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At least 307 records · Page 17

Simulation, Challenge Testing and Validation of Solutions for Residential and Commercial Occupancy Sensing/Counting and CO2 Sensing (Final Report)

Carbon dioxide sensors used for monitoring and control applications in buildings are known to be sensitive to long term drift and can be affected by variations in temperature, humidity, other gas interferents, pressure and other factors that cannot be corrected through the typical auto-calibration methods often embedded in the sensor electronics. This investigation was part of the Category D defined in the ARPA-E Saving Energy Nationwide in Structures With Occupancy Recognition (SENSOR) Financial Assistance Funding Opportunity Announcement No. DE-FOA-0001737, FFDA No. 81.135, January 18, 2017. The FOA defined target criteria for the evaluation of the Category C commercial CO2 sensors selected for review and development through the ARPA-E SENSOR program and charged the Iowa State Category D team with developing an evaluation methodology for Category C sensors in accordance with these criteria. As part of the work, the Iowa State team chose to engage the standards community in the development of the evaluation methodology. Standard development work in the D22.05 Indoor Air and D22.03 Ambient Atmospheres and Source Emissions subcommittees of ASTM International Committee D22 on Air Quality on the evaluation of low cost sensors and provision of guidance for using indoor carbon dioxide concentrations to evaluate indoor air quality and ventilation is of particular relevance to the Category D efforts. To date, three draft standards with specific input by the Iowa State Category D team have passed the subcommittee balloting stage and are being balloted in December 2022 and January 2023 in the main D22 committee. In addition to the aforementioned standards to which the PI was a contributing author, intellectual property developed in this project pertaining to “An Automated System for Evaluation of the Long Term Performance of Carbon Dioxide Sensors” and “An Automated Ground Truth System for Real-Time Reliability Assessment, Capture of Control Decisions and Energy Savings Measurements for Occupancy Recognition Systems and Other Applications” are the other major deliverables of the project. These standards and the developed intellectual property are expected to benefit the public in a number of ways stemming from their provision of means to benchmark the performance of carbon dioxide and other sensor systems. In particular, there is high interest in techniques to demonstrate the performance of low-cost carbon dioxide sensors which can be used for typical HVAC applications (e.g., demand controlled ventilation, outdoor and indoor air monitoring, estimation of occupancy, etc.).

42 ENGINEERING↗

Hybrid-energy approach enabled by heat storage and oxy-combustion to generate electricity with near-zero or negative CO 2 emissions

We assess a hybrid-energy approach that modifies a steam-turbine power plant to use renewable energy sources (electricity, plus options for geothermal and solar heat), plus fossil fuel (natural gas and coal) and/or waste biomass (e.g., Douglas fir woodchips). Heat storage allows heat to be created during periods of excess energy supply and for that heat to be converted to electricity when demanded. Excess electricity, such as from variable renewable energy (VRE), is used to generate oxygen for oxy-combustion furnaces that create very-hot, high-purity CO 2 that heats granular rock beds in insulated vessels. Cool CO 2 leaving the beds is dried, sent to compressors powered by excess VRE electricity, before being sent by pipeline to geologic CO 2 storage. Very-hot CO 2 transfers high-grade heat from storage to the power plant in a closed loop that returns medium-grade heat back to storage, allowing low- and medium-grade renewable-heat sources to be stacked beneath combustion heat, with all heat sources being converted to electricity at the same (high) thermal efficiency. Reliable, on-demand power may be generated with near-zero CO 2 emissions with fossil fuel and with negative CO 2 emissions with waste biomass. Our analyses show that with fossil fuel, up to 35% of gross power can be derived from renewable sources, while for waste biomass, it can be entirely derived from renewable sources. Because our approach has the potential to ensure that grids have a continuous supply of clean energy and because electricity is only generated once, when demanded, it could serve as an efficient alternative to bulk energy storage.

