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All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Dilute Source CO 2 Capture: Management of Atmospheric Coal-Produced Legacy Emissions (Final Technical Report)

This report presents the scientific and technical findings by Carbon Engineering Ltd (CE) resulting from the DOE sponsored research and development project on Direct Air Capture (DAC) process. The work was performed by CE under the Award DE-FE0026861 from the US Department of Energy’s (DOE) National Energy Technology Laboratory (NETL). The work plan was centered on advancing the Recipient’s DAC technology, developing a better understanding of its performance and cost. The report outlines the results from two key activities that were performed under this award: Studying the performance characteristics of the DAC plant at both pilot and lab scale Techno-economic analysis (TEA) to study two implementations of CE’s proprietary DAC process: i) An early commercial DAC process that captures ~1 MT CO 2 /year of atmospheric CO 2 (Baseline case), and ii) A modified early commercial DAC process that captures 1 MT CO 2 /year of flue gas CO 2 downstream of a subcritical PC post-CCS power plant (Case 1 Option C). Within the first key activity of the project, significant operational improvements and learnings were realized, including for key equipment in the DAC process in addition to the overall system. Learnings included impact of equipment design on the capture, calcination and slaking processes, and operational parameter modifications for optimizing the pelletization process, along with the complex interactions and associated considerations of these on overall system performance. In parallel, benchtop scale equipment was successfully utilized to validate pilot scale data, such as, retention in the pellet reactor, and capture performance parameters of the air contactor. CE continues to conduct core research and development activities; the learnings from this DOE project will contribute to the design, testing and operation activities of CE’s fully integrated DAC validation plant, as well as the first commercial DAC plant. The second key activity incorporated the above learnings, as well as input from vendors and EPC experts, to produce the TEA report. More specifically, the TEA results were based on measured pilot plant performance data for all major unit operations, and on an energy and material balance for the process at commercial scale computed using an Aspen One® process simulation. The cost estimation methodology follows AACE International recommended practices; with an uncertainty range of -15%/+30%. Depending on financial assumptions, energy costs, and the specific choice of inputs and outputs, the levelized cost per ton CO 2 captured from the atmosphere for an early commercial plant for the baseline case ranges from 227 to 304 $/t-CO 2 . And, the levelized cost to capture 98% of the flue gas CO 2 emissions in a subcritical PC power plant (Case 1 Option C) through a combination of Cansolv carbon capture system and a modified DAC system was estimated to range from 109 to 160 $/MWh of net power generated. Process improvement opportunities identified during this work, in addition to cost reduction opportunities identified during the Value Engineering exercise associated with the Baseline case indicate that significant reductions in capital costs are available as CE scales up and proceeds through deployment of initial facilities.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2019

Capture of Uranium Particles By Filtration: Effects of Filter Material and Air Humidity

Filtration of airborne particles is a standard technique for removal of radiological particles from the effluent of a nuclear reactor. The effects of humidity on filter performance and uranium particles are however less understood. We have conducted experimental runs in the Environmental Experimental Chamber (EEC) located at ORNL to study the capture of uranyl fluoride particles in supports of NNSA missions. Two filter types, one of Minimum Efficiency Reporting Value (MERV)-9 and the other of MERV-10 American Society of Heating, Refrigerating and Air-Conditioning Engineering) ASHRAE rating, were used in the investigations under two humidity conditions [15% and 65% Relative Humidity (Rh)]. Both MERV9 and MERV10 filters failed to capture uranyl fluoride particles that were smaller than 100 nm. The penetration efficiencies for both filter types were very high, greater than 80%, for particles from 10 to 100 nm. As particles became larger and wetter, the capturing efficiencies of both types of filter improved. Slightly greater than 50% of particles from 1 to 10 μm still escaped the capture by the MERV9 filters. However, MERV10 filters were able to capture higher than 50% of particles in the size range of 1 to 2 μm indicating it is likely to meet ASHRAE requirements. Overall, the capture efficiency of a filter is highly dependent on uranyl fluoride particle size, which humidity plays a major role. These two filter types simply are unable to capture particles smaller than 1 μm. A filter that has a higher ASHRAE rating like the HEPA filter has to be used to capture sub-micron particles. Questions on how uranyl fluoride behave in a condition higher than 65% Rh remain, because the particles could deliquescent at the higher humidity condition. That would complete change the size, shape, and surface properties of the uranyl fluoride particles which could lead to completely different filter performance and filtration dynamics. Furthermore, how high humidity affects filters of all MERV ratings remain unclear. Other filter characteristics such as surface charge could also be affected by high humidity condition and need to be investigated.

