Pilot Test of Novel Electrochemical Membrane System for Carbon Dioxide Capture and Power Generation (Final Report)
The goal of this U.S. Department of Energy (DOE) sponsored project under cooperative agreement DE-FE0026580 is to verify that Fuel Cell Energy’s (FCE) Electrochemical Membrane (ECM)-based Combined Electric Power and Carbon Separation (CEPACS) system can achieve at least 90% carbon dioxide (CO 2 ) capture rate from Pulverized Coal (PC) power plant flue gas with 95% CO2 purity at a cost of electricity (COE) 30% less than baseline CO 2 capture approaches. To progress towards the DOE’s ultimate carbon capture program goals, the specific objectives of Budget Period 1 (BP1) of the project are to perform a preliminary Techno-Economic Analysis (TEA) and Environmental, Health and Safety (EH&S) Risk Assessment study, as well as to complete the detailed design of a pilot-scale ECM-based CEPACS system. This final technical report summarizes the results of the preliminary TEA and EH&S assessment of an ECM-based CEPACS system designed to capture and compress >90% of CO 2 from the flue gas of a reference 550 MW (net AC) Pulverized Coal (PC) Supercritical Steam Cycle Plant. Also included in this report is a summary of the detailed design for a pilot 3 MWe (flue gas equivalent) ECM-based CEPACS system designed to capture ≥90% of CO 2 from a PC plant flue gas slipstream and produce high-purity (≥95%) CO 2 . The pilot system is designed to process a slipstream of flue gas from the Unit 5 coal-fired boiler at the James M. Barry Electric Generating Station (Plant Barry). Plant Barry is located in Bucks, Alabama and is owned and operated by Alabama Power Company, a subsidiary of Southern Company. The TEA shows that the ECM-based CO 2 capture technology has an economic advantage over the existing CO 2 capture technology and meets the DOE’s cost target and performance goals for post-combustion CO 2 capture. The EH&S study includes the identification and quantification of the emissions from the CEPACS system. Properties of the waste including reactivity, flammability, corrosivity and toxicological effects are discussed along with the methods for minimization/elimination where applicable. The study shows that no major EH&S issues are expected to hinder commercialization of the ECM technology for large scale carbon capture applications. The detailed Front End Engineering Design (FEED) package for FCE’s MW-class ECM-based CO 2 capture pilot system is complete. It is designed in accordance with the project objectives and is now at a point where equipment/component procurement, skid final design and fabrication, and site preparation activities can begin in a follow-on project phase.