30 DIRECT ENERGY CONVERSION↗

Getting allometry right at the Oak Ridge free‐air CO 2 enrichment experiment: Old problems and new opportunities for global change experiments

Societal Impact Statement Free‐air CO 2 enrichment (FACE) experiments provide essential data on forest responses to increasing atmospheric CO 2 for evaluations of climate change impacts on humanity. Understanding and reducing the uncertainty in the experimental results is critical to ensure scientific and public confidence in the models and policy initiatives that derive therefrom. One source of uncertainty is the estimation of tree biomass using mathematical relationships between biomass and easily obtained and non‐destructive measurements (allometry). We evaluated the robustness of the allometric relationships established at the beginning of a FACE experiment and discuss the challenges and opportunities for the new generation of FACE experiments. Summary Long‐term field experiments to elucidate forest responses to rising atmospheric CO 2 concentration require allometric equations to estimate tree biomass from non‐destructive measurements of tree size. We analyzed whether the allometric equations established at the beginning of a free‐air CO 2 enrichment (FACE) experiment in a Liquidambar styraciflua plantation were still valid at the end of the 12 year experiment. Aboveground woody biomass was initially predicted by an equation that included bole diameter, taper, and height, assuming that including taper and height as predictors would accommodate changes in tree structure that might occur over time and in response to elevated CO 2 . At the conclusion of the FACE experiment, we harvested 23 trees, measured dimensions and dry mass of boles and branches, and extracted and measured the woody root mass of 10 trees. Although 10 of the harvested trees were larger than the trees used to establish the allometric relationship, measured aboveground woody biomass was well predicted by the original allometry. The initial linear equation between bole basal area and woody root biomass underestimated final root biomass by 28%, but root biomass was just 21% of total wood mass, and errors in aboveground and belowground estimates were offsetting. The allometry established at the beginning of the experiment provided valid predictions of tree biomass throughout the experiment. New allometric approaches using terrestrial laser scanning should reduce an important source of uncertainty in decade‐long forest experiments and in assessments of centuries‐long forest biomass accretion used in evaluating carbon offsets and climate mitigation.

59 BASIC BIOLOGICAL SCIENCES↗

Semi-Analytical Leakage Solutions for Aquifers (SALSA) v1

SALSA is a semi-analytical modeling tool that can provide assessments of pressure perturbations and brine leakage because of fluid injection and extraction activities in sedimentary basins. Sedimentary basins typically contain vertical sequences of near-horizontal aquifers separated by less-permeable aquitards. In the context of geologic carbon sequestration (GCS), while aquitards are relied upon to contain injected buoyant free-phase CO2 and limit inter-aquifer brine flow, the large number of leaky wells (e.g., unused/unsuccessful exploration wells, or improperly plugged water or oil/gas wells) that are present in sedimentary basins creates concerns for potential leakage and groundwater contamination. The mathematical theory and solution method included in SALSA is presented in our recent manuscript under review. SALSA is the first to account for the coupled leakage through aquitards and leaky wells, with geologic pressurization sources. SALSA based on semi-analytical solutions can be computationally very efficient for problems containing many injection and leaky wells in multilayered sedimentary systems, compared to any numerical simulation software requiring local mesh refinement around each well to obtain accurate results. Therefore, stakeholders (e.g., regulators, operators) for site screening, injection and post-injection pressure behavior and assessing leakage risks can use SALSA as a fast-predictive tool in GCS applications in multilayered aquifer systems.

Cihan, Abdullah↗

Highly Efficient Regeneration Module for Carbon Capture Systems in NGCC Applications

The objective of this project is to design, fabricate, and test a highly efficient regeneration module capable of providing an ultra-lean absorption solution that is required for capturing CO 2 from dilute sources at 95% or better efficiency. By integrating this advanced regenerator module with SRI International’s Mixed Salt Process (MSP) absorption modules, SRI expects to demonstrate significant progress toward a reduction in cost of capture versus the DOE reference natural gas combined cycle (NGCC) plant with carbon capture. SRI designed, built, and tested an advanced stripper to enhance the performance of SRI’s MSP for CO 2 capture – a transformational ammonia-based solvent technology – for natural gas (NG) power sources. The testing of the advanced stripper for MSP was conducted at an SRI site using a simulated flue gas stream equivalent to about 10 kWe. The research work included modeling of the advanced stripper and integrating it with the MSP absorbers; studying the strategies for producing very highly alkaline lean solvent with minimized emissions; operating the stripper with advanced heat integration to improve process efficiencies; and collecting critically important data for a detailed techno-economic analysis (TEA). The project tasks were designed to address concerns relating to scale-up and integration of the technology to NG power plants—more specifically, to maximize the carbon capture efficiency achievable with MSP and identify pathways to achieve higher capture efficiencies and ultimately zero net carbon emissions. SRI teamed up with a process modeling company (OLI Systems), a process and chemical engineering company (Trimeric Corporation), and a cost-sharing commercial partner (Baker-Hughes – a leading multinational company that designs, manufactures, and services transformative energy technologies) to execute the project. The research findings will accelerate the MSP development and pave the way for the technology to reach the DOE’s goal, and ultimately commercialization of the MSP technology for low-cost CO 2 capture from NGCC flue gas and other dilute CO 2 sources.

