Overview of Current Directions in Carbon Capture R&D
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Future carbon capture R&D efforts need to focus on cost reductions in three main areas: materials, processes and equipment. In this webinar Ron Munson, the Institute’s Principal Manager – Capture, gave an overview of the current directions in carbon capture R&D, including development of higher performance solvents, sorbents and membranes; process improvements and intensification; equipment development; and novel equipment designs.
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Overview of Current Directions in Carbon Capture R&D
- 1. OVERVIEW OF CURRENT DIRECTIONS IN CARBON CAPTURE R&D RON MUNSON PRINCIPAL MANAGER – CARBON CAPTURE Webinar 9 July 2015
- 2. Ron Munson, Principal Manager Ron Munson is the Principal Manager, Carbon Capture at the Global CCS Institute. Ron was formerly a Senior Engineer contracting to the National Energy Technology Laboratory (NETL) in the U.S. Department of Energy (DOE). At NETL, Ron supported greenhouse gas emissions mitigation research, development and demonstration programs including carbon capture and advanced combustion systems. In addition, Ron supported the DOE programs all along the commercialization pathway, from process concept through demonstration. Ron holds a Bachelor of Science and Master of Science in Chemical Engineering from Brigham Young University.
- 3. Questions We will collect questions during the presentation. Your MC will pose these question to the panel of presenters after the presentation. Please submit your questions directly into the GoToWebinar control panel.
- 4. OVERVIEW OF CURRENT DIRECTIONS IN CARBON CAPTURE R&D RON MUNSON PRINCIPAL MANAGER – CARBON CAPTURE Webinar 9 July 2015
- 5. Presentation Overview • Background • 1st Generation Technologies • 2nd Generation Technologies • Transformational Technologies
- 6. Fossil fuel demand growing and reserves robust Source: BP Statistical Review of World Energy 2014 Fossil fuel proved reserves: 6 trillion barrels of oil equivalent Reserves to production ratio: ~75 years Source: IEA World Energy Outlook, 2014 (New policies scenario)
- 7. CCS is a vital element of a low-carbon energy future Source: IEA Energy Technology Perspectives (2014) A transformation in how we generate and use energy is needed GtCO2emissions
- 8. Mitigation cost increases in scenarios with limited availability of technologies Source: IPCC Fifth Assessment Synthesis Report, November 2014. Percentage increase in total discounted mitigation costs (2015-2100) relative to default technology assumptions – median estimate 450 138% 7% 6% 64% 2100 concentrations (ppm CO2eq) no CCS nuclear phase out limited solar/wind limited bioenergy 4 8 8 8 Symbol legend – fraction of models successful in producing scenarios (numbers indicate number of successful models) All models successful Between 80 and 100% of models successful Between 50 and 80% of models successful Less than 50% of models successful
- 9. 2015 EOR Dedicated Geological Power Generation Actual and expected operation dates for projects in 2014-2015 is a watershed period for CCS – it is a reality in the power sector and additional project approvals are anticipated Operating 20172016 Hydrogen production Natural gas processing Chemical production Iron and steel production Synthetic natural gas Fertiliser production Oil refining 2018 2019 2020 = 1Mtpa of CO2 (areas of circle are proportional to capacity) Coal-to-liquids * Injection currently suspended Boundary Dam Medicine Bow Kemper Petra Nova ROAD Sargas Texas Sinopec Shengli TCEP Peterhead White Rose HECA Don Valley Illinois Industrial Yanchang Sinopec Qilu Abu Dhabi ACTL Agrium Coffeyville Century Plant Enid Fertilizer Val Verde Air Products Lost Cabin Lula SnøhvitSleipner Shute Creek In Salah* Uthmaniyah Quest Gorgon Spectra ACTL Sturgeon Petro China Jilin Great Plains FutureGen 2.0 operation, construction and advanced planning
