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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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DOE OSTI2014

Techno-Economic Analysis of Scalable Coal-Based Fuel Cells

Researchers at The University of Akron (UA) have demonstrated the technical feasibility of a laboratory coal fuel cell that can economically convert high sulfur coal into electricity with near zero negative environmental impact. Scaling up this coal fuel cell technology to the megawatt scale for the nation’s electric power supply requires two key elements: (i) developing the manufacturing technology for the components of the coal-based fuel cell, and (ii) long term testing of a kW scale fuel cell pilot plant. This project was expected to develop a scalable coal fuel cell manufacturing process through testing, demonstrating the feasibility of building a large-scale coal fuel cell power plant. We have developed a reproducible tape casting technique for the mass production of the planner fuel cells. Low cost interconnect and cathode current collector material was identified and current collection was improved. In addition, this study has demonstrated that electrochemical oxidation of carbon can take place on the Ni anode surface and the CO and CO 2 product produced can further react with carbon to initiate the secondary reactions. One important secondary reaction is the reaction of carbon with CO 2 to produce CO. We found CO and carbon can be electrochemically oxidized simultaneously inside of the anode porous structure and on the surface of anode for producing electricity. Since CH 4 produced from coal during high temperature injection of coal into the anode chamber can cause severe deactivation of Ni-anode, we have studied how CH 4 can interact with CO 2 to produce in the anode chamber. CO produced was found able to inhibit coking and allow the rate of anode deactivation to be decreased. An injection system was developed to inject the solid carbon and coal fuels without bringing air into the anode chamber. Five planner fuel cells connected in a series configuration and tested. Extensive studies on the planner fuels and stack revealed that the planner fuel cell stack is not suitable for operation with carbon and coal fuels due to lack of mechanical strength and difficulty in sealing. We have developed scalable processes for manufacturing of process for planner and tubular cells. Our studies suggested that tubular cell stack could be the only option for scaling up the coal-based fuel cell. Although the direct feeding of coal into fuel cell can significantly simplify the fuel cell system, the durability of the fuel cell needs to be further improved before scaling up. We are developing a tubular fuel cell stack with a coal injection and a CO 2 recycling unit.

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DOE OSTI2015

Coal-by-Rail: A Business-as-Usual Reference Case

As proposed carbon emission standards reduce domestic coal use, the role of coal in the U.S. energy mix may be expected to decline. If such a decline were to occur, how would it affect rail traffic? Today, coal represents a major share of rail tonnage and gross revenue. While growth in other traffic—most notably, crude oil—may offset some of any potential decline in coal shipments, would it be sufficient? This paper explores trends in coal production volumes and use, rail tonnage and revenue, and the distribution of traffic origins and destinations in order to consider the impact of potential changes in future coal traffic. Rather than modeling discrete flows, it draws on historical data and forecasts maintained by the U.S. Department of Energy’s Energy Information Administration (EIA), industry studies and analyses, and background knowledge of the rail industry, specific routes and service territories, and commodity-level traffic volumes.

