The Impact of Cement Plant Air Ingress on Membrane-Based CO2 Capture Retrofit Cost
Not Available
54 ENVIRONMENTAL SCIENCES↗
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Examination of Factors Affecting the Cost and Performance of a Natural Gas Combined Cycle Equipped with Carbon Dioxide Capture
The purpose of this Technical Note is to report the findings of an examination of the effect of plausible deviations in select study assumptions on the reported cost and performance estimates for a power plant case drawn from NETL’s “Cost and Performance Baseline for Fossil Energy Plants Volume 1: Bituminous Coal and Natural Gas to Electricity” (known as the Fossil Energy Baseline). An F-Class NGCC power plant equipped with state-of-the-art, solvent-based, post-combustion carbon dioxide (CO2) capture (95 percent carbon capture rate)—designated as Case B31B.95—was selected for this work. This sensitivity analysis provides insight into the effects of parameter variations within and across selected categories—ambient conditions, construction cost, natural gas (NG) price, capacity factor, and finance—on the plant performance and capital and operating and maintenance (O&M) costs, and the subsequent impact on common figures of merit.
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Advanced Structured Adsorbent Architectures for Transformative Carbon Dioxide Capture Performance (Final Report)
Svante is a world leader at using solid sorbents for low-cost Carbon Dioxide (CO 2 ) capture, a technology which is recognized as critical in meeting the dual mandates of energy security/reliability and the mitigation of man-made CO 2 emissions. Svante has been developing proprietary adsorbent material compositions, forming them into structured laminates, developing and optimizing process cycles, and system design for efficient capture of CO 2 from post-combustion flue gases of thermal power plants and industrial facilities. The deployment of first-generation CO 2 capture technology has been significantly hampered by high costs and energy penalties, among other barriers. Second generation CO 2 capture technologies (including the Mark I variant of Svante’s Veloxotherm™ adsorption-based technology), utilizing single adsorbent architecture, show promise for reducing the barriers to deploying CO 2 capture plants in commercially meaningful numbers. The objective of this project was to evaluate the Recipient’s transformational (Mark-II) VeloxoTherm™ Technology via the development and bench-scale testing of an advanced structured adsorbent, including novel Bi-layer, laminated adsorbent structures and segmented beds. Svante selected, synthesized, and characterized tailored solid adsorbents for computational modeling, advanced structured adsorbent development, process simulations, and dynamic bench scale (~1-10 kg/day CO 2 captured) testing using an existing single-bed VeloxoTherm™ Station (VTS) coupled with a natural gas-fired boiler. Segmented beds used the in-house, multi-bed Process Demonstration Unit (PDU) to demonstrate key performance indicators (KPIs), such as recovery, product purity, regeneration energy, and the integrated system's productivity in lifetime analysis. Segmented beds were used at a 1 tonne per day (TPD) unit at an industrial site to provide bench-scale validation of performance in an industrial setting. Svante was developing and optimizing the post-combustion CO 2 adsorption technology architectures, including the Bi-layer and segmented laminated adsorbent structure design, integrated rapid cycle temperature swing adsorption (RC-TSA) cycle, flow path architecture, and adsorbent bed construction and packaging (including gas porting) to progress towards achievement of DOE’s Transformational CO 2 Capture goals of 95% CO 2 purity and a cost of electricity at least 30% lower than a supercritical Pulverized Coal (PC) power plant with CO 2 capture, or approximately $30 per tonne of CO 2 captured ready for demonstration by 2030. The main requirements to reach the DOE target cost of carbon capture below $30/MT using Rapid-Cycling Temperature Swing Adsorption (RC-TSA) are as follows: (1) Increased capacity at different CO 2 concentrations, (2) Increased sorbents cycle life, (3) Increased O 2 resistance, and (4) Decreased steam requirement to extract 1 kg of CO 2 .
