Pilot Testing of a Highly Efficient Pre-combustion Sorbent-based Carbon Capture System
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Engineering topics
Gribble, David
Publications and source records attributed to Gribble, David.
Demo-scale testing of a hybrid membrane-sorbent system for post-combustion CO2 capture
TDA Research is developing a novel hybrid membrane-sorbent system for the post-combustion capture of carbon dioxide (CO 2 ) from supercritical pulverized coal (PC) power generation facilities or large point industrial emitters. Here, the novel design incorporates a 1st-stage continuous membrane separator developed by Membrane Technology and Research, Inc. (MTR) with a dual-bed radial-flow sorbent contactor (designed and developed at TDA). Testing of a pilot unit at 1 MWe scale has been conducted at the site for emerging technologies at the Technology Centre Mongstad (TCM) in Mongstad, Norway using residue fluid catalytic cracker (RFCC) flue gas from Equinor’s Mongstad refinery.
20 FOSSIL-FUELED POWER PLANTS↗
A Novel Process for Carbon Dioxide Conversion to Fuel
In this project, TDA developed a new mixed metal oxide-based sorbent that converts CO2 (captured from coal fired power plants) to CO, which can then be combined with renewable H2 generated by water electrolysis or H2 from steam methane reforming to produce different liquid fuels. TDA’s absorbent-based CO2 conversion process uses a redox process, which splits the catalytic reforming of methane with CO2 reaction into two stages: CO2 reduction to CO and CH4 reforming into H2 and CO which eliminates the equilibrium limitations. The CO produced in the two-stage reactor system can then be further reacted with renewable H2 to produce methanol, naphtha, diesel, or gasoline. We worked with the Advanced Power & Energy Program (APEP) of University of California, Irvine (UCI) to design and develop the liquid fuel synthesis process that is built around this new material. We demonstrated the techno-economic viability of the new sorbent based redox process to convert CO2 into synthesis gas by demonstrating continuous carbon dioxide reduction in a prototype test system for over 585 hours while converting up to 10 kg CO2/day. With the successful completion of the R&D effort, the technology is now ready for a larger pilot-scale demonstration and the technology readiness has been raised from TRL 3 to TRL 5. In collaboration with UCI, we completed a high-fidelity process design and economic analysis. The required sale price (RSP) for gasoline (Case 1 NG-MTG) is $4.91/gal and naphtha and diesel (Case 2 NG-FT) are $4.23/gal and $6.07/gal, respectively, on a 2011 dollar basis. To put these costs in perspective, the California prices in current dollars (with its strict specifications) for regular grade gasoline from last year to current year have varied from a low of $3.10/gal in January 2021 to a high of $5.76/gal in March 2022, while prices for diesel from last year to current year have varied from a low of $3.40/gal in January 2021 to a high of $6.41/gal in May 2022 according to the U.S. Energy Information Agency data. It should be noted that the gasoline and diesel produced by these designs of Case 1 and Case 2 would be of very high quality and both nitrogen and sulfur free. These RSPs are based on a cost of imported electricity of $64/MWh based on the low-end current wind generated electricity cost (Genevieve 2011). This cost is by far the largest component of the variable costs used in computing the RSPs. A sensitivity analysis of these RSPs to the cost of imported electricity shows that the cost of the imported electricity has a significant effect on the RSPs. The life cycle analysis (LCA) shows that the total cradle-to-gate CO2 emissions for both liquid fuels (diesel and gasoline) were negative, indicating that overall more CO2 is consumed than released during production of the fuel from CO2 feed stack for both cases (-296 kgCO2 per MT gasoline for Case 1 and -705 kgCO2 per MT diesel for Case 2). On a cradle-to-grave comparison, the use of diesel produced using TDA’s process (2,457 kgCO2 per MT diesel) would release 37.6% less CO2 compared to petroleum based diesel (3,937 kgCO2 per MT diesel) while the use of gasoline produced using TDA’s process (2,792 kgCO2 per MT gasoline) would release 29.3% less CO2 compared to petroleum based gasoline (3,946 kgCO2 per MT gasoline). With the successful completion of the R&D effort, the technology is now ready for a bench-scale demonstration and the technology readiness has been raised from TRL 3 (Analytical and experimental critical function and/or characteristic proof of concept) to TRL 5 (Laboratory scale similar system validation in relevant environment).
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Integrated Water-Gas-Shift Pre-combustion Carbon Capture Process
TDA Research, Inc (TDA) has developed a highly efficient integrated WGS pre-combustion carbon capture technology and demonstrated its techno-economic viability for use in the Integrated Gasification Combined Cycle (IGCC) power plants that process coal. The new system uses a warm gas CO 2 scrubber integrated with a Water-Gas-Shift (WGS) catalyst to capture greater than 90% of the carbon emissions, which does not increase the cost of electricity (COE) as much as conventional carbon capture technologies.
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