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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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The operations of the NETL baseline Natural Gas Combined Cycle (NGCC) power plants with or without carbon capture and sequestration (CCS) on the basis of 1 MWh electricity output. To access the model referenced in the report, please visit https://www.netl.doe.gov/energy-analysis/details?id=105C34B9-F371-4D71-8F1A-EFB7F71DCAAB
The operations of the NETL baseline Supercritical Pulverized Coal (SCPC) power plants with or without carbon capture and sequestration (CCS) on the basis of 1 MWh electricity output. To access the model referenced in the report, please visit https://www.netl.doe.gov/energy-analysis/details?id=B5A2EB6F-4FBC-4883-922C-BE720FAC5A80
The operations of the NETL baseline Subcritical Pulverized Coal (SubCPC) power plants with or without carbon capture and sequestration (CCS) on the basis of 1 MWh electricity output. To access the model referenced in the report, please visit https://www.netl.doe.gov/energy-analysis/details?id=726C064C-F978-49EB-931C-5F69AD92BD5C
Material input for the construction of the NETL baseline supercritical pulverized coal (SCPC) plant with or without carbon capture and sequestration (CCS). To access the model referenced in the report, please visit https://www.netl.doe.gov/energy-analysis/details?id=404A3685-9CEF-4095-91EB-44CCF08D24F4
This presentation discusses carbon capture retrofit analyses for existing coal and natural gas power plants, and industrial facilities. Also discussed is development of an analysis tool that would quantify the cost and performance impacts of CCS retrofits.
One of the more significant issues related to carbon capture retrofits pertains to the reduction in net power output (derate) due to the large parasitic power load required for appreciable levels of carbon capture. Post-combustion capture (PCC) has been shown to reduce the net plant efficiency of an equivalent plant without capture by 20 percent or more. Yet, post-combustion amine scrubbing is anticipated to be the most viable near-term technology for reducing carbon dioxide (CO 2 ) emissions from existing coal plants. This study attempts to quantify auxiliary load replacement options for existing pulverized coal (PC) boilers to reduce the effects caused by steam and power requirements of the CCS systems and the resulting derated output of the existing plant. While individual retrofit options are highly plant-specific and, therefore, subject to unique optimization pathways, each of the proposed cases in this study attempts to examine the most promising configurations for each repowering technology.
It is increasingly clear that carbon dioxide (CO 2 ) capture and sequestration (CCS) must play a critical role in curbing worldwide CO 2 emissions to the atmosphere. Previously, we have developed ionic liquids (ILs) and phase change ionic liquids (PCILs) for post-combustion CO 2 capture. In this project, we synthesized and tested 19 ILs and PCILs and chose one of each for further development. The IL selected for further development was triethyl(octyl)phosphonium 2-cyanopyrrolide ([P 2228 ][2CNPyr]), which has the same anion but a different cation, than used in our previous work. The new cation imparts a lower viscosity than the prior cation. The PCIL selected for further development was tetraethylphosphonium benzimidazolide ([P 2222 ][BnIm]), which was developed in an Advanced Research Projects Agency-Energy (ARPA-E) project. Although we made numerous other candidates, none were better than this original PCIL. Here we showed that the CO 2 absorption by the IL and the PCIL was completely reversible, even when water was present. We determined and quantified the additional chemistry, involving the formation of bicarbonate, when water is present. The IL and PCIL were encapsulated in silicone shells using a microfluidic device. Compatibility between the IL/PCIL and the polymer, viscosity, and surface tension issues, getting sufficiently high IL/PCIL loading and leakage (likely from insufficient cross-linking), were serious challenges. Small quantities (~ 1 g) of microcapsules with good integrity of both the IL and the PCIL were produced. The CO 2 uptake by these capsules was the same as for the free IL and PCIL and the capacity of the capsules decreased only slightly even after five absorption and desorption cycles. As expected, the IL and PCIL (and subsequently the encapsulated IL and PCIL) reacted readily with SO 2 and NO, so, like aqueous amine absorbents, the CO 2 capture unit would have to be located downstream of the flue gas desulfurization and other gas treatment units. Large samples (~70 g and 100 g) of encapsulated PCIL were produced in a parallel microfluidic device and in an in-air device. These capsules were tested in a Laboratory Scale Unit (LSU) to demonstrate uptake capacity in a fluidized bed. We also used the LSU to determine recyclability and mass transfer coefficients. Unfortunately, equivalent experiments with the IL were not possible due to difficulties with producing large samples of the encapsulated IL. This IL encapsulation “scale-up” problem was not solved during the course of this project. Nonetheless, using the PCIL microcapsules we demonstrated that, as expected, the mass transfer is internally controlled. In concert with a new rate-based model of the fluidized bed, we determined that the productivity is increased by a factor of 4.75 in the microcapsule fluidized bed absorber compared to a conventional liquid-gas packed bed absorber. The initial technoeconomic model shows that the capital cost for the microcapsule IL continuous fluidized bed process is similar to that of an aqueous amine process (specifically, the Econamine FG Plus technology). However, the stripping heat requirements are about 35% less for the model IL microcapsule case compared to the monoethanolamine (MEA) case. Thus, encapsulated ILs/PCILs in a continuous fluidized bed absorber for post-combustion CO 2 capture are a significant improvement over the free IL/PCIL case and represent a major reduction in the parasitic energy requirements compared to aqueous amine process.
