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All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

Subtask 5.10 - Testing of an Advanced Dry Cooling Technology for Power Plants

The University of North Dakota’s Energy & Environmental Research Center (EERC) is developing a market-focused dry cooling technology that is intended to address the key shortcomings of conventional dry cooling technologies: high capital cost and degraded cooling performance during daytime temperature peaks. The unique aspect of desiccant dry cooling (DDC) is the use of a hygroscopic working fluid—a liquid desiccant—as a heat-transfer medium between a power plant’s steam condenser and the atmosphere. This configuration enables a number of beneficial features for large-scale heat dissipation to the atmosphere, without the consumptive use of cooling water. The overall goal of this project was to accurately define the performance and cost characteristics of DDC to determine if further development of the concept is warranted. A balanced approach of modeling grounded in applied experimentation was pursued to substantiate DDC-modeling efforts and outline the potential for this technology to cool full-scale power plants. The resulting analysis shows that DDC can be a lower-cost dry cooling alternative to an air-cooled condenser (ACC) and can even be competitive with conventional wet recirculating cooling under certain circumstances. This project has also highlighted the key technological steps that must be taken in order to transfer DDC into the marketplace. To address these issues and to offer an extended demonstration of DDC technology, a next-stage project should include the opportunity for outdoor ambient testing of a small DDC cooling cell. This subtask was funded through the EERC–U.S. Department of Energy (DOE) Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FC26-08NT43291. Nonfederal funding was provided by the Wyoming State Legislature under an award made through the Wyoming Clean Coal Technologies Research Program.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2013

Advanced Energy Systems Fuels (Sample Annual Report for SCC)

Increasing global population and quality of life demands will continue to drive the necessity for abundant and affordable potable water, clean energy, and food supplies into the future. The thermochemical conversion of carbon-based feedstocks is a promising route for the production of affordable and clean energy commodities (heat, power, transportation fuels, chemicals, plastics, etc.) due to its flexibility to accommodate a variety of feeds, as well as the inherent nature of the process to facilitate near zero greenhouse gas (GHG) emissions when coupled with carbon capture and storage. Leveraging large domestic fossil energy resources (i.e., coal) with other opportunistic energy sources (i.e., biomass) in co-feed configurations has the potential to produce nationally derived, abundant, and affordable energy commodities, including transportation fuels through coal-biomass to liquids (CBTL) routes.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2012

Carbon Capture (30 September 2012) (Annual Report)

Capture of carbon dioxide (CO 2 ) is a critical component in reducing greenhouse gas emissions from fossil fuel-based processes. The Carbon Capture research to be performed is aimed at accelerating the development of efficient, cost-effective technologies which meet the post-combustion programmatic goal of capture of 90% of the CO 2 produced from an existing coal-fired power plant with less than a 35% increase in the cost of electricity (COE), and the pre-combustion goal of 90% CO 2 capture with less than a 10% increase in COE. The specific objective of this work is to develop innovative materials and approaches for the economic and efficient capture of CO 2 from coal-based processes, and ultimately assess the performance of promising technologies at conditions representative of field application (i.e., slip stream evaluation).

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2014

Novel Non-Aqueous CO 2 Solvents and Capture Process with Substantially Reduced Energy Penalties (Final Scientific/Technical Report)

The overall objective of this 3 year project was to rapidly advance the development a family of promising NAS formulations from proof-of-concept testing through to testing in a representative process arrangement to determine the potential for this novel solvent-based process to substantially reduce (i.e., >40%) the energy demand and cost of CO 2 capture from fossil fuel-fired electricity generating units. The goal of this project was to thoroughly characterize the NASs and evaluate their performance in a small process unit to understand their potential to lower the energy demand of a CO 2 capture process and demonstrate feasibility. Detailed characterization of the thermodynamic properties of the NASs revealed large working capacities under low regeneration temperatures (i.e., <100°C) and lower heats of absorption than conventional aqueous amine solvents. The thermal energy demand for these promising NAS formulations was estimated to be approximately 40% less than conventional aqueous-amine solvents (2.06-2.15 GJt / tonne CO 2 vs 3.6 GJt / tonne CO 2 ).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2016

Final report of “A Detailed Study of the Physical Mechanisms Controlling CO2-Brine Capillary Trapping in the Subsurface” (University of Arizona, DE-SC0006696)

