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All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Development of Algal Biomass Yield Improvements in an Integrated Process

Global Algae Innovations (Global Algae) collaborated with TSD Management Associates (TSD), Scripps Institution of Oceanography at the University of California San Diego (SIO), GE Power & Water (GE), Hawaii Bioenergy (HBE), Kuehnle AgroSystems (KAS), Texas AgriLife Research (TALR), and Pacific Northwest National Laboratory (PNNL) to increase algae oil yield and optimize unit operations in order to facilitate commercial development of algal-derived, drop-in transportation fuels. All improvements were viewed through a system-wide techno economic model to ensure the work is focused on and limited to approaches that are scalable to commercially relevant size and compatible with an overall system that is economically viable. The objectives of the proposed project were (i) to develop improved strains and cultivation methods for a 40% increase in algal biofuel intermediate yield; (ii) to develop economical, scalable, low energy pre-processing technologies for harvesting, dewatering, and extraction for an 88% reduction in the downstream processing energy; and (iii) to achieve these improvements in an integrated outdoor system that reduces the projected algae biomass production cost by 58%. All project goals were exceeded, and the project was completed on schedule and budget. Two major technology breakthroughs were achieved. The first breakthrough is an improved cultivation system approach that increases algal productivity by 80% in growth phase while simultaneously reducing the energy use for cultivation by 67%. The second is a harvesting and dewatering technology that reduces energy use by 95-99%, achieves 100% capture efficiency with crystal clear permeate, and produces a 15-20% algae slurry. The harvesting and dewatering technology was commercialized and is now available to the algae industry as the Zobi Harvester®.

09 BIOMASS FUELS↗
DOE OSTI2018

Lab-Scale Development of a Solid Sorbent for CO 2 Capture Process for Coal-Fired Power Plants

It is increasingly clear that CO 2 capture and sequestration (CCS) must play a critical role in curbing worldwide CO 2 emissions to the atmosphere. Development of these technologies to cost-effectively remove CO 2 from coal-fired power plants is very important to mitigating the impact these power plants have within the world’s power generation portfolio. Currently, conventional CO 2 capture technologies, such as aqueous-monoethanolamine based solvent systems, are prohibitively expensive and if implemented could result in a 75 to 100% increase in the cost of electricity for consumers worldwide. Solid sorbent CO 2 capture processes – such as RTI’s 3rd Generation Solid Sorbent CO 2 Capture Process – are promising alternatives to conventional, liquid solvents. Supported amine sorbents – of the nature RTI has developed – are particularly attractive due to their potential for high CO 2 loadings, excellent stability over multiple cycles, reduced corrosivity/volatility and a potential to reduce the regeneration energy needed to carry out CO 2 capture. The remaining challenges for these sorbent processes have provided the framework for the project team’s research and development and target for advancing the technology beyond lab-scale testing. Previous work in this area has failed to adequately address various technology challenges such as sorbent stability and regenerability, sorbent scale-up, improved physical strength and attrition-resistance, proper heat management and temperature control, proper solids handling, as well as the proper coupling of process engineering advancements that are tailored for a promising sorbent technology. Under a cooperative agreement with the US Department of Energy, and part of NETL’s CO 2 Capture Program, RTI has led an effort to address and mitigate the challenges associated with solid sorbent CO 2 capture. The overall objective of this project was to mitigate the technical and economic risks associated with the performance and scale-up of solid sorbent-based CO 2 capture processes, enabling subsequent larger pilot demonstrations and ultimately commercial deployment. An integrated development approach has been a key focus of this project in which sorbent development, process development, and economic analyses have informed each of the other development processes. Development efforts have focused on developing novel hybrid solids-based CO 2 capture sorbents and improving their performance stability, refining process engineering and design, and evaluating the viability of the technology through detailed economic analyses. Sorbent advancements have led to a next generation, commercially-viable CO 2 capture sorbent exhibiting performance stability in various gas environments and a physically strong fluidizable form. The team has reduced sorbent production costs and optimized the production and scale-up of novel metal-organic framework (MOF) hybrid solids-based CO 2 capture sorbents, fluidizable sorbents. Refinement of the process engineering and design at the lab-scale research unit has demonstrated promising CO 2 capture performance in simulated coal-fired flue gas conditions. Long-term testing has informed the project team on the process conditions needed to operate a solids-based system for optimal performance. Data collected from all phases of testing has been used to develop a detailed techno-economic assessment of RTI’s technology. These detailed analyses show that RTI’s technology has significant economic advantages over current amine scrubbing and potential to achieve the DOE’s Carbon Capture Program’s goal of >90% CO 2 capture rate at a cost of almost $40/tonne CO 2 captured by 2025. Through this integrated technology development approach, the project team has advanced RTI’s 3rd generation CO 2 capture technology to TRL-3, according to the DOE/FE definitions for Technology Readiness Levels. At a broader level, this project has advanced the whole of the solid sorbent CO 2 capture field, with advancements in process engineering and design, technical risk mitigation, sorbent scale-up optimization, and an understanding of the commercial viability and applicability of solid sorbent CO 2 capture technologies for the U.S. existing fleet of coal-fired power plants.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Final Report: Scale-up of Algal Biofuel Production Using Waste Nutrients

