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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Techno-Economic Analysis of an Intensified Integrated Gasification Combined Cycle (IGCC) Power Plant Featuring a Combined Membrane Reactor - Adsorptive Reactor (MR-AR) System

In this work, the novel concept of a combined membrane-adsorptive reactor sequence (MRAR) is developed and implemented in an Integrated Gasification Combined Cycle (IGCC) plant. This novel MR-AR IGCC plant is subsequently analyzed from an economic viewpoint through a techno-economic analysis (TEA) of the proposed plant. This novel design can achieve over 90% carbon capture without the use of a Dual-Stage Selexol unit. The resultant intensified design is more efficient from both an economic and power production perspective than the traditional IGCC plants with pre-combustion Carbon-Capture Storage (CCS) technology. The COMSOL software package is utilized to simulate the MR-AR sequence proposed in this work, and the UNISIM software (HoneywellTM) is used to create an intensified process flowsheet of the proposed MR-AR IGCC plant, which is subsequently heat-integrated. The TEA developed for the MR-AR IGCC power plant will be used to identify the extent of process intensification the proposed design has over the traditional IGCC plants with pre-combustion CCS. Furthermore, the results demonstrate a reduction in both the cost-of-electricity (COE) and in the capital cost of the proposed design over the baseline case.

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

Chemical Looping Coal Gasification Sub-Pilot Unit Demonstration and Economic Assessment for IGCC applications (Final Report)

The Ohio State University (OSU) coal to syngas (CTS) technology is an advanced air separation process that can be applied for electricity production via an integrated gasification combined cycle (IGCC). The objective of the proposed project is to enable the OSU CLG technology for a commercially relevant demonstration by 2020. In order to accomplish this objective, small pilot scale demonstration of the CLG reactor system was performed. The small pilot test unit incorporates commercially scalable non-mechanical gas sealing and solids flow control components for extended operations of the integrated reactor system. A cumulative demonstration of greater than 100 hours was performed to confirm the reliability of the reactors (reducer and oxidizer) and non-mechanical devices in maintaining controlled solid circulation, gas sealing, and coal distribution in the reactor (reducer) as well as to confirm sustained syngas product performance. A comprehensive techno-economic analysis (TEA) of the OSU CLG process for IGCC application was conducted with the support of WorleyParsons, Ltd. (WP) and compared to the Department of Energy (DOE) baseline IGCC report. Using the data gained from the small pilot demonstration, a complete comprehensive techno-economic analysis (TEA) of the CLG process was conducted. The evaluation was used as basis to attract utilities and coal industries in Ohio. The project duration lasts 30 months (6 months of no cost extension). Ohio coal was used in the integrated CLG small pilot unit to convert to high hydrogen syngas. A demonstration of the integrated chemical looping reactor system at the 15 kW th scale accelerates technology commercialization in the near term. The 15 kWth demonstration addressed several major technology gaps, such as coal injection and distribution in the reducer, controllable solids circulation with the desired fuel to solids ratio, system pressure distribution for proper gas sealing, effects of contaminants and fuel/oxygen carrier residence time requirements. The fates of impurities, such as SO x and NO x was also investigated in unit demonstrations. WP conducted a comprehensive system TEA to optimize the OSU CLG process design for efficient electricity generation with greater than 90% CO 2 capture in IGCC applications. The conclusion of this project supports the further scale-up of the technology to a commercially applicable large pilot scale test unit for operation by 2020. More importantly, it benefits Ohio as it provides an economically competitive mean for power generation with carbon capture. Given the rise of natural gas usage and strict environmental regulations, the use of Ohio coal is expected to decrease and thus impact the coal economy in Ohio. The conclusion of this project provided way for Ohio coal to compete in the future and secure jobs in the energy sector.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1983

IGCC performance comparison for variations in gasifier type and gas turbine firing temperature

Performance estimates were made for a series of integrated coal gasification combined cycle (IGCC) power systems using three generic types of coal gasification subsystems. The objectives of this study were (1) to provide a self consistent comparison of IGCC systems using different types of gasifiers and different oxidants and (2) to use this framework of cases to evaluate the effect of a gas turbine firing temperature and cooling approach an overall system efficiency. The basic IGCC systems considered included both air and oxygen blown versions of a fluidized bed gasifier, represented by the Westinghouse design, and an entrained bed gasifier, represented by the Texaco design. Also considered were systems using an oxygen blown, fixed bed gasifier, represented by the British Gas Corporation (BGC) slagging gasifier. All of these gasifiers were integrated with a combined cycle using a gas turbine firing temperature of 1700 K (2600 F) and a compressor pressure ratio of 16:1. Steam turbine throttle conditions were chosen to be 16.6 MPa/811 K (2400 psia/1000 F) with a single reheat to 810 K (1000 F). Some of these cases were modified to allow the evaluation of the effect of gas turbine firing temperature. Turbine firing temperatures from state of the art 1365 K (2000 F) to an advanced technology 1920 K (3000 F) were analyzed. A turbine cooling technology that maintains metal temperatures below acceptable limits was assumed for each level of firing temperature. System performance comparisons were made using three advanced turbine cooling technologies for the 1920 K (3000 F) firing temperature. The results indicate that the IGCC using the BGC gasifier had the highest net system efficiency (42.1 percent) of the five gasification cases considered.