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Energy-effective and low-cost carbon capture from point-sources enabled by water-lean solvents
Aqueous amines, as the most mature carbon capture technology, are subject to high energy and cost penalties due to the large water content in their formulations. Emerging technologies are in demand to enable a transition to a low-carbon global economy. However, rigorous process modeling and techno-economic analyses are limited for emerging carbon capture technologies. Here, four CO 2 -Binding Organic Liquids (CO 2 BOLs), all water-lean solvents were presented as promising options towards energy-effective and low-cost carbon capture from point sources. Rigorous solvent property and process models were developed in Aspen Plus for a coal-fired power plant with CO 2 BOL-based carbon capture unit. Techno-economic analyses were conducted in 2018 US pricing basis. The results suggest that water-lean formulations can minimize water condensation and vaporization, leading to a 36% energy saving compared with aqueous amines. Indeed, these CO 2 BOLs can capture up to 97–99% CO 2 from coal fired plant. The estimated carbon capture cost is about $40/tonne CO 2 at 90–97% carbon capture rate, about 12–23% less expensive than the conventional aqueous amine technology. The comparison between these CO 2 BOLs showed that in addition to vapor liquid equilibrium and kinetics (key properties for aqueous solvents), viscosity, volatility, and hydrophobicity, also have strong impacts on the performance of water-lean solvents. The methods presented in this work can be used to evaluate other emerging carbon capture technologies, while the results linking costs and performance of carbon capture solvents with their properties. Additionally, this work identifies research directions and targets for further reductions in total costs of capture from either cost or energy perspectives for these leading water-lean solvents.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Effect of Packing Nonuniformity at the Fiber Bundle–Case Interface on Performance of Hollow Fiber Membrane Gas Separation Modules
High-fidelity simulations of momentum and mass transfer within a hollow fiber gas separation membrane module are here reported. The simulations capture the potential detrimental effects of poor fiber packing at the bundle–case interface on fluid distribution and performance. Results are presented for both circular and planar fiber bundles. The length over which bundle–case gaps affects flow is determined. The length increases dramatically with increasing fiber packing fraction. As the packing fraction approaches 0.6, the impact extends over the entire bundle diameter for small modules (<1000 fibers). The results clearly demonstrate the detrimental effect of poor packing along the case and can be used to develop module manufacturing guidelines. To reduce computational costs, an equivalent planar bundle module approximation is developed. The approximate simulations agree well with results from full 3-D simulations and can reduce computational costs without sacrificing fidelity.
42 ENGINEERING↗
Decarbonization of the Iron and Steel Sector: Challenges and Opportunities
The iron and steel industry is one of the largest contributors to industrial emissions in the United States (U.S.). As this industry represents an impactful opportunity for industrial decarbonization, this paper presents the techno-economics of retrofitting iron/steel plants in the U.S. with post-combustion carbon dioxide (CO2) capture technology. For a representative base plant, this analysis considers an integrated steel mill, including a blast furnace (BF) and basic oxygen furnace (BOF), and evaluates CO2 capture as applied to the three largest and highest concentration emission sources of these facilities. A levelized cost of CO2 captured (LCOC) of $80.3/tonne CO2 and $80.7/tonne CO2 was estimated for a retrofit site with 99 and 90 percent capture, respectively.
Henry, Samuel [NETL Site Support Contractor, Natio↗
Carbon Capture Design and Costing: Phase 2 (C3DC2) (Final Project Report)
ION Clean Energy’s (ION) advanced solvent is one of the leading solvent systems currently under development for post-combustion carbon dioxide (CO 2 ) capture. ION has partnered with Nebraska Power Public District (NPPD), Sargent & Lundy, Koch Modular Process Systems, and Siemens to design a commercial-scale (700 MW) capture system utilizing ION’s advanced solvent, ICE-21, retrofitted onto NPPD’s Gerald Gentleman Station in Sutherland, Nebraska, USA. The capture system was designed to take full advantage of the solvent benefits including an efficient physical plant layout, reduced energy requirements, less solvent degradation, lower emissions, and lower capital costs relative to systems built with DOE BBS case benchmark solvents. This Front-End Engineering Design (FEED) study also included an investigation of utilizing biomass co-combustion with the aim of reaching near-zero emissions for this coal-fired power generating unit. The targeted biomass was from local resources in Nebraska tied to the production of ethanol.
