Post-Combustion CO2 Capture System for Existing Coal-fired ......Jul 08, 2013 · TDA Research Inc....
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TDA Research Inc. • Wheat Ridge, CO 80033 • www.tda.com
Post-Combustion CO2 Capture System for Existing Coal-fired Power Plant
Project Review (DE-FE-0007580)
Gökhan Alptekin, PhD
Ambal Jayaraman, PhD Robert Copeland, PhD
DOE/NETL CO2 Capture
Technology Meeting Meeting
Pittsburgh, PA July 8, 2013
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TDA R e s e a r c h
Project Summary • The objective is to develop a post-combustion capture process for
coal-fired power plants and demonstrate technical feasibility (at bench-scale) and economic viability of the new concept
• A mesoporous carbon adsorbent is used to selectively remove CO2 from the flue gas, regenerating under very mild conditions
Budget Period 1 • Sorbent Optimization/scale-up and Laboratory Evaluations • Process Design and System Analysis
Budget Period 2 • Long-term Sorbent Cycling • Design of a Breadboard Prototype Test Unit • High Fidelity Process Optimization and Design
Budget Period 3 • Fabrication of the Prototype Test Unit • Concept Demonstration • System Design, Economic Analysis and EH&S Assessment
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TDA R e s e a r c h
Project Partners
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Project Duration • Start Date = October 1, 2011 • End Date = September 30, 2014 Budget • Project Budget = $3,375,000 • DOE Share = $2,700,000 • TDA/Partners Share = $675,000
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TDA R e s e a r c h
TDA’s Approach
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• The sorbent consists of a carbon material modified with surface functional groups that remove CO2 via physical adsorption • CO2-surface interaction is strong enough to allow operation at target
temperature range • Because CO2 does not covalently bond to the surface, the energy input
for the regeneration process is low • Heat of adsorption of CO2 is measured as 3.9-4.8 kcal/mol for TDA
sorbent • Selexol ~4 kcal/mol • Amine solvents ~14.4 kcal/mol • Chemical absorbents 20-40 kcal/mol
• Na2CO3 + CO2(g) + H2O(g) 2NaHCO3 (∆H = -30 kcal/mol) • The net energy loss in sorbent regeneration is expected to be much
lower than amine scrubbers • Higher process efficiency
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TDA R e s e a r c h
Integrated CO2 Capture System
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FGD Exit = 58oC Design temperature = 65-80oC Single-stage FGD
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TDA R e s e a r c h
TDA’s CO2 Capture System
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Adsorption Regeneration
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TDA R e s e a r c h
TDA’s Sorbent
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0
0.5
1
1.5
2
0 10 20 30 40 50 60 70 80 90 100 110 120
Dif
fere
ntia
l Por
e Vo
lum
e (c
m3 /
g)
Pore Width (Angstroms)
AMS 62A AMS 62B AMS 62C A mesoporous carbon is used to disperse the active sorbent phase The synthesis process
enables us to introduce surface groups active for CO2 removal
The carbon support is previously developed for ultra-capacitors, large pores to facilitate liquid transport Successfully
demonstrated for pre-combustion carbon capture (DE-FE0000469)
T= 260oC, 12,000+ cycles in lab, 2,500+ cycles in the field
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TDA R e s e a r c h
0
10
20
30
40
50
60
70
0
5
10
15
20
25
0.0 1.0 2.0 3.0 4.0
Bed
Tem
pera
ture
(°C)
Pres
sure
(psi
a), C
O2
outl
et (%
)
Time (min)
CO2 Outlet (%)
Average Bed Temperature (°C)
Inlet CO2 Concentration (dry basis)
Blank Reactor Breakthrough
CO2 Breakthrough Profile/Capacity
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CO2 capacity = 1.5% wt. at breakthrough (2% vol. CO2 at the exit)
CO2 capacity = 5.3% wt. at saturation
T=68°C, P=16 psia, GHSV= 2,000h-1, 15% CO2, 12-18% H2O,
simulated flue gas
0
1
2
3
4
5
6
55 60 65 70 75 80 85 90
CO2
Load
ing
(wt%
)
Average Bed Temperature (°C)
Saturation Capacity-18% H2O
Saturation Capacity-12% H2O
Breakthrough Capacity-18% H2O
Breakthrough Capacity-12% H2O
Working capacity
x
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TDA R e s e a r c h
Control of Water Adsorption
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The carbon surface is modified to reduce water adsorption In addition to surface functionality, surface area and pore size are also
optimized to reduce the water uptake
Bas
elin
e so
rben
t
Bas
elin
e so
rben
t
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TDA R e s e a r c h
Impact of Surface Area
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Higher surface area resulted in higher capacities due to increased number of active surface sites
T = 60°C, P = 19 psia, GHSV = 2,000 h-1
CO2 = 15%, H2O = 12-18% by vol. in simulated flue gas
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TDA R e s e a r c h
Effect of Temperature
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Better sorbent performance was observed at 65-80oC range
Competitive adsorption of water at lower temperatures Lower CO2 affinity to the surface at higher temperatures
Optimum operating temperature
Competitive water adsorption
Reduced CO2 affinity
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TDA R e s e a r c h
0
1
2
3
4
5
6
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
Capa
city
(wt%
)
H2O Adsorption Pressure/H2O Regeneration Pressure
Capacity at 2% Breakthrough
Saturation Capacity
T = 60°C, P =18 psia (adsorption), P= 4.8 psia (regeneration), CO2 = 15%, H2O = 18% in simulated flue gas
Impact of Water Concentration During Regeneration
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Water concentration (partial pressure) has shown to have little impact on the CO2 capacity of the sorbent
