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DOE OSTI2014

Jointly Sponsored Research Program on Energy Related Research

Cooperative Agreements, DE-FC26-08NT43293, DOE-WRI Cooperative Research and Development Program for Fossil Energy-Related Resources began in June 2009. The goal of the Program was to develop, commercialize, and deploy technologies of value to the nation’s fossil and renewable energy industries. To ensure relevancy and early commercialization, the involvement of an industrial partner was encouraged. In that regard, the Program stipulated that a minimum of 20% cost share be achieved in a fiscal year. This allowed WRI to carry a diverse portfolio of technologies and projects at various development technology readiness levels. Depending upon the maturity of the research concept and technology, cost share for a given task ranged from none to as high as 67% (two-thirds). Over the course of the Program, a total of twenty six tasks were proposed for DOE approval. Over the period of performance of the Cooperative agreement, WRI has put in place projects utilizing a total of $\$$7,089,581 in USDOE funds. Against this funding, cosponsors have committed $\$$7,398,476 in private funds to produce a program valued at $\$$14,488,057. Tables 1 and 2 presented at the end of this section is a compilation of the funding for all the tasks conducted under the program. The goal of the Cooperative Research and Development Program for Fossil Energy-Related Resources was to through collaborative research with the industry, develop or assist in the development of innovative technology solutions that will: • Increase the production of United States energy resources – coal, natural gas, oil, and renewable energy resources; • Enhance the competitiveness of United States energy technologies in international markets and assist in technology transfer; • Reduce the nation's dependence on foreign energy supplies and strengthen both the United States and regional economies; and • Minimize environmental impacts of energy production and utilization. Success of the Program can be measured by several criteria. Using the deployment of the federal funding with industrial participation as a performance criterion, over the course of the program, the cosponsors contributed more dollars than the federal funds. As stated earlier, a little more than half of the funding for the Program was derived from industrial partners. The industrial partners also enthusiastically supported the research and development activities with cash contribution of $\$$4,710,372.67, nearly 65% of the required cost share. Work on all of the tasks proposed under the Cooperative Agreement has been completed. This report summarizes and highlights the results from the Program. Under the Cooperative Agreement Program, energy-related tasks emphasized petroleum processing, upgrading and characterization, coal and biomass beneficiation and upgrading, coal combustion systems development including oxy-combustion, emissions monitoring and abatement, coal gasification technologies including gas clean-up and conditioning, hydrogen and liquid fuels production, and the development of technologies for the utilization of renewable energy resources. Environmental-related activities emphasized cleaning contaminated soils using microbial fuel cells, development of processes and sorbents for emissions reduction and recovery of water from power plant flue gas, and biological carbon capture and reuse. Technology enhancement activities included resource characterization studies, development of improved methods, monitors and sensors. In general the goals of the tasks proposed were to enhance competitiveness of U.S. technology, increase production of domestic resources, and reduce environmental impacts associated with energy production and utilization. Technologies being brought to commercialization as a result of the funds provided by the Cooperative Agreement contribute to the overall goals of the USDOE and the nation. Each has broad applicability both within the United States and abroad, thereby helping to enhance the competitiveness of U.S. energy technologies in international markets and assisting in technology transfer. Under the Cooperative Agreement Program, WRI has furthered the development of two different coal upgrading technologies. River Basin Energy technology was scaled-up and demonstrated at a nominal 40 tpd size. Similarly, WRI’s patented mercury removal technology further developed into WRITE Coal technology which was then integrated into oxy-combustion and gasification systems for IGCC and fuels production. Integrated systems with WRITE Coal technology applied at the front end represent substantial environmental and efficiency gains. A variation of the RBE coal upgrading technology is being commercialized as a torrefaction technology for woody biomass. WRI worked with EPRI and NIST to develop and improve mercury calibration standards for emissions monitoring. Working with Chart Energy and Chemicals, WRI scaled-up compact reactor technology for the synthesis of fuels and chemicals from syngas. Compact reactor technology represents a five-fold increase in productivity over conventional reactors making smaller-scale distributed synthesis plants an economical viability. Similarly, WRI's patented mixed alcohol synthesis catalyst production is being scaled-up in collaboration with a commercial catalyst manufacturer.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

Integration of Pumped Heat Energy Storage with Fossil-Fired Power Plant (Final Report)

