined Function (UDF). As the flow fields are highly sensitive due to surface roughness of the wall bounded flows in the combustion systems, there is significant potential to conduct further LES studies focusing on the turbulence boundary layer interaction. Accurately capturing near wall physics will elucidate the impact of rough surfaces on combustor flow and aero-thermal interactions.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

Open-Air Manufacturing of Efficient Large-Area Perovskite Solar Cells to Meet Stability and Cost Targets

This SETO-funded project (DE-EE0009516) developed a fully open-air manufacturing pathway for perovskite solar cells and modules, eliminating vacuum-based processing steps while improving device stability. Open-air ultrasonic spray deposition, solution combustion synthesis, rapid thermal processing, and atmospheric plasma curing were developed and optimized for all functional device layers — perovskite absorber, hole transport layers (HTLs), electron transport layers (ETLs), transparent conducting oxides (TCOs), and rear electrodes — without reliance on vacuum. Sprayed organic ETLs preserved perovskite crystal structure and enabled power conversion efficiencies exceeding 20%, and open-air processed TCOs and rear electrodes achieved optoelectronic performance comparable to sputtered alternatives at substantially lower manufacturing cost. Device stability was assessed through accelerated aging protocols aligned with IEC and ISOS standards, combined with high-throughput optical diagnostics that identified key degradation mechanisms and antagonistic interactions among heat, humidity, and illumination stressors. A comprehensive technoeconomic analysis quantified the cost and throughput advantages of open-air manufacturing over conventional vacuum-based processes, identifying vacuum deposition as the dominant cost driver and demonstrating a clear pathway toward the $0.02/kWh target. The project produced five peer-reviewed journal publications, eleven conference presentations, two patents/applications, and five Ph.D. dissertations.

14 SOLAR ENERGY↗
DOE OSTI2020

FINAL TECHNICAL AND ECONOMIC FEASIBILITY STUDY ON THE APPLICATION OF A HEAT INTEGRATED POST-COMBUSTION CO2 CAPTURE SYSTEM WITH HITACHI ADVANCED SOLVENT INTO EXISTING COAL-FIRED POWER PLANT

This report contains the results of a techno-economic assessment (TEA) conducted of a heat integrated post-combustion CO2 capture process with Hitachi advanced solvent for retrofit into an existing coal-fired power plant (but treated as greenfield plant on cost analysis). The process has been developed by the University of Kentucky Center for Applied Energy (UK CAER). EPRI was chiefly responsible for this analysis, with significant input from WorleyParsons, Hitachi Power Systems America (Hitachi) and UK CAER. The project also involves the design, fabrication, installation, testing, and analyses of a slipstream facility located at L&GE-KU’s E.W. Brown Generating Station to demonstrate the UK CAER carbon capture system that could utilize heat integration with the main power plant. The design, start-up, and baseline of the pilot system was performed with a generic 30 wt% MEA solvent to obtain data for direct comparison with the DOE/NETL Reference Case followed by testing Hitachi’s proprietary solvent H3-1. In this techno-economic analysis, two cases utilizing the UK CAER process are compared, using different approach temperatures and solvent, against the DOE/NETL Reference Case (Case 10). The results are shown comparing the energy demand for post-combustion CO2 capture and the net higher heating value (HHV) efficiency of the power plant integrated with the post-combustion capture (PCC) plant. A levelized cost of electricity (LCOE) assessment was performed showing the costs of the options presented in the study. The key factors contributing to the reduction of LCOE were identified as CO2 partial pressure increase at the flue gas inlet, thermal integration of the process, and performance of the Hitachi H3-1 solvent. Recent UK CAER process pilot-scale testing data and process simualtion data showed that the packing heights of absorber and stripper columns were significantly oversized in the prelimanary TEA (Task 2 of this project) and thus updated in this final TEA for the H3-1 case only. In addition, the solvent make-up cost for H3-1 was updated based on lattest test results. Finally, a heat integration with the main power plant was applied in this final TEA to increase overall energy effciency for both the MEA and H3-1 cases. Additonal reductions in capital and operational costs are expected but not taken into account here. Shorter columns result in reduced pressure drops, smaller blower head and pump hydraulic head requirements. An increase in overall energy efficiency resuls in a decreased size of the power plant, the CCS and a reduced parasitic steam requirement to the CCS. The net efficiency of the UK CAER integrated PC power plant with CO2 capture changes from 26.2% for the Reference Case 10 plant in 2010 revised DOE/NETL baseline report to 27.6% for the MEA options considered, and 29.1% for the options utilizing the Hitachi advanced solvent. The UK CAER Process + Hitachi case also produces an extra 30.9 MW of generation compared to the UK CAER Process + MEA case and total 60.9 MW more than DOE Case 10. LCOE ($/MWh) values are $172.08/MWh for the MEA option and $157.65/MWh for the Hitachi H3-1 solvent cases considered in comparison to $189.59/MWh in January 2012 dollar for the Reference Case 10. The UK CAER CCS process with MEA case lowers energy consumption for CO2 capture to 1340 Btu/lb-CO2 captured as compared to 1540 Btu/lb-CO2 in the Reference Case 10. The UK CAER CCS process with H3-1 case further lowers energy consumption for CO2 capture to 973 Btu/lb-CO2 captured, for an advantage of 36.8% less energy consumption than Case 10. The study also shows 38.1% less heat rejection associated with the carbon capture system from 3398 MBtu/hr (Case 10) to 2104 MBtu/hr for the UK CAER + MEA system. Heat rejection is reduced to 2464 MBtu/hr in the UK CAER + H3-1 case, for a 27.5 % decrease compared to Case 10. Modeling outputs show that in the UK CAER process, the cooling water that is 2-5°C cooler than conventional cooling tower water can be achieved for ambient conditions common to the midwest and other regions. The results from the techno-economic assessment show that the proposed technology can be investigated further as a viable alternative to conventional CO2 capture technology. The evaluation also shows the effect of the critical parameters on the LCOE, with the main variables being the approach temperature and CO2 partial pressure increase at the flue gas inlet. A summary of the key advantages of the UK CAER Process + H3-1 case for LCOE and other economic factors compared to the DOE Case 10 is as follows: • A lower variable operating cost by $1.56/MWh ($1.08MWh less than the UK CAER Process + MEA Case), a 11.7% reduction compared to the DOE Case 10 • A lower COE by $25.32MWh ($13.94/MWh lower than the UK CAER Process + MEA Case), a 16.9% reduction compared to the DOE Case 10 • A lower LCOE by $31.94/MWh ($17.51/MWh lower than the UK CAER Process + MEA Case), a 16.9% reduction compared to the DOE Case 10 • A lower cost of CO2 captured by $18.65/tonne CO2 ($9.44/tonne CO2 lower than the UK CAER Process + MEA Case), a 30.4% reduction compared to the DOE Case 10 • A lower cost of CO2 avoided by $34.95/tonne CO2 ($18.53 tonne CO2 lower than the UK CAER Process + MEA Case), a 38.7% reduction compared to the DOE Case 10

