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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS1974

NASA Lewis H2-O2 MHD program

Performance and power costs of H2-O2 combustion powered steam-MHD central power systems are estimated. Hydrogen gas is assumed to be transmitted by pipe from a remote coal gasifier into the city and converted to electricity in a steam MHD plant having an integral gaseous oxygen plant. These steam MHD systems appear to offer an attractive alternative to both in-city clean fueled conventional steam power plants and to remote coal fired power plants with underground electric transmission into the city. Status and plans are outlined for an experimental evaluation of H2-O2 combustion-driven MHD power generators at NASA Lewis Research Center.

Smith, J. M.↗
DOE OSTI2019

Cryogenic Carbon Capture Development (Final Report)

This project extends and leverages the work completed under funding from ARPA-E and other sources by exploring aspects of the Cryogenic Carbon Capture™ (CCC) process and issues discovered during those projects, but that were not within the scope or budget of previous projects or that became apparent during field tests. Our successful completion of the tasks outlined in this project has increased the reliability, efficiency, and scalability of the CCC process and we are better prepared for pilot-scale testing. The first phase of this project improved key areas of the process through iterative design and experiment, culminating with recommendations for improvements to the existing skid-scale system developed under non-federal funding. The second phase of this project implemented the improved unit operations into the Cryogenic Carbon Capture External Cooling Loop (CCC ECL™) skid and field tests the improved system at a coal-fired power plant. The specific areas of work in this project are: Budget Period 1: 1) Selection of the most energy-efficient drying system for ambient-pressure flue gas. Sustainable Energy Solutions, LLC (SES) has successfully demonstrated a dryer that removes bulk water using a low-temperature brine to remove about 99% of the water followed by a mol sieve 3A desiccant dryer to remove the remaining 1% water; 2) Selection and demonstration of efficient solution to fouling due to dissolved CO 2 . SES has tested several commercial heat exchangers that purport to be able to handle fouling issues similar to those experienced in the contact liquid chiller. Replicated tests using the CCC ECL™ skid and dimpled brazed plate heat exchangers demonstrate that quick throttling of refrigerant combined with a burst of clean gas mitigate the fouling caused by CO 2 solubility in contact liquid with only minor increases in parasitic load. SES models indicate that parasitic load would increase by approximately 0.0125 GJ/tonne, an order of magnitude less than what was determined to be the maximum allowable additional parasitic load caused by this system; 3) Selection and demonstration of efficient and scalable solid–liquid separation system. The screw press technology met or exceeded the 70% solids loading benchmark during several test runs exceeding 24 hours on the CCC ECL™ skid. The average solids loading during the entire 50-hour run was 67%. The energy demand for this system is less than 0.1 GJ e /tonne of CO 2 processed; 4) Optimize design and demonstration of patented desublimating heat exchangers. We designed and built a hybrid spray tower that was tested over many hundreds of hours and a 50-hour continuous test run was completed capturing over 0.5 tonne CO 2 /day at >90% capture; (5) Plan for safe dilution of oxygen-depleted, cleaned flue-gas stream. The AERSCREEN simulator developed by the EPA modeled the dispersion of oxygen-depleted flue gas from the CCC process at a commercial plant. The results indicate that this plan effectively mitigates the flue gas hazards; (6) Simulation of and experimental work related to multi-pollutant capture. SES programmed an upgrade to its solid/vapor/liquid equilibrium (SVLE) algorithm. This enables simultaneous modeling of multiple pollutants (i.e., CO 2 , SO x , NO x , Hg, HCl). Budget Period 2; (7) Modify the CCC ECL™ skid for field testing and complete shakedown testing. The plans for modifying the CCC ECL™ skid were finalized and put into place. Shakedown testing of the updated CCC ECL™ skid occurred at SES using closed-loop mode (i.e., using a synthetic flue gas consisting of only N 2 and CO 2 ) and at the Hunter Power Plant using flue gas from the coal-fired boiler. Shakedown testing took longer than expected due to delays in receiving equipment and unexpected equipment performance in the field; (8) Operate the CCC ECL™ skid in the field. Longer testing of the CCC ECL™ skid occurred at the Hunter Power Plant. Multiple tests exceeding 35 hours were completed, with a total of over 600 hours of CO 2 capture completed using flue gas at the Hunter Power Plant with an average CO 2 capture rate of over 91% during those hours. Extensive notes and documentation were acquired informing improved methods for controls, startup, operation, and shut down; (9) Determine figures of merit and quantify process improvement. SES defined figures of merit for unit operation performance and overall CCC ECL™ process performance. All figures of merit were achieved or surpassed, except for 500 continuous hours of demonstration at the Hunter Power Plant; (10) Complete an Environmental Health and Safety Risk assessment by a third party. Tri-State completed an Environmental Health and Safety Risk assessment; (11) Update techno-economic analysis with third-party validation. The techno-economic analysis has been completed. It confirms the potential large reduction in energy and cost of the CCC process compared with leading alternatives and that the estimates and estimation techniques are reliable.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Operation and Process Control Development for a Pilot-Scale Leaching and Solvent Extraction Circuit Recovering Rare Earth Elements From Coal-Based Sources