The project team of Southwest Research Institute ® (SwRI ® ), Malta Inc. (Malta), and Luminant Generation Company LLC (Luminant) completed a feasibility study for the integration of a 100-MW, 10-hour (1000-MWh) Malta Pumped Heat Energy Storage (MPHES) system with multiple full-sized fossil-fired electricity generation units (EGU) in Luminant portfolio. MPHES is a long-duration, molten-salt-energy storage technology that uses turbomachinery and heat exchangers to transfer energy to a thermal storage media when charging, and removes the heat in a similar fashion when discharging. With high round trip efficiency (60-65%) and long lifespan (30+ years), MPHES provides economic benefits to the fossil-asset owners that can be scaled to integrate with assets across their portfolio. This technology uses hardware components, workforce personnel, and skillsets similar to those used by fossil EGUs, allowing for synergy when co-locating the two technologies. Luminant has approximately 39,000 megawatts of generation across 12 states, operating in six of the seven competitive markets in the U.S. and powered by a diverse portfolio of natural gas, nuclear, coal, and solar facilities. The DeCordova plant in Granbury, Texas, a simple cycle natural gas peaker power plant, was used as the fossil-fired asset in this project. The local market in Granbury, Texas has many influences, including several nearby power plants, a Luminant-owned nuclear plant (Comanche Peak), and substantial wind energy, which causes both negative pricing at night and high market volatility. Reducing false starts of the DeCordova plant and better responding to market volatility would be an economic advantage. Luminant is currently integrating battery storage plant on site to begin addressing these challenges. Integrating long-duration storage, like MPHES, would expand this capability beyond one hour of storage and have the potential to greatly reduce the total number of gas turbine starts. The MPHES charging requirement could help offset the overnight operating costs of Comanche Peak, which cannot load follow, and the nearby Luminant-owned Wise County combined cycle plant that cycles too often. Following the assessment of Luminant’s ERCOT-based portfolio for integration compatibility with Malta’s PHES system and the project tasks of conceptual study, technoeconomic analysis, technology gap assessment, and commercialization plan, the project team effort has resulted in several key outcomes: (1) Identification of market trends in a high-wind penetration market outside a major metropolitan area; (2) Creation of a dispatching model for the MPHES system and the pairing of Li-ion battery with a gas turbine in a real time market; (3) Revenue and cost estimations for operating MPHES alongside a gas peaker plant with real dispatching considerations and comparison with variations in the Malta implementation, including doubling the storage capacity and using two discharge drivetrains; (4) Potential carbon emission reductions possible by replacing gas turbine operation with Malta PHES operation; and (5) Summary of literature-based future market predictions for Texas.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2017

Energy Conversion Loop: Process Heat Applications of Hybrid Energy Systems

Climate change due to greenhouse gas (GHG) emissions has prompted a shift from fossil fuel energy to other sources for electricity production such as nuclear, solar or wind. These alternatives since no GHG is produced, and no fossil fuels are burned. Both nuclear and other renewable energy sources are recognized as reliable technologies in the United States and around the world. However, they all have a unique set of challenges. Two of the most common renewable energy sources are solar and wind. A particular shortcoming of these two options is the variability of the energy produced; that is they are highly dependent on weather. Many times wind and/or solar power systems are not able to meet the electric demand during peak times. Replacing fossil fuels with nuclear energy is an option (non fossil fuel) for clean energy production. Two primary challenges with using nuclear energy are; wasted heat energy and the lack of load following capabilities. First, heat energy is wasted in the production stream from steam that is created while cooling the core of a nuclear reactor. This steam is initially used in turbines where the electricity is produced. However, once the steam passes through the turbines it is cooled, re-condensed to water, and reused. Large amounts of heat energy are released in the form of heat to the environment (either to the atmosphere or as waste water) and go unused. Secondly, nuclear energy is primarily a baseload power producer - the power output does not fluctuate with power demands, or is not load following. A nuclear hybrid energy system (NHES) may be a solution to the two issues mentions above. Traditional hybrid energy systems (HES) are a combination of two or more energy producers working together to create different energy commodities such as fuel or electricity. To create a NHES, normal use of the reactor for electricity production is combined with renewable power sources to meet the peak power demand of the grid. When electricity demand is high the renewable source and NPP are used in conjunction to meet the demand. When the electricity demand is low the renewable power is used to produce electricity while the NPP operates at full capacity. Rather than sending the excess heat to the cooling towers the excess energy created by the NPP (heat) is diverted to another industrial process.There is no need to decrease the power coming out of the NPP. This research proposal addresses harvesting unused thermal energy from a NPP during normal operations and in times of low power demand.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Using facility-level emissions data to estimate the technical potential of alternative thermal sources to meet industrial heat demand

