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DOE OSTI2013

Greenhouse Gas Mitigation Options in ISEEM Global Energy Model: 2010-2050 Scenario Analysis for Least-Cost Carbon Reduction in Iron and Steel Sector

The goal of the modeling work carried out in this project was to quantify long-term scenarios for the future emission reduction potentials in the iron and steel sector. The main focus of the project is to examine the impacts of carbon reduction options in the U.S. iron and steel sector under a set of selected scenarios. In order to advance the understanding of carbon emission reduction potential on the national and global scales, and to evaluate the regional impacts of potential U.S. mitigation strategies (e.g., commodity and carbon trading), we also included and examined the carbon reduction scenarios in China’s and India’s iron and steel sectors in this project. For this purpose, a new bottom-up energy modeling framework, the Industrial Sector Energy Efficiency Modeling (ISEEM), (Karali et al. 2012) was used to provide detailed annual projections starting from 2010 through 2050. We used the ISEEM modeling framework to carry out detailed analysis, on a country-by-country basis, for the U.S., China’s, and India’s iron and steel sectors. The ISEEM model applicable to iron and steel section, called ISEEM-IS, is developed to estimate and evaluate carbon emissions scenarios under several alternative mitigation options - including policies (e.g., carbon caps), commodity trading, and carbon trading. The projections will help us to better understand emission reduction potentials with technological and economic implications. The database for input of ISEEM-IS model consists of data and information compiled from various resources such as World Steel Association (WSA), the U.S. Geological Survey (USGS), China Steel Year Books, India Bureau of Mines (IBM), Energy Information Administration (EIA), and recent LBNL studies on bottom-up techno-economic analysis of energy efficiency measures in the iron and steel sector of the U.S., China, and India, including long-term steel production in China. In the ISEEM-IS model, production technology and manufacturing details are represented, in addition to the extensive data compiled from recent studies on bottom-up representation of efficiency measures for the sector. We also defined various mitigation scenarios including long-term production trends to project country-specific production, energy use, trading, carbon emissions, and costs of mitigation. Such analyses can provide useful information to assist policy-makers when considering and shaping future emissions mitigation strategies and policies. The technical objective is to analyze the costs of production and CO 2 emission reduction in the U.S, China, and India’s iron and steel sectors under different emission reduction scenarios, using the ISEEM-IS as a cost optimization model. The scenarios included in this project correspond to various CO 2 emission reduction targets for the iron and steel sector under different strategies such as simple CO 2 emission caps (e.g., specific reduction goals), emission reduction via commodity trading, and emission reduction via carbon trading.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2014

Novel Biological Conversion of Hydrogen and Carbon Dioxide Directly into Biodiesel

OPX Biotechnologies, Inc. (OPX), the National Renewable Energy Laboratory (NREL), and Johnson Matthey will develop and optimize a novel, engineered microorganism that directly produces biodiesel from renewable hydrogen (H 2 ) and carbon dioxide (CO 2 ). The proposed process will fix CO 2 utilizing H 2 to generate an infrastructure-compatible, energy-dense fuel at costs of less than $2.50 per gallon, with water being produced as the primary byproduct. NREL will perform metabolic engineering on the bacterium Cupriavidus necator (formerly Ralstonia eutropha) and a techno-economic analysis to guide future scale-up work. H 2 and CO 2 uptakes rates will be genetically increased, production of free fatty acids will be enhanced and their degradation pathway blocked in order to meet the ultimate program goals.

08 HYDROGEN↗
DOE OSTI2014

Bench-Scale Development of a Hot Carbonate Absorption Process with Crystallization-Enabled High-Pressure Stripping for Post-Combustion CO 2 Capture (Final Scientific/Technical Report)

