Development of Mixed-Salt Technology for CO Capture from Coal … · 2015. 9. 11. · Energy and Environment Center 3rd Post Combustion Capture Conference (PCCC3)Post Combustion Capture

Energy and Environment CenterEnergy and Environment Center

3rd Post Combustion Capture Conference (PCCC3)3 Post Combustion Capture Conference (PCCC3)

Development of Mixed-Salt Technology for CO2 Capture from Coal Power Plants

Indira S JayaweeraIndira S. Jayaweera

Sr. Staff Scientist and CO2 Program Leader

SRI I i l

September 8-11 2015 Regina Canada

SRI International

September 8-11, 2015 Regina Canada

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Technology BackgroundTechnology Background

Energy and Environment Center

Our Early Experience in Solvent-BasedTechnology Development from Proof-of-Concept to Pilot-ScaleEnergy and Environment Center

Ammonia technology development started in 2004

EPRI, NEXANT STATOIL & ALSTOMSTATOIL & ALSTOM

SRI work with multiple clients!

S ll B h S l L B h S lPilot‐Scale (0.25 MWth)

Post‐Combustion CO2 Capture

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Small Bench‐Scale Large Bench‐Scale( )

(For ALSTOM)


Mixed-Salt Process DetailsEnergy and Environment Center

Key benefits:- Reduced ammonia emissionsReduced ammonia emissions- Enhanced efficiency- Reduced reboiler duty

R d d CO i- Reduced CO2 compression energy

A SIGNIFICANT PARASITIC POWER REDUCTION COMPARED TO MEA !

How it works:Selected composition of potassium carbonate and ammonium salts

O ll h t f ti 35 t 60 kJ/ l (t bl )• Overall heat of reaction 35 to 60 kJ/mol (tunable)Absorber operation at 20 - 40o C at 1 atm with 30-40 wt.% mixture of saltsRegenerator operation at 70 - 180o C at 10-20 atm

• Produce high-pressure CO2 streamProduce high pressure CO2 stream

High CO2 cycling capacity No SolidsHigh CO2 cycling capacity No Solids

5K2CO3–NH3–xCO2–H2O system K2CO3 –NH3–yCO2–H2O systemCO2 Lean CO2 Rich


Published Data Showing Favorable Kinetics for CO2 Absorption in Ammonia Solutions Energy and Environment Center2 p

Pseudo first-order rate constants for CO2 absorption in NH3, MEA, and MDEA 1.8

2.0

m2 kP

a)

Puxty et al 2010 (6 MWetted wall column data

Solvent kapp/103 s‐1

NH3 at 5°C 0.31.2

1.4

1.6

e (m

mol

/s m

Puxty et al., 2010 (6 M ammonia, 5 C)Dave et al., 2009 ( 7 M ammonia, 5 C)CSIRO, 2012 ( 5 M MEA, 40 C)

NH3 at 10°C 0.7

NH3 at 20°C 1.4

NH3 at 25°C 2.10 4

0.6

0.8

1.0

sorp

tion

Rat

e MEA, 40 C)

3

MEA at 25°C 6MDEA at 25°C 0.58Concentration = 1.0 kmol m‐3

0.0

0.2

0.4

0.0 0.2 0.4 0.6 0.8 1.0

CO

2A

bs

Comparison of CO2 absorption rates for MEA and ammonia

Source:Derks and Versteeg (2009). Energy Procedia 1: 1139-1146

CO2 Loading (CO2/NH3 Molar Ratio)

Sources:Dave et al., (2009). Energy Procedia 1(1): 949-954Puxty et al., (2010). Chemical Engineering Science 65: 915-922CSIRO Report (2012). EP116217 SRI small-bench scale data

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Absorber side: Enhanced kinetics


Mixed-Salt has a Low Energy Requirement for CO2 Stripping Energy and Environment Center2 pp g