03 NATURAL GAS↗

Development, Monitoring, and Control of Fracture Thermal Energy Storage in Crystalline Rock Formations (DEMO-FTES) [Abstract]

Approximately half of global energy consumption is used for heating and cooling. Because fossil fuels are used to meet most of this demand, heating and cooling of buildings produces a large portion of global greenhouse gas (GHG) emissions. The proposed project seeks to demonstrate the feasibility of a seasonal thermal energy storage concept called fracture thermal energy storage (FTES), which has the potential to dramatically lower energy requirements for heating and cooling and improve the resilience of building energy systems. FTES is a technique for building a highly efficient heat exchanger by creating a carefully designed set of fractures in the ground below a building. This heat exchanger allows thermal energy to be stored over seasonal timeframes—for example, hot thermal energy that is easily captured in the summer or energy from waste heat sources—to meet heating needs during colder months. FTES offers a solution with a relatively small footprint and lower cost compared to currently operating aquifer thermal energy storage (ATES) systems and could be used in the many areas without aquifers suitable for ATES. If commercialized, FTES systems could exceed the 2.5 TWh of energy storage per year from the more than 2,800 ATES systems in operation worldwide, which range from 0.1 MW to 30 MW. The savings in CO2 emissions per year are also expected to match or exceed individual ATES projects, with the largest, a 30 MW system used to provide heating and cooling to the University of Technology in Eindhoven in the Netherlands, estimated to save 13,000 tons of CO2 emissions per year. FTES utilizes mature drilling and fracturing technology and therefore has the potential to be rapidly commercialized once demonstrated. The ability to construct and establish flow through an FTES heat exchanger has been demonstrated by a previous project and the potential for efficient, large-capacity energy storage has been shown using numerical models. However, no experimental validation of these numerical estimates of thermal energy storage has been made. The first crucial need to advance FTES technology is to identify the sensitivity of key metrics such as thermal energy storage and production rates, capacities, and efficiencies to design parameters such as the number of fractures, depth/temperature of fractures, size of fractures, and circulation rates. The second crucial need is experimental testing of achievable thermal performance with optimized system design parameters. The proposed scope of work seeks to systematically address these two critical needs through a highly complementary international collaboration spanning theory, laboratory, and mesoscale field evaluation. The proposed work plan calls for using dimensional analysis and existing state-of-the-art numerical simulators to design carefully scaled laboratory and 10-meter-scale field tests of the thermal efficiency of FTES. The existing advanced laboratory and intermediate-scale field testbeds that will be used for this project will allow for detailed monitoring of the system performance during the test and of how the performance changes across time and length scales. These results will determine the feasibility of full- scale FTES systems. If the thermal performance is consistent with model predictions, the results will provide a strong economic justification for rapid commercialization of FTES technology in a wide range of geographical areas.

25 ENERGY STORAGE↗

Mechanical Ventilation and Indoor Air Quality in Recently Constructed U.S. Homes in Marine and Cold-Dry Climates Data from Building America Project