A novel Hot Carbonate Absorption Process with Crystallization-Enabled High-Pressure Stripping (Hot-CAP) has been developed by the University of Illinois at Urbana-Champaign and Carbon Capture Scientific, LLC in this three-year, bench-scale project. The Hot-CAP features a concentrated carbonate solution (e.g., K 2 CO 3 ) for CO 2 absorption and a bicarbonate slurry (e.g., KHCO 3 ) for high-pressure CO 2 stripping to overcome the energy use and other disadvantages associated with the benchmark monoethanolamine (MEA) process. The project was aimed at performing laboratory- and bench-scale experiments to prove its technical feasibility and generate process engineering and scale-up data, and conducting a techno-economic analysis (TEA) to demonstrate its energy use and cost competitiveness over MEA. To meet project goals and objectives, a combination of experimental, modeling, process simulation, and economic analysis studies were applied. Carefully designed and intensive experiments were conducted to measure thermodynamic and reaction engineering data relevant to four major unit operations in the Hot-CAP (i.e., CO 2 absorption, CO 2 stripping, bicarbonate crystallization, and sulfate reclamation). The rate promoters that could accelerate the CO 2 absorption rate into the potassium carbonate/bicarbonate (PCB) solution to a level greater than that into the 5 M MEA solution were identified, and the superior performance of CO 2 absorption into PCB was demonstrated in a bench-scale packed-bed column. Kinetic data on bicarbonate crystallization were developed and applied for crystallizer design and sizing. Parametric testing of high-pressure CO 2 stripping with concentrated bicarbonate-dominant slurries at high temperatures (≥140°C) in a bench-scale stripping column demonstrated lower heat use than with MEA. The feasibility of a modified process for combining SO 2 removal with CO 2 capture was preliminarily demonstrated. In addition to the experimental studies, the technical challenges pertinent to fouling of slurry-handling equipment and the design of the crystallizer and stripper were addressed through consultation with vendors and engineering analyses. A process flow diagram of the Hot-CAP was then developed and a TEA was performed to compare the energy use and cost performance of a nominal 550-MWe subcritical pulverized coal (PC)-fired power plant without CO 2 capture (DOE/NETL Case 9) with the benchmark MEA-based post-combustion CO 2 capture (PCC; DOE/NETL Case 10) and the Hot-CAP-based PCC. The results revealed that the net power produced in the PC + Hot-CAP is 609 MWe, greater than the PC + MEA (550 MWe). The 20-year levelized cost of electricity (LCOE) for the PC + Hot-CAP, including CO 2 transportation and storage, is 120.3 mills/kWh, a 60% increase over the base PC plant without CO 2 capture. The LCOE increase for the Hot-CAP is 29% lower than that for MEA. TEA results demonstrated that the Hot-CAP is energy-efficient and cost-effective compared with the benchmark MEA process.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2013

Supply Chain Sustainability Analysis of Three Biofuel Pathways

The Department of Energy’s (DOE) Bioenergy Technologies Office (BETO) collaborates with industrial, agricultural, and non-profit partners to develop and deploy biofuels and other biologically-derived products. As part of this effort, BETO and its national laboratory teams conduct in-depth techno-economic assessments (TEA) of technologies to produce biofuels as part state of technology (SOT) analyses. An SOT assesses progress within and across relevant technology areas based on actual experimental results relative to technical targets and cost goals from design cases and includes technical, economic, and environmental criteria as available. Overall assessments of biofuel pathways begin with feedstock production and the logistics of transporting the feedstock from the farm or plantation to the conversion facility or biorefinery. The conversion process itself is modeled in detail as part of the SOT analysis. The teams then develop an estimate of the biofuel minimum selling price (MSP) and assess the cost competitiveness of the biofuel with conventional fuels such as gasoline.

09 BIOMASS FUELS↗
DOE OSTI2014

An Analysis of Methanol and Hydrogen Production via High-Temperature Electrolysis Using the Sodium Cooled Advanced Fast Reactor

