DOE OSTI2012
Air Products is carrying out a scope of work under Phase 5 of the ITM Oxygen Cooperative Agreement to design, build, and operate a ceramic membrane fabrication facility (the -CerFabII) to enable production of membrane modules to supply a conceptual 2000 ton per day (TPD) ITM Oxygen facility (the -ITM Oxygen Development FacilityII), and to perform supporting development tasks in materials development and engineering development toward industrial, carbon capture and sequestration applications. Air Products is executing this project under the American Recovery and Reinvestment Act (ARRA) with the objective to accelerate the adoption of ITM Oxygen technology to help meet the country’s goals for deploying clean power plants. The objective of this Topical Report is to address the requirements of Decision Point 3 (DP3), which pertains to the status of all Tasks within Phase 5 and most notably the project status of the CerFab (Task 30) prior to authorization of funds for equipment purchase and construction of the facility. The intent of the DP3 is to provide the opportunity for DOE-NETL to review the status of these tasks and to make recommendations on forward project direction, including a recommendation to pass into Budget Period 8. In the area of Materials Development, Air Products has specified a high pressure dilatometer system which will enable measurements of material expansion of ITM ceramic compounds at very high oxygen partial pressures consistent with CCS applications. Under Task 28.2, subcontractor Ceramatec has made significant progress since DP2 in materials selection and process development and improvement for advanced architecture module fabrication. Ceramatec has determined a materials specification, and has selected a process for making the material. Ceramatec has further developed and selected the process for applying the membrane to unsintered advanced architecture wafers with a Two Step process. Ceramatec has built submodules meeting leak rate specifications and intact 1-TPD modules compromised of advanced architecture components. Equipment and processes required for implementation of the advanced architecture design in the CerFab have been identified and are included in the Task 30 scope of equipment supply. Under Task 29.0, Air Products has developed conceptual ideas for implementation of ITM Oxygen in a 2000 TPD test unit. These concepts are proposed for scale up of the ITM technology to large scale with reduced commercial risk. Under Task 30, Air Products and Ceramatec have collaborated to re-design the CerFab process with the advanced architecture wafer production process as primary, and laid out the new process in the Tooele building; the required process equipment have been specified. The project team updated the project cost and schedule estimates, including all environmental permit schedules. The team also re-assessed project risk and costs for the commissioning and operating phases of the program. Newly projected costs for the CerFab, for which details are provided here as attachments, indicate a savings of approximately $100,000 relative to the original estimate at the time of Phase 5 contract definitization. However, an assessment of risks associated with the equipment, process, and operations of the CerFab indicate that approximately $2.9 million of costs should be expected to address various issues in the project. In addition, $1.6 million of additional spending is expected relative to the original estimate to operate the facility during Task 30.2. Air Products proposes a plan to re-direct funds from Tasks 28, 29, and 31 to Task 30 as necessary to allow the CerFab to meet the Phase 5 program objectives.