Renewable fuels can be more environmentally friendly than conventional fuels and can be produced locally, supporting energy independence. Liquid renewable fuels are of special interest due to their high energy density. Algae are a promising prospective feedstock for low carbon intensity liquid biofuels, due to their high productivity and potential for high lipid or carbohydrate content. Their ability to grow on wastewater and waste nutrients and on non-arable land are cost and sustainability advantages. The organic matter content of wastewater promotes mixotrophic and/or heterotrophic growth of both algae and bacteria, boosting biomass productivity further. However, economic and technologic challenges persist that prevent the scale-up of algal biofuels to commercial relevance. These challenges include algal harvesting, drying, dewatering, and the conversion of algal biomass to usable fuels (Hannon et al 2010, Dunlap and Shaw 2009, Pienkos et al. 2009). The US Department of Energy (DOE) Bioenergy Technologies Office (BETO) supports research to overcome these challenges and outlines the research and development goals for algal biofuels in their Multi-Year Program Plan (MYPP). The long-term goals of the MYPP for algal biofuels research are briefly as follows: develop the domestic ability to produce algal biofuels at a scale of 5 billion gallons per year (BGY) by 2030 and demonstrate technologies that produce biofuel intermediates from algae at a cost of $3/gallon of gasoline equivalent (GGE) by 2022 (BETO MYPP 2016). This research reported herein was funded to investigate methods of meeting an intermediate milestone of 2,500 gallons of biofuel intermediate per acre per year for a non-integrated process by improving algal productivity, harvesting efficiency, and conversion to biofuel intermediates. Use of wastewater and wastewater nutrients was a key distinguishing characteristic of this project. In pursuit of 2,500 gallons of biofuel intermediate (BFI) per acre per year, California Polytechnic State University, San Luis Obispo (Cal Poly) sought to develop the capability to produce biofuel intermediates from microalgae grown on municipal wastewater at a 20-acre algae-based wastewater treatment facility in Delhi, California (37.43° N), which includes 7 acres of raceway ponds. Coupling algal biofuel production with wastewater treatment capitalizes on the abundant waste nutrients and carbon present in wastewater and reduces use of clean water in algal biorefinery systems. In this research, the performance of the full-scale wastewater treatment plant was characterized by measuring productivity, wastewater treatment performance, hydraulic characteristics, and energy consumption. Nine 1,000-L pilot raceways with CO2 addition were used in experiments to maximize productivity. Low-cost, energy-efficient algae bioflocculation and settling were monitored. Population genetics were monitored in an attempt to correlate taxa with superior productivity and/or settling. Algae-bacterial biomass was converted to biofuel intermediates via bench-scale hydrothermal liquefaction (HTL), and the resulting fuel quality was characterized. To develop rapid strain screening capabilities, a climate simulating photobioreactor (“LEAPS”) was developed and validated against outdoor raceways. A techno-economic analysis (TEA) and a lifecycle assessment (LCA) were performed to model process economics and sustainability. The major outcomes of this research included demonstration of 33 g/m2-day annual average algal-bacterial productivity in pilot raceways, and a biofuel intermediate yield of 0.35 g intermediate/g algae biomass via HTL, for a yield of 4,100 gallons BFI per acre per year, assuming a 90% harvest efficiency and ignoring other minor losses. This exceeded the project goal of 2,500 gallons of BFI per acre per year and nearly met the 2030 program goal, highlighting the promise of integrating wastewater treatment and biofuels production. The biocrude BFI produced by the process is refined to diesel and naphtha fuels. These fuels are normalized to the energy content of gasoline (gallons gasoline equivalent, GGE, for comparison to other fuels). Results from the TEA of the this complete “well-to-wheel” process demonstrated that, at a 400-ha scale, a minimum fuel selling price (MFSP) of $12.55/GGE, which could be decreased 57% to $7.14/GGE when including revenue from coupling the biofuel production with the co-products of wastewater treatment services and low carbon fuel credits from California and Federal programs. Due mainly to the high capital costs of thickener centrifuges and hydrothermal processing equipment, the fuel cost is sensitive to scale, with significantly lower costs expected for larger farms. In this research project, significant advances were made in improving raceway algal productivity and fuel production from algae biomass, while also improving process economics. These outcomes brought the algal biofuel technology closer to being a sustainable and marketable process. The remainder of this executive summary is organized into the following six primary project tasks: (1) to optimize biomass productivity for a selected strain at Delhi, (2) to maximize algal productivity and harvesting efficiency in Delhi pilot ponds, (3) a full-scale raceway hydraulic characterization, (4) biomass processing to biofuel intermediates, and (5) scale-up engineering analysis, modeling, and planning.