Integration of an advanced, sodium-cooled fast spectrum reactor into nuclear hybrid energy system (NHES) architectures is the focus of the present study. A techno-economic evaluation of several conceptual system designs was performed for the integration of a sodium-cooled Advanced Fast Reactor (AFR) with the electric grid in conjunction with wind-generated electricity. Cases in which excess thermal and electrical energy would be reapportioned within an integrated energy system to a chemical plant are presented. The process applications evaluated include hydrogen production via high temperature steam electrolysis and methanol production via steam methane reforming to produce carbon monoxide and hydrogen which feed a methanol synthesis reactor. Three power cycles were considered for integration with the AFR, including subcritical and supercritical Rankine cycles and a modified supercritical carbon dioxide modified Brayton cycle. The thermal efficiencies of all of the modeled power conversions units were greater than 40%. A thermal efficiency of 42% was adopted in economic studies because two of the cycles either performed at that level or could potentially do so (subcritical Rankine and S-CO2 Brayton). Each of the evaluated hybrid architectures would be technically feasible but would demonstrate a different internal rate of return (IRR) as a function of multiple parameters; all evaluated configurations showed a positive IRR. As expected, integration of an AFR with a chemical plant increases the IRR when “must-take” wind-generated electricity is added to the energy system. Additional dynamic system analyses are recommended to draw detailed conclusions on the feasibility and economic benefits associated with AFR-hybrid energy system operation.

09 BIOMASS FUELS↗
DOE OSTI2015

Supply Chain Sustainability Analysis of Fast Pyrolysis and Hydrotreating Bio-Oil to Produce Hydrocarbon Fuels

The Department of Energy’s (DOE) Bioenergy Technology Office (BETO) aims at developing and deploying technologies to transform renewable biomass resources into commercially viable, high-performance biofuels, bioproducts and biopower through public and private partnerships. BETO and its national laboratory teams conduct in-depth techno-economic assessments (TEA) of technologies to produce biofuels. These assessments evaluate feedstock production, logistics of transporting the feedstock, and conversion of the feedstock to biofuel. There are two general types of TEAs. A design case is a TEA that outlines a target case for a particular biofuel pathway. It enables preliminary identification of data gaps and research and development needs, and provides goals and targets against which technology progress is assessed. On the other hand, a state of technology (SOT) analysis assesses progress within and across relevant technology areas based on actual experimental results relative to technical targets and cost goals from design cases, and includes technical, economic, and environmental criteria as available. In addition to the TEA process, BETO also performs a supply chain sustainability analysis (SCSA). The SCSA takes the life-cycle analysis approach that BETO has been supporting for more than 17 years. It enables BETO to identify energy consumption or environmental issues that may be associated with biofuel production. Approaches to mitigate these issues can then be developed. Additionally, the SCSA allows for comparison of energy and environmental impacts across biofuel pathways in BETO’s research and development portfolio. This report describes the SCSA of the fast pyrolysis of two woody feedstocks, pine and forest residue, to renewable gasoline and diesel.

09 BIOMASS FUELS↗
DOE OSTI2014

Conversion of CO 2 into Commercial Materials Using Carbon Feedstocks

In this project, our research focused on developing reaction chemistry that would support using carbon as a reductant for CO 2 utilization that would permit CO 2 consumption on a scale that would match or exceed anthropomorphic CO 2 generation for energy production from fossil fuels. Armed with the knowledge that reactions attempting to produce compounds with an energy content greater than CO 2 would be thermodynamically challenged and/or require significant amounts of energy, we developed a potential process that utilized a solid carbon source and recycled the carbon to effectively provide infinite time for the carbon to react. During testing of different carbon sources, we found a wide range of reaction rates. Biomass-derived samples had the most reactivity and coals and petcoke had the lowest. Because we had anticipated this challenge, we recognized that a catalyst would be necessary to improve reaction rates and conversion. From the data analysis of carbon samples, we recognized that alkali metals improved the reaction rate. Through parametric testing of catalyst formulations we were able to increase the reaction rate with petcoke by a factor of >70. Our efforts to identify the reaction mechanism to assist in improving the catalyst formulation demonstrated that the catalyst was catalyzing the extraction of oxygen from CO 2 and using this extracted oxygen to oxidize carbon. This was a significant discovery in that if we could modify the catalyst formulation to permit controlled the oxidation, we would have a very power selective oxidation process. With selective oxidation, CO 2 utilization could be effective used as one of the process steps in making many of the large volume commodity chemicals that support our modern lifestyles. The key challenges for incorporating these functionalities into the catalyst formulation were to make the oxidation selective and lower the temperature required for catalytic activity. We identified four catalyst families that had the potential to meet these challenges. Initial screening of the catalyst families did show that the reduction/oxidation activity did occur at lower temperatures and that these catalysts were able to cause carbon chain growth as well as C—C cleavage. A preliminary techno-economic feasibility of using petcoke/catalyst to produce a CO-rich syngas product was completed and showed significant economic promise. Testing of the different catalyst families demonstrated that Catalyst A was able to stably produce 5 sccm of ethylene/gram of catalyst at 900°C for one hour. For dry methane reforming, our Catalyst 4 was able to achieve production rates of > 10 sccm of CO and > 3 sccm of H2 per gram of catalyst at 600°C and 350 psig. Based on these developments, the potential for CO 2 utilization in the production of large volume commodity chemicals is very promising.

