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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Processes and systems for reforming of methane and light hydrocarbons to liquid hydrocarbon fuels

Processes for converting methane and/or other hydrocarbons to synthesis gas (i.e., a gaseous mixture comprising H 2 and CO) are disclosed, in which at least a portion of the hydrocarbon(s) is reacted with CO 2 . At least a second portion of the methane may be reacted with H 2 O (steam), thereby improving overall thermodynamics of the process, in terms of reducing endothermicity (ΔH) and the required energy input, compared to “pure” dry reforming in which no H 2 O is present. Such dry reforming (reaction with CO 2 only) or CO 2 -steam reforming (reaction with both CO 2 and steam) processes are advantageously integrated with Fischer-Tropsch synthesis to yield liquid hydrocarbon fuels. Further integration may involve the use of a downstream finishing stage involving hydroisomerization to remove FT wax. Yet other integration options involve the use of combined CO 2 -steam reforming and FT synthesis stages (optionally with finishing) for producing liquid fuels from gas streams generated in a number of possible processes, including the hydropyrolysis of biomass.

Marker, Terry↗
DOE OSTI2022

Scalable High-H 2 Flux, Robust Thin Film Solid Oxide Electrolyzer

This project was aimed at the development of proton-conducting SOEC (P-SOEC) technology that has the potential to meet key DOE H 2 production targets. A decreased proton resistance of the electrolyte and Faradaic efficiency improvements were sought to increase the fraction of consumed electrolysis power that is used to actually generate H 2 , while simultaneously decreasing cost dramatically. Moreover, the development project was intended to yield maximum durability through the use of a steam protective layer. Furthermore, sputtering was used to overcome processing challenges that have hampered P-SOEC development, while the low-temperature operation goal of 500 °C was expected to aid in mitigating thermally activated long-term degradation. The approach to high-performance, lower-temperature SOECs leveraged our existing SOFC Ni-cermet anode support and extensive thin-film sputtering layer-deposition experience. Rather than an all-in-one, reversible fuel cell approach which has many unacceptable tradeoffs, we focused on the many benefits to hydrogen generating SOECs, including the existence of synergies for reduced manufacturing costs (e.g., SOECs and SOFCs share supporting layers and overall manufacturing processing). The end result of this project was expected to increase current performance at 500 °C from approximately 0.8 A/cm 2 (at 60% Faradaic efficiency) at 1.4 V to > 1 A/cm 2 (at > 95% Faradaic efficiency) with a > 40% reduction in system cost and to enable operation of P-SOECs in steam contents >> 20% for a goal of a > 40,000 hours lifetime. To enable 500 °C operation in a very high steam atmosphere (> 20%), we proposed the use of a sputtered dense thin film (~0.1-1 µm thick) of high-stability Ba(Zr,Y)O 3 (BZY) to protect the Ba(Ce,Zr,Y,Yb)O 3 (BCZYYb) electrolyte. The BZCYYb, in turn, blocks the hole conductivity of the BZY to boost Faradaic efficiency. As FE increases, more of the consumed electricity is used in electrolysis to generate H 2 , rather than being shunted. Additionally, as cell resistance decreases, the voltage required to maintain current decreases, as well as the power required to generate the same amount of H 2 . With the proposed enhancements, these two factors result in the final 46% decrease in power needed to run the system. Likewise, a production rate of 50,000 kg H 2 /day will require 55% less active area, such that a system will need only 650 cells for an 80 cm 2 active area instead of ~1,440. Taking the 2016 DOE projected current cost and modifying the electricity cost and linearly scaling the other costs (except thermal feedstock) based on the cell area improvement, results in a 44% decrease in lifetime system cost, or a decrease from $\$$4.95/kg H 2 to $\$$2.75/kg H 2 . This is well below the 2018 DOE target of $\$$4/kg H 2 . The results from this project showed that we can create a P-SOEC with enhanced steam stability using two different electrolytes (i.e., one on top of the other) and achieve sufficiently low area specific resistance (ASR) to achieve the target performance. Unfortunately, due to extended delays at the beginning of the project and related supply chain and equipment access issues, we were not able to completely show increased Faradaic efficiency for the P-SOEC and therefore were unable to demonstrate the full proof of concept within the first budget period budget. While there are still challenges that remain to be solved, significant progress was made during this project and the concept still has merit that warrants further development.