Data were collected to characterize whole-house mechanical ventilation (WHMV) and indoor air quality (IAQ) in 55 homes in the Marine climate of Oregon and Cold-Dry climate of Colorado in the U.S. Sixteen homes were monitored for two weeks, with and without WHMV operating. Ventilation airflows; airtightness; time-resolved CO2, PM2.5 and radon; and time-integrated NO2, NOX and formaldehyde were measured. Participants provided information about IAQ-impacting activities, perceptions and ventilation use. All homes had operational cooktop ventilation and bathroom exhaust. Thirty homes had equipment that could meet the ASHRAE 62.2-2010 standard with continuous or controlled runtime and 34 had some WHMV operating as found. Thirty-five of 46 participants with WHMV reported they did not know how to operate it, and only half of the systems were properly labeled. Two-week homes had lower formaldehyde, radon, CO2, and NO (NOX-NO2) when operated with WHMV; and also had faster PM2.5 decays following indoor emission events. Overall IAQ satisfaction was similar in Oregon and Colorado, but more Colorado participants (19 vs. 3%) felt their IAQ could be improved and more reported dryness as a problem (58 vs. 14%). The collected data indicate that there are benefits of operating WHMV, even when continuous use may not be needed because outdoor pollutant concentrations are low and indoor sources do not present substantial challenges.

air quality↗

BSEC VPRM 10m Hourly Biogenic Fluxes in Baltimore (2021)

Model outputs from the Vegetation Photosynthesis and Respiration Model (VPRM: version from Horne et al. in prep). Model remote sensing inputs come from Sential 2-derived EVI and LSWI. Model meteorological inputs for two-meter air temperature and shortwave incoming come from the BSEC WRF 2021 Control Run (Foust, W. 2023). Plant functional Types (PFTs) are spatially classified using the Chesapeake Bay Program 2018 land use land cover product. The final biogenic flux (µmol CO2 m^-2 s^-1) outputs of NEE, RESP, and GEE are a weighted average based on the portion of PFTs within the cell. Individual PFT outputs are saved inside PFT directories (e.g., Crops, Grass, etc.) inside the specific month directory. Model outputs are denoted as a negative flux into the land system (i.e., photosynthesis) and a positive flux as a net release into the overlying atmosphere. Respiration (RESP) fluxes are positive and combine heterotrophic (only soil) and autotrophic sources. Gross ecosystem exchange (GEE) is a negative flux driven by only photosynthetic activity from vegetation, and the Net ecosystem exchange (NEE) is the sum of the two (i.e., NEE=RESP+GEE). Data Characteristics Spatial Resolution: 10m Temporal Resolution: Hourly File Format: VPRM_ _BSEC. .tif (Hour is in UTC) For more information on the model results, please email Jason Horne (jph6488@psu.edu). References: Foust, W. (2023). BSEC WRF 2021 Control Run Output (v0.1.0) [Data set]. MSD-LIVE Data Repository. https://data.msdlive.org/records/m0e6m-vvq17

Baltimore↗

The controlling role of atmosphere in dawsonite versus gibbsite precipitation from tetrahedral aluminate species

In highly alkaline solution, aluminum speciates as the tetrahedrally coordinated aluminate monomer, Al(OH)4- and/or dimer Al2O(OH)62-, yet precipitates as octahedrally coordinated gibbsite (Al(OH)3). This tetrahedral to octahedral transformation governs Al precipitation, which is crucial to worldwide Al production, and to the processing of caustic high-level radioactive wastes. Despite its significance, the transformation pathway remains unknown. Here we explore the roles of atmospheric water and carbon dioxide in mediating the transformation of the tetrahedrally coordinated potassium aluminate dimer salt (K2Al2O(OH)6) to gibbsite versus potassium dawsonite (KAl(CO3)(OH)2). A combination of in-situ attenuated total reflection infrared spectroscopy, ex-situ micro X-ray diffraction, and multivariate curve resolution-alternating least squares chemometrics analysis reveals that humidity plays a key role in the transformation by limiting the amount of alkalinity neutralization by dissolved CO2. Lower humidity favors higher alkalinity and incorporation of carbonate species in the final Al product to form KAl(CO3)(OH)2. Higher humidity enables more acid generation that destabilizes dawsonite and favors gibbsite as the solubility limiting phase. Because the transformation was restricted to occur in thin water films, the results suggest that transition from tetra- to octahedrally coordinated Al does not have to occur in bulk solution, as has often been hypothesized, but may instead appear on the source mineral surface.