10 SYNTHETIC FUELS↗
DOE OSTI2015

Hydrogen Selective Exfoliated Zeolite Membranes

The objective of this project was to develop and evaluate an innovative membrane technology at process conditions that would be representative of Integrated Gasification Combined Cycle (IGCC) advanced power generation with pre-combustion capture of carbon dioxide (CO 2 ). This research focused on hydrogen (H 2 )-selective zeolite membranes that could be utilized to separate conditioned syngas into H 2 -rich and CO 2 -rich components. Both experiments and process design and optimization calculations were performed to evaluate the concept of ultra-thin membranes made from zeolites nanosheets. In this work, efforts in the laboratory were made to tackle two fundamental challenges in application of zeolite membranes in harsh industrial environments, namely, membrane thickness and membrane stability. Conventional zeolite membranes have thicknesses in the micron range, limiting their performance. In this research, we developed a method for fabrication of ultimately thin zeolite membranes based on zeolite nanosheets. A range of layered zeolites (MWW, RWR, NSI structure types) suitable for hydrogen separation was successfully exfoliated to their constituent nanosheets. Further, membranes were made from one of these zeolites, MWW, to demonstrate the potential of this group of materials. Moreover, long-term steam stability of these zeolites (up to 6 months) was investigated in high concentrations of steam (35 mol% and 95 mole%), high pressure (10 barg), and high temperatures (350 °C and 600 °C) relevant to conditions of water-gas-shift and steam methane reforming reactions. It was found that certain nanosheets are stable, and that stability depends on the concentration of structural defects. Additionally, models that represent a water-gas-shift (WGS) membrane reactor equipped with the zeolite membrane were developed for systems studies. These studies had the aim of analyzing the effect of the membrane reactor integration into IGCC plants in terms of performance and economic aspects of the plants. Specifically, simulation and design optimization studies were performed using the developed stand-alone membrane reactor models to identify the membrane selectivity and permeance characteristics necessary to achieve desired targets of CO 2 capture and H 2 recovery, as well as guide the selection of the optimal reactor design that minimizes the membrane cost as a function of its surface area required. The isothermal membrane reactor model was also integrated into IGCC system models using both the MATLAB and Aspen software platforms and techno-economic analyses of the integrated plants have been carried out to evaluate the feasibility of replacing current technologies for pre-combustion capture by the proposed novel approach in terms of satisfying stream constraints and achieving the DOE target goal of 90% CO 2 capture. The results of the performed analyses based on present value of annuity calculations showed break even costs for the membrane reactor within the feasible range for membrane fabrication. However, the predicted membrane performance used in these simulations exceeded the performance achieved experimentally. Therefore, further work is required to improve membrane performance.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2015

Supply Chain Sustainability Analysis of Whole Algae Hydrothermal Liquefaction and Upgrading