08 HYDROGEN↗
DOE OSTI2023

Intra-catalyst CH 4 oxidation pathways on a Pd/Al 2 O 3 /CeZrO x -based commercial catalyst and implications on NO x conversion profiles for a natural gas vehicle exhaust under lambda modulation

The performance of a three-way catalyst (TWC) in natural gas-powered vehicles is enhanced by periodic changes in air-to-fuel ratio (λ-modulation). The reaction networks and sequences inside the catalyst that facilitate such enhanced performance have not been extensively investigated. Here, this work applied intra-catalyst measurements (SpaciMS) to analyze the transient spatiotemporal gas concentrations inside a Pd-based TWC to establish relationships between CH 4 , NO x , CO and H 2 conversion pathways. Steam reforming and partial oxidation were revealed to be the main CH 4 conversion routes. The cyclic rich-lean conditions combined with the oxygen storage capacity (OSC) of the TWC generate reduced and oxidized zones that are constantly moving within the catalyst, changing the dominant chemical reactions occurring on the surface. In the reduced zones, OSC is depleted while CH 4 is converted through steam reforming and NO x is converted through reactions with H 2 , CO, and other surface-bound reducing fragments formed by CH 4 conversion. In the oxidized zones, OSC is replenished, CH 4 is converted by partial oxidation, and H 2 , CO, and NH 3 are oxidized. The length of lean-rich phases impacts the catalyst performance significantly; too short or too long of a rich or lean phase can lower the overall conversion of reactive species. An inhibition of CH 4 conversion was observed during the rich phase possibly due to CO-poisoning of active sites. The intra-catalyst measurements revealed that the catalyst consists of three distinct reaction zones and their lengths vary with modulation conditions. Various modulation frequencies, amplitudes, λ-centers, and temperatures were investigated which allowed an understanding of how these parameters affect the reaction zones and catalyst utilization. Understandings from this work can enable adaptive λ-control strategies to optimize the overall TWC performance over a range of vehicle operating conditions.

Lean-Rich cycling↗
DOE OSTI2021

Fracture Toughness Characterization of Generation II FeCrAl Alloys after ~18 dpa Irradiation

FeCrAl alloys are promising candidate materials for the accident tolerant fuel (ATF) cladding applications due to their excellent corrosion resistance to the elevated temperature steam environment. Currently, the handbook on FeCrAl material properties contains only limited data regarding the fracture toughness properties of any FeCrAl alloy. This includes alloys currently under investigation within the Advanced Fuels Campaign (AFC) at Oak Ridge National Laboratory (ORNL). In this project, a series of irradiation capsules have been irradiated in the High Flux Isotope Reactor (HFIR) at ORNL with two Generation II FeCrAl candidate alloys, i.e., C06M and C36M, to assess the fracture response of these alloys after neutron irradiation. These alloys represent the “book-end” compositions for C26M, the alloy currently being developed as the leading candidate for LWR cladding. A total of six irradiation capsules were irradiated in HFIR at target temperatures of 200°C, 330°C, and 500°C up to target damage doses of 8 displacements per atom (dpa) and 16 dpa. These damage doses represent the expected middle and end of life damage levels for typical LWR cladding while the irradiation temperature regimes will provide insight into the role of varying microstructural features on the fracture toughness properties of neutron irradiated FeCrAl alloys. To date, irradiation of all capsules has been completed in HFIR. This report summarizes the latest results of microhardness and fracture toughness PIE for the 16 dpa capsules (FCAB2, FCAB4, and FCAB6), for which the measured irradiation conditions were: 204°C/17.6dpa, 343°C/18.3dpa, and 507°C/18.6dpa. The main conclusions of this study can be summarized as follows: 1) After the 204°C/17.6dpa irradiation, both C06M and C36M exhibited significant irradiation hardening and embrittlement 2) After the 343°C/18.3dpa irradiation, both C06M and C36M exhibited small irradiation hardening without irradiation embrittlement 3) After the 507°C/18.6dpa irradiation, both C06M and C36M exhibited irradiation softening without irradiation embrittlement 4) Comparing the microhardness and Master Curve reference temperature T 0q before and after neutron irradiation, we did not observe a linear correlation between the two parameters for both C06M and C36M. This should be mainly due to a flat response of the Master Curve reference temperature T 0q to the irradiations at 166-204°C and 315-343°C ranges 5) C06M showed a lower T 0q , meaning better toughness, than C36M at the unirradiated condition and such trend was kept even after neutron irradiation except for the 166-204°C irradiation where both materials had similar T 0q . 6) In terms of hardening and embrittlement, the irradiation effect on both C06M and C36M appeared to saturate after an irradiation dose of 7 dpa.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Design, modeling and simulation of nuclear-powered integrated energy systems with cascaded heating applications

