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DOE OSTI2017

W.A. Parish Post Combustion CO 2 Capture and Sequestration Project Final Public Design Report

The Petra Nova Project is a commercial scale post-combustion carbon dioxide capture project that is being developed by a joint venture between NRG Energy (NRG) and JX Nippon Oil and Gas Exploration (JX). The project is designed to separate and capture carbon dioxide from an existing coal-fired unit's flue gas slipstream at NRG's W.A. Parish Generation Station located southwest of Houston, Texas. The captured carbon dioxide will be transported by pipeline and injected into the West Ranch oil field to boost oil production. The project, which is partially funded by financial assistance from the U.S. Department of Energy will use Mitsubishi Heavy Industries of America, Inc.'s Kansai Mitsubishi Carbon Dioxide Recovery (KM-CDR(R)) advanced amine-based carbon dioxide absorption technology to treat and capture at least 90% of the carbon dioxide from a 240 megawatt equivalent flue gas slipstream off of Unit 8 at W.A. Parish. The project will capture approximately 5,000 tons of carbon dioxide per day or 1.5 million tons per year that Unit 8 would otherwise emit, representing the largest commercial scale deployment of post-combustion carbon dioxide capture at a coal power plant to date. The joint venture issued full notice to proceed in July 2014 and when complete, the project is expected to be the world's largest post-combustion carbon dioxide capture facility on an existing coal plant. The detailed engineering is sufficiently complete to prepare and issue the Final Public Design Report.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Topical Report – Findings on Subtask 2.7 – Wet ESP and Aerosol Testing at Coal Creek Station

Growing concerns over the impact of CO 2 emissions from combustion sources on global climate change have prompted numerous research and development projects aimed at developing cost-effective technologies for CO 2 capture. One family of technologies being demonstrated at pilot and full scale globally is postcombustion carbon capture (PCCC) systems that employ amine-based solvents. The captured CO 2 can be compressed and permanently stored underground or used for enhanced oil recovery. The proximity of North Dakota’s lignite-fired fleet of power plants to potential CO 2 storage options creates a unique atmosphere for PCCC within the state. However, the unique components present in lignite flue gas present a challenge for large-scale PCCC at North Dakota power plants by contributing to aerosol formation. Aerosols can negatively impact the long-term performance of amine-based solvents for CO 2 capture. Amine-based solvents are volatile, and flue gas particulate provides nucleation sites where amine vapors can condense as aerosols. Because aerosols cannot be easily captured at the column outlet using conventional technologies, the amine-laden aerosols escape the system and lead to accelerated solvent losses. Moreover, particulate components can chemically react with amines to form degradation products that can permanently deactivate the amine, cause fouling, and lead to hazardous emissions. Many of the elements that have been shown to catalyze solvent degradation are present in lignite coals and can exacerbate solvent replacement economics. Understanding this issue is critical to the implementation of solvent-based CO 2 capture systems as applied to lignite-fired generation systems. The Energy & Environmental Research Center (EERC) designed and carried out this project to fully characterize aerosol behavior with various control technologies installed to better optimize aerosol mitigation technology for CO 2 capture. To meet the goal of this project, the following objectives were identified: Determine the effectiveness of a wet electrostatic precipitator (WESP) on mitigating formation of problematic aerosols at Great River Energy’s Coal Creek Station, upstream of the PCCC system. Determine the effectiveness of the Mitsubishi Heavy Industries (MHI) proprietary amine emission reduction unit (AERU) as a postcapture solvent recovery system for reducing aerosol emissions and extending solvent life downstream of the PCCC system. Determine the impact of aerosols on the efficiency and degradation products of both commercial and advanced solvents within the PCCC system. Work was conducted at Coal Creek Station Unit 1 using a slipstream of flue gas from the outlet of the plant’s flue gas desulfurization (FGD) unit. Flue gas was routed through a pilot-scale FGD unit to remove SO 2 to very low levels (~1 ppm) and then through a direct contact cooler (DCC) to further cool the gas and to remove moisture. The gas exiting the DCC was then optionally routed through a WESP before passing to the CO 2 absorber columns. The MHI solvent was used to scrub CO 2 from the slipstream through a set of two absorber columns. The rich solvent was regenerated in a stripper column by heating to drive off captured CO 2 . Flue gas exiting the absorber column was routed to MHI’s proprietary AERU to recover entrained solvent. The system operated using a catch-and-release method where the CO 2 was separated to provide data on the process, but the captured CO 2 was released back into the host site stack. Particulate was measured, collected, and analyzed from multiple locations throughout the pilot-scale system. Unlike the performance observed in prior work, the inlet FGD and DCC did not remove significant particulate matter from the flue gas. This appears to be due to a difference in the nature of the particulate. The DCC seemed to increase particulate size and count, most likely owing to water condensing onto the surfaces of fly ash particles. When the WESP was operated, it achieved >95% particulate capture. Very little particulate matter or indications of solvent were detected at the AERU outlet. When operating with advanced KS 21 solvent, the particulate material at the AERU outlet was even further decreased. Solvent analysis showed that some species derived from flue gas and ash were slowly concentrating in the solvent over the duration of the test. The levels observed were reported to be within expected ranges and were not of concern to MHI. A high-level techno-economic assessment of installing CO 2 capture at Coal Creek Station suggested that, when using a standard monoethanolamine (MEA)-based solution with simple heat integration, the energy penalty to net generation would be 34%. The bulk of this was due to steam losses for regenerating solvent, followed by parasitic electrical demand for CO 2 compression and then by increased parasitic load for pushing flue gas through the absorber column. These demands could be decreased with a more advanced solvent that exhibits lower heat of regeneration and lower pressure drop than does a simple MEA solution. Further energy could be saved with more thorough heat integration to recover useful energy from the steam used for solvent regeneration. Installing a WESP was predicted to increase the cost of electricity by nearly $5/MWh. This would become cost-effective if solvent losses were roughly 10 times the baseline estimate when not using a WESP but could be returned to baseline by installing the WESP. Piping CO 2 for storage in more favorable geology could help with carbon capture and storage economics. Although storing off-site would necessitate construction of a CO 2 transport pipeline, the cost of this pipeline might be more than offset by reducing the number of wells required, the depths of the wells required, and the electrical demand for the CO 2 compressor. Additional factors that favor off-site storage costs include smaller expected CO 2 plume sizes, which translates to less monitoring and fewer landowner agreements. More detailed assessment of the specific geology in the region under and around Coal Creek Station would be needed to accurately assess the costs and benefits of different storage site options. This subtask was cofunded through the Energy & Environmental Research Center–U.S. Department of Energy Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by the North Dakota Industrial Commission.