42 ENGINEERING↗
DOE OSTI2024

Electrochemically Regenerated Solvent for Direct Air Capture with Co-generation of Hydrogen at Bench-scale

The goal of this final project report is to summarize the work conducted on project DE-FE0032125. In accordance with the Statement of Project Objectives (SOPO), the University of Kentucky Institute for Decarbonization and Energy Advancement (UK IDEA) (Recipient) developed an intensified process to capture CO 2 from ambient conditions (415 ppm CO 2 ). The process combines low-temperature solvent-aided membrane capture with electrochemically-mediated solvent regeneration to simultaneously capture ambient CO 2 while regenerating the solvent. The technology employs only two primary units, a regenerator and an absorber/contactor, while generating high purity hydrogen as a co-product that can be sold, used for energy storage, or cost-saving depolarization of the direct air capture (DAC) system during the grid peak demand, allowing for flexible operation. Since the technology is powered directly by DC electricity, it can seamlessly tie in with power sources like solar cells without the need for AC/DC converters, therefore allowing for a remote operation to further mitigate greenhouse gas generation toward deploying a negative carbon emissions technology that is completely decoupled from the carbon emissions from the power source for the DAC unit. The completion of the project results in significant progress toward the Department of Energy’s (DOE’s) goal of advancing lab and bench-scale DAC systems to a sufficient maturity level that can justify their continued scale-up through the verification testing of the electrochemically regenerated solvent system for DAC with co-generation of hydrogen at bench-scale. The technology addressed the complexities of incumbent DAC systems by demonstrating at ambient conditions (1) low gas-side pressure-drop facile CO 2 capture via an intensified membrane absorber with in-situ regenerated hydroxide as capture solvent, (2) multi-functional electrochemical regenerator for hydroxide regeneration, CO 2 concentration and hydrogen production at less than 3 V, and (3) stable DAC performance including >90% capture with air influent at the CFM scale. The data from this project enables the completion of Techno-Economic Analysis (TEA) and Life Cycle Assessment (LCA). TEA and LCA demonstrate the potential of the proposed electrochemical solvent-based process to be a viable DAC option. The analysis did not identify any obvious concern for the bench-scale operation and no apparent barriers to implementing UK IDEA carbon capture and solvent regeneration system at a larger scale.

08 HYDROGEN↗
DOE OSTI2026

Metallic Phase-Free Zn-Al Mixed Oxide Dual Function Materials Enable High Co Selectivity in Reactive Carbon Capture From Dilute Streams

Scaling conventional carbon capture and utilization methods can be limited by cost and permitting issues associated with transportation of captured CO2. Reactive carbon capture (RCC), in which a single solid-phase dual function material (DFM) is used to both capture CO2 from dilute streams (e.g., flue gas) and catalytically convert the bound species to products in a single unit operation, has the potential to reduce energy and capital costs by over 50% relative to separate capture and conversion. To incentivize adoption, high-value products such as methanol and CO should be targeted. Appealingly, CO can be produced at atmospheric pressure, thereby lowering overall H2 demand; however, high reaction temperatures (> 600 degrees C) and the use of oxidizable transition metals, such as Ni, are often necessary to drive the reverse water-gas shift (RWGS) during reactive desorption of the bound CO2. The sensitivity of these transition metals to oxygen undercuts their utility in point source RCC. To further derisk RCC, it is essential to develop metallic-phase free DFMs that are insensitive to residual oxygen in flue gas and can achieve selective reactive desorption to CO at moderate pressures (< 400 degrees C). To this end, we have developed K-modified Zn-Al mixed oxides (K/ZnAlOx) to convert captured CO2 to CO with > 97% selectivity and yields up to 53% of captured CO2 at 400 degrees C. Complementary in situ spectroscopy studies revealed the role of K-modification in improving RCC performance of unmodified ZnAlOx. The top performing DFM was also subjected to extended RCC cycling with oxygen co-fed with CO2 during the capture test to assess durability under simulated flue gas.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

The Role of Low-Carbon Fuels and Carbon Capture in Decarbonizing the U.S. Clinker Manufacturing for Cement Production: CO2 Emissions Reduction Potentials