Nuclear-renewable integrated energy systems (IES) consist of a variety of energy generation and conversion technologies and can be used to meet heterogeneous end uses (e.g., electricity, heat, and cooling demands). In addition to supply-demand balance, end-use heat demands usually require heat supply of certain temperature ranges. The effective and efficient utilization of heat produced within an IES is, therefore, a critical challenge. Here, this paper examines design options of an IES that includes heating processes of multiple temperature grades. We investigate a cascaded design configuration, where the remaining residual heat after high-grade heating processes [e.g., hydrogen production through high-temperature steam electrolysis (HTSE)] is recovered to meet the low-grade heating needs [e.g., district heating (DH)]. Additionally, a thermal energy storage system is integrated into the DH system to address the imbalance between heat supply and demand. This paper primarily focuses on the design and modeling of the proposed system and evaluates its operation with a 24-h transient process simulation using a DH demand profile with hourly resolution. The results indicate that the residual heat from the HTSE exhaust is insufficient for the DH demand, and additional topping heat directly from the reactor process steam is needed. Furthermore, the inclusion of thermal energy storage within the DH system provides the necessary balance between thermal generation and demand, thereby ensuring a consistent rated temperature of the DH supply water. This approach helps minimize the control actions needed on the reactor side.

08 HYDROGEN↗
DOE OSTI2018

Ethanol production potential from AFEX™ and steam-exploded sugarcane residues for sugarcane biorefineries

Expanding biofuel markets are challenged by the need to meet future biofuel demands and mitigate greenhouse gas emissions, while using domestically available feedstock sustainably. In the context of the sugar industry, exploiting under-utilized cane leaf matter (CLM) in addition to surplus sugarcane bagasse as supplementary feedstock for second-generation ethanol production has the potential to improve bioenergy yields per unit land. In this study, the ethanol yields and processing bottlenecks of ammonia fibre expansion (AFEX™) and steam explosion (StEx) as adopted technologies for pretreating sugarcane bagasse and CLM were experimentally measured and compared for the first time.

09 BIOMASS FUELS↗
DOE OSTI2020

EIA Thermoelectric Water Cooling Data

The U.S. Energy Information Administration (EIA) collects water cooling data for the electric power industry in the United States. This submission includes annual data from 2014 to 2019. Each spreadsheet details the generator type, fuel consumption, water consumption, cooling type, and equipment status, location, and water source for each plant.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2015

