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Solutions for Today | Options for Tomorrow
Gasification Systems Program Overview
•
Dave LyonsActing Technology Manager, Gasification
UCFERMay 17, 2017
2
Fossil Energy – Coal Research Program GoalsDriving Down the Cost of Electricity of Coal Power with CCS
0% Reduction
20% Reduction
30% Reduction
40
50
60
70
80
90
100
110
State-of-the-Art 2025 Demo 2030 Demo
Goals are for greenfield plants. Costs include compression to 2,215 psia, but exclude CO2 transport and storage costs.
Cost of Electricity Reduction Targets
Transformational Technology
IGCC orSupercritical PC
2nd-Generation Technology
COE
Rela
tive
to T
oday
’s
Coal
with
Cap
ture
(%)
3
Challenges• Low natural gas prices • Lack of stringent Greenhouse Gas (GHG) control legislation:
Gasification based power is expected to compete well in a high-carbon capture future
Opportunities• High value products from coal via syngas production/conversion• Economic stability through diversified power sources• Set stage for significant GHG control across globe through
reduced cost of electricity with CCS
Gasification SystemsEconomic Challenges & Opportunities
POWERLIQUIDFUELS
FERTILIZERCHEMICALS
4
Feed Systems• Oxygen separation• Expand fuel flexibility• Increase efficiency and reliability, and improve economicsGasifier Optimization and Plant Supporting Systems• Improve reliability• Increase efficiency and reliability, and improve economicsSyngas Processing Systems• Hydrogen and carbon dioxide separation• Control multi-contaminants to extremely low levels• Increase efficiency and reliability, and improve economics
Gasification Systems ProgramKey Technologies
5
Gasification Systems Program
Coal
ParticulateRemoval
GasCleanup
ShiftReactor
Synthesis GasConversion Transportation Fuels
and Chemicals
Carbon Dioxide Utilization & Storage
Hydrogen
Gasifier
Generator
ElectricPower
ElectricPower
Heat RecoverySteam Generator
Steam
Steam Turbine
Stack
Steam
Combustor
Fuel Cells
GasTurbine
Air Separator
Oxygen
GaseousConstituents
Solids
HydrogenSeparation
Generator
FeedPump
SyngasCooler
90%
Compressed Air
Feed Systems
Syngas Processing
Gasifier Optimization
6
Gasification Systems Program Projects
Oxygen
FEED SYSTEMSBench Scale
GTI O2 Production via ContactorRTI O2 Modular SystemsThermosolv O2 Modular SystemsUniv. S. CarolinaO2 Separation Fiber
MembranesTDA Air Separation SystemsAPCI Advanced Cryogenic Air
SeparationPraxair Hollow Fiber Air SeparationHiFunda ION-Electron Membrane
Pilot ScaleGTI Dry Coal Feed PumpPraxair Oxygen Transport Membrane
Feed Systems Key Technology:• Advanced air separation technologies are being
developed to • Significantly lower cost of oxygen production• Allow efficient integration of air separation
processes with gasification-based power and co-production plants.
• Fuel feed – innovative technology advancements to • Increase use of low-rank coals in dry feeding of
high-pressure gasifiers• Allow co-feeding of coal with biomass.
