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DOE OSTI2025

Preliminary Techno-Economic Assessment of Gas Switching Reforming (GSR) of Natural Gas for Pure Hydrogen Production and Power Generation with Integrated CO2 Capture

The increasing demand for hydrogen and the CO2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) is an advanced auto-thermal reforming technology that produces hydrogen or syngas from natural gas. It integrates inherent CO2 capture by utilizing a specialized oxygen carrier in a single fluidized bed reactor, eliminating the need for complex, energy-intensive post-combustion separation. GSR technology builds upon Chemical Looping Reforming (CLR), an experimentally proven technology with strong potential for scaling up. In this study, select oxygen carriers (OC) (NiO/Al2O3, Fe2O3-CeO2/Al2O3, and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H₂) and a combined cycle (GSR-CC) in which high-purity H₂ is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H₂ production by ~30% and improved efficiency relative to prior studies. For GSR-H₂, the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H₂, competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H2 indicate NG consumption drives ~75% of total global warming impacts (~2.3 kg CO2 eq/kg H2). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.

03 NATURAL GAS↗
DOE OSTI2024

Computational Modeling of CO2 Capture By Novel PIM-RU in a Fluidized Bed Riser

The interest in carbon capture, storage, and utilization (CCUS) has increased significantly in the past few decades as it can help mitigate the threat of global warming caused by substantial increase in CO2 emissions due to anthropogenic activities. Although several CO2 capture technologies have been developed, porous solid sorbents, which adsorb CO2 by physisorption, are considered promising candidates for post-combustion CO2 capture because of the easier recovery of adsorbed CO2 and high material stability. Some prominent types of porous solid sorbents are metal-organic frameworks (MOFs), Zeolite, mesoporous silica, and polymer-based sorbents (e.g., polymers with intrinsic microporosity or PIM). Oak Ridge National Laboratory (ORNL) recently developed a novel PIM-based sorbent, referred to here as PIM-RU. The main objective of this work is to investigate the CO2 capture performance of this sorbent using computational fluid dynamics (CFD). While process configuration and reactor design are open questions, a fluidized bed riser was selected as the contactor type for this study.

Aziz, Hossain↗
DOE OSTI2022

A Process with Decoupled Absorber Kinetics and Solvent Regeneration through Membrane Dewatering and In-Column Heat Transfer (Final Report)

This report summarizes the work conducted on project DE-FE0031604 where University of Kentucky Center for Applied Energy (UK CAER) has validated its intensified CO 2 capture process through substantial enhancements to the kinetics of the absorption process and energy reductions by absorber temperature profile modification, dewatering and heat integration technologies for achieving significant capital and operating cost reductions. To address DOE’s objective of improving post-combustion CO 2 capture technology and reducing associated cost, UK CAER employed an intensified process which combined three key aspects targeted at overcoming inherent limitations or barriers in the conventional CO 2 capture and desorption process. The process designed to be independent of the type of solvent used, included (1) the use of 3-D printed two-channel structured packing material to control the temperature profile and increase the CO 2 absorption rate in the absorber, (2) a zeolite membrane dewatering unit for dewatering of the carbon-rich solvent to decouple solvent concentration needs for CO 2 absorption and desorption, and (3) a rich-split feed with two-phase flow heat transfer prior to the stripper that provided a secondary point of vapor generation to provide energy savings in steam extraction and solvent regeneration. The project was executed over two budget periods. This involved testing of individual process components which included the advanced heat transfer packing and the dewatering membrane on UK CAER’s 30 liter per minute (L/min) CO 2 (3” Column) capture bench unit with simulated flue gas in the first budget period. Subsequent scaled-up testing of these components together with the split-feed configuration were also tested in UK CAER’s 0.1 MWth CO 2 capture unit with coal-derived flue gas in the second-budget period. Long term studies were done during this period to assess process and solvent performance over extended duration. Project partners Lawrence Livermore National Laboratory (LLNL) and Media & Process Technology (MPT) led the development efforts for the advanced packing material and dewatering membrane respectively. Data from the long term testing was used as input for an environmental, health and safety (EH&S) assessment for the process and scaled technology performed by ALL4 LLC. Trimeric Corporation also completed a techno-economic analysis (TEA) for the UK CAER technology which was compared to the DOE reference Case B12B. Tests on the 3” column capture unit showed that the advanced heat transfer packing could be used to lower the bulge temperature in the absorber, and this was also proven in the scaled testing in the 0.1 MWth CO 2 capture unit. The bulge temperature could be lowered by >10 °C, changing the temperature profile in the absorber, and showed potential to enhance absorption with the ability to tailor the profile to provide conditions suitable for a solvent’s properties and kinetics. Conditions for short term evaluation of a 19” zeolite dewatering membrane on the 3” column capture unit yielded desirable fluxes and sustained rejection rates of >80%. However, for the scaled testing of six membrane modules consisting of 21 parts of 31-inch-long membrane tubes in each bundle (surface area 0.3 m 2 ), over a more extended duration, similar rejection rates could not be achieved. With the split-feed of the rich stream to the stripper, improved heat recovery minimized waste heat exiting the top of the stripper. The stripper exhaust temperatures could be reduced by >10 °C; reducing the amount of water vaporization contributed to lowering the regeneration energy by ~ 15%. The energy benefit could be sustained from the long term monitoring of the solvent performance. The solvent properties were not significantly impacted over the long-term operations. The benefits of the UK CAER process demonstrated experimentally were mostly validated from the TEA comparing a commercial scale application of the technology to DOE reference Case B12B. The cost of CO 2 capture for the UK CAER technology was estimated to be ~$34.97/tonne of CO 2 captured; a reduction of 23% compared to Case B12B. The increase in cost of electricity was also shown to be 16% lower than that of Case B12B. The total parasitic demand was also shown to be 11% lower. The key drivers for the benefits are a result of the process intensification approaches employed in the UK CAER technology for enhanced solvent performance, effective heat recovery and improved energy performance. The EH&S assessment did not find any major environmental concerns or barriers to the full scale implementation of the technology.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Intensified Catalytic Conversion of CO2 into High Value Chemicals