High purity CO stream

20 bar

High purity CO2 stream

20 bar

CO2/H2O < 0.02

Estimated regenerator heat requirement for mixed-salt system with 0.2 to 0.6 cyclic CO2 loading. Mixed-salt process requires minimal energy

Sources: MEA data: CSIRO report (2012), EP116217K2CO3 data: GHGT-11; Schoon and Van Straelen (2011), TCCS-6Mixed-salt data; SRI modeling

y y 2 gComparison with neat K2CO3 and MEA is shown. for water stripping

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Mixed salt data; SRI modeling

Regenerator side: Reduced water evaporation


Mixed-Salt Requires Less Energy for CO2 Compression Energy and Environment CenterCO2 Compression

Amines

80

90

40

50

60

70

t-CO

2

10

20

30

40

kWh/

t

4 3 2 No. of compression stages

Mixed-Salt

0

10

0 2 4 6 8 10 12 14 16 18 20Desorber Pressure (bar)

Electricity output penalty of compression to 100 bar as a function of desorber pressureSource: Luquiaud and Gibbins., Chem Eng Res Des (2011)

8

g ( )

CO2 Compression: High-pressure CO2 release


Mixed-Salt Process Flow DiagramEnergy and Environment Center

Cleaner

>99% CO2

Exhaust

HX4

HX5

K CO richK2CO3 richSalt mixture

HX2NH3 richl

+

REGHX1 HX3

HX2Salt mixture

++++

AB

REGHX1 HX3

Flue Gas

9

+

Absorber Regenerator+ +

DOE Project OverviewDOE Project Overview(Large-Bench Scale Testing)Contract No DE FE0012959Contract No. DE-FE0012959


Project Goals, Team, Duration and BudgetEnergy and Environment Center

Project Duration:30 months Component Testing Component Testing

– Demonstrate the absorber and regenerator processes individually with high efficiency, low NH3emissions, and reduced water use compared to state-of-the-art ammonia-based technologies

Demonstrate the complete CO capture system Demonstrate the complete CO2 capture system– Integrate the absorber and the regenerator – Optimize system operation, and collect data to perform the detailed techno-economic analysis of

CO2-capture process integration to a full-scale power planp p g p p

Conduct the process economic analysis and EH&S analysis

Project Budget :~ $2.29 MProject Budget : $2.29 M

Current Project Team: NETL (Funding Agency and project overseas), SRI International, IHI Corporation, OLI Systems, Stanford University, Dr. Eli Gal, , p , y , y, ,Dr. Kaj Thomsen, and POLIMI

The overall project objective is to demonstrate that mixed-salt technology can capture CO2 at 90% efficiency and regenerate (95% CO2 purity) at a cost of $40/tonne to meet the DOE program goals.

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Absorber and Regenerator SystemsAbsorber and Regenerator Systems


Absorber InstallationEnergy and Environment Center

Structured packingStructured packing20-ft

Process control& monitoring Column Installation Installed absorber towers13System Commissioned in May 2014


Schematic and Photograph of the Absorber System Energy and Environment Centery

CO2/Air

Rich out Rich out

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0.25 to 1 t-CO2/day capacity

Energy and Environment CenterRegenerator System


Li id f dVent line

Liquid feedCO2 product gas

20-f

t

15

Results from Component Testing

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Bench-Scale Absorber PerformanceEnergy and Environment Center

Modeling and Test DataTest Data

CO2 vapor pressure at the absorber exit under various CO2-loading conditions

Better than 90% efficiency with incoming lean absorption solution and < 0.4 CO2 loading

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2 g

The observed overall rates for CO2 absorption are on the same order as those of MEA-based systems and about 5-7x higher than chilled ammonia systems


Process Ammonia ManagementEnergy and Environment Center

Test Data

ABS 1ABS 1

ABS 1 only ABS2ABS 1 only ABS2

NH3 vapor pressure at the Absorber 1 exit under various CO2-loading conditions

NH3 vapor pressure at the Absorber 1 and 2 exits under various CO2-loading conditions2 2

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Regenerator Performance Energy and Environment Center

Test Data Modeling and Test Data

Variation of attainable CO2-lean loading level with temperature for rich loadings of

Comparison of measured and modeled attainable CO lean loading at 100 to 150 ºClevel with temperature for rich loadings of

0.40 to 0.50 at 10-12 bar

Process was demonstrated with cyclic loading from 0.2 to (lean) to 0.5 (rich) at 150° C

attainable CO2-lean loading at 100 to 150 ºC.