Boiler materials for ultra supercritical coal power plants

The U.S. Department of Energy (DOE) and the Ohio Coal Development Office (OCDO) have undertaken a project aimed at identifying, evaluating, and qualifying the materials needed for the construction of the critical components of coal-fired boilers capable of operating at much higher efficiencies than current generation of supercritical plants. This increased efficiency is expected to be achieved principally through the use of advanced ultrasupercritical (A-USC) steam conditions up to 760°C (1400°F) and 35 MPa (5000 psi). A limiting factor to achieving these higher temperatures and pressures for future A-USC plants are the materials of construction. The goal of this project is to assess/develop materials technology to build and operate an A-USC boiler capable of delivering steam with conditions up to 760°C (1400°F)/35 MPa (5000 psi). The project has successfully met this goal through a focused long-term public-private consortium partnership. The project was based on an R&D plan developed by the Electric Power Research Institute (EPRI) and an industry consortium that supplemented the recommendations of several DOE workshops on the subject of advanced materials. In view of the variety of skills and expertise required for the successful completion of the proposed work, a consortium led by the Energy Industries of Ohio (EIO) with cost-sharing participation of all the major domestic boiler manufacturers, ALSTOM Power (Alstom), Babcock and Wilcox Power Generation Group, Inc. (B&W), Foster Wheeler (FW), and Riley Power, Inc. (Riley), technical management by EPRI and research conducted by Oak Ridge National Laboratory (ORNL) has been developed. The project has clearly identified and tested materials that can withstand 760°C (1400°F) steam conditions and can also make a 700°C (1300°F) plant more economically attractive. In this project, the maximum temperature capabilities of these and other available high-temperature alloys have been assessed to provide a basis for materials selection and application under a range of conditions prevailing in the boiler. A major effort involving eight tasks was completed in Phase 1. In a subsequent Phase 2 extension, the earlier defined tasks were extended to finish and enhance the Phase 1 activities. This extension included efforts in improved weld/weldment performance, development of longer-term material property databases, additional field (in-plant) corrosion testing, improved understanding of long-term oxidation kinetics and exfoliation, cyclic operation, and fabrication methods for waterwalls. In addition, preliminary work was undertaken to model an oxyfuel boiler to define local environments expected to occur and to study corrosion behavior of alloys under these conditions. This final technical report provides a comprehensive summary of all the work undertaken by the consortium and the research findings from all eight (8) technical tasks including A-USC boiler design and economics (Task 1), long-term materials properties (Task 2), steam- side oxidation (Task 3), Fireside Corrosion (Task 4), Welding (Task 5), Fabricability (Task 6), Coatings (Task 7), and Design Data and Rules (Task 8).

01 COAL, LIGNITE, AND PEAT↗
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↗
DOE OSTI2016

Integrated Cyber/Physical Impact Analysis to secure US Critical Infrastructure

In a common electric power plant, heat is used to boil water into steam which drives a turbine. The steam from the turbine outlet is condensed with cooling water. This is the common Rankine cycle and, even after decades of development is relatively inefficient and water intensive. Alternatively, a closed Brayton cycle recirculates the working fluid, and the turbine exhaust is used in a recuperating heat exchanger to heat the turbine feed. A "supercritical cycle' is a closed Brayton cycle in which the working fluid, such as supercritical carbon dioxide (sCO2), is maintained above the critical point during the compression phase of the cycle. The key property of the fluid near its critical point is its higher gas density, closer to that of a liquid than of a gas, allowing for the pumping power in the compressor to be significantly reduced resulting in improved efficiency. Other advantages include smaller component size and the reduced use of water, not only due to the increased efficiency, but also due sensible heat rejection which facilitates dry air cooling compared to air-cooled steam condensers. A Sandia National Laboratories commercialization review concluded that the technology has applicability across various power generation applications including fossil fuels, concentrated solar power and nuclear power. In 2006, Sandia National Laboratories (SNL), recognizing the potential advantages of a higher efficiency power cycle, used internal funds to establish a testing capability and began partnering with the U.S. Department of Energy Office of Nuclear Energy to develop a laboratory-scale test assembly to show the viability of the underlying science and demonstrate system performance. Since that time, SNL has generated power, verified cycle performance, and developed cycle controls and maintenance procedures. The test assembly has successfully operated in different configurations (simple Brayton, waste heat cycle, and recompression) and tested additives to the s-CO2 working fluid. Our current focus is to partner with industry and develop cycle components and control strategies sufficient to support a successful commercial offering. This paper has been developed for the Energy Policy Institute's (EPI's) 6th Annual Energy Policy Research Conference scheduled for 8 & 9 September 2016 in Santa Fe, NM. We describe the cycle in more detail and describe specific benefits and applications. The paper will also include current technology development activities and future plans.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1985

Develop and test fuel cell powered on-site integrated total energy systems: Phase 3, full-scale power plant development

A 25 cell stack of the 13 inch x 23 inch cell size (about 4kW) remains on test after 6000 hours, using simulated reformate fuel. A similar stack was previously shut down after 7000 hours on load. These tests were carried out for the purpose of assessing the durability of fuel cell stack components developed through the end of 1983. In light of the favorable results obtained, a 25kW stack that will contain 175 cells of the same size is being constructed using the same technology base. The components for the 25kW stack have been completed. A methanol steam reformer with a design output equivalent to 50kW has been constructed to serve as a hydrogen generator for the 25kW stack. This reformer and the balance of the fuel processing sub system are currently being tested and debugged. The stack technology development program focused on cost reduction in bipolar plates, nonmetallic cooling plates, and current collecting plates; more stable cathode catalyst support materials; more corrosion resistant metal hardware; and shutdown/start up tolerance.