The utilization of CO2 produced from power generation plants as a feedstock for creating new valuable products offers a strategy to reduce GHG emissions, offset carbon capture costs, and facilitate the rebalancing of the carbon cycle. After considering the thermodynamic requirement of potential products from CO2 utilization and their market size, formic acid is a desirable target that offers widespread utility in industrial chemical production and chemical energy storage as a liquid fuel. To effectively utilize CO2 from power generation plants, UK proposes an enhanced bimetallic oxide carbon utilization process (EBOCU) that enables electrochemical CO2 conversion to formic acid. The UK intensified electrocatalytic process combines three main components: 1) a novel bimetallic oxide electrocatalyst; 2) a stable electrochemical reactor using robust electrodes; and 3) a pressurized electrochemical reactor. The output from this project showed the economic viability of producing high-value formic acid from CO2 to both offset the cost associated with post-combustion CCS and reduce GHG emissions. This project developed and screened a series engineered catalysts to selectively reduce CO2 directly to formic acid. The best performing catalyst based on formic acid production, stability, and Faradaic efficiency, was immobilized on carbon electrodes, and tested inside a flow through reactor. After lab-scale testing was completed, the experimental data was used to perform a Life-Cycle Analysis (LCA) and conduct an Initial Technical and Economic Feasibility Study. The LCA showed a pathway to a net negative CO2 utilization process with the incorporation of renewable energy, while the TEA showed the potential to produce formic acid below the current commercial price. The UK EBOCU process was successfully demonstrated at the TRL3 level and has a clear pathway to further development and contribution to the nation’s ambitious decarbonization goals.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Amine-functionalized porous organic polymers for carbon dioxide capture