Carbon capture and storage (CCS) of carbon dioxide emissions generated by production or combustion of fossil fuels is a technologically viable means to reduce the build-up of CO2 in the atmosphere and oceans. Using advantages of scale and location, CCS is particularly suitable for large point sources near ubiquitous deep saline aquifers, depleted gas reservoirs, or at production reservoirs for enhanced oil recovery (EOR). In the BES-funded research project, Oregon State University (OSU) carried out capillary trapping experiments with proxy fluids that mimic the properties of the scCO2/brine system under ambient temperatures and pressures, and successfully developed a unique and novel x-ray compatible, high-pressure, elevated temperature setup to study the scCO2/brine system under challenging reservoir conditions. Both methodologies were applied to a variety of porous media, including synthetic (glass bead) and geologic (Bentheimer sandstone) materials. The University of Arizona (UA) developed pore-scale lattice Boltzmann (LB) models which are able to handle the experimental conditions for proxy fluids, as well as the scCO2/brine system, that are capable of simulating permeability in volumes of tens of millions of fluid elements. We reached the following summary findings (main institute indicated): 1. (OSU/UA) To understand capillary trapping in a multiphase fluid-porous medium system, the system must be analyzed from a pore-scale force balance perspective; trapping can be enhanced by manipulating wetting and nonwetting phase fluid properties. 2. (OSU) Pore-scale fluid connectivity and topology has a clear and direct effect on nonwetting phase capillary trapping efficiency. 3. (OSU) Rock type and flow regime also have a pronounced effects on capillary trapping. 4. (OSU/UA) There is a predictable relationship between NWP connectivity and NWP saturation, which allows for development of injection strategies that optimize trapping. The commonly used Land model (Land, 1968) does not predict amount of trapped NWP accurately. 5. (UA) There are ambiguities regarding the segmentation of large-volume gray-scale CT data into pore-volumes suitable for pore-scale modeling. Simulated permeabilities vary by three orders of magnitude and do not resemble observed values very well. Small-volume synchrotron-based CT data (such as produced by OSU) does not suffer significantly from segmentation ambiguities. 6. (UA) A standard properly parameterized Shan-Chen model LB model is useful for simulating porous media with proxy fluids as well as the scCO2/brine system and produces results that are consistent with tomographic observations. 7. (UA) A LB model with fluid-interactions defined by a (modified) Peng-Robinson Equation of State is able to handle the scCO2/brine system with variable solid phase wettability. This model is numerically stable at temperatures between 0 and 250 °C and pressures between 3 and 50 MPa, and produces appropriate densities above the critical point of CO2 and exhibits three-phase separation below. Based on above findings OSU and UA have proposed continued experimentation and pore-scale modeling of the scCO2/brine system. The reported research has extensively covered capillary trapping using proxy fluids, but due to limited beam-time availability we were unable to apply our high-pressure CO2 setup to sufficient variation in fluid properties, and initial scCO2 connectivity. New data will also allow us to test, calibrate and apply our LB models to reservoir conditions beyond those that are currently feasible experimentally. Such experiments and simulations will also allow us to provide information how suitable proxy fluids are for the scCO2/brine system. We believe it would be worthwhile to pursue the following new research questions: 1. What are the fundamental differences in the physics underlying capillary trapping at ambient vs. supercritical conditions? 2. Do newly developed pore-scale trapping interactions and relationships translate to continuum scales? A motivation for these questions was elaborated in “Capillary Trapping of Super-Critical CO2: Linking Pore and Continuum Scales to Verify new Relationships” that was submitted to DOE-BES in 2015.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2016

Nuclear Hybrid Energy Systems Initial Integrated Case Study Development and Analysis

The US Department of Energy Office of Nuclear Energy established the Nuclear Hybrid Energy System (NHES) project to develop a systematic, rigorous, technically accurate set of methods to model, analyze, and optimize the integration of dispatchable nuclear, fossil, and electric storage with an industrial customer. Ideally, the optimized integration of these systems will provide economic and operational benefits to the overall system compared to independent operation, and it will enhance the stability and responsiveness of the grid as intermittent, nondispatchable, renewable resources provide a greater share of grid power.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2017

Operation of the NETL Chemical Looping Reactor with Natural Gas and a Novel Copper-Iron Material

