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All sourcesNASA NTRSDOE OSTI
NASA NTRS1947

Wind-Tunnel Investigation of Effects of Unsymmetrical Horizontal-Tail Arrangements on Power-on Static Longitudinal Stability of a Single-Engine Airplane Model

A wind-tunnel investigation has been made to determine the effects of unsymmetrical horizontal-tail arrangements on the power-on static longitudinal stability of a single-engine single-rotation airplane model. Although the tests and analyses showed that extreme asymmetry in the horizontal tail indicated a reduction in power effects on longitudinal stability for single-engine single-rotation airplanes, the particular "practical" arrangement tested did not show marked improvement. Differences in average downwash between the normal tail arrangement and various other tail arrangements estimated from computed values of propeller-slipstream rotation agreed with values estimated from pitching-moment test data for the flaps-up condition (low thrust and torque) and disagreed for the flaps-down condition (high thrust and torque). This disagreement indicated the necessity for continued research to determine the characteristics of the slip-stream behind various propeller-fuselage-wing combinations. Out-of-trim lateral forces and moments of the unsymmetrical tail arrangements that were best from consideration of longitudinal stability were no greater than those of the normal tail arrangement.

AIRFOILS - NACA 65(216-012(MOD ) - CHAR & MOMENTS ↗
DOE OSTI2021

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

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

Wang, Zhongzhen↗
DOE OSTI2016

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

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

47 OTHER INSTRUMENTATION↗
DOE OSTI2017

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

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

03 NATURAL GAS↗
DOE OSTI2021

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

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

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

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

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

09 BIOMASS FUELS↗
DOE OSTI2020

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

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

Sjostrom, Sharon↗
DOE OSTI2018

Quantum Cascade Laser Infrared Spectroscopy for Online Monitoring of Hydroxylamine Nitrate

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

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

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

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

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2015

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

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

Chen, Shiaoguo↗
DOE OSTI2016

SkyMine Beneficial CO 2 Use Project

This Final Report addresses accomplishments achieved during Phase 1 and Phase 2 of the SkyMine® Carbon Mineralization Commercial Scale Pilot Project. The primary objectives of this project were to design, construct, and operate a system to capture CO₂ from a slipstream of flue gas from a commercial coal-fired cement kiln, convert that CO₂ into products having commercial value as an example of Carbon Capture and Beneficial Re-Use, show the economic viability of the CO₂ capture and conversion process, and thereby advance the technology to a level of commercial scale completion with the ability for further proliferation. The project also substantiates market opportunities for the technology by sales of chemicals into existing markets, and has identified opportunities to improve technology performance and reduce costs during the normal course of operations. The primary objectives of Phase 1 of the project were to elaborate proven SkyMine® process chemistry to commercial pilot-scale operation and complete the preliminary design for the pilot plant to be built and operated in Phase 2. During Phase 2, Pilot System Engineering Design, Construction and Testing, supporting research and development was conducted at a field test unit to collect data that aided in detailed designs of the commercial scale pilot unit; final detailed designs were completed; the commercial scale pilot plant is in its final stages of construction; and a test program has been designed and will be implemented to collect data from the facility to evaluate the technical viability of the process for resulting in an overall net reduction in CO 2 emitted into the atmosphere through a process that is run and conducted in a carbon negative manner. The objective of Phase 2b was to build the commercial scale pilot plant to be operated and tested in Phase 2c. By June 30, 2015, the plant was +99% constructed and completed.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Evaluation of Solid Sorbents as a Retrofit Technology for CO 2 Capture