Recent developments in CO 2 capture using porous organic polymers (POPs) have received accrescent attention due to their sorbent properties such as high CO 2 uptake capacity and selectivity, tunable chemical structure and permanent porosity. POPs are constructed using two and/or three-dimensional organic monomers (building blocks) linked to each other through covalent bonding, creating high porosity. The pore structure in POPs is exceptionally stable, which leads to their cyclable CO 2 adsorption performance. However, POPs generally suffer from low CO 2 uptake and selectivity due to their interaction with CO 2 in physisorption limits (20–40 kJ mol -1 ). Similar to that in other physisorbents, the CO 2 uptake capacity of POPs further decreases under humid conditions. Pursuant to these limitations, amine functionalization in POPs has resulted in enhanced CO 2 uptake performance with improved CO 2 selectivity over non-polar gases such as N 2 . More importantly, several types of amine-functionalized POPs showed that the CO 2 uptake could remain intact under humid conditions such as in post-combustion flue gas. This review article covers recent developments in amine-functionalized porous organic polymers. Three main categories of amine functionalization, such as direct amine synthesis, amine impregnation and amine grafting, were investigated in detail by considering the effect of amines on the sorbent properties and CO 2 capture performance of POPs. The recent findings in amine-functionalized POPs were investigated including porous polymeric networks (PPNs), covalent organic frameworks (COFs), amine linked POPs, hyper-crosslinked polymers (HCPs), conjugated microporous polymers (CMPs), benzimidazole linked polymers (BILPs), porous aromatic frameworks (PAFs) and polymers of intrinsic microporosity (PIMs).

36 MATERIALS SCIENCE↗
DOE OSTI2020

Evaluation of a New Chemical Mechanism for 2-Amino-2-methyl-1-propanol in a Reactive Environment from CSIRO Smog Chamber Experiments

Amines are considered as an emerging class of atmospheric pollutants that are of great importance to atmospheric chemistry and new particle formation. As a typical amine, 2-amino-2-methyl-1-propanol (AMP) is one of the proposed solvents for capturing CO 2 from flue gas streams in amine-based post-combustion CO 2 capture plants, and it is expected to result in AMP emission and secondary products formation in the atmosphere. However, the current knowledge of its atmospheric chemistry and kinetics is poorly understood, particularly in a reactive environment. As such, in this work we used the CSIRO smog chamber to study the photo-oxidation of AMP in the presence of VOCs–NOx surrogate mixtures over a range of initial amine concentrations. O 3 formation was significantly inhibited when AMP was added to the surrogate VOCs–NOx mixtures, implying that AMP could alter known atmospheric chemical reaction pathways and the prevailing reactivity. Simultaneously, a large amount of AMP-derived secondary aerosol was formed, with a considerably high aerosol mass yield (i.e. ratio of aerosol formed to reacted AMP) of 1.06±0.20. Based on updated knowledge of its kinetics, oxidation pathways and product yields, we have developed a new mechanism (designated as CSIAMP-19) and integrated into the Carbon Bond 6 (CB6) chemical mechanism, and evaluated it against available smog chamber data. Compared with the existing AMP mechanism (designated as CarterAMP-08), the modified CB6 with CSIAMP-19 mechanism improves prediction against AMP–VOCs–NOx experiments across a range of initial AMP concentrations, within ±10% model error for gross ozone production. Our results contribute to scientific understanding of AMP photochemistry and to the development of the chemical mechanism of other amines. The updated AMP chemical reactions scheme can be further embedded into the chemical transport model for regional modelling scenarios where AMP-related emissions are of concern.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Evaluation of a Third Generation Single-Component Water-Lean Diamine Solvent for Post-Combustion CO 2 Capture

Here this study describes a comprehensive evaluation of a recently developed water-lean diamine solvent, N1-(2-ethoxyethyl)-N2, N2-diisopropylethane-1,2-diamine (2-EEDIPEDA), to probe its potential post-combustion CO 2 capture performance. This evaluation includes (1) fundamental sorption characterization such as vapor-liquid equilibria, sorption kinetics and viscosity impacts; (2) continuous capture characterization using laboratory scale flow system using flue gas simulant; as well as (3) technoeconomic analysis of the capture process at industrial scale with projections for critical capture performance metrics. Using this evaluation, we compare the performance of 2-EEDIPEDA to our current leading water-lean amine-based solvent, 2-EEMPA, using the same baseline process plant configuration/pricing. From this comparison, we observe lower total cost of capture as low as $46.8/tonne CO 2 with 2-EEDIPEDA (20% cheaper than CANSOLV), as a direct result of solvent chemistry tuning leading to notable cost savings.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Initial Engineering Design of a Post-Combustion CO 2 Capture (PCC) System for Duke Energy’s East Bend Station Using Membrane-Based Technology

