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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

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Electrochemically Enhanced Carbonate Precipitation into Building Materials: A Scalable Carbon Sequestration Strategy

Decarbonization goals across hard-to-abate industries have prompted an urgent need for advanced carbon capture and storage technologies. Sequestering CO2 into carbonate minerals is a scalable method of carbon management with the ability to produce value-added carbon negative materials from waste streams for the construction industry. Waste streams rich in Ca and Mg such as nickel mine tailings, iron/steel slag, and reverse osmosis brines can store 7.6 Mt CO2/year as minerals. Additionally, CO2 mineralization in acid-neutralization processes currently present in industrial waste treatment can eliminate associated CO2 emissions of lime processing by improving process circularity. The carbonate minerals formed from these waste sources are valuable as components of carbon-negative concrete, which have the potential to sequester 1.8 billion Mt of CO2/year. Electrochemical means of CO2 mineralization improves the kinetics of the thermodynamically favorable mineralization process, lessening or eliminating the high energy requirements of traditional methods. Here, we investigate benchtop scale electrochemical CO2 mineralization of alkaline mining waste, highlighting the effects of key constituents in mining waste on the mineralization process.

carbon capture↗

DOE OSTI2023

Blue Bison ATR Advanced CCUS System (Final Report)

The objective of this project was to design a carbon capture system that could be installed on a 220 MMSCFD blue hydrogen (Blue H 2 ) facility (Blue H 2 Plant) utilizing auto-thermal reforming (ATR) technology and identify potential sequestration options for the carbon dioxide (CO 2 ) produced from the Blue H 2 Plant.

08 HYDROGEN↗

DOE OSTI2022

Molecular-scale mechanisms of CO 2 mineralization in nanoscale interfacial water films

The calamitous impacts of untethered carbon emission from fossil-fuel-burning energy infrastructure calls for accelerated development of large-scale CO 2 capture, utilization, and storage technologies that are underpinned by fundamental understanding of molecular-level chemical processes. In the subsurface, rocks rich in divalent metals can react with CO 2 , permanently sequestering it in the form of stable metal carbonate minerals, with the CO 2 -H 2 O composition of the post-injection pore fluid acting as a primary control variable. Herein, we compare mechanistic reaction pathways for aqueous-mediated carbonation with carbon mineralization occurring in nanoscale adsorbed water films. In the extreme of pores filled with a CO 2 -dominant fluid, carbonation reactions are confined to nanometer-thick water films coating mineral surfaces, which enable metal cation release, transport, nucleation, and crystallization of metal carbonate minerals. Though seemingly counterintuitive, laboratory studies have demonstrated facile carbonation rates in these low water environments, which in recent years has begun to be better understood in mechanistic detail. The overarching objective of this review is to delineate the unique underlying molecular-scale reaction mechanisms that govern CO 2 mineralization in these reactive and dynamic quasi-2D interfaces. Here. we highlight the importance of understanding unique properties in thin water films, such as how water dielectric properties, and consequently ion solvation/hydration behavior, can change under nanoconfinement. We conclude by identifying important frontiers for future work and opportunities to exploit these fundamental chemical insights for decarbonization technologies in the 21st century.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Production of CO2-Negative Building Composites Development

This project will investigate and utilize the basicity and enhanced reactivity of CO2 chemically captured in PNNL’s CO2BOLs carbon capture solvents to perform the first direct carboxylation of the aromatic rings (substituted phenols) in lignin and lignite. This project aims to develop a deep decarbonization approach that can sequester millions of tonnes of CO2 annually by reacting with two large-volume products, lignin, and lignite, to enable their use as composite fillers. The goal is to demonstrate that CO2-containing composites have comparable properties to conventional synthetic materials, meeting international building codes (IBC) while being able to sequester millions of tonnes of CO2 per year.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Abstract for CRADA between NETL and Georgia Tech Research Corporation (GTRC) (AGMT-1276)

Patent-pending chemisorption fiber sorbents (CHEFS) utilizing robust, patented basic immobilized amine sorbents (BIAS) are the newest innovation in carbon capture technology. This suite of fiber materials offers reliable and rapid removal of CO2 from both conventional post-combustion sources, like coal-fired power plants, and dilute air sources like those of newly recognized direct capture from air (DAC, 400 ppm CO2). Through this Cooperative Research and Development Agreement (CRADA), NETL and GTRC aim to improve and refine the fiber formulations and synthesis methods, while pushing towards scaling fiber production and testing in a pilot/semi-pilot scale 1,000-fiber module adsorption system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Moving beyond 90% Carbon Capture by Highly Selective Membrane Processes