Strege, Joshua↗

DOE OSTI2022

Passive and no-loss weather cap for protection of wind induced downdraft in sensitive exhaust systems

The invention provides a device for removing heat from a building, the device having: a first tubular member defining a first cavity; a second tubular member defining a second cavity, whereby said second tubular member resides within the first cavity and is coaxial to the first tubular member; and a double conic body coaxially residing in the first cavity and coaxially positioned with the second tubular member.Also provided is a method for removing heat from a building, the method having the steps of: directing heat-containing exhaust emanating from a flue, defining a first diameter, to a passageway received by the flue, whereby the passageway defines a longitudinal axis and a periphery circumscribing the axis; forming the directed exhaust into a slipstream, wherein the slipstream generally travels along the longitudinal axis; and routing precipitation entering the passageway to the periphery.

Lisowski, Darius D.↗

DOE OSTI2026

Reimagining Heating, Ventilation, and Air Conditioning for New Manufactured Homes

Manufactured homes represent one of the most affordable paths to home ownership for American households, but minimum-efficiency equipment and poor-quality home installation can lead to excess energy use and high operating costs. Slipstream, with partners from the Florida Solar Energy Center (FSEC), Northwest Energy Works, and Washington State University, identified and tested manufactured home HVAC innovations targeted for new construction offering the most promising mix of improved energy performance and likelihood of industry uptake.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2017

An automated lab-scale flue gas permeation membrane testing system at the National Carbon Capture Center

