OTM - An Advanced Oxygen Technology for IGCC · Performance Composite OTM Ultra low leak rates...
Transcript of OTM - An Advanced Oxygen Technology for IGCC · Performance Composite OTM Ultra low leak rates...
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Ravi Prasad, Jack Chen, Bart van Hassel, John Sirman, James White, Eric Shreiber, Joe Corpus, Joshua HarnantoRavi Prasad, Jack Chen, Bart van Hassel, John Sirman, James White, Eric Shreiber, Joe Corpus, Joshua Harnanto
San Francisco, Oct 30, 2002San Francisco, Oct 30, 2002
Gasification Technologies 2002Gasification Technologies 2002
OTM - An Advanced Oxygen Technology for IGCC
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Use of Oxygen in IGCC
Oxygen is the preferred oxidantReduced costs for gasifier, heat recovery, acid gas removalEnhanced potential for CO2 sequestrationBut added cost for ASU
O2 supply options:Cryogenic: Most mature & commercialPSA: Small-medium sizesPolymeric Membranes: Small, low purityOTM: Emerging breakthrough technology
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Why OTM?
High operating temperature enables efficient integration with IGCC
0
20
40
60
80
100
-200 25 40 700-1000
Process Temperature (C)
Ox
yge
n P
uri
ty (
%)
Cryo OTM
PolyMem
PSA
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
OTM = Oxygen Transport Membrane
•Oxides of Metals
•Oxygen Ion & Electron
Transport
•Produces Pure O2
•High T Operation
(500-1000°C)
•Pressure Driven Oxygen
Separation
Mixed Conductor Transport Mechanism
--Charge Transfer
Recombination
Charge Transfer Dissociation
-- Adsorption
O2Bulk
Diffussion
Desorption
BulkDiffussion
--IonMigration
Electron Migratione- OTM
Low Pressure Oxygen
High Pressure Air
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Praxair’s Integrated OTM Approach
IntegratedTechnology
Program
MaterialsSynthesis
PowderProduction
Thin FilmDevelopment
Element Fabrication
ProcessEngineering
SystemsEngineering
Over 25 Development Partners
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
OTM Integration in IGCCBasis for Assessment
Illinois #6 coal as feedstock
Westinghouse 501G gas turbineAnchor point for all calculations : ~272 MW power output from GT
Shell technology used for gasification
O2 production:Advanced Cryo: Advanced cryo tailored for IGCCOTM integrated with GTOTM+SOFC Integrated with GTOTM with steam integration
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
IGCC with OTM and SOFC
Air
O2
Coal
Steam CycleFlue Gas
Gasification &Clean-up
Clean Syngas
Gas Turbine
Steam &Water
Exchange
OTM
SupplementalCompressor
Steam
Sulfur
N2Air
ExtractedAir
SOFC
BFW
BFW
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
OTM integration with IGCC produces significant benefits to environment and consumer
OTM integration with IGCC produces significant benefits to environment and consumer
Cost and Efficiency of Power Generation via IGCC
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42
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52
54
Effic
ienc
y (%
HH
V)
Cryo OTMOTM
+SOFC
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42
44
46
48
50
52
Cos
t of E
lect
rici
ty
(mils
/kW
h)
Cryo OTMOTM+S
OFC
SOFC @$800/kW
SOFC @$400/kW
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Project Plan
Joint DOE/Praxair program objective:Commercialize OTM membranes for IGCC Applications
Phase1: 1999 - 2002Material developmentComposite OTM developmentProof of concept in multi-element pilot reactor
Phase2: 2002 - 2004Manufacturing of full size elementsDevelopment of specialized componentsEngineering validation in larger pilot reactor
Phase3: 2004 - 2007Pre-commercial demonstration
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
OTM Materials Options
Fluorite, AO2
Brownmillerite A2B2O5
Perovskites, ABO3
Pyrochlores, A2B2O7
O=
e -
Dual Phase
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Evolution of Advanced OTM Materials
•Simultaneous improvement of flux & strength is a significant accomplishment
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20
40
6080
100
120
O2