01 COAL, LIGNITE, AND PEAT↗
Two-stage membrane-based process utilizing highly CO 2 -selective membranes for cost and energy efficient carbon capture from coal flue gas: A process simulation study
Membrane technology for CO 2 capture has become an attractive strategy due to its cost and energy efficiency and low materials costs. In the past decade, membrane-based process designs for post-combustion power plant CO 2 capture have been developed, utilizing existing highly CO 2 -permeable membranes with relatively low CO 2 /N 2 selectivity (<50), and have obtained reasonably economic carbon capture. However, few membrane-based process designs were proposed for moderate to highly CO 2 -selective membranes (CO 2 /N 2 selectivity of 50–300, and >300, respectively), which have vastly emerged in recent years, such as various facilitated transport membranes (FTMs). Herein, we proposed a two-stage membrane-base process design targeting economic carbon capture from coal-fired flue gas. This process design features the utilization of highly CO 2 -selective membranes for one-stage CO 2 enrichment to 95% dry-base purity in the first stage and recycle of the remaining CO 2 by a highly CO 2 -permeable membrane in the second stage, in order to achieve economic CO 2 capture with 90% capture rate and >95% CO 2 product purity. Through an integration-iteration membrane model and the Aspen Plus process simulation, a sensitivity study of operating pressures (feed and permeate pressures) and membrane properties (CO 2 permeance and CO 2 /N 2 selectivity) was conducted. Critical CO 2 /N 2 selectivity of 300–400 was found for the highly CO 2 -selctive membranes to meet the demand for cost and energy efficient results. The lowest possible membrane area of 4.8 × 10 5 m 2 and fractional energy of 19.3% were obtained, which is comparable to or even more attractive than reported membrane-based process designs. Here, this work provides a new membrane process design option for highly CO 2 -selective membranes and gives insights on the influence of membrane performance and operation condition.
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Engineering Design of a Polaris Membrane CO 2 Capture System at a Cement Plant
Sargent & Lundy (S&L) and Membrane Technology and Research, Inc. (MTR) in cooperation with CEMEX, completed an initial engineering design study to evaluate the retrofit of MTR’s membrane-based post-combustion carbon dioxide (CO 2 ) capture technology to the CEMEX Balcones cement plant (Balcones) Kiln 2. The CO 2 capture plant is designed to treat the entire flue gas flow from Kiln 2; it is estimated that this system will capture 2,039 tonnes/day per day (TPD) of CO 2 , approximately 75% of current CO 2 emissions from the kiln. The captured CO 2 is compressed to 2,213 psia (152.58 bara) before flowing to the capture plant boundary tie-point. It was assumed for this study that the CO 2 would be pumped off-site and transferred by pipeline to either a CO 2 storage complex for geological sequestration or elsewhere for Enhanced Oil Recovery (EOR).
42 ENGINEERING↗
Multiscale Electricity Modeling for Evaluating Carbon Capture and Sequestration Technologies (Final Report)
Carbon capture and sequestration (CCS) technologies that can operate with a high degree of operating flexibility could provide necessary electric grid flexibility in a system with high shares of variable renewables. This project examines the deployment and dispatch potential of twelve unique flexible CCS (FLECCS) technologies that encompass post-combustion carbon dioxide (CO 2 ) capture designs, concepts using a storage media to enable energy arbitrage, and hybrid processes that integrate CCS with direct air capture (DAC) for flexibility with net zero or negative CO 2 emissions. FLECCS technology potential is explored with a multi-model, multi-scale framework including the Regional Energy Deployment System (ReEDS) electric sector capacity expansion model (CEM) and the PLEXOS production cost model (PCM). Innovative methods were developed to represent FLECCS technology operating modes, performance, and cost in the two models. ReEDS was then used to simulate nine scenarios for each FLECCS technology, three CO 2 emissions price futures reaching $\$$150, $\$$225, and $\$$300/tCO 2 in 2050; and three scenarios for FLECCS technology deployment favorability relative to competing technologies. For each CO 2 price and reference FLECCS favorability, the 2050 infrastructures from ReEDS model are downscaled and implemented in PLEXOS to examine hourly dispatch under detailed operational constraints that are not included in ReEDS. FLECCS technologies exhibited a wide range of deployment potential ranging from none to several hundred gigawatts of capacity, with outcomes highly sensitive to input cost and performance parameters that are inherently highly uncertain. When deployed, FLECCS tended to displace a combination of wind, solar, and natural gas-based technologies rather than supporting increased renewable deployment. As a result, CO 2 emissions reductions facilitated by FLECCS deployment tended to come with higher overall system costs and electricity prices. When economically competitive, FLECCS technologies can contribute significant flexible generation and firm capacity to the grid, but continued technology development and an expanded analytical scope are necessary to fully understand FLECCS deployment potential its impact on the electric power sector. Follow-on analysis incorporating captured CO 2 tax credit value from the Inflation Reduction Act (IRA) and other potential policy scenarios could be particularly valuable, as this policy can substantially change the relative competitiveness of FLECCS technologies.
