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DOE OSTI2012

Super Boiler 2 nd Generation Technology for Watertube Boilers

This report describes Phase I of a proposed two phase project to develop and demonstrate an advanced industrial watertube boiler system with the capability of reaching 94% (HHV) fuel-to-steam efficiency and emissions below 2 ppmv NO x , 2 ppmv CO, and 1 ppmv VOC on natural gas fuel. The boiler design would have the capability to produce >1500°F, >1500 psig superheated steam, burn multiple fuels, and will be 50% smaller/lighter than currently available watertube boilers of similar capacity. This project is built upon the successful Super Boiler project at GTI. In that project that employed a unique two-staged intercooled combustion system and an innovative heat recovery system to reduce NO x to below 5 ppmv and demonstrated fuel-to-steam efficiency of 94% (HHV). This project was carried out under the leadership of GTI with project partners Cleaver-Brooks, Inc., Nebraska Boiler, a Division of Cleaver-Brooks, and Media and Process Technology Inc., and project advisors Georgia Institute of Technology, Alstom Power Inc., Pacific Northwest National Laboratory and Oak Ridge National Laboratory. Phase I of efforts focused on developing 2 nd generation boiler concepts and performance modeling; incorporating multi-fuel (natural gas and oil) capabilities; assessing heat recovery, heat transfer and steam superheating approaches; and developing the overall conceptual engineering boiler design. Based on our analysis, the 2 nd generation Industrial Watertube Boiler when developed and commercialized, could potentially save 265 trillion Btu and $1.6 billion in fuel costs across U.S. industry through increased efficiency. Its ultra-clean combustion could eliminate 57,000 tons of NO x , 460,000 tons of CO, and 8.8 million tons of CO 2 annually from the atmosphere. Reduction in boiler size will bring cost-effective package boilers into a size range previously dominated by more expensive field-erected boilers, benefiting manufacturers and end users through lower capital costs.

03 NATURAL GAS↗
DOE OSTI2012

Machining Elimination through Application of Thread Forming Fasteners in Net-Shaped Cast Holes

The ultimate objective of this work was to eliminate approximately 30% of the machining performed in typical automotive engine and transmission plants by using thread forming fasteners in as-cast holes of aluminum and magnesium cast components. The primary issues at the source of engineers reluctance to implementing thread forming fasteners in lightweight castings are: • Little proof of consistency of clamp load vs. input torque in either aluminum or magnesium castings. • No known data to understand the effect on consistency of clamp load as casting dies wear. The clamp load consistency concern is founded in the fact that a portion of the input torque used to create clamp load is also used to create threads. The torque used for thread forming may not be consistent due to variations in casting material, hole size and shape due to tooling wear and process variation (thermal and mechanical). There is little data available to understand the magnitude of this concern or to form the basis of potential solutions if the range of clamp load variation is very high (> +/- 30%). The range of variation that can be expected in as-cast hole size and shape over the full life cycle of a high pressure die casting die was established in previous work completed by Pacific Northwest National Laboratory, (PNNL). This established range of variation was captured in a set of 12 cast bosses by designing core pins at the size and draft angles identified in the sited previous work. The cast bosses were cut into nuts that could be used in the Ford Fastener Laboratory test-cell to measure clamp load when a thread forming fastener was driven into a cast nut. There were two sets of experiments run. First, a series of cast aluminum nuts were made reflecting the range of shape and size variations to be expected over the life cycle of a die casting die. Taptite thread forming fasteners, (a widely used thread forming fastener suitable for aluminum applications), were driven into the various cored, as-cast nuts at a constant input torque and resulting clamp loads were recorded continuously. The clamp load data was used to determine the range of clamp loads to be expected. The bolts were driven to failure. The clamp load corresponding to the target input of 18.5 Nm was recorded for each fastener. In a like fashion, a second set of experiments were run with cast magnesium nuts and ALtracs thread forming fasteners, (a widely used thread forming fastener suitable for magnesium applications). Again all clamp loads were recorded and analyzed similarly to the Taptites in aluminum cast nuts. Results from previous work performed on the same test cell for a Battelle project using standard M8 bolts into standard M8 nuts were included as a comparator for a standard bolt and nut application. The results for the thread forming fasteners in aluminum cast holes were well within industry expectations of +/- 30% for out of the box and robustness range testing. The results for the dry and lubed extreme conditions were only slightly higher than industry expectations at +/- 35.6%. However, when compared to the actual Battelle results (+/- 40%) for a standard bolt and nut the tread forming fasteners performed slightly better. The results for the thread forming fasteners in magnesium cast holes were all well within industry expectations of +/- 30% for all three conditions. The robustness range (.05mm larger and smaller holes than the expected wear pattern of a die casting die at full life cycle) results also fell within the industry expectations for standard threaded fasteners. These results were very encouraging. It was concluded that this work showed that clamp load variation with thread forming fasteners is consistent with industry expectations for standard steel bolts and nuts at +/- 30%. There does not appear to be any significant increase in clamp load variation due to the application of thread forming fasteners in as-cast holes of aluminum or magnesium over the effective life of a die casting mold. The fully implemented potential benefit of thread forming fasteners in as-cast holes of aluminum and magnesium is estimated to be 6 trillion Btu per year for North America. Economic benefit is estimated to be nearly $800 million per year. Environmental benefits and quality improvements will also result from full implementation of this technology.