Kaufman, A.↗
NASA NTRS1976

Onboard hydrogen generation for automobiles

Problems concerning the use of hydrogen as a fuel for motor vehicles are related to the storage of the hydrogen onboard a vehicle. The feasibility is investigated to use an approach based on onboard hydrogen generation as a means to avoid these storage difficulties. Two major chemical processes can be used to produce hydrogen from liquid hydrocarbons and methanol. In steam reforming, the fuel reacts with water on a catalytic surface to produce a mixture of hydrogen and carbon monoxide. In partial oxidation, the fuel reacts with air, either on a catalytic surface or in a flame front, to yield a mixture of hydrogen and carbon monoxide. There are many trade-offs in onboard hydrogen generation, both in the choice of fuels as well as in the choice of a chemical process. Attention is given to these alternatives, the results of some experimental work in this area, and the combustion of various hydrogen-rich gases in an internal combustion engine.

Houseman, J.↗
DOE OSTI2018

Catalytic Steam and Partial Oxidation Reforming of Liquid Fuels for Application in Improving the Efficiency of Internal Combustion Engines

Here, this study investigated the potential for catalytically reforming liquid fuels in a simulated exhaust gas recirculation (EGR) mixture loop for the purpose of generating reformate that could be used to increase stoichiometric combustion engine efficiency. The experiments were performed on a simulated exhaust flow reactor using a Rh/Al 2 O 3 reformer catalyst, and the fuels evaluated included iso-octane, ethanol, and gasoline. Both steam reforming and partial oxidation reforming were examined as routes for the production of reformate. Steam reforming was determined to be an ineffective option for reforming in an EGR loop, because of the high exhaust temperatures (in excess of 700 °C) required to produce adequate concentrations of reformate, regardless of fuel. However, partial oxidation reforming is capable of producing hydrogen concentrations as high as 10%–16%, depending on fuel and operating conditions in the simulated EGR gas mixture. Meanwhile, measurements of total fuel enthalpy retention were shown to have favorable energetics under a range of conditions, although a tradeoff between fuel enthalpy retention and reformate production was observed. Of the three fuels evaluated, iso-octane exhibited the best overall performance, followed by ethanol and then gasoline. Overall, it was found that partial oxidation reforming of liquid fuels in a simulated EGR mixture over the Rh/Al 2 O 3 catalyst demonstrated sufficiently high reformate yields and favorable energetics to warrant further evaluation in the EGR system of a stoichiometric combustion engine.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2016

Updated (BP3) Technical and Economic Feasibility Study - Electrochemical Membrane for Carbon Dioxide Capture and Power Generation

This topical report summarizes the results of an updated Technical & Economic Feasibility Study (T&EFS) which was conducted in Budget Period 3 of the project to evaluate the performance and cost of the Electrochemical Membrane (ECM)-based CO2 capture system. The ECM technology is derived from commercially available inorganic membranes; the same used in FuelCell Energy’s commercial fuel cell power plants and sold under the trade name Direct FuelCell® (DFC®). The ECM stacks are utilized in the Combined Electric Power (generation) And Carbon dioxide Separation (CEPACS) systems which can be deployed as add-ons to conventional power plants (Pulverized Coal, Combined Cycle, etc.) or industrial facilities to simultaneously produce power while capturing >90% of the CO2 from the flue gas. In this study, an ECM-based CEPACS plant was designed to capture and compress >90% of the CO2 (for sequestration or beneficial use) from the flue gas of a reference 550 MW (nominal, net AC) Pulverized Coal (PC) Rankine Cycle (Subcritical steam) power plant. ECM performance was updated based on bench scale ECM stack test results. The system process simulations were performed to generate the CEPACS plant performance estimates. The performance assessment included estimation of the parasitic power consumption for CO2 capture and compression, and the efficiency impact on the PC plant. While the ECM-based CEPACS system for the 550 MW PC plant captures 90% of CO2 from the flue gas, it generates additional (net AC) power after compensating for the auxiliary power requirements of CO2 capture and compression. An equipment list, ECM stacks packaging design, and CEPACS plant layout were developed to facilitate the economic analysis. Vendor quotes were also solicited. The economic feasibility study included estimation of CEPACS plant capital cost, cost of electricity (COE) analyses and estimation of cost per ton of CO2 captured. The incremental COE for the ECM-based CO2 capture is expected to meet U.S. DOE’s target of 35%. This study has indicated that CEPACS systems offer significant benefits with respect to cost, performance, water consumption and emissions to environment. The realization of these benefits will provide a single solution to carbon dioxide capture in addition to meeting the increasing demand for electricity.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2017