The US Department of Energy in 2010 has identified several rare earth elements as critical materials to enable clean technologies. As part of ongoing research in REEs (rare earth elements) recovery from coal sources, the University of Kentucky has designed, developed and is demonstrating a ¼ ton/hour pilot-scale processing plant to produce high-grade REEs from coal sources. Due to the need to control critical variables (e.g. pH, tank level, etc.), process control is required. To ensure adequate process control, a study was conducted on leaching and solvent extraction control to evaluate the potential of achieving low-cost REE recovery in addition to developing a process control PLC system. The overall operational design and utilization of Six Sigma methodologies is discussed. Further, the application of the controls design, both procedural and electronic for the control of process variables such as pH is discussed. Variations in output parameters were quantified as a function of time. Data trends show that the mean process variable was maintained within prescribed limits. Future work for the utilization of data analysis and integration for data-based decision-making will be discussed.

coal, rare earth elements, pilot plant, automation↗
DOE OSTI2019

Conversion of Coal Wastes and Coal Plus Other Opportunity Fuel Mixtures, Such as Coal Plus Municipal Solids, to Produce Electricity and/or Liquid Fuels

For the foreseeable future, the Nation’s energy demand will continue to come largely from indigenous fossil energy resources and hydrocarbon fuels. Specifically waste coal plus other opportunity fuels need to be utilized as a feedstock to eliminate a waste stream and optimized to maximize energy yield and cleanly minimize pollutant emissions. Modular equipment is needed for installation in coal preparation locations, military installations, and research park facilities. Thermal decomposition of coal, biomass, and mixed solid waste (MSW) have been shown to reduce a waste stream while providing liquid and gaseous fuel products with low pollutant emissions. However, thermal decomposition processes have several challenges associated with preprocessing biomass and MSW, feeding and conveying material into the reactor, and post processing of syngas to remove undesirable products while upgrading to increase yield of high value products. Increasing total energy output from power plants by utilizing biomass and mixed wastes ultimately lowers energy costs, harmful environmental impacts of emissions, and has significant impacts on the energy security and sustainability of the U.S. economy. Entrained flow gasifiers (EFGs) produce very little CH4 and a wide range of H2/CO ratios (0.5–2.0) but are limited in their ability to effectively feed large biomass or MSW particles into the reactor. A solution to the feeding problems is to use pyrolysis torrefaction (PT) for conversion of waste materials to create a feedstock similar to coal and capable of grinding down and mixing with the coal feed. Mainstream experimentally explored reaction pathways for the conversion of coal waste plus municipal solids (CWPMS) and demonstrated a bench-scale reactor used for torrefaction of the municipal solid waste (MSW) to create a coal-like feed for blending with the coal waste. The material was processed in a pilot-scale EFG to determine product yield and emissions with CWPMS fuels, as well as the ash content and slagging properties of these feedstocks. The PT-EFG system was experimentally validated, where emissions and yield data were used to develop a high-fidelity process model and economic analysis. The following was accomplished in the Phase I: Determined optimal torrefaction process conditions for MSW and biomass through TGA; maximized heating value of fuel while maximizing final mass of torrefied product Demonstrated torrefaction of MSW and biomass feedstocks at 334°C, pulverized to uniform 74 µm particle size, and processed into coal-like feedstocks Demonstrated 8 lb/h pilot-scale EFG using MSW and biomass blends with waste coal; demonstrated 100% biomass in EFG Determined major effects of MSW torrefaction and co-gasifying high-ash coal waste-MSW blends have on pilot-scale EFG Demonstrated blending low-ash, low-sulfur torrefied biomass with high-ash waste bituminous and anthracite refuse coals generates a higher quality syngas compared to syngas from high-ash waste coals Demonstrated a high carbon conversion (> 99.5%) and syngas with 29.47% H2 content, and 0% CH4 content; greater water–gas shift occurs in EFG than predicted by equilibrium ASPEN Plus model Blended lower-ash, high-alkali biomass MSW to lower slag viscosities of the high-ash coal refuse sufficiently for better slag flow compared to feeding the high-ash coal Used low-sulfur biomass to greatly reduce the EFG syngas H2S concentrations and produce non-leachable slag and quench water with very little organic and trace metal contamination Developed a process model and TEA showing the modular PT EFG is cost competitive to existing power plants with the advantage of using low- or negative-value feedstocks such as waste coal stockpiles and non-landfilled MSW; providing a large incentive to implement an economical PT-EFG process