09 BIOMASS FUELS↗
DOE OSTI2018

Final Report for the Project Characterization and Valorization of Aqueous Phases Derived from Liquefaction and Upgrading of Bio-Oils

The Characterization and Valorization of Aqueous Phases Derived from Liquefaction and Upgrading of Bio-Oils project developed processes to extract value from the organics within aqueous streams derived from biomass direct liquefaction processes. The focus of the project was twofold. First, we characterized a diverse set of aqueous streams from numerous processes and feedstocks. The characterization effort served to inform this project toward development around the most prevalent compounds to maximize versatility and impact. We analyzed diverse streams from hydrothermal liquefaction of lignocellulosic, algal, and waste feedstocks; catalytic fast-pyrolysis aqueous phases; fast-pyrolysis aqueous phases; and aqueous phases produced by hydroprocessing of fast-pyrolysis bio-oil. Second, thermochemical catalytic processes were developed to convert aqueous-phase organics into useful products. These processes focused mostly on organic acids and specifically acetic acid, which was found to be ubiquitous from the characterization effort. A La x Zr y O z catalyst was discovered and developed for the ketonization of acids to ketones in the condensed aqueous phase. A dual-bed steam reforming process was developed to convert acids and other organics to hydrogen for bio-oil hydroprocessing. The dual-bed reforming process consisted of a ketonization step followed by a steam reforming step with Co as the active metal. The dual-bed process significantly reduced the rate of coke deposition versus direct steam reforming of the organic acids and beneficially produced CH 4 below the equilibrium value. Finally, we demonstrated direct conversion of aqueous-phase organics to olefins over a Zn x Zr y O z catalyst. Each thermochemical catalytic process was demonstrated with process-derived aqueous mixtures. Model compounds were used to benchmark performance and optimize conditions, but emphasis was placed on utilizing “real” aqueous streams whenever possible. A liquid-liquid extraction process using methyl tert-butyl ether as the solvent was developed to segregate dissolved inorganic species and sugars from desirable light oxygenates such as acids and alcohols. Furthermore, a carbon treatment to remove color bodies was employed after it was found the presumably heavy organic chromophore species deactivated catalysts. These economic separation processes allowed for the successful demonstration of stable catalytic processing in the condensed-phase ketonization, dual-bed reforming, and direct olefin production processes for tens to hundreds of hours, which were limited only by the quantity of feed available. Techno-economic analysis of these processes demonstrated the impact possible when capturing “waste” organics as valuable products. The condensed-phase ketonization process for converting aqueous stream acids to ketones followed by reduction and dehydration to olefins sold as a co-product resulted in the reduction of the minimum fuel selling price by about 13% compared to the anaerobic-digestion, aqueous-phase treatment base case (3.74 to 4.29/GGE). The dual-bed reforming process was commensurate in price to the anaerobic digestion base case (4.24 versus 4.29/GGE). However, the need for external natural gas to produce hydrogen for bio-oil hydroprocessing was eliminated, thereby lowering the carbon impact of the process.