Low-carbon fuels, feedstocks, and energy sources can play a vital role in the decarbonization of clinker production in cement manufacturing. Fuel switching with renewable natural gas, green hydrogen, and biomass can provide a low-carbon energy source for the high-temperature process heat during the pyroprocessing steps of clinker production. However, up to 60% of CO2 emissions from clinker production are attributable to process-related CO2 emissions, which will need the simultaneous implementation of other decarbonization technologies, such as carbon capture. To evaluate the potential of fuel switching and carbon capture technologies in decarbonizing the cement industry, a study of the facility-level CO2 emissions is necessary. This study evaluates the potential for using a single low-carbon fuel as an energy source in clinker production for cement manufacturing compared to conventional clinker production (which uses a range of fuel mixes). In addition, conventional carbon capture (operated with natural gas-based steam for solvent regeneration) and electrified carbon capture configurations were designed and assessed for net-zero emission targets. Carbon emissions reductions with and without biogenic emissions credits were analyzed to ascertain their impact on the overall carbon accounting. Results show that carbon emissions intensity of cement can vary from 571 to 784 kgCO2eq/metric ton of cement without carbon capture and from 166.33 to 438.66 kgCO2eq/metric ton of cement with carbon capture. We find that when biogenic carbon credits are considered, cement production with a sustainably grown biomass as fuel source coupled with conventional carbon capture can lead to a net-negative emission cement (−271 kgCO2eq/metric ton of cement), outperforming an electrified capture design (35 kgCO2eq/metric ton of cement). The carbon accounting for the Scope 1, 2, and biogenic emissions conducted in this study is aimed at helping researchers and industry partners in the cement and concrete sector make an informed decision on the choice of fuel and decarbonization strategy to adopt.

42 ENGINEERING↗
NASA NTRS1968

Elliptic Capture Orbits for Missions to the Near Planets

Elliptic capture orbits around Mars and Venus have often been considered as means for reducing arrival and departure energy requirements for two-way missions. It had also generally been feared that the energy savings obtained by capturing a spacecraft into a highly elliptical orbit (rather than a near circular orbit of the same periapsis) would largely be offset by the penalties incurred in aligning the semi-major axis of the ellipse in such a way as to obtain the proper orientation of the departure hyperbola. This paper, presents the results of an analysis which takes into consideration the penalties arising from the requirement to match the orientation of the elliptical orbit with the asymptote of the departure hyperbola. The scientific aspects of elliptical orbits around the target planet are discussed, and it is shown that such orbits exhibit characteristics which may be considered advantageous or disadvantageous depending on the purpose of the mission. Alignment of ' the semi-major axis of the capture, ellipse relative to the, asymptote of the escape hyperbola was found not to be a critical requirement since the kinetic energy remains high over a substantial portion of the elliptical capture orbit. This 'means that the escape stage can operate efficiently even when ignited at some angle from the true periapsis point. Considerable freedom in choosing this angle is available at little propulsive cost. The resulting latitude in the choice of angles between arrival and escape asymptotes makes it possible to consider a wide variety of interplanetary transfers and planetary staytimes without the need for separate propulsive maneuvers to realign the capture ellipse before departure., Special consideration has also been g1ven to plane change maneuvers around the planet. These may be required for reasons of orbit dynamics or scientific experimentation and are not uniquely tied to elliptical captures. The sensitivity of the mass of the excursion module to the eccentricity of the capture orbit is discussed and mass-penalty diagrams are presented. It is shown that these penalties do not materially offset the large gains obtained through the use of the elliptical capture mode.

Casal, Federico G.↗
NASA NTRS1993

Preliminary system design of a Three Arm Capture Mechanism (TACM) flight demonstration article

The overall objective of the Three Arm Capture Mechanism (TACM) is to serve as a demonstration of capability for capture of objects in space. These objects could be satellites, expended boosters, pieces of debris, etc.; anything of significant size. With this capability we can significantly diminish the danger of major collisions of debris with valuable space assets and with each other, which would otherwise produce many smaller, high velocity pieces of debris which also become concerns. The captured objects would be jettisoned into the atmosphere, relocated in 'parking' orbits, or recovered for disposition or refurbishment. The dollar value of satellites launched into space continues to grow along with the cost of insurance; having a capture capability takes a positive step towards diminishing this added cost. The effort covered is a planning step towards a flight demonstration of the satellite capture capability. Based on the requirement to capture a communication class satellite, its associated booster, or both, a preliminary system definition of a retrieval kit is defined. The objective of the flight demonstration is to demonstrate the techniques proposed to perform the mission and to obtain data on technical issues requiring an in situ space environment. The former especially includes issues such as automated image recognition techniques and control strategies that enable an unmanned vehicle to rendezvous and capture a satellite, contact dynamics between the two bodies, and the flight segment level of automation required to support the mission. A development plan for the operational retrieval capability includes analysis work, computer and ground test simulations, and finally a flight demonstration. A concept to perform a selected mission capturing a precessing communications satellite is described. Further development efforts using analytical tools and laboratory facilities are required prior to reaching the point at which a full commitment to the flight demonstration design can be made.