• Together, advancement in these technologies will have significant effect on reducing cost and increasing overall gasifier system efficiency
Bold: Current TRL of 2 or 3
7
Program Strategy– Develop a lower cost oxygen separation system to reduce the cost of electricity
production as the current technology is energy intensiveBenefits
– In lab scale, hollow fiber sorbents have been shown to be 3 to 5 times more productive than traditional adsorbent contactors and additionally have the ability to perform efficient heat integration, enabling recovery of much of the energy required for gas cooling
Objective– To further investigate and test sub-ambient air separation process based on a rapidly
cycled pressure swing adsorption (RCPSA) system that use hollow fiber-sorbent contactors
Scope of Work– Fabricate hollow fiber contactors and generate sub-ambient isotherms for these
materials– Perform RCPSA experiments and assess the efficacy of an internal phase change
materialProject Team
– Praxair Inc., Georgia Institute of Technology Project Duration
– 10/15 - 12/17
Improving Energy Efficiency of Air Separation Via Hollow Fiber SorbentsPraxair
8
Improving Energy Efficiency of Air Separation Via Hollow Fiber SorbentsPraxair
Low energy oxygen/nitrogen separation driven by sub-ambient adsorption based operation
A technology analysis plan (TAP) will be established for fiber sorbent-RCPSA system module performance:• Key parameters assessing the advanced fiber sorbent module performance
will be identifiedDetailed simulation studies of the fiber sorbent module at sub-ambient conditions will be done to establish a performance model in gPROMS:• Modeling will be done according to NETL guidelines on the input
parameters• Non-linear optimizers will then be coupled to the model to obtain trade-offs
of integrated fiber modules vs. ASU• Model results will be communicated using appropriate reporting guidelinesDetailed comparison between SOA and integrated ASU/fiber sorbent module case studies will be done• Benefits of the fiber sorbent RCPSA system will be quantified• Potential performance and cost goals will be quantifiedCost of electricity (COE) & net power plant efficiency (HHV & LHV) metrics of the integrated ASU/fiber sorbent module will be calculated and compared with SOA baselines
9
Gasification Systems Program Projects
SYNGAS PROCESSING SYSTEMSBench Scale
UK Chemical LoopingUW Catalytic GasificationVPI Catalytic GasificationTDA Small Particle Kinetic Benefits
Pilot ScaleRTI Warm Gas CleanupAlstom Chemical LoopingOSU Chemical Looping (x2)TDA Integrated CO2 Removal & WGS (x2)
CO2
H2 rich stream
Water Gas ShiftWater
Gas Shift
Syngas Processing Systems Key Technology:• Develop high-efficiency processes to
remove contaminants from raw syngas• Help reduce contaminants to
regulatory demanded limits• Remove potential contaminant
effects on downstream processes• Pursue various technologies for efficient
separation/recovery of hydrogen and carbon dioxide (CO2) from syngas
• Aid in carbon capture and storage initiatives
• Improve syngas utilization performance
Bold: Current TRL of 2 or 3
10
Program Strategy – Demonstrate new methods for improving the production and recovery of microbial
coal to methane conversion within unmineable fossil fuel resources Benefits
– There is commercial potential for using microbially enhanced methane recovery to boost methane production in current wells or to reactivate abandoned coalbed methane wells that already have infrastructure in place but are no longer producing methane actively
Objective– Develop new technology to demonstrate a new method for delivering microbes to
unmineable coal reservoirScope of Work
– Design a new ceramic proppant (used to "prop open" hydraulic fractures) specifically to have improved fluid transport properties while simultaneously delivering microbial consortia to coal seams
– Identify viable nutrients and microbial consortia for enhance methane production from coal