09 BIOMASS FUELS↗
DOE OSTI2018

Pilot Test of Novel Electrochemical Membrane System for Carbon Dioxide Capture and Power Generation (Final Report)

The goal of this U.S. Department of Energy (DOE) sponsored project under cooperative agreement DE-FE0026580 is to verify that Fuel Cell Energy’s (FCE) Electrochemical Membrane (ECM)-based Combined Electric Power and Carbon Separation (CEPACS) system can achieve at least 90% carbon dioxide (CO 2 ) capture rate from Pulverized Coal (PC) power plant flue gas with 95% CO2 purity at a cost of electricity (COE) 30% less than baseline CO 2 capture approaches. To progress towards the DOE’s ultimate carbon capture program goals, the specific objectives of Budget Period 1 (BP1) of the project are to perform a preliminary Techno-Economic Analysis (TEA) and Environmental, Health and Safety (EH&S) Risk Assessment study, as well as to complete the detailed design of a pilot-scale ECM-based CEPACS system. This final technical report summarizes the results of the preliminary TEA and EH&S assessment of an ECM-based CEPACS system designed to capture and compress >90% of CO 2 from the flue gas of a reference 550 MW (net AC) Pulverized Coal (PC) Supercritical Steam Cycle Plant. Also included in this report is a summary of the detailed design for a pilot 3 MWe (flue gas equivalent) ECM-based CEPACS system designed to capture ≥90% of CO 2 from a PC plant flue gas slipstream and produce high-purity (≥95%) CO 2 . The pilot system is designed to process a slipstream of flue gas from the Unit 5 coal-fired boiler at the James M. Barry Electric Generating Station (Plant Barry). Plant Barry is located in Bucks, Alabama and is owned and operated by Alabama Power Company, a subsidiary of Southern Company. The TEA shows that the ECM-based CO 2 capture technology has an economic advantage over the existing CO 2 capture technology and meets the DOE’s cost target and performance goals for post-combustion CO 2 capture. The EH&S study includes the identification and quantification of the emissions from the CEPACS system. Properties of the waste including reactivity, flammability, corrosivity and toxicological effects are discussed along with the methods for minimization/elimination where applicable. The study shows that no major EH&S issues are expected to hinder commercialization of the ECM technology for large scale carbon capture applications. The detailed Front End Engineering Design (FEED) package for FCE’s MW-class ECM-based CO 2 capture pilot system is complete. It is designed in accordance with the project objectives and is now at a point where equipment/component procurement, skid final design and fabrication, and site preparation activities can begin in a follow-on project phase.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

LP CO 2 Compressor Final Technical Report

This report summarizes work performed by Dresser-Rand, A Siemens Business and subcontractors, under DOE award number DE-FE0026727, in pursuit of the design, construction and test of a 10:1 pressure ratio “Low Pressure” (LP) supersonic CO 2 compressor suitable for use as a first stage in a two stage 100:1 compression system. This LP compressor, in conjunction with a corresponding 10:1 high pressure compressor, provide the overall 100:1 compression ratio required to compress CO 2 from 22 psia (as generated by a CO 2 capture system) to the 2215 psia required to transport CO 2 via a pipeline to a suitable sequestration site. The compressor demonstrates application of Dresser-Rand’s supersonic compression technology at an industrial scale using CO 2 in a closed-loop testing facility. This scope of this technical report is to summarize all phases of the program executed from August 5, 2015 to the June 30, 2018. This program included the final testing of a “high pressure” (HP) compressor that had previously been built by Dresser-Rand and the design, fabrication, assembly and test of a corresponding LP compressor. In summary, the LP compressor exceeded the target pressure ratio and efficiency goals for the program at CO 2 flowrates suitable for those expected in coal fired power plant carbon capture systems. Initial and Final Techno-Economic Analysis reports were generated to show the value this compression solution brings to carbon capture and sequestration (CC&S) systems for the Case B12B coal fired power plant model. Integration of the DATUM S compression technology into a carbon capture and sequestration system was shown to result in a 27% reduction in the Cost of Electricity for the compression system, as well as a 21,500 gallon per hour reduction in required cooling water flow for the plant.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