This report presents the scientific and technical findings by Carbon Engineering Ltd (CE) resulting from the DOE sponsored research and development project on Direct Air Capture (DAC) process. The work was performed by CE under the Award DE-FE0026861 from the US Department of Energy’s (DOE) National Energy Technology Laboratory (NETL). The work plan was centered on advancing the Recipient’s DAC technology, developing a better understanding of its performance and cost. The report outlines the results from two key activities that were performed under this award: Studying the performance characteristics of the DAC plant at both pilot and lab scale Techno-economic analysis (TEA) to study two implementations of CE’s proprietary DAC process: i) An early commercial DAC process that captures ~1 MT CO 2 /year of atmospheric CO 2 (Baseline case), and ii) A modified early commercial DAC process that captures 1 MT CO 2 /year of flue gas CO 2 downstream of a subcritical PC post-CCS power plant (Case 1 Option C). Within the first key activity of the project, significant operational improvements and learnings were realized, including for key equipment in the DAC process in addition to the overall system. Learnings included impact of equipment design on the capture, calcination and slaking processes, and operational parameter modifications for optimizing the pelletization process, along with the complex interactions and associated considerations of these on overall system performance. In parallel, benchtop scale equipment was successfully utilized to validate pilot scale data, such as, retention in the pellet reactor, and capture performance parameters of the air contactor. CE continues to conduct core research and development activities; the learnings from this DOE project will contribute to the design, testing and operation activities of CE’s fully integrated DAC validation plant, as well as the first commercial DAC plant. The second key activity incorporated the above learnings, as well as input from vendors and EPC experts, to produce the TEA report. More specifically, the TEA results were based on measured pilot plant performance data for all major unit operations, and on an energy and material balance for the process at commercial scale computed using an Aspen One® process simulation. The cost estimation methodology follows AACE International recommended practices; with an uncertainty range of -15%/+30%. Depending on financial assumptions, energy costs, and the specific choice of inputs and outputs, the levelized cost per ton CO 2 captured from the atmosphere for an early commercial plant for the baseline case ranges from 227 to 304 $/t-CO 2 . And, the levelized cost to capture 98% of the flue gas CO 2 emissions in a subcritical PC power plant (Case 1 Option C) through a combination of Cansolv carbon capture system and a modified DAC system was estimated to range from 109 to 160 $/MWh of net power generated. Process improvement opportunities identified during this work, in addition to cost reduction opportunities identified during the Value Engineering exercise associated with the Baseline case indicate that significant reductions in capital costs are available as CE scales up and proceeds through deployment of initial facilities.
