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The major goal of this project is to develop an efficient gasification system in order to convert woody biomass and agricultural residue from North Carolina to synthesis gas (syngas). Then, convert syngas into liquid fuel through catalytic process and to heat and power through a gas turbine.
This report presents the cost and performance results of an assessment of seven integrated gasification combined cycle (IGCC) plants. The primary value of this report lies not in the absolute accuracy of the capital cost estimates for the individual cases (estimated to be -15 percent/+30), but in the application of a consistent approach to allow meaningful comparisons of relative costs among the cases evaluated.
This report will update modeled costs for the production of high-octane gasoline via gasification of biomass followed by syngas cleanup and conversion to methanol/dimethyl ether. The 2018 State of Technology will be based on recent bench-scale experimental results. This report will also update previously published information for this conversion pathway in the DOE Bioenergy Technologies Office 2016 Multi-Year Program Plan with current understanding of research goals achievable by 2022 and associated modeled cost reductions. All costs will be updated to a consistent set of assumptions in 2016 dollars.
Gas Technology Institute (GTI) has concluded the Dry Solids Pump Coal - Feed Technologies (DSP-CFT) program that was initiated on October 1, 2013. The project’s primary objectives have been to gather data to increase the fidelity of the economic benefits of the Dry Solids Pump (DSP) technology for Integrated Gasification Combined Cycle (IGCC) plants, mature the technology to a Technology Readiness Level (TRL) of TRL 6 by continued testing and upgrades to the existing DSP, advance pump configuration knowledge to the point that a commercial pump can be confidently designed for low rank coal feed stocks and develop the next generation design configuration of a 1000 ton per day (tpd) DSP. After initial efforts with the existing DSP, a subscale pump was built to reduce the cost and time required to develop upgrades. The subscale development program evaluated three exit configurations and a host of geometric variations in each configuration concluding a side exit upward discharge configuration offered the greatest improvements. Both configuration and operation focused improvements were implemented on the full scale existing DSP and demonstrated 500 psi operation. An initial Techno-economic Analysis (TEA) and later update that was undertaken by Mr. Chris Higman and associates. The TEA quantifies the dramatic savings in capital and operational expenses achieved by reducing plant height and nitrogen consumption/compression, respectively in a commercial gasifier application. Drawings of the suggested design configuration for a commercial DSP feeder reflect the side exit design and incorporate lighter weight and lower cost fabrication methods. Features used for development testing are removed. A follow-on optimization program to allow the DSP technology to achieve TRL 7 is outlined.
Gasification of coal, in addition to generating syngas for power production, has the potential to produce a diverse array of high-value products. It is a challenge to understand the optimal use of this domestic coal resource amidst the potential technology options, product slates (including co-production of power), and competing feedstocks (natural gas, petroleum). This analysis seeks to begin addressing that challenge by focusing on one primary product, methanol, which also serves as a readily-transportable intermediate to many other products including olefins, gasoline, and di-methyl ether (DME).
Under a DOE funded effort, Thermosolv LLC has been developing a sorbent-based oxygen production technology for gasification and oxy-combustion applications. The sorbents utilize oxygen-storage properties of certain perovskites to (1) selectively adsorb oxygen at moderate temperature from compressed air and (2) release the adsorbed oxygen into a vacuum or a sweep gas such as CO2 and/or steam. Through cyclic operations of multiple sorbent beds such a process can be made continuous. Pressure drop across the sorbent bed and other similar design considerations dictate that the sorbent be in the form of a high surface-area-to-volume pellet and yet still possess sufficient crush strength and integrity. Process efficiency is determined by the sorption and desorption kinetics and sorbent capacity. Typical process involves cycle times in the order of 100 seconds, a time too short to fully utilize the full volume of the sorbent and the sorption capacity of the sorbent pellets. As a part of this project, Thermosolv LLC undertook the development of oxygen sorbents as a high-surface area supported sorbent on a light-weight inert support to (1) reduce the cost, (2) increase the productivity, and (3) reduce the overall weight of the reactor. Using a previously developed perovskite (LSCF 1991) with its well-characterized performance, composite sorbent pellets each consisting