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2020

10 MWE CDCL Large Pilot Plant – pre-FEED Study

Coal Direct Chemical Looping (CDCL) is an advanced oxy-combustion technology that has the potential to substantially reduce the energy penalty and the cost of electricity (COE) for coal-fired power generation with CO₂ capture. The Babcock & Wilcox Company (B&W) and The Ohio State University (OSU) have been collaborating on the development of an iron oxide oxygen-carrier based chemical looping technology for clean power generation with inherent carbon capture. In this process, coal is dried and pulverized prior to being transported into a moving-bed reducer. In the reducer, coal reacts with the oxygen-carrier particles, forming combustion byproducts, predominantly CO₂ and H₂O, while reducing the iron oxide oxidation state from Fe₂O₃ to a mixture of FeO and Fe. The reduced state particles are then transported to a combustor reactor and re-oxidized with air. Following the oxidation, the oxygen-carrier particles are regenerated, and a large amount of heat is released for steam production. The produced steam is sent to a turbine for electricity generation. Meanwhile, the CO₂–rich stream leaving the reducer is cooled, cleaned, and compressed for subsequent pipeline transportation and sequestration. By combining air separation and fuel conversion into a single system, the CDCL technology enables the intensification of oxy-combustion processes by eliminating the energy and cost intensive cryogenic air separation unit and thereby results in higher overall plant efficiencies and lower COE’s. The use of a moving-bed reducer results in high conversions of volatile hydrocarbons and high CO₂ purity, which reduces the cost of downstream CO₂ purification for sequestration or utilization. The Babcock & Wilcox Company in collaboration with The Ohio State University, Johnson & Matthey, The Electric Power Research Institute, and Dover Light & Power completed a Preliminary Front-End Engineering and Design (Pre-FEED) study of a 10 MWe coal-direct chemical looping (CDCL) pilot plant. The planned system is a modular 10 MWe CDCL large pilot facility consisting in 4 modules of 2.5 MWe each, working in parallel and to be hosted within the current structure at the City of Dover’s Municipal Power Plant. The CDCL system can achieve auto-thermal operation and includes a sub-critical steam cycle for power generation. The pilot system was designed to demonstrate full commercial operation at a reduced scale. The coal distribution per plan area is a representative slice of larger commercial arrangements. The system includes a CO₂ recycle system, but it does not include a compression system. The large pilot includes all the environmental control equipment and oxygen carrier and ash handling systems. As part of the project, the Team performed laboratory testing and carried out multiple pilot test campaigns to obtain design and performance information at the 250 kWth CDCL pilot facility at the Babcock & Wilcox Company’s Research Center. The Team demonstrated sustained operations at designed coal inputs, high coal conversion, high CO₂ purity, heat generation on the combustor, low carbon carryover between reactors and low particle attrition. Emissions generated in the reducer reactor were identified as SO₂ and NO x . The commercial manufacturing cost of oxygen carrier particle was evaluated by JM. A particle manufacturing report was generated and submitted to the DOE. Based on the results from the pilot tests and the pre-FEED design efforts, a techno-economic analysis was performed. The study shows that the CDCL process is a promising carbon-friendly technology capable of producing electricity with high efficiency. The estimated COE of the supercritical CDCL plant is $83.3 / MWh, which meets DOE’s target of less than 30% increase in COE when compared to a supercritical PC plant without CO₂ capture. This is the lowest among the existing carbon capture technologies (post-combustion and oxy-combustion) for fossil fuel power plant. CDCL is evaluated to be the most promising technology for carbon capture from the economic aspect.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Microbe-Encapsulated Silica Gel Biosorbents for Selective Extraction of Scandium from Coal Byproducts