Schaefer, Otto↗
NASA NTRS2004

Stacking Multiple Ion Captures in The High Performance Antiproton Trap (HiPAT)

The High performance Antiproton Trap (HiPAT) research project was initiated by the Marshall Space Flight Center's propulsion Research Center to examining the fundamental behavior of low energy antiprotons. Stored antiproton would ultimately be used for experimental demonstration of basic propulsive concepts. Matter-antimatter annihilation produces approximately 10(exp 8) MJ/g nearly 10 orders of magnitude more energy per unit mass than chemical based combustion, hence NASA's interest. To achieve containment, HiPAT utilizes a type of electromagnetic bottle know as a Penning trap positioned within an ultrahigh vacuum test section. Recently, the HiPAT hardware configuration has been enhanced to facilitate the capture of multiple normal matter ion burst. This endeavor is often referred to as "stacking" and used to increasing the number of captured particles. A prior normal matter experimental effort, successfully demonstrated the effectiveness of single burst capture. The stacking process is accomplished by manipulating the electric field generated by the confinement electrodes i.e. adjusting the well potential depth. These potential well values are initially configured to maximize the quantity of captured ions per burst; shallow wells with a depth of 100 volt or less (referenced to the incoming ion beam energy) are typically selected. Once captured, a cooling interval is required to reduce the energy of trapped particles below the lower extent of the "trap door" (or leading electrode) ion emitting potential. This is necessary such that a new burst of hot ions can be introduced while preventing those already inside from escaping. The cooling time is driven by a combination of mechanisms such as synchrotron radiation, background gas scattering, and resistive damping in a time scale on the order of minutes. A potential for reducing this hold period is to actively manipulate the electric field shape, using the power supply control system, to produce a deeper potential well. The trapped ions ride down the morphing well to a lower potential energy, leaving margin to once again cycle the "trap door" capturing a new burst while limiting the number of escaping ions. By adjusting the magnitude and timing of the potential well shaping, subsequent shots from the ion beam can be captured on a time scale shorter then that dictated by the standard inject, capture and cool technique. Currently, experimental tests are under way examining the functionally of this system for stacking multiple ions bursts within the HiPAT system.

Martin, James J.↗
NASA NTRS2015

Flexible Electrostatic Technology for Capture and Handling Project

To NASA unfunded & planned missions: This new capability to sense proximity, flexibly align to, and attractively grip and capture practically any object in space without any pre-designed physical features or added sensors or actuators will enable or enhance many of MSFC's strategic emphasis areas in space transportation, and space systems such as: 1. A Flexible Electrostatic gripper can enable the capture, gripping and releasing of an extraterrestrial sample of different minerals or a sample canister (metallic or composite) without requiring a handle or grapple fixture.(B) 2. Flexible self-aligning in-space capture/soft docking or berthing of ISS resupply vehicles, pressurized modules, or nodes for in-space assembly and shielding, radiator, and solar Array deployment for space habitats (C) 3. The flexible electrostatic gripper when combined with a simple steerable extendible boom can grip, position, and release objects of various shapes and materials with low mass and power without any prior handles or physical accommodations or surface contamination for ISS experiment experiments and in-situ repair.(F)(G) 4. The Dexterous Docking concept previously proposed to allow simple commercial resupply ships to station-keep and capture either ISS or an Exploration vehicle for supply or fluid transfer lacked a self-sensing, compliant, soft capture gripper like FETCH that could retract and attach to a CBM. (I) 5. To enable a soft capture and de-orbit of a piece of orbital debris will require self-aligning gripping and holding an object wherever possible (thermal coverings or shields of various materials, radiators, solar arrays, antenna dishes) with little or no residual power while adding either drag or active low level thrust.(K) 6. With the scalability of the FETCH technology, small satellites can be captured and handled or can incorporate FETCH gripper to dock to and handle other small vehicles and larger objects for de-orbiting or mitigating Orbital debris (L) 7. Many of previous MSFC and NASA proposals or concepts can now be realized or simplified by the development of the this initial and future FETCH grippers including commercial resupply, Exploration vehicle assembly, Satellite servicing, and orbital debris removal since a major part of these missions is to align to and capture some handle. Completed Project (2013 - 2014) Flexible Electrostatic Technology for Capture & Handling Project Center Innovation Fund: MSFC CIF Program | Space Technology Mission Directorate (STMD) For more information visit techport.nasa.gov Some NASA technology projects are smaller (for example SBIR/STTR, NIAC and Center Innovation Fund), and will have less content than other, larger projects. Newly created projects may not sensors or injection of permanent adhesives. With gripping forces estimated between 0.5 and 2.5 pounds per square inch or 70-300 lb./sq. ft. of surface contact, the FETCH can turn-on and turn-off rapidly and repeatedly to enable sample handling, soft docking, in-space assembly, and precision relocation for accurate anchor adhesion.