of an inert core coated by a thin layer of the functional perovskite material were produced. Several low-density, inexpensive inert solids supports in the 1/8”-1/4” size were selected to keep the pressure drop across the sorbent bed in the acceptable range. A number of commercial technologies including spray coating, dip coating, incipient impregnation of porous substrate followed by thermal annealing at various temperatures and duration were employed and tested to produce robust composite supported sorbent pellets. A sense of optimum coating thickness was developed by testing sorbent pellets of various increasing diameter pellets. LSCF-1991extrudates ranging in size from 1/32” to 3/16” were tested in a TGA and in a fixed-bed pressure swing test set-up for sorption/desorption cycles of interest. The data show that for the operational conditions of interest the coating thickness for a supported sorbent pellet needs to be approximately 1/32” (about 0.8 mm). Subsequent work thereby concentrated on developing composite pellets of various substrates, shapes and sizes with coating layer of about this size range. Candidate support materials were chosen based on cost, inertness, mechanical strength, thermal expansion and chemical stability with sorbent material, and in a size range to give an acceptable pressure drop in fixed-bad reactor configurations. Coating application methods used for application of the sorbent onto the support included precipitation, spray coating and dip coating from sorbent slurries and sol gels. For all coated supports where we could successfully apply a uniform coating of desired thickness with an acceptable handling performance in terms of exfoliation, TGA-based cyclic sorption/desorption testing was performed to determine cycling capacity of oxygen. Among nearly twenty different support materials tested, best adhesion performance was obtained from stainless saddle supports. In the bench-scale fixed-bad tests stainless steel saddle support composite pellets with a coating thickness in the 0.6 mm or so range, the composite sorbent pellet performance approached up to 95% of that of the 2 mm parent material pellets. In a parallel approach to reducing the cost of the sorbent, alternate sorbent formulations replacing/reducing the amount of cobalt in the LSCF family were also investigated. Successful formulations that could match the performance of LSCF 1991 were identified based on TGA cyclic tests as LSCF 1919 and LSF 1910. In the range of operational envelop of cycle times and other relevant process operating conditions, the reduced Co formulations showed comparable performance in the bench-scale fixed-bad cyclic operations. As a part of this project, we also attempted substitution of La and Sr with Ca and Ba, and Co with Mn, Ni and Cu with little success, but the overall project goal of reducing sorbent cost in terms of raw material and manufacturing expenses was successful.
The report focuses on 2019 state of technology (SOT) updates to a 2018 SOT report, which presented research and techno-economic analysis updates of the detailed 2015 design report, along with sensitivity analysis showing the effect of key assumptions and parameters. Relevant developments in 2019 are presented here without repeating the bulk of the material included in the previous reports. The conversion pathway presented in this report includes the gasification of biomass, steam reforming and cleanup of the syngas, followed by the conversion of the syngas to high-octane gasoline (HOG) via methanol and dimethyl-ether (DME) intermediates. Key achievements in 2019 for the DME-to-HOG conversion step include increased DME conversion, while maintaining selectivity towards desirable C5+ hydrocarbon products, reduced aromatics formation, and an increased conversion of co-fed C4 to C5+ (in experiments conducted to simulate the recycle of C4 products).
The 2020 state of technology (SOT) serves as an update to the 2019 SOT report and details the techno-economic analysis (TEA) results for producing high-octane gasoline (HOG) via indirect liquefaction (IDL). This report only describes changes to the experimental and analysis results from previous SOTs; more details regarding the full process design can be found in the 2015 design report. The conversion pathway presented in this report includes the gasification of biomass, steam reforming and cleanup of the syngas, followed by the conversion of the syngas to HOG via methanol and dimethyl-ether (DME) intermediates. Research efforts in 2020 included the collection of experimental results over a variety of isobutane (iC4) to DME ratios in the feed of the DME-to-HOG reactor, enabling the TEA to identify the effect on modeled product yield and cost. Additionally, a significant re-build of the Aspen Plus model allowed for better integration of new research, however underlying conceptual and economic assumptions remain the same as those detailed in the 2015 deign report. The 2020 SOT also considers the potential for federal carbon tax credits from CO 2 capture in the acid-gas removal step and the impact on the final minimum fuel selling price.