ADA completed a DOE-sponsored program titled Evaluation of Solid Sorbents as a Retrofit Technology for CO 2 Capture under program DE-FE0004343. During this program, sorbents were analyzed for use in a post-combustion CO 2 capture process. A supported amine sorbent was selected based upon superior performance to adsorb a greater amount of CO 2 than the activated carbon sorbents tested. When the most ideal sorbent at the time was selected, it was characterized and used to create a preliminary techno-economic analysis (TEA). A preliminary 550 MW coal-fired power plant using Illinois #6 bituminous coal was designed with a solid sorbent CO 2 capture system using the selected supported amine sorbent to both facilitate the TEA and to create the necessary framework to scale down the design to a 1 MWe equivalent slipstream pilot facility. The preliminary techno-economic analysis showed promising results and potential for improved performance for CO 2 capture compared to conventional MEA systems. As a result, a 1 MWe equivalent solid sorbent system was designed, constructed, and then installed at a coal-fired power plant in Alabama. The pilot was designed to capture 90% of the CO 2 from the incoming flue gas at 1 MWe net electrical generating equivalent. Testing was not possible at the design conditions due to changes in sorbent handling characteristics at post-regenerator temperatures that were not properly incorporated into the pilot design. Thus, severe pluggage occurred at nominally 60% of the design sorbent circulation rate with heated sorbent, although no handling issues were noted when the system was operated prior to bringing the regenerator to operating temperature. Testing within the constraints of the pilot plant resulted in 90% capture of the incoming CO 2 at a flow rate equivalent of 0.2 to 0.25 MWe net electrical generating equivalent. The reduction in equivalent flow rate at 90% capture was primarily the result of sorbent circulation limitations at operating temperatures combined with pre-loading of the sorbent with CO 2 prior to entering the adsorber. Specifically, CO 2 -rich gas was utilized to convey sorbent from the regenerator to the adsorber. This gas was nominally 45°C below the regenerator temperature during testing. ADA’s post-combustion capture system with modifications to overcome pilot constraints, in conjunction with incorporating a sorbent with CO 2 working capacity of 15 g CO 2 /100 g sorbent and a contact time of 10 to 15 minutes or less with flue gas could provide significant cost and performance benefits when compared to an MEA system.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Pilot-Scale Evaluation of an Advanced Carbon Sorbent-Based Process for Post-Combustion Carbon Capture

The overall objective of this project is to achieve the DOE’s goal to develop advanced CO 2 capture and separation technologies that can realize at least 90% CO 2 removal from flue gas steams produced at a pulverized coal (PC) power plant at a cost of less than $40/tonne of CO 2 captured. The principal objective is to test a CO 2 capture process that will reduce the parasitic plant load by using a CO 2 capture sorbent that will require a reduced amount of steam. The process is based on advanced carbon sorbents having a low heat of adsorption, high CO 2 adsorption capacity, and excellent selectivity. While the intent of this project was to produce design and performance data by testing the sorbent using a slipstream of coal-derived flue gas at the National Carbon Capture Center (NCCC) under realistic conditions and continuous long-term operation, the project was terminated following completion of the detailing pilot plant design/engineering work on June 30, 2016.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2015

Pilot testing of a membrane system for postcombustion CO 2 capture

This final report summarizes work conducted for the U.S. Department of Energy, National Energy Technology Laboratory (DOE) to scale up an efficient post-combustion CO 2 capture membrane process to the small pilot test stage (award number DE-FE0005795). The primary goal of this research program was to design, fabricate, and operate a membrane CO 2 capture system to treat coal-derived flue gas containing 20 tonnes CO 2 /day (20 TPD). Membrane Technology and Research (MTR) conducted this project in collaboration with Babcock and Wilcox (B&W), the Electric Power Research Institute (EPRI), WorleyParsons (WP), the Illinois Sustainable Technology Center (ISTC), Enerkem (EK), and the National Carbon Capture Center (NCCC). In addition to the small pilot design, build and slipstream testing at NCCC, other project efforts included laboratory membrane and module development at MTR, validation field testing on a 1 TPD membrane system at NCCC, boiler modeling and testing at B&W, a techno-economic analysis (TEA) by EPRI/WP, a case study of the membrane technology applied to a ~20 MWe power plant by ISTC, and an industrial CO 2 capture test at an Enerkem waste-to-biofuel facility. The 20 TPD small pilot membrane system built in this project successfully completed over 1,000 hours of operation treating flue gas at NCCC. The Polaris™ membranes used on this system demonstrated stable performance, and when combined with over 10,000 hours of operation at NCCC on a 1 TPD system, the risk associated with uncertainty in the durability of postcombustion capture membranes has been greatly reduced. Moreover, next-generation Polaris membranes with higher performance and lower cost were validation tested on the 1 TPD system. The 20 TPD system also demonstrated successful operation of a new low-pressure-drop sweep module that will reduce parasitic energy losses at full scale by as much as 10 MWe. In modeling and pilot boiler testing, B&W confirmed the viability of CO 2 recycle to the boiler as envisioned in the MTR process design. The impact of this CO 2 recycle on boiler efficiency was quantified and incorporated into a TEA of the membrane capture process applied to a full-scale power plant. As with previous studies, the TEA showed the membrane process to be lower cost than the conventional solvent capture process even at 90% CO 2 capture. A sensitivity study indicates that the membrane capture cost decreases significantly if the 90% capture requirement is relaxed. Depending on the process design, a minimum capture cost is achieved at 30-60% capture, values that would meet proposed CO 2 emission regulations for coal-fired power plants. In summary, this project has successfully advanced the MTR membrane capture process through small pilot testing (technology readiness level 6). The technology is ready for future scale-up to the 10 MWe size.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2017

