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At least 415 records · Page 23

Progress of Gas Injection EOR Surveillance in the Bakken Unconventional Play—Technical Review and Machine Learning Study

Although considerable laboratory and modeling activities were performed to investigate the enhanced oil recovery (EOR) mechanisms and potential in unconventional reservoirs, only limited research has been reported to investigate actual EOR implementations and their surveillance in fields. Eleven EOR pilot tests that used CO2, rich gas, surfactant, water, etc., have been conducted in the Bakken unconventional play since 2008. Gas injection was involved in eight of these pilots with huff ‘n’ puff, flooding, and injectivity operations. Surveillance data, including daily production/injection rates, bottomhole injection pressure, gas composition, well logs, and tracer testing, were collected from these tests to generate time-series plots or analytics that can inform operators of downhole conditions. A technical review showed that pressure buildup, conformance issues, and timely gas breakthrough detection were some of the main challenges because of the interconnected fractures between injection and offset wells. The latest operation of co-injecting gas, water, and surfactant through the same injection well showed that these challenges could be mitigated by careful EOR design and continuous reservoir monitoring. Reservoir simulation and machine learning were then conducted for operators to rapidly predict EOR performance and take control actions to improve EOR outcomes in unconventional reservoirs.

Energy & Fuels↗

Jipole: A Differentiable ipole-based Code for Radiative Transfer in Curved Spacetimes

Recent imaging of supermassive black holes by the Event Horizon Telescope has relied on exhaustive parameter-space searches, matching observations to large, precomputed libraries of theoretical models. As observational data become increasingly precise, the limitations of this computationally expensive approach grow more acute, creating a pressing need for more efficient methods. In this work, we present Jipole, an automatically differentiable (AD), ipole-based code for radiative transfer in curved spacetimes, designed to compute image gradients with respect to underlying model parameters. These gradients quantify how parameter changes—such as the black hole’s spin or the observer’s inclination—affect the image, enabling more efficient parameter estimation and reducing the number of required images. We validate Jipole against ipole in two analytical tests and then compare pixelwise intensity derivatives from AD with those from finite-difference methods. We then demonstrate the utility of these gradients by performing parameter recovery for an analytical model in three increasingly complex cases for the injected image: ideal, blurred, and blurred with added noise. In most cases, high-accuracy fits are obtained in only a few optimization steps, failing only in cases with extremely low signal-to-noise ratios. These results highlight the potential of AD-based methods to accelerate robust, high-fidelity model-data comparisons in current and future black hole imaging efforts.

79 ASTRONOMY AND ASTROPHYSICS↗

A Rapid Sequential Separation Method for Determination of Actinides and TENORM in Fracking Wastes - 20223

With recent advances in unconventional drilling technology in the US and around the world, the risks of environmental contamination and exposure due to technologically enhanced naturally occurring radioactive materials (TENORM) from fracking wastes have also surfaced. Although the Permian Basin (southeastern New Mexico, western Texas) has long been a modest producer of oil, the advent of fracking technology a decade ago turned it into hot property for producers. A 2018 assessment of undiscovered, technically recoverable continuous oil and gas resources by the U.S. Geological Survey estimates an average 46.3 billion barrels of oil and 281 trillion cubic feet of gas. This is likely to increase the use of unconventional drilling and TENORM generation. TENORM concentrations in oil and gas exploration and production waste can be several hundred to several thousand times higher than background TENORM concentrations. Both the thorium and uranium decay chains contribute to airborne radionuclides arising from the radon gas escaping the ground and subsequently decaying as airborne particulates. Additionally, radon decay products {sup 210}Pb and {sup 210}Po can build up in scale on the internal surfaces of oil and gas handling pipes and in sludge in refineries, becoming potential inhalation and ingestion hazards for workers. Furthermore, southeastern NM is also home to world's only licensed and operating transuranic nuclear waste repository, the DoE's Waste Isolation Pilot Plant (WIPP). Plutonium isotopes ({sup 239+240}Pu) and {sup 241}Am, are expected to account for more than 99% of the total radioactivity scheduled for disposal in the WIPP repository. Thus, an improved understanding of the environmental fate and transport of TENORM, liberated by unconventional drilling, is essential to assess how best to protect individuals and the environment. In this context, accurate measurement of TENORM and actinides in environmental and biological samples is essential. In this presentation, a new sequential method for the separation and pre-concentration of actinides (Pu, Am, Np) and TENORM (Po, U and Th) derived from oil and gas exploration is proposed. The TEVA method involves a rapid co-precipitation step to remove matrix interferences from the samples, followed by plutonium oxidation state adjustment to Pu (IV) and an incubation period of ∼ 1 hour at 50-60 deg. C to allow the resultant Po (II) to oxidize into Po(IV). The polonium, neptunium, thorium and plutonium are then separated on a TEVA column, while americium and uranium are separated on a TRU column. After separation, the alpha counting source was prepared by micro-precipitation with copper sulfide (CuS) for polonium and neodymium fluoride (NdF{sub 3}) for actinides. The efficiency and reliability of the procedures were tested by analyzing filter, drinking water and frack sand samples. The method is simple, robust and can be performed quickly with excellent removal of interferences, high chemical recovery and very good alpha peak resolution. (authors)