FINAL SCIENTIFIC/TECHNICAL REPORT: Dry Solids Pump - Coal Feed Technologies

Gas Technology Institute (GTI) has concluded the Dry Solids Pump Coal - Feed Technologies (DSP-CFT) program that was initiated on October 1, 2013. The project’s primary objectives have been to gather data to increase the fidelity of the economic benefits of the Dry Solids Pump (DSP) technology for Integrated Gasification Combined Cycle (IGCC) plants, mature the technology to a Technology Readiness Level (TRL) of TRL 6 by continued testing and upgrades to the existing DSP, advance pump configuration knowledge to the point that a commercial pump can be confidently designed for low rank coal feed stocks and develop the next generation design configuration of a 1000 ton per day (tpd) DSP. After initial efforts with the existing DSP, a subscale pump was built to reduce the cost and time required to develop upgrades. The subscale development program evaluated three exit configurations and a host of geometric variations in each configuration concluding a side exit upward discharge configuration offered the greatest improvements. Both configuration and operation focused improvements were implemented on the full scale existing DSP and demonstrated 500 psi operation. An initial Techno-economic Analysis (TEA) and later update that was undertaken by Mr. Chris Higman and associates. The TEA quantifies the dramatic savings in capital and operational expenses achieved by reducing plant height and nitrogen consumption/compression, respectively in a commercial gasifier application. Drawings of the suggested design configuration for a commercial DSP feeder reflect the side exit design and incorporate lighter weight and lower cost fabrication methods. Features used for development testing are removed. A follow-on optimization program to allow the DSP technology to achieve TRL 7 is outlined.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2018

Development of a Green Parabolic Trough Collector

This report describes in detail a research project that assesses the potential of a parabolic trough solar collector with a lumber construction to meet ambitious performance, cost, and durability goals. Instead of exploring lumber as a general question for solar collectors, the project focuses on the design optimization, laboratory testing, outdoor testing, and economic modeling of a particular scale of parabolic trough, namely, the 6m aperture and 12m long module that has become the standard in the utility-scale power plant market. As will be appreciated in the report, it is also a scale that matches well the capabilities of lumber as a structural material and the commonly available cross sections. The design and its analysis extend far beyond traditional considerations for wooden structures in the built environment, and includes a computationally efficient coupled structural-optical simulation and the empirical characterization of joint stiffness at small deformations. Laboratory testing is used to characterize cyclic joint behavior, accelerated weathering, and to validate the simulation used as the basis for building a full-scale prototype. The construction and outdoor testing of this prototype is described. A total installed cost model of the collector is presented and the impact of the cost is seen in the context of a full plant techno-economic model. The results of this model in combination with the experience with the first prototype suggest that with improvements to the design and assembly process, this collector type has the potential to lower the levelized cost of heat for industrial solar steam plants used for process heating or cogeneration.

14 SOLAR ENERGY↗
DOE OSTI2019

Improvement and Validation of the System Advisor Model

The System Advisor Model (SAM) and PVWatts tools have been key successes and core facilities of the DOE EERE suite of capabilities for the last fifteen years, and have grown into a first-class and one-of-a-kind software suite for solar energy technology systems, incorporating best-in-class models for detailed performance and techno-economic analysis. This final report describes accomplishments of this project to continue to achieve high impact for all stakeholders.

14 SOLAR ENERGY↗
DOE OSTI2018

Advanced Integrated Technologies for Treatment and Reutilized of Impaired Water in Fossil Fuel-based Power Plant Systems (Final Report)

The water-energy nexus is an important issue in regards to U.S. energy security and its significance will increase in the future due to increasing populations, energy demand, and competition for available water. The subsurface storage of carbon dioxide (along with fossil energy resource extraction), could generate significant quantities of brine, which if effectively treated could be beneficially reutilized. This document reports results from U.S. Department of Energy Project DE-FE0026315 which evaluated the use of electrocoagulation (EC) and supercritical water (SCW) treatment as a means to generate a water product for beneficial reuse from brine. The use of a novel SCW treatment system was studied with simulated and field-derived brine fluids. In addition, selective removal of high-value brine components via EC was studied. Techno-economics for treatment of high dissolved solids content brine (180,000 ppm) is also reported.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2019