A membrane-based system with a retentate recycle process in tandem with an enriching cascade was studied for >90% carbon capture from coal flue gas. A highly CO 2 -selective facilitated transport membrane (FTM) was utilized particularly to enhance the CO 2 separation efficiency from the CO 2 -lean gases for a high capture degree. A techno-economic analysis showed that the retentate recycle process was advantageous for ≤90% capture owing to the reduced parasitic energy consumption and membrane area. At >90% capture, the enriching cascade outperformed the retentate recycle process since a higher feed-to-permeate pressure ratio could be applied. An overall 99% capture degree could be achieved by combining the two processes, which yielded a low capture cost of USD47.2/tonne, whereas that would be USD 42.0/tonne for 90% capture. This FTM-based approach for deep carbon capture and storage can direct air capture for the mitigation of carbon emissions in the energy sector.

42 ENGINEERING↗

DOE OSTI2023

Coupled Hydromechanical Modeling and Assessment of Induced Seismicity at FWU: Utilizing Time-Lapse VSP and Microseismic Data

The objective of this work is to utilize integrated geomechanics, field vertical seismic profile (VSP) and microseismic data to characterize the complex subsurface stress conditions at the Farnsworth Unit (FWU). The model is based on a five-spot sector model extracted from a primary geomechanical model. The five-spot well injection pattern is characterized by extensive reservoir characterization data, such well logs, extracted cores and borehole geophone data, to facilitate the detailed examination of stress changes and microseismic event occurrences. The study utilizes field vertical seismic volumes acquired from the injection well 13-10A. The seismic volumes successfully provided snapshots of the behavior of the reservoir at distinct times. The use of VSP and microseismic data provided direct and indirect estimates of the dynamic stress changes occurring in the overburden, reservoir and underburden rock formations. In order to illuminate the stress regions and identify rocks that have undergone inelastic failure, microseismic event occurrences were utilized. Microseismic activity has been detected at the FWU; further study of its locations, timing, and magnitude was needed to deduce the nature of the changing stress state. The results of the study revealed that microseismic events were successfully modeled within the Morrow B formation. Moment magnitudes of seismic events were within the same magnitudes for events in the reservoir, suggesting the suitability of the model. The results of the study showed that the computed moment magnitudes for seismic events were insignificant to warrant safety concerns. The study findings showed the usefulness of coupled hydromechanical models in predicting the subsurface stress changes associated with CO 2 injection. The knowledge gained from this study will serve as a guideline for industries planning to undertake underground CO 2 storage, and characterize the subsurface stress changes.

02 PETROLEUM↗

DOE OSTI2023

An algal-bacterial symbiotic system of carbon fixation using formate as a carbon source

The commercial implementation of algal cultures for efficient capture of CO 2 from fossil-derived flue gases is not a reality yet due to several major challenges, particularly low gas-liquid mass transport efficiency along with loss of productivity due to pests. This study has explored an algal-bacterial symbiotic system to utilize formate as a carbon source. The algal-bacterial assemblage, after a 400-day adaptive evolution using the formate medium, has demonstrated a new capability to assimilate both formate and CO 2 to promote biomass production. The formate tolerant culture system also addresses CO 2 mass transfer limitation under high light conditions. Continuous cultivation of the assemblage on formate led to a carbon capture efficiency of 90 % with a biomass concentration of 0.92 g L -1 and biomass productivity of 0.31 g L -1 day -1 , and the system did not require CO 2 aeration. In addition, 13 C isotope tracing, proteomics, and microbial community analysis reveal a uniquely evolved community for formate utilizations and robust biomass synthesis, in which Chlorella sorokiniana is a dominant phototroph companying with highly diverse bacterial subpopulations. In the presence of formate, evidence has shown that Chlorella is able to form mutualism with formate utilizing bacteria in semi-continuous cultures, leading to a highly effective photomixotrophic metabolism. Furthermore, this study demonstrates a new route of using electrochemical-derived formate to support mutualistic algae-bacteria biorefinery while the formate as an alternative carbon source could repel pests for outdoor algal cultivations.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Environmental, Health and Safety Assessment Application of a Heat Integrated, Post-combustion CO2 Capture System Using Monoethanolamine and Hitachi H3-1 Solvent at the E.W. Brown Coal-fired Power Plant