The proposed Clean Power Plan requires CO 2 emission reductions of 30% by 2030 and further reductions are targeted by 2050. The current strategies to achieve the 30% reduction targets do not include options for coal. However, the 2016 Annual Energy Outlook suggests that coal will continue to provide more electricity than renewable sources for many regions of the country in 2035. Therefore, cost effective options to reduce greenhouse gas emissions from fossil fuel power plants are vital in order to achieve greenhouse gas reduction targets beyond 2030. As part of the U.S. Department of Energy’s Advanced Combustion Program, the National Energy Technology Laboratory’s Research and Innovation Center (NETL R&IC) is investigating the feasibility of a novel combustion concept in which the GHG emissions can be significantly reduced. This concept involves burning fuel and air without mixing these two reactants. If this concept is technically feasible, then CO 2 emissions can be significantly reduced at a much lower cost than more conventional approaches. This indirect combustion concept has been called Chemical Looping Combustion (CLC) because an intermediate material (i.e., a metal-oxide) is continuously cycled to oxidize the fuel. This CLC concept is the focus of this research and will be described in more detail in the following sections. The solid material that is used to transport oxygen is called an oxygen carrier material. The cost, durability, and performance of this material is a key issue for the CLC technology. Researchers at the NETL R&IC have developed an oxygen carrier material that consists of copper, iron, and alumina. This material has been tested extensively using lab scale instruments such as thermogravimetric analysis (TGA), scanning electron microscopy (SEM), mechanical attrition (ASTM D5757), and small fluidized bed reactor tests. This report will describe the results from a realistic, circulating, proof-of-concept test that was completed using NETL’s 50kW th circulating Chemical Looping Reactor (CLR) test facility.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2017

High temperature high velocity direct power extraction using an open-cycle oxy-combustion system

The implementation of oxy-fuel technology in fossil-fuel power plants may contribute to increased system efficiencies and a reduction of pollutant emissions. One technology that has potential to utilize the temperature of undiluted oxy-combustion flames is open-cycle magnetohydrodynamic (MHD) power generators. These systems can be configured as a topping cycle and provide high enthalpy, electrically conductive flows for direct conversion of electricity. This report presents the design and modeling strategies of a MHD combustor operating at temperatures exceeding 3000 K. Throughout the study, computational fluid dynamics (CFD) models were extensively used as a design and optimization tool. A lab-scale 60 kWth model was designed, manufactured and tested as part of this project. A fully-coupled numerical method was developed in ANSYS FLUENT to characterize the heat transfer in the system. This study revealed that nozzle heat transfer may be predicted through a 40% reduction of the semi-empirical Bartz correlation. Experimental results showed good agreement with the numerical evaluation, with the combustor exhibiting a favorable performance when tested during extended time periods. A transient numerical method was employed to analyze fuel injector geometries for the 60-kW combustor. The ANSYS FLUENT study revealed that counter-swirl inlets achieve a uniform pressure and velocity ratio when the ports of the injector length to diameter ratio (L/D) is 4. An angle of 115 degrees was found to increase distribution efficiency. The findings show that this oxy-combustion concept is capable of providing a high-enthalpy environment for seeding, in order to render the flow to be conductive. Based on previous findings, temperatures in the range of 2800-3000 K may enable magnetohydrodynamic power extraction. The heat loss fraction in this oxy-combustion system, based on CFD and analytical calculations, at optimal operating conditions, was estimated to be less than 10 percent. Furthermore, the heat transfer design removed approximately 7 MW/m2. The results observed in the lab-scale system were employed to develop a 1-MW scaled prototype. Scaling methods were based on critical design criteria found in similar systems, aimed at replicating combustion flow fields and reducing possible instabilities. A numerical simulation of the combustor wall was developed for a combined thermal steady model and static structural model. This combined model was developed predict combined stress parameters within the wall during testing conditions. Both models were developed within ANSYS FEA software package. The relative accuracy presented as well major performance parameters are discussed to assess the design's validity and ensure safety. The scaled prototype was manufactured through selective laser melting (SLM)-based additive manufacturing to reduce lead times and increase geometrical complexity. Additional CFD models were developed to optimize coolant manifold system parameters and perform a parametric study on channel geometry. An investigation on coolant manifold geometry demonstrated improvements in channel flow distribution when enlarging manifold lengths and increasing the number of tubes feeding into the flow. A three-dimensional model based on a single channel was developed to capture the effect of variable properties and thermal stratification. All cases in the simulation exhibited higher wall temperatures and lower convective coefficients than those determined through 1-D analytical equations. This implies that pressure and velocity safety factors must be implemented during system operation. Overall, the findings made in this investigation are thought to be of value to researchers and industrial practitioners when designing oxy-fuel direct power extraction systems operating at temperatures exceeding 3000 K. In addition to this, the implementation of the developed technology at pilot and commercial scales could result in a significant improvement in the efficiencies of heritage and next-generation power cycles.