Integrating Waste Heat from CO 2 Removal and Coal-Fired Flue Gas to Increase Plant Efficiency

In project DE-FE0007525, Southern Company Services demonstrated heat integration methods for the capture and sequestration of carbon dioxide produced from pulverized coal combustion. A waste heat recovery technology (termed High Efficiency System) from Mitsubishi Heavy Industries America was integrated into an existing 25-MW amine-based CO 2 capture process (Kansai Mitsubishi Carbon Dioxide Recovery Process®1) at Southern Company’s Plant Barry to evaluate improvements in the energy performance of the pulverized coal plant and CO 2 capture process. The heat integration system consists of two primary pieces of equipment: (1) the CO 2 Cooler which uses product CO 2 gas from the capture process to heat boiler condensate, and (2) the Flue Gas Cooler which uses air heater outlet flue gas to further heat boiler condensate. Both pieces of equipment were included in the pilot system. The pilot CO 2 Cooler used waste heat from the 25-MW CO 2 capture plant (but not always from product CO 2 gas, as intended). The pilot Flue Gas Cooler used heat from a slipstream of flue gas taken from downstream of Plant Barry’s air heater. The pilot also included a 0.25-MW electrostatic precipitator. The 25-MW High Efficiency System operated for approximately six weeks over a four month time period in conjunction with the 25-MW CO 2 capture facility at Plant Barry. Results from the program were used to evaluate the technical and economic feasibility of full-scale implementation of this technology. The test program quantified energy efficiency improvements to a host power plant that could be realized due to the High Efficiency System. Through the execution of this project, the team verified the integrated operation of the High Efficiency System and Kansai Mitsubishi Carbon Dioxide Recovery Process®. The ancillary benefits of the High Efficiency System were also quantified, including reduced water consumption, a decrease in toxic air emissions, and better overall air quality control systems performance.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2019

Vitrification of Hanford Tank Waste 241-AP-107 in a Continuous Laboratory-Scale Melter