An Environmental Health and Safety (EH&S) Assessment was completed for operation of a pilot scale carbon dioxide (CO2) capture system (CCS) at the Louisville Gas & Electric (LG&E) and Kentucky Utilities (KU) Energy, LLC (LG&E-KU) E. W. Brown Generating Station in Harrodsburg, Mercer County, Kentucky. The pilot system was evaluated using two CO2 capture solvents, monoethanolamine (MEA) and Hitachi’s H3-1 solvent. The purpose of the EH&S Assessment was to determine if there were any unacceptable environmental, health or safety concerns that may prevent operation or environmental permitting of a larger scale pilot scale plant. The assessment included review of process flow diagrams, input and output flow rates for primary materials, literature describing similar processes and chemicals used or created during the process, actual air emission and wastewater test data and air emission calculations. The evaluation included identification of risks related to hazardous chemicals, air emissions, wastewater discharges, solid wastes generated and employee hazards. Most potential EH&S issues that were identified are commonly found and successfully managed at large industrial facilities. No risks were identified that could not be successfully managed or would likely prevent implementation or environmental permitting of the pilot or larger scale plant. Potential exposures and resulting health risks from exposure to low concentrations of nitrosamines generated from degradation of the Hitachi H3-1 and possibly MEA solvents may be a health concern for site workers, but additional investigation is needed to accurately assess this risk. Applying the information gained from operating the pilot plant, performing air emission testing and used solvent testing to a large-scale facility at a commercial coal-fired electric generating plant suggests additional air emission control measures may be necessary to reduce potential site worker health risks and possibly community risks. Depending upon the location and regional air quality, considerable effort may be required to obtain the necessary air permit for construction and operation of a similarly configured large-scale PCCCS facility.

gas separation↗

DOE OSTI2025

Integration of renewable energy generation and storage systems for emissions reduction in an islanded campus microgrid

Microgrid connected building communities are projected to play an integral part in the clean energy transition. These types of systems, when integrated with distributed energy resources (DERs) such as combined heat and power (CHP), district heating and cooling, renewable generation, and energy storage, can provide clean, reliable power to critical facilities and vulnerable communities. The intermittent nature of renewable generation is a challenge when integrating renewables into any grid system, but particularly in islanded microgrids. The University of Texas at Austin (UT) operates an islanded microgrid powered by a CHP plant, while also utilizing district heating and cooling systems and thermal energy storage (TES). High fidelity operating data was used to develop a validated reduced order model of UT’s integrated campus energy systems to serve as a testbed for use in a case study. Hypothetical renewable energy installations on land owned by UT in west Texas were modeled and integrated into the validated campus models along with battery energy storage (BES). Simulations showed that a combination of renewable energy from wind, and optimally controlled 24-hour thermal and battery storage systems could reduce carbon dioxide emissions on campus by 45.4%. The additional retrofit of burner systems to utilize hydrogen natural gas blends resulted in an overall annual emissions reduction of 54.7%. Carbon capture and storage eliminated the majority of the remaining emissions with increased plant energy expenditure. The presented simulations display the practical limitations of a CHP system complemented by renewable generation and short-term storage in eliminating emissions. Furthermore, results highlight the need for further research and development in long duration storage technologies and hydrogen fueled turbines to increase penetration of renewable energy and reduce emissions.

CHP↗

DOE OSTI2022

Techno-Economic Analysis of Natural Gas Fuel Cell Plant Configurations

The United States (U.S.) Department of Energy (DOE) Office of Fossil Energy and Carbon Management (FECM) and the National Energy Technology Laboratory (NETL) have been pursuing the development of solid oxide fuel cell (SOFC) technology to enable future power generation systems that are consistent with the cornerstones of the DOE mission—to ensure America’s security and prosperity by addressing its energy and environmental challenges through transformative science and technology solutions. The U.S. DOE FECM SOFC Program is currently focused on the development of low-cost, highly efficient, and reliable SOFC power systems. NETL’s SOFC technology development roadmap is aligned with near-term market opportunities in the distributed generation sector to validate and advance the technology while paving the way for utility-scale (> 50 MW) natural gas and coal-derived synthesis gas-fueled applications via progressively larger system demonstrations. The present study represents a part of a series of system evaluations being developed at NETL to aid in prioritizing technological advances along research pathways to the realization of utility-scale SOFC systems, a transformational goal of the fuel cell program. In particular, the system performance of utility-scale natural gas fuel cell (NGFC) systems with and without carbon dioxide (CO 2 ) capture is presented. The objective of the study is to provide targeted research and development (R&D) guidance to the FECM SOFC Program and SOFC commercial developers to accelerate technology deployment.