The Department of Energy’s Bioenergy Technology Office (BETO) collaborates with a wide range of institutions towards the development and deployment of biofuels and bioproducts. To facilitate this effort, BETO and its partner national laboratories develop detailed techno-economic assessments (TEA) of biofuel production technologies as part of the development of design cases and state of technology (SOT) analyses. A design case is a TEA that outlines a target case for a particular biofuel pathway. It enables preliminary identification of data gaps and research and development needs and provides goals and targets against which technology progress is assessed. On the other hand, an SOT analysis assesses progress within and across relevant technology areas based on actual experimental results relative to technical targets and cost goals from design cases and includes technical, economic, and environmental criteria as available. BETO also develops supply chain sustainability analyses (SCSA) for key biofuel production technologies that are the subject of design case or SOT analyses (Dunn et al. 2013). The SCSA utilizes a life-cycle analysis to estimate the energy use and greenhouse gas (GHG) emissions associated with biofuel production and assists in comparing several biofuel pathways. This report documents an SCSA of whole algae hydrothermal liquefaction (AHTL) as the conversion technology to produce renewable diesel (RD). Jones et al. (2014) developed the design case process model that provides the material and energy intensity of the feedstock conversion step in the SCSA. In this study, conversion of algal biomass to RD is achieved by whole AHTL, as described in the design report by Pacific Northwest National Laboratory (Jones et al., 2014). Wet algal biomass, as undisrupted cells, is converted into a liquid fuel with pressurized water in a condensed phase. The SCSA for this pathway is described.

09 BIOMASS FUELS↗
DOE OSTI2015

Chemical Looping Gasification for Hydrogen Enhanced Syngas Production with In-Situ CO 2 Capture

This document is the final report for the project titled “Chemical Looping Gasification for Hydrogen Enhanced Syngas Production with In-Situ CO 2 Capture” under award number FE0012136 for the performance period 10/01/2013 to 12/31/2014.This project investigates the novel Ohio State chemical looping gasification technology for high efficiency, cost efficiency coal gasification for IGCC and methanol production application. The project developed an optimized oxygen carrier composition, demonstrated the feasibility of the concept and completed cold-flow model studies. WorleyParsons completed a techno-economic analysis which showed that for a coal only feed with carbon capture, the OSU CLG technology reduced the methanol required selling price by 21%, lowered the capital costs by 28%, increased coal consumption efficiency by 14%. Further, using the Ohio State Chemical Looping Gasification technology resulted in a methanol required selling price which was lower than the reference non-capture case.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2015

Hydropower Baseline Cost Modeling

Recent resource assessments conducted by the United States Department of Energy have identified significant opportunities for expanding hydropower generation through the addition of power to non-powered dams and on undeveloped stream-reaches. Additional interest exists in the powering of existing water resource infrastructure such as conduits and canals, upgrading and expanding existing hydropower facilities, and the construction new pumped storage hydropower. Understanding the potential future role of these hydropower resources in the nation’s energy system requires an assessment of the environmental and techno-economic issues associated with expanding hydropower generation. To facilitate these assessments, this report seeks to fill the current gaps in publicly available hydropower cost-estimating tools that can support the national-scale evaluation of hydropower resources.

13 HYDRO ENERGY↗
DOE OSTI2015

Condensing Furnace Venting Part 2: Evaluation of Same-Chimney Vent Systems for Condensing Furnaces and Natural Draft Water Heaters

In 1987, the National Appliance Energy Conservation Act prescribed the first federal minimum energy conservation standard for natural gas furnaces at an annual fuel utilization efficiency of 78%, effective January 1, 1992. One of the techno-economic issues that has prevented higher furnace efficiency standards since then is the lack of cost-effective, simple, and safe solutions that enable condensing furnaces and atmospheric combustion water heaters to vent through the same existing chimney. Part 1 of this two-part report series, published in October 2014, documents the issue, prospective solutions, and a test laboratory established to evaluate prospective venting solutions. This part 2 report documents the updated prospective solutions (because they have evolved since part 1 was written), the methodology for experimentally evaluating prospective solutions, and results of the evaluations.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2015

Recovery Act: Analysis of Low-Temperature Utilization of Geothermal Resources (Final Technical Report)