A constant pressure, mixed gas permeation testing skid was deployed at the National Carbon Capture Center to test membrane performance when continuously exposed to slipstream post-combustion flue gas. Small, laboratory scale membranes can be loaded for testing and the degree of automation allowed the skid to be run unattended for several weeks at a time. In this report, we share our experience in commissioning the skid and quantifying CO 2 , N 2 and O 2 permeances of several membranes during the first round of testing. Dense films of polydimethylsiloxane and poly(bistrifluoroethoxyphosphazene) were tested with flue gas for approximately 20 h each. Here, in addition, we successfully tested four thin film composite hollow fiber membranes made by a dip coating process, consisting of porous Torlon hollow fibers coated with a selective layer of poly(bistrifluoroethoxyphosphazene) or its mixed matrix with a metal organic framework SIFSIX-Cu-2i filler particles. Initial results suggest the polydimethylsiloxane showed comparable results to the literature data, but the coated hollow fiber membranes have lower CO 2 permeances relative to N 2 or O 2 permeances compared to their performance under idealized, dry, contaminant-free mixed gas conditions. While quantification of H 2 O permeance was performed, we found it was affected by concentration polarization even with small membrane area and a low stage cut.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Development and Validation of Smart Building Technology Modules for Academic and Professional Education (Final Technical Report)

Smart building technologies can improve building energy efficiency and resilience, reduce carbon emissions, and provide load flexibility to the grid. However, in both college curricula and building professionals’ continuing education, there is a lack of systematic instruction on smart building technologies. Slipstream, partnering with Texas A&M University (TAMU), the Society of Building Science Educators (SBSE), and the National Institute of Building Sciences (NIBS), developed a semester-long smart building curriculum for college students and 16 training videos for building professionals and the general public. The education and training cover the drivers and benefits of smart building technologies, key building energy systems, the latest sensor technologies and IoT devices, and focus on topics related to smart building controls (i.e., energy management information systems, smart building control platforms, cybersecurity, grid-interactive-efficient buildings [GEBs], smart building control methods, and occupant-centric control). The smart building curriculum for college students was taught at TAMU in the Spring semester of 2024 as part of the validation process. Student feedback was collected and summarized in a validation report by TAMU. The curriculum material was also reviewed by SBSE faculty who are interested in teaching smart building technology-related courses. Suggestions on revisions and better adoption of the materials by other faculty across the architectural, engineering, and construction (AEC) domains were compiled in a distinct validation report by SBSE. The SBSE validation report was used to create structured subsets of the curriculum material for adoption at different levels in different sub-disciplines. These subsets are categorized and offered on the SBSE website (https://www.sbse.org/courses/Smart-Building-Technologies). The 16 training videos for building professionals and the general public were previewed by 17 industry experts, and feedback and suggested changes were incorporated into the final version of these videos. The videos are organized into a smart building technology training course and published on the Whole Building Design Guide website (https://www.wbdg.org/ce/doe/bto/sbtt), which is hosted by the National Institute of Building Sciences (NIBS). Project team members created marketing materials to promote the awareness of these free, publicly available education and training resources. Outreach and marketing activities included creating short promotional videos, building project webpages, making project announcements on social media, conducting an email campaign, and directly reaching out to faculties and building professionals. This report describes the project approach, provides outlines of the training materials, along with links to resources, and identifies lessons learned in creating the content. We also suggest ways to scale the instruction of smart building concepts to empower the workforce to accelerate the adoption of smart building technologies in the real world.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2021

Kraft black liquor concentration with graphene oxide membranes: Process simulations and technoeconomic analysis

Abstract Black liquor (BL) dewatering by multi‐effect evaporation in the kraft papermaking process is highly energy‐intensive. It was previously shown that graphene oxide (GO) nanofiltration membranes can remove lignin, other organics, and inorganic salts from BL while exhibiting stability in caustic BL conditions. Here, we design and simulate several candidate dewatering processes and evaluate their technoeconomic characteristics. All processes concentrate BL from 15 to 30 wt% solutes while producing aqueous permeate. Two process options were analyzed—option A including “last‐mile” permeate treatment to reduce solutes to 0.2 wt%, and option B excluding this treatment and producing a 3–4 wt% solutes stream. These processes were simulated in custom‐built ASPEN Plus flowsheets interfaced with Microsoft Excel and MATLAB. All processes deliver large (>40%) energy savings. Detailed technoeconomic analysis showed that option A processes are profitable in mills equipped with condensing turbines, but unprofitable with only purchased fuel savings. Option B processes are profitable in both situations, but require the caustic permeate to be utilized in other kraft process units. They are also profitable with electricity generation when operated at smaller scales matching the requirements of other process units. Monte‐Carlo sensitivity analysis shows that Option A can yield median 20‐year NPVs up to ~$10MM and Option B up to ~$25MM. Overall, GO membrane‐based BL dewatering is economically promising, assuming successful slipstream piloting and scale‐up campaigns. It would have immediate sustainability benefits from large energy savings, and broader implications for biorefinery processes due to the ability to fractionate biomass feedstock components under harsh conditions.