03 NATURAL GAS↗
DOE OSTI2017

Wireless microwave acoustic sensor system for condition monitoring in power plant environments

This project successfully demonstrated novel wireless microwave acoustic temperature and pressure sensors that can be embedded into equipment and structures located in fossil fuel power plant environments to monitor the condition of components such as steam headers, re-heat lines, water walls, burner tubes, and power turbines. The wireless microwave acoustic sensor technology researched and developed through a collaborative partnership between the University of Maine and Environetix Technologies Corporation can provide a revolutionary impact in the power industry since it is anticipated that the wireless sensors will deliver reliable real-time sensing information in harsh power plant conditions that involve temperatures up to 1100oC and pressures up to 750 psi. The work involved the research and development of novel high temperature harsh environment thin film electrodes, piezoelectric smart microwave acoustic sensing elements, sensor encapsulation materials that were engineered to function over long times up to 1100oC, and a radio-frequency (RF) wireless interrogation electronics unit that are located both inside and outside the high temperature harsh environment. The UMaine / Environetix team have interacted with diverse power plant facilities, and identified as a testbed a local power generation facility, which burns municipal solid waste (MSW), the Penobscot Energy Recovery Company (PERC), Orrington, Maine. In this facility Environetix / UMaine successfully implemented and tested multiple wireless temperature sensor systems within the harsh-environment of the economizer chamber and at the boiler tubes, transferring the developed technology to the power plant environment to perform real-time sensor monitoring experiments under typical operating conditions, as initially targeted in the project. The wireless microwave acoustic sensor technology developed under this project for power plant applications offers several significant advantages including wireless, battery-free, maintenance-free operation, and operation in the harsh-environment of power plant equipment up to about 1100 oC. Their small size and configuration allows flexible sensor placement and embedding of multiple sensor arrays into a variety of components within power systems that can be interrogated by a single RF unit. The outcomes of this project and technological transfer respond to a DOE analysis need, which indicated that if one percent efficiency in coal burning is achieved, an additional 2 gigawatt-hours of energy per year is generated and the resulting coal cost savings is $300 million per year, also accompanied by a reduction of more than 10 million metric tons of CO2 per year emitted into the atmosphere. Therefore, the developed harsh environment wireless microwave acoustic sensor technology and the technological transfer achievements that resulted from the execution of this project have significant impact for power plant equipment and systems and are well-positioned to contribute to the cost reduction in power generation, the increase in power plant efficiency, the improvement in maintenance, the reduction in down-time, and the decrease in environmental pollution. The technology is also in a position to be extended to address other types of high-temperature harsh-environment power plant and energy sector sensing needs.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2017

Computational design and performance prediction of creep-resistant ferritic superalloys

Ferritic superalloys containing the B2 phase with the parent L21 phase precipitates in a disordered solid-solution matrix, also known as a hierarchical-precipitate-strengthened ferritic alloy (HPSFA), had been developed for high-temperature structural applications in fossil-energy power plants. These alloys were designed by adding Ti into a previously-studied NiAl-strengthened ferritic alloy (denoted as FBB8 in this study). Following with the concept of HPSFAs, in the present research, a systematic investigation on adding other elements, such as Hf and Zr, and optimizing the Ti content within the alloy system, has been conducted, in order to further improve the creep resistance of the model alloys. Studies include advanced experimental techniques, first-principles calculations on thermodynamic and mechanical properties, and numerical simulations on precipitation hardening, have been integrated and conducted to characterize the complex microstructures and excellent creep resistance of alloys. The experimental techniques include transmission-electron microscopy (TEM), scanning-electron microscopy (SEM), neutron diffraction (ND), and atom-probe tomography (APT), which provide the detailed microstructural information of the model alloys. Systematic tension/compression creep tests have also been conducted in order to verify the creep resistance of the potential alloy compositions. The results show that when replacing Ti with Hf and Zr, it does not form the L21 phase. Instead, the hexagonal Laves phase forms and distributes majorly along the grain boundary, or large segregation within grains. Since the Laves phase does not form parent to the B2-phase precipitates, it cannot bring the strengthening effect of HPSFAs. As a result, the FBB8 + 2 wt. % Hf and FBB8 + 2 wt. % Zr alloys have similar mechanical properties to the original FBB8. The FBB8 + Ti series alloys had also been studied, from the creep tests and microstructural characterizations, the FBB8 + 3.5 wt.% Ti possesses the greatest creep resistance, with the L21/B2 phase ratio of 4 (80% of the precipitates is the L21 phase, and 20% is the B2 phase). First-principles calculations include thermodynamics, elastic properties, and interfacial properties, which have been conducted for the understanding of the thermodynamic and mechanical properties of HPSFAs. In addition to the systematic experimental approach and first-principles calculations, a series of numerical tools and algorithms, which assist in the optimization of creep properties of ferritic superalloys, are utilized and developed. These numerical simulation results are compared with the available experimental data and previous first-principles calculations, providing the deep insight of creep mechanisms of the creep-resistant ferritic superalloys. To conclude the present research, we’ve found that (1) only FBB8 + Ti alloys have the potential of forming HPSFA, and FBB8 + Hf and FBB8 + Zr do not work. Therefore, only FBB8 + Ti alloys have desirable creep resistance, (2) the optimum composition for the FBB8 + Ti alloys is FBB8 + 3.5% Ti, which has the greatest creep resistance (218.8 MPa as the threshold stress at 700 oC), (3) first-principle calculations obtained results that could not be obtained in experiments, which are relevant to develop ferritic superalloys with the improved creep resistance, and (4) two-dimensional dislocation-dynamics simulations investigate effects of factors like precipitate volume fractions and precipitate radii in the alloy systems, which helps in developing the most desirable microstructure with greatest strengthening.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2017