- 10. 1st Generation Technologies Solvent-Based Absorption – Current State of the Art • Chemical Absorption Gas and solvent form chemical bonds Faster kinetics than physical Useful for low P operations (post-combustion) Requires significant amount of energy to regenerate – reversing chemical reaction • Physical Absorption Gas and solvent form weak physical bonds Useful for higher P operations (pre-combustion) Does not require heat to regenerate but lose CO2 pressure Advantages • 70+ years acid gas scrubbing experience • Allows good heat integration and management (useful for exothermic rxns) • Selective capture from low partial pressure CO2 streams Challenges • Dilute chemical solutions due to viscosity and corrosion • High regeneration energy (aqueous phase sensible heating, stripping) • DHrxn and kinetics tradeoff
- 11. Boundary Dam Amine-Based Post-Combustion Capture • World’s first commercial-scale power plant with a fully integrated carbon capture system • 110 MWe coal-fired power production unit • 90% Capture • Captured CO2 is compressed and transported off-site for use in enhanced oil recovery (EOR) operations at a nearby oil field
- 12. Deployment Barriers for CO2 Capture Energy Penalty • 20% to 30% less power output Cost • Increase Cost of Electricity by 80% • Adds Capital Cost by $1,500 - $2,000/KW Scale-up • 550 MWe power plant produces 13,000 TPD
- 13. Energy Penalty – Post-Combustion Example PC Boiler (With SCR) Sulfur Removal Particulate Removal Ash Coal STEAM CYCLE CO2 Capture Process* ID Fan Air Power CO2 Comp. Flue Gas CO2 To Storage 2,215 psia Low Pressure Steam Optional Bypass (<90% Capture) Two-step separation process requiring 5 energy inputs: Energy = Q (sensible) + Q (reaction) + Q (stripping) + W (Process) + W (Compression) ALL must be reduced in order to significantly reduce Capture COE impact! 23% 3% 3% 38% 0% 10% 20% 30% 40% 50% 60% 70% %IncreaseinCOE Energy Penalty Fuel Variable O&M Fixed O&M Capital
- 14. Reactor Size Reduction – Lowers Capital Cost Significant Size Reductions! ~1/3rd the Footprint of Solvent-Based Capture Conventional Absorber
- 15. DOE CCS Cost Reduction Goals 0% Reduction 20% Reduction >20% Reduction 40 50 60 70 80 90 100 110 IGCC or Supercritical PC 2nd-Generation Technology Transformational Technology COERelativetoToday'sIGCCwithCapture,% Today 2020 2030 Cost of Electricity Reduction Targets Corresponding Cost of CO2 Capture Targets ~60 ~40 <40 0 10 20 30 40 50 60 70 IGCC or Supercritical PC 2nd-Generation Technology Transformational Technology CostofCapture,2011$/tonneCO2 Today 2020 2030
- 16. R&D Areas Being Pursued
- 17. Materials Process and Equipment
- 18. Current DOE 2nd Generation Pilot Development Performer Project Focus Benefits Scale FY 14 FY 15 FY 16 FY 17 FY 18 FY 19 FY 20 FY 21 FY 22 FY 23 FY 24 FY 25 FY 26 FY 27 FY 28 FY 29 FY 30 Neumann Systems Group Nozzle-Based Solvent Delivery Modular; Solvent Agnostic 0.5 MWe Linde Advanced Amine/ Heat Integration Single Process Train 1 MWe Small Pilot University of Kentucky 2-Stage Regeneration High Pressure Regeneration 0.7 MWe Large Pilot Southern Company Heat Integration/ Exchange Thermal Management 25 MWe Demo General Electric Silicone Solvent Enhanced Energetics 1 MWe ION Engineering Non-Aqueous Solvent/ Amine Mixture Enhanced Energetics 0.7 MWe ADA-ES Amine-Based Sorbent Process Design 1 MWe TDA Alkalized Alumina Sorbent Process Cycle 1 MWe SRI Carbon-Based Sorbent Attrition Resistance 1 MWe MTR Spiral-wound Membrane Process Design 1 MWe GTI Solvent Contactor Process Intensification 1 MWe Aerojet Rocketdyne Oxy-PFBC Latent Heat Recovery 1 MWe Alstom Limestone Chemical Looping Combustion Inexpensive O2 Carrier 1 MWe Solvents Sorbents Membranes Oxygen-Fired