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DOE OSTI2015

Hydrogen Selective Exfoliated Zeolite Membranes

The objective of this project was to develop and evaluate an innovative membrane technology at process conditions that would be representative of Integrated Gasification Combined Cycle (IGCC) advanced power generation with pre-combustion capture of carbon dioxide (CO 2 ). This research focused on hydrogen (H 2 )-selective zeolite membranes that could be utilized to separate conditioned syngas into H 2 -rich and CO 2 -rich components. Both experiments and process design and optimization calculations were performed to evaluate the concept of ultra-thin membranes made from zeolites nanosheets. In this work, efforts in the laboratory were made to tackle two fundamental challenges in application of zeolite membranes in harsh industrial environments, namely, membrane thickness and membrane stability. Conventional zeolite membranes have thicknesses in the micron range, limiting their performance. In this research, we developed a method for fabrication of ultimately thin zeolite membranes based on zeolite nanosheets. A range of layered zeolites (MWW, RWR, NSI structure types) suitable for hydrogen separation was successfully exfoliated to their constituent nanosheets. Further, membranes were made from one of these zeolites, MWW, to demonstrate the potential of this group of materials. Moreover, long-term steam stability of these zeolites (up to 6 months) was investigated in high concentrations of steam (35 mol% and 95 mole%), high pressure (10 barg), and high temperatures (350 °C and 600 °C) relevant to conditions of water-gas-shift and steam methane reforming reactions. It was found that certain nanosheets are stable, and that stability depends on the concentration of structural defects. Additionally, models that represent a water-gas-shift (WGS) membrane reactor equipped with the zeolite membrane were developed for systems studies. These studies had the aim of analyzing the effect of the membrane reactor integration into IGCC plants in terms of performance and economic aspects of the plants. Specifically, simulation and design optimization studies were performed using the developed stand-alone membrane reactor models to identify the membrane selectivity and permeance characteristics necessary to achieve desired targets of CO 2 capture and H 2 recovery, as well as guide the selection of the optimal reactor design that minimizes the membrane cost as a function of its surface area required. The isothermal membrane reactor model was also integrated into IGCC system models using both the MATLAB and Aspen software platforms and techno-economic analyses of the integrated plants have been carried out to evaluate the feasibility of replacing current technologies for pre-combustion capture by the proposed novel approach in terms of satisfying stream constraints and achieving the DOE target goal of 90% CO 2 capture. The results of the performed analyses based on present value of annuity calculations showed break even costs for the membrane reactor within the feasible range for membrane fabrication. However, the predicted membrane performance used in these simulations exceeded the performance achieved experimentally. Therefore, further work is required to improve membrane performance.

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DOE OSTI2014

Degradation of TBC Systems in Environments Relevant to Advanced Gas Turbines for IGCC Systems

Air plasma sprayed (APS) thermal barrier coatings (TBCs) are used to provide thermal insulation for the hottest components in gas turbines. Zirconia stabilized with 7wt% yttria (7YSZ) is the most common ceramic top coat used for turbine blades. The 7YSZ coating can be degraded from the buildup of fly-ash deposits created in the power-generation process. Fly ash from an integrated gasification combined cycle (IGCC) system can result from coal-based syngas. TBCs are also exposed to harsh gas environments containing CO 2 , SO 2 , and steam. Degradation from the combined effects of fly ash and harsh gas atmospheres has the potential to severely limit TBC lifetimes. The main objective of this study was to use lab-scale testing to systematically elucidate the interplay between prototypical deposit chemistries (i.e., ash and its constituents, K 2 SO 4 , and FeS) and environmental oxidants (i.e., O 2 , H 2 O and CO 2 ) on the degradation behavior of advanced TBC systems. Several mechanisms of early TBC failure were identified, as were the specific fly-ash constituents responsible for degradation. The reactivity of MCrAlY bondcoats used in TBC systems was also investigated. The specific roles of oxide and sulfate components were assessed, together with the complex interplay between gas composition, deposit chemistry and alloy reactivity. Bondcoat composition design strategies to mitigate corrosion were established, particularly with regard to controlling phase constitution and the amount of reactive elements the bondcoat contains in order to achieve optimal corrosion resistance.

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DOE OSTI2015

Streamlined approach for environmental restoration (SAFER) plan for corrective action unit 412: clean slate I plutonium dispersion (TTR) tonopah test range, Nevada, revision 0

This Streamlined Approach for Environmental Restoration (SAFER) Plan addresses the actions needed to achieve closure for Corrective Action Unit (CAU) 412. CAU 412 is located on the Tonopah Test Range and consists of a single corrective action site (CAS), TA-23-01CS, Pu Contaminated Soil. There is sufficient information and historical documentation from previous investigations and the 1997 interim corrective action to recommend closure of CAU 412 using the SAFER process. Based on existing data, the presumed corrective action for CAU 412 is clean closure. However, additional data will be obtained during a field investigation to document and verify the adequacy of existing information and determine whether the CAU 412 closure objectives have been achieved. This SAFER Plan provides the methodology to gather the necessary information for closing the CAU.The following summarizes the SAFER activities that will support the closure of CAU 412:• Collect environmental samples from designated target populations to confirm or disprove the presence of contaminants of concern (COCs) as necessary to supplement existing information.• If no COCs are present, establish clean closure as the corrective action. • If COCs are present, the extent of contamination will be defined and further corrective actions will be evaluated with the stakeholders (NDEP, USAF).• Confirm the preferred closure option is sufficient to protect human health and the environment.