Improving Energy Efficiency of Air Separation via Hollow Fiber Sorbents

This report summarizes the work performed under the Department of Energy’s National Energy Technology Laboratory (DOE-NETL) Advanced Energy Systems Program award number DE-FE0026163 Improving Energy Efficiency of Air Separation via Hollow Fiber Sorbents. The overall objective of the project was to develop technology to produce oxygen for use in coal gasification processes at a significantly lower cost than that of the commercial state-of-the-art technology. The focus of the project was development and optimization of hollow fiber sorbents for use in a pressure swing adsorption (PSA) process for producing oxygen from air. The key technical advancement under this program was the development of a hollow fiber sorbent capable of producing oxygen in a PSA process. PSAs produce oxygen by using a beaded zeolite material (typically lithium exchanged zeolites or LiX) that selectively adsorb nitrogen over oxygen. For a fiber to adsorb nitrogen, LiX needed to be integrated into a polymer fiber and then activated at over 350C to remove residual moisture. After screening multiple materials and process techniques, Matrimid/LiX hollow fibers were produced that were able to withstand the activation and had crystalline nitrogen capacity close to pure LiX crystals. The fibers were dual layer fibers with a barrier layer isolating the hollow bore from the LiX embedded layer. The barrier layer was formed from an Ultem® based solution. The hollow bore was intended for encapsulating phase change materials to ensure isothermal PSA operation. Modeling work from the project suggested that the benefits of this additional complexity were marginal, thus the team fabricated non-hollow fibers comprised of Matrimid and LiX. The Matrimid/LiX fibers were loaded into a module and tested on a bench scale PSA unit. The fibers were able to separate oxygen from air, but the purity and recovery were lower than expected and lower than traditional beaded LiX zeolites, although modeling results suggested that the bed sizes for fiber sorbents could be half the size of a beaded LiX bed. Additional work will be needed to understand the shortfall and to produce fiber sorbent modules with performance equal to the targets set for this program. In addition to producing fibers, modeling work was carried out at both the fiber level and process level to guide both fiber sorbent development and to determine the optimal process conditions for a PSA using fiber sorbents. A 2D hollow fiber model was developed in gPROMS Model Builder. This model was based on literature data for mass transfer and other parameters. This model used a basic single bed PSA process to determine important fiber properties and process conditions for achieving high oxygen recovery. The preliminary 2D fiber model was a valuable tool, however, for step-out technologies, such as a PSA process with fiber sorbents, intelligent optimization and plant control was needed to effectively determine minimum power designs. Therefore, a gPROMS Process Builder-based optimization tool was developed with an “Automated Cycle Optimizer” model that was able to determine optimal cycle conditions for a fiber sorbent PSA. The results from the optimizer were used in the final power analysis. Flow sheet analysis and techno-economic analysis (TEA) was carried out to determine a lower power solution versus the baseline case. The original project scope suggested that the fiber sorbent PSA could be used to debottleneck a cryogenic air separation plant (cryo-ASU) with the combined plant having lower power than a standalone cryo-ASU. However, early flowsheet analysis showed that the PSA/cryo-ASU concept would not lead to a lower power solution. However, further flowsheet analysis suggested that an oxygen PSA combined with a nitrogen PSA could have lower power versus state-of-the-art air separation technology. Work concluded with the TEA showing a fiber sorbent oxygen PSA combined with an advanced nitrogen PSA could be up to 8% lower power versus the base case cryo-ASU. Overall, there is significant potential remaining for the zeolite hollow fiber sorbent concept, and this project successfully identified -- and ultimately remedied -- many technical challenges associated with scale-up.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2015

NETL Fischer-Tropsch Black Box Model

The purpose of the Fischer-Tropsch (F-T) Black Box Model is to allow for the screening of the impacts of F-T finished fuels production based on the input of a unique syngas composition. Utilizing the composition of the raw syngas, the model calculates the following outputs based on a facility sized to produce 50,000 bbl/day of liquid product: CO2 emissions, liquid product flows, required syngas input, and the net export electricity from the facility. NETL completed this model/study for the Connecticut Center for Advanced Technology (CCAT) to provide techno-economic and life cycle analysis modeling support for CBTL alternative jet fuel production, which forms key references to their report to the Defense Logistics Agency (their project sponsor/funder).