Keys, Andrew↗
NASA NTRS2014

Stardust Interstellar Preliminary Examination IX: High-Speed Interstellar Dust Analog Capture in Stardust Flight-Spare Aerogel

The NASA Stardust mission used silica aerogel slabs to slowly decelerate and capture impinging cosmic dust particles for return to Earth. During this process, impact tracks are generated along the trajectory of the particle into the aerogel. It is believed that the morphology and dimensions of these tracks, together with the state of captured grains at track termini, may be linked to the size, velocity, and density of the impacting cosmic dust grain. Here, we present the results of laboratory hypervelocity impact experiments, during which cosmic dust analog particles (diameters of between 0.2 and 0.4 lm), composed of olivine, orthopyroxene, or an organic polymer, were accelerated onto Stardust flight spare low-density (approximately 0.01 g/cu cm) silica aerogel. The impact velocities (3-21 km/s) were chosen to simulate the range of velocities expected during Stardust's interstellar dust (ISD) collection phases. Track lengths and widths, together with the success of particle capture, are analyzed as functions of impact velocity and particle composition, density, and size. Captured terminal particles from low-density organic projectiles become undetectable at lower velocities than those from similarly sized, denser mineral particles, which are still detectable (although substantially altered by the impact process) at 15 km/s. The survival of these terminal particles, together with the track dimensions obtained during low impact speed capture of small grains in the laboratory, indicates that two of the three best Stardust candidate extraterrestrial grains were actually captured at speeds much lower than predicted. Track length and diameters are, in general, more sensitive to impact velocities than previously expected, which makes tracks of particles with diameters of 0.4 lm and below hard to identify at low capture speeds (<10 km/s). Therefore, although captured intact, the majority of the interstellar dust grains returned to Earth by Stardust remain to be found.

Stardust↗
DOE OSTI2025

Reactive CO 2 capture and mineralization of magnesium hydroxide to produce hydromagnesite with inherent solvent regeneration

Valorization of multiple low value streams including CO 2 emissions and magnesium-hydroxide bearing mine tailings to produce magnesium carbonate through reactive CO 2 capture and mineralization provides a less explored opportunity to manage several gigatons of CO 2 emissions. To resolve the feasibility of converting magnesium hydroxide to magnesium carbonate through reactive CO 2 capture and mineralization, CO 2 capture solvents such as sodium glycinate are harnessed to capture CO 2 and react directly with Mg(OH) 2 to produce hydromagnesite (Mg 5 [(CO 3 )4(OH) 2 ]·4H 2 O). This approach eliminates the energy-intensive step of producing high purity CO 2 associated with regenerating the solvent, and redissolving CO 2 to produce magnesium carbonate. Interestingly, while temperatures below 50 °C facilitate CO 2 capture, the mineralization kinetics are slow. However, at higher temperatures, accelerated carbon mineralization is favored by the faster kinetics of Mg(OH) 2 dissolution and precipitation of magnesium carbonate. Reacting Mg(OH) 2 at 90 °C with 15 wt% solids in the presence of 2.5 M sodium glycinate after 3 hours under well-stirred conditions results in an extent of carbon mineralization of 75.5%. The theoretical maximum extent of carbon mineralization when hydromagnesite is formed is 80%. Pre-loading CO 2 on the solvent is also an effective approach to ensure that sufficient CO2 is available for reactive CO 2 capture and mineralization, particularly when dilute CO 2 and N 2 mixtures are used. Higher extents of carbon mineralization are associated with an increase in the particle size and a reduction in the cumulative pore volume. These insights unlock the feasibility of harnessing reactive CO 2 capture and mineralization as a pathway to convert magnesium-hydroxide bearing resources into industrially relevant magnesium carbonate products.