The produced lean loading well exceeds that required for > 90% CO2 capture from flue gas streams 19

Integrated System Testing


New Regenerator InstallationEnergy and Environment Center

Single‐stage regenerator used for component testing

21New Dual‐stage regenerator for integrated testing(picture taken on July 2015)

Installed reboiler (picture taken on August 2015)


Simplified PFD of the Integrated SystemEnergy and Environment Center

1. System is currently in operation with buffer tanks for lean and rich solution storage 2 Continuous operation of the absorber system was smooth and the observed results

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2. Continuous operation of the absorber system was smooth and the observed results were as expected based on the component testing


System Testing in Continuous ModeEnergy and Environment Center

Test Data Modeling and Test Data

90% CO2 capture efficiency with 0.19 to 0.40 li CO l di i Ab b 1cyclic CO2 loading in Absorber 1

Gas flow rate = 15 acfm

C i f b d dProcess Modeling: SRI (ASPEN) and OLI (ESP) Cyclic Loading = 0 18 to 0 58

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Comparison of observed and modeled temperature profiles for Absorber 1

Cyclic Loading = 0.18 to 0.58Reboiler Duty ~ 1.8 to 1.9 MJ/kg-CO2Ammonia Emission < 10 ppm


Modeling Results: Preliminary Net Power Efficiency Energy and Environment Centery

Thermodynamic ASPEN Mass & Energy Model Modeling Balance

Software package was developed for thermodynamic modeling of mixed-salt systemsystem

Process layout with two regenerator options were modeled, regenerator

i t i th 1 8energy requirement was in the range 1.8 to 2.2 MJ/kg-CO2, lowest energy option was chosen for the new regenerator designdesign

Next slide shows the summary data from system modeling by OLI (flue t diti i il t DOE C

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stream conditions similar to DOE Case 11)

Mixed-Salt Large Scale System Modeling by OLI: Process Summary

Mole Fraction Flue Gas Feed Stack Gas CO2 Product H2O 0.1537 0.0289 0.0074CO2 0.1350 0.0153 0.9924

99% Purity

Ar 0.0082 0.0110 8.17E‐6N2 0.6793 0.9128 1.84E‐4 NH3 ‐ 9.13E‐6 (6 PPM) 6.93E‐6 (3 PPM) O2 0.0238 0.0320 3.65E‐5 Temperature oC 58 23 56 42 2Temperature, C 58 23.56 42.2Pressure, atm 1.1 1.0 12Flowrate, kgmol/hr 102,548 76,309 12,571 CO2 Capture 90% CO2 Discharge Pressure, atm 12

Reboiler Energy, MJ/KG of CO2 1.97 Reboiler Steam Requirements Cooling Water RequirementsReboiler Steam Requirements Cooling Water RequirementsSteam Source IP Steam Water Source Cooling TowerTemperature, oF (oC) 803.0 (428.3) Temperature, oF (oC) 59 (15) Pressure, psia (atm) 211.9 (14.42) Pressure, psia (atm) 16.2 (1.1) Flowrate, lb/hr (KG/hr) 939,780 (426,277) Flowrate, GPM (m3/hr) 96,092 (21,829)

90% CO2 CaptureSteam/CO2 by weight = <0.9, Cyclic CO2 Loading 0.29 to 0.51

Note: Economic analysis data for the process will be available in Spring 2014


Mixed-Salt Technology SummaryEnergy and Environment Center

Process Summary• Uses inexpensive industrially available material• Uses inexpensive, industrially available material