Dembowski, Mateusz↗

Total metals, carbon, nitrogen & anion concentration data; Slate River & East River floodplains, Crested Butte, CO; May 2022-October 2022

This data package includes processed and undiluted measurements for metal, total carbon, total nitrogen, and anion concentrations from pore water (groundwater) and surface water samples from the Slate River and East River floodplains of Crested Butte, CO, focus field sites for the SLAC Floodplain Hydro-Biogeochemistry SFA. The data was generated as part of the work targeting the overarching research question for the SLAC SFA: How do ubiquitous subsurface interfaces mediate molecular-scale biogeochemical processes and groundwater quality in floodplains and watersheds? Samples were collected between May and October of 2022. These measurements were all recorded at the Arizona Laboratory for Emerging Contaminants (ALEC) at the University of Arizona located in Tucson, AZ. Groundwater samples were extracted from a network of installed rhizon (Rhizosphere Research Products, part no. 19.60.21F, 0.6 micrometer mesh size) and piezometer wells within the river floodplain. All water samples were shaded from sun exposure during extraction from the subsurface and preserved at 4C until measured at ALEC.Analysis by ICP-MS (metals):Measurements for total metals were made on the Agilent 7700x ICP-MS (for total metals) – Agilent Technologies, Santa Clara, CA. The analytical QA/QC protocol was adapted from US EPA Method 200.8 for analysis by ICP-MS. Calibration standards were prepared from multi-element stock solutions (SPEX Certiprep, Metuchen, NJ). Calibration curves include at least 7 points with correlation coefficients > 0.995. The QC protocol includes a continuing calibration blank (CCB), a continuing calibration verification (CCV) solution and at least one quality control sample (QCS) to be analyzed just after calibration and again after every 12 samples and at the completion of the run. The QCS solutions are from an independent source, such as NIST SRM 1643e - Trace elements in water, or QCS solutions from High Purity Standards (Charleston, SC). Acceptable QC responses must be between 90 and 110% of the certified value. Lastly, a suitable internal standard (usually Rh, In, Ga or Ge) is added using on-line addition into the sample line and mixing tee.Analysis by Shimadzu TOC-L (TOC/TN):The TOC-L system is a combustion technique where liquid samples are injected and combusted into CO2 for carbon detection by non-dispersive infrared (NDIR) and NO for detection by chemiluminescence. A calibration curve using five standard solutions between 0.1 and 7 ppm for carbon and 0.05 and 3.5 ppm for nitrogen is made for each type of measurement with a linearity >0.99. All samples, standards, and QC’s are prepared in 24mL scintillation vials that have been baked for 4hrs at 475 Cº and made using RO water (18.2mΩ). QC’s include a calibration blank check (CCB), continuing calibration check (CCC), and a certified reference material check (CRM). All QC’s are within ±10% error and are run before and after each batch of samples. Samples are diluted and rerun if any measurement concentrations are above the highest standard.Analysis by Ion Chromatography (Anions):The instrument used is the Thermo Scientific Dionex ICS-6000 using AS+AG22 column set for anion analysis with sodium carbonate eluent. A calibration curve using five standard solutions between 5 and 250 umol/L is made with a linearity >0.99. Standards and QC’s are prepared in 15mL polypropylene conical tubes, pipetted along with the samples into 1.5mL polypropylene vials. Dilutions are made using RO water (18.2mΩ). QC’s include a calibration blank check (CCB), continuing calibration check (CCC), and a certified reference material check (CRM). All QC’s are within ±10% error and are run before and after each batch of samples. Samples are diluted and rerun if any measurement concentrations are above the highest standard.All files are in csv format.

54 ENVIRONMENTAL SCIENCES↗

Catalytic monoterpenes conversion over Pd and zeolite to sustainable aviation fuel