Introduction: The staged pressurized oxy-combustion (SPOC) process, developed by Washington University in St. Louis (WUSTL), is an oxy-combustion carbon capture technology that employs a steam power cycle to generate electricity. As with atmospheric-pressure oxy-combustion processes, carbon dioxide (CO 2 ) capture rates of 90% or higher can be achieved. The staged-combustion approach of the SPOC process, when operated at elevated gas pressure, allows for near elimination of flue gas recycle (FGR) and leads to significant improvements in efficiency and reduced costs. The primary goal of this project was to investigate the potential for SPOC for flexible operation beyond the capabilities of conventional coal-fired power plants, particularly those employing carbon capture and storage (CCS). Oxy-combustion differs from conventional coal combustion in that the combustion of coal is carried out using oxygen as opposed to air. The resultant flue gas is a mixture of primarily CO 2 and water, greatly simplifying CO 2 capture. As SPOC does the oxy-combustion process under pressure, it is higher efficiency and lower cost than atmospheric oxy-combustion. The project was led by the Electric Power Research Institute, Inc., with the assistance of WUSTL, Doosan Babcock (DBL – boiler plant original equipment manufacturer), and Air Liquide (AL – air separation experts). The specific objectives of the project were to: (1) Evaluate the SPOC concept and develop a risk-based approach to the heating surface layout ensuring that performance (gas and steam side), manufacturing, transportation, and plant erection considerations were fully accounted for in the system design. (2) Improve the technology to ensure its performance and cost potential are substantially better than today’s baseline pulverized coal power plant with post-combustion capture (PCC) or atmospheric oxy-combustion, and show progress toward performance commensurate with projected commercial operation, including 90% or more CO 2 capture. (3) Address critical technology gaps and improving overall system performance for the technology. (4) Perform combustion tests at scale under commensurate pressure to the commercial operating system validate combustor and advance the SPOC combustion modeling tools that will facilitate full-scale design. Combustion Testing: Testing was initially carried out at atmospheric pressure with methane to ensure that all systems were correctly operating. Following this, the testing then proceeded to moderate pressure operation at 4 bara, where different stoichiometric conditions were used across an extended heat input range, showing that a stable flame could be maintained. Testing then proceeded at 10 and 15 bara where it was shown that the ignition system needed to be replaced at these operating conditions. When testing recommenced, a similar stable flame shape was achieved, without any methane support, and the full 100 kWth coal oxy-combustion was demonstrated. Heat flux measurements showed 400 kW/m 2 (0.126 MMBtu/hr-ft 2 ) from the flame, within the 450 kW/m 2 (0.142 MMBtu/hr-ft 2 ) preferred limit defined by DBL for the full-scale design case. Carbon monoxide and carbon-in-ash measurements showed that complete combustion was possible with ultra-low excess oxygen at 1 vol % in the product flue gas. This allowed the full-scale models to be calculated based on this level of excess oxygen, improving the performance of the system as lower feed oxygen is produced in the air separation unit (ASU), saving auxiliary power. Full-Scale Design: The full-scale design is sized to deliver 550 MWe net electrical power output to allow direct comparison with the National Energy Technology Laboratory (NETL) baseline cases using the same Montana Powder River Basin (PRB) fuel. The cases used for direct comparison are: Case S12A (supercritical [SC] coal without CO 2 capture), Case S12B (SC coal with PCC at 90% CO 2 capture, and Case S12F (atmospheric oxy-combustion SC coal with 90% CO 2 capture). The SPOC stages were configured to be identical arrangements, allowing for a more straightforward design, construction, and control strategy. Each stage consists of two PVs, the first being the combustor PV module and the second being the convective PV module. The combustor module is the tallest vessel, with local coal feeding equipment and the burner FGR and oxygen plenums at the top and ash management at the bottom. The combustor module is effectively an open cross section with membrane tubes around the circumference – this unobstructed slender profile ensures that the relatively slower burnout mechanism needed for the low-speed turbulent mixing burner can proceed unimpeded and that molten ash will not attach to any surfaces at an angle to the predominant flue gas flow. The steam turbine used in the SPOC design is essentially the same unit utilized in the atmospheric oxy-combustion case except the degree of heat recovery possible allows the low-pressure (LP) feedwater heater train to be eliminated. This is a result of being able to capture the latent heat of evaporation of the moisture produced in the combustion (normally lost to the stack). The SPOC system outperforms the NETL atmospheric oxy-combustion baseline case by 3.3% points and the PCC case by 7.5% points. This performance increase is mainly a result of the improved heat recovery possible from the product flue gas and from the reduced auxiliary power consumption from the ASU and the CO 2 compression and purification unit over the atmospheric equivalent. The combined improvement in boiler efficiency and reduction in the steam turbine heat rate resulted in a net improvement in the overall plant efficiency by 0.61%, to 35.6% on a HHV basis. This relatively small improvement in plant efficiency between sub-bituminous and bituminous