Wang, Zhongzhen↗

DOE OSTI2016

Response characteristics of stable mixed-potential NH 3 sensors in diesel engine exhaust

Here, a mixed-potential, electrochemical sensor platform is extended to NH 3 sensing by the introduction of a new gold alloy working electrode. A planar, pre-commercial NH 3 sensor utilized LANL’s controlled interface approach, and a Pd-Au alloy working electrode was tested in exhaust of a GM 1.9 L diesel engine downstream of a diesel oxidation catalyst through a slipstream arrangement. A fraction of the exhaust was pulled across the sensor with a pump at 20 L/min. In order to simulate NH 3 slip inside of a full SCR emissions control system, NH 3 was injected immediately upstream of the sensor using a calibrated mass flow controller. The sensor response quantitatively tracked the NH 3 as measured via Fourier transform infrared (FTIR) analyzer. A calibration curve was obtained in the exhaust from an ammonia staircase response with the engine running at steady-state engine conditions resulting in low background concentrations of NO x and HC (<20 ppm) during calibration. Exhaust gas recirculation (EGR) switching and sweeps were used to evaluate the NH 3 sensor response under different amounts of total background NO x . The calibration curve was used to directly compare the [NH 3 ] calculated from sensor response to the gas phase composition measured via FTIR. In general, there was excellent quantitative agreement between the sensor response and the actual NH 3 in the exhaust gas, and fast response time such that transients (<5 ppm) could be easily discerned from baseline. A LANL pre-commercial NO x sensor was tested simultaneously with the NH 3 sensor and the extent of cross-sensitivity between the two sensors will be discussed.

47 OTHER INSTRUMENTATION↗

DOE OSTI2017

Pilot testing of a heat integrated 0.7 MWe CO 2 capture system with two-stage air-stripping: Amine degradation and metal accumulation

An advanced 0.7 MWe small pilot coal-fired post-combustion CO 2 capture system with heat integration combined with two-stage stripping was tested here on a slipstream of flue gas by the University of Kentucky Center for Applied Energy Research (UKy-CAER). Evaluation of solvent degradation products was performed to determine the impact of oxygen exposure due to incorporation of the secondary air stripper into the conventional amine absorber/stripper system. The overall degradation rates and products observed during the testing campaign were comparable to previously published reports using 30% monoethanolamine (MEA) as the baseline/commissioning solvent. The rates of heat stable salt accumulation and amine degradation were similar to those from conventional CO 2 capture systems using MEA. Metal accumulation as the result of material corrosion inside the system from an improperly constructed material was observed. Finally, the impact of the secondary air stripper appears negligible relative to other published MEA campaigns tested at similar flue gas conditions and system operating hours.

03 NATURAL GAS↗

DOE OSTI2021

Lab-scaled performance evaluation of novel water-lean solvents for post combustion CO 2 capture

Here, this work focuses on demonstrating the energetic performance and operational reliability in a continuous system of RTI's water-lean solvents for post-combustion CO 2 capture applications. RTI's Non-Aqueous Solvent, NAS-1A was subjected to 100 h of continuous, CO 2 capture and regeneration operation using a Lab-scale Gas Absorption System (LsGAS) while the CO 2 capture efficiency, mass balance, and total energy inputs were monitored. Throughout the test period, NAS-1A demonstrated stable operation with 90% CO 2 capture while requiring about 15% lower total energy input for solvent regeneration compared to 30 wt% monoethanolamine (MEA) solution. The use of a slipstream of CO 2 -rich solvent from the absorber sump reduced the regenerated CO 2 temperature before the gas was further cooled by the overhead condenser at the top of the desorber. The rich-split setup combined with a wash section may be an effective approach to remove water and solvent vapor from the regenerated CO 2 as well as to recover heat at the top of the desorber. NAS-1B was later developed and included a modifier component that lowers the heat of CO 2 absorption and reduces the vapor pressure of the amine component. The total energy inputs for 90% CO 2 capture with NAS-1B was found to be 25% less than that of the MEA. A gas chromatograph was used to monitor the amine concentration in the gas leaving the absorber wash section. It was found that under similar operating conditions, the presence of the modifier in NAS-1B reduces the amine in the absorber off-gas from 143 ppm in NAS-1A to 20 ppm.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Catalytic Hot-Gas Filtration with a Supported Heteropolyacid Catalyst for Preconditioning Biomass Pyrolysis Vapors