36 MATERIALS SCIENCE↗
DOE OSTI2012

RENEWABLE ENERGY AND ENVIRONMENTAL SUSTAINABILITY USING BIOMASS FROM DAIRY AND BEEF ANIMAL PRODUCTION

The Texas Panhandle is regarded as the "Cattle Feeding Capital of the World", producing 42% of the fed beef cattle in the United States within a 200-mile radius of Amarillo generating more than 5 million tons of feedlot manure /year. Apart from feedlots, the Bosque River Region in Erath County, just north of Waco, Texas with about 110,000 dairy cattle in over 250 dairies, produces 1.8 million tons of manure biomass (excreted plus bedding) per year. While the feedlot manure has been used extensively for irrigated and dry land crop production, most dairies, as well as other concentrated animal feeding operations (CAFO's), the dairy farms utilize large lagoon areas to store wet animal biomass. Water runoff from these lagoons has been held responsible for the increased concentration of phosphorus and other contaminates in the Bosque River which drains into Lake Waco—the primary source of potable water for Waco's 108,500 people. The concentrated animal feeding operations may lead to land, water, and air pollution if waste handling systems and storage and treatment structures are not properly managed. Manure-based biomass (MBB) has the potential to be a source of green energy at large coal-fired power plants and on smaller-scale combustion systems at or near confined animal feeding operations. Although MBB particularly cattle biomass (CB) is a low quality fuel with an inferior heat value compared to coal and other fossil fuels, the concentration of it at large animal feeding operations can make it a viable source of fuel. The overall objective of this interdisciplinary proposal is to develop environmentally benign technologies to convert low-value inventories of dairy and beef cattle biomass into renewable energy. Current research expands the suite of technologies by which cattle biomass (CB: manure, and premature mortalities) could serve as a renewable alternative to fossil fuel. The work falls into two broad categories of research and development. Category 1 – Renewable Energy Conversion. This category addressed mostly in volume I involves developing. Thermo-chemical conversion technologies including cofiring with coal, reburn to reduce nitrogen oxide (NO, N2O, NOx, etc.) and Hg emissions and gasification to produce low-BTU gas for on-site power production in order to extract energy from waste streams or renewable resources. Category 2 – Biomass Resource Technology. This category, addressed mostly in Volume II, deals with the efficient and cost-effective use of CB as a renewable energy source (e.g. through and via aqueous-phase, anaerobic digestion or biological gasification). The investigators formed an industrial advisory panel consisting fuel producers (feedlots and dairy farms) and fuel users (utilities), periodically met with them, and presented the research results; apart from serving as dissemination forum, the PIs used their critique to red-direct the research within the scope of the tasks. The final report for the 5 to 7 year project performed by an interdisciplinary team of 9 professors is arranged in three volumes: Vol. I (edited by Kalyan Annamalai) addressing thermo-chemical conversion and direct combustion under Category 1 and Vol. II and Vol. III ( edited by J M Sweeten) addressing biomass resource Technology under Category 2. Various tasks and sub-tasks addressed in Volume I were performed by the Department of Mechanical Engineering (a part of TEES; see Volume I), while other tasks and sub-tasks addressed in Volume II and IIII were conducted by Texas AgriLife Research at Amarillo; the TAMU Biological & Agricultural Engineering Department (BAEN) College Station; and West Texas A&M University (WTAMU) (Volumes II and III). The three volume report covers the following results: fuel properties of low ash and high ash CB (particularly DB) and MB (mortality biomass and coals, non-intrusive visible infrared (NVIR) spectroscopy techniques for ash determination, dairy energy use surveys at 14 dairies in Texas and California, cofiring of low quality CB with high quality coal, emission results and ash fouling behavior, using CB as reburn fuel for NOx and Hg reduction, gasification of fuels to produce low quality gases, modeling of reburn, pilot scale test results, synthesis of engineering characterization, geographical mapping, a transportation cost study to determine potential handling and transportation systems for co-firing with coal at regional coal-fired power plants, software analyses for the design of off-site manure, pre-processing and storage systems for a typical dairy farm or beef cattle feedlot, recursive production functions/systems models for both cattle feedlots, systems modeling, stocks and flows of energy involved in the CAFO system, feedback from an Industry Advisory Committee (IAC) to the investigators on project direction and task emphasis and economics of using CB as cofiring and reburn fuel.