– Verify heating value, cost, and production rates of the nutrients and microbial consortia Project Team
– University of UtahProject Duration
– 10/14 - 9/17
Ceramic Proppant Design for In-Situ Microbially Enhanced MethaneRecoveryUniversity of Utah
11
Gasification Systems Program Projects
RIC: NETL’s Research and Innovation Center
GASIFIER OPTIMIZATION AND PLANT SUPPORTING SYSTEMS
Bench ScaleNETL/RIC Microbial Enhanced Coalbed
Systems (MECBM)NETL/RIC Process and Reaction
IntensificationNETL/RIC Virtual Reactor Design,
Validation, and OptimizationNETL/RIC Modular StudiesMontana St. Opt. of Microbial Activity (x2)Univ. of Utah Ceramic ProppantS. Illinois Univ. Optimized MicrobialPenn St. Univ. MECBM
Gasifier Optimization and Plant Supporting Systems Key Technology:• Improving the performance and reducing
the costs of advanced gasifiers• Better kinetic/particle models for
development of optimally configured gasifier
• New reactors for smaller applications• Increased efficiencies, better
economics• Coal bed methane microbe
conversion
Bold: Current TRL of 2 or 3
12
Advancing Coal Catalytic Gasification to Promote Optimum Syngas ProductionVirginia Polytechnic Institute & State University (VPI)
Program Strategy – Syngas production from catalytic coal gasification
Benefits– Improved use of fossil fuels, in particular low-rank coal, by using
suitable catalysts to advance gasification and create cleaner synthesis gas
Objective– Work involves experiments, kinetic modeling, and computational
fluid dynamics to advance catalytic gasification of coal and coal-biomass mixtures
Scope of Work– Characterization of the chemical kinetics and reaction mechanisms– Development of a set of models that can be integrated into MFIX,
OpenFOAM and other CFD modeling environmentsProject Team– VPI, University of Delaware, Northeastern University, Utah State
UniversityProject Duration 10/14 - 7/17
13
• Microbial Enhanced Coalbed Systems (MECS) • Coal-to-Methane Characterization and Stimulation• Micro-Field Laboratory
• Process and Reaction Intensification • Microwave Reactions for Gasification• Non-Traditional Thermal Reactors• Enabling Materials and Manufacturing Technologies• Gasification Test Stand• Oxygen Carrier Development• Fischer-Tropsch Catalyst Development and Testing• CHP Reactor Design, Construction, and Testing• CTL Reactor Design, Construction, and Testing
• Virtual Reactor Design, Validation, and Optimization • Simulation-Based Optimization Toolset• CFD Application and Validation for Chemical Looping Devices• Biomass to Syngas Reactor Application and Validation
• Defining and Evaluating Modular Performance and Cost Metrics• Gasification Feasibility Study for 1 MWe Coal to Power• C&CBTL Feasibility Study for 1MWe Coal to Liquids• A 1 MWe Coal to Heat and Power Process with Improved Economics• A 1 MWe Coal to Liquids Process with Improved Economics
Modular Systems : NETL-RIC Research Areas
Dual E-Band Applicator
Standing Wave applicator
Advanced Reactor Simulation and Optimization Toolset
Advanced manufacturing enables non-traditional geometries
Questions?For more information, please contact:
Dave Lyons, Acting Gasification Technology [email protected]
16
Energy Diversity and SecurityGasification can: Convert coal to power Convert coal to valuable products
(chemicals/fuels) Superior environmental performance,
including GHG Feasible for carbon capture
Recoverable Reserves at
Active Mines
477
Demonstrated Reserve
Base
Estimated Recoverable
Reserves 255
18.3
U.S. Coal Resourcesbillion short tons
Why the Interest in Coal Gasification?U.S. Has A Lot of Coal!
1,669
Identified Resources
3,906
TotalResources
https://www.eia.gov/energyexplained/index.cfm?page=coal_reserves
17
Benefits and Products of Gasification
Gasification can be• Used to make: hydrogen,
fertilizer, chemicals (methanol, plastics, etc.) and transportation fuels
• Lowest cost option to make power with almost total carbon dioxide (CO2) capture and storage
Gasification can play in the global market, including developing countries
WATER
