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DOE OSTI2022

Puerto Rico Grid Resilience and Transitions to 100% Renewable Energy Study (PR100) (Six-Month Progress Update) [Slides]

Puerto Rico has committed to meeting its electricity needs with 100% renewable energy by 2050, along with realizing interim goals of 40% by 2025, 60% by 2040, the phase-out of coal-fired generation by 2028, and a 30% improvement in energy efficiency by 2040, as established in Puerto Rico Energy Public Policy Act (Act 17). Since hurricanes Irma and Maria in September 2017, DOE and its national laboratories have provided Puerto Rico energy system stakeholders with tools, training, and modeling support to enable planning and operation of the electric power grid with more resilience against further disruptions. On February 2, 2022, DOE, FEMA, and six national laboratories launched the two-year Puerto Rico Grid Resilience and Transitions to 100% Renewable Energy Study (PR100) to conduct comprehensive analysis of stakeholder-driven pathways to Puerto Rico's energy future. The robust and objective energy analysis entails five activities, with an emphasis on power system reliability, resilience, and generation planning. This presentation was delivered in a public webinar on July 21, 2022, providing a high level summary of the progress in the first six months of the study, including presentation of four initial scenario definitions based on extensive stakeholder input.

14 SOLAR ENERGY↗
DOE OSTI2022

Sorbent Based Post-Combustion CO 2 Slipstream Testing

TDA Research, Inc. has developed a low-cost sorbent (alkalized alumina) based technology for post-combustion CO 2 capture. The sorbent runs in an isothermal process for adsorption and regeneration. Neither temperature swing nor pressure swing is needed. TDA designed a system which operated 10 fixed beds to simulate a moving bed process. The flow pattern was optimized to minimize the steam usage for regeneration. An excellent sorbent (Batch 1) was also developed with collaboration with our partner. The sorbent degraded after long term operation. We developed a reprocessing procedure, which can be conducted in situ, to restore the sorbent capture capacity as the fresh sorbent after running for about 1250 hours. The reprocessing extended the sorbent longevity significantly. TDA designed a pilot unit (40’ x 32’ x 11.5’), processing flue gas equivalent to 0.5 MW of power generation. It had 10 beds and each bed could hold 1.75 m 3 of sorbent. We worked with Springs Fabrication, Inc. to complete the construction of the pilot unit. It was then shipped and installed at NCCC. The pilot unit was kept running in 24-hour mode when the flue gas and steam were available. It could run automatically without operator on site. Parametric and long-term (2 months) tests were carried out successfully. The results showed that TDA’s process can achieve 90% capture and 95% CO 2 purity for both coal and NG flue gases. For coal flue gas, the system reached performance target when processing up to 0.62 MW flue gas, 24% higher than the design capacity. Thus, capital cost could be saved on the reactors and sorbent. The strip air flow was designed to be 0.25 of that of the flue gas. The test data showed the strip/flue ratio can be reduced to as little as 0.18, which saves the power consumption for the strip air blower. The pressure drop was found to be lower than what the empirical equation calculated. The sorbent still had 91.7% of original capacity after 3-month test. With the data from the pilot test, we updated the TEA. For a 550-MW e supercritical coal fired power plant with CO 2 capture, the capture cost for TDA’s process is $34.9/tonne CO 2 captured, which meets DOE’s goal of $40/tonne and is 17.1% less than the DOE baseline Case 12. Therefore, TDA’s process has a good potential for commercialization.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Integration of 5G and Time Sensitive Networks in Fossil Energy Generation Systems: A Case Study

Precise timing and data transmission within stringent time constraints are critical for numerous applications, such as robotics, virtual and augmented reality, industrial automation, energy and medical business, and various other sectors. Time-sensitive networks (TSN) and fifth-generation wireless communications (5G) are crucial for industrial communications, enabling convergent communication for various services using a common network core. Applications that are time-sensitive and require deterministic communications with low latency fall into this category, such as generation plant systems. This paper presents a simulated model of 5G-TSN for a fossil power plant based on the wired network parameters implemented in situ. Metrics analysis, comparison and future work are presented. © 2024 IEEE.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Optimal CO2 Transport and Storage Cost Screening: Application Example