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DOE OSTI2014

Evaluation of Carbon Dioxide Capture From Existing Coal Fired Plants by Hybrid Sorption Using Solid Sorbents

A novel hybrid solid sorbent technology for CO₂ capture and separation from coal combustion-derived flue gas was evaluated. The technology – Capture of CO₂ by Hybrid Sorption (CACHYS™) – is a solid sorbent technology based on the following ideas: 1) reduction of energy for sorbent regeneration, 2) utilization of novel process chemistry, 3) contactor conditions that minimize sorbent-CO₂ heat of reaction and promote fast CO₂ capture, and 4) low-cost method of heat management. This report provides key information developed during the course of the project that includes sorbent performance, energy for sorbent regeneration, physical properties of the sorbent, the integration of process components, sizing of equipment, and overall capital and operational cost of the integrated CACHYS™ system. Seven sorbent formulations were prepared and evaluated at the lab-scale for energy requirements and CO₂ capture performance. Sorbent heat of regeneration ranged from 30-80 kJ/mol CO₂ and was found to be dependent on process conditions. Two sorbent formulations (designated HCK-4 & HCK-7) were down-selected for additional fixed-bed testing. Additional testing involved subjecting the sorbents to 100 continuous cycles in the fixed-bed reactor to determine performance as a function of time. The working capacity achieved for HCK-4 sorbent ranged from 5.5-8.0 g CO₂/100 g sorbent, while the HCK-7 typically ranged from 8.0-10.0 g CO₂/100 g sorbent. Overall, there was no deterioration in capacity with continuous cycling for either sorbent. The CACHYS™ bench-scale testing system designed and fabricated under this award consists of a dual circulating fluidized-bed adsorber and a moving-bed regenerator. The system takes a flue gas slipstream from the University of North Dakota’s coal-fired steam plant. Prior to being sent to the adsorber, the flue gas is scrubbed to remove SO₂ and particulate. During parametric testing of the adsorber, CO₂ capture achieved using the 2-bed configuration with recirculation in both beds was 65-70% with a high flue gas CO₂ loading (~7%) and up to 85% with a low flue gas CO₂ loading (~4%). A sorbent regenerator system consisting of a pre-heater, desorber, and cooler is used to heat the CO₂-rich sorbent with direct and indirect steam producing a nearly 100% pure stream of CO₂. Parametric testing of the regenerator system demonstrated the impact of process conditions on both desorption rate and the heat of regeneration. Clear evidence of the use of specific process conditions that lower the overall energy of desorption was identified. This observation validates measurements made at the laboratory-scale. Several longer-term continuous tests were conducted to evaluate the performance of the sorbent/process as a function of time. Using a 2-bed configuration, sustained capture efficiency of 40-60% with a high flue gas CO₂ loading (~8%) and 70-80% with a low flue gas CO₂ loading (~4%) were achieved. However, sorbent working capacity was found to be considerably lower than laboratory-scale measurements. The low working capacity is attributed to insufficient sorbent/gas contact time in the adsorber. Sorbent properties that had a significant impact on CO₂ capture performance were identified. The results show that controlling these sorbent properties substantially improves CO₂ capture performance, with preliminary estimates indicating that relative improvement of ~30% is possible. Testing culminated with an operationally trouble-free test of 15 hours with sustainable performance. Overall, several practical strategies to increase performance of the sorbent and process were identified. The initial technical and economic assessment of the CACHYS™ process estimated the cost of CO2 capture was $36.19/ton with a 48.6% increase in levelized cost of electricity (LCOE) for the 550 MWe net plant. Using additional data gathered over the course of the project, and with revised technical and economic assumptions, the estimated cost of CO₂ capture with the CACHYS™ process is $39/ton (only includes the cost of the CO2 capture system) with an increase in LCOE of 55.9%. Overall, CACHYS™ represents a significant improvement over the benchmark MEA system, and has demonstrated progress towards achieving DOE’s goals for CO₂ capture technologies.