The Electric Power Research Institute (EPRI) led a U.S. Department of Energy (DOE) funded study for a membrane-based post-combustion CO 2 capture (PCC) system retrofit to an existing U.S. coal power plant. EPRI teamed with technology suppliers, Membrane Technology and Research (MTR), engineering consultants Nexant, Trimeric Corporation and Bechtel Power Corporation, to develop a first-of-a-kind initial design and cost estimate for a PCC system at Duke Energy’s East Bend Station (EBS) in Kentucky. This project provides a comprehensive overview of the plant design proposed and develops estimated costs to within +/- 30% accuracy for retrofitting the existing EBS coal-fired power plant with the latest MTR’s second-generation Polaris™ membrane technology for CO 2 flue gas removal. The projects primary objective was to develop a design for Duke Energy that will require “minimally invasive surgery” on their existing 600-MWe coal-fired power plant, located on the Ohio River in Boone County, Kentucky. Unlike the current commercially available solvent-based capture systems that require a reliable source of steam to operate, the MTR membrane-based capture system is driven primarily by electric power. This direct, bolt-on approach to retrofitting carbon capture could potentially reduce the impact on the existing power plant, by minimal disruption of the existing facility’s infrastructure and operating procedures. This may also reduce the amount of retrofit downtime before the power plant can resume normal operations. A second objective was to reduce the cost of each ton of captured CO 2 while maintaining the existing 600 MW net output of the East Bend Station. With this aim in mind, various options to provide the necessary auxiliary power for the capture system were evaluated for the site. The full report describes in detail the overall design, layout and components of the entire EBS membrane capture system. The equipment and sizes, the capital cost estimate encompassing both engineering design and construction for the carbon capture process and balance of plant systems is presented. A detailed techno-economic analysis is also undertaken to examine the business case for capture.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Developing new alkaline ceramics as possible CO 2 chemisorbents at high temperatures: The lithium and sodium yttriates (LiYO 2 and NaYO 2 ) cases

In this work, lithium and sodium yttriates (LiYO 2 and NaYO 2 ) were synthesized, characterized and tested as possible carbon dioxide (CO 2 ) captors. All the experimental syntheses and analyses were supported by the theoretical thermodynamic calculations, showing that both ceramics would be able to chemisorb CO 2 in a wide temperature range. Therefore, both ceramics were prepared by solid-state reaction and structurally characterized. In fact, the structural characterization evidenced that sodium atoms are located in a octahedral close-packed structure, while lithium ions are not so packed. The lithium ions are, indeed, in a highly distorted tetrahedron, tending to square-planar coordination. Then, based on the theoretical and structural analysis, LiYO 2 and NaYO 2 samples were investigated for the CO 2 capture process through dynamic and isothermal thermogravimetric experiments. All these experiments showed that LiYO 2 has better CO 2 capture properties than NaYO 2 , which was further correlated with the crystal structures of each ceramic. Furthermore, both ceramics presented similar CO 2 capture efficiencies regardless of the CO 2 concentration. Finally, LiYO 2 sample was tested for cyclic CO 2 chemisorption-desorption processes. The obtained results showed that the CO 2 capture efficiency is maintained high at least through 10 cycles. Therefore, these alkaline yttriates seem to present interesting alternatives as high and moderate temperature CO 2 captors, applicable for post-combustion industrial capture processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Compact Absorber Technology Leads to Significant Reduction in the Cost of Point Source CO 2 Capture

The size of columns in traditional absorption-based processes for CO 2 capture contributes significantly to the overall capital cost. A demonstrated method to reduce the cost of point source CO 2 capture, focusing on reducing the absorber height by increasing the liquid-to-gas reaction contact area and decreasing the CO 2 diffusion resistance without increasing gas-side pressure drop is presented along with techno-economic analysis results. Bench-scale tests on the unique Compact Absorber showed overall CO 2 mass transfer enhancement of varying degrees compared to a traditional packed column for similar process conditions, demonstrating that a 60+% reduction in size of a typical post-combustion absorber with a packing height of 70-100 ft and total height of 150-180 ft can be achieved. The techno-economic analysis showed significant cost reductions when the Compact Absorber is combined with other transformative aspects of the University of Kentucky Institute for Decarbonization and Energy Advancement point source CO 2 capture process compared to the U.S. Department of Energy National Energy Technology Laboratory pertinent reference case for pulverized coal plants with CO 2 capture. Here, a levelized cost of electricity excluding CO 2 transportation and storage of $\$95.6$/MWh was estimated, which is a 9% reduction, with a total capital cost contribution of $45/MWh, which is a 12% reduction. Additionally, a breakeven CO 2 sales price also referred to as the cost of CO 2 capture, of $36.70/tonne was estimated when the UK hindered primary amine solvent is used, which is a 20% reduction compared to the reference case.