Industry is frequently highlighted as the world's largest energy-using end-use sector. More specifically, the demand for heat drives much of the demand for energy and fossil fuels in the industrial sector. We conduct a top-down analysis to characterize historical energy and fossil fuel use in 14 top-GHG-emitting industries in the United States, their heat demand requirements, and the potential to substitute heat from geothermal, solar thermal (including concentrating technologies), and small modular nuclear reactors to meet these needs while reducing fossil-fuel use and greenhouse gas (GHG) emissions. We base this analysis on publicly-available facility-level GHG emissions and fuel-combustion data, in addition to assumed requirements for process temperature, to demonstrate the potential value to industry energy analysts of the U.S. Environmental Protection Agency's Greenhouse Gas Reporting Program data. We estimate on a county level that the adoption of these alternative heat sources could have reduced 2015 fossil-fuel use by approximately 31% and combustion GHG emissions by approximately 24%. The most extensive substitution opportunities are in the ethyl alcohol manufacturing and wet corn-milling industries; petroleum refining represents the largest absolute emissions mitigation potential. This initial top-down analysis of substitution potential does not consider more detailed technical factors, including resource availability that will influence the actual deployment of alternative energy technologies. The analysis also does not consider the economic or market factors, including the expected cost to build and operate these generators. We do assume process byproducts that are extensively used for combustion fuels would not be good candidates for substitution for alternative energy generators. Based on these caveats, our analysis could be considered a top-range estimate for this mix of heat generators and industry heat demands. Any subsequent analysis of these alternate energy sources should increase the level of technical, economic, and policy detail.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Machine learning and deep learning for mineralogy interpretation and CO 2 saturation estimation in geological carbon Storage: A case study in the Illinois Basin

Carbon capture and storage (CCS) is a promising approach to simultaneously maintaining energy security and reducing carbon dioxide (CO 2 ) emissions under the current energy portfolio that is dominated by fossil fuel energy. Pre-injection formation characterization and post-injection CO 2 monitoring are two critical tasks to guarantee storage efficiency in CCS. The CCS projects in the Illinois Basin, the first large-scale CO 2 injection into saline aquifers in the United States, employed conventional and the latest pulsed neutron logging (PNL) tools for mineralogy interpretation and CO 2 saturation estimation, which provide valuable references for future CCS projects. Because of the inherent fuzziness of petrophysical measurements and complex subsurface heterogeneity, interpreting well-logging data is time-consuming, and its accuracy can be user-biased. In recent years, data-driven methods have been widely used to capture the non-linear patterns between input features and interpretation results. This work applied and evaluated four commonly used machine learning (ML) models, including ridge regression (RR), random forest (RF), gradient boosting regression (GBR), support vector regression (SVR), and one deep learning (DL) model, the artificial neural network (ANN). We optimized the hyperparameters of the four ML models and the DL model using the simulated annealing algorithm and the grid search strategy, respectively. The input features of the mineralogy interpretation models were eleven conventional well-logging parameters, and the label data (i.e., ground truth) were the porosity and volumetric fractions of six minerals, including quartz, feldspar, dolomite, calcite, clay, and iron minerals. The results demonstrated that the GBR and RF models were superior in predicting volumetric fractions of minerals and porosity; label data with low coefficient of variation (CV) values tended to yield better performance. For CO 2 saturation estimation, the RF was the best-performing model, followed by SVR, ANN, GBR, and RR. Furthermore, we conducted feature importance ranking using the permutation importance algorithm and found that the formation sigma and well pressure were the most important features in this study. In conclusion, the study of CCS projects in the Illinois Basin bridges the gap between the limited knowledge and understanding of geological carbon storage and the increasing demand for reliable, cost-effective, and sustainable energy solutions.

58 GEOSCIENCES↗
DOE OSTI2017

Enabling CCS via Low-temperature Geothermal Energy Integration for Fossil-fired Power Generation

Here, among the key barriers to commercial scale deployment is the cost associated with CO 2 capture. This is particularly true for existing large, fossil-fired assets that account for a large fraction of the electricity generation fleet in developed nations, including the U.S. Fitting conventional combustion technologies with CO 2 capture systems can carry an energy penalty of thirty percent or more, resulting in an increased price of power to the grid, as well as an overall decrease in net plant output. Taken together with the positive growth in demand for electricity, this implies a need for accelerated capital build-out in the power generation markets to accommodate both demand growth and decreased output at retrofitted plants. In this paper, the authors present the results of a study to assess the potential to use geothermal energy to provide boiler feedwater preheating, capturing efficiency improvements designed to offset the losses associated with CO 2 capture. Based on NETL benchmark cases and subsequent analysis of the application using site-specific data from the North Valmy power plant, several cases for CO 2 capture were evaluated. These included geothermally assisted MEA capture, CO2BOLs capture, and stand-alone hybrid power generation, compared with a baseline, no-geothermal case. Based on Case 10, and assuming 2.7 MMlb/h of geothermally sourced 150 ºC water, the parasitic power load associated with MEA capture could be offset by roughly seven percent, resulting in a small (~1 percent) overall loss to net power generation, but at levelized costs of electricity similar to the no-geothermal CCS case. For the CO 2 BOLs case, the availability of 150°C geothermal fluid could allow the facility to not only offset the net power decrease associated with CO 2 BOLs capture alone, but could increase nameplate capacity by two percent. The geothermally coupled CO 2 BOLs case also decreases LCOE by 0.75 ¢/kWh relative to the non-hybrid CO 2 BOLs case, with the improved performance over the MEA case driven by the lower regeneration temperature and associated duty for CO 2 BOLs relative to MEA.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2017