03 NATURAL GAS↗

DOE OSTI2022

Cost and Performance Baseline for Fossil Energy Plants, Volume 3 – Low Rank Coal and Natural Gas to Electricity

Presentation by the National Energy Technology Laboratory (NETL) on performance and cost results of utilizing low rank coals and natural gas to produce electricity, including the effects of carbon capture. The coal plants are located in elevated terrain, and the natural gas plants are sited in the same conditions to allow comparability of elevation impacts. The study reports on overall performance of both fuel types, without and with carbon capture, and gives comparisons of the levelized cost of electricity for each unit. This presentation was given at the 2022 Pittsburgh Coal Conference.

James, III, Robert E.↗

DOE OSTI2026

Technoeconomic analysis and life cycle assessment of purification processes for captured CO 2 streams

Captured carbon dioxide (CO 2 ) streams contain impurities that must be removed to meet specifications for safe transport, storage, and utilization. Among these impurities, oxygen poses challenges due to its high reactivity and potential to cause corrosion, motivating stringent purity limits below 10 ppmv. Building on recent experimental demonstrations of catalytic oxygen removal using hydrogen (H 2 ), carbon monoxide (CO), methanol (CH 3 OH), and methane (CH 4 ) as reducing agents, this study presents a technoeconomic (TEA) and life cycle assessment (LCA) of these four catalytic purification pathways. Process flowsheets were developed and simulated in Aspen Plus for CO 2 streams representative of both low-temperature and high-temperature capture processes, with integrated heat recovery and energy optimization. Results showed that total purification costs were dominated by feedstock procurement and electricity consumption. Among the studied reducing agents, the CH 4 -assisted route achieved the lowest purification cost and highest CO 2 recovery. Sensitivity analyses showed that the H 2 route became competitive at H 2 prices below $\$$0.56/kg to $\$$0.84/kg, depending on the CO 2 feed temperature conditions. In conclusion, environmental impacts were primarily driven by indirect CO 2 emissions from raw material production and utility consumption.

CO2 pipeline specifications↗

DOE OSTI2022

Direct Air Capture and Sequestration of CO 2 by Accelerated Indirect Aqueous Mineral Carbonation under Ambient Conditions

Mineralization of gaseous carbon dioxide into solid carbonates using alkaline industrial residues such as coal fly ash has a dual advantage of reducing the carbon dioxide footprint of coal power plants and improving ash utilization. However, the slow mineral carbonation rate under atmospheric conditions is a major challenge, especially when using natural minerals or industrial residues for direct air capture (DAC) of CO 2 . In this study, using coal fly ash samples and concentrated alkali carbonate aqueous solutions as a recyclable solvent, we show the feasibility of coupling mineral carbonation with DAC under atmospheric conditions. Findings show that carbonation efficiency is best under alkaline conditions, achieving as high as ~80% conversion to calcium carbonates within 1 h in a 1.9 M sodium carbonate solution. Based on the experimental results, a process coupling DAC and mineral carbonation that operates entirely under ambient conditions is proposed. Here, the techno-economic and life cycle assessments for the proposed process project a levelized cost of $\$116$–133/t-CO 2 -sequestered (US $\$2019$) and process carbon emissions (GWP) in the range of 0.03–0.25 t-CO 2 e/t-CO 2 -sequestered. Considering the low cost, simplicity, and gigaton-scale sequestration potential, we believe that DAC based on alkaline industrial residue carbonation can be considered a “low-hanging fruit” in the pursuit of negative emissions to combat climate change.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Storage Field Development Plan: One Earth Energy