Full realization of the potential of what might be considered “low-grade” geothermal resources will require that we examine many more uses for the heat than traditional electricity generation. To demonstrate that geothermal energy truly has the potential to be a national energy source we will be designing, assessing, and evaluating innovative uses for geothermal-produced water such as hybrid biomass-geothermal cogeneration of electricity and district heating and efficiency improvements to the use of cellulosic biomass in addition to utilization of geothermal in district heating for community redevelopment projects. The objectives of this project were: 1) to perform a techno-economic analysis of the integration and utilization potential of low-temperature geothermal sources. Innovative uses of low-enthalpy geothermal water were designed and examined for their ability to offset fossil fuels and decrease CO 2 emissions. 2) To perform process optimizations and economic analyses of processes that can utilize low-temperature geothermal fluids. These processes included electricity generation using biomass and district heating systems. 3) To scale up and generalize the results of three case study locations to develop a regionalized model of the utilization of low-temperature geothermal resources. A national-level, GIS-based, low-temperature geothermal resource supply model was developed and used to develop a series of national supply curves. We performed an in-depth analysis of the low-temperature geothermal resources that dominate the eastern half of the United States. The final products of this study include 17 publications, an updated version of the cost estimation software GEOPHIRES, and direct-use supply curves for low-temperature utilization of geothermal resources. The supply curves for direct use geothermal include utilization from known hydrothermal, undiscovered hydrothermal, and near-hydrothermal EGS resources and presented these results at the Stanford Geothermal Workshop. We also have incorporated our wellbore model into TOUGH2-EGS and began coding TOUGH2-EGS with the wellbore model into GEOPHIRES as a reservoir thermal drawdown option. Additionally, case studies for the WVU and Cornell campuses were performed to assess the potential for district heating and cooling at these two eastern U.S. sites.

15 GEOTHERMAL ENERGY↗
DOE OSTI2015

Process Design and Economics for the Conversion of Lignocellulosic Biomass to Hydrocarbon Fuels. Thermochemical Research Pathways with In Situ and Ex Situ Upgrading of Fast Pyrolysis Vapors

This report was developed as part of the U.S. Department of Energy’s Bioenergy Technologies Office’s efforts to enable the development of technologies for the production of infrastructurecompatible, cost-competitive liquid hydrocarbon fuels from biomass. Specifically, this report details two conceptual designs based on projected product yields and quality improvements via catalyst development and process integration. It is expected that these research improvements will be made within the 2022 timeframe. The two conversion pathways detailed are (1) in situ and (2) ex situ upgrading of vapors produced from the fast pyrolysis of biomass. While the base case conceptual designs and underlying assumptions outline performance metrics for feasibility, it should be noted that these are only two of many other possibilities in this area of research. Other promising process design options emerging from the research will be considered for future techno-economic analysis.

09 BIOMASS FUELS↗
DOE OSTI2015

Sustainable Energy in Remote Indonesian Grids. Accelerating Project Development

Sustainable Energy for Remote Indonesian Grids (SERIG) is a U.S. Department of Energy (DOE) funded initiative to support Indonesia’s efforts to develop clean energy and increase access to electricity in remote locations throughout the country. With DOE support, the SERIG implementation team consists of the National Renewable Energy Laboratory (NREL) and Winrock International’s Jakarta, Indonesia office. Through technical assistance that includes techno-economic feasibility evaluation for selected projects, government-to-government coordination, infrastructure assessment, stakeholder outreach, and policy analysis, SERIG seeks to provide opportunities for individual project development and a collective framework for national replication office.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2015

Low-Energy Solvents For Carbon Dioxide Capture Enabled By A Combination Of Enzymes And Vacuum Regeneration