Electrochemical Membrane for Carbon Dioxide Capture and Power Generation

FuelCell Energy, Inc. (FCE), in collaboration with AECOM Corporation (formerly URS Corporation) and Pacific Northwest National Laboratory, has been developing a novel Combined Electric Power and Carbon-dioxide Separation (CEPACS) system. The CEPACS system is based on electrochemical membrane (ECM) technology derived from FCE’s carbonate fuel cell products featuring internal (methane steam) reforming and carrying the trade name of Direct FuelCell®. The unique chemistry of carbonate fuel cells offers an innovative approach for separation of CO 2 from existing fossil-fuel power plant exhaust streams (flue gases). The ECM-based CEPACS system has the potential to become a transformational CO 2 -separation technology by working as two devices in one: it separates the CO 2 from the exhaust of other plants such as an existing coal-fired plant and simultaneously produces clean electric power at high efficiency using a supplementary fuel. The development effort was carried out under the U.S. Department of Energy (DOE) cooperative agreement DE-FE0007634. The overall objective of this project was to successfully demonstrate the ability of FCE’s ECM-based CEPACS system technology to separate ≥90% of the CO 2 from a simulated Pulverized Coal (PC) power plant flue gas stream and to compress the captured CO2 to a state that can be easily transported for sequestration or beneficial use. In addition, a key objective was to show, through the technical and economic feasibility study and bench scale testing, that the ECM-based CEPACS system is an economical alternative for CO 2 capture in PC power plants, and that it meets DOE’s objective related to the incremental cost of electricity (COE) for post-combustion CO 2 capture (no more than 35% increase in COE). The project was performed in three budget periods (BP). The specific objective for BP1 was to complete the Preliminary Technical and Economic Feasibility Study. The T&EF study was based on the carbon capture system size suitable for a reference 550 MW PC power plant. The specific objectives for BP2 were to perform (flue gas) contaminant effect evaluation tests, small area membrane tests using clean simulated flue gas, design a flue gas pretreatment system for processing of the gas feed to ECM, update the Technical & Economic Feasibility Study (T&EFS) incorporating results of contaminant effect tests and small area membrane tests, and to prepare a test facility for bench scale testing. The specific objectives for BP3 were to perform bench scale testing (parametric and long-duration testing) of a 11.7 m 2 ECM-based CO 2 capture, purification and compression system, and update (as final) the Technical and Economic Feasibility Study. In addition, an Environmental Health and Safety evaluation (assessment) of the ECM technology was included. This final technical report presents the progress made under the project.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2017

Novel Silica Nanostructured Platforms with Engineered Surface Functionality and Spherical Morphology for Low-Cost High-Efficiency Carbon Capture

