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At least 325 records · Page 18

Techno-Economic Analysis of Synthetic Fuels Pathways Integrated with Light Water Reactors

The purpose of this work is to identify, model, and compare two possible synfuel production routes utilizing CO 2 as the feedstock. Heat from an LWR nuclear plant is integrated wherever possible as a means to positively affect the economics of the LWR. Process and economic modeling for a conceptual synfuel production plant co-located (or in near proximity) with an LWR is presented, including the cost of CO 2 captured from an ethanol plant, compressed, and transported to the LWR hybrid plant, co-electrolysis of the CO 2 with water in a solid oxide electrolyzing cell (SOEC) system to produce syngas, and thermo-catalytic conversion of the syngas to transportation fuel. The hybrid LWR/synfuels plant is assumed to be located within 50-150 miles of an ethanol plant, e.g., located in the Midwest region of the United States. Performance and nth plant economics for the co-electrolysis-based processes are evaluated and compared with biomass-gasification-based technology for the synfuel routes considered. Sensitivity analysis around the price of CO 2 and electricity, two of the major cost drivers, is presented for each case. Consideration of a carbon credit is also included in the sensitivity analysis.

08 HYDROGEN↗

Metal-Supported Ceria Electrolyte-based SOFC Stack for Scalable, Low-Cost, High-Efficiency and Robust Stationary Power Systems (Final Report)

This is the end of project report for the DOE Project DE-FE-0027844 “Metal-Supported Ceria Electrolyte-based SOFC Stack for Scalable, Low-Cost, High-Efficiency and Robust Stationary Power Systems”. The objectives of the project were to develop several technologies required for the mass adoption of Solid Oxide Fuel Cell systems for medium to large power generation applications. The key achievements of this project were: 1) Development of fuel cells with complete internal fuel reforming capability. 2) Fuel cell power scale up with production of cells with larger active areas. 3) Assembly of an integrated 5 kW modular stack platform capable of installation into medium to large power systems. 4) Demonstration of a 10 kW Fuel Cell Power System utilizing the integrated 5 kW modular stack platform. 5) Cost modelling to show system cost of $1,500/kW are achievable at production volumes. 6) Development of cathode air poison getters for reduced degradation and extended fuel cell life. 7) Assessment of fuel poison on anode degradation, particularly poisons frequently produced from the process of gasification of coal. The Cummins led Voice of Customer (VOC) work identified several significant markets for natural gas powered fuel cell systems, where the end customer is interested in reducing energy consumption and emissions, or increasing reliability of electrical supply. Data centers and truck Auxiliary Power Units (APU) were highlighted as 2 key future markets for fuel cell systems.

30 DIRECT ENERGY CONVERSION↗

Techno-Economic Analysis of Synthetic Fuels Pathways Integrated with Light Water Reactors

The purpose of this work is to identify, model, perform techno-economic analysis, and compare two possible synfuel production routes utilizing CO 2 as the feedstock. Heat from an LWR nuclear plant is integrated wherever possible to positively affect the economics of the LWR by converting power to fuels during times of low grid electricity demand. Process and economic modeling for a conceptual synfuel production plant co-located (or in near proximity) with an LWR is presented, including the cost of CO 2 captured from an ethanol plant, compressed, and transported to the LWR hybrid plant, co-electrolysis of the CO 2 with water in a solid oxide electrolyzing cell (SOEC) system to produce syngas, and thermocatalytic conversion of the syngas to transportation fuel. The hybrid LWR/synfuels plant is assumed to be located within 50–150 miles of an ethanol plant (e.g., located in the midwest region of the United States). Performance and nth-plant economics for the co-electrolysis-based processes are evaluated and compared with biomass-gasification-based technology for the synfuel routes considered. Sensitivity analysis around the price of CO 2 and electricity, two of the major cost drivers, is presented for each case. Consideration of a carbon credit is also included in the sensitivity analysis.

10 SYNTHETIC FUELS↗

Preliminary Technoeconomic Analysis for Power Generation from Coal Water Slurry Using Modular Staged-OMB Gasifier

Trimeric performed a technoeconomic analysis for a proposed 5 MWe gross modular gasification power generation facility. The cost estimate was used to determine the economic advantages of the proposed modular, staged-OMB gasifier in comparison to other modular gasifier designs. The project, Staged OMB for Modular Gasifier/Burner, is led by The University of Kentucky Center for Applied Energy Research (UK CAER) and supported by East China University of Science and Technology (ECUST) and Trimeric Corporation. A high-level summary of the findings from this project are presented below.