Towards sustainable agriculture: Fossil-free ammonia

We report that about 40% of our food would not exist without synthetic ammonia (NH 3 ) for fertilization. Yet, NH 3 production is energy intensive. About 2% of the world's commercial energy is consumed as fossil fuels for NH 3 synthesis based on the century-old Haber-Bosch (H.-B.) process. The state of the art and the opportunities for reducing the fossil energy footprint of industrial H.-B. NH 3 synthesis are discussed. It is shown that even a hypothetical utterly revolutionary H.-B. catalyst could not significantly reduce the energy demand of H.-B. NH 3 as this is governed by hydrogen production. Renewable energy-enabled, fossil-free NH 3 synthesis is then evaluated based on the exceptional and continuing cost decline of renewable electricity. H.-B. syngas (H 2 , N 2 ) is assumed to be produced by electrolysis and cryogenic air separation and then supplied to an existing H.-B. synthesis loop. Fossil-free NH 3 could be produced for energy costs of about $232 per tonne NH 3 without claiming any economic benefits for the avoidance of about 1.5 tonnes of CO 2 released per tonne NH 3 compared to the most efficient H.-B. implementations. Research into alternatives to the H.-B. process might be best targeted at emerging markets with currently little NH 3 synthesis capacity but significant future population growth in markets such as Africa. Reduced capital intensity, good scale-down economics, tolerance for process upsets and contamination, and intermittent operability are some desirable characteristics of NH 3 synthesis in less developed markets and for stranded resources. Lastly, processes that are fundamentally different from H.-B. may come to the fore under these specific boundary conditions.

03 NATURAL GAS↗
DOE OSTI2024

Does How we Decarbonize Matter? An Examination of the Potential Energy Poverty Impacts of Fossil Asset Replacements

Replacing fossil assets with low-carbon alternatives will influence the costs associated with maintaining a competent, reliable grid (i.e., total systems costs). Noting over time any resulting system cost increases will likely be borne by consumers, this paper aims to provide insight into the potential energy poverty impacts that may result.

Harker Steele, Amanda [NETL] (ORCID:00000003233986↗
DOE OSTI2013

Today's Leaders for a Sustainable Tomorrow

Today's Leaders for a Sustainable Tomorrow is a collaboration of five residential environmental learning centers (Audubon Center of the North Woods, Deep Portage Learning Center, Laurentian Environmental Center, Long Lake Conservation Center and Wolf Ridge Environmental Learning Center) that together increased energy efficiency, energy conservation and renewable energy technologies through a number of different means appropriate for each unique center. For energy efficiency upgrades the centers installed envelope improvements to seal air barriers through better insulation in walls, ceilings, windows, doors as well as the installation of more energy efficient windows, doors, lighting and air ventilation systems. Through energy sub-meter monitoring the centers are able to accurately chart the usage of energy at each of their campuses and eliminate unnecessary energy usage. Facilities reduced their dependence on fossil fuel energy sources through the installation of renewable energy technologies including wood gasification, solar domestic hot water, solar photovoltaic, solar air heat, geothermal heating and wind power. Centers also installed energy education displays on the specific renewable energy technologies used at the center.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS1975

Future US energy demands based upon traditional consumption patterns lead to requirements which significantly exceed domestic supply

Energy consumption in the United States has risen in response to both increasing population and to increasing levels of affluence. Depletion of domestic energy reserves requires consumption modulation, production of fossil fuels, more efficient conversion techniques, and large scale transitions to non-fossile fuel energy sources. Widening disparity between the wealthy and poor nations of the world contributes to trends that increase the likelihood of group action by the lesser developed countries to achieve political and economic goals. The formation of anticartel cartels is envisioned.