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DOE OSTI2014

CO 2 Binding Organic Liquids Gas Capture with Polarity Swing Assisted Regeneration

This report outlines the comprehensive bench-scale testing of the CO 2 -binding organic liquids (CO 2 BOLs) solvent platform and its unique Polarity Swing Assisted Regeneration (PSAR). This study outlines all efforts on a candidate CO 2 BOL solvent molecule, including solvent synthesis, material characterization, preliminary toxicology studies, and measurement of all physical, thermodynamic and kinetic data, including bench-scale testing. Equilibrium and kinetic models and analysis were made using Aspen Plus™. Preliminary process configurations, a technoeconomic assessment and solvent performance projections for separating CO 2 from a subcritical coal-fired power plant are compared to the U.S. Department of Energy's Case 10 monoethanolamine baseline.

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DOE OSTI2015

Chemical Looping Gasification for Hydrogen Enhanced Syngas Production with In-Situ CO 2 Capture

This document is the final report for the project titled “Chemical Looping Gasification for Hydrogen Enhanced Syngas Production with In-Situ CO 2 Capture” under award number FE0012136 for the performance period 10/01/2013 to 12/31/2014.This project investigates the novel Ohio State chemical looping gasification technology for high efficiency, cost efficiency coal gasification for IGCC and methanol production application. The project developed an optimized oxygen carrier composition, demonstrated the feasibility of the concept and completed cold-flow model studies. WorleyParsons completed a techno-economic analysis which showed that for a coal only feed with carbon capture, the OSU CLG technology reduced the methanol required selling price by 21%, lowered the capital costs by 28%, increased coal consumption efficiency by 14%. Further, using the Ohio State Chemical Looping Gasification technology resulted in a methanol required selling price which was lower than the reference non-capture case.

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DOE OSTI2015

Development and Test of a 1,000 Level 3C Fiber Optic Borehole Seismic Receiver Array Applied to Carbon Sequestration

To address the critical site characterization and monitoring needs for CCS programs, US Department of Energy (DOE) awarded Paulsson, Inc. in 2010 a contract to design, build and test a fiber optic based ultra-large bandwidth clamped borehole seismic vector array capable of deploying up to one thousand 3C sensor pods suitable for deployment into high temperature and high pressure boreholes. Paulsson, Inc. has completed a design or a unique borehole seismic system consisting of a novel drill pipe based deployment system that includes a hydraulic clamping mechanism for the sensor pods, a new sensor pod design and most important – a unique fiber optic seismic vector sensor with technical specifications and capabilities that far exceed the state of the art seismic sensor technologies. These novel technologies were all applied to the new borehole seismic system. In combination these technologies will allow for the deployment of up to 1,000 3C sensor pods in vertical, deviated or horizontal wells. Laboratory tests of the fiber optic seismic vector sensors developed during this project have shown that the new borehole seismic sensor technology is capable of generating outstanding high vector fidelity data with extremely large bandwidth: 0.01 – 6,000 Hz. Field tests have shown that the system can record events at magnitudes much smaller than M-2.3 at frequencies up to 2,000 Hz. The sensors have also proved to be about 100 times more sensitive than the regular coil geophones that are used in borehole seismic systems today. The fiber optic seismic sensors have furthermore been qualified to operate at temperatures over 300°C (572°F). The fibers used for the seismic sensors in the system are used to record Distributed Temperature Sensor (DTS) data allowing additional value added data to be recorded simultaneously with the seismic vector sensor data.