10 SYNTHETIC FUELS↗

Wabash CarbonSAFE (Subtask 3.1 - Application of the NRAP Tools to the Wabash CarbonSAFE Site for Risk Assessment Associated with Geologic Carbon Storage Activities)

This report documents a risk assessment of CO 2 containment loss and induced shear failure due to geologic carbon storage at the Wabash CarbonSAFE site. The operator, Wabash Valley Resources, has proposed adapting the onsite integrated gasification combined cycle (IGCC) facilities to produce hydrogen and injecting the byproduct CO 2 stream into the subsurface Potosi dolomite formation. The purpose of this study is to assess (1) CO 2 sequestration performance relative to the CarbonSAFE goals of storing 50 Mt over 30 years, (2) the risk of containment loss due to leakage along a wellbore and into an overlying aquifer, and (3) the state of stress and risk of reactivating existing fractures. This study relied upon the initial site characterization work performed by the Illinois State Geologic Survey (ISGS) along with analogue data collected from other carbon sequestration projects in the region.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Computed Tomography Scanning and Geophysical Measurements of the Wabash No.1 Core

The computed tomography (CT) facilities and the Multi-Sensor Core Logger (MSCL) at the National Energy Technology Laboratory (NETL) in Morgantown, West Virginia were used to characterize Mt. Simon core from the Wabash CarbonSAFE project, Wabash No. 1 well. The primary impetus of the work in this report is a collaboration between NETL Research and Innovation Center and the Illinois State Geological Survey at the Prairie Research Institute, University of Illinois Urbana-Champaign in Champaign, Illinois. The resultant datasets are presented in this report and can be accessed from NETL's Energy Data eXchange (EDX) online system using the following link: https://edx.netl.doe.gov/dataset/wabash-no-1-well. The Wabash No. 1 well was drilled as part of a U.S. Department of Energy (DOE) funded Carbon Storage Assurance Facility Enterprise field project to assess the feasibility of developing a commercial-scale geological storage complex at the Wabash Valley Resources Integrated Gasification Combined Cycle plant near Terre Haute, Indiana. All equipment and techniques used were non-destructive, enabling future examinations and analyses to be performed on these cores. None of the equipment used was suitable for direct visualization of the pore space in fine-grained structures; fractures, discontinuities, and millimeter scale features were readily detectable with the methods tested. Imaging with the NETL medical CT scanner was performed on the entire core. Qualitative analysis of the medical CT images, coupled with X-ray fluorescence (XRF), P-wave, and magnetic susceptibility measurements from the MSCL were useful in identifying zones of interest for more detailed analysis. The ability to quickly identify key areas for more detailed study with higher resolution will save time and resources in future studies. The combination of methods used provides a multi-scale analysis of the core; the resulting macro and micro descriptions are relevant to many subsurface energy-related examinations traditionally performed at NETL.

54 ENVIRONMENTAL SCIENCES↗

Business Environment Study (Subtask 5.1)

In 2016, WVR acquired the Wabash Integrated Gasification Combined Cycle (IGCC) Plant north of Terre Haute, Indiana. Initially, WVR intended to use the plant to produce ammonia using syngas converted to hydrogen. Part of the business plan was to capture and sequester the CO 2 byproduct with the goal of a net-zero carbon emitting plant. Now, with the demand for clean hydrogen-based power and fuel cell energy, the plant intends to produce power and sell hydrogen as a fuel source, still with the intent to sequester CO 2 and achieve net-zero emissions. The Wabash CarbonSAFE project’s objectives are to establish the feasibility of developing a commercial-scale geological storage complex at the WVR plant in Vigo County, Indiana, for storage of 50 million tonnes or more of CO 2 . The plant is expected to produce up to 2 million tons (1.82 million tonnes) of CO 2 annually as a byproduct of hydrogen production. Wabash CarbonSAFE has examined the feasibility of geologic storage of the CO 2 in the Potosi Dolomite Storage Complex of the Illinois Basin via an onsite characterization well at the WVR plant site. This document explores the business requirements to undertake such a project, outlining the outside influences on a business venture such as legislation, legal, regulatory, and business climate factors. This document then discusses the CO 2 source, potential partner sources, and the business financials that allow CCS to be commercially viable for Wabash Valley Resources.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Advanced Syngas Cleanup Using Radically Engineered Modular Systems