CO2 capture↗
DOE OSTI2020

Application of a Heat Integrated Post-combustion CO 2 Capture System with Hitachi Advanced Solvent into Existing Coal-Fired Power Plant (Final Technical Report)

The goal of this final project report is to comprehensively summarize the work conducted on project DE-FE0007395. In accordance with the Project Management Plan (PMP), Revision F dated 5/10/2019, and Statement of Project Objectives (SOPO) within, the University of Kentucky (UK) Center for Applied Energy Research (CAER) (Recipient) has successfully demonstrated a unique, versatile CO 2 capture system (CCS) using a heat integrated process combined with two-stage stripping for process intensification, heat recovery and demineralized (DM) water generation. This project involved the design, fabrication, installation, testing of and data analysis from the UK CAER 0.7 MWe small pilot scale CO2 capture process installed at Kentucky Utilities (KU) E.W. Brown Generating Station in Harrodsburg, KY. During each of the four project Budget Periods (BPs), UK CAER met all project deliverables, all project milestones, with National Energy Technology Laboratory (NETL) approved adjustments made to the campaign long-term hours during BP4. The CCS was constructed in modular skids. Two solvent campaigns were initially conducted; the first with a 30 wt% monoethanolamine (MEA) as a baseline, and the second with the Hitachi H3-1 advanced solvent. Additional tests were performed with two advanced solvents including CAER and Proprietary Solvent C. Short-period testing with a higher concentration of 40 wt% MEA was conducted to evaluate the potential saving with high alkalinity. From the various solvent campaigns, unique aspects of the UK CAER CCS technology, as well as its flexibility and versatility were experimentally validated and demonstrated. With respect to solvent evaluation efforts in identifying candidates with significant operational and capital cost savings potential, performance of solvents were evaluated to determine the energy requirements for regeneration; environmental impacts from secondary emissions and degradation products; degradation rates, solvent make-up rates and stability. The assessments were done from parametric tests that determined optimum operating conditions for the individual solvents to maximize process efficiency and minimize the parasitic load of the power plant, and from long term campaigns (1000 hours for 30 wt% MEA and 1000 hours for H3-1) which collectively informed the techno-economic analyses (TEA) of the process. The long term campaigns included corrosion studies which used three types of metal coupons in different sections of the process: (absorber, primary stripper, lean carbon-loaded and rich carbon loaded flow streams in process) to mimic heat and flow dynamics process equipment were exposed to. The estimated corrosion rates were used to elucidate corrosion mechanisms and to further guide process material selection for potential capital cost savings.

gas separation↗
DOE OSTI2020

Bench scale development of a hybrid membrane-absorption CO 2 capture process (Final Report)

This final technical report describes work conducted for the Department of Energy (DOE) on the development of a bench-scale hybrid membrane-absorption carbon dioxide (CO 2 ) capture system for coal-fired power plant applications (Cooperative Agreement number DE-FE0013118). The work was conducted by Membrane Technology and Research, Inc. (MTR) with major support from the University of Texas at Austin (UT Austin) from April 1, 2013 through September 30, 2018. The overall goal of this project was to evaluate two variations of a hybrid membrane-absorption capture system combining the MTR air-swept PolarisTM membrane technology, which enriches flue gas to ~20% CO 2 , with UT Austin’s absorption-based advanced flash stripper (AFS) using piperazine (PZ), to determine the superior hybrid variant and to assess the potential of hybrid capture systems to achieve a lower cost-of-capture, compared to NETL’s reference amine-based capture plant. This project included the evaluation, development and testing of a hybrid membrane-absorption CO 2 capture system for coal-fired power plant applications using the MTR high-gas-flow, low-pressure-drop membrane contactor. The ability of the membrane contactor to enrich coal-fired flue gas from its normal content of ~13% CO 2 into a smaller volume of gas containing 20-25% CO 2 – with minimal energy input – could reduce the cost of the final concentration process, regardless of whether it is absorption, adsorption, cryogenic, or membrane-based. In this project, we are evaluating the feasibility of a hybrid system combining the MTR sweep membrane technology with the UT Austin piperazine-based advanced flash stripper (PZAS) capture system.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Modular Adaptive Packing for Integrally Cooled Absorbers