07 ISOTOPE AND RADIATION SOURCES↗

Minimizing Transuranic Waste Generated in Hot Cells at Oak Ridge National Laboratory Through Use of a Non-Destructive CO{sub 2} Pellet Cleaning System - 19577

Wastes generated in shielded hot cells containing materials contaminated with transuranic (TRU) waste present unique problems in waste disposal at Department of Energy (DOE) sites. Oak Ridge National Laboratory (ORNL) routinely processes materials contaminated with TRU waste from the High Flux Isotope Reactor (HFIR) and from other sources (both on and off-site) in their hot cell facilities, generating wastes that require eventual disposal. The waste streams generated by these processes are often high activity and exhibit high dose rates, driving them into the remote-handled (RH) category at the Waste Isolation Pilot Plant (WIPP). Reduction of the TRU waste footprint is desirable from a disposal cost perspective due to constraints with RH waste processing and a lack of space availability at the WIPP. Historically TRU waste generated at ORNL has been processed by the TRU Waste Processing Center (TWPC), which belongs to the Department of Energy's Office of Environmental Management (DOE-EM). Now that Oak Ridge legacy TRU waste is reaching its final stage, DOE-EM has turned over the mission of processing newly-generated TRU waste streams to the DOE Office of Science at ORNL. To reduce the volume of potential TRU waste occupying valuable space in the ORNL Hot Cells, a non-destructive CO{sub 2} pellet cleaning system will be used to capture particulate contaminants removed from the surfaces of waste inside the ORNL Non-Reactor Nuclear Facilities (NNFD) Hot Cells at the Irradiated Fuels Examination Laboratories (IFEL). The particulate will be segregated by particle size and captured for disposal later. This action will separate some of the TRU isotopes (particulate) from the larger waste volume (debris waste items), resulting in both lower waste disposal costs and reduced TRU waste volumes. This will be accomplished through a specialized cyclone separator. Secondary wastes are usually generated through other methods of decontamination, such as water jets and abrasive agents. These secondary wastes are absent with the CO{sub 2} pelletized system, due to sublimation of the dry ice upon impact. This is an important consideration with IFEL, a facility whose primary mission is to perform a series of R and D testing on nuclear fuel rods. Liquid is not a feasible method of decontamination as the IFEL's drains in the Hot Cells were plugged years ago due to Resource Conservation and Recovery Act (RCRA) regulations. Constraints at IFEL, such as criticality safety concerns with use of hydrogenous materials, are also alleviated with the non-destructive CO{sub 2} pellet cleaning system. These are a couple of the considerations why this method of decontamination is preferred. Due to concerns with oxidizers at WIPP grouting will be performed on the contaminated particulate produced during the trapping by the cyclone separation phase. This method will comply with mitigating oxidizing properties in TRU waste, required by the recently published Basis of Knowledge (BoK) document as part of Acceptable Knowledge (AK) by WIPP. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Novel Full-Ceramic Multi-Tubular Membrane Systems for Pre-Combustion CO2 Capture with Simultaneous H2 Production: Fabrication, Performance Testing, and 3D CFD Modeling

