Application of a Heat Integrated Post-combustionCO2 Capture System with Hitachi Advanced Solvent

into Existing Coal-fired Power PlantAward Number DE-FE0007395

Heather Nikolic and Kunlei Liu University of Kentucky - Center for Applied Energy Research

Power Generation and Utility Fuels Grouphttp://www.caer.uky.edu/powergen/home.shtml

University of KentuckyCenter for Applied Energy Research

www.caer.uky.edu

www.caer.uky.edu

Expertiseand CCS Projects

32 employees+

8 co-op

Catalyst Chemistry

MaterialScience/

chemistry

Analytical Chemistry

Mechanical Engineering

Chemical Engineering

Thermo-engineering

Electrical Engineering

Elec to Heat(DEDI)

CDI(DOE and UWyo)

2MWth CO2 Capture(DOE, DEDI and CMRG)

Aqueous Corrosion(DOE and CMRG)

Pilot-Plant CO2 Capture(CMRG)

Chemical Looping(DOE, UWyo and DEDI)

Solvent Development(DOE and CMRG)

Catalytic Solvent and Enrichment

(DOE and CMRG)Solvent Degradation

(CMRG)

Coal-NG to Liquid(CAER)

Bench-scale Enzyme(DOE)

Inorganic Membrane(DOE and CMRG)

Catalytic Gasification for H2-rich Syngas (DOE)

UKy-CAER CCSProject Overview

• 2 MWth (0.7 MWe) advanced post-combustion CO2 capture pilot • Catch and release program • Designed as a modular configuration • Testing at Kentucky Utilities E.W. Brown Generating Station, Harrodsburg,

KY, approximately 30 miles from UKy-CAER• Includes several UKy-CAER developed technologies• Two solvent testing campaigns (MEA baseline and advanced H3-1)

Lexington Harrodsburg

Project Organization

Project PartnersSub-contractors

Project Performance Dates

BP1: October 1, 2011 to January 31, 2013 [16 months]BP2: February 1, 2013 to August 31, 2013 [7 months]BP3: September 1, 2013 to March 31, 2015 [19 months]BP4: April 1, 2015 to September 30, 2016 [18 months]

2011 2012 2013 2014 2015 2016

BP1 BP2 BP3 BP4

We are here!

Project Goal and Objectives

Goal– Develop a pathway to achieve the US DOE NETL post-combustion

CCS target of 90% CO2 capture with a cost increase (LCOE) of less than 35% ($40/tonne CO2 captured)

Objectives– To demonstrate a heat-integrated post-combustion CO2 capture

system with an advanced solvent– To collect corrosion data leading to selection of appropriate materials

of construction for a 550 MWe commercial-scale carbon capture plant– To gather data on solvent degradation, water management, system

dynamic control and other information during the long-term verification campaigns

– To provide data and design information for larger-scale pilot plant followed by a commercial-scale project

Technology DescriptionTwo-stage Stripping

Liquid Desiccant Loop

■ Non-linear relationship between relative humidity for wet air and the wet-bulb temperature

■ Provide warm, water-saturated airto the secondary air stripper and provide cooling water to the system: Heat Recovery

■ Non-linear chemical absorption -desorption relationship between carbon loading and CO2 partial pressure

VLE

Dat

a C

olle

cted

at U

Ky-

CAE

R.

Warm water saturated air

Cold process cooling water

Cooling Water Holding Tank

Components and their Locations

AbsorberTwo-stageCooling Tower

Primary Stripper

Secondary Air Stripper

Activated Carbon Filter

Module 1Module 4 (Stairs)

Module 5Module 6

Cooling Water Loop

Cooling Water Circulation pump

Amine Loop

Several Pumps

Cooling Tower Blower

Testing Activities Planned

BP4 Testing and EvaluationsMEA Testing Campaigns

Parametric and long term verification studies, including dynamic studies

H3-1 Testing Campaigns

Parametric and long term verification studies, including dynamic studies

Corrosion Studies

Corrosion coupons will be placed at four processes locations andremoved periodically during both solvent long term verification runs to monitor the performance of two UKy-CAER developed corrosion resistant coatings.

Solvent Degradation Studies

Levels of solvent degradation products will monitored during the MEA campaign.

Solvent Emissions Monitoring

Gas sampling at the exit of each column will occur during the MEA campaign to evaluate the effectiveness of the UKy-CAER solvent recovery systems.

Accurate Modeling ofAll Column Profiles

Each column includes liquid/gas sampling ports to experimentally determine carbon contents along the profiles. The experimental data will be used to improve UKy-CAER developed models.

As of September 2, 2015:– On schedule– Within budget– Total 375 hours of

parametric and long term operation

– 263 tons of CO2 separated– 0 safety incidents– 0 environmental incidents

8-11 September 2015

Project Status

Technical and EconomicAnalysis

All at 90% capture rate and CO2 compression to 2200 psia.