Reactive CO2↗
DOE OSTI2019

Cryogenic Carbon Capture Development (Final Report)

This project extends and leverages the work completed under funding from ARPA-E and other sources by exploring aspects of the Cryogenic Carbon Capture™ (CCC) process and issues discovered during those projects, but that were not within the scope or budget of previous projects or that became apparent during field tests. Our successful completion of the tasks outlined in this project has increased the reliability, efficiency, and scalability of the CCC process and we are better prepared for pilot-scale testing. The first phase of this project improved key areas of the process through iterative design and experiment, culminating with recommendations for improvements to the existing skid-scale system developed under non-federal funding. The second phase of this project implemented the improved unit operations into the Cryogenic Carbon Capture External Cooling Loop (CCC ECL™) skid and field tests the improved system at a coal-fired power plant. The specific areas of work in this project are: Budget Period 1: 1) Selection of the most energy-efficient drying system for ambient-pressure flue gas. Sustainable Energy Solutions, LLC (SES) has successfully demonstrated a dryer that removes bulk water using a low-temperature brine to remove about 99% of the water followed by a mol sieve 3A desiccant dryer to remove the remaining 1% water; 2) Selection and demonstration of efficient solution to fouling due to dissolved CO 2 . SES has tested several commercial heat exchangers that purport to be able to handle fouling issues similar to those experienced in the contact liquid chiller. Replicated tests using the CCC ECL™ skid and dimpled brazed plate heat exchangers demonstrate that quick throttling of refrigerant combined with a burst of clean gas mitigate the fouling caused by CO 2 solubility in contact liquid with only minor increases in parasitic load. SES models indicate that parasitic load would increase by approximately 0.0125 GJ/tonne, an order of magnitude less than what was determined to be the maximum allowable additional parasitic load caused by this system; 3) Selection and demonstration of efficient and scalable solid–liquid separation system. The screw press technology met or exceeded the 70% solids loading benchmark during several test runs exceeding 24 hours on the CCC ECL™ skid. The average solids loading during the entire 50-hour run was 67%. The energy demand for this system is less than 0.1 GJ e /tonne of CO 2 processed; 4) Optimize design and demonstration of patented desublimating heat exchangers. We designed and built a hybrid spray tower that was tested over many hundreds of hours and a 50-hour continuous test run was completed capturing over 0.5 tonne CO 2 /day at >90% capture; (5) Plan for safe dilution of oxygen-depleted, cleaned flue-gas stream. The AERSCREEN simulator developed by the EPA modeled the dispersion of oxygen-depleted flue gas from the CCC process at a commercial plant. The results indicate that this plan effectively mitigates the flue gas hazards; (6) Simulation of and experimental work related to multi-pollutant capture. SES programmed an upgrade to its solid/vapor/liquid equilibrium (SVLE) algorithm. This enables simultaneous modeling of multiple pollutants (i.e., CO 2 , SO x , NO x , Hg, HCl). Budget Period 2; (7) Modify the CCC ECL™ skid for field testing and complete shakedown testing. The plans for modifying the CCC ECL™ skid were finalized and put into place. Shakedown testing of the updated CCC ECL™ skid occurred at SES using closed-loop mode (i.e., using a synthetic flue gas consisting of only N 2 and CO 2 ) and at the Hunter Power Plant using flue gas from the coal-fired boiler. Shakedown testing took longer than expected due to delays in receiving equipment and unexpected equipment performance in the field; (8) Operate the CCC ECL™ skid in the field. Longer testing of the CCC ECL™ skid occurred at the Hunter Power Plant. Multiple tests exceeding 35 hours were completed, with a total of over 600 hours of CO 2 capture completed using flue gas at the Hunter Power Plant with an average CO 2 capture rate of over 91% during those hours. Extensive notes and documentation were acquired informing improved methods for controls, startup, operation, and shut down; (9) Determine figures of merit and quantify process improvement. SES defined figures of merit for unit operation performance and overall CCC ECL™ process performance. All figures of merit were achieved or surpassed, except for 500 continuous hours of demonstration at the Hunter Power Plant; (10) Complete an Environmental Health and Safety Risk assessment by a third party. Tri-State completed an Environmental Health and Safety Risk assessment; (11) Update techno-economic analysis with third-party validation. The techno-economic analysis has been completed. It confirms the potential large reduction in energy and cost of the CCC process compared with leading alternatives and that the estimates and estimation techniques are reliable.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Bench scale development of a hybrid membrane-absorption CO 2 capture process (Final Report)