This Storage Field Development plan presents the Storage Complex characterization results, construction, monitoring, and operational plans, and costs associated with the proposed One Earth Sequestration Carbon Capture and Storage (OES-CCS) site in McLean County, Illinois, near Gibson City. The proposed storage complex, known as the Mt. Simon Storage Complex, comprises the Cambrian Mt. Simon Sandstone reservoir and the primary seal, the Cambrian Eau Claire Formation. The lowermost Underground Source of Drinking Water (USDW) identified for the site is the Ordovician St. Peter Sandstone. Geologic characterization of the Mt. Simon Storage Complex at the OES-CCS site was performed by the Illinois Storage Corridor CarbonSAFE Phase III project, which also prepared and submitted three UIC Class VI applications to construct three injection wells; the permit applications were submitted and are in the federal EPA review process. A characterization well, OEE #1, was drilled to collect site-specific data. These data were analyzed and used to develop the UIC Class VI applications. The OEE #1 well will be converted to an in-zone monitoring (IZM) well for the injection phase. The proposed buildout for the OES-CCS site includes (1) three injection wells (OES #1, OES #2, and OES #3), (2) two IZM wells, (3) two above confining zone (ACZ) monitoring wells, one of which will be used to monitor the lowermost USDW, (4) capture and compression facilities, and (5) transportation facilities, i.e., pipelines. A pre-operational testing program was proposed in the Class VI permit application and will be employed at the site pending approval. Additional pre-injection (baseline), syn-injection, and post-injection monitoring and site care procedures will be followed by OES to ensure that injection activities are protective of human health and the environment. Injection is scheduled to begin in 2025, distributed across the three injection wells in accordance with the permit operating conditions. One Earth Sequestration intends to inject up to 90 million tonnes of CO 2 over a period of approximately 20 years. Injection will begin at approximately 0.5 million tonnes of CO 2 annually and ramp up to a maximum of 4.5 million tonnes annually. Daily injection rates are expected to range from 1,400 to 1,500 tonnes per day initially and reach a maximum of approximately 4,225 tonnes per day, depending on site geology and injectivity at each injection well location, and CO 2 availability. The costs associated with the OES-CCS project include pre-operational costs (e. g. additional seismic data acquisition and well drilling), capture and transportation facility and equipment costs, predicted field operating expenditures (OpEx), and decommissioning and post-injection site care (PISC) costs. The risks associated with project activities, such as site construction, injection operations, and verification of secure storage were evaluated, and mitigation strategies proposed to alleviate those risks.

09 BIOMASS FUELS↗

DOE OSTI2020

Environmental, Health and Safety Assessment Application of a Heat Integrated, Post-combustion CO 2 Capture System Using Monoethanolamine and Hitachi H3-1 Solvent at the E.W. Brown Coal-Fired Power Plant

An Environmental Health and Safety (EH&S) Assessment was completed for operation of a pilot scale carbon dioxide (CO 2 ) capture system (CCS) at the Louisville Gas & Electric (LG&E) and Kentucky Utilities (KU) Energy, LLC (LG&E-KU) E. W. Brown Generating Station in Harrodsburg, Mercer County, Kentucky. The pilot system was evaluated using two CO 2 capture solvents, monoethanolamine (MEA) and Hitachi’s H3-1 solvent. The purpose of the EH&S Assessment was to determine if there were any unacceptable environmental, health or safety concerns that may prevent operation or environmental permitting of a larger scale pilot scale plant. The assessment included review of process flow diagrams, input and output flow rates for primary materials, literature describing similar processes and chemicals used or created during the process, actual air emission and wastewater test data and air emission calculations. The evaluation included identification of risks related to hazardous chemicals, air emissions, wastewater discharges, solid wastes generated and employee hazards. Most potential EH&S issues that were identified are commonly found and successfully managed at large industrial facilities. No risks were identified that could not be successfully managed or would likely prevent implementation or environmental permitting of the pilot or larger scale plant. Potential exposures and resulting health risks from exposure to low concentrations of nitrosamines generated from degradation of the Hitachi H3-1 and possibly MEA solvents may be a health concern for site workers, but additional investigation is needed to accurately assess this risk. Applying the information gained from operating the pilot plant, performing air emission testing and used solvent testing to a large-scale facility at a commercial coal-fired electric generating plant suggests additional air emission control measures may be necessary to reduce potential site worker health risks and possibly community risks. Depending upon the location and regional air quality, considerable effort may be required to obtain the necessary air permit for construction and operation of a similarly configured large-scale PCCCS facility.

gas separation↗