The overall objective of this project was to address key knowledge gaps and develop modular sorbent-based warm syngas cleanup designs that will enable 1- to 5-MW REMS-based plants to be cost-competitive with large state-of-the-art commercial plants utilizing all of our abundant domestic coal reserves. We proposed to develop two potential new desulfurization process designs specifically targeted for REMS plants for combined heat and power or polygeneration from coal gasification. The first design is a modification of our commercially offered dual transport reactor design based Warm-gas Desulfurization Process (WDP) where the transport-reactor regenerator is replaced with a fluidized-bed regenerator. This design leverages the learnings obtained from our pre-commercial demonstration testing of the WDP technology for over 3,000 hours and conclusions from the lessons learned workshop. The second design is a fixed-bed process that leverages the successful composition and chemistry of our WDP sorbent to develop an effective fixed-bed sorbent formulation and fixed-bed process design. These two potential desulfurization process designs have a strong technical likelihood of success and offer the best opportunity to effectively employ design standardization, mass production and advanced manufacturing techniques to enable cost competitiveness for syngas cleanup at smaller scale.

01 COAL, LIGNITE, AND PEAT↗

Controlling Structural, Electronic, and Energy Flow Dynamics of Catalytic Processes through Tailored Nanostructures

MoS 2 (molybdenum disulfide) is a highly-versatile catalyst material for support of numerous reactions from hydrodesulfurization and denitrogenation to the focus of this renewal proposal: hydrogenation of CO/CO 2 towards (higher) alcohols. At the same time, MoS 2 is a non-toxic, environmentally-benign and rather inert material- which under ambient conditions for some time has served as a lubricant and, more recently, as next-generation electronic material. The apparent contrast between inertness and stability in ambient, and catalytic activity under reactive conditions is puzzling and calls for a synergistic theoretical and experimental investigation with the long-term objective of enabling the rational design of MoS 2 -based catalysts for alcohol-formation reactions by providing a microscopic understanding of the environmental factors that determines site activity and selectivity. Our research project seeks answers to the questions (a) what conformation does MoS 2 adopt under reaction conditions (as opposed to that under ultrahigh vacuum and low temperatures)?; (b) what reaction pathways exist on such a material?; (c) how can the local environment of the active sites be manipulated so as to make MoS 2 an efficient catalyst for production of higher alcohol from syngas? In particular, research strategies will explore how the basal plane composed of sulfur atoms can be activated so as to exhibit a reactivity of its own, by addressing three research targets and building on extensive preliminary and enabling work: (1) vacancies and vacancy aggregates on the basal plane; (2) non-local catalyst transformation through alkali doping, hydrogenation and phase transition; (3) fabrication of a metal-nanoparticle-activated MoS 2 system, in which particle anchoring, reactive sites and pathways as well as selectivity are controlled by design, as an example of predictive development of a catalyst material,. All strategies are directed to improve the efficacy of the key reactive sites and selectivity of chemical pathways by design, to replace the inefficient methodology of trial and error in catalyst development. This research project represents a synergistic combination of computational guidance, foundational surface-science-based experiments and validation under reactive conditions that aims at transformative new insights into the working of MoS 2 -based hydrogenation-catalysts, a topic squarely at the center of the interest of DOE BES. Guided and led by Talat Rahman, a computational physicist, this project will apply density functional theory to understand structure, reaction pathways and chemical potentials associated with MoS 2 -based CO/CO 2 hydrogenation, augmented by kinetic Monte Carlo methods for reaction rates and prefactors as well as ab-initio molecular dynamics for evaluation of thermal stability. Complementary experimental input and validation will originate from co-PI Ludwig Bartels, a physical chemist and materials scientist, whose group focuses on local imaging and preparation of MoS 2 materials, from co-PI Peter Dowben, an experimental physicist, whose group is expert in the spectroscopy of occupied and unoccupied electronic states, and from senior collaborator Michael White of Brookhaven National Laboratory, whose group generates high-resolution electronic and activity information on size-selected well-defined metal chalcogenide clusters. This collaborative effort will enable a comprehensive understanding of the correlation of structural integrity and catalytic activity of MoS 2 in forms ranging from extended films to individual particles with known geometries and binding sites. Alcohol formation from syngas is a rapidly emerging application that has great potential through facile, economic, and decentralized biomass gasification. CO 2 activation is one of the most pressing concerns of our time: increasing CO 2 levels in the atmosphere change the climate and expose the globe to environmental transformations with the potential for enormous economic and societal impact. We will investigate CO/CO 2 hydrogenation via an interdisciplinary research collaboration with established synergy – one that, in accordance with the mission of the DOE, involves accredited Hispanic-Serving Institutions and that, through student exchange with international collaborators and National Labs, will directly benefit a broad spectrum of communities and generate human resources in sciences essential to their future.