10 SYNTHETIC FUELS↗
DOE OSTI2015

NETL Fischer-Tropsch Black Box Model Documentation

The purpose of the Fischer-Tropsch (F-T) Black Box Model is to allow for the screening of the impacts of F-T finished fuels production based on the input of a unique syngas composition. Utilizing the composition of the raw syngas, the model calculates the following outputs based on a facility sized to produce 50,000 bbl/day of liquid product: CO 2 emissions, liquid product flows, required syngas input, and the net export electricity from the facility. NETL completed this model/study for the Connecticut Center for Advanced Technology (CCAT) to provide techno-economic and life cycle analysis modeling support for CBTL alternative jet fuel production, which forms key references to their report to the Defense Logistics Agency (their project sponsor/funder).

10 SYNTHETIC FUELS↗
DOE OSTI2019

Thermal Energy Storage for Dispatchable Geothermal Power

Dispatchable generation refers to sources of electricity that can be turned on or off, or can adjust their power output accordingly to an order. Geothermal plants are usually used for base-load power rather than dispatchable power. Flexibility is a challenge for a geothermal plant because the heat source does not naturally respond quickly to changes in demand. The current state-of-the-art approach to address this challenge is to maintain the geothermal fluid flows at relatively steady rates while providing a bypass around the generation equipment as needed. Under part load, some of the geothermal fluid is pumped to the surface, bypasses the generation equipment, and is re-injected to the ground without extracting any useful enthalpy. This approach is robust but necessarily incurs high parasitic power draws at part load due to the constant, full-flow pumping power requirements. There are even more challenges and unknowns for steam and flash geothermal plants, which were the focus for this project. As a process improvement to this existing configuration of a dispatchable geothermal plant, we examined the use of a phase-change thermal-energy storage (TES) unit that will provide some “inertia” against temperature fluctuations. The TES phase change material (PCM) could be in the form of eutectic molten nitrate salts, organic sugar alcohols, or the like based on the required temperature. This configuration allowed the power plant to meet the ramp rate requirements while allowing the geothermal resource to drawn down at the duty-cycle-averaged extraction rate rather than the full-rated-output extraction rate. The project team performed an experimental and computational evaluation of a peak shaving technical approach that used thermal storage to switch between two nominal operating points: full rated power and 50% power. In the initial requirements definition phase, the team decided to examine the PCM/TES-enhanced geothermal plant in the context of a 40-MW two-stage flash plant operating in mid-Southern California. Steady-state process simulations were used to understand the equipment sizing and the energetics. Dynamic process simulations were used to understand the response rate of the system to changes in requested power output from the utility. The technical approach was also guided by a techno-economic analysis (TEA) and a high-level analysis of the reservoir. Recognizing that performance of the thermal storage was a key risk element, high-fidelity finite-element simulations of the PCM-TES heat exchanger were performed to better understand its performance and temporal response. These simulations were validated with a subscale PCM-TES experimental apparatus that mimicked the geometry of the full-scale system. The key outcomes of this Phase I project were that: 1) the PCM-TES heat exchanger met the target for gravimetric energy storage density, 2) the dispatchable geothermal plant met its target for response rate, 3) the peak shaving approach reduces the number of production wells and does not disturb the wellfield, and 4) the incentives for properly remunerating dispatchable operation were identified.

15 GEOTHERMAL ENERGY↗
DOE OSTI2018

Solid Oxide Based Electrolysis and Stack Technology with Ultra-High Electrolysis Current Density (>3A/cm 2 ) and Efficiency

