cost effective air separation system (contract no. de-fe-0024060)
TRANSCRIPT
TDA Research Inc. Wheat Ridge, CO 80033 www.tda.com
Cost Effective Air Separation System (Contract No. DE-FE-0024060)
Gökhan AlptekinAmbal JayaramanRobert Copeland
DOE Gasification Systems and Coal & Coal-Biomass to
Liquids Workshop
Morgan town, WV
August 10, 2015
TDAR e s e a r c h
Project Objective
• The project objective is to demonstrate techno-economic viability of a new air separation technology that can be integrated into the coal gasification and oxy-combustion process
• A high temperature chemical absorbent that is selective for O2removal is the key for the process• Early proof-of-concept demonstrations in an SBIR Phase II project
high oxygen uptake and stable performance• Project Tasks
• Sorbent optimization and scale-up• Testing in a fully-equipped sub-scale unit to fully demonstrate the
concept at the bench-scale• Bench-top demonstration of life (min 10,000 cycles)• A high fidelity process design and cost analysis supported by Aspen
PlusTM simulations• IGCC process and oxy-combustion
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Project Partners
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• A second contract is being worked out to carry-out prototype evaluation (DE-FE-0026142)
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Introduction Oxygen-blown gasifiers provides
smaller size and higher efficiency and substantially reduce NOx and improve gas purity with the removal of N2
ASU is one of the largest cost items in an IGCC plant (consumes 5% of plant power and constitutes ~15% of plant cost)
Low cost oxygen is also critical for the oxy-combustion applications
The cryogenic air separation is the choice of technology at large-scale 600 MW gasifier requires ~170 ton
O2/day Cryo-separation is highly energy
intensive due to the thermal inefficiencies inherent in the low operating temperatures
Air-fired Oxy-fired210 MW oxy-fired PC combustion power plant (Nskala et al., 2008)
(Kobayashi, 2002)
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TDA’s Approach
TDA’s process uses a unique sorbent to support an oxidation-reduction (redox) process
Unlike conventional chemical looping combustion sorbents that also work via a similar redox process, oxygen can be released by changing process conditions No use of reducing gases (e.g., CH4, H2, CO, syngas) that will
consume oxygen MOx = MOy + x/2y O2(g)
The metal oxide phase auto-reduces by changing T, P, oxygen partial pressure The auto-reduction releases oxygen, which can be recovered as a
pure product
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Separation Process Sorbent removes some (~30%)
but not all the O2 from high pressure air drawn into the gas turbine Vitiated high pressure air put
back in the GT after boosting the pressure
Regeneration is carried out using warm sweep gas (superheated steam) ideallyunder isobaric/isothermal conditions Partial pressure difference to
drive the O2 from the sorbent Other options
Pressure swing assisted regeneration
Temperature swing assisted Pressure swing
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Integrated with IGCC Power Plant
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Process Scheme #1
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Integration to the IGCC/CTL Plant
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Particul. Removal
Acid Gas Removal
Cont. RemovalGasifier
Coal
Oxygen
Air
Exhaust
Steam Turbine
Gas Turbine
HRSG
RegenerationAbsorption
Combustor
Steam
Clean syngas to combined cycle
Clean syngas to chemical
plant (optional)
CombustorWater
Condenser
Water
SteamSyngas
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645-77 - Sorbent #1
25.0
25.1
25.2
25.3
25.4
25.5
0 200 400 600 800 1000
Time, min
Wei
ght,
mg
670
680
690
700
710
720
Tem
pera
ture
(o C)
O2/N2 cycling41 cycles
Cycle duration = 17 minWeight change = 1.11%
T = 700C
Mn3O4 cycling at 800oC
14.8
14.9
15
15.1
15.2
15.3
15.4
15.5
0 200 400 600 800 1000 1200 1400Time, min
Wei
ght,
mg
700
720
740
760
780
800
820N2/O2 cycling 210 cycles Cycle time = 10 min
wt. Change = 3.63%
Temperature, oC
Early Results in TGA
Sorbent can be regenerated by concentration swing Switching from pure O2 to
pure N2
Higher capacity at 800oC 3.63% wt. O2 loading at
800oC (10 min full cycle time)
T=800oC
T=700oC
• Similar trends at 700oC• Lower capacity if the same
cycle time is maintained due to slower kinetics during regeneration
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Sorbent Optimization
Oxygen release was documented over a wide range of temperatures
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Flow Experiments in Small & Large Reactors
Oxygen release was documented over a wide range of reactor configurations
0
5
10
15
20
25
0 100 200 300 400Time (min)
Oxy
gen
conc
entr
atio
n (%
)
0
200
400
600
800
1000
Pres
sure
(psi
g) /
Tem
pera
ture
(o C)
OxygenpressureTemperature
absorption step desorption step
2” InconelReactor
Tube Furnace
Pressure control valve
On-line O2Analyzer
Control Box
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Long-term Durability
Sorbent maintained performance for 200 cycles12
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System Design
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Absorption Process
Heat Exchanger
O2Regeneration
Heat Recovery Steam
Generator
O2
Water
Water
LP Steam and Natural Gas
O2 and Steam
LP Steam
Regeneration Process
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IGCC without CO2 Capture
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TDA Steam Plant ChangesScaled up Steam Plant 292,692Steam extration ‐43,351LP steam Generated 11,194Methane expander 540Net Steam Power 261,075
Auxiliary PowerGT Air Boost 584Added Air Compressor 60,617O2 Compressor 10,260Internal O2 Compressor 10,981Net Axilary Load changes 82,441
Power SummaryGas Turbine Power, kW 515,395Sweet Gas Expander, kW 7,500Stem Turbine, kW 261,075Total Power, kW 783,970Auxiliary Load, kW 109,771Net Power, kWe 674,199Net Plant Efficiency %, HHV 40.43%
GE Gasifier
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Preliminary Process Analysis
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IGCC without CO2 Capture (GE Gasifier – DOE Case 1) New sorbent-based ASU can increase the plant efficiency to
40.4%, in comparison to 39% with the same plant equipped with cryogenic separation
Cost of electricity (COE) on a $2011 basis is expected to be $93.2 per MWhr (versus $101.2 per MWhr with cryogenic ASU)
IGCC with CO2 Capture (GE Gasifier – DOE Case 2) New sorbent-based ASU could reduce the cost of CO2 captured
on a $ 2011 basis, for both the conventional Selexol-based and TDA’s warm gas CO2 capture technology to $38.8/tonne and $29.3/tonne respectively
Assumption = Cost of the new ASU is the same as cryogenic plant
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Vision for Commercialization
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• Slipstream to pilot-scale demonstrations to increase technical maturity from TRL = 4 to TRL = 6
• Develop a complete technology package for licensing• Intellectual Property• Process Design Package• Sorbent Manufacturing
• Privately Owned / Began operations in 1987• Two facilities in Wheat Ridge and Golden, CO
• 50,000 ft2 of office and lab space• 82 full-time technical staff
• More than half with advanced degrees (28 PhDs)
C 60 (Ih)
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Contact
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Gokhan Alptekin, PhDVice President, Technology
TDA Research, Inc.12345 W. 52nd Avenue
Wheat Ridge, CO 80033Tel: 303 940 2349Fax: 303 422 7763Cell:720 352 7919
Email: [email protected]