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Advanced Solid Sorbent-Based CO2Capture Process
3rd Post Combustion Capture ConferencepRegina, Canada
Dr. Markus Lesemann
www.rti.orgRTI International is a registered trademark and a trade name of Research Triangle Institute.
RTI I t ti l
Energy Technologies
Energy TechnologiesDeveloping advanced
RTI InternationalTurning Knowledge Into Practice
Developing advanced process technologies for energy applications by
partnering with industry leaders
Biomass Natural GasConversion Natural Gas
CarbonCarbon Capture & Utilization
Industrial Water
3,700 staffWork in 75 countries
One of the world’s leading research organizations
Syngas Processing
Emerging Sustainable
Energies
Work in 75 countries
2,600Active projects
Scientific staffHighly qualified with tremendous breadthHighly qualified with tremendous breadth
$788 millionResearch budget
Energy Technologies
RTI develops advanced process technologies in partnership with leaders intechnologies in partnership with leaders in energy
From concept to large scale demonstration
Full alignment with industry objectives– Defined commercialization pathways– Flexible intellectual property
arrangements– Potential leveraging of industrial R&D
funding with government provided f difunding
Syngas Processing
Biomass Conversion Natural Gas
Carbon Capture & Utilization
Industrial Water
Emerging Sustainable
Energies
Solid Sorbent CO2 CaptureAdvantages
• Potential for reduced energy loads and lower capital and operating costs
• High CO2 loading capacity; higher utilization of CO2 capture sites
• Relatively low heat of absorption; no heat of
70ºC70ºC 110ºC110ºC70ºC 110ºC
y p ;vaporization penalty (as with aqueous amines)
• Avoidance of evaporative emissions• Superior reactor design for optimized gas70 C70 C70 C • Superior reactor design for optimized gas-
solid heat and mass transfer and efficient operation
Challenges
Heat management / temperature control
Sorbent Chemistry (PEI)Sorbent Chemistry (PEI)Sorbent Chemistry (PEI)
• Heat management / temperature control• Solids handling / solids circulation control• Physically strong / attrition-resistant sorbent• Stability of sorbent performance
4
Primary: CO2 + 2RNH2 ⇄ NH4+ + R2NCOO-
Secondary: CO2 + 2R2NH ⇄ R2NH2+ + R2NCOO-
Tertiary: CO2 + 2R3N ⇄ R4N+ + R2NCOO-
Primary: CO2 + 2RNH2 ⇄ NH4+ + R2NCOO-
Secondary: CO2 + 2R2NH ⇄ R2NH2+ + R2NCOO-
Tertiary: CO2 + 2R3N ⇄ R4N+ + R2NCOO-
Primary: CO2 + 2RNH2 ⇄ NH4+ + R2NCOO-
Secondary: CO2 + 2R2NH ⇄ R2NH2+ + R2NCOO-
Tertiary: CO2 + 2R3N ⇄ R4N+ + R2NCOO-
y p
Technical Approach & Scope
Start w/ process engineering analysis Start w/ promising sorbent chemistry
• Concluded that circulating, • PSU’s Molecular Basket S b t ff hi h CO
Sorbent Development
Sorbent Development
Process Development
Process Development
staged, fluidized-bed design exhibits significant promise.
Development Needs:O d d
Sorbents offer high CO2loading; reasonable heat of absorption (66 kJ/mol).
Development Needs:DevelopmentDevelopmentDevelopmentDevelopment• Optimize reactor design and process arrangement.
Development Approach:D t il d fl idi d b d
Development Needs:• Improve thermal stability.• Reduce leaching potential.• Reduce production cost.
EconomicsEconomics
• Detailed fluidized bed reactor modeling.
• Bench-scale evaluation of reactors designs.
• Convert to fluidizable form.
Development Approach:• Modify support selection.
• Demonstration of process concept.
• Simplify amine tethering.• Scalable production methods.