Inorganic membranes show promise for application in pre-combustion CO2 capture with simultaneous H2 production. State-of-the-art systems for use under high temperature and pressure conditions consist of multiple membrane tube bundles prepared in a "candle-filter" configuration, in which the membrane tubes are open at one end and sealed at the other. This configuration is used for practical reasons, specifically the need to minimize potential problems due to thermal expansion mismatch, at high temperatures, between the ceramic tube bundle and the steel housing. The primary technical problem with the candle-filter configuration for use in commercial-scale installations is the inability to purge the permeate side (typically the tube side), a feature that is crucial for high H2 recovery. In this study, we fabricated dual-end open, commercial-size ceramic multiple-tube bundles made of zeolite, palladium (Pd), and carbon molecular sieve (CMS) membranes that enable permeate-side (tube-side) purge for gas separation applications. Experimental gas separation data with these membrane bundles under harsh operating conditions (temperatures up to 350 and pressures up to 800 psig), to be presented at the meeting, manifest excellent performance. Parallel to the membrane bundle construction and testing efforts, we have also developed a detailed 3D CFD modeling package using COMSOL Multiphysics software to gain more insight into the effect on the H2 purity and recovery of the detailed geometry of the multi-tubular membrane system, including the number of tubes used, their dimensions, and placement in the bundle, as well as the number, type, and positioning of internal baffles and other flow-enhancement accessories. The CFD package is validated with experimental data from different systems (1-tube, 3-tube, and 19-tube bundles), and shows high accuracy in predicting the experimental results (<5 % error in all cases). The results of our study show that the detailed internal geometry of these multi-tubular membrane systems has a considerable impact on the performance of the system as the flow maldistribution within the shell-side can substantially decrease (>40%) the H2 recovery.

20 FOSSIL-FUELED POWER PLANTS↗

Mineral Recovery Enhanced Desalination (MRED) process: An innovative technology for desalinating hard brackish water

Desalination of water containing high concentrations of calcium, dissolved carbon dioxide, sulfate, silica and other sparingly soluble salts is difficult because of the scaling potential. An innovative pre-treatment scheme was investigated at bench scale that selectively removes these constituents and produces a soft water to enable desalination with high feed water recovery. The process first removes dissolved carbon dioxide by air stripping at low pH. Magnesium is removed by precipitation at high pH. Calcium is removed by ion exchange (IX), and sulfate is removed by nanofiltration (NF). Cation regenerant from IX, containing calcium, and concentrate from NF, containing sulfate, is combined to precipitate gypsum. Concentrate from the desalination process consisting of a concentrated NaCl solution is used to regenerate the IX resins. The selective precipitation, IX, and NF processes were tested in laboratory experiments and produced magnesium hydroxide and gypsum at greater than 90% and 95% purity respectively. A process model was developed to calculate process performance, mass and liquid flow rates. Finally, the MRED process offers the following benefits: 1) greater recovery of brackish feedwater by a desalination process, 2) recovery of marketable commodities and 3) reduction in the volume and mass of waste products from the treatment process.

42 ENGINEERING↗

EBSD Study on Processing Domain Parameters of Oxide Dispersion Strengthened 18Cr Ferritic Steel

