Engineering topics

Fulton, Don

Publications and source records attributed to Fulton, Don.

3 records

DOE OSTI2018

Integrated Testing of a Membrane CO 2 Capture Process with a Coal-Fired Boiler

This final technical report describes work conducted by Membrane Technology and Research, Inc. (MTR) for the Department of Energy, National Energy Technology Laboratory (DOE NETL) to demonstrate integrated operation of the MTR small pilot membrane CO 2 capture system with Babcock & Wilcox Enterprises, Inc.’s (B&W) Small Boiler Simulator-II (SBS-II) pilot coal boiler (award number DE-FE0026414). The work was performed from July 1, 2015 through March 31, 2018. The overall goal of this project was to operate the existing MTR small pilot membrane CO 2 capture system at an appropriately-sized coal-fired boiler to test integrated operation with CO 2 recycle to the boiler. MTR was assisted in this project by B&W, which hosted the integrated membrane-boiler field test at the B&W Research Facility in Barberton, OH. This report details the work performed to prepare the B&W site, modify the existing MTR membrane system, install the MTR system at B&W, and operate an integrated membrane-boiler field test with CO 2 recycle to the boiler. Detailed analysis of the integrated membrane-boiler test data was conducted to validate prior B&W computational fluid dynamics (CFD) modeling and SBS-II boiler tests with CO 2 -laden air that showed modest effects of recycled CO 2 on boiler performance. The integrated test results also demonstrated how various membrane parameters impact the performance of a dynamic boiler system. Key results for all tasks and recommendations for future research are discussed in this report.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2015

Pilot testing of a membrane system for postcombustion CO 2 capture

This final report summarizes work conducted for the U.S. Department of Energy, National Energy Technology Laboratory (DOE) to scale up an efficient post-combustion CO 2 capture membrane process to the small pilot test stage (award number DE-FE0005795). The primary goal of this research program was to design, fabricate, and operate a membrane CO 2 capture system to treat coal-derived flue gas containing 20 tonnes CO 2 /day (20 TPD). Membrane Technology and Research (MTR) conducted this project in collaboration with Babcock and Wilcox (B&W), the Electric Power Research Institute (EPRI), WorleyParsons (WP), the Illinois Sustainable Technology Center (ISTC), Enerkem (EK), and the National Carbon Capture Center (NCCC). In addition to the small pilot design, build and slipstream testing at NCCC, other project efforts included laboratory membrane and module development at MTR, validation field testing on a 1 TPD membrane system at NCCC, boiler modeling and testing at B&W, a techno-economic analysis (TEA) by EPRI/WP, a case study of the membrane technology applied to a ~20 MWe power plant by ISTC, and an industrial CO 2 capture test at an Enerkem waste-to-biofuel facility. The 20 TPD small pilot membrane system built in this project successfully completed over 1,000 hours of operation treating flue gas at NCCC. The Polaris™ membranes used on this system demonstrated stable performance, and when combined with over 10,000 hours of operation at NCCC on a 1 TPD system, the risk associated with uncertainty in the durability of postcombustion capture membranes has been greatly reduced. Moreover, next-generation Polaris membranes with higher performance and lower cost were validation tested on the 1 TPD system. The 20 TPD system also demonstrated successful operation of a new low-pressure-drop sweep module that will reduce parasitic energy losses at full scale by as much as 10 MWe. In modeling and pilot boiler testing, B&W confirmed the viability of CO 2 recycle to the boiler as envisioned in the MTR process design. The impact of this CO 2 recycle on boiler efficiency was quantified and incorporated into a TEA of the membrane capture process applied to a full-scale power plant. As with previous studies, the TEA showed the membrane process to be lower cost than the conventional solvent capture process even at 90% CO 2 capture. A sensitivity study indicates that the membrane capture cost decreases significantly if the 90% capture requirement is relaxed. Depending on the process design, a minimum capture cost is achieved at 30-60% capture, values that would meet proposed CO 2 emission regulations for coal-fired power plants. In summary, this project has successfully advanced the MTR membrane capture process through small pilot testing (technology readiness level 6). The technology is ready for future scale-up to the 10 MWe size.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2015

Low-pressure

This final technical progress report describes work conducted by Membrane Technology and Research, Inc. (MTR) for the Department of Energy (DOE NETL) on development of low-pressure membrane contactors for carbon dioxide (CO 2 ) capture from power plant flue gas (award number DE-FE0007553). The work was conducted from October 1, 2011 through September 30, 2014. The overall goal of this three-year project was to build and operate a prototype 500 m 2 low-pressure sweep membrane module specifically designed to separate CO 2 from coal-fired power plant flue gas. MTR was assisted in this project by a research group at the University of Toledo, which contributed to the computational fluid dynamics (CFD) analysis of module design and process simulation. This report details the work conducted to develop a new type of membrane contactor specifically designed for the high-gas-flow, low-pressure, countercurrent sweep operation required for affordable membrane-based CO 2 capture at coal power plants. Work for this project included module development and testing, design and assembly of a large membrane module test unit at MTR, CFD comparative analysis of cross-flow, countercurrent, and novel partial-countercurrent sweep membrane module designs, CFD analysis of membrane spacers, design and fabrication of a 500 m 2 membrane module skid for field tests, a detailed performance and cost analysis of the MTR CO 2 capture process with low-pressure sweep modules, and a process design analysis of a membrane-hybrid separation process for CO 2 removal from coal-fired flue gas. Key results for each major task are discussed in the report.

42 ENGINEERING↗