Stochl, R. J.↗
DOE OSTI2016

A multi-objective optimization approach to optimal sensor location problem in $\mathrm{IGCC}$ power plants

Integrated Gasification Combined Cycle (IGCC) power plants provide a cleaner and more efficient way to obtain energy from coal. In order to operate an IGCC power plant in a safe and stable manner, several input and output process parameters need to be monitored. However, due to economic and operational constraints, it is infeasible to place sensors at every input and output process parameter location. Hence, it becomes important to select the most effective sensor locations which lead to maximum information gain about the plant conditions. Practical issues present in an IGCC power plant, such as harsh physical conditions and variability in process parameters, make the optimal sensor location problem an especially complicated one. Further, sensors can have multiple objectives and they can produce uncertainties due to measurement errors. Here this work considers hybrid hardware and virtual sensing for advanced power systems with multiple objectives. In order to solve this real world large scale problem, we use a novel algorithm called Better Optimization of Nonlinear Uncertain Systems (BONUS). BONUS works in probability distribution space and avoids sampling for each optimization and derivative calculations iterations. A new algorithm for multi-objective optimization is also developed specifically for problem. The result of this nonlinear stochastic multi-objective problem is the non-dominated, or Pareto set, which provides trade-offs between various objectives like observability, cost, and thermal efficiency. This is the first attempt at solving the problem of optimal sensor deployment in advanced power plants, with consideration of hybrid hardware and virtual sensing and incorporation of uncertainty with multiple objectives.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2018

Kemper County IGCC Final Public Design Report

The Kemper County IGCC plant is a lignite-fueled 2-on-1 Integrated Gasification Combined-Cycle (IGCC) facility incorporating the air-blown Transport Integrated Gasification (TRIG™) technology jointly developed by Southern Company; KBR; and the United States Department of Energy (DOE) at the Power Systems Development Facility (PSDF) in Wilsonville, Alabama. The plant is owned by Mississippi Power Company (MPC) and has a calculated nameplate capacity of 830 MW with a peak net output of 582 MW. As a result of advanced emissions-control equipment, the facility is designed to produce marketable products of ammonia (NH3), sulfuric acid (H 2 SO 4 ), and carbon dioxide (CO 2 ). The plant is designed to capture 65 percent of the carbon entering to sell for enhanced oil recovery (EOR), which makes the Kemper County plant’s carbon emissions comparable to those of a natural-gas-fired combined cycle power plant. This report describes the basic design and function of the plant as determined at the end of the Detailed Design phase of the project. The technical sections of the report were completed in October 2013, and the cost information was incorporated into Section 6.0 in March 2018.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2018

Topical Report: Kemper County IGCC Final Public Design Report

The Kemper County IGCC plant is a lignite-fueled 2-on-1 Integrated Gasification Combined-Cycle (IGCC) facility incorporating the air-blown Transport Integrated Gasification (TRIG™) technology jointly developed by Southern Company; KBR; and the United States Department of Energy (DOE) at the Power Systems Development Facility (PSDF) in Wilsonville, Alabama. The plant is owned by Mississippi Power Company (MPC) and has a calculated nameplate capacity of 830 MW with a peak net output of 582 MW. As a result of advanced emissions-control equipment, the facility is designed to produce marketable products of ammonia (NH 3 ), sulfuric acid (H 2 SO 4 ), and carbon dioxide (CO 2 ). The plant is designed to capture 65 percent of the carbon entering to sell for enhanced oil recovery (EOR), which makes the Kemper County plant’s carbon emissions comparable to those of a natural-gas-fired combined cycle power plant. This report describes the basic design and function of the plant as determined at the end of the Detailed Design phase of the project. The technical sections of the report were completed in October 2013, and the cost information was incorporated into Section 6.0 in March 2018.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2018