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DOE OSTI2015

Rayleigh Scattering Combustion Diagnostic

A laser Rayleigh scattering (LRS) temperature diagnostic was developed over 8 weeks with the goal of studying oxy-combustion of pulverized coal char in high temperature reaction environments with high concentrations of carbon dioxide. Algorithms were developed to analyze data collected from the optical diagnostic system and convert the information to temperature measurements. When completed, the diagnostic will allow for the kinetic gasification rates of the oxy-combustion reaction to be obtained, which was previously not possible since the high concentrations of high temperature CO 2 consumed thermocouples that were used to measure flame temperatures inside the flow reactor where the combustion and gasification reactions occur. These kinetic rates are important for studying oxy-combustion processes suitable for application as sustainable energy solutions.

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DOE OSTI2014

Tunable Diode Laser Sensors to Monitor Temperature and Gas Composition in High-Temperature Coal Gasifiers

The integrated gasification combined cycle (IGCC) when combined with carbon capture and storage can be one of the cleanest methods of extracting energy from coal. Control of coal and biomass gasification processes to accommodate the changing character of input-fuel streams is required for practical implementation of integrated gasification combined-cycle (IGCC) technologies. Therefore a fast time-response sensor is needed for real-time monitoring of the composition and ideally the heating value of the synthesis gas (here called syngas) as it exits the gasifier. The goal of this project was the design, construction, and demonstration an in situ laserabsorption sensor to monitor multiple species in the syngas output from practical-scale coal gasifiers. This project investigated the hypothesis of using laser absorption sensing in particulateladen syngas. Absorption transitions were selected with design rules to optimize signal strength while minimizing interference from other species. Successful in situ measurements in the dusty, high-pressure syngas flow were enabled by Stanford’s normalized and scanned wavelength modulation strategy. A prototype sensor for CO, CH4, CO2, and H2O was refined with experiments conducted in the laboratory at Stanford University, a pilot-scale at the University of Utah, and an engineering-scale gasifier at DoE’s National Center for Carbon Capture with the demonstration of a prototype sensor with technical readiness level 6 in the 2014 measurement campaign.

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DOE OSTI2015

Curbing Air Pollution and Greenhouse Gas Emissions from Industrial Boilers in China

China’s industrial boiler systems consume 700 million tons of coal annually, accounting for 18% of the nation’s total coal consumption. Together these boiler systems are one of the major sources of China’s greenhouse gas (GHG) emissions, producing approximately 1.3 gigatons (Gt) of carbon dioxide (CO 2 ) annually. These boiler systems are also responsible for 33% and 27% of total soot and sulfur dioxide (SO2) emissions in China, respectively, making a substantial contribution to China’s local environmental degradation. The Chinese government - at both the national and local level - is taking actions to mitigate the significant greenhouse gas (GHG) emissions and air pollution related to the country’s extensive use of coal-fired industrial boilers. The United States and China are pursuing a collaborative effort under the U.S.-China Climate Change Working Group to conduct a comprehensive assessment of China’s coal-fired industrial boilers and to develop an implementation roadmap that will improve industrial boiler efficiency and maximize fuel-switching opportunities. Two Chinese cities – Ningbo and Xi’an – have been selected for the assessment. These cities represent coastal areas with access to liquefied natural gas (LNG) imports and inland regions with access to interprovincial natural gas pipelines, respectively.

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DOE OSTI2015

Feasibility studies to improve plant availability and reduce total installed cost in IGCC plants

The main purpose of this project is to look at technologies and philosophies that would help reduce the costs of an Integrated Gasification Combined Cycle (IGCC) plant, increase its availability or do both. GE’s approach to this problem is to consider options in three different areas: 1) technology evaluations and development; 2) constructability approaches; and 3) design and operation methodologies. Five separate tasks were identified that fall under the three areas: Task 2 – Integrated Operations Philosophy; Task 3 – Slip Forming of IGCC Components; Task 4 – Modularization of IGCC Components; Task 5 – Fouling Removal; and Task 6 – Improved Slag Handling. Overall, this project produced results on many fronts. Some of the ideas could be utilized immediately by those seeking to build an IGCC plant in the near future. These include the considerations from the Integrated Operations Philosophy task and the different construction techniques of Slip Forming and Modularization (especially if the proposed site is in a remote location or has a lack of a skilled workforce). Other results include ideas for promising technologies that require further development and testing to realize their full potential and be available for commercial operation. In both areas GE considers this project to be a success in identifying areas outside the core IGCC plant systems that are ripe for cost reduction and ity improvement opportunities.