This paper presents the results of an experimental study aimed to identify hot working domains in oxide dispersion strengthened (ODS) 18Cr ferritic steel over a wide range of temperatures (1323-1473 K) and strain rates (0.01-10 s{sup −1}). The experimental data were obtained by uniaxial compression test using the Gleeble-1500D simulator in this range of temperature and strain rate. An inverse relationship with temperature and positive strain rate sensitivity associated with dynamic recovery and recrystallization, which is influenced by temperature and strain rate, was derived from the flow stress. Based on the processing map generated at 0.5 true strain, using rate dynamic material model (DMM) approach and the calculated instability parameter (ξ(ϵ́))>0, the optimum processing domain has been determined for this steel. The most favorable processing parameters are found in the temperature ranges of 1350-1450 K with a strain rate of 0.01 s{sup −1} and 1473 K with a strain rate 0.1 s{sup −1} with peak efficiency of 30 and 35%, respectively. The material flow behavior was studied using scanning electron microscopy (SEM)-based EBSD microstructural characterization. The steel subjected to 1323 K at high strain rate 10 s{sup −1} in the low-efficiency workability region showed low aspect ratio as compared to the elongated bamboo-like initial microstructure; however, minimum strain rate (0.01 s{sup −1}) showing that localized slip/shearing is the key mechanism and fiber texture studied from the intensity distribution of inverse pole figure showed the presence of significant amount of θ-fibers. In contrast, dynamic recrystallization dominated at higher efficiency region in the safe domain of processing map and γ-fiber texture was evident in the specimen deformed at 1373 and 1473 K with strain rate of 0.01 and 0.1 s{sup −1}, respectively, which is responsible for the change in the initial 〈1 1 0〉//ED α-fiber texture.

36 MATERIALS SCIENCE↗

In-situ packaging ultra-uniform 3D hematite nanotubes by polyaniline and their improved gas sensing properties

Highlights: • Ultra-uniform 3D α-Fe{sub 2}O{sub 3} nanotubes were packaged by PANI through the two-stage solution processes. • PANI/α-Fe{sub 2}O{sub 3}-based sensor could detect low concentration of acetone (1 ppm) at lower temperature of 180 °C. • The unique structure of α-Fe{sub 2}O{sub 3} support and its synergetic effect with PANI layers improved the sensor performances. - Abstract: This paper reports the PANI (polyaniline)-packaged three-dimensional (3D) α-Fe{sub 2}O{sub 3} nanotubes P/N heterojunction, which was constructed successfully though a facile hydrothermal reaction without adding any surfactant followed by in-situ chemical polymerization in the liquid phase. The structure and morphology of the products were characterized by means of FESEM, XRD, TEM & HRTEM, TGA and FT-IR. Gas sensing test results found that, the PANI/α-Fe{sub 2}O{sub 3} nanocomposite sensor exhibited obviously higher response, lower working temperature (180 °C), fast response and recovery speeds, good selectivity and excellent stability to acetone gas, indicating its promising application for high-performance acetone sensors. The enhanced gas sensing performances can be attributed to the factors like ultra-uniform 3D nanotube-like structure for α-Fe{sub 2}O{sub 3}, the noticeable advantages of PANI, as well as the construction of heterojunction barrier at their interface. The as-prepared PANI/α-Fe{sub 2}O{sub 3} nanocomposite may be also applied in other areas like photocatalysis, water purification, ion batteries, optical devices, and so on.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

EGS Collab Experiment 2: Results of Tracer Tests

Multiple sets of tracer tests were conducted at the EGS Collab Testbed 2 on the 4100 L at the Sanford Underground Research Facility (SURF), Lead, SD. The enclosed data package includes: tracer recovery results, water balance calculations and rationales, water flow measurement for north ditch, (manual) water flow measurements at different production points, and a tracer-interpretation paper presented at the Stanford Geothermal Workshop, 2023.

15 GEOTHERMAL ENERGY↗

Development of a Novel Bioprocess for Synthesizing and Purifying Adipic Acid

Through DOE’s Bioenergy Technologies Office and the Energy Efficiency and Renewable Energy Small Business Voucher (SBV) Pilot, ZymoChem, Inc received support to work with the ABPDU to accelerate the development of a novel adipic acid (AA) bioprocess by evaluating technologies to demonstrate the following: 1) Process development of AA via ZymoChem’s carbon-conserving (C 2 ) pathway in 2L bioreactors, using industrial feedstocks, and as a salt with hexamethylenediamine (HMDA), i.e., the industrially desired form of AA as AA-HMDA is the precursor for nylon 6,6 synthesis. 2) Pilot scale aerobic fermentation at the 300 L scale (stage 1) followed by a high cell density (HCD) anaerobic resting cell biotransformation (RCB) at the 50 L scale (stage 2). 3) Demonstration of a viable recovery process at the 50 L scale for purifying the product (i.e., AA-HMDA salt) and deliver multiple kg-quantity batches of purified product for further testing.