Updated (BP3) Technical and Economic Feasibility Study - Electrochemical Membrane for Carbon Dioxide Capture and Power Generation

This topical report summarizes the results of an updated Technical & Economic Feasibility Study (T&EFS) which was conducted in Budget Period 3 of the project to evaluate the performance and cost of the Electrochemical Membrane (ECM)-based CO 2 capture system. The ECM technology is derived from commercially available inorganic membranes; the same used in FuelCell Energy’s commercial fuel cell power plants and sold under the trade name Direct FuelCell® (DFC®). The ECM stacks are utilized in the Combined Electric Power (generation) And Carbon dioxide Separation (CEPACS) systems which can be deployed as add-ons to conventional power plants (Pulverized Coal, Combined Cycle, etc.) or industrial facilities to simultaneously produce power while capturing >90% of the CO 2 from the flue gas. In this study, an ECM-based CEPACS plant was designed to capture and compress >90% of the CO 2 (for sequestration or beneficial use) from the flue gas of a reference 550 MW (nominal, net AC) Pulverized Coal (PC) Rankine Cycle (Subcritical steam) power plant. ECM performance was updated based on bench scale ECM stack test results. The system process simulations were performed to generate the CEPACS plant performance estimates. The performance assessment included estimation of the parasitic power consumption for CO 2 capture and compression, and the efficiency impact on the PC plant. While the ECM-based CEPACS system for the 550 MW PC plant captures 90% of CO 2 from the flue gas, it generates additional (net AC) power after compensating for the auxiliary power requirements of CO 2 capture and compression. An equipment list, ECM stacks packaging design, and CEPACS plant layout were developed to facilitate the economic analysis. Vendor quotes were also solicited. The economic feasibility study included estimation of CEPACS plant capital cost, cost of electricity (COE) analyses and estimation of cost per ton of CO 2 captured. The incremental COE for the ECM-based CO 2 capture is expected to meet U.S. DOE’s target of 35%. This study has indicated that CEPACS systems offer significant benefits with respect to cost, performance, water consumption and emissions to environment. The realization of these benefits will provide a single solution to carbon dioxide capture in addition to meeting the increasing demand for electricity.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Numerical Investigation of Susceptor-Catalyst Design for Ethylene Generation in Radio Frequency Based Reactors

Ethylene is the most widely produced petrochemical component in the world. Whether reactors are heated directly or indirectly via steam, manufacturers use economies of scale to overcome inherent thermodynamic inefficiencies when burning fossil fuels. While allowing large-scale operations to use alternative sources of energy and raw materials, new methods of supplying energy to chemical reactor systems can reduce the energy waste produced by conventional processes. One viable method for effectively supplying energy to reactor systems is electromagnetic (EM) induction heating. Using the properties of radio frequency (RF) waves, heterogeneous catalysts can be precisely targeted for heating inside reactors. Site-selective heating can greatly lower the energy requirements of the process by supplying heat to reaction sites while reducing needless heat transfer elsewhere. In this study, a microscale model was used to help create guidelines for susceptors and catalysts to improve ethylene production. The oxidative dehydrogenation of ethane is investigated by utilizing several catalysts and potential catalyst/susceptor combinations, with heat provided by an EM susceptor. Having the susceptors and catalyst function separately results in higher gradients in both heat and mass transfer, which drives transport through the catalyst region, while still providing adequate heating for endothermic reactions. However, using a susceptive core with a catalyst covering produces the maximum ethylene concentration.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