Poster on “Optimal CO2 Transport and Storage Cost Screening: Application Example” for the CCUS 2025 conference held in Houston, Texas March 3-5, 2025. A major challenge to commercial scale CCS deployment from the perspective of coal and natural gas-fired power plants is understanding cost-optimal CO2 transport and viable geologic storage options. This study demonstrates unique workflows, using NETL-developed, publicly-available models and tools, to efficiently estimate optimal CO2 transport and storage (T&S) costs for each of the CO2 sources in NETL’s Carbon Capture Retrofit Databases (CCRD) for Electricity Generating Units. The results demonstrate the impact of cost-drivers on optimal T&S, and trends in optimal T&S data, based on real point sources that could be retrofitted with CO2 source technologies.

application example↗
DOE OSTI2020

W.A. Parish Post-Combustion CO 2 Capture and Sequestration Demonstration Project (Final Technical Report)

The Petra Nova Project (Project) is a commercial scale post-combustion carbon capture project developed by a joint venture between NRG Energy, Inc. (NRG) and JX Nippon Oil Exploration (EOR) Limited (JX). The Project is designed to separate and capture carbon dioxide (CO2) from an existing coal-fired unit’s flue gas slipstream at NRG’s W.A. Parish Electric Generating Station (WAP) located southwest of Houston, Texas. The captured CO2 is dried, compressed, and transported via an 81-mile pipeline to the West Ranch oilfield (West Ranch) in Jackson County, Texas, where it is injected to boost oil production. The Project, which is partially funded by a grant (Grant) from the United States (U.S.) Department of Energy (DOE) under the Clean Coal Power Initiative (CCPI) Round 3, uses the Kansai Mitsubishi Carbon Dioxide Recovery advanced amine-based CO 2 absorption technology (KM-CDR Process®), which was jointly developed by Mitsubishi Heavy Industries, Ltd. (MHI) and the Kansai Electric Power Co. Inc., to treat and capture at least ninety percent (90%) of the CO 2 from a 240-megawatt equivalent (MWe) flue gas slipstream off of Unit 8 at WAP. When operating at full capacity, the Project captures approximately 5,200 short tons of CO 2 per day, which would otherwise be emitted into the atmosphere, representing the largest commercial scale deployment of post-combustion CO2 capture technology at a coal power plant to date. Under the Grant, the Project was managed in 3 phases: (1) Phase 1: Project Definition / Front End Engineering Design (FEED) (2) Phase 2: Detailed Engineering, Procurement & Construction (3) Phase 3: Demonstration and Monitoring. On December 29, 2016, commercial operation of the Project was achieved, ending Phase 2 and starting Phase 3, a 3-year demonstration period running from January 1, 2017 through December 31, 2019. The key objectives of Phase 3 were to (a) demonstrate the specific advanced technologies constructed during Phase 2 and (b) monitor the injected CO 2 at West Ranch to demonstrate technologies and protocols for monitoring, verification, and accounting (MVA). As of the end of Phase 3, Petra Nova captured 3,904,978 short tons of CO 2 (3,542,537 metric tons) that was transported to West Ranch. To support the DOE obligation to monitor, verify, and account for the sequestered CO 2 at West Ranch, Petra Nova contracted with the Bureau of Economic Geology (in the Jackson School of Geosciences at The University of Texas at Austin) to (a) design a monitoring program, (b) draft an MVA Plan for DOE review and approval, and (c) working with Petra Nova and the operator of West Ranch to manage and report on the MVA activity. This report discussed the technical aspects of the project during each of the 3 phases of the project as identified above.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Climate Influences on Capacity Expansion Planning with Application to the Western U.S