Topical Report: Kemper County IGCC Commissioning and Startup Report

The Kemper County IGCC plant was a lignite-fueled 2 x 1 Integrated Gasification Combined-Cycle (IGCC) facility that demonstrated the air-blown Transport Integrated Gasification (TRIG™) technology jointly developed by Southern Company, KBR, Inc. (KBR), and the U.S. Department of Energy (DOE) at the Power Systems Development Facility (PSDF) in Wilsonville, Ala. The plant is owned by Mississippi Power Company (MPC) and has a calculated nameplate capacity of 830 MW with a peak net output of 582 MW. As a result of advanced emissions control equipment, the facility is designed to produce marketable products of ammonia (NH 3 ), sulfuric acid (H 2 SO 4 ), and carbon dioxide (CO 2 ). The plant is designed to capture 65 percent of the carbon producing a CO 2 stream for use in enhanced oil recovery (EOR), making the plant carbon emissions comparable to those of a natural gas-fired combined cycle power plant. This report describes the unit commissioning activities from the end of construction through first coal operations to the gasifier. These activities include precommissioning planning, commissioning of major equipment, and operation of processes leading up to first coal feed.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Analyses of hot/warm CO2 removal processes for IGCC power plants

Abstract Compared with a pulverized coal power plant, the integrated gasification combined cycle (IGCC) has several advantages, including, among others better environmental performance and low CO 2 capture cost. Hot/warm CO 2 removal from syngas has also been a subject of research due to its potentially higher thermal efficiency. In this study, we proposed a generic adsorption based hot/warm CO 2 removal process for IGCC power plants. Through analyses of the proposed generic process we have demonstrated that higher temperature of the hot/warm CO 2 removal process will results in larger heat of adsorption, which in turns may increase energy consumption of the process. Under most of the operating temperature range, hot/warm CO 2 removal process will lead to more electricity loss compared to the baseline Selexol process. However, if the adsorption step takes place at a temperature close to or higher than the highest steam temperature in steam cycle, our analysis indicates that the process may lead to minimal electricity loss. The study also provided some other insights into the pathways for hot/warm CO 2 removal process to improve its energy performance through process and sorbent designs. Graphical Abstract

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

Kemper County IGCC (Final Project Report)

The Kemper County IGCC plant was a lignite-fueled 2-on-1 Integrated Gasification Combined-Cycle (IGCC) facility that demonstrated the air-blown Transport Integrated Gasification (TRIG™) technology jointly developed by Southern Company, KBR, Inc. (KBR), and the U.S. Department of Energy (DOE) at the Power Systems Development Facility (PSDF) in Wilsonville, Ala. The plant is owned by Mississippi Power Company (MPC) and has a calculated nameplate capacity of 830 MW with a peak net output of 582 MW. As a result of advanced emissions control equipment, the facility is designed to produce marketable products of ammonia (NH 3 ), sulfuric acid (H 2 SO 4 ), and carbon dioxide (CO 2 ). The plant is designed to capture 65 percent of the carbon producing a CO 2 stream for use in enhanced oil recovery (EOR), making the plant carbon emissions comparable to those of a natural gas-fired combined cycle power plant. This report describes operation activities post commissioning of the plant and through suspension of the facility. This includes first coal feed testing and syngas production for combustion within the combustion turbine up to the final day of operation.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2019

Abradable Sealing Materials for Emerging IGCC-Based Turbine Systems (Final Report)