Source record↗
DOE OSTI2024

Titanium-Cerium Electrode-Decoupled Redox Flow Batteries Integrated With Fossil Fuel Assets For Load-Following, Long-Duration Energy Storage

Operation of fossil plants at partial capacity with frequent cycling results in decreased efficiency, increased emissions and increased wear and maintenance. The objective of this project is to advance the integration of a titanium-cerium electrode-decoupled redox flow battery (RFB) system with conventional fossil-fueled power plants through technical and economic system-level studies and component scale-up and R&D. The Ti-Ce chemistry has a pathway to meet the DOE cost targets of $\$$100/kWh and $\$$0.05/kWh-cycle owing to the use of low-cost, earth abundant elemental actives and incorporation of inexpensive carbon felt electrodes and non-fluorinated anion exchange membrane (AEM) separators. The initial unit cell design was scaled up, with some modifications made to improve ease of manufacturing, from 25 cm 2 cell area to 400 cm 2 . Electrochemical tests demonstrated operation at a current density up to 50 mA/cm 2 , which is on par with other commercial RFB offerings. Furthermore, the Ti-Ce technology developed by WashU was evaluated and tested by industrial team partner, Giner, Inc., in their modular 3-cell stack. Several cell design modifications and alternate component material selections were successfully implemented to accommodate this chemistry while reducing polarization and leakage. Results from stack testing show high columbic efficiency and indicate that further optimization of cell compression and components will lead to successful operation of the Ti-Ce ED-RFB over longer duration at the multi-cell stack level. Engineering and cost analysis showed that an RFB system with power output on the order of 100 MW and with a charge/discharge duration of approx. 12 hours is the most cost effective for integration with fossil plants. At this scale, projected cycling of fossil fuel power plants can be significantly reduced. The use of a storage system is shown to reduce the fossil plant standalone cost of electricity by $\$$7/MWh, through increased capacity factor and improved average efficiency, in the scenario of high penetration of renewable power.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Subtask 2.6 – Optimization of Aerosol Mitigation Technology for Postcombustion CO 2 Capture

Growing concerns over the impact of CO 2 emissions from combustion sources on global climate change have prompted numerous research and development projects aimed at developing cost-effective technologies for CO 2 capture. One family of technologies being demonstrated at pilot and full scale globally is postcombustion CO 2 capture (PCCC) systems that employ amine-based solvents. The captured CO 2 can be compressed and permanently stored underground or used for enhanced oil recovery (EOR). The proximity of North Dakota’s lignite-fired fleet of power plants to potential CO 2 storage options creates a unique atmosphere for PCCC within the state. However, the aerosols present in lignite flue gas present a challenge for large-scale PCCC at North Dakota power plants. Aerosols can negatively impact the long-term performance of amine-based solvents for CO 2 capture. Amine-based solvents are volatile, and aerosols provide nucleation sites where amine vapors can condense. Because aerosols cannot be easily captured at the column outlet using conventional technologies, the amine-laden aerosols escape the system and lead to accelerated solvent losses. Moreover, aerosol components can chemically react with amines to form degradation products that can permanently deactivate the amine, cause fouling, and lead to hazardous emissions. Many of the elements that have been shown to catalyze solvent degradation are present in lignite coals and can exacerbate solvent replacement economics. Understanding this issue is critical to the implementation of solvent-based CO 2 capture systems as applied to lignite-fired generation systems. The Energy & Environmental Research Center (EERC) designed and carried out this project to optimize aerosol mitigation technology for PCCC at a lignite-fired power plant. To meet the goal of this project, the following objectives were identified: Determine the effectiveness of a wet electrostatic precipitator (WESP) on collection of aerosols at a low-rank coal-fired power station. Determine the impact of aerosols on the efficiency and degradation products of amine-based carbon capture systems fired with low-rank fuels. Work was conducted at Minnkota Power Cooperative’s (MPC’s) Milton R. Young (MRY) Station Unit 2 using a slipstream of flue gas from the outlet of the plant’s flue gas desulfurization (FGD) unit. To gather initial data for sizing and specifying a WESP for this system, a temporary pilot-scale WESP was rented and installed on-site. Several different conditions were tested to examine the impact of flow rate, voltage, and current on WESP performance. The WESP was effective at removing large particulate (>200 nm) but caused an increase in fine particulate (<75 nm). Fine particulate material at the inlet and outlet of the WESP was collected, analyzed, and showed that crystalline sulfates carried over from the plant’s FGD unit were being converted to fine aerosols and SO 2 was being converted to SO 3 through the WESP. Additionally, the high moisture content of the flue gas stream at this sample location also contributed to an overall increase in aerosol mass under some of the test conditions. Using the results from the rented WESP, the project team installed a smaller-scale WESP upstream of the EERC’s slipstream CO 2 capture system. Flue gas was routed through a pilot-scale FGD unit to remove SO 2 to very low levels (~1 ppm) and then through a direct contact cooler (DCC) to further cool the gas and to remove moisture. The gas exiting the DCC was then routed through the new WESP before passing to the CO 2 absorber columns. Fluor’s amine-based solvent was used to scrub CO 2 from the slipstream through a set of two absorber columns. The rich solvent was regenerated in a stripper column by heating to drive off captured CO 2 . The system operated using a catch-and-release method where the CO 2 was separated to provide data on the process, but the captured CO 2 was released back into the host site stack. Aerosols and sulfur species were measured at multiple locations throughout the pilot-scale system. The inlet FGD and DCC removed much of the particulate matter and gaseous sulfur upstream of the WESP. With this configuration, the WESP achieved >95% particulate capture. The new WESP did not show any of the increases in SO 3 or other aerosol species that had been consistently observed with the larger-scale WESP installed immediately downstream of the plant’s full-scale FGD unit. Particulate samples captured and analyzed from the WESP inlet did not show any presence of crystalline sulfate materials, indicating that the pilot-scale FGD and DCC were efficient at reducing carryover from the plant’s full-scale FGD unit. A set of parametric tests were conducted on the new WESP to assess the impacts of flow rate, voltage, number of online WESP fields, and gas-phase sulfur content on aerosol and sulfur transformations. The results showed that the WESP performed similarly well at all sets of conditions. Sulfur and particulate matter exiting the WESP were further reduced through the absorber column as the amine-based solvent captured some of the residual contaminants. Solvent analysis showed that these species were slowly concentrating in the solvent over the duration of the test. When the WESP was taken offline and the sulfur slip through the FGD allowed to rise, the sulfate content in the solvent rose sharply, showing that the extra FGD and WESP were effective at reducing sulfate and cation uptake. This would be expected to extend amine-based solvent life by slowing the formation of heat-stable salts and other degradation products. This subtask was cofunded through the EERC–U.S. Department of Energy Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by the North Dakota Industrial Commission and MPC.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Pumped-Storage Hydropower using Abandoned Underground Mines (PSH-AUM) as an Innovative Energy Storage Technology for Fossil-Integrated Systems