Electric power system planners utilize a variety of planning tools to inform decisions concerning generation and transmission additions to the electric grid, the need for operational changes, and to evaluate potential stressors on the system. Numerous factors contribute to the planning process including projected fuel and technology costs, policy and load profiles. There is also a growing recognition of the interdependency of the electric grid with other natural and engineered systems. Here we explore how future climate change and hydropower operability might influence decisions related to electricity capacity expansion planning and operations. To do so we assemble a multi-model framework. Specifically, water resource modeling is used to simulate climate impacts on future water supply for thermoelectric and hydropower generation. Separately, temperature impacts on electricity load are evaluated. Together, these climate factors spatially constrain a capacity expansion model that projects generation and transmission additions to the grid. The projected new capacity-builds are then evaluated on their operations, reliability, and cost under average and extreme climate conditions using production cost modeling. This coupled framework is demonstrated on the electric grid in the Western U.S., supporting capacity expansion planning by WECC, the North American Electric Reliability Corporation (NERC) regional entity responsible for reliability assurance of the Western Interconnection. This region was selected in part because the West is unique in that it has high potential for renewable penetrations and is experiencing large retirements/displacements of baseload resources, primarily coal, leading to possible operational challenges in terms of changing resource mix and the need for resource flexibility. Toward this challenge, planning scenarios encompass a range of alternative energy, climate and drought futures. In this context we explore answers to two strategic questions: 1) How does changing climate influence electricity expansion planning (generation and transmission) and future operations, including type and capacity of new builds, system reliability, cost and environmental impacts? 2) How does the representation of hydropower in the modeling framework influence the evaluation of bulk power system operations? Results indicate that climate has a measurable influence on recommendations concerning the capacity, type and location of new generation and transmission additions, with up to 17 GW additional capacity needed by 2038 to meet peak loads (~6.6% increase over capacity-builds based on historical climate). The extent of additional infrastructure needs is strongly influenced by future water availability for hydropower and the potential deployment of demand response technologies. Systems designed for future climate conditions were found to maintain high system reliability under a range of electricity and water availability scenarios (including significant drought), with minimal system curtailments. Additional capacity needs due to higher load tend to increase cumulative 20-year investment and operating costs by $\$$5-$\$$17 billion and generation costs increase by 9 to 19%. Finally, changing the representation of hydropower flexibility has a relatively small influence on capacity expansion in the Western Interconnection through 2038, but hydropower flexibility impacts generation costs to a similar extent as climate.

13 HYDRO ENERGY↗
DOE OSTI2020

Update of Emission Factors of Greenhouse Gases and Criteria Air Pollutants, and Generation Efficiencies of the U.S. Electricity Generation Sector

The last decade has seen a steady evolution of the electricity generation sector. Fuels used for electricity generation have shifted from coal to cleaner energy sources such as natural gas and renewables including solar, wind, and other renewable sources. The share of U.S. electricity generated from coal decreased from 45% in 2010 to 24% in 2019, and is expected to decrease further to 13% by 2050. The conversion efficiency of electricity generation has also increased gradually for fuels such as natural gas due as less-efficient old generators are retired and more-efficient generators replace them. These changes in the electricity generation industry are likely to cause changes in the emissions from power generation units. Emission factors of greenhouse gases (GHG) including CO 2 , CH 4 , and N 2 O, and criteria air pollutants (CAPs) including CO, NO x , PM 10 , PM 2.5 , and SO x , from power plants are important parameters for estimating life-cycle emissions associated with vehicle electrification, energy systems, and the production of materials and chemicals. The electricity generation technologies and associated emission factors in the Greenhouse Gases, Regulated Emissions, and Energy Use in Technologies (GREET) model need to be updated to reflect recent developments in the electricity generation sector. The most recent update of the electricity generation emission factors in GREET adopted a mixed method. The emission factors of CH 4 , N 2 O, NO x , and SOx were estimated using a “topdown” approach by dividing the total emissions by the total net electricity generation, because emission data of these pollutants are readily available in the Emissions & Generation Resource Integrated Database (eGRID). For other CAPs such as CO, VOC, PM 10 , and PM 2.5 , emission data were not reported in eGRID. A “bottom-up” method was used to estimate the emission factors for these pollutants by considering generic uncontrolled emission factors and the pollutant removal efficiencies of emission control technologies adopted in the electricity generation sector. However, the uncontrolled emission factors and the emission removal efficiencies of various emission control technologies considered in the 2012 study came from the legacy AP-42 emission factors, and may not reflect the actual emission performances of the electricity generation sector of today. To leverage new data that recently became available, especially emission data measured from continuous emission monitoring systems (CEMS), we developed a new “top-down” approach to estimate efficiencies and GHG and CAP emission factors for electricity generation from combustion of individual fuel types by individual combustion technologies on the basis of power-generation data from U.S. Energy Information Administration’s (EIA’s) form EIA-923, and plant emission data from Environmental Protection Agency’s (EPA’s) Clean Air Markets Division (CAMD) dataset and National Emissions Inventory (NEI) dataset. Detailed discussion of the method and data used in this study can be found in Section 2.1. With this topdown approach, we aim to improve the estimates of energy efficiencies and emission factors for power plants using a more consistent methodology, and to update the emission factors, generation efficiencies, and generation technologies mixes in GREET to reflect recent technology advancements in the electricity generation sector.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Novel Algae Technology for CO2 Utilization