COAL/PETCOKE
OXYGEN
BIOMASS
POWER
LIQUIDFUELS
FERTILIZER
CHEMICALSHYDROGEN
GAS CLEANUP/
GAS SEPARATION
CO2(for reuse/storage)
18
Gasification Systems Program Projects
RIC: NETL’s Research and Innovation Center
SYNGAS PROCESSING SYSTEMSBench Scale
UK Chemical LoopingUW Catalytic GasificationVPI Catalytic GasificationTDA Small Particle Kinetic Benefits
Pilot ScaleRTI Warm Gas CleanupAlstom Chemical LoopingOSU Chemical Looping (x2)TDA Integrated CO2 Removal & WGS (x2)
Oxygen
CO2
H2 rich stream
Water Gas Shift
RIC Microbial Enhanced Coalbed SystemsRIC Process and Reaction IntensificationRIC Virtual Reactor Design, Validation, and OptimizationRIC Modular Studies
FEED SYSTEMSBench Scale
GTI O2 Production via ContactorPraxair Hollow Fiber Air SeparationHiFunda Ion-Electron MembraneTDA Air Separation SystemsRTI O2 Modular SystemsThermosolv O2 Modular SystemsUSC O2 Separation Fiber MembranesAPCI Advanced Cryogenic Air Separation
Pilot ScaleGTI Dry Coal Feed PumpPraxair Oxygen Transport Membrane
Montana St Opt. of Microbial Activity (x2)U. of Utah Ceramic ProppantSIU Optimized MicrobialPSU MECBM
Water Gas Shift
Bench-scaleGASIFIER OPTIMIZATION AND PLANT SUPPORTING SYSTEMS
Bold: Current TRL of 2 or 3
19
Gasification Systems Program ProjectsCurrent TRL of 2 or 3
RIC: NETL’s Research and Innovation Center
SYNGAS PROCESSING SYSTEMSBench Scale
UK Chemical LoopingUW Catalytic GasificationVPI Catalytic Gasification
Pilot ScaleOSU Chemical LoopingTDA Warm Gas Multi-Contaminant
Removal System
Oxygen
CO2
H2 rich stream
Water Gas Shift
RIC Microbial Enhanced Coalbed SystemsRIC Process and Reaction IntensificationRIC Virtual Reactor Design, Validation, and OptimizationRIC Modular Studies
FEED SYSTEMSBench Scale
GTI O2 Production via ContactorPraxair Hollow Fiber Air SeparationHiFunda ION-Electron MembraneTDA Air Separation SystemsRTI O2 Modular SystemsThermosolv O2 Modular SystemsUSC O2 Separation Fiber
MembranesAPCI Advanced Cryogenic Air
Separation
Montana St Opt. of Microbial Activity (x2)U of Utah Ceramic ProppantSIU Optimized MicrobialPSU MECBM
Water Gas Shift
Bench-scaleGASIFIER OPTIMIZATION AND PLANT SUPPORTING SYSTEMS
20
• Enable cost-competitive U.S. production of ultra-clean liquid transportation fuels (gasoline, diesel/jet fuel)
• At or below lifecycle greenhouse gas (GHG) emissions from conventional petroleum
• Either drop-in fuels or refinery feedstock• Combine fossil technologies with renewable
or other low carbon footprint technologies to reduce overall GHG emissions impact
• Novel hydrogen production technologies
DOE Vision for Coal and Coal-Biomass to Liquids
TECHNOLOGIES EXIST TO DO THIS NOW – except for costNEED TO DEVELOP LOWER COST AND MORE EFFICIENT TECHNOLOGIES
21
Coal and Coal-Biomass to Liquids Technical Challenges and Opportunities
GaseousConstituents
Solids
Coal
ParticulateRemoval
GasCleanup
ShiftReactor
Synthesis GasConversion
Transportation Fuels and Chemicals
Carbon Dioxide Utilization & Storage
Hydrogen
Gasifier Steam
Air Separator
Oxygen
HydrogenSeparation
FeedPump
SyngasCooler
Compressed Air
Biomass
And Direct Coal Conversion Technologies
Challenges• Coal-biomass mixed feedstock chemical
kinetics/reactive properties• Processing/feeding coal-biomass mixtures
into the gasifier across a pressure gradient• Product characterization from gasifying coal-
biomass mixtures• High capital costs• Environmental concerns• Lower cost H2 donor systems/production
systems• Low value product production through
Fischer-Tropsch (FT) process• Heat management/catalyst life issues• Biomass contaminant impact on FT and
Water Gas Shift processes
Opportunities• Production of high value products (gasoline, jet
fuel, chemicals) from coal comparable to similar products from petroleum
• Economic stability through diversified transportation fuel sources
• Technology exports to countries with low domestic oil supplies, leading to more stable global oil prices
22