09 BIOMASS FUELS↗
DOE OSTI2012

Development of Surface Engineered Coating Systems for Aluminum Pressure Die Casting Dies: Towards a ‘Smart’ Die Coating

The main objective of this research program was to design and develop an optimal coating system that extends die life by minimizing premature die failure. In high-pressure aluminum die-casting, the die, core pins and inserts must withstand severe processing conditions. Many of the dies and tools in the industry are being coated to improve wear-resistance and decrease down-time for maintenance. However, thermal fatigue in metal itself can still be a major problem, especially since it often leads to catastrophic failure (i.e. die breakage) as opposed to a wear-based failure (parts begin to go out of tolerance). Tooling costs remain the largest portion of production costs for many of these parts, so the ability prevent catastrophic failures would be transformative for the manufacturing industry.The technology offers energy savings through reduced energy use in the die casting process from several factors, including increased life of the tools and dies, reuse of the dies and die components, reduction/elimination of lubricants, and reduced machine down time, and reduction of Al solder sticking on the die. The use of the optimized die coating system will also reduce environmental wastes and scrap parts. Current (2012) annual energy saving estimates, based on initial dissemination to the casting industry in 2010 and market penetration of 80% by 2020, is 3.1 trillion BTU's/year. The average annual estimate of CO2 reduction per year through 2020 is 0.63 Million Metric Tons of Carbon Equivalent (MM TCE).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2012

Preliminary Assessment of a Propane-Air Backup System for the Anchorage, Alaska, Area

A propane-air backup system has been proposed as a method to supplement the natural gas supply in the Anchorage, Alaska, area. Companies in most industries require a back-up system for their primary energy source when there is a risk of energy interruption or when such a backup system offers a significant economic benefit. This is true especially for companies using natural gas that have loads greater than 2 million Btu per hour (Algas SDI, Inc. 2011). Many industrial processes operate continuously. An interruption in the fuel supply could halt mass production and result in major economic losses. In some cases—the glass industry, for example —fuel interruptions can be devastating, resulting not only in production losses but, potentially, in hundreds of thousands of dollars lost in capital investments. Most glass furnaces are fueled by natural gas and a disruption in natural gas service results in loss of glass production over several days. Mitigating this risk by using a back-up fuel system is imperative. Identifying a reliable and environmentally friendly energy source that will also offer the lowest possible manufacturing costs can increase a company’s competitiveness. Propane-air back-up systems allow companies to benefit from lower interruptible natural gas rates while relying on a propane-air system when needed.

