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Pre-combustion CO2 Capture
@ National Carbon Capture Center
(NCCC)
Tony Wu
Southern Company
July 10, 2013
2013 NETL CO2 Capture Technology Meeting, Pittsburgh, PA
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PSDF: Power Systems Development Facility
2
PSDF and NCCC
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PSDF: Power Systems Development Facility
3
PSDF and NCCC
PSDF
1996 Adv. Combustion
1999 Gasification & Hi Temp
Filtration
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PSDF: Power Systems Development Facility
Post-Combustion @ Plant Gaston
4
Pre-Combustion
PSDF and NCCC
NCCC
2008 CO2 Capture
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• Serve as centralized R&D testing facility
– Capable of multiple testing simultaneously
– ~8,000 gasifier run hrs produce 2.5X testing
hrs
– Effective performance comparison between
technologies tested
• Make available realistic syngas for
performance verification – Flexible in capacity & process conditions
• Leverage existing infrastructure and on-site expertise in power plant, process engineering and integration, design, and O&M areas
• Provide independent data acquisition and
analysis for developers as needed
5 Accelerating CO2 capture technology commercialization
Pre-combustion
Test Facility
Post-combustion
Test Facility
Benefits of NCCC
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CO2 Capture Technology Landscaping
Based on NCCC’s Technology Database
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Pro
gre
ss t
o C
om
mer
cial
izat
ion
Technology Development Time Scale
Basic R&D
Lab Scale Commercial Demonstration Small Pilot Large Pilot
NCCC Program Focus
7
Integrated CO2 capture
system testing
Transfer laboratory
work to more
realistic conditions
Sub-system or component
testing at larger-scale
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8
T.O./Stack
Transport
Gasifier
T.O./Stack Fixed Bed Rxr
50-80 pph/each
Pilot Test Unit #2
0.45 MWe, 7.5 tpd CO2
1,500 pph Syngas
Future Upgrade
1.5 MWe, 25 tpd CO2
5,000 pph Syngas
0.30 MWe, 5.0 tpd CO2
1,000 pph Syngas
SCU Expansion Pilot Test Unit #1
500-1,000 pph
200 pph
SCU: Syngas Conditioning Unit
Simplified SCU Slipstream Schematic
Continued R&D • Coal Feeder • Biomass co-
feed • Hi Temp
Filtration • Ash Handling • Hi Temp Sensor
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Syngas In 1,500 pph
Syngas out
Interface to Capture Test
SCU – 2009 (100 lb/hr Syngas Treatment Capability) 9
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SCU Expansion 2012
Existing SCU-2009
(100 lb/hr Syngas)
Expanded SCU-2012
(1000 lb/hr Syngas) 10
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NCCC Roles Civil/Construction
•Ground preparation
•Weather protection
•Skid installation
•Interconnecting interface piping & wiring
Process Development
•Develop PFD for syngas, N2, Air, cooling water
•Low temp gas cleanup process
•Warm gas cleanup process
•H2 enrichment
Mechanic, Electric Design and I&C
•Design for syngas/N2/Air/ cooling water supply
•Design for electrical supply, heat tracing
•Provide necessary instrumentation for process monitoring and alarm
•Vendor skid design review and recommendation for improvement and safe operation
Operation
•24x7 monitoring and operating
•Trouble-shoot field issues
•Component replacement
•Data logging and analytical support
Four 12-pack H2 Cylinders
Analytic Lab
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Bench
Pilot
(>500 lb/hr)
WGCU (warm gas cleanup)
JM/NETL Hg Sorbent
Catalyst
WGS
Southern Research F-T
Solvent
NETL/ U of Pitt
U of AL
SRI International
Membrane
H2/CO2
WPI
MTR
MPT
Eltron
MTR CO2
Sorbent
TDA
Chemical Looping
OSU SCL
12
Current Technology Testing Scope
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WGS Catalysts Evaluation
WGS Catalyst
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CO + H2O H2 + CO2
NETL May 2012
• 1.0 reduction ~ 40 MW gain (500 MW Plant)
• $275 MM saving over 30-year plant life
• Results implemented at Kemper County IGCC TRIG Project
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Solvent Characterization
• Parr Reactor – Flexible batch absorption and
regeneration process
– Capacity: 5 liter
– Syngas and bottle gases
• Chemical Solvents – Ammonia-based solvent
– Amino acid salts (potassium-prolinate)
– Carbonates (K & Na)
• Physical Solvents – DEPG (dimethyl ether and
polyethylene glycol)
– PDMS (polydimethylsiloxane)
– GTA (glycerol triacetate)
– MEI(methylimidazoles)
Note: PDMS , GTA (U of Pitt/NETL) and MEI (U of AL)
N2 or Syngas
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Membrane Test Configuration
WGS H2S
Removal
COS
Hydrolysis
WGS Cooler /
Condenser
Coalescing
Filters
WPI H2 Membrane
MTR CO2 Membrane
MTR H2
Membrane
MPT H2 Membrane
H2 Enrichment
H2 Enrichment
50 lb/hr
50 lb/hr
1-10 lb/hr
10 lb/hr
1,5
00 lb
/hr S
yn
ga
s He
ad
er
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CO2 Solid Sorbent (TDA) Cabinet #1-Syngas Pre-treatment Cabinet #2- CO2 Removal
Sulfur guard beds (2)
WGS/Heater
Gas
Analyzers
Sorbent reactors (6.8 liter) w/
heating jackets (4)
Chiller
Dry-Rite
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Technology Scale Up MTR CO2 membranes
Field Small module, 50 lb/hr
OSU SCL
(Syngas Chemical Looping)
Lab 25 kW
Field Pilot Skid
260 kW, 880
lb/hr Syngas
17 Field Pilot Skid (500 lb/hr Syngas)
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MTR CO2 Membrane and OSU SCL
Chiller Skid
Membrane Skid
Compressor Skid
Integrated MTR CO2 Membrane System
Commissioned in Summer 2012 OSU SCL System
Plan for Commissioning in Fall 2013
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Basic R&D
Lab Scale Commercial Demonstration Small Pilot Large Pilot
Summary: NCCC Focus
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Syngas ≤10 lb/hr
WPI H2 Membrane
MTR H2 Membrane
MPT H2 Membrane
TDA Solid Sorbent
NETL/UPitt/UA Solvent
Syngas 500 lb/hr
MTR CO2 Membrane
SRII Ammonia Solvent
Syngas ≈ 50 lb/hr
MTR CO2 Membrane
MPT H2 Membrane
WGS Catalyst
Syngas ≈ 900 lb/hr
OSU Chemical Looping
DOE FOA-785
( Up to 1,700 lb/hr)
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Acknowledgements
• DOE/NETL Sponsorship – Mike Mosser, Project Manager, NETL
• EPRI
• Industrial Sponsors – Utility: AEP, Luminant, NRG,
– Coal producer: Arch Coal, Peabody, Rio Tinto
• Technology Developers’ Participation – Eltron, JM, NETL, MPT, MTR, OSU, Southern
Research, SRI International, Stanford U, TDA, UPitt, UA, WPI, WGS catalyst developers
20