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TDA R e s e a r c h
Impact of Contaminants
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Sorbent maintained a stable working capacity at 62oC cycling in the presence of 70 ppmv NO and up to 300 ppmv of SO2
Adsorption - 62ºC, 300h-1, 1 psig (15.2% CO2, 2.8%O2, bal N2, or 300 ppm SO2 or 70ppm NO)
Regeneration = 300h-1, 1psig, N2 Only, 62ºC
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TDA R e s e a r c h
Multiple VSA Cycles
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Sorbent maintained capacity and removal efficiency over 4,200 cycles
T = 58-70°C, Pads = 14-18 psia, Pdes = 3 psia, GHSV = 250 or 2,000 h-1
CO2 = 15%, H2O = 12-18% by vol. in simulated flue gas
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TDA R e s e a r c h
Production Scale-up
• A continuous rotary kiln was setup to carry out the carburization and activation processes • 12 lb/hr production capacity (continuous)
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Continuous rotary kiln
Feeder
Exhaust gas treatment
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TDA R e s e a r c h
Improvements in Mechanical Integrity
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2” screw extruder Pellets before treatment Pellets after treatment
• The crush strength of the pellets are improved to 2.5-3 lbf/mm (typical range for the commercial samples)
• Among the various approaches, forming the pellets prior to carburization provided the highest strength pellets • Also provides high yields
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TDA R e s e a r c h
Prototype Unit Design
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Electronics Box
Air Lines for Bladder Valves
Screw Elevator
Lock hoppers
Lock hoppers
Adsorber
Regenerator
Solid Flow Control Valves
Vacuum Pump
Surge Tank
Adsorber
Flue Gas Inlet
CO2 Depleted Flue Gas to Vent
Lock hoppers
RegenSteam Inlet
Recovered CO2 & H2O
Air Purge Inlet
Regenerator
Screw elevator
Solid Flow Control Valves
Lock hoppers
Solid Flow Control Valves
Purge Vent
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TDA R e s e a r c h
Gas-Solid Contactors
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Prototype Adsorber Reactor
2-5 ACFM flue gas flow 7-8 ft3/h of sorbent circulation
Solids In Gas out
Gas In
Solids Out
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TDA R e s e a r c h
Cold Flow Visualization Unit
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A clear cold flow visualization system (absorber, regenerator along with the bladder valves) was assembled To monitor desired solids distribution To optimize the control of solids flow rate
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TDA R e s e a r c h
Preliminary Flow Tests
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First, single-reactor flow tests in clear reactors were completed in a dedicated test stand
The operation of bladder valves were optimized The air pressure outside of the bladder is adjusted to control the
orifice size (thereby control of the solid flow rate)
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TDA R e s e a r c h
Slipstream Testing with the Unit - GTI
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6’
6’
24 inches
Vacuum Pump
Elevator, Adsorber, Regeneratorand enclosed, insulated tower
Blower
BlowerCondenser
Condenser
• A slipstream test will be carried out at GTI • All facility requirements are identified
• Skid size/footprint, consumables, analytical needs • A preliminary design review is scheduled by the end of summer
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TDA R e s e a r c h
Site Preparation Work - GTI
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• GTI completed all site modifications, including installation of a coal feeder and modifications to an existing boiler
• The test system will provide 4 CFM flue gas slipstream at the desired gas composition/purity
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TDA R e s e a r c h
Plant Layout/Packed Beds – B&W
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• Cost analysis for the packed bed carbon capture design is underway • Based on the data from the prototype unit, B&W will also design a
moving-bed carbon capture system
Flue Gas Out
Low P Steam In
Steam Out
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TDA R e s e a r c h
System Analysis Results - UCI
• TDA’s CO2 capture system achieves 29.6% efficiency in comparison to 26.2% with the amine scrubbers (DOE/NETL-2010/1397) • 19.7% efficiency drop vs. “no CO2 capture” case 24
Case 9 (No-CO2
Capture, DOE Report Data)
Case 9 (No-
CO2 Capture,
Aspen)
Case 10 AMINE (DOE Report Data)
Case 10 AMINE (Aspen)
Case 10A TDA_VSA (Aspen)
CARBON CAPTURED, % 0 0 90 90 90GROSS POWER GENERATED (AT GENERATOR TERMINALS), KWE
STEAM TURBINE POWER 582600 582600 672700 672700 814185AUXILIARY LOAD SUMMARY, KWE
CO2 REMOVAL POWER -- -- 22400 22084 --SORBENT CONVEYING POWER -- -- -- -- 9147
CO2 COMPRESSION POWER -- -- 48790 48791 133406PUMPING & COOLING TOWER 9390 8899 18730 18559 16809
OTHER LOADS 23190 23185 32820 32816 33394TOTAL AUXILIARIES, KWE 32580 32084 122740 122250 192756
NET POWER, KWE 550020 550516 549960 550451 621430% NET PLANT EFFICIENCY, % HHV 36.8 36.81 26.2 26.18 29.56CONSUMABLESAS-RECEIVED COAL FEED, KG/H 198391 198392 278956 278957 278957LIMESTONE SORBENT FEED, KG/H 19691 19944 28404 28831 28831RAW WATER USAGE, GPM 5896 6541.678 11224 11212 10172
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TDA R e s e a r c h
Acknowledgements
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DOE/NETL Andrew O’Palko - DOE Project Manager
Partners Ashok Rao - University of California, Irvine Bartev Sakadjian – B&W Chuck Sishtla – GTI Paula Walmet – MWV Illinois Clean Coal Institute