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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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At least 721 records · Page 40
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Reactive catalytic fast pyrolysis of biomass to produce high-quality bio-crude

Reactive catalytic fast pyrolysis (RCFP) of biomass with atmospheric pressure hydrogen was investigated in a lab-scale fluidized bed reactor with varying reaction conditions (temperature and hydrogen concentration) and catalysts. Presence of atmospheric hydrogen with candidate RCFP catalysts was found to improve the yield and quality of bio-crude and minimize the char and coke formation. Here, a molybdenum-based catalyst was the most effective at hydrodeoxygenating biomass pyrolysis vapors to produce a hydrocarbon-rich bio-crude intermediate with low oxygen content (<10 wt%). Higher hydrogen concentration and moderate reaction temperature (450 °C) favored higher bio-crude yields and quality. A yield of 43.2 C% in the C 4+ organic fraction with as low as 6.2 wt% oxygen in the liquid was obtained under optimized reaction conditions. The resulting bio-crude contained primarily aliphatic and aromatic hydrocarbons, with small amounts of simple ketones, furans, and phenols. Up to 41.5% carbon in the biomass feed was converted into gas and condensable hydrocarbons with 29.7% in the condensable C 4+ fraction. The improved bio-crude quality is expected to be more compatible with existing petroleum refining infrastructure.

09 BIOMASS FUELS↗
DOE OSTI2020

Solvent-induced membrane stress in biofuel production: molecular insights from small-angle scattering and all-atom molecular dynamics simulations

The disruptive effect of organic solvents on microbial membranes represents a significant challenge to the economical production of green fuels and value-added chemicals from lignocellulosic feedstocks. One route to overcoming this challenge is to engineer microbes with membranes capable of resisting organic solvent stresses. In this regard, it is useful to understand the mechanisms by which organic solvents disrupt typical biomembranes. In this study, molecular dynamics (MD) simulation, complemented by small-angle X-ray and neutron scattering (SANS/SAXS), provide a molecular-scale view of the disruption of a microbial model membrane by 1-butanol and tetrahydrofuran (THF), two common water–organic cosolvent mixtures of importance in biofuel production. Solvent interactions at the interface between the head-group and fatty acid tail regions lead to more dramatic membrane changes than interactions solely at the head-groups or tails. Although both organic solvents are found to partition into the membrane, the depth of solvent penetration into the membrane is quite different. Specifically, 1-butanol localizes near the interface between the lipid heads and tails at low concentrations, but partitions into both the head and tail regions at high concentrations. In contrast, THF, overall, partitions less than 1-butanol and prefers the lipid tail regions. Importantly, the presence of 1-butanol near the head/tail interface introduces drastic membrane changes not seen with THF. The organic solvent interactions with the lipids lead to membrane thinning and fluidization, but more so for 1-butanol than for THF. These results suggest that an aim for the future engineering of robust membranes could be to design lipid head groups that reduce the accumulation of organic solvents at the head–tail interface and that rational designs need also be cognizant of the different solvent-specific mechanisms responsible for membrane disruption.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Curvature-controlled geometrical lensing behavior in self-propelled colloidal particle systems

In many biological systems, the curvature of the surfaces cells live on influences their collective properties. Curvature should likewise influence the behavior of active colloidal particles. We show using molecular simulation of self-propelled active particles on surfaces of Gaussian curvature (both positive and negative) how curvature sign and magnitude can alter the system's collective behavior. Curvature acts as a geometrical lens and shifts the critical density of motility-induced phase separation (MIPS) to lower values for positive curvature and higher values for negative curvature, which we explain theoretically by the nature of parallel lines in spherical and hyperbolic space. Curvature also fluidizes dense MIPS clusters due to the emergence of defect patterns disrupting the crystalline order inside the clusters. Using our findings, we engineer three confining surfaces that strategically combine regions of different curvature to produce a host of novel dynamical behaviors, including cyclic MIPS on spherocylinders, directionally biased cyclic MIPS on spherocones, and position dependent cluster fluctuations on metaballs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

The Effects of Polyolefin Structure and Source on Pyrolysis-Derived Plastic Oil Composition

Seven types of plastics were pyrolyzed in a fluidized bed reactor: post-consumer recycled (PCR) high-density polyethylene (HDPE), PCR polypropylene (PP), virgin resins of varying molecular weights of HDPE, virgin resins of low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), and (PP). Pyrolysis produced non-condensable gases (C1-C3), liquid phase products (C4-C40), and solids (C40+ and chars), with alkane, alkene, alkadiene, aromatic, and multi-cycloaromatics as the predominant compounds. Polymer structure had the greatest impact on product distribution, with minimal influence from molecular weight. Branches in polyethylene (PE) acted as thermal defects initiating degradation. Higher branch density in PE led to increased concentrations of aromatics, branched alkanes, and internal alkenes. PP and PE exhibited distinct degradation mechanisms, with PP requiring less energy for decomposition and yielding more oil. Here, pyrolysis oil from PCR HDPE and PCR PP contained a higher proportion of branched compounds. Additives in PCR plastics may promote isomerization during pyrolysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