• Coal-Biomass Feed and Gasification – Use of biomass mixed with coal to reduce the greenhouse gas (GHG) impact of traditional coal to liquids (CTL) approaches, technologies of interest include:
• Coal-biomass feed systems• Optimization of coal-biomass gasification, and use of resultant syngas
• Advanced Fuels Synthesis – Catalyst and reactor optimization for producing liquid hydrocarbon fuels from syngas resulting from gasification of coal-biomass mixtures, technologies of interest include:
• Advanced syngas processing through intensification/co-production/co-feeding in a Fischer-Tropsch plant to produce (primarily) diesel fuel
• Improvements to direct coal liquefaction (DCL) processes• Hybrid systems using a combination of DCL and syngas-based liquid fuel
production (may also include co-production/co-feeding systems)• GHG emission reduction technologies other than carbon capture and
storage or biomass co-feed
Coal and Coal-Biomass to Liquids ProgramKey Technologies
23
Coal and Coal-Biomass to Liquids ProgramGasification-Based Technologies: Coal-Biomass Feed and Gasification, and Advanced Fuels Synthesis (syngas conversion into transportation fuel)
And Direct Coal Conversion Technologies (which don’t use gasification at all)KEY: Gray shaded areas are not
applicable to C&CBTL Program
GaseousConstituents
Solids
Coal
ParticulateRemoval
GasCleanup
ShiftReactor
Synthesis GasConversion
Transportation Fuels and Chemicals
Carbon Dioxide Utilization & Storage
Hydrogen
Gasifier Steam
Air Separator
Oxygen
HydrogenSeparation
FeedPump
SyngasCooler
Compressed Air
Biomass
24
C&CBTL Program Projects
CO2
H2 rich stream
Water Gas Shift
COAL-BIOMASS FEED AND GASIFICATION
Princeton Synthetic Jet Fuel Production from Lignite/ Biomass w/ CO2 Capture
Battelle Direct CTL Jet Fuel from Biomass Derived Solvents
Water Gas Shift
Coal-Biomass Feed and Gasification Key Technology:• Advance scientific knowledge of the
feeding and conversion of biomass and coal-biomass mixtures as essential upstream steps for production of liquid transportation fuels with a lower net GHG emissions than conventional oil refining
• Handling and processing of coal/biomass mixtures
• Feed system compatibility• Downstream component impact• Conversion optimization
• Future work considerations could focus on modular energy systems
25
Program Strategy• Develop a hybrid, direct coal-to-liquids (CTL) jet fuel process using novel biomass derived solvents to produce commercially viable jet
fuel cost competitive with petroleum, with equal or lower carbon footprintBenefits • High hydrogen-donor bio-oil solvents and two-stage catalytic syncrude hydrogenation/hydrotreating technologies to be advanced by
project development efforts• Eliminating molecular hydrogen required for producing syncrudeObjective• Demonstrate hybrid, direct CTL process for producing coal/bio-solvent syncrude and method for conversion of syncrude into jet fuel• Demonstrate straightforward path to near-term commercial production, significant reduction in capital and operating costs, and
substantial reduction in greenhouse gas emissions without carbon capture and storageScope of Work• Develop and refine major process steps at continuous bench scale, including: (1) biomass conversion to high hydrogen-donor solvents;
(2) coal dissolution in biomass-derived solvents to produce syncrude; and, (3) two-stage catalytic hydrogenation/ hydrotreating of syncrude to jet fuel and other distillates
• Scale-up to continuous, pre-pilot scale• Estimate process economics and greenhouse gas emissions reductionAccomplishments• Completed bench‐scale coal liquefaction testing and bench‐scale syncrude hydrogenation testing• Syncrude preparation underwayProject Team• Battelle Memorial Institute, Quantex, ARA, Intertek, PennState, UDRIProject Duration 10/14 – 6/17
Direct Coal to Liquid for Jet Fuel Using Biomass Derived SolventsBattelle Memorial Institute
26
C&CBTL Program Projects
RIC: NETL’s Research and Innovation Center
ADVANCED FUELS SYNTHESISBench Scale
RTI Hybrid CTL ProcessAltex GHG-reduced CBTL Jet Fuel ProcessCerametec GHG Reduction and Cost-Competitive