Hydrogen, a valuable commodity gas, is increasingly recognized as an important fuel and energy storage pathway of the future. This project aims to develop an innovative solid oxide based electrolysis cell and stack technology with ultra-high steam electrolysis current (>3A/cm 2 ) for potentially ultra-low-cost, highly efficient hydrogen production from diverse renewable sources. In this project, solid oxide based high power density cells (HiPoD cells) were developed. Those cells demonstrated capability of operating at ultra-high electrolysis current density of 6 A/cm 2 at 1.67V. During a long term steady state electrolysis test, a HiPoD cell was operated for more than 1000 hours at 3 A/cm 2 with a low degradation rate of 1.8% per 1000 hours. A 20-cell electrolysis stack was built using HiPoD cells and an ultra-compact, low-cost stack design platform. This stack was used to explore the boundaries of high current density electrolysis operation and achieved an incredible stack current density of 3 A/cm 2 with an average cell voltage of only 1.493 V. The stack was further operated in steady-state electrolysis at 2 A/cm 2 for more than 1000 hours with an overall degradation of 0.57% per 1000 hours. With an improved understanding of electrolysis operation at ultra-high current density, a new compact stack architecture (CSA) design with scalability up to 55 kW (or 38 kg H 2 per day) was tested. A number of 45-cell CSA stack was built and demonstrated 10 kW and 245 g/hr hydrogen production at 1.8 A/cm 2 electrolysis current density. In addition to cell and stack development, a preliminary system design was developed by integrating the inputs from electrochemistry, cell/stack performance data, and system level implications of configuration and operational parameters. A module design was created based on a circular array of six stacks surrounded in a cool pressure vessel. Further architectural and controls strategies such as stack power control and instrumentation were determined through the development of the module. A comprehensive techno-economic study of an ultra-high current density SOEC system integrated with renewable energy sources has been conducted. To determine the estimated cost of hydrogen for the system, the H2A Current Distributed Hydrogen Production Model version 3.101 was applied. Annual system production cases at both commercial and industrial electricity rates as per the H2A model was analyzed. The option of meeting DOE 2020 Advanced Electrolysis Technologies targets were discussed. Feedstock electricity represents the bulk of projected hydrogen cost with either electricity rate. At an annual production volume of 250 units, H2A hydrogen cost of $2.3/kg can be achieved at electricity cost around 3.5¢/kWh.

08 HYDROGEN↗
DOE OSTI2015

Comprehensive Analysis of Coal and Biomass Conversion to Jet Fuel: Oxygen Blown, Transport Reactor Integrated Gasifier (TRIG) and Fischer-Tropsch (F-T) Catalyst Configurations Modeled and Validated Scenarios

This study evaluates the technological/process, life cycle environmental, and economic perspective of 20 discreet F-T jet fuel production scenarios. The technological/process model provides a process level evaluation of the 10 alternate CBTL facility scenarios considered in this study. Aspen Plus simulation models for the CBTL facility scenarios were developed to determine the composition and flows of all of the major streams in the plants. These were used to develop conceptual level cost estimates for capital and operating costs for the major process units. NETL completed this study for the Connecticut Center for Advanced Technology (CCAT) to provide techno-economic and life cycle analysis modeling support for CBTL alternative jet fuel production, which forms key references to their report to the Defense Logistics Agency (their project sponsor/funder).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2015

Comprehensive Analysis of Coal and Biomass Conversion to Jet Fuel: Oxygen Blown, Entrained-Flow Gasifier (EFG) and Fischer-Tropsch (F-T) Catalyst Configurations Modeled and Validated Scenarios

This study evaluates the technological/process, life cycle environmental, and economic perspective of 10 discreet F-T jet fuel production scenarios. The technological/process model provides a process level evaluation of the 10 alternate CBTL facility scenarios considered in this study. Aspen Plus simulation models for the CBTL facility scenarios were developed to determine the composition and flows of all of the major streams in the plants. These were used to develop conceptual level cost estimates for capital and operating costs for the major process units. NETL completed this study for the Connecticut Center for Advanced Technology (CCAT) to provide techno-economic and life cycle analysis modeling support for CBTL alternative jet fuel production, which forms key references to their report to the Defense Logistics Agency (their project sponsor/funder).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2015

Coal and Biomass to Liquids (CBTL) Greenhouse Gas Optimization Tool Documentation

This report is the user documentation for the NETL CBTL Jet Fuel Model submitted under a separate approval routing. The documentation is intended to accompany the model. The documentation explains how to the use the model. The documentation does not contain any energy analysis findings. NETL completed this model/report as part of a study for the Connecticut Center for Advanced Technology (CCAT) to provide techno-economic and life cycle analysis modeling support for CBTL alternative jet fuel production, which forms key references to their report to the Defense Logistics Agency (their project sponsor/funder).

01 COAL, LIGNITE, AND PEAT↗