ChemPren: a new and economical technology for conversion of waste plastics to light olefins

With the ever-increasing demand for plastics, sustainable recycling methods are key necessities. Here, the current plastics industry can manage to recycle only 10% of the 400 million metric tons of plastic produced globally. Waste plastics, in the current infrastructure, land up mostly in landfills. Although a lot of research efforts have been spent on processing and recycling co-mingled mixed plastics, energy-efficient sustainable and scalable routes for plastic upcycling are still lacking. Catalytic valorization of waste plastic feedstock is one of the potential scalable routes for plastic upcycling. Silica-alumina based materials, and zeolites have shown a lot of promise. A major interest lies in restricting catalyst deactivation, and refining product selectivity and yield for such catalytic processes. This article highlights ChemPren technology as a clean energy solution to waste plastic recycling. Co-mingled, mixed plastic feedstock along with spray dried, attrition resistant, ZSM-5 containing catalysts is preprocessed with an extruder to form optimally sized particles and fed into a fluidized bed reactor for short contact times to produce selectively and in high yields ethylenes, propylenes and butylenes. This techno-economic perspective indicates that the ChemPren technology can produce propylene at $\$$0.16 per lb, whereas the current selling price of virgin propylene is $0.54 per lb. This technology can serve as a platform for mixed plastic upcycling, with more advancements necessary in the form of robust and resilient catalysts and reactor operation strategies for tuning product selectivity.

25 - ENERGY STORAGE↗
DOE OSTI2014

Annealing effect on the particle size and chemical composition of activated carbon obtained from vacuum furnace of teak sawdust

Activated carbon was produced from sawdust by using physical method in a high temperature vacuum furnace without additional chemical. Fast pyrolysis process was carried out prior in fluidized a bed furnace to produce char before activation process. Experiments were conducted to investigate the influence of various process parameters such as particle size, activation temperature and activation time on the quality of the activated carbon. In addition, the chemical composition studies were done by using x-ray fluorescence (XRF) spectroscopy. The crystallite sizes were calculated by using Scherer equation based on x-ray diffraction (XRD) spectroscopy data. The pyrolysis temperature and time were varied from 600°C to 900°C and from 3 hours to 6 hours, respectively. The particle size of activated carbon was increase with increasing temperature. The composition and crystallite size of the prepared activated carbon was compared with the non-activated carbon. The results indicated that the teak sawdust carbon could be employed as a low cost alternative to produce commercial activated carbon.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Shape-driven, emergent behavior in active particle mixtures

Abstract Active particle systems can vary greatly from one-component systems of spheres to mixtures of particle shapes at different composition ratios. We investigate computationally the combined effect of anisotropy and stoichiometry on the collective behavior of two-dimensional active colloidal mixtures of polygons. We uncover three emergent phenomena not yet reported in active Brownian particle systems. First, we find that mixtures containing hexagons exhibit micro-phase separation with large grains of hexagonal symmetry. We quantify a measurable, implicit ‘steric attraction’ between the active particles as a result of shape anisotropy and activity. This calculation provides further evidence that implicit interactions in active systems, even without explicit attraction, can lead to an effective preferential attraction between particles. Next, we report stable fluid clusters in mixtures containing one triangle or square component. We attribute the fluidization of the dense cluster to the interplay of cluster destabilizing particles, which introduce grain boundaries and slip planes into the system, causing solid-like clusters to break up into fluid clusters. Third, we show that fluid clusters can coexist with solid clusters within a sparse gas of particles in a steady state of three coexisting phases. Our results highlight the potential for a wide variety of behavior to be accessible to active matter systems and establish a route to control active colloidal systems through simple parameter designs.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2016

Compartmentalization of the Coso East Flank geothermal field imaged by 3-D full-tensor MT inversion

Previous magnetotelluric (MT) studies of the high-temperature Coso geothermal system in California identified a subvertical feature of lowresistivity (2-5Ohmm) and appreciable lateral extent (>1 km) in the producing zone of the East Flank field. However, these models could not reproduce gross 3-D effects in the recorded data. We perform 3-D full-tensor inversion and retrieve a resistivity model that out-performs previous 2-D and 3-D off-diagonal models in terms of its fit to the complete 3-D MT data set as well as the degree of modelling bias. Inclusion of secondary Zxxand Zyydata components leads to a robust east-dip (60°) to the previously identified conductive East Flank reservoir feature, which correlates strongly with recently mapped surface faults, downhole well temperatures, 3-D seismic reflection data, and local microseismicity. We perform synthetic forward modelling to test the best-fit dip of this conductor using the response at a nearby MT station. We interpret the dipping conductor as a fractured and fluidized compartment, which is structurally controlled by an unmapped blind East Flank fault zone.