2D materials↗

Policy, Regulatory, Legal, and Permitting Evaluation Task 6.0 (Technical Report)

This report revisits and updates work completed for the Phase I CarbonSAFE Illinois - East Sub Basin project, the precursor to the Phase II Wabash CarbonSAFE project; the current report summarizes the policy, regulatory, legal, and permitting considerations to-date as related to geologic CO 2 storage at the Wabash Valley Resources (WVR) gasification plant site in Vigo County, Indiana.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Transformational Solid Oxide Fuel Cell (SOFC) Technology

This project was conducted under the Co-operative Agreement No. DE-FE0027584 with the US Department Energy to developed advanced Solid Oxide Fuel Cell (SOFC) Technologies. The overall objective of this project was to advance SOFC technology at the cell and stack level to enhance cell robustness and durability, increase performance, and reduce balance-of-plant (BOP) requirements. By reducing system complexity combined with the increases in power density and efficiency, the ultimate goal of the project was to increased reliability and to reduce capital and operating costs of installed systems. The project was focused on pathways that will reduce the cost of the SOFC cell and stack, including the following areas: Robust, redox tolerant cell technology Lower cost cell manufacturing through advances in cell design, which will reduce the amount of material, energy and time used in the fabrication of SOFCs High performance, low temperature electrolyte based on improvement of established materials Innovative SOFC stack architecture which truly integrates Balance of Plant functionality into the stack level design Thermal management of the fuel cell stack for increased durability and expanded window of operation Novel stack design amenable for use in sub-MW to multi-MW-scale power plants and having low replacement cost The incorporation of balance-of-plant (BOP) equipment into the stack platform increased the economic viability of smaller scale systems. The project objectives were met by a multi-prong approach, including new cell design complemented with modifications to existing cell technology, as well as a new stack design incorporating components typically included in the BOP, such as heat exchangers, oxidizer, fuel reformers, and recycle systems. The project culminated with demonstration of a stack test validating the viability of the cell and stack improvements. A cost model was also developed to estimate costs for the advanced stack technology at high volume manufacturing levels. The net outcome of the project is SOFC cell and stack technology with costs significantly below current DOE targets without compromising and, in some cases, improving on the performance and degradation rate demonstrated with the current state-of-the-art stack design. The results of this project advanced the reliability, robustness, and endurance of low-cost SOFC technology that ultimately are ready to be deployed in coal power systems with greater than 60 percent efficiency (based on higher heating value of fuel) and the capability for ≥97% CO 2 capture at a cost-of-electricity that is approximately 40 percent below presently available Integrated Gasification Combined Cycle systems.

03 NATURAL GAS↗

Wabash CarbonSAFE Static and Dynamic Modeling: Task 9.0 (Technical Report)