Reducing the gap between rotating and stationary parts in gas turbine engines, and mitigating gas leakage via these paths, can significantly increase the performance and attendant efficiency. One approach to reducing such gaps is to deploy abradable coatings on the stationary shroud components as seals, to reduce the blade-tip clearances under operational conditions. Abradable coatings must be able to withstand high temperature oxidation, thermal cycling, and erosion, while providing optimal controlled abrasion and associated shape retention. Existing abradable seals utilized in power generation turbines have generally been optimized for use with natural gas-fired systems; however, preliminary testing of syngas and high-hydrogen-content (HHC) fired turbines has shown that the stability of hot-section materials (and presumably abradable sealing materials) may be substantially altered due to characteristic changes in the combustion by-products (partial pressures of water vapor, etc.) as well as characteristic impurities and particulate matter entrained in the fuel. The primary focus of this research program has been to develop a mechanistic understanding of how the altered combustion environments modify the thermo-mechanical stability and performance of the sealing materials, including the requisite abradable sealing behavior. A key component of the research program carried out has been an exploration of mechanisms underpinning observed degradation processes, and an assessment of connections to the combustion environments and characteristic non-combustible constituents. The ultimate goal of the project has been to advance the goals of the Advanced Turbine Program by developing materials design protocols leading to turbine hot-section components with improved resistance to service lifetime degradation under advanced fuels exposures. This research program has evaluated the performance and degradation of ceramic abradable seals used in the high-temperature turbine sections of gas turbine engines. The focus has been two-fold: (1) to understand performance of such materials in relation to the turbines operating on coal-derived syngas and high hydrogen content (HHC) fuels, ultimately seeking an improved understanding of factors that control performance and durability of abradable seal materials for these combustion environments (and play into materials design protocols); and (2) to evaluate the potential of alternative materials as abradable seals for the higher temperatures expected with IGCC and HHC fueled turbine systems. In particular, we carried out an initial assessment of multi-layered systems of existing abradable seal materials (YSZ) and other ceramics. The research program also investigated several classes of abradable coatings under simulated exposures to syngas-based combustion environments, evaluating the relevant wear behavior, hardness, stability under cyclic oxidation, and general thermo-mechanical behavior. The research also attempted to develop alternatives to carrying out full-scale combustion-based abradability test rig exposures to evaluate materials system performance. The research has been focused on correlating the measured thermo-mechanical behavior, and controlled abrasive wear, with the intrinsic properties of the multilayer coatings and processing-controlled microstructural features that have shown attractive machinability characteristics based on weak interfacial bonding between the constituent phases at elevate temperatures (while maintaining thermochemical stability). This program has resulted in an improved mechanistic understanding of factors governing performance of high temperature abradable seals, and degradation mechanisms unique to IGCC-based power generation turbine systems and the realization of coal-derived syngas and HHC-based combustion environments – ultimately with the goal of developing a knowledge base upon which the design of coatings that retain optimal sealing characteristics and are more resistant to the observed wear/attack mechanisms, important aspects of advancing the goals of the DOE Advanced Turbine Program.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Combined Sorbent/WGS-based CO 2 Capture Process with Integrated Heat Management for IGCC Systems

Southern Research has developed a combined CO 2 capture water-gas shift (WGS) process for integrated gasification combined cycle (IGCC) applications. A highly efficient regenerable magnesium based sorbent was prepared to remove CO 2 . It offers high and stable CO 2 capacity with minimum requirement for temperature and pressure swings. Under optimized conditions, the sorbents achieved up to 8 mmol/g of CO 2 working capacity and remained stable over 500 cycles of adsorption and regeneration. The selected WGS process achieved 96% CO per pass conversion and remained isothermal during the test duration that lasted over 500 cycles. The approach showed potential to reduce cost of electricity (COE) compared to the baseline carbon capture approaches. The process is for bench-scale and pilot development. In a commercial embodiment, syngas from the gasifier is cooled to warm gas conditions. It then enters the CO 2 sorbent-shift reactor that uses an efficient MgO-based CO 2 sorbent and a commercial catalyst to shift the CO to CO 2 and capture 90% + of the carbon. Using a dual-bed arrangement, the sorbent is regenerated periodically by a combination of pressure and temperature swing to maintain steady state conditions and produce a 95+ % CO 2 stream for sequestration. The hydrogen rich syngas is sent to the IGCC for power production. In addition to consolidating CO 2 capture with WGS, the proposed process reduces parasitic energy losses by operating at warm gas temperatures and reduces parasitic plant load (i.e., steam and auxiliary power) by reducing energy required for regeneration. The project consisted of 3 budget periods (BP) of laboratory-scale research and testing with go/no-go decisions after BP-1 and BP-2. In the 12 month BP-1, it was shown show that one promising sorbent maintained the required CO 2 capacity and durability of >1.5 mmol/g over 100 cycles. Also based on sorbent and WGS experiments in separate reactors and combined reactor modeling, it was shown that the process had the potential to capture 90% of the CO 2 at a lower than conventional amine-based approach. In the 18 month BP-2, a lab scale combined sorbent/WGS reactor system was built, commissioned, and tested with the promising sorbent from BP-1. 90% carbon capture was demonstrated over 100 cycles and it was shown that the process continued to have potential to capture 90% of the carbon at a cost that was less than the conventional amine-based approach. In the 6 month BP-3, a long term test was conducted using the best SR sorbent. The required durability of > 2 mmol/g was demonstrated after 500 cycles. Also, 90% carbon capture and 96% CO conversion was maintained over 1000 cycles. A technical and economic feasibility study was carried out to compare the proposed pre-combustion approach to a gasification plant employing a conventional pre-combustion approach and a conventional pulverized caol (PC) plant employing a conventional post combustion CO 2 capture approach.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2016

Opportunities for increasing CO 2 storage in deep, saline formations by active reservoir management and treatment of extracted formation water: Case study at the GreenGen IGCC facility, Tianjin, PR China