Waste terpenes from wood drying are typically processed using a Regenerative Thermal Oxidizer (RTO) and converted to CO2 which is then released to the atmosphere. A novel alternative to this approach is to capture these terpenes using Fluidized Bed Concentrator (FBC) technology developed by CaptisAire which provides a useful waste carbon feedstock for subsequent upgrading. We have developed a catalytic approach where these waste terpenes (comprised of pinenes, limonene, and camphene), are converted to aromatic, and cycloalkane hydrocarbons suitable for use as a Sustainable Aviation Fuel (SAF) blendstock without the need for additional hydrogen. This provides a renewable source for aviation fuel aromatics and increases the potential blend content of renewably sourced alkanes from Hydroprocessed Esters and Fatty Acids (HEFA) and Alcohol to Jet (ATJ) processes. Terpenes were converted in a batch reactor at 260 °C and 120 psi N2 using a combination of Pd/C and H-BEA zeolite. Experimental results infer the role of the zeolite Brønsted acid to facilitate isomerization of pinenes and camphene to limonene, which then undergoes subsequent dehydro-aromatization to p-cymene using Pd/C. Hydrogen release from the dehydro-aromatization process, enables inert conversion of monoterpenes to cycloalkanes without additional hydrogen. Monoterpenes conversion to C10 aromatics (60%) and C10 cycloalkanes (40%) in an inert environment, provides a viable route for SAF blendstock sourced directly from captured waste terpenes. Transition to commercial off-the-shelf catalysts, facilitates scale-up of the terpene conversion process and improves commercial viability. We subsequently created hydrocarbon blends using HEFA or ATJ and converted terpenes, providing a 100% SAF blend with potential to replace traditional Jet-A.

Lawal, Ajibola [ORNL] (ORCID:0000000187266570)↗

System and method thermopile energy harvesting for subsurface well bore sensors

A system and method for powering a borehole sensor with thermal energy is disclosed. The system includes a tubular pipe inserted into a subsurface borehole. A borehole casing is coaxially disposed with the tubular pipe. An annular space between the casing and the tubular pipe has a power source placed in the borehole to power a sensor in response to a temperature gradient between a surface of the casing and a surface of the tubular pipe. The method includes attaching thermopiles on the borehole casing or tubing; placing the thermopile in the annulus between the casing and the tubing; inducing a thermal gradient across the thermopile; generating an electrical energy in response to the temperature gradient; powering the sensor from the generated energy; and monitoring vertical expansion of a CO2 plume.

Bryan, Charles R.↗

AN OVERVIEW OF THE DESIGN AND PERFORMANCE TESTING OF A 275 BAR INTEGRALLY GEARED SUPERCRITICAL CO2 COMPRESSOR FOR POWER GENERATION

An integrally geared compressor-expander (compander) for supercritical CO2 (sCO2) was developed to convert thermal energy to electricity. With operating pressures of 275 bar, this turbomachine represents the state of the art in integrally geared machine architecture, hitting compressor inlet densities of 600 kg/m3 and discharge pressures of 275 bar. The product development was funded by the Department of Energy’s Energy Efficiency and Renewable Energy Office under EE0007114 to advance the state of the art in concentrated solar power applications; however, the technology itself is agnostic to heat source, and is predicted to achieve a thermal-to-electric conversion efficiency of 50% for any indirect heat source capable of providing turbine inlet temperatures of 700°C or greater. While the program encompassed the design and testing for the compressor and turbine elements, this paper will focus on the compressor design and operation. The paper will begin with an introduction to the cycle design and analysis of an indirectly heated integrally geared sCO2 compander, a discussion of the mechanical and aerodynamic design of the compressor that is a two stage radial compressor operating subcritically at 27,512 rpm, and will then proceed to describe the test facility and measured data to characterize the performance and robustness of the machine. The paper will conclude with a discussion on lessons learned throughout the course of commissioning and testing. Practical aspects of testing a compressor operating near the dome including complications relating to obtaining an accurate compressor flow map, efficiency calculations, flow unsteadiness, and associated measurement uncertainties will be discussed.

wilkes, jason↗

Critical Analysis of Replacements for R-410A in Heat Pump Applications

Using low-GWP refrigerants can reduce the Green House Gas (GHG) emission of HVAC systems. Research has shown that using heat exchangers with small diameter tubes is a promising solution to meet the performance goals of heat pump using low-GWP refrigerants due to reduced refrigerant charge, reduced flammable impact and environmental impact. However, application of small diameter tube requires in-depth component design optimization to make the new system adapt to low-GWP refrigerants.In this paper, multi-objective optimizations using Particle Swarm Optimization (PSO) algorithm on a R-410A residential 5-ton air source heat pump is performed for improved system performance and reduced material cost. Five R-410A alternatives, i.e., R-32, R-454A, R-454B, R-454C and R-455A are investigated. R-455A and R-454C have GWP lower than 150. As a result of optimization, 12.4%-19.1% Energy Efficiency Ratio (EER) improvement and up to 71% HXs material cost saving is achieved. Life Cycle Climate Performance (LCCP) analysis shows that optimized systems reduce total CO2 emission by 13%-33% depending on the choice of refrigerant and climate zone.The optimal heat exchangers resulting from this research can fit into the original R-410A fan-coil units. The proposed heat pump design method establishes a production and installation path to produce cost-effective low-GWP heat pumps easily accepted by end users.