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DOE OSTI2014

The National Carbon Capture Center at the Power Systems Development Facility

The National Carbon Capture Center (NCCC) at the Power Systems Development Facility supports the Department of Energy (DOE) goal of promoting the United States’ energy security through reliable, clean, and affordable energy produced from coal. Work at the NCCC supports the development of new power technologies and the continued operation of conventional power plants under CO 2 emission constraints. The NCCC includes adaptable slipstreams that allow technology development of CO 2 capture concepts using coal-derived syngas and flue gas in industrial settings. Because of the ability to operate under a wide range of flow rates and process conditions, research at the NCCC can effectively evaluate technologies at various levels of maturity and accelerate their development path to commercialization. During its first contract period, from October 1, 2008, through December 30, 2014, the NCCC designed, constructed, and began operation of the Post-Combustion Carbon Capture Center (PC4). Testing of CO 2 capture technologies commenced in 2011, and through the end of the contract period, more than 25,000 hours of testing had been achieved, supporting a variety of technology developers. Technologies tested included advanced solvents, enzymes, membranes, sorbents, and associated systems. The NCCC continued operation of the existing gasification facilities, which have been in operation since 1996, to support the advancement of technologies for next-generation gasification processes and pre-combustion CO 2 capture. The gasification process operated for 13 test runs, supporting over 30,000 hours combined of both gasification and pre-combustion technology developer testing. Throughout the contract period, the NCCC incorporated numerous modifications to the facilities to accommodate technology developers and increase test capabilities. Preparations for further testing were ongoing to continue advancement of the most promising technologies for future power generation processes.

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DOE OSTI2015

Design and construction of coal/biomass to liquids (CBTL) process development unit (PDU) at the University of Kentucky Center for Applied Energy Research (CAER)

This report describes a first phase of a project to design, construct and commission an integrated coal/biomass-to-liquids facility at a capacity of 1 bbl. /day at the University of Kentucky Center for Applied Energy Research (UK-CAER) – specifically for construction of the building and upstream process units for feed handling, gasification, and gas cleaning, conditioning and compression. The deliverables from the operation of this pilot plant [when fully equipped with the downstream process units] will be firstly the liquid FT products and finished fuels which are of interest to UK-CAER’s academic, government and industrial research partners. The facility will produce research quantities of FT liquids and finished fuels for subsequent Fuel Quality Testing, Performance and Acceptability. Moreover, the facility is expected to be employed for a range of research and investigations related to: Feed Preparation, Characteristics and Quality; Coal and Biomass Gasification; Gas Clean-up/ Conditioning; Gas Conversion by FT Synthesis; Product Work-up and Refining; Systems Analysis and Integration; and Scale-up and Demonstration. Environmental Considerations - particularly how to manage and reduce carbon dioxide emissions from CBTL facilities and from use of the fuels - will be a primary research objectives. Such a facility has required significant lead time for environmental review, architectural/building construction, and EPC services. UK, with DOE support, has advanced the facility in several important ways. These include: a formal EA/FONSI, and permits and approvals; construction of a building; selection of a range of technologies and vendors; and completion of the upstream process units. The results of this project are the FEED and detailed engineering studies, the alternate configurations and the as-built plant - its equipment and capabilities for future research and demonstration and its adaptability for re-purposing to meet other needs. These are described in some detail in this report, along with lessons learned.