The United States, the world’s largest energy user and second largest CO2 emitter, is heavily dependent on fossil energy. In 2014, U.S. coal burning utilities emitted ~1562 million (MM) tons/year (TPY) of CO2 into the atmosphere, accounting for 76% of the total US power sector emissions1. Hence, reducing the CO2 emission footprint from coal plants is widely viewed as a key element in mitigating global warming. Despite significant interest, implementation of CO2 capture technologies has been constrained by the high capture cost which significantly increases the total cost of electricity. Not only is capturing CO2 with traditional technologies expensive, but generally the CO2 has little value and additional expense must be incurred for sequestration. This project funded by a SBIR grant from the U.S. D.O.E. to Helios-NRG in collaboration with the State University of New York at Buffalo (UB) and Membrane Technology and Research Inc. (MTR) aimed to develop a novel, algae based technology to capture CO2 from the effluent of coal-based power plants and convert it to renewable bio-fuels and higher value co-products such as animal feed and nutraceuticals with the potential to enable a substantial reduction in the net cost of carbon capture. The Phase 2 project was aimed at further demonstrating the technical feasibility of the proposed multi-stage continuous (MSC) flow CO2 capture system and the generation of high-value co-products to offset the CO2 capture cost. The project was completed and the project objectives were met and exceeded. A first-of-a-kind integrated, laboratory scale MSC process unit was fabricated and tested in a greenhouse. The tests were conducted with the preferred algae species identified in Phase I and simulated flue gas containing contaminants at levels typically present in the post flue gas desulfurization (FGD) stream, including ~12% CO2, acid gas (SOX, NOX), and a large number of heavy metals. The tests were successful and demonstrated a 25g/m2/day seasonal average algae productivity and an 80% CO2 capture efficiency. Two new algae species were identified for high-value nutraceutical production. Studies to improve growth rate and nutraceutical content of these algae species were performed and a pathway for further improvements was identified. A new dewatering technology called DeAqua was further advanced. Significant improvement in the performance index was achieved. The anti-fouling membrane was developed and fabricated into a module. The fabricated membrane module was tested with algae slurry and demonstrated improved fouling resistant properties, that can potentially reduce the cost and energy of the critical dewatering step. Test data were used to simulate operation of the overall process. The preliminary economic analysis was updated and modelled based on a 5000-acre algae farm. To the extent possible, the financial and operating assumptions used were the same as those used in the DOE’s 2022 projections for algae technology for CO2 capture and utilization. The results showed the proposed technology’s potential to significantly reduce the cost of CO2 capture compared to current options and that the high value products generated from the CO2 captured can make a step change in the cost of carbon capture. Plans to advance the technology to Phase 2B were developed and potential end-user partners were identified.

Maloney, James↗
DOE OSTI2022

Repurposing Fossil-Fueled Assets For Energy Storage

The annual retirement of U.S. coal-fired electricity generation units (CF-EGU) is at an all-time high and is expected to continue. This loss of reliable baseload generation, combined with predicted growth of variable renewable energy (VRE) generation, is expected to stress grid reliability as the number of load-following resources drops below the experienced load variability. Many regions are already experiencing challenges, and fossil retirement-related warnings by the North American Electric Reliability Corp. are becoming more dire. All CF-EGU retirements pose significant challenges to asset owners, local workforces, and their communities. Repurposing a retiring CF-EGU as a long-duration energy storage plant can address these challenges and offer a suite of additional benefits to asset owners, the grid, and society. This project performed a techno-economic evaluation and assessment of repurposing a Duke Energy fossil-fueled asset (in particular, a coal plant) into an energy storage system by integrating the retiring asset with a Malta long duration Pumped Heat Energy Storage (PHES) system. The project validated the technoeconomic benefits of repurposing retiring coal plants into long-duration energy storage using Malta’s PHES. Key findings for this project are summarized below: (1) Technical: (a) Retiring coal plants (and other steam turbine fossil generation) can be repurposed to enable the clean energy transition using Malta’s technology. (b) For older retiring coal plants, repurposing the site and electrical interconnection for a standalone PHES plant is the most economically favorable option. (c) For newer coal plants where there is also a local peaking capacity need, repowering the steam cycle into a hybrid integration with PHES is attractive. (d) A process was developed to assist fossil generation owners in choosing the best path for each plant’s circumstances. (2) Economic (a) Communities facing economic challenges caused by the retirement of fossil generation would benefit from repurposing the plant as long-duration energy storage using Malta’s PHES. (b) On a $/MW basis, repowering retiring coal units into Malta PHES plants can maintain the same number and types of jobs and economic activity. (c) For a 70% carbon reduction scenario, a 10-hour Malta PHES plant is more economic for the asset owner than similar-power 4-hour batteries. This project showed that repurposing a retiring coal unit into thermal energy storage, by integrating it with a Malta PHES system, makes techno-economic sense. At least two integration options are available, with the optimal solution depending on the coal plant and its location. Repurposing retiring coal plant into energy storage results in economic benefits for the plant owner and local communities.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1975