During ex situ catalytic fast pyrolysis (CFP) of biomass, the separation of reactive char and alkali/alkaline particulates from biomass pyrolysis vapors by hot-gas filtration (HGF) leads to improved vapor stability and quality. HGF in tandem with chemical tailoring (e.g., partial deoxygenation) of the clean pyrolysis vapors, denoted as catalytic hot-gas filtration (CHGF), has the potential to further improve vapor composition by removing reactive oxygen moieties and protect downstream upgrading catalysts from fouling. Downstream upgrading refers to both vapor phase upgrading (e.g., ex situ CFP) and condensed phase upgrading (e.g., hydrotreating). Consequently, CHGF (as a single unit operation) was evaluated for preconditioning pyrolysis vapors for downstream upgrading processes. In order to understand the effective operating conditions that successfully filter and partially deoxygenate pyrolysis vapors, a titania-supported molybdenum heteropolyacid (Mo-HPA/TiO 2 ) catalyst was studied for use in CHGF. Here, pine pyrolysis vapors were generated in a small pilot-scale pyrolyzer and transferred to a CHGF unit via a continuous-flow slipstream. In the CHGF unit, the pyrolysis vapors were filtered and upgraded over a packed Mo-HPA/TiO 2 catalyst bed. Real-time monitoring and identification of the products formed were achieved by molecular beam mass spectrometry. The results showed that under a hydrogen-rich environment, the pine vapors were partially deoxygenated and alkylated over the Mo-HPA/TiO 2 catalyst. Reactivity studies revealed that an increase in hydrogen concentration and a reduction in weight-hourly space velocity enhanced deoxygenation and alkylation. Time-on-stream (TOS) studies showed stable product formation up to 1 h with little change in catalyst activity. Additionally, the liquid product was collected using a custom fractional condensation unit (built in-house) and analyzed by gas chromatography mass spectrometry to confirm that the product was partially deoxygenated and alkylated. The combination of CHGF and fractional condensation allowed for chemical and physical removal of both foulant and value-added compounds (e.g., phenols, alkylphenols, methoxyphenols, cyclopentenones) for additional enhancement of downstream upgrading processes. The pre- and postreaction catalysts were characterized using temperature-programmed desorption, N 2 physisorption, and elemental analysis with results indicating some catalyst coking. A hydrogen-based catalyst regeneration procedure restored the reacted catalyst activity to that of fresh Mo-HPA/TiO 2 .

09 BIOMASS FUELS↗

DOE OSTI2020

Pilot testing of CO2 capture from a coal-fired power plant—Part 2: Results from 1-MWe pilot tests

Abstract Using a 1-MWe slipstream pilot plant, solid-sorbent-based post-combustion CO2 capture was tested at a coal-fired power plant. Results from pilot testing were used to develop a preliminary full-scale commercial design. The sorbent selected for pilot-scale evaluation during this project consisted of an ion-exchange resin that incorporated amines covalently bonded to the substrate. A unique temperature-swing-absorption (TSA) process was developed that incorporated a three-stage fluidized-bed adsorber integrated with a single-stage fluidized-bed regenerator. Overall, following start-up and commissioning challenges that are often associated with first-of-a-kind pilots, the pilot plant operated as designed and expected, with a few key exceptions. The two primary exceptions were associated with: (i) handling characteristics of the sorbent, which were sufficiently different at operating temperature than at ambient temperature when design specifications were established with lab-scale testing; and (ii) CO2 adsorption in the transport line between the regenerator and adsorber that preloaded the sorbent with CO2 prior to entering the adsorber. Results from the pilot programme demonstrate that solid-sorbent-based post-combustion capture can be utilized to achieve 90% CO2 capture from coal-fired power plants.