This final technical report describes work conducted for the Department of Energy (DOE) on the development of a bench-scale hybrid membrane-absorption carbon dioxide (CO 2 ) capture system for coal-fired power plant applications (Cooperative Agreement number DE-FE0013118). The work was conducted by Membrane Technology and Research, Inc. (MTR) with major support from the University of Texas at Austin (UT Austin) from April 1, 2013 through September 30, 2018. The overall goal of this project was to evaluate two variations of a hybrid membrane-absorption capture system combining the MTR air-swept PolarisTM membrane technology, which enriches flue gas to ~20% CO 2 , with UT Austin’s absorption-based advanced flash stripper (AFS) using piperazine (PZ), to determine the superior hybrid variant and to assess the potential of hybrid capture systems to achieve a lower cost-of-capture, compared to NETL’s reference amine-based capture plant. This project included the evaluation, development and testing of a hybrid membrane-absorption CO 2 capture system for coal-fired power plant applications using the MTR high-gas-flow, low-pressure-drop membrane contactor. The ability of the membrane contactor to enrich coal-fired flue gas from its normal content of ~13% CO 2 into a smaller volume of gas containing 20-25% CO 2 – with minimal energy input – could reduce the cost of the final concentration process, regardless of whether it is absorption, adsorption, cryogenic, or membrane-based. In this project, we are evaluating the feasibility of a hybrid system combining the MTR sweep membrane technology with the UT Austin piperazine-based advanced flash stripper (PZAS) capture system.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2026

Transformational Sorbent System for Post-Combustion Carbon Capture (Final Report)

As part of this DOE Contract (Transformational Sorbent System for Post-Combustion Carbon Capture, DE-FE0031734),TDA Research Inc. developed a transformational sorbent system for post combustion CO 2 capture process that captures more than 95% of CO 2 emissions from a coal fired power plant, recovering CO 2 at 95% purity with a cost of CO 2 capture significantly lower than with amine-based system (~$30 per tonne (MT) of CO 2 captured). TDA’s transformational sorbent system uses a novel, highly stable, high-capacity metal organic framework (MOF) based CO 2 sorbent in a new vacuum/concentration swing adsorption (VCSA) process that allows us to use high efficiency vacuum pumps with a low auxiliary load. A pulverized coal fired power plant equipped with TDA’s transformational sorbent system for post combustion CO 2 capture is expected to efficiently produce electricity with a low Cost of Electricity (COE) and capture greater than 95% of the CO 2 from the power plant exhaust.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Investigating Combinations of Alkali Metal Oxides and Hydrogenation Catalysts for Reactive Capture of CO2 to Useful C1 Products

As the world endures environmental crises associated with climate change and the rise of atmospheric CO2 concentrations from anthropogenic CO2 emission, carbon capture and utilization (CCU) technologies are increasingly necessary. Reactive carbon capture (RCC) technologies, in which capture and conversion of CO2 occur in a single reactor, are more energetically and economically attractive by avoiding the need to purify, compress, and transport the captured CO2. To this end, dual function materials (DFMs) - composed of sorbents and catalysts co-dispersed on the same high surface area carrier - have been developed. The sorbent component allows for selective capture of CO2 from a gas stream and the catalyst component subsequently performs the in-situ conversion of the adsorbed CO2 upon introduction of a reactive gas (typically H2). The end product of the most established DFM, comprised of Ru and/or Ni with an alkaline sorbent, is methane via the CO2 methanation reaction. While renewable methane would be an excellent transition fuel, fossil methane is inexpensive (averaging $2.57/MMBTU in pre-pandemic 2019) and the economics of renewable methane utilization are noncompetitive. This requires the design and investigation of DFMs that enable CO2 capture and conversion to more valuable and more useful C1 products like CO or methanol (average price of methanol was $20.61/MMBTU in pre-pandemic 2019). These products can then be further upgraded to high energy density synthetic fuels, and related carbonaceous products, for more sustainable alternatives in industries that are difficult to decarbonize, specifically heavy duty vehicles and aviation. Herein, we report various sorbent + catalyst combinations to achieve the production of useful C1 products through reactive capture of CO2.

carbon capture↗
DOE OSTI2024

Insights from FEED studies for retrofitting existing fossil power plants with carbon capture technology