Start w/ preliminary economic screening
• Conducted detailed technical and economic evaluations• Basis: DOE/NETL’s Cost and Performance Baseline for Fossil Energy Plants
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gy• Further reduction needed reduced power consumption & capital cost
Technology Development Approach
Pilot Demo Commercial
Previous Work Current Project Future Development< 2011 2011-15 2016 - 18 2018-22 > 2022
Prototype Testing (2015)
Proof-of-Concept / Feasibility
Laboratory Validation (2011 – 2013)
Pilot0.5 - 5 MW (eq)
Demo~ 50 MW
Commercial
PrototypeTesting Operational FMBR prototype capable of 90% CO2 capture Parametric and long-term testing
Updated EconomicsFavorable technical economic environmental study (i e meets
Economic analysis Favorable technology feasibility study
Sorbent development Successful scale-up of fluidized-bed sorbent
Favorable technical, economic, environmental study (i.e. meets DOE targets)
Process development Working multi-physics, CFD model of FMBR Fabrication-ready design and schedule for single-stage
contactor
Relevant Environment Validation (2013 – 2014)
Process development Fully operational bench-scale FMBR unit capable of absorption / desorption operation Fabrication ready design and schedule for high fidelity bench scale FMBR prototype Fabrication-ready design and schedule for high-fidelity, bench-scale FMBR prototype
Sorbent development Scale-up of sorbent material with confirmation of maintained properties and performance
98 97654
2 31
Technology Readiness Level
Preliminary Technology Feasibility Study
Summary• Total cost of CO2 captured ~ 39.7 $/T-CO2• > 25% reduction in cost of CO2 capture,
0.1 4.1
Breakdown of the Main Contributors to the Cost of CO2Captured, $/T‐CO2
Capital Cost(10 2%)0.1 4.1
Breakdown of the Main Contributors to the Cost of CO2Captured, $/T‐CO2
Capital Cost(10 2%)
2 pwith > 40% reduction possible with advances in sorbent stability and reactor design
• ~ 40% reduction in energy penalty; significant reduction in total capture plant
14.85.5
Capital Cost
Steam
Electricity(37 3%)
(10.2%)
(13.7%) 14.85.5
Capital Cost
Steam
Electricity(37 3%)
(10.2%)
(13.7%)
g p pcost (compared to SOTA)
C R d i P h
5.3
Variable OperatingFixed Operating
(37.3%)
(13.5%)5.3
Variable OperatingFixed Operating
(37.3%)
(13.5%)
Cost Reduction PathwaySorbent
• Improve CO2 capacity• Improve long-term stability; minimize losses
9.9
CO2 TS&M Cost
Total CO2 Capture Cost ‐ 39.7 $/T‐CO2(25.1%)
(13.5%)
9.9
CO2 TS&M Cost
Total CO2 Capture Cost ‐ 39.7 $/T‐CO2(25.1%)
(13.5%) p g y• Reduce production costs
Process• Heat recovery from absorber /
compression train and integration into compression train and integration into process
• Recycle attrited sorbent particles for removal of acid gases
• Explore lower cost MOCs and compatibility
TEA to be revised in 2015 using bench-scale test data and updated guidelines from NETL
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p p y
Current Status of Project
• Test EquipmentTest Equipment
• Sorbent Scale-up
• Bench-scale Prototype Testing
N S B h l T i• Next Steps – Bench-scale Testing
• Next Steps – Sorbent DevelopmentNext Steps Sorbent Development
• Application to Other Industrial CO2 Sources
8
Test EquipmentPacked-bed Reactor• Fully-automated operation and data analysis; multi-cycle
absorption-regeneration• Rapid sorbent screening experiments• Measure dynamic CO2 loading & rate• Test long-term effect of contaminants
“Visual” Fluidized‐bed Reactor• Verify (visually) the fluidizability of PEI-supported CO2
capture sorbentsO h l d
99
• Operate with realistic process conditions• Measure P and temperature gradients• Test optimal fluidization conditions
Test Equipment
RTI’s Bench-scale Solid Sorbent CO2 Capture
Prototype System
Flue gas throughput: 300 and 900 SLPM Flue gas throughput: 300 and 900 SLPM Solids circulation rate: 75 to 450 kg/hSorbent inventory: ~75 kg of sorbent
C l d i i Currently conducting prototype testing to evaluate sorbent performance and
process design effectiveness
1010
Development Progress – Sorbent Scale-upImprove the thermal and performance stability and production cost of PEI based sorbents whileObjective Improve the thermal and performance stability and production cost of PEI-based sorbents whiletransitioning fixed-bed MBS materials into a fluidizable form.
Previous WorkPrevious Work• Stability improvements through addition of moisture
and PEI / support modifications.Suitable low cost commercial supports identified • Suitable low-cost, commercial supports identified (1000x cost reduction).
• Converted sorbent to a fluidizable form.