Establishing an inexpensive and environmentally friendly scandium (Sc) supply is critical for the development of clean energy technologies. However, refining Sc from Sc-bearing sources using current technologies poses economic and environmental challenges due to its low concentration relative to base metals and chemically similar lanthanides. In this work, we developed a biosorption-based flow-through process for extraction of Sc from low-grade feedstocks. A novel biosorbent material was synthesized by encapsulating Arthrobacter nicotianae, a bacterium that selectively adsorbs Sc, within a porous silica matrix. Through the use of several complementary microscopy techniques, we demonstrated a highly porous biosorbent structure with a high cell-loading density and a homogenous cell distribution. Batch adsorption assays revealed selective Sc adsorption over lanthanides and common based metals, with the exception of Fe(III), as evidenced by separation factors greater than 50. The MESG particles were packed into fixed-bed columns to enable adsorption under flow-through conditions, which demonstrated effective Sc extraction at flow rates up to 0.08 cm/s and high stability for reuse; greater than 95% of the adsorption capacity was maintained after 10 consecutive adsorption/desorption cycles. When applied to a lignite coal leachate, whose Fe content was depleted through pH-mediated precipitation, the MESG particles yielded Sc breakthrough at 30 bed volumes, whereas all other metals broke through after only a few bed volumes. Following desorption, an eluate with a 124-fold increase in Sc purity was achieved relative to the lignite leachate with Sc constituting 96.4% of the total REEs. This study established a rapid, facile, and scalable cell immobilization approach that enables the use of microbial biomass for Sc recovery from low-grade sources.

Dong, Ziye↗
DOE OSTI2023

A Clean Energy Korea by 2035

The current global energy crisis has massive implications for the people and economy of South Korea (Korea), where at least 90% of energy use depends on foreign fossil fuels. Clean electricity accounts for only 39% of total generation, with electricity demand expected to increase 30% by 2035. This study shows that Korea can achieve 80% clean electricity by 2035 by capitalizing on rapid technological improvements and decreasing costs of solar, wind, and battery technology. Doing so would slightly lower electricity supply costs, significantly reduce dependence on imported natural gas and coal, and dramatically cut power sector emissions. Further, this study finds that Korea’s power grid under a clean energy scenario will maintain reliability without coal generation or new natural gas plants. To realize these significant economic, environmental, and energy security benefits, policies such as an 80% clean electricity standard by 2035 and corresponding renewable energy deployment goals are required.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Conceptual Design of Pulverized Coal Electricity Generating Units for Flexible Operation

This National Energy Technology Laboratory (NETL) study addresses the conceptual design of greenfield pulverized coal (PC) plants intended for flexible rather than high capacity factor baseload operation. The United States has plentiful, low-cost natural gas resources - studies of aggressive decarbonization scenarios of the US energy sector suggest that the variability of carbon-free power can be economically addressed using dispatchable natural gas-fueled generation. Globally, natural gas resources are not as plentiful or low cost; consequently, some regions of the world are anticipated to continue to rely upon coal generation, even as they pursue decarbonization efforts. To support the increased utilization of variable renewable generation in these coal-dependent regions, plant designs must target low-capacity factor coal plants with increased emphasis on flexibility attributes such as start-up times, ramp rates, minimum load, and part-load heat rates. While much work has been performed on the improvement of the flexibility for existing coal plants originally designed for baseload service, little public literature exists on clean sheet design for flexible operation. This conceptual design study aims to define the features, performance characteristics, and costs for greenfield coal plants intended for flexible operation. Quantifying these characteristics provides critical information required by utility owners, grid planners, energy market modelers, and energy policy decision makers in coal-dependent regions of the world to better understand how coal-fired power plants can support a transition to low carbon generation.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Natural gas shortages during the “coal-to-gas” transition in China have caused a large redistribution of air pollution in winter 2017