Low-activity waste (LAW) stored in underground tanks on the Hanford Site in Washington State is planned to be filtered for solids removal and processed through ion exchange columns for cesium removal. These pretreatment steps will allow the waste to be transferred to the Hanford Tank Waste Treatment and Immobilization Plant’s LAW Facility for immobilization into glass. The liquid waste will be combined with glass-forming chemicals (GFCs) to form a waste feed slurry that can be fed to electric melters for vitrification. The process of continuously converting the aqueous feed slurry into a melt is dynamic and includes multiple reactions, degassing, and dissolution processes that depend on heat from the melt below. In this conversion process, waste components are partitioned into one of two streams: glass and off-gas. Washington River Protection Solutions has requested processing information and chemical information associated with these waste products for actual waste from Hanford tank 241-AP-107 (referred to herein as AP-107). To acquire this type of information, a small-scale melter system was designed that would not require high volumes of input waste or the large resource commitment of a full-scale melter system, while also providing dynamic information that would be difficult to determine from batch reactions in a crucible system. A continuous laboratory-scale melter (CLSM) has been designed to operate with a continuous feeding process while periodically pouring glass product and collecting off-gas. The CLSM vessel has been sized to collect the relevant process and chemical information from obtainable volumes of AP-107 waste samples. A total 8.6 L of actual AP-107 tank waste were received after filtering for solids removal and ion exchange for cesium removal. This volume of AP-107 waste was mixed with GFCs to form an estimated 11.8 L of melter feed slurry. A mass of 7.01 kg of glass product were poured from the CLSM vessel during 10.07 hours of charging the AP-107 melter feed, indicating that about 15.0 kg of melter feed was vitrified into glass. The CLSM system was also designed with the capability to fully divert the flow of off-gas produced in the CLSM vessel to a sampling line that could capture the volatile species of interest, such as technetium-99 ( 99 Tc). This novel sampling system avoided the difficulties of slipstream sampling and could be activated once the feeding reached a steady state within the CLSM vessel. Off-gas product samples captured via high-efficiency particulate air (HEPA) filters using this method, as well as selected glass product samples were sent to an analytical lab for chemical analysis.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Accelerate Performance (Final Technical Report)

Encouraging commercial building owners to set measurable energy goals before design begins can drive design and contractor teams to develop innovative energy efficiency solutions within conventional building budgets. A federal building owner piloted this technique and created a large-scale zero-energy office building on a budget comparable to local market construction rates. The successes and lessons learned from this performance-based project formed the basis of Accelerate Performance, an expanded program using utilities as the primary outreach channel to replicate the approach. Four utilities partnered with Slipstream, a not-for-profit program implementer, to develop pilot incentive offerings to focus building owners on the whole building rather than on individual building components and systems. The original performance-based procurement process and its successful implementation in a federal building project informed all these efforts. The experiences and lessons learned in different new construction markets led to further process adaptations as well as the development of templates and tools to streamline outreach and technical support efforts. The approach can be adapted to utility new construction programs and is a powerful tool for engaging many building owners early in the project planning process as they make critical energy decisions that impact the performance of the building. The approach has led to real energy savings in building projects by encouraging cost-effective, low-risk, and creative design solutions. The performance-based approach was tested in a variety of applications including different building types and owner types, with many owners adopting performance-based procurement techniques, some with variations, but all maintaining the same core principles. Over the course of the project, nearly 100 building projects were impacted and additional projects will continue to be supported through ongoing program offerings with three leading utilities.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

ION Engineering Commercial Carbon Capture Design & Costing (C3DC) (Final Report)

ION Engineering LLC (ION) has coupled its proven, solvent-based CO 2 capture technology with an exceptionally qualified design and engineering team to complete a pre FEED for a 300-megawatt equivalent commercial-scale CO 2 capture plant for Gerald Gentleman Station’s (GGS) Generation Unit 2 (GGS2). The remarkable team was comprised of ION, Nebraska Public Power District (NPPD), Sargent & Lundy (S&L) with continued support from Koch Modular Process Systems (KMPS), and Siemens. The overall objective of the project was to provide the engineering design and cost estimate at an American Association of Cost Engineers (AACE) Class 3 estimate, resulting in accuracy ranges of -20 to +30% for the capital cost estimate. The project team was successful in completing this objective and was able to overcome the challenges that were presented during the process. A conservative interest rate of 7.0% with a financing term of 20 years was used based on interest rates utilized by S&L for this level of study. The resulting annualization factor is multiplied by the total EPC cost to calculate an annualized capital expenditure. It is estimated that the carbon capture facility treating a 300 MWe slipstream will capture 1.9 million tonnes per year of CO 2 at a capacity factor of 85%. The resulting cost of capture for the CO 2 island was determined to be $\$$36.55/tonne. Utilizing an interest rate of 4.5%, supported by historical rates for previous large capital projects in the power industry, reduces the cost of capture to $32.52/tonne. These cost of capture numbers continue to further ION’s case for commercial deployment of ION’s solvent technology.

20 FOSSIL-FUELED POWER PLANTS↗