09 BIOMASS FUELS↗

Communication-Constrained Robust Control and Learning of Grid-Connected

The electric grid of things (EGoT) promises great potential for innovative grid services by tapping into vast load flexibility. However, the unique characteristics of EGoT, being a part of the cyber-physical electric power system, present both opportunities and challenges, especially concerning supply-demand balancing, stability, and communication constraints. Traditionally, centralized control was employed to ensure balance and stability in power systems. However, with the massive influx of EGoT devices, new strategies are needed to efficiently coordinate and control these distributed devices for optimal grid operations. While some studies have explored efficiency and economic models, there remains a gap in ensuring reliability under everyday operations and resilience during extreme conditions. Addressing this gap, this project develops the technology for an Energy Service Interface (ESI) that includes novel pricing, control, learning, and distributed optimization algorithms, which will enable utilities to recruit EGoT assets for crucial grid services such as load flexibility, voltage regulation, and situation-awareness. The key novelty of the proposed technology is the careful distribution of learning and control functions across utility and EGoT asset owners such that provably efficient and resilient grid operations are attained while respecting communication and information-exchange constraints. Specifically, the project team develops machine-learning enhanced load modeling methods to allow EGoT asset owners to learn their load capability and flexibility, and develops pricing-based and decentralized learning-based control so that asset owners can coordinate to meet system-wide demand-supply balance and reliability goals. For extreme situations involving high-impact, low-probability catastrophic events (termed the “black-sky” events), the team also develops (1) a “Feeder-Operating Center-on-a-Laptop” (FOCAL) software that can assist utility personnel in leveraging EGoT assets to accelerate the service recovery of damaged feeders, and (2) distributed optimization algorithms that can coordinate the operation points of EGoT devices under severe communication constraints. The proposed technology has been extensively tested and evaluated through simulations and on a testbed. In summary, as we transition into a more interconnected and digital power grid era, our project’s findings and developments offer a pivotal step toward guaranteeing both efficiency and resilience in the face of both everyday operations and rare “black-sky” events.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Gain Stability of Hamamatsu R5912-MOD Photo-Multipliers at Low Temperature

The Photon Detection System is a crucial component of the ICARUS detector in the Short Baseline Neutrino (SBN) Program at Fermi National Accelerator Laboratory (FNAL). It consists of 360 Photo Multiplier Tubes (PMTs) 8” Hamamatsu R5912-MOD and, since June 2020, it has been operated at the liquid Argon cryogenic temperature. During these years, the PMTs have shown gain losses as an aging effect. Using a climatic chamber at the INFN Sezione di Catania, we confirmed a stable gain for a single PMT 8” Hamamatsu 5912-MOD when operated at room temperature, and a persistent gain loss at temperatures around -70°C, although far from the liquid Argon one. No gain recovery was obtained bringing the PMT back to room temperature. We suspect that dynode deterioration due to temperature gradient plays a significant role in this phenomenon. During our test, the PMT was illuminated by a 520 nm laser source and operated in current mode. The laser beam was split into two optical fibers, the first one transmitting light through Neutral Density filters and then diffusing it over the surface of the PMT photocathode. The other optical fiber was used for an independent reference measurement of the injected light via a bolometric photodetector. In this presentation, the main technical characteristics of the measurement system are shown together with preliminary results which need further investigation to elucidate the underlying mechanisms driving the gain loss and to propose new mitigation strategies.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Fermilab PIP II Machine Protection System Digitized Data Noise Elimination Scheme and Its FPGA Implementation

In Fermilab's PIP-II machine protection system, beam loss signals from various detectors are digitized at 125 MS/s. Noise from both high-frequency sources and low-frequency 60 Hz AC power equipment can con-taminate the data. To suppress noise across these ranges especially 60 Hz and its harmonics, which overlap with beam loss signal frequencies advanced digital processing beyond standard filtering is re-quired. Several real-time functional blocks were simu-lated and tested on an FPGA: (1) a dual time-constant discharging integrator filter, (2) a de-ripple baseline extraction and storage block, and (3) a fast-recovery discharging integrator. The nonlinear IIR integrator filter removes high-frequency noise and feeds into the baseline extractor. Upon detecting abrupt beam loss, it switches to a longer time constant to prevent baseline distortion. The de-ripple block calculates a valid base-line by averaging over multiple 60 Hz periods, storing results in a 4096-word FPGA RAM. This baseline is subtracted from raw data before integration by the fast-recovery block, which resets quickly after use. All blocks achieved expected performance.