TDA Research, Inc (TDA) has developed a highly efficient integrated WGS pre-combustion carbon capture technology and demonstrated its techno-economic viability for use in the Integrated Gasification Combined Cycle (IGCC) power plants that process coal. The new system uses a warm gas CO 2 scrubber integrated with a Water-Gas-Shift (WGS) catalyst to capture greater than 90% of the carbon emissions, which does not increase the cost of electricity (COE) as much as conventional carbon capture technologies.
P&G intends to replace as much as their current heat and power by renewable energy sources. For 2014, P&G’s total energy including electricity, natural gas and steam is approximately 1,540,000 MMBTU annually (Table 2). The biomass and wastes around P&G facility can be grouped into six categories (Figure 6): (1) Agriculture residue and grass, (2) Refuse (inorganic) solid material, (3) Food waste, (4) Organic waste stream, (5) livestock manure, (6) wastewater and sludge. The six feedstock sources can provide a total energy of 3,520,000 MMBTU per year (Table 10), among which the agriculture residue is the biggest fraction, about 67%, followed by livestock manures 27%. Therefore, the available energy sources around P&G facility are enough to meet their energy needs. These energy feedstocks would be treated by two processes: anaerobic digestion for biogas subsequently for heat and power and thermochemical process (combustion, pyrolysis and gasification) for heat and power (Figure 8 and 9). For AD, a one-stage complete mixing digester is preferable; and fluidized bed reactors are favorable for thermochemical process.
Co-gasification of waste plastic and waste coal/biomass in steam was investigated to evaluate the effects of operating conditions and low-cost catalyst compositions of coal ash on syngas production and tar mitigation. The results demonstrate the benefits of waste plastic conversion with coal or biomass. A better understanding of these processes will facilitate the development of more accurate kinetic models for industrial-scale chemical recycling.
This project aims were to develop and demonstrate a scalable, integrated process to convert sewage sludge into renewable natural gas (RNG), enabling wastewater treatment plants (WWTPs) to become net energy producers. The system proposal integrates autothermal hydrothermal liquefaction (AT-HTL), supercritical salt precipitation (SCSP), and hydrothermal gasification (HTG), collectively forming the Supercritical Sludge-to-Gas (SC-S2G) platform. Initially, batch hydrothermal liquefaction reactions were used to screen sewage sludge using AT-HTL (later termed RI-HTL) conversion to biocrude, aqueous and char phases compared to hydrothermal liquefaction (HTL). Significant improvement in biocrude yield using peroxide addition at O:C ratio of 0.05 and under conditions of 300°C for 10 minutes gave 57% biocrude yield and 85% fluid carbon yield (biocrude plus aqueous), while minimizing the loss of carbon to char solids (~7%). Hence, RI-HTL was shown to be effective for conversion of real sewage sludge. The corrosion of the alloy reactor tubes or vessels is an important factor when developing a process that includes an oxidant and a chemically complex feed like sewage sludge. We investigated the corrosion rates on metal alloys at 350°C for 240 hours. Corrosion rates of 0.21 and 0.26 mpy for 304L and 316L stainless steel were measured respectively. The corrosion information obtained in this investigation was utilized by PNNL for design, materials sourcing and construction of the pilot scale continuous flow system.
Hydrothermal Liquefaction (HTL) and Catalytic Hydrothermal Gasification (CHG) proof-of-concept bench-scale tests were performed to assess the potential of the Genifuel hydrothermal process technology for handling municipal wastewater sludge. HTL tests were conducted at 300-350°C and 20 MPa on three different feeds: primary sludge (11.9 wt% solids), secondary sludge (9.7 wt% solids), and post-digester sludge (also referred to as digested solids) (16.0 wt% solids). Corresponding CHG tests were conducted at 350°C and 20 MPa on the HTL aqueous phase output using a ruthenium based catalyst. A comprehensive analysis of all feed and effluent phases was also performed. Total mass and carbon balances closed to within ± 15% in all but one case. Biocrude yields from HTL tests were 37%, 25%, and 34% for primary sludge, secondary sludge, and digested solids feeds, respectively. The biocrude yields accounted for 59%, 39%, and 49% of the carbon in the feed for primary sludge, secondary sludge, and digested solids feeds, respectively. Biocrude composition and quality were comparable to that seen with biocrudes generated from algae feeds. Subsequent hydrotreating (i.e., upgrading) of the biocrude produced from primary sludge and digested solids resulted in a product with comparable physical and chemical properties to petroleum crude oil. CHG product gas consisted primarily of methane, with methane yields (relative to CHG input) on a carbon basis of 47%, 61%, and 64% for aqueous feeds that were the output of HTL tests with primary sludge, secondary sludge, and digested solids, respectively. Siloxane concentrations in the CHG product gas were below the detection limit and well below fuel input composition limits set by several engine manufacturers. Relative to that of the sludge feeds, the HTL-CHG process resulted in a reduction in chemical oxygen demand (COD) of greater than 99.9% and a reduction in residual solids for disposal of 94-99%. The test results, as a whole, support further long term testing in a larger scale integrated system that is representative of what would be installed at a water resource recovery facility (WRRF) in order to fully assess the technical and economic viability of this technology for wastewater sludge treatment.
