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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
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