Folga, Steve↗
DOE OSTI2012

U.S. Manufacturing Energy Use and Greenhouse Gas Emissions Analysis

The United States (U.S.) manufacturing sector uses significant amounts of energy to convert raw materials into usable products. The U.S. manufacturing sector is estimated to consume over one quarter of all U.S. energy use. According to manufacturing energy use statistics from the U.S. Department of Energy’s Energy Information Administration (EIA), the U.S. manufacturing sector consumed 21.1 quadrillion Btu (quads) of fuel and feedstock energy [EIA 2009] in 2006. When the estimated electricity and steam losses outside the plant (offsite) are included in this total, the primary and feedstock energy consumed by U.S. manufacturing increases to 27.6 quads. Total U.S. energy consumption for all sectors in 2006 was 99.8 quads [EIA 2010a]. Of this total, the industrial sector consumed 32.5 quads, or 33%. Of this 33%, manufacturing consumed approximately 28%, while non-manufacturing sectors (including agriculture, mining, and construction) consumed the remaining 5% of industrial energy.

Brueske, Sabine↗
DOE OSTI2013

Phase Conjugation of High Energy Lasers

In this report we explore claims that phase conjugation of high energy lasers by stimulated Brillouin scattering (SBS) can compensate optical aberrations associated with severely distorted laser amplifier media and aberrations induced by the atmosphere. The SBS media tested was a gas cell pressurized up to 300 psi with SF 6 or Xe or both. The laser was a 10 Hz, 3J, Q-switched Nd:YAG with 25 ns wide pulses. Atmospheric aberrations were created with space heaters, helium jets and phase plates designed with a Kolmogorov turbulence spectrum characterized by a Fried parameter, r o , ranging from 0.6 – 6.0 mm. Phase conjugate tests in the laboratory were conducted without amplification. For the strongest aberrations, D/r o ~ 20, created by combining the space heaters with the phase plate, the Strehl ratio was degraded by a factor of ~50. Phase conjugation in SF 6 restored the peak focusable intensity to about 30% of the original laser. Phase conjugate tests at the outdoor laser range were conducted with laser amplifiers providing gain in combination with the SBS cell. A large 600,000 BTU kerosene space heater was used to create turbulence along the beam path. An atmospheric structure factor of C n 2 = 5x10 -13 m 2/3 caused the illumination beam to expand to a diameter 250mm and overfill the receiver. The phase conjugate amplified return could successfully be targeted back onto glints 5mm in diameter. Use of a lenslet arrays to lower the peak focusable intensity in the SBS cell failed to produce a useful phase conjugate beam; The Strehl ratio was degraded with multiple random lobes instead of a single focus. I will review literature results which show how multiple beams can be coherently combined by SBS when a confocal reflecting geometry is used to focus the laser in the SBS cell.

Bliss, David E.↗
DOE OSTI2013

Analysis of the Production Cost for Various Grades of Biomass Thermal Treatment

Process flow sheets were developed for the thermal treatment of southern pine wood chips at four temperatures (150, 180, 230, and 270 degrees C) and two different scales (20 and 100 ton/hour). The larger capacity processes had as their primary heat source hot gas assumed to be available in quantity from an adjacent biorefinery. Mass and energy balances for these flow sheets were developed using Aspen Plus process simulation software. The hot gas demands in the larger processes, up to 1.9 million lb/hour, were of questionable feasibility because of the volume to be moved. This heat was of low utility because the torrefaction process, especially at higher temperatures, is a net heat producer if the organic byproduct gases are burned. A thermal treatment flow sheet using wood chips dried in the biorefinery to 10% moisture content (rather than 30% for green chips) with transfer of high temperature steam from the thermal treatment depot to the biorefinery was also examined. The equipment size information from all of these cases was used in several different equipment cost estimating methods to estimate the major equipment costs for each process. From these, factored estimates of other plant costs were determined, leading to estimates (± 30% accuracy) of total plant capital cost. The 20 ton/hour processes were close to 25 million dollars except for the 230 degrees C case using dried wood chips which was only 15 million dollars because of its small furnace. The larger processes ranged from 64-120 million dollars. From these capital costs and projections of several categories of operating costs, the processing cost of thermally treated pine chips was found to be $28-33 per ton depending on the degree of treatment and without any credits for steam generation. If the excess energy output of the two 20 ton/hr depot cases at 270 degrees C can be sold for $10 per million BTU, the net processing cost dropped to $13/ton product starting with green wood chips or only $3 per ton if using dried chips from the biorefinery. Including a 12% return on invested capital raised all of the operating cost results by about $20/ton.