The objective of the Wabash CarbonSAFE project’s static and dynamic modeling task is to assess the feasibility of storing 50 million tonnes (1.67 million metric tonnes annually; MMTA) of industrially-sourced carbon dioxide (CO 2 ) in a commercial-scale geological storage complex at Wabash Valley Resources LLC (WVR) gasification facility near Terre Haute, Indiana over a period of 30 years. The targeted formations for storing CO 2 are: 1) Mt. Simon Sandstone (MSS) and the 2) Potosi Dolomite (Knox Group). All of the available data from the recently drilled Wabash #1 stratigraphic test well (now plugged and abandoned) were used in the construction of both the static and dynamic models. Geologic models were constructed to characterize both the Mt. Simon Sandstone and Potosi Dolomite storage complexes. Dynamic simulation models were constructed and used to assess the feasibility of injecting CO 2 into the Mt. Simon and Potosi formations. The geocellular models for the Potosi Dolomite and Mt. Simon Sandstone were built using Petrel™, Schlumberger’s reservoir modeling software. The dynamic simulations were run using Landmark’s Nexus ® reservoir simulation software.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Cost and Performance Baseline for Fossil Energy Plants Volume 1: Bituminous Coal and Natural Gas to Electricity

This revised report presents an independent assessment of the cost and performance of select fossil energy power systems—integrated gasification combined cycle (IGCC), pulverized coal (PC), and natural gas combined cycle (NGCC) plants—using a systematic, transparent technical and economic approach. The cost and performance of fossil fuel-based generation technologies represented in this report (and the series at large) are important inputs to assessments and determinations of technology combinations to be utilized to meet the projected demands of future power markets. In addition to informing technology comparisons, the reference plant configurations found in this report provide perspective for regulators and policy makers. From a research and development perspective, this report is used to assess goals and metrics and to provide a consistent basis for comparing developing technologies.

01 COAL, LIGNITE, AND PEAT↗

Strategies for Achieving the DOE Hydrogen Shot Goal: Thermal Conversion Approaches

In July 2021 the United States (U.S.) Department of Energy (DOE) launched the first of a series of Department-wide Energy Earthshot goals designed to accelerate breakthroughs of more abundant, affordable, and reliable clean energy solutions within the decade. The Hydrogen Shot goal seeks to reduce the cost of clean hydrogen to $\$$1 per 1 kilogram in 1 decade ("1 1 1"). Today, thermal conversion of fossil fuels represents the predominant, lowest cost method of hydrogen production. In 2020 approximately 75 percent of global, dedicated hydrogen production was produced via fossil fuels using thermal conversion approaches such as steam reforming and gasification. However, carbon management techniques such as CO 2 capture and sequestration (CCS) and pyrolysis are not widely represented in the current fossil-based hydrogen production fleet. Lowering the cost of clean hydrogen production from commercial and advanced thermal conversion-based technologies is critical for successfully achieving the Hydrogen Shot goal. This report presents the findings from an initial screening analysis of several scenarios that explore cost drivers related to clean hydrogen production. The screening encompasses commercially available and developing thermal conversion technology alternatives as well as factors exogenous to the plant such as feedstock/byproduct pricing, CO 2 pipeline and storage infrastructure costs, and scale to assess potential pathways towards meeting the Hydrogen Shot goal. Additionally, this report presents initial Research and Development (R&D) strategies to advance thermal conversion technology towards meeting the Hydrogen Shot goal.

08 HYDROGEN↗

Computed Tomography Scanning and Geophysical Measurements of the CarbonSAFE Seal Integrity Wells in the Illinois Basin

The U.S. Department of Energy’s (DOE) National Energy Technology Laboratory (NETL) researchers in Morgantown, West Virginia, utilized computed tomography (CT) facilities and the Multi-Sensor Core Logger (MSCL) to evaluate the integrity of three cores (Geophysical Monitor #2 (GM2), Verification Well #1 (VW #1), and Wabash #1 for the Illinois Basin Carbon Storage Assurance Facility Enterprise (CarbonSAFE) efforts. This work was carried out in collaboration with the Illinois State Geological Survey (ISGS) as part of their efforts to analyze cores from two field locations, including the Illinois Basin-Decatur Project (IBDP) and second stage Illinois Industrial Carbon Capture and Storage (IL-ICCS) sites at Decatur, Illinois, and the Wabash CarbonSAFE project at the Wabash Valley Resources Integrated Gasification Combined Cycle plant in Terre Haut, Indiana. The results of this study are presented in several formats and are available online on the Energy Data eXchange (EDX). The rock characterization was conducted using non-destructive techniques, allowing for future analysis of the cores. While the equipment used did not provide direct visualization of shale pore space, it allowed for detection of fractures and discontinuities. Low resolution CT imagery with the NETL medical CT scanner was performed on the entire core. Qualitative analysis of the medical CT images, coupled with x-ray fluorescence (XRF), P-wave, and magnetic susceptibility measurements from the MSCL were utilized to identify areas of interest for further study as well as fractured zones. The ability to quickly identify key areas for more detailed study with higher resolution will save time and resources in future studies. The combination of methods used provided a multi-scale analysis of this core and provided both a macro and micro description of the core that is relevant for many subsurface energy-related examinations traditionally performed at NETL.