Current WorkGen1 Sorbent (chosen for scale-up)Gen1 Sorbent (chosen for scale-up)• PEI on a fluidizable, commercially-produced silica
support.• Optimized Gen1 sorbent through: solvent selection;
d i d PEI l di % ti drying procedure; PEI loading %; regeneration method; support selection; etc.
Gen2 Sorbent (promising next step)• Extremely stable sorbent, high CO2 loadings (11 Extremely stable sorbent, high CO2 loadings (11
wt%).• Provisional patent application filed.
Bench-scale Prototype Testing
Prototype system operation is stable, working on performance optimization
100%
110%
120%
130%
140%Stage‐1 Stage‐2 Stage‐3 Stage‐4
• Cumulative testing to date: 500+ circulation hours; ~200 CO2 capture hours.
• Sorbent circulation rate was controlled and monitored b t f th i d 50%
60%
70%
80%
90%
100%
O2 capture, %
by measurement of the riser pressure drop
10%
20%
30%
40%
50%CO
• Absorber temperature rise linked to CO2 capture• The sorbent is capable of rapid removal of CO2 from the
0%
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19:12:31flue gas
• Capture of 90% of the CO2 in the simulated flue gas stream demonstrated
FG Composition
CO2 H2O N2
15 vol% 3 vol% Balance
11
Bench-scale Prototype TestingExtensive parametric studies ongoing to clearly correlate process variables with system performance:system performance:• Very good control of sorbent circulation and
capture performanceOth f f ti i ti• Other focus areas for process optimization• Absorber temperature• Temperature profiles and heat p p
management• Flue gas velocity• Sorbent bed height• Sorbent bed height• Pressure drop• CO2 concentration variations
Sorbent performance studies• Sorbent stability and attrition observations
E t i b t li t t d t t
11
• Extensive sorbent sampling at steady-state conditions
Sorbent DevelopmentG 1 S S CGen1 Sorbent Improvement Supporting BsCEU testing
• Transfer knowledge gained from improvement work to sorbent scale-up( )• Additional optimization approaches (preparation variables: PEI, prep steps)
• Work with manufacturers on support modifications/tailoring and to streamline production process
Gen2 Sorbent Development – Water-stable Sorbents• BenefitsBenefits
• Improved water stability• Next steps in preparing water-stable sorbents / challenges
• Density improvementDensity improvement• Conversion to fluidizable form
Novel Hybrid Sorbent ConceptsNovel Hybrid Sorbent Concepts• Hybrid-metal organic frameworks and hybrid dendrimers
• Transformation into fluidizable form
14
• Evaluation of impact of flue gas contaminants• New $1.6 million award from U.S. DOE / NETL
Cement Application – Ongoing Demo in NorwayObjective: Demonstrate RTI’s advanced solid sorbent CO capture Objective: Demonstrate RTI’s advanced, solid sorbent CO2 capture process in an operating cement plant and evaluate economic feasibility
N ’ C t Pl t B ik N RTI’ L b l S b t T t U itNorcem’s Cement Plant – Brevik, Norway RTI’s Lab-scale Sorbent Test Unit
Ph t S NPhase I – Complete
• Performed sorbent exposure testing with real cement flue gas using lab-scale test unit
Photo Source: Norcem
• Performed techno-economic study
Phase II – Awarded (July ‘14 to June ‘16)
Pil t fi ld t ti f RTI’ t h l t
15Photo Source: Norcem
• Pilot field testing of RTI’s technology at Norcem’s Brevik cement plant
Acknowledgements
Funding provided by:• The U.S. DOE/National Energy Technology Laboratory (Cooperative Agreement DE-
FE0007707)FE0007707)• Masdar (Abu Dhabi Future Energy Company)
• DeVaughn Body• Ernie Johnson• Martin Lee • Xiao Jiang• Martin Lee• Tony Perry• Pradeep Sharma• JP Shen
• Wenying Quan• Siddarth Sitamraju• Wenjia Wang• Tianyu Zhang
RTI Team PSU Team• JP Shen • Tianyu Zhang
Masdar• Alexander Ritschel• Mohammad Abu Zahra
D Vi t Q• Thomas O. Nelson
Team • Dang Viet Quang• Amaka NwobiCo-Authors
• Atish Kataria• Marty Lail• Paul Mobley
M t h S k i
16
• Mustapha Soukri
Contact
Dr. Markus LesemannSr. Director, Business DevelopmentE T h l Di i iEnergy Technology DivisionRTI [email protected]
Contact
+1.919.599.4096
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