09 BIOMASS FUELS↗
DOE OSTI2014

Process Design and Economics for the Conversion of Algal Biomass to Hydrocarbons: Whole Algae Hydrothermal Liquefaction and Upgrading

This report provides a preliminary analysis of the costs associated with converting whole wet algal biomass into primarily diesel fuel. Hydrothermal liquefaction converts the whole algae into an oil that is then hydrotreated and distilled. The secondary aqueous product containing significant organic material is converted to a medium btu gas via catalytic hydrothermal gasification.

09 BIOMASS FUELS↗
DOE OSTI2013

Fuel Flexible, Low Emission Catalytic Combustor for Opportunity Fuel Applications

Limited fuel resources, increasing energy demand and stringent emission regulations are drivers to evaluate process off-gases or process waste streams as fuels for power generation. Often these process waste streams have low energy content and/or highly reactive components. Operability of low energy content fuels in gas turbines leads to issues such as unstable and incomplete combustion. On the other hand, fuels containing higher-order hydrocarbons lead to flashback and auto-ignition issues. Due to above reasons, these fuels cannot be used directly without modifications or efficiency penalties in gas turbine engines. To enable the use of these wide variety of fuels in gas turbine engines a rich catalytic lean burn (RCL®) combustion system was developed and tested in a subscale high pressure (10 atm.) rig. The RCL® injector provided stability and extended turndown to low Btu fuels due to catalytic pre-reaction. Previous work has shown promise with fuels such as blast furnace gas (BFG) with LHV of 85 Btu/ft3 successfully combusted. This program extends on this work by further modifying the combustor to achieve greater catalytic stability enhancement. Fuels containing low energy content such as weak natural gas with a Lower Heating Value (LHV) of 6.5 MJ/m3 (180 Btu/ft3 to natural gas fuels containing higher hydrocarbon (e.g ethane) with LHV of 37.6 MJ/m3 (1010 Btu/ft3) were demonstrated with improved combustion stability; an extended turndown (defined as the difference between catalytic and non-catalytic lean blow out) of greater than 250oF was achieved with CO and NOx emissions lower than 5 ppm corrected to 15% O2. In addition, for highly reactive fuels the catalytic region preferentially pre-reacted the higher order hydrocarbons with no events of flashback or auto-ignition allowing a stable and safe operation with low NOx and CO emissions.

Eteman, Shahrokh↗
DOE OSTI2015

Improving Gas Furnace Performance: A Field and Laboratory Study at End of Life

In 2010, natural gas provided 54% of total residential space heating energy the U.S. on a source basis, or 3.5 Quadrillion Btu. Natural gas burned in furnaces accounted for 92% of that total, and boilers and other equipment made up the remainder. A better understanding of installed furnace performance is a key to energy savings for this significant energy usage. Natural gas furnace performance can be measured in many ways. The annual fuel utilization efficiency (AFUE) rating provides a fixed value under specified conditions, akin to the EPA miles per gallon rating for new vehicles. The AFUE rating is provided by the manufacturer to the consumer and is a way to choose between models tested on the same basis. This value is commonly used in energy modeling calculations. ASHRAE 103 is a consensus furnace testing standard developed by the engineering community. The procedure provided in the standard covers heat-up, cool down, condensate heat loss, and steady-state conditions and an imposed oversize factor. The procedure can be used to evaluate furnace performance with specified conditions or with some variation chosen by the tester. In this report the ASHRAE 103 test result will be referred to as Annualized Efficiency (AE) to avoid confusion, and any non-standard test conditions will be noted. Aside from these two laboratory tests, steady state or flue loss efficiency can be measured in the field under many conditions; typically as found or tuned to the manufacturers recommended settings. In this report, AE and steady-state efficiency will be used as measures of furnace performance.