• 55.8% increase in Cost of Electricity from RC9

• $46.93/tonne CO2 Captured, lower than RC10 by $14.38/tonne CO2

(RC9) (RC10)

USDOE

Target Pathway to Target:• Hybrid process with pre-concentrating membrane• Advanced catalytic solvent• Flue gas drying• Absorber gas inter-conditioner

Process Stability

Set points:Steam pressure – 100 psia, (changed from 80 psia at ~2:06 pm)Gas flow – 1400 acfmStripper bottom temperature held steady at ~250 F

PreliminaryOperational Results

1300

1350

1400

1450

1500

50

100

150

200

250

300

1:55 PM 2:09 PM 2:24 PM 2:38 PM 2:52 PM 3:07 PM 3:21 PM 3:36 PM

Gas f

low

(acf

m)

Pres

s (ps

ia) /

Tem

p (o F

)

Steam Press Stripper Bott T Gas flow

PreliminaryOperational Results

Secondary Air Stripping

8-11 September 2015

PreliminaryExperimental Results

≥ 90% capture consistently obtained

Parametric Conditions

Solvent Flow Rate(Ib/h)

Stripper Pressure

(psia)

Inlet CO2Concentration (%)

Absorber Inlet Temperature

(°F)Capture (%)

22225 22 12 104 9422225 22 14 104 9022225 22 16 104 95

25400 22 12 104 9425400 22 14 104 9425400 22 16 104 93

31750 22 12 104 9231750 22 14 104 9131750 22 16 104 93

22225 36 12 104 9222225 36 14 104 9022225 36 16 104 92

25400 36 12 104 9225400 36 14 104 9225400 36 16 104 93

31750 36 12 104 9331750 36 14 104 9231750 36 16 104 94

22225 51 12 104 9222225 51 14 104 9122225 51 16 104 91

25400 51 12 104 9225400 51 14 104 9325400 51 16 104 94

31750 51 12 104 9231750 51 14 104 9431750 51 16 104 93

MEA Parametric Campaign

8-11 September 2015

Energy ConsumptionDOE Reference Case 10 1540 BTU/lb-CO2

UKy-CAER CCS process MEA case, according to TEA 1340 BTU/lb-CO2

UKy-CAER CCS process MEA case, experimentalparametric campaign

1150 to 1650 BTU/lb-CO2

UKy-CAER CCS process H3-1 case, according to TEA 937 BTU/lb-CO2

UKy-CAER CCS process H3-1 case, experimental campaign

Scheduled for 2016

UKy-CAER advanced CCS process with UKy-CAER advanced solvent

Estimated920 to 1320 BTU/lb-CO2

PreliminaryExperimental Results

Experimental Results Compared to TEA

8-11 September 2015

PreliminaryCorrosion Results

Corrosion Coupon Locations

A106 SS304Ni Plated

A106

Ni2Al3/Al2O3 Plated

A106

S=Stripper

After125 hours:

• Distinct variations in corrosion product are seen throughout the system for A106 and Ni.

• SS304 and Ni2Al3/Al2O3show high levels of corrosion resistance even in the stripper.

A=Absorber

CL=Cold Lean

HR=Hot Rich

Initial condition

8-11 September 2015

T107

P103

C104

KNOCK

C102

C101

IC

CV

SP

B101

CONDI

RLHX

C105E114

L9

V1

V2

C1

R9

R1

R2

L1

G0

G4

C9

C2

G3

C3

G2

G5

E1

E3

R4

R3

E2G1

WA T

L2

A2

L3

AIR

PreliminaryModeling Results

CO2 exiting absorber (vol%)Modelpredicted = 1.11Experimentally measured = 1.26

Lean solvent stream exiting secondary air stripper C/NModel predicted = 0.369Experimentally measured = 0.338

CO2 exiting secondary air stripper (vol%)Modelpredicted = 1.8Experimentally measured = 2.0

Lean solvent stream entering absorber C/NModel predicted = 0.352Experimentally measured = 0.315

Rich solvent stream exiting absorber C/NModel predicted = 0.510Experimentally measured = 0.480

8-11 September 2015

PreliminaryModeling ResultsModeling Results

Lessons LearnedDesignPhase

1. There is a difference in standards between a University and a commercial facility. Maintaining a good working relationship, that benefits both organizations, is crucial to working through a project of this nature.

2. OSHA standards are not black and white.

3. A host site safety review of all areas of the project where safety standards may apply would be helpful for good communication and to address potential issues earlier rather than later.

4. Full spill containment foundation is a good idea.

Construction Phase

1. A construction manager is a good idea.

2. Finding unknown buried things is common during excavation. Budget and schedule allowances should be made.

3. Verify dimensions of equipment bolt holes and foundation bolts, as fabrication and construction occurs – and have a plan to deal with mismatched dimensions.

4. Shipping road surveys need to be complete – from shop door to anchor bolts!

Operations Phase

1. During all the tedious start up activities, it’s worth it for the researchers to do what they can!

2. Consider an in-line, continuous alkalinity measurement, with automatic, continuous amine addition

3. Our process is very sensitive to ambient conditions with respect to water assumption from the air on rainy days.

The Next StepScale Up

from 0.7 MWe to 10 MWe

• UKy-CAER recently awarded another project (DE FOA-0001190) to design a scaled-up CCS

• Continue with UKy-CAER unique process

• TBD Host site• TBD Advanced Solvent

We are interesting in working with a new advanced solvent and will welcome any interest.

Please contact us.heather.nikolic@uky.edu859.420.0842

José Figueroa, DOE NETL

CMRG Members

Donnie Duncan, LG&E and KUDavid Link, LG&E and KU

Michael Manahan, LG&E and KUEileen Saunders, LG&E and KU

Jeff Fraley, LG&E and KU

Acknowledgements