58 GEOSCIENCES↗

A modular chemo-selective oxygen production unit to deliver oxygen for advanced combustion systems

Commercial oxygen generation technologies deploy either cryogenic air separation or vacuum pressure swing adsorption (VPSA). These technologies can provide nearly pure oxygen but are only economically viable at oxygen production rates of 100-7,000 tonnes/day. The state-of-theart cryogenic air separation plants are impending the theoretical limits of thermodynamic efficiency but cannot be scaled down to cater future needs. Therefore, there is great incentive to develop a new approach for oxygen separation that can accommodate the upcoming demands. Our proposed research approach address to find novel methodologies to provide energy efficient modular O 2 on demand systems for modular gasification and other applications. Small scale modular systems for O 2 production offer certain benefits including enhanced energy efficiency, reduced operating costs and flexibility to tailor location specific needs. Our hypothesis is that a small modular system could be engineered using solvent-based capture and thermal release of oxygen, to enable “oxygen on demand” for any combustion-related technology.

42 ENGINEERING↗

Hydrogen Safety Review for Gas Turbines, SOFC, and High Temperature Hydrogen Production

This report presents an introduction and summary on hydrogen safety issues, as they relate to hydrogen production, storage, and use in the energy sector, primarily as related to electricity generation by gas turbines, and solid oxide fuel cells (SOFC), and hydrogen production from gasification and steam methane reforming processes. The impetus behind this effort is the U.S. DOE goal for decarbonization of the power generation sector by the year 2035. In many cases, hydrogen is expected to replace natural gas as the primary fuel source (or form of energy storage) to achieve this goal. Advanced technologies for large-scale energy production using hydrogen as a fuel source which can be deployed over the next 5–10 years will be required. However, to develop and mature these hydrogen-based technologies, it will be critical to identify the safety issues related to widespread use of hydrogen as a fuel source, so that they may be addressed prior to widespread deployment.

08 HYDROGEN↗

Development of a Pre-Combustion CO 2 Capture Process Using High-Temperature PBI Hollow-Fiber Membranes

The overall objective of this project was to evaluate the advantages of transformational polybenzimidazole (PBI) polymer hollow-fiber membrane (HFM)-based, carbon dioxide (CO 2 ) capture and purification technology at bench-scale using an actual coal-derived syngas stream from a coal gasification facility. The project was carried out over two budget periods. The technical objectives in Budget Period 1 (BP1) included preparing HFs and modules and upgrading the available skid for field testing. The technical objectives for BP2 were to field-test the skid unit with actual coal-derived syngas from an oxygen-blown gasifier to obtain performance data, update the Techno-Economic Analysis (TEA) that would assist with future process scale-up, and provide information on the design of a small pilot-scale test unit. The goal was to advance the PBI-HFM CO 2 capture and gas separation system for pre-combustion applications beyond second-generation economic performance predictions and make progress toward meeting overall fossil energy performance goals of CO 2 capture with 95% CO 2 purity at a cost of electricity (COE) 30% less than baseline capture approaches. The research program was designed with progressive technical tasks leading to both dynamic and steady-state testing of the PBI-HFM skid with actual coal-derived syngas. The work plan was to: (1) fabricate sufficient Generation-2 (GEN-2) fibers for module fabrication; (2) upgrade the fiber skid to accommodate large fiber modules for bench-scale field testing; (3) conduct dynamic and steady-state testing with coal-derived syngas from an oxygen-blown gasifier and obtain system performance data; (4) perform a TEA and environmental, health, and safety (EH&S) assessment; (5) update the State-Point Data Table, Technology Gap Analysis (TGA), and Technology Maturation Plan (TMP); (6) uninstall and return the test skid to the Recipient’s facilities; and (7) submit a Final Report that describes the results and analysis of the project research effort.

03 NATURAL GAS↗