58 GEOSCIENCES↗
DOE OSTI2024

A Techno-Economic Analysis of a 50MWth Light-Trapping Cavity-Planar Solar Receiver Tower Capital Expenditures and its Cost Mitigation Strategies

To maximize thermal efficiency, the National Renewable Energy Laboratory (NREL) has proposed a light-trapping cavity-planar receiver design intended to capture energy from reradiating surfaces. This system implements a macroscale light trapping mechanism induced by panels with triangular channels, this mechanism allows for elevated temperatures on the receiver panels and in turn the temperature of the HTF; using this design coupled with the implementation of a fluidized particle flow as the HTF, it can be expected for some components to reach a peak working temperature of nearly 1000 degrees C cyclically throughout each day-night cycle. While these temperatures correlate to higher efficiency of the CSP tower they also demand intense thermomechanical properties from the materials used to make the receiver panels. In this analysis, we will list our assumptions to provide clarity on the significance of our calculation. This cost analysis will be conducted using a combination of both case study data and surveying industry to determine costs that are relevant to the current market trends. This analysis represents an early attempt to establish the Capital Expenditures required for a CSP tower of such design to determine the feasibility of implementing such a system in the industry.

concentrated solar power (CSP)↗
DOE OSTI2015

Analysis of Powder Airborne Release Fractions for Vessel Ruptures

The Department of Energy handbook for airborne releases from nonreactor nuclear facilities bases its bounding airborne release fraction (ARF) for pressurized powders on tests conducted at Pacific Northwest Laboratory (PNL). An analysis is presented that correlates the ARF from these tests. The amount of powder that becomes airborne is correlated in terms of an adjusted airborne release fraction (AARF) equal to the product of the powder entrainment from the powder bed and the ratio of the total vessel volume to the volume occupied by the powder bed. Powder entrainments and release fractions at low pressures are correlated using a fluidized bed analogy. The analysis shows that the entrainment is enhanced by a sonic shock if the pressure prior to the rupture exceeds approximately 33 psig. A secondary, three-dimensional shock is predicted to occur at an initial pressure of approximately 332 psig. A correlation based on this analysis is used to predict the ARF for ruptures of vessels containing plutonium oxide. It is assumed that the oxide is pressurized by hydrogen that is radiolytically generated from adsorbed moisture.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

High-capacity rotary drum for atomic layer deposition onto powders and small mechanical parts in a hot-walled viscous flow reactor

Atomic layer deposition (ALD) is uniquely capable of providing uniform thin-film coatings on powder substrates, but powder processing has historically required an ALD reactor designed specifically for powders-e.g., a fluidized bed. Tubular hot-walled viscous-flow reactors commonly employed in laboratory-scale ALD research for coating planar substrates such as silicon have been employed previously to coat gram quantities of powder spread out in a thin layer on a tray, but larger quantities of powder introduce long diffusion pathways where reactants are unable to percolate to the bottom of the powder bed to provide uniform coating in reasonable time periods. In this work, we report a rotary drum with a capacity of 100s of grams that is compatible with conventional tubular hot-walled ALD reactors and provides uniform coatings on powders in viscous flow operation. We benchmark this system using Al 2 O 3 ALD with trimethylaluminum and water. We examine the effect of rotation speed and powder quantity on saturation time via in situ quadrupole mass spectroscopy measurements and gravimetric analysis. Finally, the rotary drum we report is able to provide homogenous coating of up to 75g of silica gel powder with a total surface area of similar to 1500m 2 in viscous flow operation with precursor utilization as high as 70%.