Carbon capture is an integral part of the CO 2 mitigation efforts, and encompasses, among other measures, the demonstration of effective and inexpensive CO 2 capture technologies. The project demonstrated a novel platform—the amine-functionalized stellate mesoporous silica nanosphere (MSN)—for effective CO 2 absorption. The reported CO 2 absorption data are superior to the performance of other reported silica matrices utilized for carbon capture, featuring an amount of over 4 milimoles CO 2 /g sorbent at low temperatures (in the range of 30-45 ºC), selected for simulating the temperature of actual flue gas. The reported platform is highly resilient, showing recyclability and 85 % mass conservation of sorbent upon nine tested cycles. Importantly, the stellate MSNs show high CO 2 selectivity at room temperature, indicating that the presence of nitrogen in flue gas will not impair the CO 2 absorption performance. The results could lead to a simple and inexpensive new technology for CO 2 mitigation which could be implemented as measure of CO 2 mitigation in current fossil-fuel burning plants in the form of solid sorbent.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2016

Benefits of Hot Isostatic Pressure/Powdered Metal (HIP/PM) and Additive Manufacturing (AM) To Fabricate Advanced Energy System Components

Advanced Energy systems require large, complex components produced from materials capable of withstanding severe operating environments (high temperature, pressure, corrosivity). Such parts can be difficult to source, as conventional material processing technologies must be tailored to ensure a safe and cost effective approach to large-scale manufacture of quality structural advanced alloy components that meet the performance specifications of AE systems. (HIP/PM) has shown advantages over other manufacturing methods when working with these materials. For example, using HIP’ing in lieu of casting means significant savings in raw material costs, which for expensive, high-nickel alloys can be considerable for large-scale production. Use of HIP/PM also eliminates the difficulties resulting from reactivity of these materials in the molten state and facilitates manufacture of the large size requirements of the AE industry, producing a part that is defect and porosity free, thus further reducing or eliminating time and expense of post processing machining and weld repair. New advances in Additive Manufacturing (AM) techniques make it possible to further expand the benefits of HIP/PM in producing AE system components to create an even more robust manufacturing approach. Traditional techniques of welding and forming sheet metal to produce the HIP canisters can be time consuming and costly, with limitations on the complexity of part which can be achieved. A key benefit of AM is the freedom of design that it offers, so use of AM could overcome such challenges, ultimately enabling redesign of complete energy systems. A critical step toward this goal is material characterization of the required advanced alloys, for use in AM. Using Haynes 282, a high nickel alloy of interest to the Fossil Energy community, particularly for Advanced-UltraSuperCritical (AUSC) operating environments, as well as the crosscutting interests of the aerospace, defense and medical markets, this research pursued three new methods of manufacturing these advanced alloys: 1) Directly built AM parts; 2) AM cans for HIP/PM; and 3) AM cans produced in the final part material. The project utilized Carpenter atomized A-282 in varied mesh sizes customized for both AM and HIP, ExOne’s binderjet technology, the fastest metal 3D printing technique on the market at the current time, coupled with an alloy specific sintering profile to produce a sufficiently dense part for final HIP by Bodycote. Final parts were subjected to chemical and physical property tests and results were compared to published and gathered data. Chemistry results for all the parts were within the published criteria. Furthermore, the AM and HIP/PM parts showed measurable improvement over previous A282 HIP/PM results, in part due to an improved HT spec, and a marked improvement over results from A282 castings. These results indicate that combining AM and HIP/PM in the manner set forth in this project provides a credible manufacturing approach of these activities are set forth in this Final Technical Report.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Optimization of Advanced Steels for Cyclic Operation through an Integration of Material Testing, Modeling and Novel Component Test Validation

The efforts in this project were focused in three primary objectives, provided below: • To develop the needed microstructural processing and performance relationships and associated material models for specific constituents in fabricated weldments (such as the parent material, heat affected zone regions and weld metal), • Apply these metallurgical relationships through modeling of a welded pressure bearing power plant component subjected to cyclic operational conditions under both mechanical and thermal loading, and • Validate the model through novel structural feature and component tests. An attempt was made to optimize the heat treatment schedule to reduce or eliminate the presence of boron nitride (BN) in the matrix of the Grade 92 material. BN has been shown to be a primary nucleation source for creep damage. Proper evaluation of material behavior, and as assessed in this research, included the influence of geometric notches (such as those from poor fabrication or design) and metallurgical notches (such as weldments or poorly processed parent material). Better practice methodologies were implemented in the theoretical design of a high-temperature, critical component for cyclic operation. It was demonstrated that vessel testing can be reliably performed and provides a critical link between standard testing, structural assessment and validation. While the goal of an improved Grade 92 steel was not achieved in this project, there is considerable value in applying the documented testing and assessment methodologies to assess material and/or component behavior. This is especially true for materials and/or designs which are expected to be subjected to flexible operating modes. Design of a cycling state of the art thick wall steam header for long term operation with a state of the art ferritic steel was a task in this project. Implementation of that task showed how many factors including plant operating mode, creep strength, creep ductility, fatigue strength, and resistance to crack growth should be considered and evaluated to properly design high temperature components for long term service (200,000 operating hours or more) in a modern Fossil energy power plant. The current ASME non-nuclear boiler design code does not mandate this level of complex analysis nor does it provide all the metallurgical and mechanical properties data needed to perform this kind of design analysis.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Lab-scale Development of a Hybrid Capture System with Advanced Membrane, Solvent system, and Process Integration