An integrated bench-scale system combining the attributes of the bio-renewable enzyme carbonic anhydrase (CA) with low-enthalpy CO 2 absorption solvents and vacuum regeneration was designed, built and operated for 500 hours using simulated flue gas. The objective was to develop a CO 2 capture process with improved efficiency and sustainability when compared to NETL Case 10 monoethanolamine (MEA) scrubbing technology. The use of CA accelerates inter-conversion between dissolved CO 2 and bicarbonate ion to enhance CO 2 absorption, and the use of low enthalpy CO 2 absorption solvents makes it possible to regenerate the solvent at lower temperatures relative to the reference MEA-based solvent. The vacuum regeneration-based integrated bench-scale system operated successfully for an accumulated 500 hours using aqueous 23.5 wt% K 2 CO 3 -based solvent containing 2.5 g/L enzyme to deliver an average 84% CO 2 capture when operated with a 20% enzyme replenishment rate per ~7 hour steady-state run period. The total inlet gas flow was 30 standard liters per minute with 15% CO 2 and 85% N 2 . The absorber temperature was 40°C and the stripper operated under 35 kPa pressure with an approximate 77°C stripper bottom temperature. Tests with a 30°C absorber temperature delivered >90% capture. On- and off-line operational measurements provided a full process data set, with recirculating enzyme, that allowed for enzyme replenishment and absorption/desorption kinetic parameter calculations. Dissolved enzyme replenishment and conventional process controls were demonstrated as straightforward approaches to maintain system performance. Preliminary evaluation of a novel flow-through ultrasonically enhanced regeneration system was also conducted, yet resulted in CO2 release within the range of temperature-dependent release, and further work would be needed to validate the benefits of ultrasonic enhanced stripping. A full technology assessment was completed in which four techno-economic cases for enzyme-enhanced aqueous K 2 CO 3 solvent with vacuum stripping were considered and a corresponding set of sensitivity studies were developed. The cases were evaluated using bench-scale and laboratory-based observations, AspenPlus® process simulation and modeling, AspenTech’s CCE® Parametric Software, current vendor quotations, and project partners’ know-how of unit operations. Overall, the DOE target of 90% CO 2 capture could be met using the benign enzyme-enhanced aqueous K 2 CO 3 -based alternative to NETL Case 10. The model-predicted plant COE performance, scaled to 550 MWe net output, was 9% higher than NETL Case 10 for an enzyme-activated case with minimized technical risk and highest confidence in physical system performance utilizing commercially available equipment. A COE improvement of 2.8% versus NETL Case 10 was predicted when favorable features of improved enzyme longevity and additional power output from a very low pressure (VLP) turbine were combined, wherein corresponding high capital and operational costs limited the level of COE benefit. The environmental, health and safety (EH&S) profile of the system was found to be favorable and was compliant with the Federal EH&S legislation reviewed. Further work on a larger scale test unit is recommended to reduce the level of uncertainty inherent in extrapolating findings from a bench-scale unit to a full scale PCC plant, and to further investigate several identified opportunities for improvement. Production feasibility and suitability of carbonic anhydrases for scale-up testing was confirmed both through the current project and through parallel efforts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Development of a Novel Gas Pressurized Stripping Process-Based Technology for CO₂ Capture from Post-Combustion Flue Gases

A novel Gas Pressurized Stripping (GPS) post-combustion carbon capture (PCC) process has been developed by Carbon Capture Scientific, LLC, CONSOL Energy Inc., Nexant Inc., and Western Kentucky University in this bench-scale project. The GPS-based process presents a unique approach that uses a gas pressurized technology for CO₂ stripping at an elevated pressure to overcome the energy use and other disadvantages associated with the benchmark monoethanolamine (MEA) process. The project was aimed at performing laboratory- and bench-scale experiments to prove its technical feasibility and generate process engineering and scale-up data, and conducting a techno-economic analysis (TEA) to demonstrate its energy use and cost competitiveness over the MEA process. To meet project goals and objectives, a combination of experimental work, process simulation, and technical and economic analysis studies were applied. The project conducted individual unit lab-scale tests for major process components, including a first absorption column, a GPS column, a second absorption column, and a flasher. Computer simulations were carried out to study the GPS column behavior under different operating conditions, to optimize the column design and operation, and to optimize the GPS process for an existing and a new power plant. The vapor-liquid equilibrium data under high loading and high temperature for the selected amines were also measured. The thermal and oxidative stability of the selected solvents were also tested experimentally and presented. A bench-scale column-based unit capable of achieving at least 90% CO₂ capture from a nominal 500 SLPM coal-derived flue gas slipstream was designed and built. This integrated, continuous, skid-mounted GPS system was tested using real flue gas from a coal-fired boiler at the National Carbon Capture Center (NCCC). The technical challenges of the GPS technology in stability, corrosion, and foaming of selected solvents, and environmental, health and safety risks have been addressed through experimental tests, consultation with vendors and engineering analysis. Multiple rounds of TEA were performed to improve the GPS-based PCC process design and operation, and to compare the energy use and cost performance of a nominal 550-MWe supercritical pulverized coal (PC) plant among the DOE/NETL report Case 11 (the PC plant without CO₂ capture), the DOE/NETL report Case 12 (the PC plant with benchmark MEA-based PCC), and the PC plant using GPS-based PCC. The results reveal that the net power produced in the PC plant with GPS-based PCC is 647 MWe, greater than that of the Case 12 (550 MWe). The 20-year LCOE for the PC plant with GPS-based PCC is 97.4 mills/kWh, or 152% of that of the Case 11, which is also 23% less than that of the Case 12. These results demonstrate that the GPS-based PCC process is energy-efficient and cost-effective compared with the benchmark MEA process.