03 NATURAL GAS↗
DOE OSTI2014

Look-ahead driver feedback and powertrain management

Commercial medium and heavy vehicles, though only a small portion of total vehicle population, play a significant role in energy consumption. In 2012, these vehicles accounted for about 5775.5 trillion btu of energy consumption and 408.8 million tons of CO2 emissions annually, which is a quarter of the total energy burden of highway transportation in the United States [1]. This number is expected to surpass passenger car fuel use within the next few decades. In the meantime, most commercial vehicle fleets are running at a very low profit margin. It is a well known fact that fuel economy can vary significantly between drivers, even when they operate the same vehicle on the same route. According to the US Environmental Protection Agency (EPA) and Natural Resource Canada (NRCan), there is up to 35% fuel economy difference between drivers within the same commercial fleet [2] [3], [4]. Similar results were obtained from a Field Operation Test conducted by Eaton Corporation [5]. During this test as much as 30% fuel economy difference was observed among pick-up-and-delivery drivers and 11% difference was observed among line-haul drivers. The driver variability can be attributed to the fact that different drivers react differently to driving conditions such as road grade, traffic, speed limits, etc. For instance, analysis of over 600k miles of naturalistic heavy duty truck driving data [5] indicates that an experienced driver anticipates a downhill and eases up on the throttle to save fuel while an inexperienced driver lacks this judgment.

Verma, Rajeev↗
DOE OSTI2015

Improving Gas Furnace Performance: A Field and Laboratory Study at End of Life

In 2010, natural gas provided 54% of total residential space heating energy the U.S. on a source basis, or 3.5 Quadrillion Btu. Natural gas burned in furnaces accounted for 92% of that total, and boilers and other equipment made up the remainder. A better understanding of installed furnace performance is a key to energy savings for this significant energy usage. In this project, the U.S. Department of Energy Building America team Partnership for Advanced Residential Retrofit examined the impact that common installation practices and age-induced equipment degradation may have on the installed performance of natural gas furnaces over the life of the product, as measured by steady-state efficiency and annual efficiency. The team identified 12 furnaces of various ages and efficiencies that were operating in residential homes in the Des Moines, Iowa, metropolitan area and worked with a local heating, ventilation, and air conditioning contractor to retrieve furnaces and test them at the Gas Technology Institute laboratory for steady-state efficiency and annual efficiency. Prior to removal, system airflow, static pressure, equipment temperature rise, and flue loss measurements were recorded for each furnace as installed in the house.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2011

Evaluation of the Relative Merits of Herbaceous and Woody Crops for Use in Tunable Thermochemical Processing