The objective of the project is to achieve lab-scale demonstration of a transformational hybrid membrane/solvent system for the capture of CO 2 from flue gas. A novel process integration scheme was proposed to overcome the low partial pressure of CO 2 present in flue gas. This scheme takes advantage of the potential synergies inherent in the membrane and solvent capture systems. The proposed hybrid technology replaces the second-stage membrane with a solvent capture process. The combustion air is used as a sweeping gas in the solvent stripper. This overall configuration has the major advantages of requiring much less air and eliminating the problems associated with oxygen slip in the membrane-based systems. Even more importantly, because of the presence of the air sweep in the stripper, much lower temperatures are required for solvent regeneration, which enables heat integration to the point that no process steam is required. This project was to perform lab-scale demonstration of Liquid Ion Solutions (LIS) transformational hybrid membrane/solvent system for post-combustion CO 2 capture while demonstrating significant progress toward achievement of the overall fossil energy performance goals of 90% CO 2 capture rate with 95% CO 2 purity at a cost of electricity 30% less than baseline capture approaches. This report is written chronologically based on budget periods. Each budget period discusses the work performed and its results. At the end of each budget period the milestone charts are provided to show the progress. This project was not able to meet its stated goals. The performances of the power plant equipped with the hybrid process and Baseline Case B12B were compared. The simulation results showed that the power plant equipped with hybrid CO2 capture process has an improved thermal efficiency of 33.4% compared to the Baseline Case B12B, which is 32.5%. However, the COE for the hybrid process is $146.3/MWh which is higher than the $142.8/MWh for Case B12B. If this process were to be applied as a retrofit, it may make sense to use this configuration as it does not require any change in an existing plant configuration and steam cycle. However, for a new powerplant the capital cost is higher than the Case B12B. On the membrane development side, we successfully showed that interfacially-controlled envelope (ICE) membranes work. The inclusion of surface modified nano-particles results in much higher gas diffusivities. The Gen-1 ICE membrane developed under this project showed exceptional improved permeability for CO 2 . However, we ran into major problems which were associated with the scalability and reproducibility of the poly(phosphozene) polymers. The issues with scale-up are and batch to batch variability is also discussed. At the end of this report we have provided our recommendations on materials development for better membrane materials and alluded to the use of much simpler chemistry while keeping the concept of ICE membrane intact. It is also clear that vacuum and compression equipment is costly. If a process which can eliminate the use of vacuum and compression equipment would significantly decrease the overall cost of capture. Some thoughts regarding such system is also provided in the outlook portion of this report.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Device-scale CFD study for mass transfer coefficient and effective mass transfer area in packed column

Carbon dioxide (CO 2 ) is a significant contributor of greenhouse gases emissions responsible for global warming. The fossil-fueled power plant is one of the major sources of CO 2 emission worldwide and needs to be mitigated. Post-combustion carbon capture by chemical absorption can be a promising technology to reduce CO 2 emission from power plants. The absorption is carried out via countercurrent flow in the packed columns. Although monoethanolamine (MEA) is a popular solvent, it has also limitations such as high volatility of solvent, corrosivity that leads to product degradation and damage to apparatuses, low CO 2 loading capacity, etc. Therefore, alternate solvents are being explored as prospective materials for carbon capture. A water-lean solvent, CO 2 binding organic liquids (CO2BOL), is currently being developed as a prospective material in carbon capture at the Pacific Northwest National Laboratory. Since the development of the material is at the primitive stage, it needs extensive investigation before industrial deployments. Hydrodynamics and mass transfer phenomena in the packed column using CO 2 BOL is unknown. Computational fluid dynamics (CFD) can be a useful tool to understand these phenomena in the packed column. Before employing the extensive CFD investigations, one needs to carefully validate CFD predictions for accurate flow predictions. This report demonstrates the validation of multiphase flow simulations against the experimental results for both structured and random packed columns. The reactive multiphase flow simulations using volume of fluid method were conducted at a wide range of liquid loads and contacts angles. The effective area is one of the critical factors dictating interphase mass transfer due to chemical reactions. Accordingly, CFD-predicted effective areas were compared with the experimental results of Tsai et al. [1] for Mellapak 250.Y structured packing. Both results matched well at different liquid loads in the presence of fast chemical kinetics using caustic solvents. Further, reactive multiphase flow simulations were also conducted in pall ring random packing to compute effective areas in the presence of fast chemical reactions. The CFD-predicted effective area compared well with correlation developed by Song et al. [2]. With successful validations, the current simulation framework can be further used for prediction of hydrodynamics and mass transfer phenomena using CO 2 BOL solvents in the packed column. Subsequently, it would be helpful in design optimization of a packed column. In addition to validation of the CFD model, this report also explains the mechanism for enhanced liquid side mass transfer for a structured packed column as compared to the wetted wall column.