47 OTHER INSTRUMENTATION↗
DOE OSTI2018

Viscous control of cellular respiration by membrane lipid composition

Lipid composition determines the physical properties of biological membranes and can vary substantially between and within organisms. We describe a specific role for the viscosity of energy-transducing membranes in cellular respiration. Engineering of fatty acid biosynthesis in Escherichia coli allowed us to titrate inner membrane viscosity across a 10-fold range by controlling the abundance of unsaturated or branched lipids. These fluidizing lipids tightly controlled respiratory metabolism, an effect that can be explained with a quantitative model of the electron transport chain (ETC) that features diffusion-coupled reactions between enzymes and electron carriers (quinones). Lipid unsaturation also modulated mitochondrial respiration in engineered budding yeast strains. Thus, diffusion in the ETC may serve as an evolutionary constraint for lipid composition in respiratory membranes.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2019

Interrelationship of Thermal Effects on Calcium Sulfate Dihydrate Casts Containing Borax and Kaolin: Differential Thermal Analysis (DTA), Thermogravimetric Analysis (TGA), and Contact Dilatometry

The core composition of gypsum wallboard is calcium sulfate dihydrate (CaSO 4 ·2H 2 O) with varying impurities, additives, or both. This study compares here two commercially calcined sources of hemihydrate (CaSO 4 ·½H 2 O) from a natural source and a synthetic by-product of flue gas desulfurization and neutralization to reagent grade hemihydrate. Two common ingredients, borax and kaolin, are mixed into a slurry with distilled water. The analysis supports the hypothesis that minor components in the cast have an effect on the high temperature performance of gypsum casts. The analysis is enhanced when the differential thermal analysis, thermogravimetric analysis, and dilatometry data are combined to study the changes in density versus heat flow. Specifically, the thermal performance is affected by (1) the impurities found in hemihydrate sources; (2) during the fluidization phase, the reaction of borax with free Ca ++ ions to form new borate salts that melt at lower temperatures; and (3) the intercalation of these and other ions with kaolin, providing thermal stability by reducing the formation of thermally active salts.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Thermomechanical Modeling and Analysis of a High-Temperature Light Trapping Planar Cavity Receiver

Solar energy harnessed through concentrating solar power (CSP) systems offers a promising path to sustainable energy production, with the efficiency and longevity of these systems relying on key components like solar receivers. This study analyzes the thermomechanical behavior of an innovative enclosed light-trapping solar receiver optimized for particle heating applications. The receiver utilizes sheet metal alloys to form enclosed cavities that reflect and trap incoming solar flux, as well as enclosed channels that contain fluidized particle beds absorbing solar heat. Finite element analysis (FEA) is applied to predict the receiver's thermomechanical performance under extreme solar flux conditions. Temperature distributions from a thermal model simulating a multi-panel assembly at steady state are input into the FEA thermomechanical model for stress analysis. A key aspect of the analysis focuses on evaluating creep-fatigue damage, with a design target of achieving a 30- year service life. Various stress relief techniques are also proposed to extend the receiver's service life. The results highlight the significant impact of the particle-to-wall heat transfer coefficients (HTCs), ranging from 800 W/m2*K to 1400 W/m2*K. The 800 W/m2*K case shows a maximum von Mises stress of 164 MPa, while the 1400 W/m2*K case reduces it to 150 MPa. The creep life increases from 4,000 hrs in the 800 W/m2*K case to over 100,000 hrs in the 1400 W/m2*K case with Inconel 740H used, indicating that higher HTCs reduce stress and extend lifespan. This research advances the design of high-efficiency, low-stress solar receivers for particle-based thermal energy storage in CSP and industrial heating applications.

concentrating solar power↗
DOE OSTI2024

Retrofitting Holcim Ste. Genevieve Cement Plant with CO2 Capture Plant Using Air Liquide Cryocap™ FG Technology