This report summarizes the work and findings of the grant work conducted from January 2009 until September 2011 under the collaboration between Ceres, Inc. and Choren USA, LLC. This DOE-funded project involves a head-to-head comparison of two types of dedicated energy crops in the context of a commercial gasification conversion process. The main goal of the project was to gain a better understanding of the differences in feedstock composition between herbaceous and woody species, and how these differences may impact a commercial gasification process. In this work, switchgrass was employed as a model herbaceous energy crop, and willow as a model short-rotation woody crop. Both crops are species native to the U.S. with significant potential to contribute to U.S. goals for renewable liquid fuel production, as outlined in the DOE Billion Ton Update (http://www1.eere.energy.gov/biomass/billion_ton_update.html, 2011). In some areas of the U.S., switching between woody and herbaceous feedstocks or blending of the two may be necessary to keep a large-scale gasifier operating near capacity year round. Based on laboratory tests and process simulations it has been successfully shown that suitable high yielding switchgrass and willow varieties exist that meet the feedstock specifications for large scale entrained flow biomass gasification. This data provides the foundation for better understanding how to use both materials in thermochemical processes. It has been shown that both switchgrass and willow varieties have comparable ranges of higher heating value, BTU content and indistinguishable hydrogen/carbon ratios. Benefits of switchgrass, and other herbaceous feedstocks, include its low moisture content, which reduce energy inputs and costs for drying feedstock. Compared to the typical feedstock currently being used in the Carbo-V® process, switchgrass has a higher ash content, combined with a lower ash melting temperature. Whether or not this may cause inefficiencies in the process, needs to be verified by long term test runs. Currently, there are not sufficient operational test data available for the Carbo-V® process for the utilization of higher ash content feedstocks. The application of currently evolving biomass pretreatment technologies, such as pelletization and torrefaction, will be able to expand the portfolio of biomass varieties and species acceptable in gasification processes. Tests showed that 6 mm diameter pellets of switchgrass were superior to 8 mm diameter pellets produced in a flat dye press, and that torrefaction of switchgrass produced an excellent (but currently costly) feedstock that could be handled, crushed, and combusted in a manner compatible with any coal-fed gasification facility. Ceres will use this information in the development of high yielding, dedicated energy crops specifically tailored for thermochemical conversion. CHOREN will make use of the information for improvement or development of low cost, highly efficient biomass gasification processes that convert a wide variety of biomass feedstocks to fuels, chemicals, heat and power via the production of tar free green syngas on an industrial scale.

09 BIOMASS FUELS↗
DOE OSTI2015

Catalyst-Assisted Manufacture of Olefins from Natural Gas liquids: Prototype Development and Full-Scale Testing

The steam cracking of ethane to ethylene consumes the greatest amount energy of any process currently practiced by the US chemical industry. U.S. ethylene production consumed an estimated 450 trillion BTU of energy to produce nearly 53 billion pounds of ethylene in 2010. A significant portion of this energy consumption is to overcome the insulating effect of coke (carbonaceous deposits) on the internal surfaces of cracker furnace tubes. This buildup of coke is the result of both metal-catalyzed coke formation on the tube walls (“filamentous coke”), and deposition of gas-phase coke on the tube walls (“amorphous coke”). Coke buildup requires a continuous increase in energy input (firing of external coil tube wall) to achieve the same conversion of ethane feedstock to ethylene product, until the tubes must be taken out of service and the coke removed by steam treatment (“decoking”). This step interrupts production and increases the cost of ethylene. Coke buildup also shortens the coil life by increasing the rate of “creep” (sagging) that occurs due to higher temperature operation and migration of the deposited carbon into the coil metal.