Pumped-storage hydropower (PSH) provides around 95% of all utility-scale energy storage in the U.S. and globally. Additional deployment of PSH is hampered by excessively long permitting and commissioning requirements and is constrained to locations for which natural topography provides suitable elevation relief between the upper and lower reservoirs (the ΔH challenge). The purpose of this research was to evaluate Pumped-Storage Hydropower using Abandoned Underground Mines (PSH-AUM) as a means to solve the ΔH challenge and initiate the commercialization pathway for a promising new energy storage technology. Four primary tasks were conducted: Screening and ranking of candidate sites for project development; multiphase reservoir modeling to evaluate mine performance; techno-economic analysis and preliminary designs for PSH-AUM systems integrated with fossil-fuel power units; and stakeholder engagement to identify pathways to commercialization of this new technology. Key results were achieved in each of the four primary tasks. Candidate site screening determined that nearly 10,000 underground mines were spatially locatable, of which more than 100 sites appear suitable for integration with existing fossil power plants that are expected to remain in longer-term operation. Mine reservoir models were developed using PNNL’s STOMP simulator and parameterized using candidate site data to evaluate interactions with the surrounding groundwater system and confirm the potential for some mines to accommodate inflows and outflows on the order of 100 m3/s over 8-hour durations (1.6 GWh system) without excessive aqueous pressures. Techno-economic analysis resulted in a project cost optimization scheme to identify key sensitivities and the development of preliminary designs that can minimize overall costs of deployment. Finally, stakeholder engagement with industry, state government, and local economic development leaders confirmed the viability of PSH-AUM as a promising new technology. Our Phase I project results suggest that PSH-AUM technology has a domestic market potential on the order of $100+ Billion with ample space for technology development to commercialization within the next decade.

13 HYDRO ENERGY↗
DOE OSTI2019

Technical and economic feasibility of solar flat-plate collector thermal energy systems for small and medium manufacturers

Manufacturing industries require process heating for a wide variety of operations, such as drying, cooking, washing, and sterilizing. Studies of industrial energy consumption have shown that more than 50% of industrial heating demand is in the low (<60 °C), medium (60-150 °C), and medium-high (<250 °C) temperature ranges. A significant fraction of this low temperature thermal energy could be generated by commercially available solar flat-plate collector thermal energy systems, which would reduce the use of fossil fuels, energy cost volatility, and carbon emissions. However, manufacturing industries have not been able to take advantage of solar flat-plate collector systems for two main reasons: First, information is not readily available about when and what flat-plate collector system sizes can be economically applied and, second, manufacturers often do not have appropriate personnel or analysis tools to make decisions about installation of solar flat-plate collector systems. The goal of this research is to provide design decision support to small- and medium-sized manufacturers in conducting feasibility analysis for the application of solar flat-plate collector systems in their operations. The $\bar{φ}, f$-chart method and modified $\bar{φ}, f$-chart design method are used to predict the amount of energy collected by solar flat-plate collectors. A simplified model is proposed to assess the cost of solar flat-plate collector energy systems. To demonstrate the presented feasibility analysis methodology, a decision support software application is developed. What-if scenarios are presented for several geographic locations of varying climates. A sensitivity analysis of savings-to-investment ratio (SIR) was performed by changing selected input parameters by ±30% from the base case. It was found that SIR is sensitive to natural gas price, followed by collector area dependent cost, discount rate, cost of the auxiliary gas heater, and cost of the preheating system.