Process intensification is one cornerstone in ION Clean Energy’s (ION) efforts to lowering CO2 capture cost. ION has modeled, designed, and fabricated an innovative gas-liquid contactor known as Modular Adaptive Packing (MAP). During two successful SBIR Phase I and II projects entitled: “Rapid Design and Testing of Novel Gas-Liquid Contacting Devices for Post-Combustion CO2 Capture via 3D-printing”, ION developed and proved this new technology at bench scale. MAP, a 3D-printed lattice-structured packing, combines the absorber gas/liquid contactor with an innovative in-situ heat-exchanger. Thanks to the capabilities of 3D-printing, the lattice structure of MAP contains hollow channels through which coolant water can be pumped to remove the heat of reaction from CO2 absorption. ION refers to this novel method of heat exchange as intracooling. After 25.4 cm (10 in) diameter MAP modules were fabricated, ION built and tested a packing characterization rig at its pilot facility in Boulder, Colorado, U.S.A. To provide baseline results for the characterization rig, ION tested Sulzer’s Mellapak™ 250Y (MP250Y) as a standard structured packing. ION’s MAP was then compared directly to the baseline MP250Y packing to evaluate key indicators including pressure drop, liquid hold-up, and effective area. MAP has a higher pressure drop than MP250Y at the same gas velocities in addition to greater liquid holdup. However, ION found that MAP displays a higher wetting coverage of 93% compared to 65% for MP250Y and reduces shearing forces that result in undesirable droplet formation. Using Optimized Gas Treating’s (OGT) rate-based simulation software ProTreat®, a conceptual evaluation of MAP was modeled for a CO2 absorber using 30 wt% MEA solvent over a range of lean loadings at 90% CO2 capture from a coal-fired power plant. ION modeled a 25-meter column absorber for both the standard MP250Y packing and a hybrid column. The hybrid absorber contained 10 m of MP250Y packing at the top and bottom with the middle 5 meters comprised of MAP. Compared to a traditional intercooled absorber, MAP can remove 22% more heat and increase overall MEA carrying capacity by 4% without increasing overall pressure drop.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Sorbent Based Post-Combustion CO 2 Slipstream Testing

TDA Research, Inc. has developed a low-cost sorbent (alkalized alumina) based technology for post-combustion CO 2 capture. The sorbent runs in an isothermal process for adsorption and regeneration. Neither temperature swing nor pressure swing is needed. TDA designed a system which operated 10 fixed beds to simulate a moving bed process. The flow pattern was optimized to minimize the steam usage for regeneration. An excellent sorbent (Batch 1) was also developed with collaboration with our partner. The sorbent degraded after long term operation. We developed a reprocessing procedure, which can be conducted in situ, to restore the sorbent capture capacity as the fresh sorbent after running for about 1250 hours. The reprocessing extended the sorbent longevity significantly. TDA designed a pilot unit (40’ x 32’ x 11.5’), processing flue gas equivalent to 0.5 MW of power generation. It had 10 beds and each bed could hold 1.75 m 3 of sorbent. We worked with Springs Fabrication, Inc. to complete the construction of the pilot unit. It was then shipped and installed at NCCC. The pilot unit was kept running in 24-hour mode when the flue gas and steam were available. It could run automatically without operator on site. Parametric and long-term (2 months) tests were carried out successfully. The results showed that TDA’s process can achieve 90% capture and 95% CO 2 purity for both coal and NG flue gases. For coal flue gas, the system reached performance target when processing up to 0.62 MW flue gas, 24% higher than the design capacity. Thus, capital cost could be saved on the reactors and sorbent. The strip air flow was designed to be 0.25 of that of the flue gas. The test data showed the strip/flue ratio can be reduced to as little as 0.18, which saves the power consumption for the strip air blower. The pressure drop was found to be lower than what the empirical equation calculated. The sorbent still had 91.7% of original capacity after 3-month test. With the data from the pilot test, we updated the TEA. For a 550-MW e supercritical coal fired power plant with CO 2 capture, the capture cost for TDA’s process is $34.9/tonne CO 2 captured, which meets DOE’s goal of $40/tonne and is 17.1% less than the DOE baseline Case 12. Therefore, TDA’s process has a good potential for commercialization.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Engineering Design of a Linde-BASF Advanced Post-Combustion CO 2 Capture Technology at a Linde Steam Methane Reforming H 2 Plant