The Chinese “coal-to-gas” and “coal-to-electricity” strategies aim at reducing dispersed coal consumption and related air pollution by promoting the use of clean and low-carbon fuels in northern China. Here, we show that on top of meteorological influences, the effective emission mitigation measures achieved an average decrease of fine particulate matter (PM 2.5 ) concentrations of ~14% in Beijing and surrounding areas (the “2+26” pilot cities) in winter 2017 compared to the same period of 2016, where the dispersed coal control measures contributed ~60% of the total PM 2.5 reductions. However, the localized air quality improvement was accompanied by a contemporaneous~15% upsurge of PM 2.5 concentrations over large areas in southern China. We find that the pollution transfer that resulted from a shift in emissions was of a high likelihood caused by a natural gas shortage in the south due to the coal-to-gas transition in the north. The overall shortage of natural gas greatly jeopardized the air quality benefits of the coal-to-gas strategy in winter 2017 and reflects structural challenges and potential threats in China’s clean-energy transition.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Lignite-Derived Carbon Materials for Lithium-Ion Battery Anodes

This project involved collaboration between the University of North Dakota (UND) College of Engineering & Mines, Clean Republic, LLC (CR), and the North American Coal Corporation (NACoal) to develop advanced LIBs anodes from lignite-derived carbon materials. The overall goal of the project was to develop advanced anode materials for LIBs from lignite-derived carbon feedstocks.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Funding a Just Transition Away from Coal in the U.S. Considering Avoided Damage from Air Pollution

Abstract Coal is declining in the U.S. as part of the clean energy transition, resulting in remarkable air pollution benefits for the American public and significant costs for the industry. Using the AP3 integrated assessment model, we estimate that fewer emissions of sulfur dioxide, nitrogen oxides, and primary fine particulate matter driven by coal’s decline led to $300 billion in benefits from 2014 to 2019. Conversely, we find that job losses driven by less coal plant and mining activity resulted in $7.84 billion in foregone wages over the same timeframe. While the benefits were greatly distributed (mostly throughout the East), costs were highly concentrated in coal communities. Transferring a small fraction of the benefits to workers could cover these costs while maintaining societal net benefits. Forecasting coal fleet damages from 2020 to 2035, we find that buying out or replacing these plants would result in $589 billion in air quality benefits, which considerably outweigh the costs. The return on investment increases when policy targets the most damaging capacity, and net benefits are maximized when removing just facilities where marginal benefits exceed marginal costs. Evaluating competitive reverse auction policy designs akin to Germany’s Coal Exit Act, we find that adjusting bids based on monetary damages rather than based only on carbon dioxide emissions – the German design – provides a welfare advantage. Our benefit–cost analyses clearly support policies that drive a swift and just transition away from coal, thereby clearing the air while supporting communities needing assistance.

Dennin, Luke R. (ORCID:0000000205405520)↗
DOE OSTI2017

Reinventing Design Principles for Developing Low-Viscosity Carbon Dioxide-Binding Organic Liquids for Flue Gas Clean Up

Anthropogenic carbon dioxide (CO 2 ) emission from point sources, such as coal fired-power plants, account for the majority of the green houses gasses in the atmosphere. Capture, storage and utilization are required to mitigate adverse environmental effects. Aqueous amine-based CO 2 capture solvents are currently considered the industry standard, but deployment to market is limited by their high regeneration energy demand. In that context, energy efficient and less-viscous water-lean transformational solvent systems known as CO 2 Binding Organic Liquids (CO 2 BOLs) are being developed in our group to advance this technology to commercialization. Herein, we present a logical design approach based on fundamental concepts of organic chemistry and computer simulations aimed at lowering solvent viscosity. Conceptually, viscosity reduction would be achieved by systemmatic methods such as introduction of steric hindrance on the anion to minimize the intermolecular cation-anion interactions, fine tuning the electronics, hydrogen bonding orientation and strength, and charge solvation. Conventional standard trial-and-error approaches while effective, are time consuming and economically expensive. Herein, we rethink the metrics and design principles of low-viscosity CO 2 capture solvents using a combined synthesis and computational modeling approach. We critically study the impacts of modyfying factors such as as orientation of hydrogen bonding, introduction of higher degrees of freedom and cation or anion charge solvation and assess if or how each factor impacts viscosity of CO 2 BOL CO 2 capture solvents. Ultimately, we found that hydrogen bond orientation and strength is predominantly influencing the viscosity in CO 2 BOL solvents. With this knowledge, a new 1-MEIPADM-2-BOL CO 2 BOL variant was synthesized and tested, resulting in a solvent that is approximately 60% less viscous at 25 mol% CO 2 loading with respect to our base compound 1-IPADM-2-BOL. The insights gained from the current study redefines the fundamental concepts and understanding of what influences viscosity in concentrated organic CO 2 capture solvents.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1973

Operating Room Environment Control. Part A: a Valve Cannister System for Anesthetic Gas Adsorption. Part B: a State-of-the-art Survey of Laminar Flow Operating Rooms. Part C: Three Laminar Flow Experiments

An anesthetic gas flow pop-off valve canister is described that is airtight and permits the patient to breath freely. Once its release mechanism is activated, the exhaust gases are collected at a hose adapter and passed through activated coal for adsorption. A survey of laminar air flow clean rooms is presented and the installation of laminar cross flow air systems in operating rooms is recommended. Laminar flow ventilation experiments determine drying period evaporation rates for chicken intestines, sponges, and sections of pig stomach.