Li, Zhenning↗

Retrofitting Holcim Ste. Genevieve Cement Plant with CO2 Capture Plant Using Air Liquide Cryocap™ FG Technology

The global cement manufacturing industry is a major contributor to carbon dioxide emissions. The International Energy Agency's "Net Zero Emissions by 2050 Scenario" identifies CCS as a major strategy for meeting that goal. This project is among the first attempts to transfer capture technology developed at coal-fired power plants to the cement industry. The main objective of the project is to execute and complete a front-end engineering and design (FEED) studies for commercial-scale, carbon capture projects that separates 95% of the total CO2 emissions at the Holcim (US) Ste. Genevieve cement manufacturing facility using Air Liquide’s Pressure Swing Adsorption system (PSA) assisted Cryocap™ technology. The Holcim Ste. Genevieve cement plant in Missouri, US, boasts one of the largest single cement production lines in the world, with a capacity of approximately 12,000 t/day. The plant currently uses traditional fuels, namely coal and petcoke. The captured CO2 will be pipeline and geological storage grade. The industrial host site emits approximately 3.0 million tonne CO2/yr. Air Liquide’s Cryocap™ technology has been developed over the last 18+ years for CO2 capture applications. It has been shown to be applicable to a variety of industrial applications (e.g., steel, cement, SMR, Fluidized Catalytic Crackers (FCCs)). Cryocap™ FG consists of a Pressure Swing Adsorption (PSA) unit coupled with a Cryogenic System. The PSA pre-concentrates the CO2 from the flue gas, while the cryogenic unit enables the CO2 purity to be increased to the desired level. The project team is led by the Prairie Research Institute at the University of Illinois at Urbana-Champaign. The tasks include: complete FEED study for retrofitting the industrial facility with a carbon capture system to support developing a detailed cost estimate; business case analysis outlining the anticipated revenue and credits if projects was built and operated; technoeconomic analysis (TEA) outlining how capture system achieves DOE capture goals; and life cycle (LCA) analysis demonstrating zero net carbon emissions. The FEED study was successfully completed. This includes completing the process basis of design; preliminary engineering; outside battery limits (OSBL) detailed engineering including a Zero Liquid Discharge (ZLD) wastewater treatment system; inside battery limits (ISBL) detailed engineering [1]. An overall project capital cost estimate within a -20%/+30% accuracy was developed. The major contributors to the Total Plant Cost (TPC), by system, are the costs associated with the Outside Battery Limit (OSBL) section of the plant which includes a new river water intake structure and a Zero Liquid Discharge (ZLD) system. By cost category, the major contributors to the TPC are equipment and subcontractor costs, followed closely by engineering, construction management, home office and contractor fees. The TEA has been created to reflect the findings of the project. It analyzes the economic performance of the Cryocap™ technology by reviewing the estimated capital costs, operating cost, and revenue. The Cost of Capture (COC) associated with the Cryocap™ technology for 95% CO2 capture, when considering NETL 2018 economic assumptions (42/58 debt/equity ratio, 5.15% interest on debt and 1.42% return on equity in real dollars) and 2022 economic assumptions (42/58 debt/equity ratio, 8.82% interest on debt and 4.90% return on equity in real dollars) was found to be much lower than that for the DOE-NETL’s base-line cases. The highest contributors to the COC are annualized capital expenditures (CAPEX) and electricity consumption which can be offset by using lower cost renewable sources. The LCA was conducted using OpenLCA which is an open-source software that is recommended by NETL. The database utilized for this study was a modified version of TRACI 2.1 (developed by the US. Environmental Protection Agency’s National Risk Management Research Laboratory and modified by NETL). The Cryocap™ FG technology does not consume fuels in significant quantities and does not utilize specialized chemical solvents subject to decomposition, such as those utilized in amine-based carbon capture systems. The Cryocap™ FG technology mainly utilizes electricity as its energy input; hence, its calculated emissions are mainly associated with the generation of electricity offsite and are dependent on the energy matrix of the grid at the time of project implementation. The water consumption impact of the Cryocap™ FG is mostly for makeup of the water lost by evaporation in the cooling tower; however, the carbon capture plant will be equipped with a ZLD system to avoid effluent streams and minimize water consumption. The successful construction and operation of this plant based on this study results will provide a means to demonstrate an economically attractive and transformational capture technology that can be used to retrofit existing plants and be deployed at new plants.