Environmental considerations

A comparison was made between the environmental impact of the present nuclear-heated process and the currently commercial hydrogen-producing process utilizing coal for heating, i.e., the Lurgi coal gasification process. This comparison is based on the assumption that both plants produce the same quantity of H2, i.e., 269 cu m/sec of approximately the same purity, that all pollution abatement equipment is of the same design and efficiency for both the Lurgi process and the nuclear process, and that the energy required for the fresh nuclear fuel and the fuel recycle is generated in a power plant which is also provided with pollution abatement equipment. The pollution caused by the auxiliary units is also taken into account. As regards process water usage, the data show that the water required for the nuclear route, including the nuclear fuel production, is approximately 78% of that required for the Lurgi route.

Source record↗
DOE OSTI2021

Demonstrations of Holistic, Lower Cost/Energy Effluent Water Management Approaches for Coal-Fired Energy Plants

The project work conducted under DOE award DE-FE0031678 was comprised of three overarching project goals: (1) evaluate the performance of Saltworks’ Flex EDR Selective process for treating wet flue gas desulfurization (FGD) wastewater, (2) conduct bench-scale testing of wastewater encapsulation as a byproduct management technology for the EDR generated brine, and (3) develop a dynamic water balance model encompassing the results of the aforementioned testing.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1977

Velocity and temperature distributions of coal-slag layers on magnetohydrodynamic generators walls

Approximate analytical expressions are derived for the velocity and temperature distributions in steady state coal slag deposits flowing over MHD generator walls. Effects of slag condensation and Joule heating are included in the analysis. The transport conditions and the slag temperature at the slag-gas interface are taken to be known parameters in the formulation. They are assumed to have been predetermined either experimentally or from the slag properties and the gas dynamic calculations of the free stream flow. The analysis assumes a power law velocity profile for the slag and accounts for the coupling between the energy and momentum conservation equations. Comparisons are made with the more exact numerical solutions to verify the accuracy of the results.

Pian, C. C. P.↗
DOE OSTI2020

Oxy-Combustion System Process Optimization

The overall objective of this work is to develop a new chemical absorbent-based, high pressure, CO 2 purification system to remove the residual oxygen that currently contaminates the recovered CO 2 , and to optimize the Pressurized Oxy-Combustion (POxC) process to minimize the Cost of Electricity (COE) generated in this advanced combustion process. TDA developed and validated the performance of the oxygen removal system for CO 2 purification. In collaboration with the Advanced Power & Energy Program (APEP) of University of California, Irvine (UCI), we optimized the POxC process, including thermal management, heat integration, and power cycle optimization using process design and modeling supported with Aspen Plus® process simulations. The techno-economic analysis results indicate that the pressurized oxycombustion coal power plant with Ion-transport membrane (ITM) air separation unit (ASU) (Case 2 – 30.55%) does not show an advantage over a cryogenic ASU (Case 1 – 31.24%) while TDA’s sorption-based ASU (Case 4 - 32.61%) shows a significant advantage over the cryogenic ASU (Case 1 – 331.24%). The specific plant costs show a wide range with a low of $2544/kW for Case 11C (TDA ASU, co-sequestering the SO x , and ultra-supercritical steam cycle) to a high of $2975/kW for Case 12A (cryogenic ASU and sCO 2 cycle). In general, the ITM ASU based cases have lower specific plant costs than the corresponding cryogenic ASU based cases while the TDA ASU based cases show the lowest specific plant costs. The main reason for lowering these costs is the higher overall plant thermal efficiency which decreases the plant cost on a $ per kW basis. Next comparing the cases with different power cycle working fluid conditions in terms of temperature and pressure while all utilizing steam, similar trends as the plant costs may be observed. However, with the supercritical CO 2 (sCO 2 ) cycle, the increase in thermal efficiency of the sCO 2 cycle was not able to offset its increase in plant cost making the plant costs higher than those of the corresponding steam cycle cases. The Cost of Electricity (COE) again shows similar trends as the specific plant costs. The COE for Case 11C at $110.1/MWh is also the lowest, but among all cases that do not co-sequester the SO x , Case 12C (TDA ASU and sCO 2 cycle) has the lowest COE at $\$$117.5/MWh while the highest is for Case 8A (cryogenic ASU and supercritical steam cycle) at $130.4/MWh.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Assessing the Key Requirements for 450 GW of Renewable Capacity in India by 2030