Chen, Shiaoguo↗
DOE OSTI2015

Mitigation of Syngas Cooler Plugging and Fouling

This Final Report summarizes research performed to develop a technology to mitigate the plugging and fouling that occurs in the syngas cooler used in many Integrated Gasification Combined Cycle (IGCC) plants. The syngas cooler is a firetube heat exchanger located downstream of the gasifier. It offers high thermal efficiency, but its’ reliability has generally been lower than other process equipment in the gasification island. The buildup of ash deposits that form on the fireside surfaces in the syngas cooler (i.e., fouling) lead to reduced equipment life and increased maintenance costs. Our approach to address this problem is that fouling of the syngas cooler cannot be eliminated, but it can be better managed. The research program was funded by DOE using two budget periods: Budget Period 1 (BP1) and Budget Period 2 (BP2). The project used a combination of laboratory scale experiments, analysis of syngas cooler deposits, modeling and guidance from industry to develop a better understanding of fouling mechanisms and to develop and evaluate strategies to mitigate syngas cooler fouling and thereby improve syngas cooler performance. The work effort in BP 1 and BP 2 focused on developing a better understanding of the mechanisms that lead to syngas cooler plugging and fouling and investigating promising concepts to mitigate syngas cooler plugging and fouling. The work effort focused on the following: • analysis of syngas cooler deposits and fuels provided by an IGCC plant collaborating with this project; • performing Jet cleaning tests in the University of Utah Laminar Entrained Flow Reactor to determine the bond strength between an ash deposit to a metal plate, as well as implementing planned equipment modifications to the University of Utah Laminar Entrained Flow Reactor and the one ton per day, pressurized Pilot Scale Gasifier; • performing Computational Fluid Dynamic modeling of industrially relevant syngas cooler configurations to develop a better understanding of deposit formation mechanisms; • performing Techno-Economic-Analysis for a representative IGCC plant to investigate the impact on plant economics, in particular the impacts on the Cost of Electricity (COE), due to plant shutdowns caused by syngas cooler plugging and fouling and potential benefits to plant economics of developing strategies to mitigate syngas cooler fouling; and • performing modeling and pilot scale tests to investigate the potential benefits of using a sorbent (fuel additive) to capture the vaporized metals that result in syngas cooler fouling. All project milestones for BP 1 and BP 2 were achieved. DOE was provided a briefing on our accomplishments in BP1 and BP2 and our proposed plans for Budget Period 3 (BP 3). Based on our research the mitigation technology selected to investigate in BP 3 was the use of a sorbent that can be injected into the gasifier with the fuel slurry to capture vaporized metals that lead to the deposit formation in the syngas cooler. The work effort proposed for BP 3 would have focused on addressing concerns raised by gasification industry personnel for the impacts on gasifier performance of sorbent injection, so that at the end of BP 3 the use of sorbent injection would be at “pre-commercial” stage and ready for use in a Field Demonstration that could be funded by industry or DOE. A Budget Continuation Application (BCA) was submitted to obtain funding for BP3 DOE but DOE chose to not fund the proposed BP3 effort.

47 OTHER INSTRUMENTATION↗