Sjostrom, Sharon↗

DOE OSTI2018

Quantum Cascade Laser Infrared Spectroscopy for Online Monitoring of Hydroxylamine Nitrate

We describe a new approach for high sensitivity and real-time online measurements to monitor the kinetics in the processing of nuclear materials and other chemical reactions. Mid infrared (Mid-IR) quantum cascade laser (QCL) high-resolution spectroscopy was used for rapid and continuous sampling of nitrates in aqueous and organic reactive systems, using pattern recognition analysis and high sensitivity to detect and identify chemical species. In this standoff or off-set method, the collection of a sample for analysis is not required. To perform the analysis, a flow cell was used for in situ sampling of a liquid slipstream. A prototype was designed based on attenuated total reflection (ATR) coupled with the QCL beam to detect and identify chemical changes and be deployed in hostile environments, either radiological or chemical. The limit of detection (LOD) and the limit of quantification (LOQ) at 3 σ for hydroxylamine nitrate ranged from 0.3 to 3 and from 3.5 to 10 g·L −1 , respectively, for the nitrate system at three peaks with wavelengths between 3.8 and 9.8 μ m.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Modeling, Design, and Testing of a Novel Biphasic Solvent-Enabled Absorption System for Post-Combustion Carbon Capture

A novel absorption process enabled by a new class of biphasic solvents for post-combustion carbon capture (BiCAP) is presently being developed at the University of Illinois at Urbana-Champaign. The new biphasic solvents are water-lean solvent blends that develop dual liquid phases with the absorbed CO2 highly enriched in one of the phases. These solvents are superior in CO2 capacity and have high thermal and oxidative stability compared to MEA. The BiCAP technology features a unique process configuration of multi-stage CO2 absorption and liquid–liquid phase separation during CO2 absorption, allowing continual separation and removal of the CO2-enriched liquid phase for maintaining low solvent viscosity and a fast absorption rate. A 40 kWe-scale skid has recently been constructed at the Abbott Power Plant in Champaign, IL, to test the BiCAP solvent in continuous operation with a slipstream of real post-combustion flue gas. Along with improvements in the stripping configuration including cold feed bypass, the process is expected to achieve a minimum reboiler duty of 2,210 kJ/kg CO2 captured at a stripper operating pressure of 6 bar.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2014

Re-utilization of Industrial CO 2 for Algae Production Using a Phase Change Material

This is the final report of a 36-month Phase II cooperative agreement. Under this project, Touchstone Research Laboratory (Touchstone) investigated the merits of incorporating a Phase Change Material (PCM) into an open-pond algae production system that can capture and re-use the CO 2 from a coal-fired flue gas source located in Wooster, OH. The primary objective of the project was to design, construct, and operate a series of open algae ponds that accept a slipstream of flue gas from a coal-fired source and convert a significant portion of the CO 2 to liquid biofuels, electricity, and specialty products, while demonstrating the merits of the PCM technology. Construction of the pilot facility and shakedown of the facility in Wooster, OH, was completed during the first two years, and the focus of the last year was on operations and the cultivation of algae. During this Phase II effort a large-scale algae concentration unit from OpenAlgae was installed and utilized to continuously harvest algae from indoor raceways. An Algae Lysing Unit and Oil Recovery Unit were also received and installed. Initial parameters for lysing nanochloropsis were tested. Conditions were established that showed the lysing operation was effective at killing the algae cells. Continuous harvesting activities yielded over 200 kg algae dry weight for Ponds 1, 2 and 4. Studies were conducted to determine the effect of anaerobic digestion effluent as a nutrient source and the resulting lipid productivity of the algae. Lipid content and total fatty acids were unaffected by culture system and nutrient source, indicating that open raceway ponds fed diluted anaerobic digestion effluent can obtain similar lipid productivities to open raceway ponds using commercial nutrients. Data were also collected with respect to the performance of the PCM material on the pilot-scale raceway ponds. Parameters such as evaporative water loss, temperature differences, and growth/productivity were tracked. The pond with the PCM material was consistently 2 to 5°C warmer than the control pond. This difference did not seem to increase significantly over time. During phase transitions for the PCM, the magnitude of the difference between the daily minimum and maximum temperatures decreased, resulting in smaller daily temperature fluctuations. A thin layer of PCM material reduced overall water loss by 74% and consistently provided algae densities that were 80% greater than the control pond.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Evaluation of Carbon Dioxide Capture From Existing Coal Fired Plants by Hybrid Sorption Using Solid Sorbents