Wu, Jinyuan [Fermilab] (ORCID:0000000344329521)↗

Carbon Capture utilizing Hybrids: Membrane and Liquefaction

Air Liquide is developing a next generation polyimide membrane material (PI-2) for application in our cold membrane hybrid process for CO 2 capture. Combining the PI-2 membrane operation with an integrated CO 2 compression and purification unit significantly reduces the overall cost of CO 2 capture. The current work is aimed at developing the PI-2 material to a commercial scale, then validating its performance under real flue gas conditions. Previous work showed promising results for the cold membrane hybrid process utilizing the commercially available Air Liquide PI-1 membrane bundles. The cold membrane technology was demonstrated at the National Carbon Capture Center (NCCC) with a 0.3 MWe field-test unit incorporating 12” diameter PI-1 commercial bundle. The cost of 90% CO 2 capture from a 550 MWe net coal power plant was estimated to be between 40 and $45/tonne. The novel PI-2 membrane was tested at a smaller scale (1” modules) and exhibited up to 10 times the CO 2 permeance and similar CO 2 /N 2 selectivity as the PI-1 membrane. This corresponds to a potential cost reduction of $3/tonne for CO 2 capture. The current project seeks to develop this next generation PI-2 material to a technology readiness level of 5 via manufacturing scale-up and testing with 600 - 1,000 Nm3/h of real flue gas, 0.2 - 0.3 MWe equivalents. 6” diameter commercial membrane bundles have been fabricated and tested at NCCC. These bundles met the project success criteria with a productivity of over 640 Nm3/hr and permeate purity in excess of 60%, at 90% CO 2 recovery. An advanced bundle formation technique, which further lowers the bundle cost and CO 2 capture cost, is also being developed under the scope of this project. Further manufacturing scale-up is underway to verify the technique. A final techno-economic analysis (TEA) for a 550 MWe net power plant has been initiated.

Hasse, Dave↗

Fermilab PIP II machine protection system digitized data noise elimination scheme and its FPGA implementation

In Fermilab's PIP-II machine protection system, beam loss signals from various detectors are digitized at 125 MS/s. Noise from both high-frequency sources and low-frequency 60 Hz AC power equipment can contaminate the data. To suppress noise across these ranges especially 60 Hz and its harmonics, which overlap with beam loss signal frequencies advanced digital processing beyond standard filtering is required. Several real-time functional blocks were simulated and tested on an FPGA: (1) a dual time-constant discharging integrator filter, (2) a de-ripple baseline extraction and storage block, and (3) a fast-recovery discharging integrator. The nonlinear IIR integrator filter removes high-frequency noise and feeds into the baseline extractor. Upon detecting abrupt beam loss, it switches to a longer time constant to prevent baseline distortion. The de-ripple block calculates a valid baseline by averaging over multiple 60 Hz periods, storing results in a 4096-word FPGA RAM. This baseline is subtracted from raw data before integration by the fast-recovery block, which resets quickly after use. All blocks achieved expected performance.

Wu, J. [Fermilab] (ORCID:0000000344329521)↗

Post-Closure Inspection Letter Report for Closed Non-Resource Conservation and Recovery Act (RCRA) Corrective Action Units (CAUs) On the Nevada National Security Site (NNSS), For Calendar Year 2019, With Errata Sheet

Post-Closure inspection letter report for the following CAUs for calendar year 2019 including CAUs located on the Nevada Test and Training Range (NTTR) that are accessed through the NNSS Main Gate. Use restriction issues that were identified in 2018 inspections were addressed in 2019.