The global cement manufacturing industry is a major contributor to carbon dioxide emissions. The International Energy Agency's "Net Zero Emissions by 2050 Scenario" identifies CCS as a major strategy for meeting that goal. This project is among the first attempts to transfer capture technology developed at coal-fired power plants to the cement industry. The main objective of the project is to execute and complete a front-end engineering and design (FEED) studies for commercial-scale, carbon capture projects that separates 95% of the total CO2 emissions at the Holcim (US) Ste. Genevieve cement manufacturing facility using Air Liquide’s Pressure Swing Adsorption system (PSA) assisted Cryocap™ technology. The Holcim Ste. Genevieve cement plant in Missouri, US, boasts one of the largest single cement production lines in the world, with a capacity of approximately 12,000 t/day. The plant currently uses traditional fuels, namely coal and petcoke. The captured CO2 will be pipeline and geological storage grade. The industrial host site emits approximately 3.0 million tonne CO2/yr. Air Liquide’s Cryocap™ technology has been developed over the last 18+ years for CO2 capture applications. It has been shown to be applicable to a variety of industrial applications (e.g., steel, cement, SMR, Fluidized Catalytic Crackers (FCCs)). Cryocap™ FG consists of a Pressure Swing Adsorption (PSA) unit coupled with a Cryogenic System. The PSA pre-concentrates the CO2 from the flue gas, while the cryogenic unit enables the CO2 purity to be increased to the desired level. The project team is led by the Prairie Research Institute at the University of Illinois at Urbana-Champaign. The tasks include: complete FEED study for retrofitting the industrial facility with a carbon capture system to support developing a detailed cost estimate; business case analysis outlining the anticipated revenue and credits if projects was built and operated; technoeconomic analysis (TEA) outlining how capture system achieves DOE capture goals; and life cycle (LCA) analysis demonstrating zero net carbon emissions. The FEED study was successfully completed. This includes completing the process basis of design; preliminary engineering; outside battery limits (OSBL) detailed engineering including a Zero Liquid Discharge (ZLD) wastewater treatment system; inside battery limits (ISBL) detailed engineering [1]. An overall project capital cost estimate within a -20%/+30% accuracy was developed. The major contributors to the Total Plant Cost (TPC), by system, are the costs associated with the Outside Battery Limit (OSBL) section of the plant which includes a new river water intake structure and a Zero Liquid Discharge (ZLD) system. By cost category, the major contributors to the TPC are equipment and subcontractor costs, followed closely by engineering, construction management, home office and contractor fees. The TEA has been created to reflect the findings of the project. It analyzes the economic performance of the Cryocap™ technology by reviewing the estimated capital costs, operating cost, and revenue. The Cost of Capture (COC) associated with the Cryocap™ technology for 95% CO2 capture, when considering NETL 2018 economic assumptions (42/58 debt/equity ratio, 5.15% interest on debt and 1.42% return on equity in real dollars) and 2022 economic assumptions (42/58 debt/equity ratio, 8.82% interest on debt and 4.90% return on equity in real dollars) was found to be much lower than that for the DOE-NETL’s base-line cases. The highest contributors to the COC are annualized capital expenditures (CAPEX) and electricity consumption which can be offset by using lower cost renewable sources. The LCA was conducted using OpenLCA which is an open-source software that is recommended by NETL. The database utilized for this study was a modified version of TRACI 2.1 (developed by the US. Environmental Protection Agency’s National Risk Management Research Laboratory and modified by NETL). The Cryocap™ FG technology does not consume fuels in significant quantities and does not utilize specialized chemical solvents subject to decomposition, such as those utilized in amine-based carbon capture systems. The Cryocap™ FG technology mainly utilizes electricity as its energy input; hence, its calculated emissions are mainly associated with the generation of electricity offsite and are dependent on the energy matrix of the grid at the time of project implementation. The water consumption impact of the Cryocap™ FG is mostly for makeup of the water lost by evaporation in the cooling tower; however, the carbon capture plant will be equipped with a ZLD system to avoid effluent streams and minimize water consumption. The successful construction and operation of this plant based on this study results will provide a means to demonstrate an economically attractive and transformational capture technology that can be used to retrofit existing plants and be deployed at new plants.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2015

Green Gasoline from Wood using Carbona Gasification and Topsoe TIGAS Process

This final report presents the results of a four-year technology demonstration project carried out by a consortium of companies sponsored in part by a $25 million funding by the Department of Energy (DOE) under the American Recovery and Reinvestment Act (ARRA). The purpose of the project was to demonstrate a new, economical technology for the thermochemical conversion of woody biomass into gasoline and to demonstrate that the gasoline produced in this way is suitable for direct inclusion in the already existing gasoline pool. The process that was demonstrated uses the Andritz-Carbona fluidized-bed steam-oxygen gasification technology and advanced tar reforming catalytic systems to produce a clean syngas from waste wood, integrated conventional gas cleanup steps, and finally utilizes Haldor Topsoe’s (Topsoe) innovative Topsoe Improved Gasoline Synthesis (TIGASTM) syngas-to-gasoline process. Gas Technology Institute (GTI) carried out the bulk of the testing work at their Flex Fuel development facility in Des Plaines, Illinois; UPM in Minnesota supplied and prepared the feedstocks, and characterization of liquid products was conducted in Phillips 66 labs in Oklahoma. The produced gasoline was used for a single-engine emission test at Southwest Research Institute (SwRI®) in San Antonio, TX, as well as in a fleet test at Transportation Research Center, Inc. (TRC Inc.) in East Liberty, Ohio. The project benefited from the use of existing pilot plant equipment at GTI, including a 21.6 bone dry short ton/day gasifier, tar reformer, Morphysorb® acid gas removal, associated syngas cleanup and gasifier feeding and oxygen systems.

09 BIOMASS FUELS↗
DOE OSTI2014

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

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

01 COAL, LIGNITE, AND PEAT↗