Flu
x
(% H
urd
le R
ate
)
OTM1 OTM2 OTM3
Generation of Material
0
20
40
60
80
100
Rel
ativ
e S
tren
gth
OTM1 OTM2 OTM3
Generation of Material
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Components of Praxair’s High Performance Composite OTM
Ultra low leak rates achieved in a single firing step
0100200300400500600700800900
0 20 40 60 80
Differential Pressure, PSI
Flow
Rat
e, C
C/S
ec Generation 2
Al2O3
Generation 1
Year 1 Year 2 Year 3
1.E-12
1.E-11
1.E-10
1.E-09
1.E-08
1.E-07
1.E-06
1.E-05
1.E-04
Lea
k R
ate
[cc/
sec]
Target Leak Rate
Low resistance Substrates Gas Tight Films
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
PSC: Commercial Technology for OTM Powder Production
Calcination
Y1Ba2Cu3O7
Each particle isan intimate mixture of Y2O3,CuO, BaCO3
Advanced Process
CalcinationY1Ba2Cu3Ox
BaCO3
CuO
Y2O3
CuO
Y2Ba1Cu1O5Ba2CO3
Y2O3
Conventional
Micro-scale stoichiometry controlWell suited for complex, multi-cation chemistriesHighly flexible - Over 400 mixed oxide compositions made
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Element Fabrication
Praxair has access to fabrication technology fromAmocoBPStatoilWestinghouse
Praxair & its partners have fabricated and tested a wide range of element geometries
Plates, monoliths, tubes….
Final selection is based on many considerations
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Assessment of ElementGeometry
Tubular Variants: Preferred configuration
Attribute Tubular Planar MonolithSealing Best Difficult Very Difficult
Manifolding Easier Difficult Very Difiicult
Strength Self Supporting Not self supporting Could be self supporting
FabricationExisting Technology
Multiple Options Most advanced for
large size
Existing technology for small size
Difficult for large size
Very Difficult for any size
Scaleup Easy Difficult Very Difficult
Mnf Yield on Functional Element
High Low for complex geometry Low
Area/Volume Ratio Medium High Very High
Thermal Management Easy Fair Difficult
Replacement Single tube Entire stack Entire Monolith
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Praxair Technology for Large OTM Elements
Unique semi works manufacturing facility operational
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Seal Technology Development at Praxair
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100
Prod
uct O
2 Pu
rity
(%)
1997 1999 2001 2002
0%
20%
40%
60%
80%
100%
0 240 480 720 960 1200
Hours
Leak
(% ta
rget
max
imum
)
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1000
Temperature (°C
)
Commercial Target Maximum
0%
20%
40%
60%
80%
100%
Cycle #
Leak
(% ta
rget
max
imum
)
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400
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600
700
800
900
1000
Temperature (°C
)
Commercial Target Maximum
1 5 10 2115
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Multi-Element Pilot Reactor
• 0.2 TPD capacity•Pilot plant producing high purity O2 using composite tubes•Target Flux demonstrated•Life test in progress
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Advances in OTM Technology at Praxair
120% of target flux achieved @ 150C lower temperature
6x flux improvement
Oxygen purity > 99.5%
Successful 1000+ hr life test @ 275psi & 900C
Thin Film MembraneStable flux performanceNo membrane degradation
10 thermal cycles (25-900C at 275 psi) achieved with no degradation0
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100110120
O2
Flux
(% o
f Tar
get)
19
99
20
00
20
01
20
02
He Purged
Un- Purged
1050C
1050C
950C
900C
Gasification 2002RP 10-30--02
Copyright 2002 Praxair Technology, Inc. All rights reserved.
Summary
Ceramic membranes offer potential for low cost oxygenLowest capital cost, power consumption, and oxygen cost2-7% gain in efficiency COE reduction of 8-15%
Project has made substantial progress120% of commercial flux achievedHigh pressure cyclable seals & gas tight membranes99.5%+ O2 purity reached at 275 psi ∆PMulti-element pilot system operational
Pilot and pre-commercial demonstrations are essential steps to commercialization