Bhown, Abhoyjit S.↗
DOE OSTI2020

Cooperative Research and Development Agreement between National Energy Technology Laboratory and Birla Carbon U.S.A., Inc. [Abstract]

NETL researchers will be collaborating with Birla Carbon, U.S.A., Inc. (Birla Carbon) to leverage NETL's patented catalyst work on methane decomposition to commercialize an efficient and a cost-effective process for production of hydrogen and valuable carbon from natural gas. This catalytic methane decomposition is a promising technology, however, finding an appropriate catalyst to perform all the functions has been a challenge. NETL has developed a suitable catalyst for the process which has shown promising results. The heat required for this endothermic catalytic decomposition process is provided by combustion of a portion of the hydrogen. This process is cost effective, energy efficient, and environmentally friendly with minimal CO 2 mitigation costs. The objectives of the project include evaluation of the effect of feed gas composition on the performance, reduction of the catalyst production cost, and conduction of an in-depth large-scale cost analysis for a process suitable for applications at Birla Carbon.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Advanced nuclear reactor integration opportunities for the pulp and paper industry in the U.S. context: Technical perspectives, gap analysis, and preliminary technoeconomic assessment

Pulp and paper (P&P) manufacturing requires a large amount of low-pressure (LP) steam to digest, wash wood fibers and dry pulp into paper. Most of the LP steam is extracted from backpressure turbines that produce power from high-pressure (HP) steam. This HP steam is generated from burning wood waste material; bark is burned in hog boilers, and lignin is boiled in a black liquor recovery boiler. In a typical integrated P&P mill, 50–100% of the steam is produced from these sources, while additional steam is produced in natural gas (NG), fuel oil, or coal boilers. The other energy-intensive process in the plant is the chemical-recovery section (e.g., lime kiln), which requires high-temperature processing from NG combustion to retrieve and recirculate spent chemicals. This paper assesses the energy and heat demand and material balances of a typical generic kraft pulp mill, along with the nuclear heat, steam, and power integration opportunities to replace conventional combustion systems. The paper also addresses steam and electricity generation through a comprehensive technical and engineering gap analysis of five different nuclear-integration opportunities and their process economics, thus enabling the lignin and bark to be further processed into biobased chemicals or fuels, as well as the potential to reduce overall emissions from kraft pulping. Preliminary findings have shown that the P&P industry could achieve technological benefits by integrating their current manufacturing process with small modular nuclear reactors (SMNRs) on a national level. This research aims to set the path forward for a cleaner and more resilient P&P industry.

Advanced nuclear reactor↗