54 ENVIRONMENTAL SCIENCES↗

A Heuristic Approach to the Post-disturbance and Stochastic Pre-disturbance Microgrid Formation Problem

Microgrid formation is a potential solution in post-disaster electric grid recovery efforts. Recent works propose distribution level microgrid formation models using mixed-integer linear programming techniques. However, these models can only be solved for small and medium size power systems due to their computational intractability. In this article we introduce a heuristic approach that allows to approximately solve the post-disturbance microgrid formation problem for medium to large, more realistic, instances. Furthermore, the proposed approach allows to approximately solve the pre-disturbance microgrid formation problem (a stochastic version of the post-disturbance problem), in which the aim is to allocate extra generation capacity to the network to immunize it, as best as possible, against an uncertain cascading failure. Our results are illustrated by solving versions of the problem on ten test cases with up to 3012 buses.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Enabling Coal Technology with Carbon Capture for Future Markets with Flameless Pressurized Oxy-Combustion (FPO)

Future markets for power are expected to require more load following power plants, which reduces output during the night and early morning. This is when the demand for electricity is the lowest, so plants must respond rapidly at any time to peak loads resulting from the variable output of wind and solar power. A coal power plant based on Flameless Pressurized Oxy-combustion (FPO) can go from 5% to 100% of capacity rate in less than 30 minutes in response to fluctuating demand, operating at capacity when power prices are highest. FPO is a proven oxy-combustion technology that was developed to recover energy from low ranking coal, other brown fuels and wastes. ITEA began developing FPO in 2003 on a 5-MWth pilot in Gioia del Colle, Italy, to destroy hazardous industrial waste and as such, design objectives were very high combustion efficiencies and capture of metals in the fuel in the vitreous slag. The technology was subsequently deployed in 2009 at the 15-MWth scale at the Jurong Island petrochemical cluster in Singapore for waste incineration. FPO is an oxy-combustion process whereby oxygen is separated from the air, and it is used in combustion with recirculated flue gas to maintain combustion temperatures at acceptable levels. The resultant flue gas is primarily CO 2 and water, which allows for a relatively simple and cheap CO 2 capture process. This is in contrast to air-combustion systems which require a complex and costly post-combustion capture (PCC) process. Coal is fed to the combustor slurried in water, and the combustor operates at elevated pressure (approximately 12 bar) which improves the overall efficiency and reduces the size and cost of the combustor. Notably, the FPO cycle maintains high efficiency by recovering most of the heat of vaporisation of the contained water. The combustor is designed to coalesce the molten ash particles so that they settle to the chamber walls and drain to the outlet, significantly reducing the particulate content in the exhaust gas and allowing the use of coals with up to 40% alkaline ash content. FPO is a low-emission technology: zero thermal NOx minimises overall NOx; any organic nitrogen is converted to elemental nitrogen (N2). Total organic content (TOC) at combustor exit is hundreds of times lower than for traditional combustion processes, with dioxin and furans close to zero. Work commenced on a DOE funded pilot demonstration project in October 2016 to provide the design for a 50-MWth FPO pilot plant that can fire a wide range of high-to-low rank coals. The project will investigate updating and improving the cycle for power generation with CO 2 capture by incorporating a turbo-expander with a principal steam power island that utilizes a heat recovery steam generator, increasing the overall efficiency of the cycle. A cost study is also performed on the updated FPO design as part of the project. The FPO pilot plant built based on the design will then be demonstrated over a 3-year test program to generate data for the design of a commercial-scale 500 MWth firing module commercial power plant with integral carbon capture and sequestration (CCS), which could start construction in 2025. A discussion of the levelized cost of electricity (LCOE) of various cases are presented, including a comparison of established supercritical with PCC (SCPC) technologies with FPO fitted with CO 2 compression and liquefaction, and FPO ready for carbon capture and sequestration (CCS-ready). This would enable CO 2 capture for use in enhanced oil recovery (EOR) or sequestration when market conditions make it attractive to do so. In addition, a comparison of LCOE of FPO and conventional processes for firing low-ranking coals with high water and ash content will be provided.

01 COAL, LIGNITE, AND PEAT↗