- 19. Neumann Systems Group – Enhanced Contactor Project SummaryProject Summary Approach Design and construct a module of the NeuStream-C absorber technology Colorado Springs Utilities Drake #7 coal-fired power plant. Advantages • Significant reduction in absorber capital cost • Compact, modular and scalable gas/liquid contactor • Broadly applicable to solvent-based systems • Novel NOx control possible Challenges • Maintaining optimal gas/liquid dispersion in full scale equipment
- 20. Southern Company Services – Heat Integration Project SummaryProject Summary Approach Design, build and install an integrated heat integration system as part of the 25 MWe MHI solvent CO2 capture system being tested at Southern Company’s Plant Barry Advantages • Efficient use of traditionally wasted heat in coal-fired flue gas and captured CO2 • Reduced water use and parasitic energy Challenges • Control schemes to maintain a proper steam cycle/carbon capture plant heat balance • Developing specific operating parameters and controls to manage the threat of acid gas condensation Heat Integration of Power Plant and CCS, Including HES Plant Barry
- 21. Linde – Advanced Solvent/Process Project SummaryProject Summary Approach Test BASF’s advanced amine-based solvent process technology and Linde’s novel equipment and process innovations on a 1 MWe slipstream at the National Carbon Capture Center Advantages • Solvent more stable, higher capacity, faster kinetics and ~30% lower energy demand than MEA • Projected up to 60% lower electrical energy load • Novel intercooler • Integrated absorber/wash unit • High pressure regeneration • Low cost materials of construction (projected ~30% capital savings) Challenges • Sustaining performance projections through scale up
- 22. ADA-ES – Amine-Based Sorbent Project SummaryProject Summary Approach Test ADA-ES’s advanced amine-based sorbent technology and process innovations on a 1 MWe slipstream at Southern Company’s Plant Miller Advantages • High working capacity • Low heat capacity minimizes heat input needs • Reactor design (CFB) alleviates pressure drop • Fundamental sorbent chemistry is well-known • Components of process equipment are mature Challenges • Long-term stability of sorbent • Ability to control sorbent temperatures and counteract changes resulting from the heat of reaction, potential erosion, and/or corrosion of process equipment
- 23. KEPCO – Dry Sorbent Project SummaryProject Summary Approach Test KEPCO’s carbonate-based sorbent technology and process innovations on a 10 MWe slipstream at KEPCO’s Plant Hadong Advantages • High sorption capacity • Minimize influence of water & pollutants • Good regenerability • Utilization of waste heat • Low specific heat capacity Challenges • Sorbent attrition • Presence of liquid water • Emergency shutdown Process schematic of KEPCO dry sorbent process KEPCO – Hadong Thermal Power Station 10MWe Pilot Plant Reference: Chong Kul Ryu, KEPCO, CSLF Forum 2014
- 24. MTR – Advanced Membrane/Process Project SummaryProject Summary Approach Develop and test a spiral-wound membrane process on a 1 MWe slipstream at the National Carbon Capture Center Advantages • Compact equipment • Smaller footprint • Efficient scale-up 20-25x larger than current modules • Capital cost reduction • Reduced process complexity Challenges • Overcoming sweep side pressure drop • Effective use of all membrane area • Maximizing packing density while minimizing pressure drop
- 25. Calcium Looping Project SummaryProject Summary Approach Pilot-scale testing at multiple sites to support scale-up • 1 MWth at TU Darmstad (GE) • 200 kWth at University Stuttgart (GE) • 1.9 MWth at ITRI (Taiwan) Advantages • High capture rate (>90%) • Heat integration opportunities to enhance efficiency of associated power generation facility Challenges • Energy requirements • Solids handling and transport • Sorbent attrition CaO sorbent particles