(potassium and ammonium salts)• Requires no feedstream polishing

D h d• Does not generate hazardous waste• Has the potential for easy permitting in many localities• Uses known process engineering p g g

Demonstrated Benefits• Enhanced CO2 capture efficiency•

Enhanced CO2 capture efficiency• High CO2-loading capacity• High-pressure release of CO2

E t d B fitExpected Benefits• Reduced energy consumption compared to MEA• Reduced auxiliary electricity loads compared to the

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y ychilled ammonia process

• Possible flexible carbon capture operation

Plans for Future Testing and Commercialization


Scale-up Plan of Mixed-Salt Process for CO2 Capture from Coal Power Plants Energy and Environment Center2 p

Mixed-salt scale-up timeline proposed by IHI corporationed sa t sca e up t e e p oposed by co po at o

SRI’s Bench-scale System

2013 2015 2020 2025 2030

Pilot PlantPilot Plant1 MW

(Future program)

Validation Stage PlantValidation Stage Plant10-20 MW

Demonstration Plant/Full-scale Plant

100-300 MW

Bench-scale Plant 0.25 to 1 ton-CO2/day (Existing program with DOE)

2828SRI is inviting additional partners for future process scale-up demonstrations


Current Project LocationEnergy and Environment Center

SRI 6 MW PlantSRI 6 MW Plant

CO2 yard for mini-pilot testing (up to 100 acfm)

S-building: large bench and mini-pilot studies

P-building: lab-scale tests

SRI’s site in Menlo Park, CA (~ 65 acres)SRI also has a test site near Livermore, CA (480 acres) 29


AcknowledgementsEnergy and Environment Center

NETL (DOE)

• Mr. Steve Mascaro, Ms. Lynn Bricket, and other NETL staff members

SRI Team

• Dr. Indira Jayaweera, Dr. Palitha Jayaweera, Dr. Jianer Bao, Ms. Regina Elmore, Dr. Srinivas Bhamidi, Mr. Bill Olson, Dr Marcy Berding Dr Chris Lantman and Ms Barbara HeydornDr. Marcy Berding, Dr. Chris Lantman, and Ms. Barbara Heydorn

Collaborators

OLI Systems (Dr Prodip Kondu and Dr Andre Anderko) POLIMI• OLI Systems (Dr. Prodip Kondu and Dr. Andre Anderko), POLIMI (Dr. Gianluca Valenti and others), Stanford University (Dr. Adam Brant and Mr. Charles Kang), Dr. Eli Gal, and Dr. Kaj Thomsen

Industrial Partner

• IHI Corporation (Mr. Shiko Nakamura, Mr. Okuno Shinya,

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Dr. Kubota Nabuhiko, Mr. Yuichi Nishiyama, and others)


DisclaimerEnergy and Environment Center

This presentation includes an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees,Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information apparatus product or process disclosed or representsinformation, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark manufacturer or otherwise does not necessarily constitutetrademark, manufacturer, or otherwise does not necessarily constitute or imply endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of

h d h i d il fl h fauthors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

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Headquarters: Silicon ValleyHeadquarters: Silicon ValleySRI International333 Ravenswood AvenueMenlo Park, CA 94025‐3493650.859.2000

Contact:

Dr. Indira Jayaweera

Washington, D.C. SRI International1100 Wilson Blvd Suite 2800

[email protected]

Dr Marcy Berding 1100 Wilson Blvd., Suite 2800Arlington, VA 22209‐3915703.524.2053

Princeton New Jersey

Dr. Marcy [email protected]

C Princeton, New JerseySRI International Sarnoff201 Washington RoadPrinceton, NJ 08540609.734.2553

Dr. Chris [email protected]

Additional U.S. and international locations

www.sri.com

Thank You

Development of Mixed-Salt Technology for CO Capture from Coal … · 2015. 9. 11. · Energy and Environment Center 3rd Post Combustion Capture Conference (PCCC3)Post Combustion Capture

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