coals shows the value of useful moisture latent heat recovery offered by the SPOC system when using low rank fuels. Flexibility and Turndown: The SPOC system has inherent high turndown capabilities because of a demonstrated high range of combustion stability and the ability to bypass stages, thereby reducing steam generation rates proportionally without altering firing rates in operating stages. ASU units do not generally offer significant turndown opportunities as they are limited by the performance of the compression plant. The baseline SPOC design has a 2-train ASU configuration, needed to be able to meet the 10,500 tonnes per day duty, that can deliver efficient turndown points between 85–100% load with both trains operating, and at 45–50% load with a single train operating. Outside these operating points, the flexibility and efficiency are limited and may be uncompetitive at loads below 45% as the ASU systems are unable to turndown beyond 85% for the base case and 70% for the flexible case. The ASU cold box for the flexible case was designed to operate at loads between 40-100%, below this operating range the purity of the produced oxygen cannot be guaranteed, resulting in additional load for the CPU equipment. The additional power consumption of these cases yields an uneconomic operating condition with poor efficiency when operating at low loads such as 25% and 12%. To address this flexibility constraint, AL evaluated how the ASU configuration could be altered to deliver efficient oxygen supply over the load range. This involved integrating the compressor duties across both ASU trains into a shared duty arrangement with multiple compressors, strategically sized to deliver the duty required across all load ranges between 40–100% by enabling different combinations of the main air compressors and the booster air compressors. The oxygen purity cannot be guaranteed below 40% load for each train – the power consumption at 25% and 12% loads were estimated based on the multi-compressor configuration at maximum turndown as these load cases were not considered in the flexible ASU design. With a different cold box configuration, i.e. number of trains, the entire load range could be delivered within oxygen purity specifications. Although there is a small efficiency reduction at full load, there are significant improvements in overall plant performance during low-load operation. The exact ASU configuration needed will therefore be dependent on the expected operating profile of the unit. Economic Analysis: Cost estimates for the baseline and the flexible cases were developed using NETL baseline case data for common BOP items and an Association for the Advancement of Cost Engineering International Class 5 (conceptual/screening study) assessment of key components unique to the SPOC system. The capital, operating, and maintenance costs were assessed along with the first-year power cost, levelized cost of electricity, and CO 2 captured and avoided cost for the SPOC cases were compared against the relevant NETL baseline cases in January 2019 dollars. Both SPOC cases achieve a lower cost that the alternative NETL baseline cases (with the flexible SPOC case being slightly higher than the baseline SPOC case due to the compounded impact of higher capital costs and lower efficiency at full load). The SPOC cases deliver a lower cost of CO 2 avoided than the NETL baseline cases due to greater efficiency in generating low-carbon power. However, the cost of CO 2 captured is higher because the higher efficiency of the SPOC process generates less CO 2 , hence less needs to be captured, resulting in a high capital cost being shared over a reduced CO 2 quantity. The flexible ASU adds 1.6% overall to the plant cost in comparison to the baseline case, but the efficiency improvements at loads below 50% are significant. Subsequently, depending on the plant load-profile expectation, the flexible ASU would be beneficial if the plant spends a significant portion of its operating life below 50% load. This kind of operating profile is likely to be required for all fossil plants when more renewable electricity generators are installed on the local grid, particularly solar power that can be predicted ahead of time, allowing for appropriate pricing signals to be incorporated into the diurnal cycle. R&D Recommendations: SPOC, while a promising technology, is a relatively recent concept and, as such, operability issues of combustor design and steam-side integration for such systems at a scale relevant to commercial deployment have not been evaluated. WUSTL has conducted extensive small pilot-scale (100 kWth) research to understand and advance pressurized oxy-combustion processes, including investigation of combustion and flame characteristics, radiative heat flux, burner operability, turn down, char burnout, ash characteristics, water-wash column operation, etc. for pressurized oxy-combustion systems. Nonetheless, at this stage in the development of the SPOC process, what is needed is a large-scale pilot plant that can serve to study pressurized oxy-combustion systems and components at a scale commensurate with the maturity of the technology. A scale of 10 MWth, which includes steam-side integration and two stages would yield essential information with respect to heat transfer characteristics both in the radiative and convective sections of the pressure vessels, and the ability to operate the fuel staging process. In addition, while modeling results indicate that combustion and flame characteristics improve with scale, direct studies of the combustor at this scale will ensure that the models can be relied upon for scale up to commercial scale. Furthermore, a detailed analysis must be performed to understand the scaling aspects of key components and systems.