Meyer, J. S.↗
DOE OSTI2022

Design for Carbon Conversion Product Pathways with Nuclear Power Plant Integration (PCC)

Coal is a globally abundant resource that historically has been used for power generation via combustion. As the power industry replaces coal with cleaner methods of generation, energy rich coal could be used in other chemical and fuel applications. This study presents a coal utilization option in which coal combustion is replaced with a carbon-free nuclear power plant and the coal is upgraded to valuable products for a variety of markets. Coal is prepared for conversion first by the pyrolysis process, which will optimize solid, liquid, and gaseous products based on the market size and potential product value, maximizing the monetary value of coal. This process is designed using bituminous coal from the Appalachian region as a basis to provide a pathway to preserve or transition coal-related jobs and create new jobs associated with the clean energy transition. Process modeling will be used to determine each component’s sensitivities, costs, inputs, and outputs Advanced and light-water reactors are considerations to supply the heat, steam, and electricity to the process. This paper focuses on the technical and market analysis used to determine the optimal processes and product pathways for the carbon refinery. Product pathways are on activated carbon, formic acid synthesis, and methanol synthesis for further upgrading to marketable chemical and polymer products.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

M2CT-22IN1202096 Design for Carbon Conversion Product Pathways with Nuclear Power Plant Integration

Coal is a globally abundant resource that historically has been used for power generation via combustion. As the power industry replaces coal with cleaner methods of generation, energy-rich coal could be used in other chemical and fuel applications. This study presents a coal utilization option in which coal combustion is replaced with a carbon-free nuclear power plant and the coal is upgraded to valuable products for a variety of markets. Coal is prepared for conversion first by the pyrolysis process, which will optimize solid, liquid, and gaseous products based on the market size and potential product value, maximizing the monetary value of coal. This process is designed using bituminous coal from the Appalachian region as a basis to provide a pathway to preserve or transition coal-related jobs and create new jobs associated with the clean energy transition. Process modeling in the AspenOne Suite will be used to determine each component’s sensitivities, costs, inputs, and outputs. Dispatch modeling in the FORCE toolset will optimize the entire system and calculate the NPV for the refinery lifetime. Advanced and light-water reactors are considerations to supply the heat, steam, and electricity to the process. This paper focuses on the technical and market analysis used to determine the optimal processes and product pathways for the carbon refinery. Product pathways are on activated carbon, formic acid synthesis, and methanol synthesis for further upgrading to marketable chemical and polymer products.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

M2CT-22IN1202096 Design for Carbon Conversion Product Pathways with Nuclear Power Plant Integration

Coal is a globally abundant resource that historically has been used for power generation via combustion. As the power industry replaces coal with cleaner methods of generation, energy-rich coal could be used in other chemical and fuel applications. This study presents a coal utilization option in which coal combustion is replaced with a carbon-free nuclear power plant and the coal is upgraded to valuable products for a variety of markets. Coal is prepared for conversion first by the pyrolysis process, which will optimize solid, liquid, and gaseous products based on the market size and potential product value, maximizing the monetary value of coal. This process is designed using bituminous coal from the Appalachian region as a basis to provide a pathway to preserve or transition coal-related jobs and create new jobs associated with the clean energy transition. Process modeling in the AspenOne Suite will be used to determine each component’s sensitivities, costs, inputs, and outputs. Dispatch modeling in the FORCE toolset will optimize the entire system and calculate the NPV for the refinery lifetime. Advanced and light-water reactors are considerations to supply the heat, steam, and electricity to the process. This paper focuses on the technical and market analysis used to determine the optimal processes and product pathways for the carbon refinery. Product pathways are on activated carbon, formic acid synthesis, and methanol synthesis for further upgrading to marketable chemical and polymer products.

01 COAL, LIGNITE, AND PEAT↗