14 SOLAR ENERGY↗
DOE OSTI2024

Development of Manganese and Iron Mixed Metal Oxides for Thermochemical Energy Storage

Energy storage plays an essential role for sustainable and renewable energy use in an effort to reduce carbon emissions. Thermochemical energy storage (TCES) is a favorable alternative to fossil fuel energy systems and a promising solution to the intermittency problem of renewable energy sources (such as solar energy). TCES stores energy in the form of chemical bonds using reversible redox reactions (such as manganese metal oxides). This study developed manganese oxide (Mn2O3) and iron oxide (Fe2O3) with an inert dispersant of silicon dioxide (SiO2) (Mn-Fe-Si) for potential large scale energy storage application. These metal oxides are nontoxic, cheap, and relatively abundant. The materials were prepared with varying metal oxide content using physical mixing in a ball mill, pressure pelletization and calcination at different temperatures. Redox cycle tests were conducted using differential scanning calorimetry combined with thermogravimetric analysis (TGA-DSC). The Mn-Fe-Si materials had higher cyclability and energy release compared to the pure metal oxides and manganese oxide with SiO2. The calcination temperature had a significant effect on releasable energy due to the interactions between the oxides. The Mn-Fe-Si mixture calcined at high temperature (1000oC) showed the highest average energy storage density.

Wilkinson, Olivia↗
DOE OSTI2014

SUBTASK 2.19 – OPERATIONAL FLEXIBILITY OF CO2 TRANSPORT AND STORAGE

Carbon dioxide (CO2) is produced in large quantities during electricity generation and by industrial processes. These CO2 streams vary in terms of both composition and mass flow rate, sometimes substantially. The impact of a varying CO2 stream on pipeline and storage operation is not fully understood in terms of either operability or infrastructure robustness. This study was performed to summarize basic background from the literature on the topic of operational flexibility of CO2 transport and storage, but the primary focus was on compiling real-world lessons learned about flexible operation of CO2 pipelines and storage from both large-scale field demonstrations and commercial operating experience. Modeling and pilot-scale results of research in this area were included to illustrate some of the questions that exist relative to operation of carbon capture and storage (CCS) projects with variable CO2 streams. It is hoped that this report’s real-world findings provide readers with useful information on the topic of transport and storage of variable CO2 streams. The real-world results were obtained from two sources. The first source consisted of five full-scale, commercial transport–storage projects: Sleipner, Snøhvit, In Salah, Weyburn, and Illinois Basin–Decatur. These scenarios were reviewed to determine the information that is available about CO2 stream variability/intermittency on these demonstration-scale projects. The five projects all experienced mass flow variability or an interruption in flow. In each case, pipeline and/or injection engineers were able to accommodate any issues that arose. Significant variability in composition has not been an issue at these five sites. The second source of real- world results was telephone interviews conducted with experts in CO2 pipeline transport, injection, and storage during which commercial anecdotal information was acquired to augment that found during the literature search of the five full-scale projects. The experts represented a range of disciplines and hailed from North America and Europe. Major findings of the study are that compression and transport of CO2 for enhanced oil recovery (EOR) purposes in the United States has shown that impurities are not likely to cause transport problems if CO2 stream composition standards are maintained and pressures are kept at 10.3 MPa or higher. Cyclic, or otherwise intermittent, CO2 supplies historically have not impacted in-field distribution pipeline networks, wellbore integrity, or reservoir conditions. The U.S. EOR industry has demonstrated that it is possible to adapt to variability and intermittency in CO2 supply through flexible operation of the pipeline and geologic storage facility. This CO2 transport and injection experience represents knowledge that can be applied in future CCS projects. A number of gaps in knowledge were identified that may benefit from future research and development, further enhancing the possibility for widespread application of CCS. This project was funded through the Energy & Environmental Research Center–U.S. Department of Energy Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FC26-08NT43291. Nonfederal funding was provided by the IEA Greenhouse Gas R&D Programme.