We have conducted comprehensive exergy analyses of three integrated gasification combined cycle with carbon capture and storage (IGCC-CCS) power plant configurations: (1) a baseline model using Selexol™ for H 2 S/CO 2 removal; (2) a modified version that adds a H 2 -selective membrane before the Selexol™ acid gas removal system; and (3) a modified baseline version that uses a CO 2 -selective membrane before the Selexol™ acid gas removal system. While holding the coal input flow rate and the CO 2 captured flow rates constant, it was determined that the H 2 -selective membrane case had a higher net power output (584 MW) compared to the baseline (564 MW) and compared to the CO 2 -selective membrane case (550 MW). Interestingly, the CO 2 -selective membrane case destroyed the least amount of exergy within the power plant (967 MW), compared with the Baseline case (999 MW) and the H 2 -membrane case (972 MW). The main problem with the CO 2 -selective membrane case was the large amount of H 2 (48 MW worth of H 2 chemical exergy) remaining within the supercritical CO 2 that exits the power plant. Finally, regardless of the CO 2 capture process used, the majority of the exergy destruction occurred in the gasifier (305 MW) and gas turbine (~380 MW) subsystems, suggesting that these two areas should be key areas of focus of future improvements.
Global waste generation is a ubiquitous challenge, driving a paradigm shift towards viewing waste as a valuable resource for a circular economy across diverse sectors. While innovative waste-to-resource pathways are crucial, rigorous Life Cycle Assessment (LCA) is essential to ensure the pathways are an important part of current practices. However, LCA application to waste valorization varies, leading to incomparable results due to differing methodological choices. This paper examines three key nuances in waste-as-resource LCAs: the zero-burden assumption, the biogenic carbon neutrality assumption, and the benchmark assumption for emissions avoidance. Using a waste gasification to hydrogen case study, we demonstrate how these methodological decisions impact LCA outcomes. Our findings reveal that waste composition significantly influences the results and highlight challenges associated with biogenic carbon accounting under various system boundary assumptions. Emissions avoidance accounting requires multi-functional unit perspectives and robust benchmark selection. This paper clarifies these accounting approaches, empirically illustrates their influence, and discusses broad implications for accurate sustainability assessment, emphasizing the critical role of transparent LCA choices for effective policy and investment in circular economy solutions.
As human exploration moves beyond low Earth orbit, innovative life support and resource production systems become forerunners for human colonization. Plasma systems allow for complex chemical processes while mitigating consumable needs. Plasma technology and applications can redefine the space environment. With this, scientists at NASA are looking to close known space technology gaps and create a paradigm shift in space-based applications. NASA’s Kennedy Space Center is exploring the use of low-temperature plasma for applications in agriculture, sanitation ,regolith reduction, waste gasification, water activation, and nutrient recovery techniques. Using low temperature plasmas, we report on the success criteria and experimental results for plasma applications for crewed transit and planetary habitation.
Human life amongst other planets requires vast technological advancements to sustain nutritional, environmental, and logistical needs. Plasma systems allow for advanced chemical processing while mitigating consumable needs or reliance on industrial infrastructure. Scientists at NASA’s Kennedy Space Center are attempting to close technology gaps with research into plasmas and their applications. Some such work includes the use of plasma for waste gasification, water activation, nutrient recovery techniques, lunar regolith reduction for oxygen extraction, and space crop production support. Here we report on the needs, success criteria, and results of plasma efforts for crewed transit and planetary habitation.