03 NATURAL GAS↗
DOE OSTI2017

Hybrid Molten Bed Gasifier for High Hydrogen Syngas Production

The techno-economic analyses of the hybrid molten bed gasification technology and laboratory testing of the HMB process were carried out in this project by the Gas Technology Institute and partner Nexant, Inc. under contract with the US Department of Energy’s National Energy Technology Laboratory. This report includes the results of two complete IGCC and Fischer-Tropsch TEA analyses comparing HMB gasification with the Shell slagging gasification process as a base case. Also included are the results of the laboratory simulation tests of the HMB process using Illinois #6 coal fed along with natural gas, two different syngases, and steam. Work in this 18-month project was carried out in three main Tasks. Task 2 was completed first and involved modeling, mass and energy balances, and gasification process design. The results of this work were provided to Nexant as input to the TEA IGCC and FT configurations studied in detail in Task 3. The results of Task 2 were also used to guide the design of the laboratory-scale testing of the HMB concept in the submerged combustion melting test facility in GTI’s industrial combustion laboratory. All project work was completed on time and budget. A project close-out meeting reviewing project results was conducted on April 1, 2015 at GTI in Des Plaines, IL. The hybrid molten bed gasification process techno-economic analyses found that the HMB process is both technically and economically attractive compared with the Shell entrained flow gasification process. In IGCC configuration, HMB gasification provides both efficiency and cost benefits. In Fischer-Tropsch configuration, HMB shows small benefits, primarily because even at current low natural gas prices, natural gas is more expensive than coal on an energy cost basis. HMB gasification was found in the TEA to improve the overall IGCC economics as compared to the coal only Shell gasification process. Operationally, the HMB process proved to be robust and easy to operate. The burner was stable over the full oxygen to fuel firing range (0.8 to 1.05 of fuel gas stoichiometry) and with all fuel gases (natural gas and two syngas compositions), with steam, and without steam. The lower Btu content of the syngases presented no combustion difficulties. The molten bed was stable throughout testing. The molten bed was easily established as a bed of molten glass. As the composition changed from glass cullet to cullet with slag, no instabilities were encountered. The bed temperature and product syngas temperature remained stable throughout testing, demonstrating that the bed serves as a good heat sink for the gasification process. Product syngas temperature measured above the bed was stable at ~1600ºF. Testing found that syngas quality measured as H 2 /CO ratio increased with decreasing oxygen to fuel gas stoichiometric ratio, higher steam to inlet carbon ratio, higher temperature, and syngas compared with natural gas. The highest H 2 /CO ratios achieved were in the range of 0.70 to 0.78. These values are well below the targets of 1.5 to 2.0 that were expected and were predicted by modeling. The team, however, is encouraged that the HMB process can and will achieve H 2 /CO ratios up to 2.0. Changes needed include direct injection of coal into the molten bed of slag to prevent coal particle bypass into the product gas stream, elevation of the molten bed temperature to approximately 2500ºF, and further decrease of the oxygen to fuel gas ratio to well below the 0.85 minimum ratio used in the testing in this project.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2017

Advanced control for ground source heat pump systems

Ground source heat pumps (GSHP), also known as geothermal heat pumps (GHP), are proven advanced HVAC systems that utilize clean and renewable geothermal energy, as well as the massive thermal storage capacity of the ground, to provide space conditioning and water heating for both residential and commercial buildings. GSHPs have higher energy efficiencies than conventional HVAC systems. It is estimated, if GSHPs achieve a 10% market share in the US, in each year, 0.6 Quad Btu primary energy consumption can be saved and 36 million tons carbon emissions can be avoided (Liu et al. 2017). However, the current market share of GSHPs is less than 1%. The foremost barrier preventing wider adoption of GSHPs is their high installation costs. To enable wider adoption of GSHPs, the costeffectiveness of GSHP applications must be improved.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

Sacrificial Protective Coating Materials that can be Regenerated In-Situ to Enable High Performance Membranes

In the pulp and paper industry, weak black liquor concentration is carried out using energy intensive evaporators. Briefly, after wood digestion, water is evaporated to concentrate weak black liquor to the point where the black liquor can be burned in a recovery boiler, which ultimately leads to the recovery of digestion chemicals. Because it is less energy intensive than heat-driven separation, pressure-driven separation of water from black liquor using membranes could reduce the energy usage by 55 trillion Btu yr -1 and carbon dioxide emissions by more than 11 million metric tons CO 2 per year if the first two evaporators are replaced. However, weak black liquor is a hot, corrosive, and highly fouling feed with organic molecules, colloids, and ions that clog membranes within hours of operation. We have shown that membrane-based concentration of weak black liquor is feasible, but only with our antifouling and anti-clogging technology that is based on a sacrificial Bio-inspired Living Skin concept. This concept is based on a conformal coating that is formed at the membrane surface and within the pores. Weak foulant adhesion dramatically decreases membrane fouling while the superhydrophilicity of the coating increases the water permeability. Moreover, the coating can be completely removed during backflushing, which removes foulants that may irreversibly adhere to the coating over long periods of time. The skin shedding completely regenerates the membrane surface and pores, restoring the original flux. This is followed by in-situ recoating, using the existing membrane plumbing and pumps, which essentially creates a brand new membrane surface.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