Linde carried out an initial engineering design study for a Linde-BASF advanced post combustion CO 2 capture technology to be installed at a commercial-scale steam methane reforming (SMR) hydrogen plant located in the US Gulf Coast. This pre-FEED equivalent study included following: (1) basic design, including specific project scope definition and design basis, (2) basic engineering, including development of process flow diagrams and heat & material balances, (3) inside the battery limit (ISBL) equipment and systems specification, (4) balance of plant outside the battery limit (OSBL) equipment and systems specifications, (5) technology maturation plan, (6) hazard and operability (HAZOP) review, (7) environmental, health and safety (EH&S) assessment and environmental permitting analysis, (8) constructability review, (9) ISBL and OSBL EPC cost estimation, and (10) commercial-scale techno-economic analysis including capital expenditures (CAPEX) and operating expenditures (OPEX) and CO 2 capture cost estimates.

08 HYDROGEN↗
DOE OSTI2024

Technoeconomic Analysis of Kraft Pulp Mill Integration with an Advanced Nuclear Reactor

This study focuses on post-combustion capture and oxy-fuel combustion for the boilers at the mill, as well as steam integration with the nuclear power plant. The primary goal of the research outlined in this report is to design, analyze, and document the integration of industrial-scale HTGR with a reference Kraft Pulp Mill. The purpose is to deliver reliable, cost-effective, and sustainable clean energy alternatives while reducing CO2 emissions. Specifically, this study focuses on 6 different scenarios that include carbon capture equipment and some of them use nuclear power to meet the heat and electricity needs of the reference plant. Also, 2 of these scenarios are created while also producing clean hydrogen through integrated High-Temperature Steam Electrolysis (HTSE). This report offers a detailed techno-economic assessment of different scenarios for a Kraft Pulp Mill, including an analysis of tax credits (section 45V, 45Q, and 48E) provided by the Inflation Reduction Act (IRA) of 2022. The evaluation explores the potential economic benefits and challenges of incorporating different configurations, including nuclear energy, into Kraft Pulp Mill operations, with particular attention to energy efficiency, economic implications, and environmental impact. By assessing both the technical feasibility and economic viability, this analysis aims to identify existing gaps and propose solutions for the successful implementation of nuclear integration. The findings are intended to provide valuable insights for stakeholders considering the adoption of advanced nuclear reactors in the pulp and paper industries.

08 HYDROGEN↗
DOE OSTI2024

Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Coal and Biomass – Integration of Combustor Boiler and DCC

Utilities and grid operators worldwide are under significant pressure to incorporate intermittent renewable sources while strategizing on how to maintain the necessary stability and reliability of the grid. The development of a power plant which will be capable of flexible operation to meet the needs of the grid as more intermittent sources like wind and solar energy are incorporated is key to maintain the reliability of the grid. Through the use of innovative and cutting-edge technologies that improve efficiency and reduce carbon emissions, and being small compared to today's conventional utility-scale power plants, the modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. Specifically, the process offers: 1) a modular plant design that allows for better operational flexibility; 2) the utilization of fuel-staging and pressurized oxy-combustion, resulting in smaller plant size, improved plant efficiency, and reduced costs for pollutant and CO2 removal compared to traditional power plants with post-combustion capture technology; and 3) the use of small modular boilers and pollutant removal units that can be constructed off-site leading to reduced capital costs for the plant. WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustor-boiler system and the direct contact cooler. To demonstrate the boiler convective section and to obtain critical data for commercial-scale pressurized boiler design, a simulated convective heat transfer boiler test section was designed and integrated with the combustor (radiant section). A direct contact cooler (DCC) was integrated with the combustor-boiler to demonstrate the dynamic operation of the integrated system and the performance of the DCC, including the efficiency for simultaneous removal of NOx and SOx. This talk will present an update on the evaluation of the critical components for system integration, including heat transfer data from the simulated boiler, scrubbing efficiency for the DCC under different operating conditions, and CFD modeling and validation for burner and boiler development.

Magalhaes, Duarte↗