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.

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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

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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

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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

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• 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

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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

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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

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• 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

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• 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

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• Mustapha Soukri

Contact

Dr. Markus LesemannSr. Director, Business DevelopmentE T h l Di i iEnergy Technology DivisionRTI Internationalmlesemann@rti.org

Contact

+1.919.599.4096

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