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DOE OSTI2019

Multiscale Modeling of CO 2 Migration and Trapping in Fractured Reservoirs with Validation by Model Comparison and Real-Site Applications (Final Technical Report)

This report documents the accomplishments achieved during the project titled “Multiscale Modeling of CO 2 Migration and Trapping in Fractured Reservoirs with Validation by Model Comparison and Real-Site Applications” funded by the US Department of Energy, Office of Fossil Energy. The objectives of the project were to develop modeling capabilities for predicting CO 2 and brine migration in fractured reservoirs during geologic carbon storage and to investigate the feasibility of carbon storage in fractured reservoirs using the newly developed modeling capabilities. To achieve these objectives new mass transfer functions were developed to adapt existing dual-continuum approaches – a commonly used approach in hydrocarbon reservoir modeling – to the CO 2 -brine system. In the dual-continuum approach the undisturbed rock matrix and the fractures are modeled as two separate continua, which are coupled through mass exchange of CO 2 and brine between the two continua. Mass transfer functions represent the mass exchange between fractures and the rock matrix, without requiring highly resolved numerical grids of individual fractures, thus allowing large modeling domains relevant to geologic carbon storage questions (tens of meters to hundreds of kilometers). Mass transfer functions for the exchange of both free-phase CO 2 and brine between fractures and rock matrix were developed for both the injection phase and the post-injection phase. During the injection phase the fractures are filled with CO 2 , while the rock matrix is initially filled with brine. Therefore, a mass transfer function was developed that is based on vertical displacement of brine by CO 2 in the rock matrix due to gravitational forces. Once CO 2 injection ceases and CO 2 migrates away from the direct vicinity of the injection site, the fractures will begin to re-fill with brine, while the rock matrix will have high CO 2 saturations. For these conditions a mass transfer functions was developed that is based on spontaneous imbibition, as the pore spaces in the rock matrix are much smaller than in the fractures. For formations with low permeability or high capillary entry pressure of the rock matrix, free-phase CO 2 may not be able to enter the rock matrix. However, free-phase CO 2 at the interface between fractures and rock matrix can dissolve into brine resident in the rock matrix. Therefore, additional mass transfer functions were developed based on aqueous-phase diffusion of CO 2 through the rock matrix. These mass transfer functions are based on existing solutions for diffusion and were expanded to be applicable to a variety of block shapes relevant to dual-continuum modeling. Implementations of the newly developed mass transfer functions showed that they give accurate results when compared to highly resolved models. In addition to developing new transfer functions, a new vertically-integrated dual-continuum modeling framework was developed. This development takes advantage of fast vertical segregation of CO 2 and brine in the fractures due to the density difference between CO 2 and brine and the high permeability of the fractures. Therefore, a vertically-integrated vertical equilibrium model for the fractures is coupled with a vertically-distributed model for the rock matrix. The newly developed approach significantly reduces the computational effort, but is only accurate for fracture permeabilities of 100 mD or higher. Finally, the newly developed models were applied to real and hypothetical geologic carbon storage sites to investigate the feasibility of using fractured reservoirs for carbon storage. The general results were, that storage of CO 2 – both as free-phase and dissolved – is feasible, but that storage capacities are likely lower than in unfractured systems. While the high permeability of the fractures reduces the injection pressure (or permits higher injection rates), fast migration of CO 2 may limit the overall storage volume, because CO 2 may escape laterally with not enough of the rock matrix being swept for effective storage.

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