A novel hybrid solid sorbent technology for CO₂ capture and separation from coal combustion-derived flue gas was evaluated. The technology – Capture of CO₂ by Hybrid Sorption (CACHYS™) – is a solid sorbent technology based on the following ideas: 1) reduction of energy for sorbent regeneration, 2) utilization of novel process chemistry, 3) contactor conditions that minimize sorbent-CO₂ heat of reaction and promote fast CO₂ capture, and 4) low-cost method of heat management. This report provides key information developed during the course of the project that includes sorbent performance, energy for sorbent regeneration, physical properties of the sorbent, the integration of process components, sizing of equipment, and overall capital and operational cost of the integrated CACHYS™ system. Seven sorbent formulations were prepared and evaluated at the lab-scale for energy requirements and CO₂ capture performance. Sorbent heat of regeneration ranged from 30-80 kJ/mol CO₂ and was found to be dependent on process conditions. Two sorbent formulations (designated HCK-4 & HCK-7) were down-selected for additional fixed-bed testing. Additional testing involved subjecting the sorbents to 100 continuous cycles in the fixed-bed reactor to determine performance as a function of time. The working capacity achieved for HCK-4 sorbent ranged from 5.5-8.0 g CO₂/100 g sorbent, while the HCK-7 typically ranged from 8.0-10.0 g CO₂/100 g sorbent. Overall, there was no deterioration in capacity with continuous cycling for either sorbent. The CACHYS™ bench-scale testing system designed and fabricated under this award consists of a dual circulating fluidized-bed adsorber and a moving-bed regenerator. The system takes a flue gas slipstream from the University of North Dakota’s coal-fired steam plant. Prior to being sent to the adsorber, the flue gas is scrubbed to remove SO₂ and particulate. During parametric testing of the adsorber, CO₂ capture achieved using the 2-bed configuration with recirculation in both beds was 65-70% with a high flue gas CO₂ loading (~7%) and up to 85% with a low flue gas CO₂ loading (~4%). A sorbent regenerator system consisting of a pre-heater, desorber, and cooler is used to heat the CO₂-rich sorbent with direct and indirect steam producing a nearly 100% pure stream of CO₂. Parametric testing of the regenerator system demonstrated the impact of process conditions on both desorption rate and the heat of regeneration. Clear evidence of the use of specific process conditions that lower the overall energy of desorption was identified. This observation validates measurements made at the laboratory-scale. Several longer-term continuous tests were conducted to evaluate the performance of the sorbent/process as a function of time. Using a 2-bed configuration, sustained capture efficiency of 40-60% with a high flue gas CO₂ loading (~8%) and 70-80% with a low flue gas CO₂ loading (~4%) were achieved. However, sorbent working capacity was found to be considerably lower than laboratory-scale measurements. The low working capacity is attributed to insufficient sorbent/gas contact time in the adsorber. Sorbent properties that had a significant impact on CO₂ capture performance were identified. The results show that controlling these sorbent properties substantially improves CO₂ capture performance, with preliminary estimates indicating that relative improvement of ~30% is possible. Testing culminated with an operationally trouble-free test of 15 hours with sustainable performance. Overall, several practical strategies to increase performance of the sorbent and process were identified. The initial technical and economic assessment of the CACHYS™ process estimated the cost of CO2 capture was $36.19/ton with a 48.6% increase in levelized cost of electricity (LCOE) for the 550 MWe net plant. Using additional data gathered over the course of the project, and with revised technical and economic assumptions, the estimated cost of CO₂ capture with the CACHYS™ process is $39/ton (only includes the cost of the CO2 capture system) with an increase in LCOE of 55.9%. Overall, CACHYS™ represents a significant improvement over the benchmark MEA system, and has demonstrated progress towards achieving DOE’s goals for CO₂ capture technologies.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2015

