Evaluation of Carbon Dioxide Capture From Existing Coal Fired Plants by Hybrid Sorption Using Solid

Sorbents

Steve Benson Srivats Srinivasachar

2

Presentation Overview

Project Overview

Technology Fundamentals

Project Scope

Current Status

Plans for Future Testing

Project Team

US Department of Energy - NETL

UND Institute for Energy Studies

Envergex LLC

Lignite Energy Council/NDIC

ALLETE Group

Minnesota Power

BNI Coal

SaskPower

Barr Engineering

Solex Thermal

Project Objectives

Develop a process using solid sorbents that will efficiently capture CO2 from flue gas streams and regenerate into a pure CO2 stream, with a lower operating cost than current methods.

Goal: 90 percent CO2 removal at no more than 35 percent increase in the cost of electricity.

Combine existing technologies to create a new sorbent which will have high CO2 loading capacity and a process with low reaction energies.

Budget – Funding Sources

Total Funds = $3.69 Million

$2,952,000 $350,000

$145,000

$150,000

$75,000

$18,000

0 1,000,000 2,000,000 3,000,000

DOE-NETL

NDIC

UND

ALLETE

SaskPower

Solex

Proj

ect F

undi

ng G

roup

Performance period: 10/1/11 to 09/30/14

Background on the Proposed Technology and Scientific/Technical Merit

Technology Background

The hybrid sorption CACHYSTM process uses an additive-enhanced regenerable alkali carbonate sorbent for CO2 capture.

Reactions

MxNy(carbonate-based) + a.CO2(g) Product

Product + Steam MxNy + a.CO2(g)

Sorbents prepared from bulk commodity materials – low cost target.

Reacts with CO2 to form adduct. Reversible with the addition of heat.

Additive – increases adsorption kinetics and reduces sorption energy.

Initial concept testing conducted by Envergex and UND under DOE STTR program.

CACHYSTM Hybrid Sorption Process

Coal-fired Boiler Flue Gas Desulfurization

Scrubber

CO2-loaded Sorbent to

Regenerator

Treated Sorbent to Carbonator

HX-1

Sorbent Treatment

Regenerated Sorbent

CO

2 Ads

orbe

r

Reg

ener

ator

Filter Flue Gas: Low CO2

Flue Gas: Low SO2, High CO2/H2O ~ 60oC

Compressed CO2

HX - Condenser

Extraction Steam (~150-170oC)

HX - Cooling

HX - Heat

Filter

HX-2

60-80oC ~ 1 bara

CO

2-AD

SOR

BER

DES

OR

BER

CACHYSTM Process Benefits

Benefits Low reaction heat ~ 40-80 kJ/mol

CO2

High sorbent capacity

Increased sorption kinetics

Use of low cost, abundantly available materials

Challenges Confirmation of energetics

Confirmation of sorbent capacity

Sorbent integrity

Sorbent handling

0 20 40 60 80

100 120 140 160 180 200

Hea

t of r

eact

ion

(kJ/

mol

CO

2)

Project Scope

Technical Approach and Project Scope

Scope of work includes eight main tasks:

Task 1: Project Management and Planning

Task 2: Initial Technology and Economic Feasibility Study

Task 3: Determination of Hybrid Sorbent Performance Metrics

Task 4: Bench-Scale Process Design

Task 5: Bench-Scale Process Procurement and Construction

Task 6: Initial Operation of the Bench-Scale Unit

Task 7: Bench-Scale Process Testing

Task 8: Final Process Assessment

Decision Points and Success Criteria Decision Point Basis for Decision/Success Criteria

Completion of Budget Period 1 Year 1

1. Successful completion of all work proposed in Budget Period 1 2. Demonstrate sorbent CO2 equilibrium capacity of greater than 70 g of CO2/kg of

sorbent 3. Demonstrate a heat of sorption of 80 kJ/mol of CO2 or less

4. Submission of a Topical Report – Preliminary Technical and Economic Feasibility Study

5. Submission/approval of a Continuation Application to DOE

Completion of Budget Period 2 Year 2

1. Successful completion of all work proposed in Budget Period 2 2. Submission of a bench-scale engineering design package 3. Complete construction of a bench-scale CACHYS™ system

4. Submission of a test matrix for the bench-scale testing campaign

5. Submission/approval of a Continuation Application to DOE

End of Project Year 3

1. Successful completion of all work proposed 2. Complete continuous testing of integrated bench-scale CACHYS™ process for 1 month 3. Submission of a Topical Report – Final Technical and Economic Feasibility Study

4. Submission of a Topical Report – Preliminary EH&S Assessment

5. Submission of a Final Report

Project Results

Bed Reactor Testing

Components

A Mass Flow Controllers

B Bubbler

C Air Preheater

D Steam Generator

E Reactor

F Condenser

G Water Knockout Drum

H 5 Gas Analyzer

I Manual Steam Control #1

J Manual Steam Control #2

T1 Thermocouple – Air In

T2 Thermocouple – Reactor Wall

T3 Thermocouple – Air Out

P1 Pressure Transducer (Bottom)

P2 Pressure Transducer (Top)

A

B C

D

E F

G

H I

J

T1

T2

T3

P1

P2 Heated Steam Mixed Gas N2

CO2

Bed Reactor Testing Results

CO2 Adsorption Capacity (g

CO

2/100

g S

orbe

nt)

0

1

2

3

4

5

6

7

8

9

Cycle 2 Cycle 3 Cycle 4 Cycle 5

6-13-2012 HCK-2 Sorbent

Adsorption

Desorption

CO2 Adsorption Capacity

0 1 2 3 4 5 6 7 8 9

10 11

Cycle 2 Cycle 3 Cycle 4 Cycle 5 Cycle 6

6-26-2012 HCK-5 Sorbent

Adsorption

(g C

O2/1

00 g

Sor

bent

)

Adsorption-Desorption Cycle: TGA/DSC

-90 -80 -70 -60 -50 -40 -30 -20 -10

0 A B C D E F

Heat of Adsorption (kJ/mol CO2)

CO2 Sorption Energetics

0

20

40

60

80

100

120

140

A B C D

Des

orpt

ion

Ener

gy (

kJ/m

ol C

O2)

w/Exotherm

w/o Exotherm

CO2 Sorption Energetics

Next Steps

Year 2

Task 4. Bench-Scale Unit Design

Task 5. Bench-Scale Unit Procurement and Construction

Task 6. Initial Operation of the Bench-Scale Unit

Year 3

Task 7- Bench-Scale Process Testing

Task 8 - Final Process Assessment

Acknowledgements

Project Funding and Cost Share DOE-NETL

Lignite Energy Council/NDIC

ALLETE (Minnesota Power and BNI Coal)

SaskPower

Solex

UND

DOE-NETL Project Manager – Andrew Jones

Contact Information

Steven A. Benson, Ph.D. Institute for Energy Studies, University of North Dakota

(701) 777-5177; Mobile: (701) 213-7070 steve.benson@engr.und.edu

Srivats Srinivasachar, Sc.D. Envergex LLC

(508) 347-2933; Mobile: (508) 479-3784 srivats.srinivasachar@envergex.com