01 COAL, LIGNITE, AND PEAT↗

Toward sustainable, cell-free biomanufacturing

Industrial biotechnology is an attractive approach to address the need for low-cost fuels and products from sustainable resources. Unfortunately, cells impose inherent limitations on the effective synthesis and release of target products. One key constraint is that cellular survival objectives often work against the production objectives of biochemical engineers. Additionally, industrial strains release CO2 and struggle to utilize sustainable, potentially profitable feedstocks. Cell-free biotechnology, which uses biological machinery harvested from cells, can address these challenges with advantages including: (i) shorter development times, (ii) higher volumetric production rates, and (iii) tolerance to otherwise toxic molecules. In this review, we highlight recent advances in cell-free technologies toward the production of non-protein products beyond lab-scale demonstrations and describe guiding principles for designing cell-free systems. Specifically, we discuss carbon and energy sources, reaction homeostasis, and scale-up. Expanding the scope of cell-free biomanufacturing practice could enable innovative approaches for the industrial production of green chemicals.

59 BASIC BIOLOGICAL SCIENCES↗

Computational Modeling of a 3D Printed Recuperator and Subsequent Experimental Loop for Supercritical Carbon Dioxide Cycles

Oak Ridge National Laboratory (ORNL), in collaboration with mechanical-thermal energy storage (mTES) provider EarthEn, a US Department of Energy (DOE) Lab-Embedded Entrepreneurship Program (LEEP) recipient at ORNL’s Innovation Crossroads 2023, is utilizing a state-of-the-art patented 3D printing technique to design an additively manufactured (AM) supercritical CO2 (sCO2) recuperator (REC) for EarthEn’s charge/discharge cycle. The AM REC will be printed at ORNL’s Manufacturing Demonstration Facility using Inconel Alloy 718 and tested on a closed-loop, ∼100 kW scale experimental facility that is under construction. The testing will compare the printed design against a commercial-off-the-shelf Printed Circuit Heat Exchanger (PCHE) REC. The design of the sCO2 facility is guided by a Modelica-based system model which is primarily dependent on the open-source TRANSFORM library developed at ORNL and uses the open-source CoolProp library for thermophysical properties of sCO2 via the External Media library. It is envisioned that an iterative process will be followed between the physical loop and the system model wherein the initial experimental data will be used to tune the model, which in turn will be used to guide future loop operation. Simultaneously, the AM REC is being designed using computer-aided design models, and it is also being analyzed for hydraulic and thermomechanical response using commercial computational fluid dynamics software, Simcenter STAR-CCM+, on highperformance computing resources.1

See, Nate [ORNL] (ORCID:0000000178581202)↗

CCUS Plume Monitoring: Verifying Surface CSEM Measurements to Log Scale Available

Conference presentation at Society of Petrophysicists and Well Log Analysts (SPWLA) 64th Annual Symposium, Lake Conroe, Texas, June 10–14, 2023. In carbon capture, utilization, and storage (CCUS) monitoring, dynamic plume monitoring and reservoir seal are key issues. Plume monitoring is best addressed with electromagnetics (sensitive to the resistivity contrast) and reservoir leakage with microseismics. A case history from North Dakota illustrates how we can tie surface-controlled source electromagnetic (CSEM) measurements to the three-dimensional (3D) anisotropic models derived from the available logs. This allows us to certify baseline measurements within the context of the borehole information.

20 FOSSIL-FUELED POWER PLANTS↗