03 NATURAL GAS↗
Abstract for CRADA between NETL and Georgia Tech Research Corporation (GTRC) (AGMT-1276)
Patent-pending chemisorption fiber sorbents (CHEFS) utilizing robust, patented basic immobilized amine sorbents (BIAS) are the newest innovation in carbon capture technology. This suite of fiber materials offers reliable and rapid removal of CO2 from both conventional post-combustion sources, like coal-fired power plants, and dilute air sources like those of newly recognized direct capture from air (DAC, 400 ppm CO2). Through this Cooperative Research and Development Agreement (CRADA), NETL and GTRC aim to improve and refine the fiber formulations and synthesis methods, while pushing towards scaling fiber production and testing in a pilot/semi-pilot scale 1,000-fiber module adsorption system.
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Methodology for Estimating Performance and Cost of Natural Gas Combined Cycle Plants with Carbon Capture
This document describes a methodology that allows developers and evaluators to assess the status of developmental, natural gas combined cycle (NGCC) power plant post-combustion carbon dioxide (CO 2 ) separation technologies with respect to NETL performance and cost metrics. Developmental CO 2 separation technologies that might apply for NGCC post-combustion power generation can be placed into several categories, including, but not limited to membranes, solvents, sorbents, adsorbents, and phase-change technologies. The intent of this product is to provide a consistent methodology for high-level comparison of in-development technology to a standardized baseline.
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Preliminary Techno-Economic Assessment of Gas Switching Reforming (GSR) of Natural Gas for Pure Hydrogen Production and Power Generation with Integrated CO2 Capture
The increasing demand for hydrogen and the CO2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) is an advanced auto-thermal reforming technology that produces hydrogen or syngas from natural gas. It integrates inherent CO2 capture by utilizing a specialized oxygen carrier in a single fluidized bed reactor, eliminating the need for complex, energy-intensive post-combustion separation. GSR technology builds upon Chemical Looping Reforming (CLR), an experimentally proven technology with strong potential for scaling up. In this study, select oxygen carriers (OC) (NiO/Al2O3, Fe2O3-CeO2/Al2O3, and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H₂) and a combined cycle (GSR-CC) in which high-purity H₂ is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H₂ production by ~30% and improved efficiency relative to prior studies. For GSR-H₂, the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H₂, competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H2 indicate NG consumption drives ~75% of total global warming impacts (~2.3 kg CO2 eq/kg H2). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.