Mil-Spec Jet Fuel from CTLH-Quest Wave Liquefaction Mechanisms for
Coal/Biomass Jet Fuel ProductionSRI Indirect Liquefaction of Coal-Biomass for
Jet Fuel ProductionTDA Poison Resistant WGS Catalysts for
Biomass/Coal GasificationNETL/RIC FT Catalyst Development and TestingNETL/RIC Biomass to Syngas Reactor Application and
ValidationNETL/RIC Modular Studies
Pilot ScaleUK C&CBTL Gasification/Syngas Conversion
via FT
CO2
H2 rich stream
Water Gas ShiftWater
Gas Shift
Advanced Fuels Synthesis Key Technology:• Catalyst/reactor optimization
for producing liquid hydrocarbon fuels and valuable by-products from coal/coal-biomass mixtures
• Fuel synthesis product distribution
• Future work may include:• Direct coal conversion• Solid carbon product by-
products
27
Program Strategy • Design, construct and operate coal/biomass-to-liquids (CBTL) facility at 1 bbl/day liquid fuels
capacity, provides developers affordable test bed for new “downstream” concepts and technologiesBenefits• CBTL technology enables production of valuable clean fuel and chemical products from domestic
coal while reducing CO2 emissions, enhancing U.S. energy security and independenceObjective• Compare compositions of Fischer-Tropsch (F-T) liquid fuels produced from coal-derived syngas
with mixture of coal and 8-15% biomass (torrefied basis) • Assess economics of CBTL process and compare cost of adding biomass to limit net CO2
emissions; investigate coal-torrefied biomass feed handling and preparation, (torrefaction releases water contained in biomass as well as superfluous volatiles making it more stable and easier to transport)
Scope of Work• Installation and shakedown of water-gas-shift, F-T synthesis, and hydrocracking• Commencement of initial integrated refinery runs (feed to gasification to separations and upgrading)• Continuous production runs of mini-refinery to produce quantities of liquid hydrocarbons • Analysis of technology and processes, including; scalability, cost, economics, product qualityProject Team• University of Kentucky Center for Applied Energy ResearchProject Duration • 10/12 – 9/17
Small Scale Pilot Plant for the Gasification of Coal and Coal/Biomass Blends andConversion of Derived Syngas to Liquid Fuels Via Fischer-Tropsch Synthesis University of Kentucky (UK) Center for Applied Energy Research (CAER)
28
C&CBTL Program Projects
RIC: NETL’s Research and Innovation Center
ADVANCED FUELS SYNTHESISBench Scale
RTI Hybrid CTL ProcessAltex GHG-reduced CBTL Jet Fuel
ProcessCeramatec GHG Reduction and Cost-
Competitive Mil-Spec Jet Fuel from CTL
H-Quest Wave Liquefaction Mechanisms for Coal/Biomass Jet Fuel Production
SRI Indirect Liquefaction of Coal-Biomass for Jet Fuel Production
TDA Poison Resistant WGS Catalysts for Biomass/Coal Gasification
RIC FT Catalyst Development and TestingRIC Biomass to Syngas Reactor
Application and ValidationRIC Modular Studies
Pilot ScaleUK C&CBTL Gasification and Syngas
Conversion via FT
CO2
H2 rich stream
Water Gas Shift
COAL-BIOMASS FEED AND GASIFICATION
Princeton Synthetic Jet Fuel Production from Lignite/Biomass w/ CO2 Capture
Battelle Direct CTL Jet Fuel from Biomass Derived Solvents
Water Gas Shift
Bold: Current TRL of 2 or 3
29
C&CBTL Program ProjectsCurrent TRL of 2 or 3
RIC: NETL’s Research and Innovation Center
ADVANCED FUELS SYNTHESISBench Scale
RTI Hybrid CTL ProcessAltex GHG-reduced CBTL Jet Fuel
ProcessCeramatec GHG Reduction and Cost-
Competitive Mil-Spec Jet Fuel from CTL
H-Quest Wave Liquefaction Mechanisms for Coal/Biomass Jet Fuel Production
SRI Indirect Liquefaction of Coal-Biomass for Jet Fuel Production
TDA Poison Resistant WGS Catalysts for Biomass/Coal Gasification
RIC FT Catalyst Development and TestingRIC Biomass to Syngas Reactor
Application and ValidationRIC Modular Studies
Pilot ScaleUK C&CBTL Gasification and Syngas
Conversion via FT
CO2
H2 rich stream
Water Gas Shift
COAL-BIOMASS FEED AND GASIFICATION
Battelle Direct CTL Jet Fuel from Biomass Derived Solvents
Water Gas Shift