This webinar discusses carbon capture retrofit analyses for existing coal and natural gas power plants, and industrial facilities. Also discussed is development of an analysis tool that would quantify the cost and performance impacts of CCS retrofits.
SimCCS2.0 is an open-source software package for industry, researchers, and government to design carbon dioxide (CO2) capture, transport, and storage (CCS) infrastructure that optimally links CO2 sources (e.g., power plants) with CO2 sinks (e.g., saline aquifers, depleted oil fields) to reduce industry carbon footprints and increase energy production.
The U.S. Department of Energy is leading the development of CCS through collaborative projects and programs to not only develop and demonstrate the technology but to also quantify the risks and provide tools that site operators can use to develop a site-specific understanding of their risk to enable successful project operations. This report summarizes results and findings from the application of risk-assessment tools to an industrial-scale Geologic Carbon Storage (GCS) project. Specifically, we applied the National Risk Assessment Partnership’s (NRAP) Open Integrated Assessment Model (NRAP-Open-IAM) and State of Stress Assessment Tool (SOSAT) to two candidate sites being considered for storage by the Integrated Midcontinent Stacked Carbon Storage Hub (IMSCS-Hub) project team. These sites, Sleepy Hollow Field in Nebraska and Patterson Field in Kansas, have historical oil and gas production and thus are attractive candidates to store the 50 million metric tons (Mt), which is the CarbonSAFE objective. Because these sites have historical operations, they have a significant number of existing wells that pose a risk for well leakage. Additionally, the storage formations will undergo significant pore pressure perturbation (i.e., increase due to CO 2 injection). Hence, we have selected the two NRAP tools best suited to study the risks associated with well leakage and geomechanical risks. The objective of the study was not only to assess the risk at the site, but to also improve the NRAP tools through application using real site data on an ongoing project.
Concern over greenhouse gas emissions, such as CO2 from fossil fuel combustion, is leading to new regulations on fossil-fuel fired power generation facilities. Using amine-based solutions for CO2 capture in power plants is the most common method utilized industrially and studied in the laboratory environment. However, a limited number of amines are available for carbon capture research after balancing the capital cost and energy penalty. In the carbon capture process, physical properties such as viscosity, surface tension, wettability, etc. are found to play important roles in solvent performance. In this context, we are exploring an approach to enhance the CO2 capture of amine solvents by tuning the physical properties of the amine solvents by the addition of additives. These additives in the amine solution utilize controlled bubble generation to increase liquid-gas contact surface area. This method can increase mass transfer in the absorber column, specifically at the bottom where the mass transfer is limited. These additives can enhance the CO2 capture efficiency by changing the physical property of the solvent which in turn can lower the capital cost associated with the system. This work can be applied to all common aqueous amine solvent and would be of great interest to those in the CCS community.
The vertical borehole array at Farnsworth Unit, TX is used to monitor microseismic activity in the subsurface around the Carbon Capture and Sequestration (CCS) reservoir. The array consists of 16 3-component seismometers spaced vertically in a single borehole. Tube or borehole waves traveling up or down the borehole can corrupt signals of interest, such as microseismic events. A denoising convolutional neural network (DCNN) was trained to remove borehole waves from seismic waveforms of microseismic events for the purpose of reducing unwanted signal detections and better characterizing events of interest. This R&D leverages the work of Sandia colleague Rigo Tibi, who used a DCNN developed by Greg Beroza at Stanford University to improve the signal-to-noise ratio (SNR) of teleseismic events detected by the International Monitoring System.
Southeast Regional Carbon Sequestration Partnership (SECARB): CCS Demo Update
The objective of this study was to characterize the performance and cost of newly constructed coal-fired power plants capable of meeting the Carbon Pollution Standard, without the use of carbon capture and sequestration (CCS). The specific configurations that were investigated are combined heat and power applications, and coal-fired power plants co-firing natural gas in the boiler. The reference coal plants, or technology base cases, considered include supercritical (SC) pulverized coal (PC), advanced ultra-supercritical (AUSC) PC, and IGCC plants. The reference cases considered are taken from the report "Cost and Performance Baseline for Fossil Energy Plants Volume 1: Bituminous Coal and Natural Gas to Electricity Revision 3."
Southeast Regional Carbon Sequestration Partnership (SECARB): CCS in the US
Southeast Regional Carbon Sequestration Partnership (SECARB): CCS in the US