03 NATURAL GAS↗
Big Data Analysis and Technical Review of Regeneration for Carbon Capture Processes
Carbon capture remains an integral technology to mitigate pollution from one of the most prevalent greenhouse gases. CO 2 desorption/absorbent regeneration for both solid- and liquid-based systems is widely recognized as an energy-intensive and costly process operation. Consequently, tremendous work was devoted towards developing new absorbents and regeneration processes to promote their economic feasibility for extensive implementation. In this review, we broadly and deeply review more than 10,000 papers and extract the hidden trends of carbon capture and absorbents regeneration in the past few decades, using a novel data-mining analysis technique. We comprehensively analyzed an array of recent absorbent regeneration methods utilized in post-combustion, pre-combustion, carbon capture from industrial point sources, and direct air carbon capture, with an emphasis on sorbent and solvent-based techniques. In conclusion, advanced regeneration methods in these techniques were illustrated and discussed, followed by recommendations for further research efforts.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Compact Absorber Technology Leads to Significant Reduction in the Cost of Point Source CO 2 Capture
The size of columns in traditional absorption-based processes for CO 2 capture contributes significantly to the overall capital cost. A demonstrated method to reduce the cost of point source CO 2 capture, focusing on reducing the absorber height by increasing the liquid-to-gas reaction contact area and decreasing the CO 2 diffusion resistance without increasing gas-side pressure drop is presented along with techno-economic analysis results. Bench-scale tests on the unique Compact Absorber showed overall CO 2 mass transfer enhancement of varying degrees compared to a traditional packed column for similar process conditions, demonstrating that a 60+% reduction in size of a typical post-combustion absorber with a packing height of 70-100 ft and total height of 150-180 ft can be achieved. The techno-economic analysis showed significant cost reductions when the Compact Absorber is combined with other transformative aspects of the University of Kentucky Institute for Decarbonization and Energy Advancement point source CO 2 capture process compared to the U.S. Department of Energy National Energy Technology Laboratory pertinent reference case for pulverized coal plants with CO 2 capture. Here, a levelized cost of electricity excluding CO 2 transportation and storage of $\$95.6$/MWh was estimated, which is a 9% reduction, with a total capital cost contribution of $45/MWh, which is a 12% reduction. Additionally, a breakeven CO 2 sales price also referred to as the cost of CO 2 capture, of $36.70/tonne was estimated when the UK hindered primary amine solvent is used, which is a 20% reduction compared to the reference case.
CO2 capture↗
High-efficiency carbon dioxide capture using an algal amino acid salt solution
Not Available
59 BASIC BIOLOGICAL SCIENCES↗
In-house synthesized poly(ether ether ketone) ionenes. II. ToF-SIMS spectra in the negative ion mode
Time-of-flight secondary ion mass spectrometry (ToF-SIMS) was used to analyze poly(ether ether ketone) (PEEK) based membranes. PEEK membranes have been shown to be effective in the separation of CO 2 from flue gases (post-combustion technique). The PEEK membranes were synthesized using novel aromatic ether-ketone linkages inspired by PEEK with polymeric backbone bistriflimide [Tf2N]− counterions. One of the keys to advancing this technology is developing membranes that are selective and permeable toward CO 2 , in which PEEK based membranes have been shown to be. Furthermore, the compatibility between various water lean solvents also needs to be investigated. Surface analytical techniques such as x-ray photoelectron spectroscopy and ToF-SIMS are useful for investigating chemical changes between membranes. Herein, we present ToF-SIMS data obtained in the negative ion mode for four different PEEK membranes designed for use in CO 2 capture systems. Positive ion mode spectra are reported in Paper I.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Intensified Catalytic Conversion of CO2 into High Value Chemicals
The utilization of CO2 produced from power generation plants as a feedstock for creating new valuable products offers a strategy to reduce GHG emissions, offset carbon capture costs, and facilitate the rebalancing of the carbon cycle. After considering the thermodynamic requirement of potential products from CO2 utilization and their market size, formic acid is a desirable target that offers widespread utility in industrial chemical production and chemical energy storage as a liquid fuel. To effectively utilize CO2 from power generation plants, UK proposes an enhanced bimetallic oxide carbon utilization process (EBOCU) that enables electrochemical CO2 conversion to formic acid. The UK intensified electrocatalytic process combines three main components: 1) a novel bimetallic oxide electrocatalyst; 2) a stable electrochemical reactor using robust electrodes; and 3) a pressurized electrochemical reactor. The output from this project showed the economic viability of producing high-value formic acid from CO2 to both offset the cost associated with post-combustion CCS and reduce GHG emissions. This project developed and screened a series engineered catalysts to selectively reduce CO2 directly to formic acid. The best performing catalyst based on formic acid production, stability, and Faradaic efficiency, was immobilized on carbon electrodes, and tested inside a flow through reactor. After lab-scale testing was completed, the experimental data was used to perform a Life-Cycle Analysis (LCA) and conduct an Initial Technical and Economic Feasibility Study. The LCA showed a pathway to a net negative CO2 utilization process with the incorporation of renewable energy, while the TEA showed the potential to produce formic acid below the current commercial price. The UK EBOCU process was successfully demonstrated at the TRL3 level and has a clear pathway to further development and contribution to the nation’s ambitious decarbonization goals.
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