Recent United States Department of Energy (DOE) sponsored front-end engineering design (FEED) studies for retrofitting existing fossil-fueled power plants with state-of-the-art carbon capture technology contain previously overlooked real-world design considerations for near-term deployment of carbon capture. Insights from examining seven recently published FEED study reports are summarized in this paper. This includes a discussion of the design, performance, and cost implications associated with (1) location-specific considerations such as water availability, land availability, and accessibility; (2) host-plant-specific factors such as flue gas specifications, allowable degree of integration between the capture system and host plant, and operational mode; and (3) miscellaneous factors such as market conditions, permitting requirements, and business case incentives. In conclusion, this manuscript highlights (1) water availability as a key design and cost driver, with host plant steam extraction increasing capture system cooling water availability, (2) modularization and constructability impacts on the number of capture trains, (3) the impacts of host plant operational mode and capacity factor on the business case for installing capture, and (4) the merit of continued research, development, and demonstration efforts addressing steam extraction, host plant tie-in at the stack, solvent reclamation and air emissions control.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Biogenic carbon capture at pulp mills via sodium spiking and oxy-fuel calcination

Over 13 million metric tons of biogenic carbon dioxide (CO 2 ) are mineralized yearly in United States (US) pulp mill recovery boilers as molten sodium carbonate. The mineralized CO 2 is released downstream in the rotary lime kiln where it can be captured at a relatively low cost for permanent sequestration. The use of biocarbon and bioenergy at pulp mills enables the possibility for atmospheric carbon removal when biogenic CO2 is captured and sequestered. We demonstrate the feasibility of capturing biogenic CO 2 via sodium spiking coupled with oxy-fuel calcination in the rotary lime kiln at existing kraft pulp mills. Sodium (Na) spiking elevates the Na ion loading in the kraft chemical looping process by replacing chlorine-based bleaching with a highly alkaline bleaching sequence. Chemical pulping processes are modeled and simulated to understand the technical limits of implementing sodium spiking in existing pulp mills. Each 1 % of sodium added to the bleaching operations increases the rate of CO 2 mineralization by 4 %, and the maximum increase in sodium content in the kraft process is 9 %. Without sodium spiking, estimated CO 2 capture costs are $131 and $107/mt CO 2 for air and oxy-fuel combustion, respectively. With the implementation of sodium spiking, the cost of CO 2 captured decreases by 27 % and 31 %, showing costs of $96 and $74/mt CO 2 for air and oxy-fuel combustion, respectively. Oxy-fuel combustion reduces the costs of CO 2 capture compared to air combustion, but merged deployment with sodium spiking seems to be the most cost-effective pathway to integrate carbon capture.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2019

Post Combustion Carbon Capture using Polyethylenimine (PEI) functionalized Titanate Nanotubes

In order to overcome the drawbacks of solvent amines such as, MEA and DEA, scientists and engineers are looking for some great alternatives for CO 2 capture. Different PEIs have widely been investigated to functionalize different solid support materials used for CO 2 capture in recent 15 years. This report provides an overview of the recent advances of such PEI-functionalized adsorbents, in which PEI are loaded on different silica materials, nanotubes, membranes and other materials such as, mesoporous alumina, clay, activated carbon, fly ash, mesoporous carbon, mesoporous sponge-like TUD-1, metal organic frameworks, nanofibrillated cellulose, porous chitosan bead, resin, glass fiber, zeolites, etc. Among them, PEI-funtionalized PTNTs using titanate nano tubes is selected, and various PEIfunctionalized PTNTs were fabricated for CO 2 capture from the flue gas in fossil energy power generation. To investigate the effects of synthesis conditions on the CO 2 capture capacities, two different temperatures (130 and 140°C) and three times (1, 3 and 5 days) were used in the hydrothermal process. Material characterization with TEM and XRD confirmed that PTNTs were successfully synthesized in all the cases, and PEI was loaded onto the PTNTs with the wet impregnation process. The nano-tubular size, porosity and surface areas of the PTNTs varied with the synthesis conditions, and the PTNTs synthesized at 130°C possess the bigger pore size than those synthesized at 140°C. The CO 2 capture experiment using simulated flue gas under wet condition showed that overall highest capture capacity of 78-79 mg g-1 was achieved with the adsorbents synthesized at 130°C and with the synthesis time of 3 or 5 days. Besides, the CFD simulation model is developed by using MFIX for the PEI-PTNTs solid sorbents suggested in our carbon capture experiments. For this, the simulation model is calibrated through adjusting the concentration of active amines sites based on the comparison between simulation and experiment. After that, the simulation model of the adjusted titan-based solid sorbent is used for checking the performance of the solid sorbents and finding the optimized flow rate in the reactor model developed by NETL.

36 MATERIALS SCIENCE↗