- 26. Aerojet Rocketdyne – Pressurized Oxycombustion Project SummaryProject Summary Approach Develop and test the pressurized fluidized bed combustion concept and validate associated models with a 1 MWth unit operated at CANMET facilities. Advantages • Combines best features of atmospheric CFB and bubbling fluidized bed technologies in smaller package • Predictable behavior over very wide range of flow rates • Constant temperatures throughout bed Challenges • Achieving appropriate reaction rates • In-bed heat exchange
- 27. Alstom – Limestone Chemical Looping Project SummaryProject Summary Approach Address technology gaps to improve and optimize the Limestone Chemical Looping Combustion (LCL-C™) process through operation of a 1 MWe prototype system Advantages • Air separation unit (ASU) is not required for oxygen production • CO2 separation takes place during combustion • Alternate process configurations for both combustion and gasification • Low-cost limestone carrier Challenges • Scale-up • Solids handling and transport • Oxygen carrying capacity and reactivity
- 28. Transformational Technologies DOE/NETL Workshop September 2014 Selected Topic Areas • Computational Exploration • Experimental Exploration • Advanced Manufacturing • CO2 Desublimation • Process Intensification • Electrochemical-Based Capture • Phase Change Solvents • Oxygen Transport Membranes
- 29. ATK – Supersonic Expansion Project Summary Project Summary Approach Develop a novel Inertial CO2 Extraction System (ICES) that converts flue gas CO2 to a solid using supersonic expansion Status Testing underway at 0.25 – 0.5 MW scale Advantages • No moving parts • Small footprint • No chemicals/additives or other consumable media • No refrigeration expense • Inexpensive construction Challenges • Solid CO2 management/self pressurization • Minimization of “slip gas” removed with solid CO2 • Development of optimized supersonic contour to maximize particle size/migration and minimize pressure losses Amine Plant for flowrate equivalent of 0.5 MW Power Same 0.5 MW Capacity ICES Unit (not including compressor and solids treatment)
- 30. Fuel Cell Energy – Capture + Power Production Project Summary Project Summary Approach Developing an electrochemical membrane (ECM)- based Combined Electric Power and Carbon Dioxide Separation (CEPACS) system for CO2 capture that also provides additional electrical power generation Advantages • Net efficiency of a CEPACS-equipped PC plant with greater than 90% CO2 capture is estimated to be ~8 percentage points higher than the net efficiency of a baseline PC plant without CO2 capture • ECM technology anticipated to significantly reduce flue gas NOX emissions (60 to 70%) and reduce CO2 capture cost. Challenges • Contaminant tolerance of ECM technology must be characterized via testing
- 31. GE Global Research – Phase Change Solvent Project Summary Project Summary Approach GE Global Research will design, build, and test a bench-scale CO2 capture process that utilizes a phase- changing aminosilicone solvent (GAP-0) developed in a previous ARPA-E project. Advantages • Rapid CO2 absorption • High CO2 loading (>17%) • Good thermal stability • Low vapour pressure • Low heat capacity • >11% working capacity at 6 bar Challenges • Uneven heating of extruder with recovered heat • Corrosion of process equipment • Incomplete decarboxylation in extruder • higher heat of reaction than MEA (made up for by other positive characteristics)
- 32. Summary • Materials Higher-performance solvents, sorbents, and membranes ─ enhanced separation kinetics ─ lower stripping energy requirements ─ enhanced permeability/selectivity • Process Improvements Heat Integration Process Intensification • Equipment Novel Designs Advanced Manufacturing Techniques
- 33. Questions / Discussion Please submit your questions in English, directly into the GoToWebinar control panel.
- 34. Please submit any feedback to: webinar@globalccsinstitute.com GLOBALCCSINSTITUTE.COM