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DOE OSTI2015

Additive Manufacturing for Cost Efficient Production of Compact Ceramic Heat Exchangers and Recuperators

An additive manufacture technique known as laminated object manufacturing (LOM) was used to fabricate compact ceramic heat exchanger prototypes. LOM uses precision CO2 laser cutting of ceramic green tapes, which are then precision stacked to build a 3D object with fine internal features. Modeling was used to develop prototype designs and predict the thermal response, stress, and efficiency in the ceramic heat exchangers. Build testing and materials analyses were used to provide feedback for the design selection. During this development process, laminated object manufacturing protocols were established. This included laser optimization, strategies for fine feature integrity, lamination fluid control, green handling, and firing profile. Three full size prototypes were fabricated using two different designs. One prototype was selected for performance testing. During testing, cross talk leakage prevented the application of a high pressure differential, however, the prototype was successful at withstanding the high temperature operating conditions (1300 °F). In addition, analysis showed that the bulk of the part did not have cracks or leakage issues. This led to the development of a module method for next generation LOM heat exchangers. A scale-up cost analysis showed that given a purpose built LOM system, these ceramic heat exchangers would be affordable for the applications.

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DOE OSTI2015

International Energy Agency (IEA) Greenhouse Gas (GHG) Weyburn-Midale CO₂ Monitoring and Storage Project

The IEAGHG Weyburn-Midale CO₂ Monitoring and Storage Project (WMP) began in 2000 with the first four years of research that confirmed the suitability of the containment complex of the Weyburn oil field in southeastern Saskatchewan as a storage location for CO₂ injected as part of enhanced oil recovery (EOR) operations. The first half of this report covers research conducted from 2010 to 2012, under the funding of the United States Department of Energy (contract DEFE0002697), the Government of Canada, and various other governmental and industry sponsors. The work includes more in-depth analysis of various components of a measurement, monitoring and verification (MMV) program through investigation of data on site characterization and geological integrity, wellbore integrity, storage monitoring (geophysical and geochemical), and performance/risk assessment. These results then led to the development of a Best Practices Manual (BPM) providing oilfield and project operators with guidance on CO₂ storage and CO₂-EOR. In 2013, the USDOE and Government of Saskatchewan exercised an optional phase of the same project to further develop and deploy applied research tools, technologies, and methodologies to the data and research at Weyburn with the aim of assisting regulators and operators in transitioning CO₂-EOR operations into permanent storage. This work, detailed in the second half of this report, involves seven targeted research projects – evaluating the minimum dataset for confirming secure storage; additional overburden monitoring; passive seismic monitoring; history-matched modelling; developing proper wellbore design; casing corrosion evaluation; and assessment of post CO₂-injected core samples. The results from the final and optional phases of the Weyburn-Midale Project confirm the suitability of CO₂-EOR fields for the injection of CO₂, and further, highlight the necessary MMV and follow-up monitoring required for these operations to be considered permanent storage.

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DOE OSTI2015

Carbon Absorber Retrofit Equipment (CARE)

During Project DE-FE0007528, CARE (Carbon Absorber Retrofit Equipment), Neumann Systems Group (NSG) designed, installed and tested a 0.5MW NeuStream® carbon dioxide (CO 2 ) capture system using the patented NeuStream® absorber equipment and concentrated (6 molal) piperazine (PZ) as the solvent at Colorado Springs Utilities’ (CSU’s) Martin Drake pulverized coal (PC) power plant. The 36 month project included design, build and test phases. The 0.5MW NeuStream® CO 2 capture system was successfully tested on flue gas from both coal and natural gas combustion sources and was shown to meet project objectives. Ninety percent CO 2 removal was achieved with greater than 95% CO 2 product purity. The absorbers tested support a 90% reduction in absorber volume compared to packed towers and with an absorber parasitic power of less than 1% when configured for operation with a 550MW coal plant. The preliminary techno-economic analysis (TEA) performed by the Energy and Environmental Research Center (EERC) predicted an over-the-fence cost of $25.73/tonne of CO 2 captured from a sub-critical PC plant.

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