In this policy brief, we assess the prerequisites for India to achieve 450 GW of solar and wind cumulative installed capacity by 2030. We examine requirements such as availability of land, new transmission buildout, financing and pace of deployment, as well as the impact on grid reliability and cost of generation. We also examine the impact of policies promoting domestic manufacturing. Deploying 307 GW of solar and 142 GW of wind capacity would use only about 1.25% of land that is categorized as barren or waste, which is equivalent to about 0.22% of the total land area in India. Because of the good solar resource across large swaths of India, the solar energy buildout—and thus the land use—potentially can be spread out. India would need about 280 GW of new interstate transmission capacity by 2030, a little over double the transmission expansion that has already been planned through 2025. However, most of the new transmission buildout is driven by the near doubling of electricity demand between 2020 and 2030. The total investment needed (in generation and storage resources) to realize this target is around USD 26.5 billion annually, which is 20% lower than the annual investment in India’s power sector across all generation resources between 2015 and 2019. We estimate that using domestically manufactured panels instead of imported panels may increase solar PPA prices by about 10%–15% in the medium term, but solar power would still be a cost-effective way to meet growing demand instead of building new fossil fuel-based power plants, because the price of electricity from solar plants has fallen below the variable cost of most existing coal units. To reach this target, India would need to build about 35–40 GW of solar and wind capacity every year in this decade. India’s power sector achieved a pace of capacity addition of 22 GW per year in the previous decade (including thermal and renewable). Policy and regulatory measures would be needed to increase the pace of deployment.

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

Integrated Energy System Investigation for the Eastman Chemical Company, Kingsport, TN Facility

The industrial manufacturing industry is looking to implement new methods of energy production to ensure a consistent energy supply while reducing economic costs and environmental impacts. Much of the manufacturing industry relies on fossil fuels—primarily coal and natural gas—of which there are finite resources subject to price volatility due to an inelastic demand. These resources also come with significant negative environmental impacts related to emissions. While complete independence from fossil fuels is not immediately realistic, options are available to significantly reduce dependency on fossil fuel supplies, including integrated energy systems (IESs) which tightly couple nuclear energy source generators with energy consumers (i.e., industrial factories) to fulfill power and energy requirements. Once realized, optimized IESs may yield significant economic and environmental benefits over traditionally isolated generator and consumer facilities. This report presents a feasibility study for siting an IES to meet the steam and electricity needs of Eastman Chemical Company’s facility in Kingsport, Tennessee. This study explored reactor technology options, evaluation,and optimization,with a focus on meeting the facility’s operational and reliability requirements. This work is part of an ongoing effort by Eastman to be good environmental stewards and meet the demands of their customers by shifting to more environmentally sustainable solutions for their energy needs. Outcomes of this report are also of general interest and value to any design or development team seeking to deploy an IES,as many topics described herein are generally applicable to any nuclear power facility.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Integrated Energy System Investigation for the Eastman Chemical Company, Kingsport, Tennessee Facility

The industrial manufacturing industry is looking to implement new methods of energy production to ensure a consistent energy supply while reducing economic costs and environmental impacts. Much of the manufacturing industry relies on fossil fuels—primarily coal and natural gas—of which there are finite resources subject to price volatility due to an inelastic demand. These resources also come with significant negative environmental impacts related to emissions. While complete independence from fossil fuels is not immediately realistic, options are available to significantly reduce dependency on fossil fuel supplies, including integrated energy systems (IESs) which tightly couple nuclear energy source generators with energy consumers (i.e., industrial factories) to fulfill power and energy requirements. Once realized, optimized IESs may yield significant economic and environmental benefits over traditionally isolated generator and consumer facilities. This report presents a feasibility study for siting an IES to meet the steam and electricity needs of Eastman Chemical Company’s facility in Kingsport, Tennessee. This study explored reactor technology options, evaluation, and optimization, with a focus on meeting the facility’s operational and reliability requirements. This work is part of an ongoing effort by Eastman to be good environmental stewards and meet the demands of their customers by shifting to more environmentally sustainable solutions for their energy needs. Outcomes of this report are also of general interest and value to any design or development team seeking to deploy an IES, as many topics described herein are generally applicable to any nuclear power facility.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