Jensen, Melanie↗
DOE OSTI2021

Topical Report – Findings on Subtask 2.7 – Wet ESP and Aerosol Testing at Coal Creek Station

Growing concerns over the impact of CO 2 emissions from combustion sources on global climate change have prompted numerous research and development projects aimed at developing cost-effective technologies for CO 2 capture. One family of technologies being demonstrated at pilot and full scale globally is postcombustion carbon capture (PCCC) systems that employ amine-based solvents. The captured CO 2 can be compressed and permanently stored underground or used for enhanced oil recovery. The proximity of North Dakota’s lignite-fired fleet of power plants to potential CO 2 storage options creates a unique atmosphere for PCCC within the state. However, the unique components present in lignite flue gas present a challenge for large-scale PCCC at North Dakota power plants by contributing to aerosol formation. Aerosols can negatively impact the long-term performance of amine-based solvents for CO 2 capture. Amine-based solvents are volatile, and flue gas particulate provides nucleation sites where amine vapors can condense as aerosols. Because aerosols cannot be easily captured at the column outlet using conventional technologies, the amine-laden aerosols escape the system and lead to accelerated solvent losses. Moreover, particulate components can chemically react with amines to form degradation products that can permanently deactivate the amine, cause fouling, and lead to hazardous emissions. Many of the elements that have been shown to catalyze solvent degradation are present in lignite coals and can exacerbate solvent replacement economics. Understanding this issue is critical to the implementation of solvent-based CO 2 capture systems as applied to lignite-fired generation systems. The Energy & Environmental Research Center (EERC) designed and carried out this project to fully characterize aerosol behavior with various control technologies installed to better optimize aerosol mitigation technology for CO 2 capture. To meet the goal of this project, the following objectives were identified: Determine the effectiveness of a wet electrostatic precipitator (WESP) on mitigating formation of problematic aerosols at Great River Energy’s Coal Creek Station, upstream of the PCCC system. Determine the effectiveness of the Mitsubishi Heavy Industries (MHI) proprietary amine emission reduction unit (AERU) as a postcapture solvent recovery system for reducing aerosol emissions and extending solvent life downstream of the PCCC system. Determine the impact of aerosols on the efficiency and degradation products of both commercial and advanced solvents within the PCCC system. Work was conducted at Coal Creek Station Unit 1 using a slipstream of flue gas from the outlet of the plant’s flue gas desulfurization (FGD) unit. Flue gas was routed through a pilot-scale FGD unit to remove SO 2 to very low levels (~1 ppm) and then through a direct contact cooler (DCC) to further cool the gas and to remove moisture. The gas exiting the DCC was then optionally routed through a WESP before passing to the CO 2 absorber columns. The MHI solvent was used to scrub CO 2 from the slipstream through a set of two absorber columns. The rich solvent was regenerated in a stripper column by heating to drive off captured CO 2 . Flue gas exiting the absorber column was routed to MHI’s proprietary AERU to recover entrained solvent. The system operated using a catch-and-release method where the CO 2 was separated to provide data on the process, but the captured CO 2 was released back into the host site stack. Particulate was measured, collected, and analyzed from multiple locations throughout the pilot-scale system. Unlike the performance observed in prior work, the inlet FGD and DCC did not remove significant particulate matter from the flue gas. This appears to be due to a difference in the nature of the particulate. The DCC seemed to increase particulate size and count, most likely owing to water condensing onto the surfaces of fly ash particles. When the WESP was operated, it achieved >95% particulate capture. Very little particulate matter or indications of solvent were detected at the AERU outlet. When operating with advanced KS 21 solvent, the particulate material at the AERU outlet was even further decreased. Solvent analysis showed that some species derived from flue gas and ash were slowly concentrating in the solvent over the duration of the test. The levels observed were reported to be within expected ranges and were not of concern to MHI. A high-level techno-economic assessment of installing CO 2 capture at Coal Creek Station suggested that, when using a standard monoethanolamine (MEA)-based solution with simple heat integration, the energy penalty to net generation would be 34%. The bulk of this was due to steam losses for regenerating solvent, followed by parasitic electrical demand for CO 2 compression and then by increased parasitic load for pushing flue gas through the absorber column. These demands could be decreased with a more advanced solvent that exhibits lower heat of regeneration and lower pressure drop than does a simple MEA solution. Further energy could be saved with more thorough heat integration to recover useful energy from the steam used for solvent regeneration. Installing a WESP was predicted to increase the cost of electricity by nearly $5/MWh. This would become cost-effective if solvent losses were roughly 10 times the baseline estimate when not using a WESP but could be returned to baseline by installing the WESP. Piping CO 2 for storage in more favorable geology could help with carbon capture and storage economics. Although storing off-site would necessitate construction of a CO 2 transport pipeline, the cost of this pipeline might be more than offset by reducing the number of wells required, the depths of the wells required, and the electrical demand for the CO 2 compressor. Additional factors that favor off-site storage costs include smaller expected CO 2 plume sizes, which translates to less monitoring and fewer landowner agreements. More detailed assessment of the specific geology in the region under and around Coal Creek Station would be needed to accurately assess the costs and benefits of different storage site options. This subtask was cofunded through the Energy & Environmental Research Center–U.S. Department of Energy Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by the North Dakota Industrial Commission.

Strege, Joshua↗