Development of a Novel Gas Pressurized Stripping Process-Based Technology for CO₂ Capture from Post-Combustion Flue Gases

A novel Gas Pressurized Stripping (GPS) post-combustion carbon capture (PCC) process has been developed by Carbon Capture Scientific, LLC, CONSOL Energy Inc., Nexant Inc., and Western Kentucky University in this bench-scale project. The GPS-based process presents a unique approach that uses a gas pressurized technology for CO₂ stripping at an elevated pressure to overcome the energy use and other disadvantages associated with the benchmark monoethanolamine (MEA) process. The project was aimed at performing laboratory- and bench-scale experiments to prove its technical feasibility and generate process engineering and scale-up data, and conducting a techno-economic analysis (TEA) to demonstrate its energy use and cost competitiveness over the MEA process. To meet project goals and objectives, a combination of experimental work, process simulation, and technical and economic analysis studies were applied. The project conducted individual unit lab-scale tests for major process components, including a first absorption column, a GPS column, a second absorption column, and a flasher. Computer simulations were carried out to study the GPS column behavior under different operating conditions, to optimize the column design and operation, and to optimize the GPS process for an existing and a new power plant. The vapor-liquid equilibrium data under high loading and high temperature for the selected amines were also measured. The thermal and oxidative stability of the selected solvents were also tested experimentally and presented. A bench-scale column-based unit capable of achieving at least 90% CO₂ capture from a nominal 500 SLPM coal-derived flue gas slipstream was designed and built. This integrated, continuous, skid-mounted GPS system was tested using real flue gas from a coal-fired boiler at the National Carbon Capture Center (NCCC). The technical challenges of the GPS technology in stability, corrosion, and foaming of selected solvents, and environmental, health and safety risks have been addressed through experimental tests, consultation with vendors and engineering analysis. Multiple rounds of TEA were performed to improve the GPS-based PCC process design and operation, and to compare the energy use and cost performance of a nominal 550-MWe supercritical pulverized coal (PC) plant among the DOE/NETL report Case 11 (the PC plant without CO₂ capture), the DOE/NETL report Case 12 (the PC plant with benchmark MEA-based PCC), and the PC plant using GPS-based PCC. The results reveal that the net power produced in the PC plant with GPS-based PCC is 647 MWe, greater than that of the Case 12 (550 MWe). The 20-year LCOE for the PC plant with GPS-based PCC is 97.4 mills/kWh, or 152% of that of the Case 11, which is also 23% less than that of the Case 12. These results demonstrate that the GPS-based PCC process is energy-efficient and cost-effective compared with the benchmark MEA process.

Chen, Shiaoguo↗

DOE OSTI2014

The National Carbon Capture Center at the Power Systems Development Facility

The National Carbon Capture Center (NCCC) at the Power Systems Development Facility supports the Department of Energy (DOE) goal of promoting the United States’ energy security through reliable, clean, and affordable energy produced from coal. Work at the NCCC supports the development of new power technologies and the continued operation of conventional power plants under CO 2 emission constraints. The NCCC includes adaptable slipstreams that allow technology development of CO 2 capture concepts using coal-derived syngas and flue gas in industrial settings. Because of the ability to operate under a wide range of flow rates and process conditions, research at the NCCC can effectively evaluate technologies at various levels of maturity and accelerate their development path to commercialization. During its first contract period, from October 1, 2008, through December 30, 2014, the NCCC designed, constructed, and began operation of the Post-Combustion Carbon Capture Center (PC4). Testing of CO 2 capture technologies commenced in 2011, and through the end of the contract period, more than 25,000 hours of testing had been achieved, supporting a variety of technology developers. Technologies tested included advanced solvents, enzymes, membranes, sorbents, and associated systems. The NCCC continued operation of the existing gasification facilities, which have been in operation since 1996, to support the advancement of technologies for next-generation gasification processes and pre-combustion CO 2 capture. The gasification process operated for 13 test runs, supporting over 30,000 hours combined of both gasification and pre-combustion technology developer testing. Throughout the contract period, the NCCC incorporated numerous modifications to the facilities to accommodate technology developers and increase test capabilities. Preparations for further testing were ongoing to continue advancement of the most promising technologies for future power generation processes.

01 COAL, LIGNITE, AND PEAT↗