Carbon capture, utilization and storage (CCUS) seeks beneficial applications for CO 2 recovered from fossil fuel combustion. This study evaluated the potential for removing formation water to create additional storage capacity for CO 2 , while simultaneously treating the produced water for beneficial use. Furthermore, the process would control pressures within the target formation, lessen the risk of caprock failure, and better control the movement of CO 2 within that formation. The project plans to highlight the method of using individual wells to produce formation water prior to injecting CO 2 as an efficient means of managing reservoir pressure. Because the pressure drawdown resulting from pre-injection formation water production will inversely correlate with pressure buildup resulting from CO 2 injection, it can be proactively used to estimate CO 2 storage capacity and to plan well-field operations. The project studied the GreenGen site in Tianjin, China where Huaneng Corporation is capturing CO 2 at a coal fired IGCC power plant. Known as the Tianjin Enhanced Water Recovery (EWR) project, local rock units were evaluated for CO 2 storage potential and produced water treatment options were then developed. Average treatment cost for produced water with a cooling water treatment goal ranged from 2.27 to 2.96 US$/m 3 (recovery 95.25%), and for a boiler water treatment goal ranged from 2.37 to 3.18 US$/m 3 (recovery 92.78%). Importance analysis indicated that water quality parameters and transportation are significant cost factors as the injection-extraction system is managed over time. Our study found that in a broad sense, active reservoir management in the context of CCUS/EWR is technically feasible. In addition, criteria for evaluating suitable vs. unsuitable reservoir properties, reservoir storage (caprock) integrity, a recommended injection/withdrawal strategy and cost estimates for water treatment and reservoir management are proposed.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Comprehensive Exergy Analysis of Three IGCC Power Plant Configurations with CO 2 Capture

We have conducted comprehensive exergy analyses of three integrated gasification combined cycle with carbon capture and storage (IGCC-CCS) power plant configurations: (1) a baseline model using Selexol™ for H 2 S/CO 2 removal; (2) a modified version that adds a H 2 -selective membrane before the Selexol™ acid gas removal system; and (3) a modified baseline version that uses a CO 2 -selective membrane before the Selexol™ acid gas removal system. While holding the coal input flow rate and the CO 2 captured flow rates constant, it was determined that the H 2 -selective membrane case had a higher net power output (584 MW) compared to the baseline (564 MW) and compared to the CO 2 -selective membrane case (550 MW). Interestingly, the CO 2 -selective membrane case destroyed the least amount of exergy within the power plant (967 MW), compared with the Baseline case (999 MW) and the H 2 -membrane case (972 MW). The main problem with the CO 2 -selective membrane case was the large amount of H 2 (48 MW worth of H 2 chemical exergy) remaining within the supercritical CO 2 that exits the power plant. Finally, regardless of the CO 2 capture process used, the majority of the exergy destruction occurred in the gasifier (305 MW) and gas turbine (~380 MW) subsystems, suggesting that these two areas should be key areas of focus of future improvements.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2017

CO 2 capture from IGCC gas streams using the AC-ABC process

The objective of this project was to develop a novel, low-cost CO 2 capture process from pre-combustion gas streams. The bench-scale work was conducted at the SRI International. A 0.15-MWe integrated pilot plant was constructed and operated for over 700 hours at the National Carbon Capture Center, Wilsonville, AL. The AC-ABC (ammonium carbonate-ammonium bicarbonate) process for capture of CO 2 and H 2 S from the pre-combustion gas stream offers many advantages over Selexol-based technology. The process relies on the simple chemistry of the NH 3 -CO 2 -H 2 O-H 2 S system and on the ability of the aqueous ammoniated solution to absorb CO 2 at near ambient temperatures and to release it as a high-purity, high-pressure gas at a moderately elevated regeneration temperature. It is estimated the increase in cost of electricity (COE) with the AC-ABC process will be ~ 30%, and the cost of CO 2 captured is projected to be less than $27/metric ton of CO 2 while meeting 90% CO 2 capture goal. The Bechtel Pressure Swing Claus (BPSC) is a complementary technology offered by Bechtel Hydrocarbon Technology Solutions, Inc. BPSC is a high-pressure, sub-dew-point Claus process that allows for nearly complete removal of H 2 S from a gas stream. It operates at gasifier pressures and moderate temperatures and does not affect CO 2 content. When coupled with AC-ABC, the combined technologies allow a nearly pure CO 2 stream to be captured at high pressure, something which Selexol and other solvent-based technologies cannot achieve.

08 HYDROGEN↗